GSi TopDry User manual

PNEG-1894
TopDry Chute Controller
Installation Manual
PNEG-1894
Date: 08-26-15

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 for Bins ..................................................................................................................... 4
Cautionary Symbols Definitions ............................................................................................................ 5
Safety Cautions ..................................................................................................................................... 6
Safety Sign-Off Sheet ......................................................................................................................... 10
Chapter 2 Decals ..................................................................................................................................................11
Chapter 3 Controller Layout ...............................................................................................................................13
Chapter 4 Installation ..........................................................................................................................................14
Chute Controller Installation for TopDry System ................................................................................. 14
Locating the Chute Pulley Assembly ................................................................................................... 14
Attaching the Mounting Plate and Gussets to the Stiffener ................................................................. 16
Assembling the Chain Guard .............................................................................................................. 18
Installing the Housing Assembly ......................................................................................................... 19
Testing that the Sprocket Correctly Activates the Limit Switch ........................................................... 20
Connecting the Cable to the Turnbuckle ............................................................................................. 21
Leveling the Dump Chutes .................................................................................................................. 23
Chapter 5 Wiring and Schematic Diagrams ......................................................................................................24
Actuator Wiring Schematic .................................................................................................................. 24
TopDry Chute Control Panel Wiring Schematic .................................................................................. 25
Chapter 6 Warranty ..............................................................................................................................................27

4PNEG-1894 TopDry Chute Controller
1. Safety
Safety Guidelines for Bins
Safety guidelines 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, which should be carefully followed in all cases. Authorities having jurisdiction must be
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.
This product is intended for the use of grain storage only. Any other use is a misuse of the product.
Sidewall bundles or sheets must be stored in a safe manner. The safest method of storing sidewall
bundles is by laying them horizontally with the arch of the sheet upward, like a dome. Sidewall sheets
stored on edge must be secured so that they cannot fall over and cause injury. Use care when handling
and moving sidewall bundles.
This product has sharp edges, which may cause serious injury. To avoid injury,
handle sharp edges with caution and always use proper protective clothing and
equipment.
ST-0035

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, 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 symbol indicates a mandatory action.
ST-0005

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
Follow Safety Instructions
• Warning: If the information in the manual is not
followed exactly, a fire or explosion may 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.
ST-0025-1

1. Safety
PNEG-1894 TopDry Chute Controller 7
Maintain Equipment and Work Area
• Understand service procedures before doing work.
• Keep area clean and dry.
• Do not service equipment while it is operating. Disconnect and
lock-out power and fuel supply before entering equipment or before
performing maintenance.
• Keep your equipment in proper working condition. Replace worn or
broken parts immediately.
• Depressurize the fuel train before disassembling for service.
• Allow the fan to run for 20 minutes with the burner off to purge
products of combustion and to cool the components before entering.
• Ensure grain chutes are empty by performing a manual dump before
entering the bin.
• Check regularly for any developing gas plumbing leaks. Do not
operate the dryer if any gas leak is detected. Shut down and repair
before further operation.
• Before attempting to remove and reinstall the fan blade, contact GSI
for the recommended procedure.
ST-0031-1
For Your Safety
• If you smell gas:
— Do not try to light any appliance.
— Extinguish any open flames.
— Do not touch any electrical switch.
— Immediately call your gas supplier. Follow the gas supplier’s
instructions.
— If you cannot reach your gas supplier, call the fire department.
• The use and storage of gasoline and other flammable vapors and
liquids in open containers in the vicinity of this appliance is hazardous.
• Improper installation, adjustment, alteration, service or maintenance
can cause property damage, injury or death. Read the installation,
operating and maintenance instructions thoroughly before installing or
servicing this equipment. Installation and service must be performed
by a qualified installer, service agency or the gas supplier.
ST-0024-1

1. Safety
8PNEG-1894 TopDry Chute Controller
Install and Operate Electrical Equipment Properly
• Electrical controls should be installed by a qualified electrician and
must meet the standards set by the National Electric Code, Canadian
Electrical Code and all local and state codes.
• Disconnect and lock out all power sources before installing wires and
cables or servicing equipment.
ST-0027-1
Handle and Use Equipment Properly
• Equipment is intended for the use of grain drying only. Any other use is
a misuse of this equipment.
• The operating instructions in this manual pertain to the common cereal
grains as indicated. When drying any other grain, contact GSI for
additional recommendations.
• On LP fired units, set pressure regulator to avoid excessive gas
ressure applied to the burner during ignition and operation. Do not
exceed maximum recommended drying temperatures.
• Equipment has sharp edges that may cause serious injury. To avoid
injury, handle sharp edges with caution and use proper protective
clothing and equipment at all times.
• All guards must be in place before and during operation. Images of
guards removed in this manual are for illustration purposes only.
• Use caution when working around high-speed fans, gas burners,
augers and auxiliary conveyors which can start automatically.
• Keep hands, feet, and clothing away from moving parts.
• Do not bypass any safety device or interlock.
• Do not enter the dryer or bin while it is operating.
• Do not operate in an area where combustible material will be drawn
into the dryer.
ST-0029-1

1. Safety
PNEG-1894 TopDry Chute Controller 9
Exercise Caution When Drying Flammable Grains
• Be aware that some grains are highly flammable including but not
limited to rapeseed, canola, linseed, sunflower and milo.
• All grain and seed must be whole (minimal cracking or crushing), clean
and dust free before drying.
• Avoid dust and chaff from being drawn into the fan and heater.
• To reduce risk of fire, keep the fan, heater, drying plenum and ducts
clean at all times.
• In the event of a fire (or suspected fire):
1. Shut down the entire dryer.
2. Turn off the fuel at the tank or supply valve.
3. Shut off and lock electrical power.
4. Evacuate the area.
5. Call the fire department.
ST-0032-1

1. Safety
10 PNEG-1894 TopDry Chute Controller
Safety Sign-Off Sheet
Below is a sign-off sheet thatcan be 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

PNEG-1894 TopDry Chute Controller 11
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
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

2. Decals
12 PNEG-1894 TopDry Chute Controller
On bin door
covers DC-GBC-1A Danger Keep Clear of Augers
On bin door
covers DC-GBC-2A Warning Unload
Instructions
Location Decal # Decals Description
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
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

PNEG-1894 TopDry Chute Controller 13
3. Controller Layout
Figure 3A Chute Pulley Cable Location

14 PNEG-1894 TopDry Chute Controller
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 13.)
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
PNEG-1894 TopDry Chute Controller 15
Figure 4C

4. Installation
16 PNEG-1894 TopDry Chute Controller
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
PNEG-1894 TopDry Chute Controller 17
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
18 PNEG-1894 TopDry Chute Controller
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
aroundthesmallsprocket and outthroughtheback panel andinbetween theidlersprocketmounting
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

4. Installation
PNEG-1894 TopDry Chute Controller 19
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
20 PNEG-1894 TopDry Chute Controller
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 24 and 25
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: Forsystem to functionwhentesting travel withthecover removed,thetamperswitch (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