GSi 2000 Series User manual

PNEG-900
Series 2000 Autoflow
Fan/Heater and Control
Installation Instructions
Installation Manual
PNEG-900
Date: 07-29-11

2PNEG-900Series 2000 Autoflow Fan/Heater and Control Installation Instructions
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
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 3
Contents
Chapter 1 Safety .....................................................................................................................................................4
Safety Guidelines .................................................................................................................................. 4
Series 2000 Autoflow Installation and Operating Instructions ............................................................... 5
Safety Precautions ................................................................................................................................ 5
Safety Sign-Off Sheet ........................................................................................................................... 7
Chapter 2 Decals ....................................................................................................................................................8
Chapter 3 Installation ..........................................................................................................................................10
Fan/Heater Mounting .......................................................................................................................... 10
Autoflow Control Box Mounting ........................................................................................................... 10
Series 2000 Autoflow Control Box Bolt Pattern ................................................................................... 12
Control Box Mounting .......................................................................................................................... 13
Fill System Control Box Bolt Pattern ................................................................................................... 14
Multi-Grain Temperature Sensor ......................................................................................................... 17
Grain Temperature Sensor Mounted to Leveling Band Post .............................................................. 18
Close-Up Detail of Grain Temperature Sensor Wiring ........................................................................ 19
Plenum Temperature Sensor .............................................................................................................. 20
Plenum High-Limit Installation ............................................................................................................. 21
Top Dry Plenum High-Limit Installation ............................................................................................... 22
Wet Supply Rotary Switch ................................................................................................................... 23
Storage Chamber High-Limit Rotary Switch Installation ..................................................................... 25
Drying Chamber Rotary Switches Mounted in Bin Roof ..................................................................... 27
Drying Chamber Low-Level Rotary Switch Installation ....................................................................... 28
Drying Chamber High-Level Rotary Switch Installation ...................................................................... 30
Drying Chamber Overflow Rotary Switch Installation ......................................................................... 31
Liquid Propane (LP) ............................................................................................................................ 32
Natural Gas (NG) ................................................................................................................................ 33
Chapter 4 Electrical Power Supply .....................................................................................................................34
Conduit Runs ...................................................................................................................................... 34
Grounding ........................................................................................................................................... 35
Power Supply ...................................................................................................................................... 35
Transformer and Wiring Voltage Drop ................................................................................................ 35
Machine to Earth Grounding ............................................................................................................... 35
Proper Installation of Ground Rod ....................................................................................................... 36
Power/Motor Wiring ............................................................................................................................. 38
Electrical Load Information .................................................................................................................. 39
Autoflow to Master Fan/Heater Unit Interconnect ............................................................................... 41
Autoflow to Actuator Interconnect ....................................................................................................... 42
Autoflow to Wet Supply Rotary Switch Interconnect ........................................................................... 43
Autoflow to Storage Chamber Rotary Switch Interconnect ................................................................. 44
Autoflow to Drying Chamber Rotary Switches Interconnect ............................................................... 44
Autoflow to Fill System Control Box Interconnect ............................................................................... 46
Autoflow to Ground Interconnect ......................................................................................................... 47
Master to Slave Interconnect .............................................................................................................. 48
Slave to Slave Interconnect ................................................................................................................ 49
Battery Hook-Up .................................................................................................................................. 50
Dump Chute Cable Installation ........................................................................................................... 50
Chapter 5 Warranty ..............................................................................................................................................53

4PNEG-900Series 2000 Autoflow Fan/Heater and Control Installation Instructions
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. Failure to read this manual and its
safety instructions is a misuse of the equipment and may lead to serious injury or death.
DANGER
WARNING
CAUTION
NOTICE
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a
hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE is used to address practices not related to
personal injury.
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Personnel operating or working around equipment should read this manual. This
manual must be delivered with the equipment to its owner. Failure to read this manual
and its safety instructions is a misuse of the equipment.
WARNING! BE ALERT!

1. Safety
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 5
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.
Our foremost concern is your safety and the safety of others associated with 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
required from the personnel. Avoid any alterations to the equipment. Such alterations may produce a very
dangerous situation where SERIOUS INJURY or DEATH may occur.
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.
Safety Precautions
READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE
SAVE FOR FUTURE REFERENCE
1. Read and understand the operating manual before trying to operate the dryer.
2. PowersupplyshouldbeOFFforserviceofelectricalcomponents.UseCAUTIONincheckingvoltage
or other procedures requiring power to be ON.
3. Checkfor gas leaksat all gaspipeconnections.If anyleaksare detected, DO NOT operate thedryer.
Shut down and repair before further operation.
4. NEVER attempt to operate the dryer by jumping or otherwise bypassing any safety devices
on the unit.
5. Set pressure regulator to avoid excessive gas pressure applied to burner during ignition and when
burner is in operation. DO NOT exceed maximum recommended drying temperature.
6. Keep the dryer clean. DO NOT allow fine material to accumulate in the plenum or drying chamber.
7. Use CAUTION in working around high speed fans, gas burners, augers and auxiliary conveyors
which can START AUTOMATICALLY.
8. DO NOT operate in any area where combustible material will be drawn into the fan.
9. BEFORE attempting to remove and re-install 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.
Proper Use of Product
This product is intended for the use of drying small grains only. Any other use is a misuse of the product.
This product has sharpedges. These sharp edges may cause serious injury. To avoid injury handle sharp
edges with caution and use proper protective clothing and equipment at all times.
Guards are removed for illustration purposesonly. All guards must be in place before and during operation.

1. Safety
6PNEG-900Series 2000 Autoflow Fan/Heater and Control Installation Instructions
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
hazardstopersonnelwhich cannot be completelysafeguardedagainstwithout interfering withthe efficient
operation of the dryer and reasonable access to its components.
Use extreme caution in working around high speed fans, gas-fired heaters, augers and auxiliary
conveyors, which may start without warning when the dryer is operating on automatic control.
Continued safe, dependable operation of automatic equipment depends, to a great degree, upon
the owner. For a safe and dependable dryingsystem, follow the recommendations within this manual and
make it a practice to regularly inspect the unit for any developing problems or unsafe conditions.
Take special note of the Safety Precautions on Page 5 before attempting to operate the dryer.
CAUTION
Keep the dryer clean. Do not allow fine material to accumulate in the plenum
chamber or surrounding the outside of the dryer.

1. Safety
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 7
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.
Date Employee Name Supervisor Name

8PNEG-900Series 2000 Autoflow Fan/Heater and Control Installation Instructions
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. The decal DC-GBC-1A
shown on Page 9 should be present on the inside bin door cover of the 2 ring door, 24" porthole door cover
and the roof manway cover.
If a decal is damaged or is missing contact:
GSI Decals
1004 E. Illinois St.
Assumption, IL. 62510
Phone: [phone]
A free replacement will be sent to you.
Roof Damage Warning and Disclaimer
The manufacturer does not warrant any roof damage caused by excessive vacuum or internal
pressure from fans orotherairmovingsystems. Adequate ventilation and/or “makeup air” devices
should be provided for all powered air handling systems. The manufacturer does not recommend
the use of downward flow systems (suction). Severe roof damage can result from any blockage of
air passages. Running fans during high humidity/cold weather conditions can cause air exhaust
or intake ports to freeze.
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!

2. Decals
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 9
HIGH VOLTAGE.
Will cause serious
injury or death.
Lockout power
before servicing.
DC-1224
DC-1227
Flame and pressure beyond
door can cause serious
injury. Do not operate with
service door removed. Keep
head and hands clear.
WARNING
Stay clear of rotating
blade. Blade could start
automatically. Can cause
serious injury. Disconnect
power before servicing.
DC-1225
WARNING
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!
Failure to heed these
warnings will result in
serious injury or death.
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.
DC-GBC-1A
DC-1225
DC-1227
DC-GBC-1A
DC-1224

10 PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions
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. Fan legs should set on the platform.
Top Dry Bin Eave Height
Autoflow Control Box Mounting
Figure 3A Autoflow Control Box Mounted on Bin
# of Rings Eave Height
518'-5"
622'-1"
725'-9"
829'-5"
933'-1"
10 36'-9"
11 40'-5"

3. Installation
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 11
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. KeepinmindthatwirewillbeusedtointerconnecttheAutoflowcontrolboxwiththefan/heaterunit(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.
Figure 3B Component Placement

3. Installation
12 PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions
Series 2000 Autoflow Control Box Bolt Pattern
Figure 3C Illustration of the bolt pattern for the autoflow control box.

3. Installation
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 13
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. Keep in mind thatwire will be usedto interconnect thefill system controlbox with the Autoflow control
box; and, that power wires will have to be run from the entrance panel to the fill system control box
to power the fill system and aeration fan motors, which will also run from the fill system control box.
3. Use the pattern in Figure 3E on Page 14 to drill holes for the fill system control box.
Figure 3D Fill System Control Box Mounted to Bin

3. Installation
14 PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions
Fill System Control Box Bolt Pattern
Figure 3E Illustration of the bolt pattern for the fill system control box.

3. Installation
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 15
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. Keep in mind that wire will be used to interconnect the actuator control box with the Autoflow control
box; and, that a 110V power supply will need to run from the entrance panel to the actuator control
box to power the 24V DC battery charger.
4. Use the pattern in Figure 3G on Page 16 to drill holes for the actuator control box.
5. If the horizontal seam bolts are within 1" horizontally of the hole pattern shown, existing holes may
be used to attach the actuator.
6. Use four (4) 5/16" x 1-1/4" bin bolts and washers with bolt heads to the inside of the bin.
7. Do not attach the dump chute cable to the actuator at this time. The cable should not be installed until
after the actuator unit is completely wired and tested.
Figure 3F Actuator Control Box Mounted to Bin

3. Installation
16 PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions
Actuator Control Box Mounting (Continued)
Figure 3G Bolt Pattern to Drill Holes for the Actuator Control Box

3. Installation
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 17
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 3J on Page 18.)
3. Mount the brackets with bin bolts so that the sensor is 10-1/2" above the floor sheet rib.
4. Wire tie the cords so they feed up the leveling band post and across the top leveling band.
5. Route the cords through the space between the roof and the top sidewall sheet. There should be
enough on all temperature sensor brackets to exit the drying chamber at the same place.
6. Route the cords into the junction box after the junction box has been mounted to the bin.
7. Wire the four (4) temperature sensors as shown in Figure 3H and on Page 19.
Figure 3H Illustration of the grain temperature sensor interconnection.

3. Installation
18 PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions
Grain Temperature Sensor Mounted to Leveling Band Post
Figure 3I
Figure 3J Illustration of grain temperature sensor mounted on outside leveling band post.

3. Installation
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 19
Close-Up Detail of Grain Temperature Sensor Wiring
Figure 3K

3. Installation
20 PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions
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. Use two (2) self-drilling screws to mount the housing to the bin sidewall.
5. Caulk between the housing and the sidewall to seal the gaps.
IMPORTANT: If the top dry is a 2 fan unit, do not mount the plenum temperature sensor between the
2 fan/heater units.
Figure 3L Plenum Temperature Sensor on the Bin Sidewall