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GSi PNEG-728 Operation Download Page 8

Autoflow Operation

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SAFETY SIGN-OFF SHEET

Summary of Contents for PNEG-728

Page 1: ...1 Autoflow Operation 1 Autoflow Operation PNEG 728 ...

Page 2: ...Autoflow Operation 2 This page was left blank intentionally ...

Page 3: ...er Supply 8 Electronic Monitoring Control System 9 Dryer Control Panel 10 Set Up Standard 14 Set Up Extended 15 Fill System Control Box 18 Error Messages 20 Pre Season Checks 24 Top Dry Autoflow Theory of Operation 27 Start Up Procedure 29 TopDry Autoflow Drying Rates for Shelled Corn 32 TopDry Batch Drying Rates for Shelled Corn 33 Warranty 34 ...

Page 4: ...RING HIGH HUMIDITY COLD WEATHER CONDITIONS CAN CAUSE AIR EXHAUST OR INTAKE PORTS TO FREEZE Thank you for choosing a Top Dry Series Autoflow It is designed to give excellent performance and ser vice for many years This manual describes the installation for all standard production Top Dry single fan multi fan and Heater Control units Different models are avail able for liquid propane or natural gas ...

Page 5: ...ead and understood by all people in the grain handling area The ro tating blade fire warning decals and voltage danger decal must be displayed on the fan can The bot tom right decal should be present on the inside bin door cover of the two ring door 24 porthole door cover and the roof manway cover If a decal is damaged or is missing contact The GSI Group Inc 1004 E Illinois St Assumption IL 62510 ...

Page 6: ...Autoflow Operation 6 DECAL PLACEMENT ...

Page 7: ...t is recommended that each component of this product be examined to determine if there areanysafetyconsiderationstobetaken Anyandallnecessarypersonal protectiveequipmentshouldbewornatalltimeswhenhandling assem bling installing and operation of the product and or components Guards are removed for illustration purpose only All guards must be in place before during operation Use Caution in the Operat...

Page 8: ...______________________________________________________________________________________ _____________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________ ____________________________________________________________________________...

Page 9: ...e drop during motor starting should not ex ceed 14 of normal voltage and after motor is running Transformer and Wiring Voltage Drop ELECTRICAL POWER SUPPLY Dave any ideas what to put here if anything at full speed it should be within 8 of normal voltage Check Electrical Load Information for HP ratings and maximum amp loads to properly size wire and fusing elements Standard electrical safety practi...

Page 10: ...Autoflow Operation 10 CONTROL SYSTEM Electronic Monitoring Control System ...

Page 11: ...does not light up Control Power Switch The power to the Electronic Monitoring Control System is turned on or off with the control power CONTROL SYSTEM switch The switch lights up when placed in the on position If the switch is placed in the on position and the light does not light up make sure that the emergency stop switches located on the Autoflow control box is pulled out 24 Volt Power Switch T...

Page 12: ...hamber 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 drying fan s will not run When placed in the on position the main drying fan s come on and stay on when the dryer is running Dryer Control Panel continued Dump Switch This switch controls the operation of the linear actuator housed in the actuator c...

Page 13: ...13 Autoflow Operation CONTROL PANEL ...

Page 14: ...Autoflow Operation 14 CONTROL SYSTEM Electronic Monitoring Control System ...

Page 15: ...the drying chamber low level rotary switch the drying cycle starts if the fan switch is placed in the auto or on position and the aux 1 timer begins to time down If grain falls away from the drying chamber low level rotary switch before the time on the aux 1 timer reaches zero no error is given and the dryer continues in the drying cycle If grain falls away from the drying chamber low level rotary...

Page 16: ... time the dryer calls for grain The aux 1 delay is set using the same procedure as the dry and unload timers but the reset button does not need to be pressed to enter the new values into memory immediately Setting the Unload Delay The value set on the unload delay is the amount of time that both fill system number one and fill system number two run after grain falls away from the wet supply rotary...

Page 17: ...an s should be started with the drying chamber low level rotary switch If the drying chamber high level rotary switch is se lected to control the starting of the main drying fan s the dry cycle and main drying fan s will not start until grain reaches the drying chamber high level rotary switch Again this mode of operation is not recommended 3 The third variable to set is the dryer model Use the in...

Page 18: ...uttons to select the high flame delay Press the enter button when the correct high flame delay is displayed 12 The twelfth variable is the status of the wet grain and drying chamber low level rotary switches By pressing the dry timer switch the user can directly enter the shutdown history retrieval By pressing the unload timer switch the status of these two rotary switches can be altered Use the i...

Page 19: ...19 Autoflow Operation CONTROL SYSTEM ...

Page 20: ...Autoflow Operation 20 CONTROL SYSTEM ...

Page 21: ...21 Autoflow Operation CONTROL SYSTEM ...

Page 22: ...Autoflow Operation 22 CONTROL SYSTEM ...

Page 23: ...drying chamber during the dump cycle and once the drying process starts it does not stop until the dryer is stopped This is the standard mode of operation Grain High Level YES When the display on the dryer control panel reads grain high level yes the grain in the Grain High Level NO When the display on the dryer control panel reads grain high level no the grain in the drying chamber has not reache...

Page 24: ... is sparking Electrically there is a loss of 12vDC on J1 10 on the input output board Burner 1 Vapor High Temperature The LP gas vapor temperature sensor located on the gas pipe train downstream from the vaporizer coil on fan and heater number one has opened indicating that the vaporizer coil is run ning too hot and must be adjusted This sensor is set at 200 degrees Fahrenheit and automatically th...

Page 25: ...e is a loss of 12vDC on J5 6 or J5 10 on the input output board 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 Electrically there is a loss of 12vDC on J4 12 on the input output board Fan 2 Motor Overload The thermal overload in the control box on fan number two has tripped indicatin...

Page 26: ...level rotary switch If the enter button is pushed the dryer will restart but the fill system s will not restart Electrically there is a loss of 12vDC on J4 2 and the presence of 12vDC on J4 8 on the input output board Out of Grain Warning This message is displayed after the dump cycle when the dryer has been restarted by pressing the enter button after a wet supply empty error has been given Canno...

Page 27: ...tches are located on the front panel of the Autoflow fan and heater control box Fan This switch allows the user to turn off the drying fan while at the fan and heater unit It the Autoflow is running and the fan is running the fan will stop when the fan service switch is placed in the off position but the dryer will continue running as though the fan was on If the burner is running when the fan ser...

Page 28: ...Autoflow Operation 28 FILL SYSTEM CONTROL BOX ...

Page 29: ...tion Fan These start and stop switches are used to start and stop the aeration fan manually In order to use the start and stop switches for the aeration fan the control power switch on the Autoflow control box must be placed in the on position and the dryer must be stopped When the start switch for the aeration fan is pushed the aeration fan is pushed the aeration fan starts and will not shut off ...

Page 30: ... All discharge flow plates should be adjusted evenly around the bin Inspect each discharge flow plate and make sure that the bottom brackets on each flow plate have not collapsed due to pressure from walking around the drying chamber Inspect the leveling bands Make sure that all leveling bands are installed properly and are in good shape Rotary Switches View the drying chamber switches from the pe...

Page 31: ... observe the fan rotation The fan should run counterclockwise Sometimes on three phase models the motor will run backwards This can easily be reversed by first turning off the power at the main disconnect then interchanging any two of the three power supply wires coming into the motor starter in the fan control box Reverse the two outside wires L1 and L3 and leave the middle one in the same positi...

Page 32: ...gulator in and out on LP units or by open ing and closing the main ball valve on natural gas units The high fire pressure should be approxi mately 6 15 lbs for LP units and 6 10 lbs for natural gas units At this time adjust the Hi Lo thermostat all the way to the right Watch the thermometers When the temperature in dryer gets to the desired setpoint 160 180 turn the knob back to the left until the...

Page 33: ...ermostat the fan heater unit s will cycle to Low Fire When the Plenum Temperature falls ten degrees below the Cycle Setpoint the fan heater unit s will cycle back to High Fire The fan heater unit s will continue to cycle throughout the drying When grain reaches the Chamber High Level Rotary Switch the Load Delay will begin to count down When the Load Delay reaches zero Fill System 2 will shut off ...

Page 34: ...on of the next Dump Cycle after which an out of Grain error is displayed on the Dryer Control Panel and the dryer stops If the Storage Chamber High Limit Rotary Switch becomes covered with grain during the Dump Cycle the dryer will continue through the Dump Cycle and will continue to the next Dry Cycle When the Dry Cycle is complete the unit will not continue to the Dump Cycle A Storage Chamber Fu...

Page 35: ...o and the Grain Temperature Setpoint on the Moisture Control Thermostat has not been reached the unit will go into Temperature Hold When the grain temperature reaches the Grain Temperature Setpoint on the Moisture Control Thermostat the unit will continue to the Cool Cycle In the Cool Cycle the burner will shut off the Cool Timer will begin to count down and the main drying fans will continue to r...

Page 36: ... charger The actuator control box is mounted to the bin sidewall Aeration Fan The aeration fan is located at the bottom on the outside of the bin and is used to cool grain in the storage chamber The aeration fan is designed to deliver about 1 4 cubic feet of air per minute per bushel of grain in the storage chamber The motor starter for the aeration fan is located in the Fill System Control Box Ae...

Page 37: ...n in the drying chamber before dumping it into the storage chamber On Autobatch units it controls how long to dry the grain before cooling it in the cool cycle Dryer Control Panel The dryer control panel is located on the Autoflow Control Box It con tains the start and stop switches and the selector switches for the dryer The dryer control panel also contains the screen where the dyer status and e...

Page 38: ... Fill system 2 is not required for proper operation of the Autoflow unit however the computer must be TERMINOLOGY instructed on the number of fill systems the unit has This is done in the set up mode detailed later The motor starter for fill system 2 is located in the Fill System Control Box Fill System Control Box The fill system control box houses the motor starters for the fill system s and the...

Page 39: ...ated in the drying chamber to sense the grain temperature The grain tempera ture setpoint is set on the moisture control thermo stat Out of Grain Timer The value set on the out of grain timer is the amount of time that grain has to reach the drying chamber low level rotary switch when the dryer is refilling after the dump cycle in an Autobatch system When the dump cycle is complete the out of grai...

Page 40: ...d dried A wet storage tank can be a hopper tank or a flat bottom bin Wet Supply Rotary Switch The wet supply rotary switch is located in the wet storage tank The wet supply rotary switch warn the computer when the wet storage tank is empty Start Up Procedure At the beginning of each harvest and before filling the dryer will grain make sure to inspect the dryer for rodent damage and system integrit...

Page 41: ...etpoint 150 drying temperature 108 grain temperature setpoint 140 drying temperature 110 grain temperature setpoint 130 drying temperature 113 grain temperature setpoint 120 drying temperature 115 grain temperature setpoint When drying at a temperature lower than 150 the grain temperature setpoint on the moisture control thermostat may require a lower setting at night 11 Press the reset button for...

Page 42: ...ow decrease the grain temperature setpoint on the moisture control thermostat five de grees for each additional point of moisture to be added 30 After the moisture control thermostat is adjusted decrease the time on the dry timer by one half The dry timer should not be set lower than the amount of time it takes the dryer to refill after the dump cycle 31 Restart the dryer The time on the dry timer...

Page 43: ...0 25 347 18 4 404 21 5 428 26 6 439 32 8 715 20 1 BTU HR 30 217 29 5 253 34 5 267 42 6 274 52 6 446 32 3 20 642 9 9 748 11 6 791 14 4 811 17 7 1 321 10 9 3 hp 18 200 25 406 15 7 474 18 4 501 22 7 514 28 0 837 17 2 Inline Centrifugal 30 254 25 2 296 29 5 313 36 4 321 44 9 523 27 6 20 584 14 9 648 17 5 682 21 1 160 25 370 23 5 411 27 7 432 33 4 10 16 H P 30 231 37 7 256 44 4 270 53 5 42 FAN 20 748 1...

Page 44: ...4 3 803 31 9 10 16 H P 30 281 63 3 457 39 0 502 51 1 42 FAN 20 909 19 5 1 477 12 0 1 623 15 8 5 75 MILLION 180 25 576 30 9 936 19 0 1 028 24 9 BTU HR 30 360 49 5 584 30 4 642 39 9 20 1 065 16 7 1 730 10 2 1 901 13 4 5 7 hp 24 200 25 674 26 4 1 096 16 2 1 204 21 3 Inline Centrifugal 30 421 42 2 684 26 752 34 1 20 753 23 6 1 355 18 9 160 25 477 37 3 858 29 8 20 H P 30 298 59 8 536 47 8 42 FAN 20 963...

Page 45: ...he following directives EMC Directive 89 336 EEC Amended 92 31 and 93 68 Low Voltage Directive 73 23 EEC Machine Directive 89 392 EEC ____________________ ______________ Printed Name Date The person signing the document must have sufficient authority to ensure that the provisions required for the Declaration of Conformity are carried out The EMC Test Report and any other supporting documentation m...

Page 46: ...Y PROBLEMS MODIFICATIONS TO THE PRODUCT NOT SPECIFICALLY COVERED BY THE CONTENTS OF THIS MANUAL WILL NULLIFY ANY PRODUCT WARRANTY THAT MIGHT HAVE BEEN OTHERWISE AVAILABLE THE FOREGOING WARRANTY SHALL NOT COVER PRODUCTS OR PARTS WHICH HAVE BEEN DAMAGED BY NEGLIGENT USE MISUSE ALTERATION OR ACCIDENT THIS WARRANTY COVERS ONLY PRODUCTS MANUFACTURED BY GSI THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL ...

Page 47: ...26 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 ...

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