GSi Autoflow 2000 Series User manual

2000 Autoflow
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Series 2000 Autoflow
Fan/Heater and Control
Installation Instructions
Installation
Manual
PNEG-900
PNEG-900

2000 Autoflow
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This equipment shall be installed in accordance iwth the current INSTALLATIONCODESFOR
GASBURNINGAPPLICANCESANDEQUIPMENT,CAN1_B149.1andB149.2,or applicable
provincial regulations which should be carefully followed in all cases. Authorities having
jurisdiction shuld be consulted before installations are made.

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RoofWarning,Operation & Safety................................................................................4
SafetyAlertDecals.......................................................................................................5
SafetyPrecautions........................................................................................................6
SafetySign-off Sheet...................................................................................................7
an/HeaterandControlBoxMounting..............................................................................8
AutoflowControlBoxBoltPattern.................................................................................10
Fill System Control Box Mounting.............................................................................11
FillSystem Control Bolt Pattern..................................................................................12
Actuator Control Box Mounting.................................................................................13
Multi-GrainTemperatureSensorWiring.........................................................................15
GrainTemperatureSensor Mounted to LevelingBand Post........................................16
Close-upofGrainTemperatureSensorWiring.............................................................17
PlenumTemperatureSensorInstallation..........................................................................18
Airswitch Installation.................................................................................................19
WetSupplyRotary Switch..........................................................................................21
Storage Chamber High Limit Rotary Switch Installation...........................................22
DryingChamber Rotary Switches...............................................................................25
Drying Chamber Low-Level Rotary Switch Installation............................................26
Drying Chamber High-Level Rotary Switch Installation...........................................28
DryingChamber Overflow Switch Installation.............................................................30
LPFuelSpecificationsandRecommendations................................................................32
NGFuelSpecificationsandRecommendations...............................................................33
cuit Runs................................................................................................................34
ElectricalPowerSupply...................................................................................................35
Ground Rod.....................................................................................................36
MotorWiring........................................................................................................37
MainPowerSchematic.................................................................................................37
ElectricalLoadInformation.............................................................................................38
Wire Size Information................................................................................................39
Fill System Control Box Electrical Load Information.................................................40
AutoflowtoMaster Fan/Heater Unit Interconnect...........................................................42
Autoflow to Actuator Interconnect.............................................................................43
Autoflow to Wet Supply Rotary Switch Interconnect.................................................44
Autoflow to Storage Chamber Rotary Switch Interconnect.......................................45
AutoflowtoDrying Chamber Rotary Switches Interconnect..........................................46
Autoflow to Fill System Control Box Interconnect....................................................48
Autoflow to Ground Interconnect............................................................................ 49
Masterto Slave Interconnect......................................................................................50
SlavetoSlave Interconnect.........................................................................................51
BatteryHookUp.........................................................................................................52
DumpChute Cable Installation...................................................................................53
Wrranty.......................................................................................................................55
TABLE OF CONTENTS

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Roof Damage Warning and Disclaimer
WARNING! BE ALERT!
Personnel operating or working
around electric fans 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.
The symbol shown is used to call your
attentionto instructionsconcerning your
personal safety. Watch for this sym-
bol; it points out important safety pre-
cautions. It means "ATTENTION",
"WARNING", "CAUTION", and
"DANGER". Read the message and
be cautious to the possibility of per-
sonal injury or death.
Safety Alert Symbol
GSI DOES NOT WARRANT ANY ROOF DAMAGE
CAUSEDBY EXCESSIVE VACUUM OR INTERNAL
PRESSURE FROM FANS OR OTHER AIR MOVING
SYSTEMS. ADEQUATE VENTILATION AND/OR
"MAKEUPAIR"DEVICESSHOULDBEPROVIDED
FOR ALL POWERED AIR HANDLING SYSTEMS.
GSIDOESNOTRECOMMENDTHEUSEOFDOWN-
WARD FLOW SYSTEMS (SUCTION). SEVERE
ROOF DAMAGE CAN RESULT FROM ANY
BLOCKAGE OF AIR PASSAGES. RUNNING FANS
DURINGHIGH HUMIDITY/COLD WEATHERCON-
DITIONS CAN CAUSE AIR EXHAUST OR INTAKE
PORTS TOFREEZE.
Thank you for choosing a Top Dry Series 2000
Autoflow unit. It is designed to give excellent per-
formance and service for many years.
Thismanualdescribes theinstallationfor all stan-
dard production Top Dry Series 2000 single fan,
multi-fan and 2000 Series Autoflow units. Differ-
ent models are available for liquid propane or natu-
ral gas fuel supply, with either single phase 230 volt,
or three phase 208, 220, 380, 460 or 575 volt electri-
cal power.
The principal concern of the GSI Group, Inc.
("GSI") is your safety and the safety of others asso-
Series 2000 Autoflow Installation & Operating Instructions
ROOF WARNING, OPERATION & SAFETY
As owner and/or operator, it is your responsibil-
ity to know what requirements, hazards and precau-
tions exist, and to inform all personnel associated
withthe equipment, or who are in the fan area. Avoid
any alterations to the equipment. Such alterations
may produce a very dangerous situation, where se-
rious injury or death may occur.
ciated with grain handling equipment. This manual
is written to help you understand safe operating pro-
cedures, and some of the problems that may be en-
countered by the operator or other
personnel.

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The GSI Group, Inc. recom-
mends contacting your local
power company, and having a
representativesurvey your instal-
lation so the wiring is compatible
with their system, and adequate
power is supplied to your unit.
Safety decals should be read
and understood by all people in
the grain handling area. The ro-
tating blade, fire warning decals
and voltage danger decal must be
displayedon thefan 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
217-226-4421
A free replacement will be sent to
you.
SAFETY

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1. Read and understand the operating manual before trying to operate the
dryer.
2. Power supply should be OFF for service of electrical components. Use
CAUTION in checking voltage or other procedures requiring power to
be ON.
3. Check for gas leaks at all gas pipe connections. If any leaks are de-
tected, do not operate the dryer. 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 maxi-
mum 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 START AUTOMATICALLY.
8. Donotoperateinanyareawherecombustiblematerialwillbedrawninto
the fan.
9. Beforeattempting to remove and reinstall any propellor,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 sharp edges! 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 purposes only. All guards must be
in place before and during operation.
Use Caution in the
Operation of this
Equipment
The design and manufacture of this
dryer is directed toward operator
safety. However, the very nature
of a grain dryer having a gas burner,
highvoltageelectrical equipment and
high speed rotating parts, does
present a hazard to personnel, which
can not be completely safeguarded
against, without interfering with ef-
ficient operation and reasonable ac-
cess to components.
Use extreme caution in working
around high speed fans, gas-fired
heaters,augers and auxiliary convey-
ors, which may start without warn-
ing when the dryer is operating on
automatic control.
READTHESEINSTRUCTIONS
BEFOREOPERATIONAND SERVICE
SAVEFORFUTUREREFERENCE
Continued safe, dependable opera-
tion of automatic equipment de-
pends, to a great degree, upon the
owner. For a safe and dependable
dryingsystem,follow the recommen-
dationswithin thismanual, and make
it a practice to regularly inspect the
operation of the unit for any devel-
opingproblems orunsafe conditions.
Take special note of the safety pre-
cautionslisted above before attempt-
ing to operate the dryer.
KEEP THE DRYER CLEAN
DO NOT ALLOW FINE
MATERIAL TO ACCUMULATE
IN THE PLENUM CHAMBER
OR SURROUNDING THE OUT-
SIDE OF THE DRYER
SAFETY PRECAUTIONS

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Date Employer’ s Signature Employee
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SAFETY SIGN-OFF SHEET
Employees working on or around grain drying equipment
must read this manual and sign-off on this sheet.

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Fan and Heater Mounting
1. Inspect the fan platform for properinstallation
per instructions in the Top Dry erection manual.
2. Raise the Top Dry fan and heater units to the
plat form. Use the table to the right to deter-
mine the height of the platform from the base of the
TopDry unit.
3. Mount the Top Dry fan and heater units to the
bin entrance sheets. Fan legs should set on the
plat form.
Top Dry Bin Eave Height
Number
of Rings
5
6
7
8
9
10
11
Eave
Height
18’-5”
22’-1”
25’-9”
29’-5”
33’-1”
36’-9”
40’-5”
Autoflow Control Box Mounting
1. The Autoflow Control Box should be
mounted at eye-level. Make sure to mount
the Autoflow control box so that the fan
and heater unit(s) are in view.
Autoflow Control box mounted on bin.
2. Keep in mind that wire will be used to inter
connect the Autoflow control Box with the
INSTALLATION
fan and heater unit(s), Fill System Control
Box, Actuator and all rotary switches.
3. Use the hole pattern in Figure 1 to drill holes
for mounting the Autoflow Control Box.
Note:Do not installthis control panelnear any
Transfomers orany otherdevice thatwill
produceanElectro MagneticField.

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Component Placement
INSTALLATION

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Series 2000 Autoflow Control Box Bolt Pattern
Figure 1: Illustration of the bolt pattern for the Autoflow control box.
INSTALLATION

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1) TheFillSystem
control Box should be
mountedateye-level.
Makesure to install
theFillSystem
Control Box so that
theFillSystem(s)and
Aerationfanarein
view.
2) Keep in mindthat
wirewill be used to
interconnecttheFill
SystemControl Box
withtheAutoflow
ControlBox;and,
thatpowerwireswill
havetoberunfrom
theentrancepanelto
theFill System
controlBoxto power
theFill Systemand
Aerationfanmotors,
whichwillalsorun
fromtheFillSystem
ControlBox.
3) Use the pattern in
Figure2todrill
holes for the Fill
SystemControl Box.
Fill System Control Box Mounting
CONTROL BOX MOUNTING
Fill System Control ox Mounted to in

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CONTROL BOX MOUNTING
Fill System Control Box Mounting
Figure 2: Fill System Control ox olt Pattern

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CONTROL BOX MOUNTING
Actuator Control Box Mounting
1) Markthethird sidewall
ringfromthegroundto
indicatethe cablepathif
dumpchutesand cable are
already installed.
2) Make sure that all dump
chutesandchainsare
EVENLYadjusted so that
whenonechuteislevel
the others are level as
well.
3) Keep in mindthatwire
will be used to
interconnecttheActuator
ControlBoxwiththe
AutoflowControlBox;
and, that a 110V power
supply willneedtorun
from the entrance panel to
theActuator Control Box
to power the 24V DC
battery charger.
4) Use the pattern inFigure
3todrill holesfor the
ActuatorControl Box.
5) Ifthehorizontalseam
boltsarewithin1”
horizontallyofthehole
pattern shown, existing
holesmay be used to
attachtheactuator.
6) Use four 5/16”x 1.1/4”
bin bolts and washers
withboltheadstothe
inside of the bin.
7) Do not attachthe dump chutecable to theactuator at
this time. The cable should not be installed until after
the actuator unit is completely wired and tested.
Actuator Control ox Mounted to in

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CONTROL BOX MOUNTING
Actuator Control Box Mounting
Figure 3: Bolt pattern to drill holes for the Actuator Control
Box

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Multi-Grain Temperature Sensor
1. Remove the two wires attached to the grain tem-
perature sensor connected to terminal #22 and
terminal #23 in the fan control box.
2. Mount the four grain temperature sensor brack-
ets evenly around the drying chamber on out
side leveling band posts (figure 5).
3. With bin bolts mount the bracket so the sensor is
10.1/2” above the floor sheet rib.
on all temperature sensor brackets to exit the dry
ing chamber at the same place.
6. Run the cords into the junction box after the junc
tion box has been mounted to the bin.
7. Wire the four temperature sensors as shown be
low and on page 17.
INSTALLATION
band post, and across the top leveling band.
5. Take the cords through the space between the roof
andthe top sidewall sheet.There should be enough
4. Wire tie the cords so they feed up the leveling
Figure 4: Illustration of the Grain Temperture Sensor Interconnection

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INSTALLATION
Figure 5: Illustration of grain temperature sensor mounted on outside le eling
band post.
Grain Temperature Sensor Mounted to Leveling Band Post

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INSTALLATION
Close-Up Detail of Grain Temperture Sensor Wiring

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Plenum Temperature Sensor
The plenum temperature sensor is
the small grey PVC junction box at-
tached by a cord to the fan/heater
control box on the master fan/heater
unit.
1. On either side of the fan/heater,
drillone 3/4” hole even withthe
fan/heaterunit in a valley on the
binsidewall.
2. Insert the probe through the
3/4” hole.
3. Position the housing so the cord
exitsthe housing horizontally,
and the tabs fall on the sidewall
peaks.
4. Use two self drilling screws to
mount the housing to the bin
sidewall.
5. Caulk between the housing and
the sidewall to seal.
Important!
If the Top Dry is a two fan unit,
do not mount the plenum tem-
perature sensor between the two
fan/heater units.
Plenum temperature sensor on the bin sidewall.
INSTALLATION

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Plenum hi-limit installation
INSTALLATION

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INSTALLATION
TOPDRYPLENUMHILIMITINSTALLATION
1. Assemble two pieces of conduit together with coupler.
2. Mount conduit clamps to conduit assembly.
3. Locate conduit assembly on the bottom of a rafter at least 2 feet to one side of the fan entrance. Do not install
between two fan entrances.
4. Mark bin wall where conduit will pass through and drill a hole just large enough to allow the conduit to pass
through. Seal this with caulking when complete.
5. Install white PVC box assembly on outside of bin wall.
6. Insert 10’ capillary into conduit assembly.
7. Connect SJO cord to hi limit and connect wires to terminals 20 and 21 on the master fan terminal strip. These
terminals are J7-08, and J7-03.