Series 2000 Autoflow Fan/Heater and Control Installation Instructions Installation Manual PNEG-900 Date: 02-07-13 PNEG-900
This equipment shall be installed in accordance with the current INSTALLATION CODES FOR GAS BURNING APPLICANCES AND EQUIPMENT, CAN1_B149.1 and B149.2 or applicable provincial regulations which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.
Table of Contents Contents Chapter 1 Safety .....................................................................................................................................................4 Safety Guidelines .................................................................................................................................. 4 Series 2000 Autoflow Installation and Operating Instructions ............................................................... 5 Safety Precautions ...................
1. Safety Safety Guidelines This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections.
1. Safety Series 2000 Autoflow Installation and Operating Instructions Thank you for choosing a Top Dry Series 2000 Autoflow unit. It is designed to give excellent performance and service for many years. This manual describes the installation for all standard production Top Dry Series 2000 single fan, multi-fan and 2000 Series Autoflow units. Different models are available for liquid propane or natural gas fuel supply, with either 1 phase 230 volt or 3 phase 208, 220, 380, 460 or 575 volt electrical power.
1. Safety Use Caution in the Operation of this Equipment This dryer is designed and manufactured with operator safety in mind. However, the very nature of a grain dryer having a gas burner, high voltage electrical equipment and high speed rotating parts, presents hazards to personnel which cannot be completely safeguarded against without interfering with the efficient operation of the dryer and reasonable access to its components.
1. Safety Safety Sign-Off Sheet As a requirement of O.S.H.A., it is necessary for the employer to train the employee in the safe operating and safety procedures for this equipment. This sign-off sheet is provided for your convenience and personal record keeping. All unqualified persons are to stay out of the work area at all times. It is strongly recommended that another qualified person who knows the shut down procedure be in the area in the event of an emergency.
2. Decals The GSI recommends contacting your local power company and having a representative survey the installation so the wiring is compatible with their system and adequate power is supplied to the 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.
2. Decals Rotating flighting will kill or dismember. Flowing material will trap and suffocate. Crusted material will collapse and suffocate. Keep clear of all augers. DO NOT ENTER this bin! HIGH VOLTAGE. Will cause serious injury or death. Lockout power before servicing. If you must enter the bin: 1. Shut off and lock out all power. 2. Use a safety harness and safety line. 3. Station another person outside the bin. 4. Avoid the center of the bin. 5. Wear proper breathing equipment or respirator.
3. Installation Fan/Heater Mounting NOTE: Do not install this control panel near any transformers or any other device that will produce an electro magnetic field. 1. Inspect the fan platform for proper installation per instructions in the Top Dry erection manual. 2. Raise the Top Dry fan/heater units to the platform. Use the Table below to determine the height of the platform from the base of the Top Dry unit. 3. Mount the Top Dry fan/heater units to the bin entrance sheets.
3. Installation 1. The Autoflow control box should be mounted at eye-level. Make sure to mount the Autoflow control box so that the fan/heater unit(s) are in view. 2. Keep in mind that wire will be used to interconnect the Autoflow control box with the fan/heater unit(s), fill system control box, actuator and all rotary switches. 3. Use the hole pattern in Figure 3C on Page 12 to drill holes for mounting the Autoflow control box.
3. Installation Series 2000 Autoflow Control Box Bolt Pattern Figure 3C Illustration of the bolt pattern for the autoflow control box.
3. Installation Control Box Mounting Fill System Control Box Mounting 1. The fill system control box should be mounted at eye-level. Make sure to install the fill system control box so that the fill system(s) and aeration fan are in view. 2.
3. Installation Fill System Control Box Bolt Pattern Figure 3E Illustration of the bolt pattern for the fill system control box.
3. Installation Actuator Control Box Mounting 1. Mark the third sidewall ring from the ground to indicate the cable path if dump chutes and cable are already installed. 2. Make sure that all dump chutes and chains are EVENLY adjusted so that when one chute is level the others are level as well. 3.
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3. Installation Multi-Grain Temperature Sensor 1. Remove the two (2) wires attached to the grain temperature sensor connected to terminal #22 and terminal #23 in the fan control box. 2. Mount the four (4) grain temperature sensor brackets evenly around the drying chamber on outside leveling band posts. (See Figure 3I on Page 18.) 3. Mount the brackets with bin bolts so that the sensor is 8-1/2" above the floor sheet rib for Auto drying mode and 10-1/2" above the floor sheet rib for Batch drying mode.
3. Installation Grain Temperature Sensor Mounted to Leveling Band Post Figure 3I Illustration of grain temperature sensor mounted on outside leveling band post.
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3. Installation Plenum Temperature Sensor The plenum temperature sensor is the small grey PVC junction box attached by a cord to the fan/heater control box on the master fan/heater unit. 1. On either side of the fan/heater, drill one 3/4" hole even with the fan/heater unit in a valley on the bin sidewall. 2. Insert the probe through the 3/4" hole. 3. Position the housing so the cord exits the housing horizontally and the tabs fall on the sidewall peaks. 4.
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3. Installation Top Dry Plenum High-Limit Installation 1. Assemble two (2) pieces of conduit together with coupler. 2. Mount conduit clamps to conduit assembly. 3. Locate conduit assembly on the bottom of a rafter at least 2' to one side of the fan entrance. Do not install between 2 fan entrances. 4. Mark bin wall where conduit will pass through and drill a hole just large enough to allow the conduit to pass through. Seal hole with caulking when complete. 5.
3. Installation Wet Supply Rotary Switch 1. Drill a 2" diameter hole through the hopper bottom. If a flat bottom bin is being used for a wet storage tank the Wet Supply Rotary switch would be mounted 45° up the sidewall from the center of the bin. Example: If the wet storage bin is 18' in diameter then the Wet Supply Rotary switch would be mounted 9' up the sidewall. 2. If the bin is 2.66" corrugation, the hole should be centered on an outside hill. 3. If the bin is 4.
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3. Installation Storage Chamber High-Limit Rotary Switch Installation 1. Drill a 2" diameter hole through the sidewall 3' below the fan/heater. 2. If the bin is 2.66" corrugation, the hole should be centered on an outside hill. 3. If the bin is 4.00" corrugation, the hole should be centered on an outside valley. 4. Use the mounting plate as a pattern and drill four (4) 3/8" holes through the sidewall at the switch location so the plate can be bolted to the bin. 5.
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3. Installation Drying Chamber Rotary Switches Mounted in Bin Roof The three (3) Drying Chamber rotary switches are used by the Series 2000 Autoflow to monitor the location of grain in the drying chamber. The rotary switch with the shortest shaft extension is the Drying Chamber Overflow Rotary switch. It is used as a safety in the event the Chamber High-Level Rotary switch fails. The rotary switch with the longest extension is the Drying Chamber Low-Level Rotary switch.
3. Installation Drying Chamber Low-Level Rotary Switch Installation 1. Drill a 2" diameter hole through the roof panel at the location shown in Figure 3R. See component placement on Page 11 for proper placement in relation to fill auger. 2. Use the mounting plate as a pattern and drill four (4) 3/8" holes through the roof panel at the switch location so the plate can be bolted to the roof. 3. Attach the flex coupling to the rotary switch power pack using a roll pin. 4.
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3. Installation Drying Chamber High-Level Rotary Switch Installation 1. Drill a 2" diameter hole through the roof panel at the location shown in Figure 3R on Page 28. See component placement on Page 11 for proper placement in relation to fill auger. 2. Assemble 1/4" shaft to rotary switch with 1/4" coupler and rolled pins. 3. Screw 1-1/4" pipe coupler to bottom of rotary switch. 4. Insert 1-1/4" pipe through adjustable roof mount weldment.
3. Installation Drying Chamber Overflow Rotary Switch Installation 1. Drill a 2" diameter hole through the roof panel at the location shown in Figure 3R on Page 28. See component placement on Page 11 for proper placement in relation to fill auger. 2. Use the mounting plate as a pattern and drill four (4) 3/8" holes through the roof panel at the switch location so the plate can be bolted to the roof. 3. Attach the flex coupling to the rotary switch power pack using a roll pin. 4.
3. Installation Liquid Propane (LP) Top Dry dryers have internal vaporizers and are designed to operate on liquid draw from the supply tank. Avoid using propane supply tanks that have been used for vapor draw for long periods of time. When using liquid draw systems, any moisture that may be present in tanks or lines may freeze when the system is used in cold weather. To avoid this situation, purge the system with methanol.
3. Installation Natural Gas (NG) This dryer is designed to operate on natural gas. Natural gas units have a larger orifice to accommodate lower pressures sometimes found with natural gas and do not have vaporizer coils like liquid propane units. A regulated pressure of 10 PSI minimum, 30 PSI maximum must be provided at the field connection point on the fan/heater unit, with gas available in sufficient volume to maintain the operating pressure.
4. Electrical Power Supply Conduit Runs Control Wires Run #1 Autoflow control box to master fan/heater control box. Five (5) - Control wires 16 gauge minimum. (NOTE: A shielded two (2) conductor 16 gauge cable should be used for the network connections.) Run #2 Autoflow control box to actuator control box. Five (5) - Control wires 16 gauge minimum. Run #3 Autoflow control box to wet supply rotary switch. Four (4) - Control wires 16 gauge minimum.
4. Electrical Power Supply Grounding All control boxes should be properly grounded with a ground lug mounted in each control box. Power Supply An adequate power supply and proper wiring are important factors to achieve 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 on Page 39.
4. Electrical Power Supply Proper Installation of Ground Rod The ground rod should not be driven into dry ground. Follow these instructions for proper installation: 1. Dig a hole large enough to hold 1 to 2 gallons of water. 2. Fill hole with water. 3. Insert rod through water and jab it into the ground. 4. Continue jabbing the rod up and down. The water will work its way down the hole, making it possible to work the rod completely into the ground.
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4. Electrical Power Supply Power/Motor Wiring The Figure 4C details the configuration for correct main power installation. Use the diagram in conjunction with the electrical load information and wire size information provided. The diagram details the correct main power installation for 220V 1 PH, 230V 3 PH, 460V 3 PH, 575V 3 PH and 380V 3 PH 50 Hz power supplies.
4. Electrical Power Supply Electrical Load Information The Chart below provide information for the electrician wiring the grain dryer and are a reference guide for parts. It is recommended that you contact your local power company and have a representatives survey the installation to see that the wiring is compatible with their system and that adequate power is supplied to the unit. NOTE: The only thing connected to the recommended service amps should be the grain dryer.
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4. Electrical Power Supply Autoflow to Master Fan/Heater Unit Interconnect The master fan/heater unit is the only fan and heater in a single fan unit. In two (2) fan units it is the fan/heater with the air switch, plenum temperature sensor and grain temperature sensor connected to it. DO NOT run the control wires for the master fan/heater in the same conduit as the power wires for the fan motor. To wire the master fan/heater unit to the Autoflow control box do the following.
4. Electrical Power Supply Autoflow to Actuator Interconnect The actuator control box houses the 24V DC linear actuator, two (2) 12V DC batteries and a 24V DC battery charger. The linear actuator raises and lowers the dump chutes to unload grain automatically from the drying chamber to the storage chamber. The two (2) 12V DC batteries act as a back-up to prevent wet grain from dumping into the storage chamber during a power outage. The 24V DC battery charger provides a continuous recharge to the batteries.
4. Electrical Power Supply Autoflow to Wet Supply Rotary Switch Interconnect The 110V AC rotary switch located in the wet storage tank is used to inform the computer on the availability of wet grain. The Wet Supply Rotary switch use 110V AC to power the motor and 12V DC+ to switch a signal back to the computer. To wire the Wet Supply Rotary switch to the Autoflow control box do the following: 1. Run four (4) control wires from the Autoflow control box to the Wet Supply Rotary switch. 2.
4. Electrical Power Supply Autoflow to Storage Chamber Rotary Switch Interconnect The 110V AC rotary switch located in the storage tank is used to inform the computer on the availability of wet grain. The Storage Chamber Rotary switch is mounted 3' below the fan/heater unit(s). The Storage Chamber Rotary switch use 110V AC to power the motor and 12V DC+ to switch a signal back to the computer. To wire the storage chamber rotary switch to the Autoflow control box do the following: 1.
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4. Electrical Power Supply Autoflow to Fill System Control Box Interconnect The fill system control box houses the starter(s) for the fill system(s) that load grain into the Top Dry Autoflow unit and for the aeration fan. DO NOT run the control wires for the fill system control box in the same conduit used for the power wires for the fill system and aeration fan motors. To wire the fill system control to the Autoflow control box do the following. 1.
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4. Electrical Power Supply Master to Slave Interconnect A slave fan/heater unit can be added to operate in unison with the master fan/heater unit. The interconnect between the master and slave fan/heater units remains the same regardless of the type or presence of a control center. To wire a slave fan/heater unit to a master fan/heater unit do the following: NOTE: Do NOT use solid wire for interconnection. 1. Run four (4) 16 gauge MTW type wires from the master fan/heater unit to the slave fan/heater unit.
4. Electrical Power Supply Slave to Slave Interconnect A second slave fan/heater unit can be added to operate in unison with the master fan/heater unit and another slave fan/heater unit. This would create a three (3) fan unit. The interconnect between the first slave fan/heater unit and the second slave fan/heater unit remains the same regardless of the type or presence of a control center.
4. Electrical Power Supply Battery Hook-Up Two (2) lawn and garden type 12V DC batteries are required for proper operation of the actuator control box. The two (2) 12V DC batteries are wired in series to provide the 24V DC linear actuator with the voltage required to operate. The two (2) 12V DC batteries should be mounted on the shelves provided in the actuator control box. To wire the two (2) 12V DC batteries to the 24V DC battery charger do the following: 1.
4. Electrical Power Supply 6. The linear actuator should extend down 16". 7. Place the Dump switch in the “AUTO” position and press the Stop switch. 8. The linear actuator should retract and stop. 9. Place the Control Power switch in the “OFF” position and push the Emergency Stop switch in on the Autoflow and actuator control boxes. 10. Route the cable as shown in Figure 4O. 11. Make sure that all dump chutes are approximately 5° below level when in the closed position. 12.
NOTES 52 PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions
5. Warranty GSI Group, LLC 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.
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. GSI Group 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.gsiag.
