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Table of Contents

PNEG-696 

TopDry Series 2000 Autoflow

3

Contents

Chapter 1  Safety .....................................................................................................................................................5

Cautionary Symbols Definitions  ............................................................................................................ 5
Fan/Heater Installation and Operating Instructions ............................................................................... 6
Safety Precautions  ................................................................................................................................ 7
Safety Sign-Off Sheet  ........................................................................................................................... 8

Chapter 2  Safety Decals  ........................................................................................................................................9

Chapter 3  Electrical Power Supply .....................................................................................................................11

Power Supply  ...................................................................................................................................... 11
Transformer and Wiring Voltage Drop  ................................................................................................ 11
Machine to Earth Grounding ............................................................................................................... 11

Chapter 4  Control Panel  ......................................................................................................................................12

Dryer Control Panel Featuring the Electronic Monitoring Control System  .......................................... 13
Moisture Control Switch  ...................................................................................................................... 13
Control Power Switch .......................................................................................................................... 13
Aeration Fan Switch  ............................................................................................................................ 13
Load Auger Switch  .............................................................................................................................. 13
Fan Switch  .......................................................................................................................................... 14
Heater Switch ...................................................................................................................................... 14
Dump Switch  ....................................................................................................................................... 14
Dry and Hold Switch ............................................................................................................................ 14
Dryer Power Start Switch  .................................................................................................................... 14
Dryer Power Stop Switch  .................................................................................................................... 14

Chapter 5  Control System ...................................................................................................................................15

Electronic Monitoring Control System  ................................................................................................. 15
Turning On the Electronic Monitoring Control System  ........................................................................ 15
Setting the Dry, Cool and Unload Timers ............................................................................................ 16
Setting the Delays  ............................................................................................................................... 16
Set-Up: Standard  ................................................................................................................................ 17
Set-Up: Extended ................................................................................................................................ 17
Plenum and Grain Temperature Settings, Screens Button Options .................................................... 19

Chapter 6  Fill System Control Box  .....................................................................................................................20

Fill System #1 ...................................................................................................................................... 21
Fill System #2 ...................................................................................................................................... 21
Aeration Fan ........................................................................................................................................ 21
Emergency Stop Switch  ...................................................................................................................... 21

Summary of Contents for TopDry Autoflow 2000 Series

Page 1: ...PNEG 696 TopDry Series 2000 Autoflow Operation Manual PNEG 696 Date 09 27 20 ...

Page 2: ...s 2000 Autoflow All information illustrations photos and specifications in this manual are based on the latest information available at the time of publication The right is reserved to make changes at any time without notice ...

Page 3: ...oring Control System 13 Moisture Control Switch 13 Control Power Switch 13 Aeration Fan Switch 13 Load Auger Switch 13 Fan Switch 14 Heater Switch 14 Dump Switch 14 Dry and Hold Switch 14 Dryer Power Start Switch 14 Dryer Power Stop Switch 14 Chapter 5 Control System 15 Electronic Monitoring Control System 15 Turning On the Electronic Monitoring Control System 15 Setting the Dry Cool and Unload Ti...

Page 4: ...t of Grain 23 Fill 1 Motor Overload 24 Fill 2 Motor Overload 24 Aeration Overload 24 Grain High Limit 24 Chapter 8 Pre Season Checks 25 Set Control Switches 25 Control Power Switch 25 Drying Chamber 25 Rotary Switches 25 Dump Chutes 25 Linear Actuator 26 Power Start Button 26 Fuel Check 26 Fan 26 Aeration Fan 26 Fill System 27 Air Switch 27 Burner Test Fire 27 Dryer Shut Down 27 Emergency 27 Chapt...

Page 5: ...ath This symbol indicates a potentially hazardous situation which if not avoided may result in serious injury or death This symbol indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury This symbol is used to address practices not related to personal injury This symbol indicates a general hazard This symbol indicates a prohibited activity This symbo...

Page 6: ...h this equipment We want to keep you as a customer This manual is to help you understand safe operating procedures and some problems that may be encountered by the operator and other personnel As owner and or operator it is your responsibility to know what requirements hazards and precautions exist and to inform all personnel associated with the equipment or in the area Safety precautions may be r...

Page 7: ... any propeller make certain to read the recommended procedure listed within the servicing section of the manual 10 Clean grain is easier to dry Fine material increases resistance to airflow and requires removal of extra moisture 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 b...

Page 8: ...erating 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 Date Employee Name Supervisor Name ...

Page 9: ...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 Running fans dur...

Page 10: ...erious injury DC 1227 WARNING GSI Group 217 226 4421 Stay clear of rotating blade Blade could start automatically Can cause serious injury Disconnect power before servicing DC 1225 GSI Group 217 226 4421 WARNING Automatic equipment can start at any time Do not enter until fuel is shut off and electrical power is locked in off position Failure to do so will result in serious injury or death DC 973 ...

Page 11: ...ltage Voltage drop during motor starting should not exceed 14 of normal voltage and after motor is running 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 practices and codes should be used Refer to National Electrical Code Standard Handbook by National ...

Page 12: ... Switch Timers Control Power Aeration Fan Load Auger Fan Heater OFF ON Auto Fan runs with drying fan OFF ON Auto OFF ON Auto Fan starts and runs automatically OFF ON Fan runs continuosly Low Fire High Fire Heater 1 Auto ON OFF Heater ON during batch dry cycle only Heater ON when fan running Low Fire High Fire Heater 2 Manual Close Manual Open Dump Auto System must be stopped to manually dump OFF O...

Page 13: ...nate make sure that the Emergency Stop switches located on the Autoflow control box and Fill System control box are pulled out Aeration Fan Switch This switch controls the operation of the aeration fan located at the bottom of the bin The switch illuminates when the aeration fan comes ON When placed in the AUTO position the aeration fan starts and stops with the main drying fans When placed in the...

Page 14: ...near actuator is moving When placed in the MANUAL CLOSE POSITION the linear actuator in the actuator control box retracts raising the dump chutes When placed in the AUTO position the linear actuator extends at the beginning of the dump cycle lowering the dump chutes and retracts at the end of the dump cycle raising the dump chutes When placed in the MANUAL OPEN position the linear actuator extends...

Page 15: ...arnings on its liquid crystal display LCD Figure 5A Electronic Monitoring Control System 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 Dry Cool Dump Enter Modify Timers Program Setup Delays Screens Help Plenum Grain Temps Hours Dumps Rese...

Page 16: ...elay The Refill Delay is used only on batch units It is the amount of time that the unit has to refill after the dump cycle If the unit does not refill before the time on the refill delay is at zero the unit will give a dry chamber empty error This delay is not shown in Autoflow mode High Level Switch Delay The value set on the High Level Switch delay is the amount of time that fill system runs af...

Page 17: ...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 Press the enter button when the correct month is displayed Set Year Use the increase and decrease buttons to select the correct year Press the enter button when the correct year is displ...

Page 18: ...fits your system The four 4 models are as follows 1 AF2 Autoflow with two 2 main drying fans 2 AF1 Autoflow with one main drying fan 3 AB2 Autobatch with two 2 main drying fans 4 AB1 Autobatch with one main drying fan Most systems will be either an Autoflow with one fan or an Autoflow with two 2 fans Press the enter button when the correct model number is displayed Select Temp Scale Use the increa...

Page 19: ...erature set point is set here Use the increase and decrease buttons to change the grain temperature set point Press the enter button when done Screens By pressing the screens button you can toggle between two 2 screens Screen 1 displays the current plenum and grain temperatures and their set points in parenthesis Screen 2 displays the status of the Drying Chamber Rotary switches and the total numb...

Page 20: ...l System Control Box Figure 6A Grain system inc Assumption IL 217 226 4421 WARNING Fill system and aeration fans will not run when switches are placed in the OFF position AUTO ON Fill System 1 OFF Fill System 2 Aeration fan AUTO ON OFF AUTO ON OFF ...

Page 21: ...ll System 2 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 If the switch is placed in the OFF position fill system 2 will not start and will stop if running If the dryer control power is ON fill system 2 can be activated by placing the switch in the ON position When placed in the ON position fill system 2 will ...

Page 22: ...r can be adjusted by bending it so it is immersed in flame If the burner is not lighting make sure that the dryer is getting fuel all solenoids are opening and the ignitor is sparking Fan 1 Vapor High Limit 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 running too ho...

Page 23: ... may need to be adjusted Fan 2 Loss of Airflow The contacts on the Air switch located in the slave fan opened due to the fan not turning or the Air switch may need to be adjusted 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 restar...

Page 24: ...ad in the fill system control box for fill system number two 2 has tripped indicating an overcurrent condition The overload must be reset manually Aeration Overload The thermal overload in the fill system control box for the aeration fan has tripped indicating an overcurrent condition The overload must be reset manually Grain High Limit The grain temperature in the drying chamber is too high The g...

Page 25: ...arge 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 in are good shape Rotary Switches View the Drying Chamber Rotary switches from the peak ...

Page 26: ...enty of fuel If using natural gas make sure an adequate supply is available If using LP gas slowly open the main fuel supply valve at the tank If using natural gas turn ON the valve along the supply line Then open the ball valve on the fan heater unit s Inspect all gas lines and connections for possible leaks Any gas leaks need to be fixed immediately Fan Make sure that all Toggle switches on the ...

Page 27: ...e the Heater switch on the Autoflow control box in the ON position Start the main drying fan s if they are not already running Make sure the fuel supply is ON The burner should ignite after a short purge delay Gas pressure should be shown on the gauge Adjust the high fire gas pressure by turning the regulator in and out on LP units or by opening and closing the main ball valve on natural gas units...

Page 28: ...he fan heater unit s will cycle to low fire When the plenum temperature falls 10 below the cycle set point the fan heater unit s will cycle back to high fire The fan heater units will continue to cycle throughout the drying process When grain reaches the Chamber High Level Rotary switch the fill 2 delay will begin to count down When the fill 2 delay reaches zero fill system 2 will shut off and the...

Page 29: ...e 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 If the Storage Chamber High Limit Ro...

Page 30: ...he drying rate Initial Dryer Start Up 1 Be sure the Control Power switch is OFF Turn ON the main power supply disconnect for the Autoflow control box fan and heaters and all fill systems 2 Pull out the Emergency Stop switches on the Autoflow control box fill systems control box and the actuator control box 3 Set the switches on the Autoflow control box as follows Moisture Control Switch ON Aeratio...

Page 31: ...rain temperature reaches the grain temperature set point the dryer should continue to the dump cycle 19 The dump chutes should lower grain should dump from the drying chamber into the storage chamber and the fill system s should start 20 After the dump cycle the dryer should continue to the beginning of the next dry cycle 21 After the fourth dump stop the dryer 22 Test the moisture of the dried gr...

Page 32: ...grain has been loaded into the drying chamber and turn OFF the Moisture Control switch 2 Set the time on the dry timer for twice the recommended amount using the following charts for the specific bin size fan and heater size drying temperature and grain input moisture content 3 Push the reset button 4 Turn the Dry and Hold switch to the ON position 5 Turn the Load Auger switch to the OFF position ...

Page 33: ...Million BTU 160 20 584 14 9 648 17 5 711 25 0 25 370 23 5 411 27 7 450 39 5 30 231 37 7 256 44 4 281 63 3 180 20 748 11 6 830 13 7 909 19 5 25 473 18 4 525 21 6 576 30 9 30 296 29 5 328 34 7 360 49 5 200 20 875 9 9 971 11 7 1065 16 7 25 554 15 7 615 18 5 674 26 4 30 346 25 2 384 29 6 421 42 2 30 HP 42 Fan 10 25 Million BTU 160 20 740 15 4 806 22 0 25 469 24 3 511 34 8 30 293 38 9 319 55 8 180 20 9...

Page 34: ...illion BTU 160 20 1154 15 4 1269 20 2 25 731 24 3 803 31 9 30 457 39 0 502 51 1 180 20 1477 12 0 1623 15 8 25 936 19 0 1028 24 9 30 584 30 4 642 39 9 200 20 1730 10 2 1901 13 4 25 1096 16 2 1204 21 3 30 684 26 0 752 34 1 30 HP 42 Fan 10 25 Million BTU 160 20 819 31 3 1452 17 6 25 519 49 4 920 27 8 30 324 79 1 574 44 6 180 20 1048 24 4 1858 13 8 25 664 38 6 1177 21 7 30 415 61 8 735 34 8 200 20 122...

Page 35: ... 8 14 9 16 5 17 5 18 1 25 0 25 9 4 23 5 10 4 27 7 11 4 39 5 30 5 9 37 7 6 5 44 4 7 1 63 3 82 20 19 0 11 6 21 1 13 7 23 1 19 5 25 12 0 18 4 13 3 21 6 14 6 30 9 30 7 5 29 5 8 3 34 7 9 1 49 5 93 20 22 2 9 9 24 7 11 7 27 1 16 7 25 14 1 15 7 15 6 18 5 17 1 26 4 30 8 8 25 2 9 8 29 6 10 7 42 2 22 37 kW 106 68 cm 2 5 Million kCal 71 20 18 8 15 4 20 5 22 0 25 11 9 24 3 13 0 34 8 30 7 4 38 9 8 1 55 8 82 20 ...

Page 36: ...29 3 15 4 32 2 20 2 25 18 6 24 3 20 4 31 9 30 11 6 39 0 12 8 51 1 82 20 37 5 12 0 41 2 15 8 25 23 8 19 0 26 1 24 9 30 17 8 30 4 16 3 39 9 93 20 43 9 10 2 48 3 13 4 25 27 8 16 2 30 6 21 3 30 17 4 26 19 1 34 1 22 37 kW 106 68 cm 2 5 Million kCal 71 20 20 8 31 3 36 9 17 6 25 13 2 49 4 23 4 27 8 30 8 2 79 1 14 6 44 6 82 20 26 6 24 4 47 2 13 8 25 16 9 38 6 29 9 21 7 30 10 5 61 8 18 7 34 8 93 20 31 2 20...

Page 37: ... DESIGN OF SUCH PRODUCTS The sole and exclusive remedy for any claimant is set forth in this Limited Warranty and shall not exceed the amount paid for the product purchased This Warranty only covers the value of the warranted parts and equipment and does not cover labor charges for removing or installing defective parts shipping charges with respect to such parts any applicable sales or other taxe...

Page 38: ... be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4421 Fax 1 217 226 4420 www gsiag com Copyright 2015 by The GSI Group LLC Printed in the USA CN 315236 GSI is a worldwide brand of AGCO Corporation ...

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