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Autoflow Operation TABLE OF CONTENTS Roof Damage Warning and Disclaimer.............................................................................4 Safety.............................................................................................................................5 Safety Precautions........................................................................................................6 Safety Sign-Off Sheet..................................................................................
SAFETY 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.
Autoflow Operation SAFETY The GSI Group 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.
DECAL PLACEMENT 6 Autoflow Operation
Autoflow Operation SAFETY PRECAUTIONS 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.
SAFETY SIGN-OFF SHEET Date Employers Signature Autoflow Operation Employee ________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ ____________________________________________________________________________
Autoflow Operation ELECTRICAL POWER SUPPLY 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). In 220V 1-phase and 220V 3-phase systems, a separate neutral wire is required for the 120V heater circuit, and should be connected to terminal #1 in the master heater.
CONTROL SYSTEM Electronic Monitoring Control System 10 Autoflow Operation
Autoflow Operation 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.
CONTROL SYSTEM Autoflow Operation Dryer Control Panel, continued drying fan senses an increase in static pressure and closes. In the Autoflow mode, when placed in the auto position, the main drying fan(s) start when grain reaches the drying chamber low level rotary switch and do not stop until the dryer shuts down or is stopped manually by pressing the stop switch. In the Autobatch mode, the main drying fan(s) shut off automatically in the dump cycle.
Autoflow Operation CONTROL PANEL 13
CONTROL SYSTEM Electronic Monitoring Control System 14 Autoflow Operation
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.
CONTROL SYSTEM Autoflow Operation Setting the Load Delay Setting the Unload Delay The value set on the load delay is the amount of time that fill system number two runs after grain reaches the drying chamber high level rotary switch. This delay is not used with only one fill system controlled by the Autoflow.
Autoflow Operation Set-up Mode The set-up mode is used to program the computer with different variables that influence how the dryer will operate. With the dryer stopped and in the main drying screen, press the increase and decrease buttons at the same time to enter the set-up mode. 1). The first variable to be set is the number of fill system that are to be controlled by the dryer. Use the increase and decrease buttons to toggle between one or two fill systems.
CONTROL SYSTEM Autoflow Operation displayed. 9). The ninth variable is the airswitch test. Use the increase and decrease buttons to toggle between yes or no. If no is selected, the dryer does not require proof of airflow before the burner lights. If yes is selected, the dryer requires proof of airflow to light the burner. Each time the dryer control power is shut off, the airswitch test defaults to yes. 10). The tenth variable is the fan delay.
Autoflow Operation CONTROL SYSTEM 19
CONTROL SYSTEM 20 Autoflow Operation
Autoflow Operation CONTROL SYSTEM 21
CONTROL SYSTEM 22 Autoflow Operation
CONTROL SYSTEM Autoflow Operation Dryer Status By viewing the display on the dryer control panel the user can quickly determine what mode of operation the dryer is in, what cycle the dryer is in, the location of grain relative to the drying chamber rotary switches, and the current status of the dryer. The Electronic Monitoring Control System flashes the current status of the dryer on the display on the dryer control panel.
CONTROL SYSTEM the fan is running and there is proof of airflow, the burner is getting ready to ignite. Unload When the display is flashing unload, the dump chutes have been lowered and the dryer is in the dump cycle. Autoflow Operation The Electronic Monitoring Control System displays the error message and sounds a warning signal to alert the user.
CONTROL SYSTEM Autoflow Operation resets itself when cool. The vaporizer is adjusted by loosening the bolt and moving the vaporizer coil away from the flame. Electrically there is a loss of 12vDC+ on J1-5 on the input/output board. needs to be lowered, or the cycle setpoint on the Hi-lo thermostat needs to be increased, if the error is displayed frequently. Electrically there is a loss of 12vDC+ on J1-11 on the input/output board.
CONTROL SYSTEM Drying Chamber Overflow The grain level in the drying chamber has reached the drying chamber overflow rotary switch. Grain will have to be dumped from the drying chamber to the storage chamber before the unit can be restarted. This error indicates that either the drying chamber high level rotary switch is faulty or the time on the Load delay or Aux.1 delay needs to be lowered. Electrically there is the presence of 12vDC+ on J4-6 on the input/output board.
Autoflow Operation CONTROL SYSTEM Auxiliary Fill Motor Overload Aeration Fan Motor Overload The thermal overload, in the fill system control box for fill system number two; has tripped, indicating an over current condition. Make sure the emergency stop switch on the fill system control box is pulled out as this will inhibit the motor starter from engaging. The overload must be reset manually. Electrically there is a loss of 12vDC on J4-16 on the input/output board.
FILL SYSTEM CONTROL BOX 28 Autoflow Operation
Autoflow Operation FILL SYSTEM CONTROL BOX Fill System Control Box The fill system control box houses the motor starters for fill system #1, fill system #2 and the aeration fan. Start and stop switches are located on the front of the fill system control box and the emergency stop, and aeration fan lockout switches are located on the side of the control box. Fill System #1 These start and stop switches are used to start and stop fill system #1 manually.
FILL SYSTEM CONTROL BOX Autoflow Operation Set Control Switches ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ MOISTURE CONTROL Switch AERATION FAN Switch LOAD AUGER Switch FAN Switch HEATER Switch DUMP Switch DRY and HOLD Switch Autoflow Emergency Stop Switch Actuator Emergency Stop Switch Fill System Control Box Emergency Stop Switch 24 VOLT POWER Switch On Off Off Off Off Auto Off Out Out Out On Control Power Switch Rotary Switches Turn the control power switch on. The switch will light up.
Autoflow Operation tape measure to measure the stroke on the linear actuator. The stroke should be between 12 and 14. If the stroke on the actuator is not 12 to 14, the actuator should be adjusted. Make sure that all pulleys and cables are able to move freely when the actuator is moving. With the actuator extended, enter the storage chamber. View each dump chute individually. Make sure that each dump chute opened completely when the actuator extended.
FILL SYSTEM CONTROL BOX Autoflow Operation in the on position. Place the aeration fan switch on the Autoflow control box in the on position. Go to the master fan and heater unit. Place the fan service switch in the on position. The master fan should start. In two fan, units the slave fan should start after the fan delay. In single fan units the light on the master fan service switch should light up after the master fan reaches half speed.
THEORY OF OPERATION Autoflow Operation Top Dry Autoflow Theory of Operation Emergency Stop Switches Status Control Panel Switches Status: Control Power: 24v Power: Moisture Control Thermostat: Aeration Fan: Load Auger: Fan: Heater: Dump: Dry & Hold: On On On Auto Auto Auto Auto Auto Off When the Top Dry is in a ready state; that is, with no grain the Drying Chamber and wet grain in the Wet Storage Tank, Fill System #1 and Fill System #2 will start to fill the Drying Chamber with wet grain when the star
THEORY OF OPERATION Autoflow Operation After the Dump Cycle, the unit returns to the beginning of the Dry Cycle, the Fill system(s) refill the Drying Chamber and the process begins again. If the Dry Timer reaches zero after the grain temperature reaches the Grain Temperature Setpoint on the Moisture Control Thermostat the unit does not enter Temperature Hold. It goes right to the Dump Cycle.
Autoflow Operation When the Top Dry is in a ready state; that is, with no grain in the Drying Chamber and wet grain in the Wet Storage Tank, Fill System #1 and Fill System #2 will start to fill the Drying Chamber with wet grain when the start switch is pressed on the Dryer Control Panel. In single fill system units only Fill System #1 will start.
THEORY OF OPERATION/TERMINOLOGY restarted by pressing the start switch. When the start switch is pressed the screen on the Dryer Control Panel will read Press Enter to Dry Remaining Grain. If the enter button is pushed the dryer will restart without running the fill system(s). The dryer will remain running until the completion of the next Dump Cycle, after which an Out of Grain error is displayed on the Dryer Control Panel and the dryer stops.
Autoflow Operation TERMINOLOGY Cycle Setpoint-The cycle setpoint is the plenum temperature that the fan and heater unit(s) will try to maintain in the bin. The cycle setpoint is the plenum temperature that the burner will cycle from high-fire to low-fire. The cycle setpoint is set on the hi-lo thermostat. Dryer Control Panel-The dryer control panel is located on the Autoflow Control Box. It contains the start and stop switches and the selector switches for the dryer.
TERMINOLOGY Drying Chamber Overflow Rotary Switch-The drying chamber overflow rotary switch is one of three rotary switches located in the drying chamber. The drying chamber overflow rotary switch has the shortest shaft of the three drying chamber rotary switches. The drying chamber overflow rotary switch warns the computer when grain is getting too high in the drying chamber. Dump Cycle-On Autoflow units the dump cycle is the cycle entered into after completion of the dry cycle.
Autoflow Operation Linear Actuator-The linear actuator is attached to the cable that controls the dump chutes. When the dryer enters into the dump cycle the linear actuator extends giving slack to the dump chute cable. When slack is given to the dump chute cable the dump chutes open dumping grain from the drying chamber into the storage chamber. The linear actuator is located in the actuator control box. Load Delay-The load delay is not used in single fill systems.
TERMINOLOGY/START UP PROCEDURE The storage chamber high level rotary switch is located in the storage chamber 3, below the fan and heater unit(s). The storage chamber high level rotary switch warns the computer when the storage chamber is full. Temperature Hold-Temperature hold is the state the dryer is in when the dry timer has reached zero but the grain temperature on the moisture control thermostat has not reached the grain temperature setpoint.
START UP PROCEDURE Autoflow Operation 4) Make sure there is wet grain in the wet supply tank. 11) Press the reset button for timer changes to take effect immediately. 5) Turn the control power switch to the on position. 12) Set the grain temperature setpoint on the moisture control thermostat chart below. 6) The screen will display a copyright message and software version number, total running time in hours and minutes and the model number, and the serial number and c current time and date.
START UP PROCEDURE/LAST FILL Start Up Procedure cont. 21) After the dump cycle the dryer should continue to the beginning of the next dry cycle. 22) Just before the second dump go into the drying chamber. 23) Place your arm in the grain next to the outside leveling band post. 24) When the dump cycle begins your arm should travel from the outside leveling band post to the bin sidewall. If your arm does not make it to the sidewall, increase the time on the unload timer.
DRYING RATES Autoflow Operation TOP DRY AUTOFLOW SERIES DRYING RATES FOR SHELLED CORN AUTO FLOW SERIES FAN & HEATER Unit(s) 10 - 12 H.P. 36" FAN 3.5 MILLION BTU/HR 3 hp 18" Inline Centrifugal 10-16 H.P. 36" FAN 4.5 MILLION BTU/HR 3 hp 18" Inline Centrifugal 10-16 H.P. 42" FAN 5.75 MILLION BTU/HR 3 hp 18" Inline Centrifugal 20 H.P. 42" FAN 6.75 MILLION BTU/HR 3 hp 18" Inline Centrifugal 30 H.P. 42" FAN 8.75 MILLION BTU/HR 3 hp 18" Inline Centrifugal 40 H.P. 42" FAN 10.
TOP DRY AUTOFLOW SERIES Autoflow Operation TOP DRY AUTOFLOW SERIES AUTO FLOW SERIES 30' Dia. 1-Fan 30' Dia. 2- Fan 36' Dia. 1-Fan 36' Dia. 2-Fan Plenum Moisture Minutes Minutes Minutes Minutes Temperature Content Between Between Between Between (fahrenheit) Wet Basis BU/HR Dumps BU/HR Dumps BU/HR Dumps BU/HR Dumps 20% 819 21.7 160 25% 519 34.3 30% 324 54.9 10 - 12 H.P. 20% * 1,048 * 16.9 36" FAN 180 25% * 664 * 26.8 3.5 MILLION 30% * 415 * 42.9 BTU/HR 20% * 1,227 * 14.5 200 25% * 777 * 22.
DECLARATION OF CONFORMITY Autoflow Operation Declaration of Conformity We, The GSI Group, Inc. 1004 E. Illinois St.
WARRANTY Autoflow Operation THE GSI GROUP, INC. (GSI) WARRANTS ALL PRODUCTS MANUFACTURED BY GSI TO BE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDITIONS FOR A PERIOD OF 12 MONTHS AFTER RETAIL SALE TO THE ORIGINAL END USER OF SUCH PRODUCTS. GSIS ONLY OBLIGATION IS, AND PURCHASERS SOLE REMEDY SHALL BE FOR GSI, TO REPAIR OR REPLACE, AT GSIS OPTION AND EXPENSE, PRODUCTS THAT, IN GSIS SOLE JUDGMENT, CONTAIN A MATERIAL DEFECT DUE TO MATERIALS OR WORKMANSHIP.
Autoflow Operation 1004 E. Illinois St. Assumption, IL 62510 Phone 217-226-4421 Fax 217-226-4498 May 1998 THIS EQUIPMENT SHALL BE INSTALLED IN ACCORDANCE WITH THE CURRENT INSTALLATION CODES AND APPLICABLE REGULATIONS WHICH SHOULD BE CAREFULLY FOLLOWED IN ALL CASES. AUTHORITIES HAVING JURISDICTION SHOULD BE CONSULTED BEFORE INSTALLATIONS ARE MADE.
