2003 Series 2000 Autoflow Operation Software Version 2.
Series 2000 Autoflow Operation TABLE OF CONTENTS Roof Damage Warning and Disclaimer.............................................................................4 Safety.............................................................................................................................5 Safety Precautions........................................................................................................6 Safety Sign-Off Sheet......................................................................
SAFETY Series 2000 Autoflow Operation Roof Damage Warning and Disclaimer GSI DOES NOT WARRANT ANY ROOF DAMAGE CAUSED BY EXCESSIVE VACUUM OR INTERNAL PRESSURE FROM FANS OR OTHER AIR MOVING SYSTEMS. ADEQUATE VENTILATION AND/OR "MAKEUP AIR" DEVICES SHOULD BE PROVIDED FOR ALL POWERED AIR HANDLING SYSTEMS. GSI DOES NOT RECOMMEND THE USE OF DOWNWARD FLOW SYSTEMS (SUCTION). SEVERE ROOF DAMAGE CAN RESULT FROM ANY BLOCKAGE OF AIR PASSAGES.
Series 2000 Autoflow Operation SAFETY Grain Systems, Inc. recommends contacting your local power company, and having a representative survey your installation so the wiring is compatible with their system, and adequate power is supplied to your unit. Safety decals should be read and understood by all people in the grain handling area. The rotating blade, fire warning decals and voltage danger decal must be displayed on the fan can.
SAFETY PRECAUTIONS Series 2000 Autoflow Operation READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE SAVE FOR FUTURE REFERENCE 1. Read and understand the operating manual before trying to operate the dryer. 2. 3. 4. 5. 6. Use Caution in the Operation of this Equipment The design and manufacture of this Power supply should be OFF for service of electrical components. Use dryer is directed toward operator CAUTION in checking voltage or other procedures requiring power to safety.
Series 2000 Autoflow Operation Date SAFETY SIGN-OFF SHEET Employer’s Signature Employee ________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ _______________________________________________________________
ELECTRICAL POWER SUPPLY Series 2000 Autoflow Operation Power Supply An adequate power supply and proper wiring are important factors for maximum performance and long life of the dryer. Electrical service must be adequate enough to prevent low voltage damage to motors and control circuits (see Electrical Load Information). boards, and the ignition system. The ground rod must be in accordance with local requirements.
Series 2000 Autoflow Operation CONTROL PANEL Electronic Monitoring Control System 9
CONTROL PANEL Dryer Control Panel Featuring the Electronic Monitoring Control System The control panel provides easy access to gauges and controls, and the illuminated switches provide a quick reference for every operating function. The patent pending Electronic Monitoring Control System is a computerized control system that gives instant information regarding dryer operation. Moisture Control Switch This switch determines if the grain temperature setpoint is used in the operation of the dryer.
Series 2000 Autoflow Operation CONTROL PANEL Heater Switch This switch controls the operation of the burner(s). The switch lights up when the burner is on. When the burner is on small lights above and below the heater switch indicate if the burner(s) are in high fire or low fire.
CONTROL SYSTEM Series 2000 Autoflow Operation Electronic Monitoring Control System 12
Series 2000 Autoflow Operation Electronic Monitoring Control System The Electronic Monitoring Control System controls all timing functions and safety circuit checks. It is designed to simplify dryer operation by providing printed messages and warnings on its liquid crystal display (LCD). Turning On The Electronic Monitoring Control System Turn the control power switch to the “on” position. The monitor will display a copyright message, software version number and will enter the main drying screen.
CONTROL SYSTEM FILL 1 DELAY - This delay is not used in units with only one fill system controlled by the Autoflow. The value set on the fill 1 delay is the amount of time that fill system number one runs after grain reaches the drying chamber high level rotary switch. LOW LEVEL DELAY - The value set on the low level delay acts as a buffer to allow grain to fall away from the drying chamber low level rotary switch after the drying fans start without giving an error.
Series 2000 Autoflow Operation Set-up : Extended The set-up mode is used to program the computer with different variables that influence how the dryer will operate. This mode is accessed by holding in on the modify button when turning on the control panel. SET DATE - Use the increase and decrease buttons to select the correct day of month. Press the enter button when the correct day of month is displayed. SET MONTH - Use the increase and decrease buttons to select the correct year.
CONTROL SYSTEM # OF FILL SYSTEMS - Use the increase and decrease buttons to toggle between one or two fill systems. Press the enter button when the number of fill systems displayed on the screen equals the number of fill systems that the computer will be controlling. If one fill system is selected only one fill system will be controlled by the computer. The Hi Level SWdelay will be used to delay the shut off of the fill system after the drying chamber is full.
Series 2000 Autoflow Operation FILL SYSTEM CONTROL BOX 17
FILL SYSTEM CONTROL BOX Series 2000 Autoflow Operation Fill System Control Box Fill System #2 The fill system control box houses the motor starters for fill system #1, fill system #2 and the aeration fan. Switches are located on the front of the fill system control box, and an emergency stop switch is located on the side of the control box. This switch is used to start and stop fill system #2 manually. The switch should be left in the “auto” position for normal dryer operation.
Series 2000 Autoflow Operation Error Messages When the dryer shuts down the user can quickly determine what caused the shutdown by viewing the display on the dryer control panel. The Electronic Monitoring Control System displays the error message and sounds a warning signal to alert the user. The displayed error conditions and their electrical cause are as follows: Burner 1 Loss Flame The flame sensor in burner number one has failed to detect flame.
ERROR MESSAGES Fan 1 Motor Overload The thermal overload in the control box on fan number one has tripped, indicating an overcurrent condition. The overload must be reset manually. Fan 2 Motor Overload The thermal overload in the control box on fan number two has tripped, indicating an overcurrent condition. The overload must be reset manually. Fan 1 Loss Of Airflow The contacts on the airswitch, located in the master fan opened due to the fan not turning, or the airswitch may need to be adjusted.
Series 2000 Autoflow Operation Wet Supply Empty Press To Dry Remaining Grain This message is displayed when the start button is pushed and grain has fallen away from the wet supply rotary switch and there is still grain against the drying chamber low level rotary switch. If the enter button is pushed the dryer will restart, but the fill system(s) will not restart.
PRE-SEASON CHECKS Series 2000 Autoflow Operation Power Start Button Rotary Switches View the drying chamber rotary switches from the peak hole on top of the dryer. Make sure that all three rotary switches are spinning freely. Double check the seal on each rotary switch top. The number one cause of switch failure is water. Make sure when the electrician replaced the top on the rotary switch that no creases formed in the gasket.
Series 2000 Autoflow Operation PRE-SEASON CHECKS Fill System Prepare the wet storage tank to deliver grain to the dryer. Make sure all personnel are away from any machinery that is controlled by the Autoflow. Place the load auger switch in the “Auto” position. The fill system(s) should begin to load grain from the wet supply tank to the dryer. When the display on the Autoflow control box reads “GRAIN LOW LEVEL YES” close the valve that supplies the fill system(s) with wet grain from the wet supply tank.
AUTOFLOW THEORY Top Dry Autoflow Theory Of Operation: Control Panel Switch Status: Control Power: “on” Moisture Control Thermostat: “on” Aeration Fan: “auto” Load Auger: “auto” Fan: “auto” Heater: “auto” Dump: “auto” Dry & Hold: “off” Emergency Stop Switch Status: Autoflow Control Box Emergency Stop: “pulled out” Fill System Control Box Emergency Stop: “pulled out” Actuator Control Box 24v Switch: “on” Aeration Fan Bypass: “enabled” When the Top Dry is in a ready state; that is, with no grain in the Dry
Series 2000 Autoflow Operation If the Wet Storage Tank becomes empty while the fill systems are running, the Fill 1 and Fill 2 Delays starts to count down. When the Fill 1 and Fill 2 Delays reach zero the fill system(s) shut off along with the dryer and a Wet Supply Hopper Empty “Out of Grain” error is displayed on the Dryer Control Panel screen. If there is grain against the Drying Chamber Low Level Rotary Switch the unit can be restarted by pressing the start switch.
START UP PROCEDURE 7) The screen should read “STOPPED”. The chamber high level and the chamber low level should both read “NO”. 8) Set the dry timer using the following charts for the specific bin size, fan and heater size, drying temperature and grain input moisture content.
Series 2000 Autoflow Operation 28) Any time a change is made to the grain temperature setpoint the dryer must dump four times before the full effect of the change will be made on the moisture of the grain. Normal Start Up When the dryer is started with grain in the drying chamber that has already been partially dried, the dryer can be started without making any adjustments to time or temperature; however, the moisture of the grain should be checked after the fourth dump.
DRYING RATES Series 2000 Autoflow Operation TOP DRY AUTOFLOW SERIES DRYING RATES FOR SHELLED CORN AUTOFLOW SERIES FAN & Plenum Moisture HEATER Temperature Content o F Unit(s) Wet Basis 20% 160 25% 15 H.P. 30% 36" FAN 20% 180 25% 3.5 30% Million 20% BTU 200 25% 30% 20% 160 25% 15 H.P. 30% 40" FAN 20% 180 25% 6.25 30% Million 20% BTU 200 25% 30% 20% 160 25% 30 H.P. 30% 42" FAN 20% 180 25% 10.25 30% Million 20% BTU 200 25% 30% 20% 160 25% 40 H.P. 30% 42" FAN 20% 180 25% 10.
DRYING RATES Series 2000 Autoflow Operation TOP DRY AUTOFLOW SERIES DRYING RATES FOR SHELLED CORN AUTOFLOW SERIES FAN & Plenum Moisture HEATER Temperature Content o F Unit(s) Wet Basis 20% 160 25% 15 H.P. 30% 36" FAN 20% 180 25% 3.5 30% Million 20% BTU 200 25% 30% 20% 160 25% 15 H.P. 30% 40" FAN 20% 180 25% 6.25 30% Million 20% BTU 200 25% 30% 20% 160 25% 30 H.P. 30% 42" FAN 20% 180 25% 10.25 30% Million 20% BTU 200 25% 30% 20% 160 25% 40 H.P. 30% 42" FAN 20% 180 25% 10.
Series 2000 Autoflow Operation Autoflow Series Drying Rates Shelled Corn (Metric Measurements) AUTOFLOW SERIES FAN & Plenum Moisture HEATER Temp. Content o C Unit(s) Wet Basis 20% 71 25% 11.19 kW 30% 91.44 cm 20% 82 25% 1.125 30% Million 20% kCal 93 25% 30% 20% 71 25% 11.19 kW 30% 101.60 cm 20% 82 25% 1.5 30% Million 20% kCal 93 25% 30% 20% 71 25% 22.37 kW 30% 106.68 cm 20% 82 25% 2.5 30% Million 20% kCal 93 25% 30% 20% 71 25% 29.83 kW 30% 106.68 cm 20% 82 25% 2.5 30% Million 20% kCal 93 25% 30% 6.
Series 2000 Autoflow Operation Autoflow Series Drying Rates Shelled Corn (Metric Measurements) AUTOFLOW SERIES FAN & Plenum Moisture HEATER Temp. Content o C Unit(s) Wet Basis 20% 71 25% 11.19 kW 30% 91.44 cm 20% 82 25% 1.125 30% Million 20% kCal 93 25% 30% 20% 71 25% 11.19 kW 30% 101.60 cm 20% 82 25% 1.5 30% Million 20% kCal 93 25% 30% 20% 71 25% 22.37 kW 30% 106.68 cm 20% 82 25% 2.5 30% Million 20% kCal 93 25% 30% 20% 71 25% 29.83 kW 30% 106.68 cm 20% 82 25% 2.5 30% Million 20% kCal 93 25% 30% 9.
Limited Warranty The GSI Group, LLC. (“GSI”) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier.
1004 E. Illinois St.
