Gsi Topdry 2000 series User manual

PNEG-1264

TopDry Wiring Diagrams

Installation Manual

PNEG-1264

Date: 10-22-15

2PNEG-1264 TopDry Wiring Diagrams

Table of Contents

PNEG-1264 TopDry Wiring Diagrams 3

Contents

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

Cautionary Symbols .............................................................................................................................. 5

Fan/Heater Installation and Operating Instructions ............................................................................... 6

Safety Precautions ................................................................................................................................ 6

Safety Sign-Off Sheet ........................................................................................................................... 8

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

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

Power Supply ...................................................................................................................................... 11

Transformer and Wiring Voltage Drop ................................................................................................ 11

Machine to Earth Grounding ............................................................................................................... 11

Proper Installation of Ground Rod ....................................................................................................... 11

Chapter 4 Series 2000 Master Fan/Heater Wiring (Domestic and CGA Models) ............................................12

Series 2000 Master Heater Board Input/Output .................................................................................. 12

Series 2000 Master 220V 1 PH and 220V 3 PH Internal Wiring ......................................................... 13

Series 2000 Master 460V 3 PH Internal Wiring .................................................................................. 14

Series 2000 Master External Wiring .................................................................................................... 16

Series 2000 Master Ignitor/Probe Wiring ............................................................................................ 17

Series 2000 Master 15 HP 220V 1 PH Capacitor Wiring (Baldor) ...................................................... 18

Chapter 5 Series 2000 Master Fan/Heater Wiring (European Models) ............................................................19

Series 2000 Master Heater Board Input/Output .................................................................................. 19

Series 2000 Master 380V 3 PH Internal Wiring .................................................................................. 20

Series 2000 Master 380V 3 PH External Wiring ................................................................................. 21

Series 2000 Master Ignitor/Probe Wiring ............................................................................................ 22

Chapter 6 Series 2000 Slave Fan/Heater Wiring (All Models) ..........................................................................24

Series 2000 Slave Heater Board Input/Output ................................................................................... 24

Series 2000 Slave Internal Wiring ....................................................................................................... 25

Series 2000 Slave External Wiring ...................................................................................................... 26

Series 2000 Slave Ignitor/Probe Wiring .............................................................................................. 27

Series 2000 Slave 15 HP 220V 1 PH Capacitor Wiring (Baldor) ........................................................ 28

Chapter 7 Series 2000 Batch Control Box Wiring .............................................................................................29

Series 2000 Batch Remote Display Wiring - Domestic and

CGA Units ........................................................................................................................................... 29

Series 2000 Batch Remote Display Wiring - European Units ............................................................. 30

Series 2000 Batch Economy Control Wiring - Domestic and

CGA Units ........................................................................................................................................... 31

Series 2000 Batch Economy Control Wiring - European Units ........................................................... 32

Series 2000 Autoflow Front Panel ....................................................................................................... 33

Chapter 8 Series 2000 Autoflow Control Box Wiring .......................................................................................34

Series 2000 Autoflow Input/Output Board Wiring ................................................................................ 34

Series 2000 Autoflow Terminal Strip Wiring ........................................................................................ 35

Series 2000 Autoflow Door Internal Wiring ......................................................................................... 36

Series 2000 Autoflow Door External Wiring ........................................................................................ 37

Series 2000 Autoflow Actuator ............................................................................................................ 38

Chapter 9 Series 2000 Autoflow Actuator Wiring .............................................................................................39

Series 2000 Autoflow Actuator Schematic .......................................................................................... 39

Series 2000 Autoflow Actuator Wiring ................................................................................................. 40

Series 2000 Autoflow Fill System Control Box .................................................................................... 41

Table of Contents

4PNEG-1264 TopDry Wiring Diagrams

Chapter 10 Series 2000 Autoflow Fill System Control Box Wiring ..................................................................42

0 Fill Systems, 1 Aeration Fan Internal Wiring .................................................................................. 42

0 Fill Systems, 1 Aeration Fan Door Wiring ....................................................................................... 43

1 Fill Systems, 0 Aeration Fan Internal Wiring .................................................................................. 44

1 Fill Systems, 0 Aeration Fan Door Wiring ....................................................................................... 45

1 Fill Systems, 1 Aeration Fan Internal Wiring .................................................................................. 46

1 Fill Systems, 1 Aeration Fan Door Wiring ....................................................................................... 47

2 Fill Systems, 0 Aeration Fan Internal Wiring .................................................................................. 48

2 Fill Systems, 0 Aeration Fan Door Wiring ....................................................................................... 49

2 Fill Systems, 1 Aeration Fan Internal Wiring .................................................................................. 50

2 Fill Systems, 1 Aeration Fan Door Wiring ....................................................................................... 51

Chapter 11 Warranty ............................................................................................................................................53

PNEG-1264 TopDry Wiring Diagrams 5

1. Safety

Cautionary Symbols

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.

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 indicates a potentially hazardous situation which,

if not avoided, may result in property damage.

This symbol indicates a general hazard.

This symbol indicates a prohibited activity.

This symbol indicates a mandatory action.

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.

WARNING! BE ALERT!

1. Safety

6PNEG-1264 TopDry Wiring Diagrams

Fan/Heater Installation and Operating Instructions

Thank you for choosing a TopDry Series 2000 unit. It is designed to give excellent performance and

service for many years.

This manual describes the wiring for all standard production TopDry Series 2000 single fan, multi-fan and

2000 Series Heater Control 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 which 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 tothe 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.UseCAUTIONin checkingvoltage

or other procedures requiring power to be ON.

3. Checkfor gasleaksat all gaspipeconnections.If any leaks are detected, 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 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 reinstall 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.

This product is intended for the use of grain handling only. Any other use is considered a misuse

of the product.

Some edges of the product components can be sharp. It is recommended that each component of

this product be examined to determine if there are any safety considerations to be taken. Any and

all necessary personal protective equipment should be worn at all times when handling,

assembling, installing and operation of the product and/or components.

Guards are removed for illustration purpose only. All guards must be in place

before/during operation.

1. Safety

PNEG-1264 TopDry Wiring Diagrams 7

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

hazards to personnel which can not be completely safeguarded against without interfering with the

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 drying system, 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 6 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

8PNEG-1264 TopDry Wiring Diagrams

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 auger. 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

PNEG-1264 TopDry Wiring Diagrams 9

2. Decals

Roof Damage Warning and Disclaimer

The manufacturer does not warrant any roof damage caused by excessive vacuum or internal

pressure from fansor other air moving systems. Adequate ventilationand/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

GSI Group, Inc. 217-226-4421

2. Decals

10 PNEG-1264 TopDry Wiring Diagrams

The GSI Group recommends contacting the 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-973 given

below 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: 1-217-226-4421

A free replacement will be sent to you.

DC-1225

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

DANGERDANGER

DC-1224

High voltage.

Will cause serious

injury or death.

Lockout power

before servicing.

Flame and pressure beyond

door. Do not operate with

service door removed. Keep

head and hands clear. Can

cause serious injury.

DC-1227

WARNING

GSI Group 217-226-4421

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

DANGERDANGER

GSI Group 217-226-4421

PNEG-1264 TopDry Wiring Diagrams 11

3. Electrical Power Supply

Power Supply

An adequate power supply and proper wiring are important factors for maximum performance and long

life of the dryer. Electrical service must be adequate enough to prevent low voltage damage to motors and

control circuits. (See electrical load information.)

Transformer and Wiring Voltage Drop

It is necessary to know the distance from the unit to the available transformer, and the horsepower

of the fan unit. Advise the service representative of the local power supplier that an additional load will be

placed on the line. Each fan motor should be wired through a fused or circuit breaker disconnect switch.

Check on KVA rating of transformers, considering total horsepower load. The power supply wiring, main

switch equipment and transformers must provide adequate motor starting and operating voltage. 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 Fire

Protection Association.)

Machine to Earth Grounding

It is very important that a Machine to Earth Ground Rod be installed at the fan. This is true even if there is

a ground at the pole 15 feet (15') away. Place the ground rod that comes standard, within 8 feet (8')

of the dryer and attach it to the dryer control panel with at least a #6 solid, bare copper ground wire and

the clamp provided. The grounding rod located at the power pole will not provide adequate grounding

for the dryer. The proper grounding will provide additional safety in case of any short and will ensure

long life of all circuit boards, and the ignition system. The ground rod must be in accordance with

local requirements.

Proper Installation of Ground Rod

It is not recommended that the rod be driven into

dry ground.

Follow these instructions for proper installation:

1. Dig a hole large enough to hold 1 to 2 gallons

of water.

2. Fill hole with water.

3. Insert rod through water and jab it into

the ground.

4. Continue jabbing the rod up and down. The

water will work its way down the hole, making

it possible to work the rod completely into the

ground. This method of installing the rod

gives a good conductive bond with the

surrounding soil.

5. Connect the bare copper ground wire to the

rod with the proper ground rod clamp.

(See Figure 3A.)

6. Connect the bare copper ground wire to the

fan control boxes with a grounding lug.

7. Ground wire must not have any breaks

or splices. Figure 3A

Dig a hole large enough to hold 1 or 2 gallons

of water. Work the ground rod into the earth

until it is completely in the ground.