GSi PNEG-1894 User manual

PNEG-1894
TopDry Chute Controller
Installation Manual
PNEG-1894
Version: 5.1
Date: 09-27-20

2PNEG-1894 TopDry Chute Controller
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.

Table of Contents
PNEG-1894 TopDry Chute Controller 3
Contents
Chapter 1 Safety .....................................................................................................................................................4
Safety Guidelines .................................................................................................................................. 4
Cautionary Symbols Definitions ............................................................................................................. 5
Safety Cautions ..................................................................................................................................... 6
Safety Sign-Off Sheet ............................................................................................................................ 9
Chapter 2 Decals ..................................................................................................................................................10
Chapter 3 Controller Layout ...............................................................................................................................12
Chapter 4 Installation ..........................................................................................................................................13
Chute Controller Installation for TopDry System ................................................................................. 13
Locating the Chute Pulley Assembly ................................................................................................... 13
Attaching the Mounting Plate and Gussets to the Stiffener ................................................................. 15
Assembling the Chain Guard ............................................................................................................... 17
Installing the Housing Assembly .......................................................................................................... 18
Testing that the Sprocket Correctly Activates the Limit Switch ........................................................... 19
Connecting the Cable to the Turnbuckle ............................................................................................. 20
Leveling the Dump Chutes .................................................................................................................. 22
Chapter 5 Wiring and Schematic Diagrams ......................................................................................................23
Actuator Wiring Schematic .................................................................................................................. 23
TopDry Chute Control Panel Wiring Schematic .................................................................................. 24
Chapter 6 Warranty ..............................................................................................................................................25

4PNEG-1894 TopDry Chute Controller
1. Safety
Safety Guidelines
Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is
written to help you understand safe operating procedures and problems that can be encountered by the
operator and other personnel when using this equipment. Save these safety guidelines for future
reference.
As owner or operator, you are responsible for understanding the requirements, hazards, and precautions
that exist and to inform others as required. Unqualified persons must stay out of the work area at all times.
Alterations must not be made to the equipment. Alterations can produce dangerous situations resulting in
SERIOUS INJURY or DEATH.
This equipment must be installed in accordance with the current installation codes and applicable
regulations,whichmustbecarefully followed inall cases. Authoritieshavingjurisdiction mustbe consulted
before installations are made.
When necessary, you must consider the installation location relative to electrical, fuel and water utilities.
Personnel operating or working around equipment must read this manual. This manual must be delivered
with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the
equipment.
ST-0001-3

1. Safety
PNEG-1894 TopDry Chute Controller 5
Cautionary Symbols Definitions
Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential
safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we
use the symbols that are defined below.
NOTICE
DANGER
WARNING
CAUTION
This symbol indicates an imminently hazardous situation
which, if not avoided, will result in serious injury or death.
This symbol indicates a potentially hazardous situation
which, if not avoided, can result in serious injury or death.
This symbol indicates a potentially hazardous situation which,
if not avoided, can 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 symbol indicates a mandatory action.
ST-0005-2

1. Safety
6PNEG-1894 TopDry Chute Controller
Safety Cautions
Use Personal Protective Equipment
Eye
Protection
Hearing
Protection
Hand
Protection
Head
Protection
Respiratory
Protection Foot
Protection
Fall
Protection
• Use appropriate personal protective equipment:
• Wear clothing appropriate to the job.
• Remove all jewelry.
• Tie long hair up and back.
ST-0004-1
ST-0025-3
Follow Safety Instructions
• Warning: If the information in the manual is not followed exactly,
a fire or explosion can result, causing property damage, personal
injury or loss of life.
• Carefully read all safety messages in this manual and safety
signs on your machine. Keep signs in good condition. Replace
missing or damaged safety signs. Be sure new equipment
components and repair parts include the current safety signs.
Replacement safety signs are available from the manufacturer.
• Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
• If you do not understand any part of this manual or need
assistance, contact your dealer.
• Retain these instructions for future reference.

1. Safety
PNEG-1894 TopDry Chute Controller 7
ST-0075-1
Install and Operate Electrical Equipment Properly
• Electrical controls must be installed by a qualified electrician and
must meet the standards set by applicable local codes (National
Electrical Code for the US, Canadian Electric Code, or EN60204
along with applicable European Directives for Europe).
• Lock-out power source before making adjustments, cleaning, or
maintaining equipment.
• Make sure all equipment and bins are properly grounded.
Install and Operate Equipment Properly
• Make sure grain chutes are empty by performing a manual dump
before entering the bin.
• Before attempting to remove and reinstall the fan blade, contact GSI
for the recommended procedure.
ST-0031-2
Sharp Edge Hazard
• This product has sharp edges, which can cause serious injury.
• To avoid injury, handle sharp edges with caution and always use
proper protective clothing and equipment.
ST-0036-2
Maintain Equipment and Work Area
• Understand service procedures before doing work. Keep area
clean and dry.
• Never service equipment while it is operating. Keep hands, feet,
and clothing away from moving parts.
• Keep your equipment in proper working condition. Replace worn
or broken parts immediately.
ST-0003-1

1. Safety
8PNEG-1894 TopDry Chute Controller
ST-0055-1
Confined Space Hazards and Entry Procedures
• Note that the interior of this equipment is considered a confined
space. Maintenance of this equipment can require access to the
confined space.
• Access doors must be shut and locked except when access is
required.
• Doors giving access to dangerous equipment must be safety
interlocked.
• The following entry procedures must be followed:
— Be aware of all possible hazards present inside the
confined space and wear personal protective equipment (PPE)
as needed.
— Complete a permit to work and follow all permit required
confined space entry procedures defined by the site manager.
— Make sure that the area has been purged of any hazardous
products or gases. Check the atmosphere for harmful gases
or vapors with a suitable gas analyzer and make sure levels
are safe before entering.
— Do not smoke or use naked flames.
— Lock out and tag out power supplies and fuel supplies to
all equipment.
— Do not work alone. Work in teams of at least three so that help
is immediately available in the event of an emergency.
— Confirm that all personnel have safely exited the equipment
and tools have been recovered once work is complete.

1. Safety
PNEG-1894 TopDry Chute Controller 9
Safety Sign-Off Sheet
Below is a sign-off sheet that canbe used to verify that all personnel have read and understood the safety
instructions. This sign-off sheet is provided for your convenience and personal record keeping.
Date Employee Name Supervisor Name
ST-0007

10 PNEG-1894 TopDry Chute Controller
2. Decals
The safety decals on your equipment are safety indicators which must be carefully read and understood
by all personnel involved in the installation, operation, service and maintenance of the equipment.
To replace a damaged of missing decal, contact us to receive a free replacement.
GSI Decals
1004 E. Illinois St.
Assumption, IL. 62510
Phone: [phone]
Location Decal # Decals Description
Located next to
aeration system. DC-995 Caution, Vacuum
Pressure
On bin door
covers DC-GBC-1A Danger, Keep Clear of Augers
Excessive vacuum (or pressure) may
damage roof. Use positive aeration
system. Make sure all roof vents are
open and unobstructed. Start roof
fans when supply fans are started.
Do not operate when conditions exist
that may cause roof vent icing.
DC-969
CAUTION
GSI Group, Inc. 217-226-4421
Rotating flighting will
kill or dismember.
Flowing material will
trap and suffocate.
Crusted material will
collapse and suffocate.
DANGER
Keep clear of all augers.
DO NOT ENTER this bin!
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.
Failure to heed these
warnings will result in
serious injury or death.
DC-GBC-1A
GSI GROUP, INC. 217-226-4421

2. Decals
PNEG-1894 TopDry Chute Controller 11
On bin door
covers DC-GBC-2A Warning, Unload
Instructions
Outside and
inside enclosures
of chute control DC-1945 Warning, Moving
Parts
Outside control
box of chute
control DC-1948 Danger, High
Voltage
Location Decal # Decals Description
WARNING
GSI GROUP, INC. 217-226-4421
1. Use CENTER FLOOR OUTLET ONLY until NO grain
remains above this outlet.
2. Side floor outlets to be used ONLY when above
condition is satisfied.
3. Lock all side floor outlets to avoid accidental
premature use.
4. See manufacturers instructions for proper use of
factory supplied sidedraw (wall) discharge systems.
UNLOADING INSTRUCTIONS:
Failure to heed these warnings
could result in serious injury, death,
structural damage or collapse of tank.
DC-GBC-2A
Déplacer des pièces
peut écraser et couper.
Gardez les mains
éloignées. Ne pas faire
fonctionner sans avoir
de gardes en place.
L’omission de faire ceci
pourra résulter à de
sérieuses blessures.
Moving parts can crush
and cut. Keep hands
clear. Do not operate
without guards in place.
Failure to do so could
result in serious injury.
DC-1945
WARNING AVERTISSEMENT
GSI Group 217-226-4421
DANGER DANGER
8
4
91
-
C
D
Lockout power
before servicing.
Will cause serious
injury or death.
HIGH VOLTAGE
Couper/verrouiller le
courant avant l’entretien.
Causera de sérieuses
blessures ou la mort.
HAUTE TENSION
DC-1948GSI Group 217-226-4421

12 PNEG-1894 TopDry Chute Controller
3. Controller Layout
Figure 3A Chute Pulley Cable Location

PNEG-1894 TopDry Chute Controller 13
4. Installation
Chute Controller Installation for TopDry System
The chute controller is mounted to the side of a TopDry bin and actuates the chutes that allow the grain
to transfer from the drying floor to the bin floor.
NOTE: Before beginning the chute controller installation, make sure the pulley bracket is properly
installed. The pulley bracket must be position above the chute controller location before installing
the stiffener mounting plate.
Locating the Chute Pulley Assembly
1. Position the pulley in the hole that is located 9-3/8" (23.8 cm) horizontally from the center of the
stiffener. NOTE: When positioning the pulley, ensure the pulley cable does not interfere with the
dump chutes. This can only be accomplish at every other stiffener. (See Figure 4A below and
Figure 3A on Page 12.)
Figure 4A
Field drill five (5) 3/8" diameter holes as shown in Figure 4B. Attach the pulley assembly with
5/16" x 3/4" bolts with the neoprene on the inside of the bin. (See Figure 4B.)
Figure 4B

4. Installation
14 PNEG-1894 TopDry Chute Controller
Figure 4C

4. Installation
PNEG-1894 TopDry Chute Controller 15
Attaching the Mounting Plate and Gussets to the Stiffener
1. Position the bottom edge of the stiffener mounting plate 13" from the bottom of the stiffener.
2. Field drill all six (6) holes in the stiffener using the mounting plate as a template for hole locations,
making sure that the holes are drilled on the peaks of corrugation ridge.
3. Attach the stiffener mounting plate (A) using six (6) bolts (B) and nuts (C). (See Figure 4D.)
Figure 4D
Ref # Part # Description
ATD-101327 Stiffener Mounting Plate
B S-10275 Bolt, HHCS 3/8"-16 x 1-1/2" YDP Grade 8 or Grade 8.2
CS-7383 Nylock Nut 3/8"-16 Zinc Grade 5

4. Installation
16 PNEG-1894 TopDry Chute Controller
4. Attach the lower mounting gussets (D) to stiffener mounting plate (A) using three (3) flange bolts (E)
and nuts (F) for each mounting gusset. (See Figure 4E.)
Figure 4E
Ref # Part # Description
ATD-101327 Stiffener Mounting Plate
D TD-101326 Lower Mounting Gussets
ES-6606 Flange Bolt 5/16"-18 x 3/4" ZN Grade 5
F S-3611 Flange Nut 5/16"-18 YDP Grade 2

4. Installation
PNEG-1894 TopDry Chute Controller 17
Assembling the Chain Guard
1. Position the chute controller assembly so that all sides are accessible. Remove the cover from the
chute position controller enclosure.
2. Align the top and bottom tabs of the rear chain guard (B) with holes in the idler sprocket mounting
brackets (C) and attach by inserting flange bolts (D) through the sides and tightening with flange
nuts (E). (See Figure 4F.)
3. Feed chain (A) that is part of the chute position controller drive from the chute position controller
aroundthesmall sprocketandoutthroughthebackpanel andin betweentheidler sprocketmounting
brackets (C). (See Figure 4F.)
4. Replace cover and secure for lifting. (See Figure 4F.)
Figure 4F
Ref # Part # Description
ATD-101357 #40 Roller Chain
B TD-101336 Rear Chain Guard
CTD-101332 Idler Sprocket Mounting Bracket
D S-6606 Flange Bolt 5/16"-18 x 3/4" ZN Grade 5
ES-3611 Flange Nut 5/16"-18 YDP Grade 2
F TD-101521 Chute Controller Sprocket Bracket

4. Installation
18 PNEG-1894 TopDry Chute Controller
Installing the Housing Assembly
1. Lift the housing assembly onto the lower mounting gussets (A), aligning holes in the bottom
of the chute position controller enclosure with the holes in the lower mounting gussets.
2. Remove cover to attach chute position controller enclosure to gussets with six (6) flange bolts (B)
and flange nuts (C). (See Figure 4G.)
3. Field drill all four (4) holes in the bin sidewalls through the four (4) holes in the sidewall mounting
brackets (D), making sure that the holes are drilled on the peaks of the corrugation ridges. Use bolts
to attach housing to bin.
Figure 4G
Ref # Part # Description
ATD-101326 Lower Mounting Gussets
B S-6606 Flange Bolt 5/16"-18 x 3/4" ZN Grade 5
CS-3611 Flange Nut 5/16"-18 YDP Grade 2
D TD-101331 Sidewall Mounting Bracket
Chute position controller enclosure weighs approximately 275 lbs. pounds. Failure
to use proper equipment and personnel when lifting could cause bodily injury or
damage to equipment.
WARNING

4. Installation
PNEG-1894 TopDry Chute Controller 19
Testing that the Sprocket Correctly Activates the Limit Switch
1. Field drill two (2) holes in bottom of chute position controller electrical box (A) large enough to
accommodate cables for power and Autoflow controls. Refer to wiring diagrams on Pages 23 and 24
to feed conduit for wiring to the main power breaker and Autoflow controls. (See Figure 4H.)
2. After wiring and before attaching the chain to the cable, test that the sprocket travels from the open
limit switch position to the close limit switch position. To test sprocket travel:
NOTE: Forsystemto functionwhentesting travelwiththe coverremoved,the tamperswitch(B) must
be depressed.
a. Use tape to secure tamper switch in the depressed position.
b. Ensure the sprocket (C) is in the open position when beginning testing. Use the manual dump
chute switch located on the main control panel to move between the open and closed positions.
Set the sprocket travel to the closed position on the Autoflow control and observe the bolts in the
sprocket (C) travel from the open (clockwise) position to the closed (counterclockwise) position
to the limit switch (D) as shown in Figure 4H.
Figure 4H
Ref # Part # Description
ATD-101349 Chute Position Controller Electrical Box
B TD-101463 Tamper Switch
CTD-101351 Sprocket
D TD-101465 Limit Switch
Disconnect all power sources before attempting to connect wiring. All wiring
should be done by a certified electrician. Follow all national and local
electrical codes.
WARNING

4. Installation
20 PNEG-1894 TopDry Chute Controller
Connecting the Cable to the Turnbuckle
1. Run the cable from the inside of the bin through the sidewall sheet over the chute pulley on the bin
eave and down to the chain tunbuckle from the controller. (See Figure 4I.)
Figure 4I
Ref # Part # Description
ATD-101335 Front Chain Guard
B TD-101336 Rear Chain Guard