GSi TopDry Autoflow 36 FT DIAMETER Instructions for use

TopDry™ Autoflow – 36 Ft
Models:
36 FT DIAMETER
Construction Manual
PNEG–4936
Version 2.3
Date: 08-31-16
PNEG–4936

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.
2PNEG–4936 TopDry Autoflow

Contents
Chapter 1 Safety Precautions ....................................................................................................................7
Safety Guidelines........................................................................................................................7
Cautionary Symbol Definitions......................................................................................................8
Safety Cautions...........................................................................................................................9
Safety Decals ...........................................................................................................................17
Safety Sign-off Sheet.................................................................................................................20
Chapter 2 General Overview....................................................................................................................21
General Information...................................................................................................................21
Tools Required for Construction..................................................................................................21
Guidelines for Proper Storage of Grain Bin Materials Prior to Construction.....................................22
Guidelines for Construction Procedures and Lifting Jack Usage....................................................22
Location of TopDry Components and Accessories .......................................................................24
Chapter 3 Foundation..............................................................................................................................27
Foundation Guidelines...............................................................................................................27
Selecting the Proper Site Location..............................................................................................27
Scribe the Diameter...................................................................................................................27
Preparing the Foundation Forms ................................................................................................28
Foundation Forms .....................................................................................................................29
Placing the Reinforcement .........................................................................................................29
Anchor Bolt Detail .....................................................................................................................30
Anchor Bolt Chart......................................................................................................................31
Inline Centrifugal Fan Pad Guidelines .........................................................................................32
Duct and Drying Fan Pad ...........................................................................................................33
Frost Free Foundation Guidelines...............................................................................................34
Chapter 4 Hardware Requirements..........................................................................................................35
Bolt and Nut Pairings.................................................................................................................35
Hardware for 2–Post Sidewall Sheets on 4 in. Corrugation Bins ....................................................36
Bolt Torque Specifications..........................................................................................................36
Identifying Bolt Grades ..............................................................................................................37
Color Chart for Bin Hardware Bucket Lids ...................................................................................38
Bolt Identification.......................................................................................................................38
Bolt S-10260.............................................................................................................................38
Bolt S-7483...............................................................................................................................39
Bolt S-7485...............................................................................................................................39
Bolt S-7487...............................................................................................................................40
Chapter 5 Assembling Sidewall Sheets ...................................................................................................41
Orientation Detail for Top Sidewall Sheets ................................................................................... 41
Sidewall Gauge Sheet ...............................................................................................................42
Color Codes for Sidewall Gauge Identification .............................................................................42
Caulking and Bolting Detail for Standard Sidewall Sheets.............................................................43
Guidelines for Constructing Sidewall Sheets ...............................................................................45
Chapter 6 Stiffeners.................................................................................................................................47
Stiffener Starting Location..........................................................................................................48
Color Codes for Stiffener Gauge Identification .............................................................................49
Top Stiffeners............................................................................................................................49
Standard Stiffeners....................................................................................................................50
Stiffener Splice..........................................................................................................................51
Base Stiffeners .........................................................................................................................52
Base Boot.................................................................................................................................53
One-Ring Top Stiffener (16 Ga) to a One-Ring Stiffener (12-16 Ga)...............................................54
One-Ring Top Stiffener (16 Ga) to a Two-Ring Stiffener (12-16 Ga) ...............................................54
Two-Ring Top Stiffener (16 Ga) to a Two-Ring Stiffener (12-16 Ga) ...............................................55
Two-Ring Stiffener (10 Ga) to a Two-Ring Stiffener (8 Ga) ............................................................55
PNEG–4936 TopDry Autoflow 3

Two-Ring Stiffener (12 - 16 Ga) to a Two-Ring Stiffener (12 - 16 Ga) .............................................56
Two-Ring Stiffener (5 - 8 Ga) to a Base Stiffener (5 - 8 Ga) ...........................................................56
Two-Ring Stiffener (10 - 16 Ga) to a Base Stiffener (10 Ga) ..........................................................57
Two-Ring Stiffener (12 - 16 Ga) to a Base Stiffener (12 -14 Ga).....................................................57
Two-Ring Stiffener (5 - 8 Ga) to a Base Stiffener (5 Ga)................................................................58
Transitional Stiffener (10 Ga) to a Base Stiffener (8 Ga) ...............................................................58
Base Stiffener (8 Ga) to a Base Boot (10 Ga)...............................................................................59
Base Stiffener (10-14 Ga) to a Base Boot (10 Ga)........................................................................59
Base Stiffener (5 Ga) to a Base Boot (10 Ga)...............................................................................60
Stiffener Gauges .......................................................................................................................60
Chapter 7 TopDry Drying Floor ................................................................................................................61
Wall Bracket Installation.............................................................................................................62
C-Channel Installation ...............................................................................................................63
Drying Floor Center Collar Assembly ..........................................................................................65
Rafter and Floor Support Purlin Installation .................................................................................67
Intermediate Purlin Installation ...................................................................................................69
Chute Hopper and Intermediate Chute Bracket Installation ...........................................................70
Installing Floor Sheets ...............................................................................................................71
Flashing Bolt Installation ............................................................................................................72
Eave Flashing Installation ..........................................................................................................73
Eave Flashing Splice Installation ................................................................................................74
Chute Installation ......................................................................................................................76
Intermediate Chute Installation ...................................................................................................77
Assembling the Inside Cable Pulley ............................................................................................78
Assembling the Outside Cable Pulley .........................................................................................79
Chute Chain Assembly ..............................................................................................................81
Leveling Band Post Installation...................................................................................................83
Leveling Band Installation ..........................................................................................................84
Grain Temperature Sensor Installation ........................................................................................88
Center Cone Assembly..............................................................................................................89
Chapter 8 Roof Assembly........................................................................................................................91
Roof Assembly Instructions........................................................................................................91
Center Collar Assembly .............................................................................................................93
Assembling the Intermediate Center Collar..................................................................................94
Roof Flashing ...........................................................................................................................94
Roof Panel Installation...............................................................................................................96
Installing the Round Manway Cover............................................................................................99
Roof Ring Locations ................................................................................................................ 101
Roof Ring Installation ..............................................................................................................102
Perforated Center Band Installation ..........................................................................................104
Chapter 9 Chute Controller....................................................................................................................105
Chute Control and Cable Location ............................................................................................ 105
Chute Controller Mounting Plate and Gussets Installation........................................................... 106
Installing the Chute Controller Housing ..................................................................................... 107
Chain Guard Assembly............................................................................................................108
Testing the Limit Switch Activation ............................................................................................109
Attaching the Cable to the Turnbuckle....................................................................................... 111
Leveling the Discharge Chutes................................................................................................. 112
Chapter 10 Duct Installation .................................................................................................................... 113
Fan Diffuser Installation ........................................................................................................... 114
Top Elbow Duct Section ........................................................................................................... 116
44 in. Duct Section Assembly ................................................................................................... 117
32 in. Expansion Section Assembly .......................................................................................... 118
Bottom Elbow Duct Section......................................................................................................121
Typical Duct Assembly.............................................................................................................122
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Fan/Heater Mounting............................................................................................................... 124
Chapter 11 Accessories .......................................................................................................................... 125
TopDry Access Door Assembly ................................................................................................ 125
Access Door Platform..............................................................................................................126
Cross Over Platform Assembly.................................................................................................128
Door Placement ......................................................................................................................129
Two Ring Door Installation .......................................................................................................130
GSI Group, LLC Limited Warranty .........................................................................................135
PNEG–4936 TopDry Autoflow 5

NOTES
6PNEG–4936 TopDry Autoflow

1Safety Precautions
Topics Covered in this Chapter
▪ Safety Guidelines
▪ Cautionary Symbol Definitions
▪ Safety Cautions
▪ Safety Decals
▪ Safety Sign-off Sheet
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 regula-
tions, which must 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.
ST-0001–3
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Chapter 1: Safety Precautions
Cautionary Symbol 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.
Table 1-1 Description of the different cautionary symbols
Symbol Description
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
8PNEG–4936 TopDry Autoflow

Chapter 1: Safety Precautions
Safety Cautions
Use Personal Protective Equipment
• Use appropriate personal protective equipment:
Eye
Protection
Respiratory
Protection
Foot
Protection
Hearing
Protection
Head
Protection
Fall
Protection
Hand
Protection
• 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 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.
ST-0025–2
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Chapter 1: Safety Precautions
Unload the Bin Correctly
• Use CENTER FLOOR OUTLET ONLY until NO grain
remains above this outlet.
• Side floor outlets to be used ONLY when above condition
is satisfied.
• Lock all side floor outlets to avoid accidental premature
use.
• See manufacturers instructions for proper use of factory
supplied sidedraw (wall) discharge systems.
ST-0060–1
Install and Operate Electrical Equipment Properly
• Electrical controls must 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.
• Lock-out power source before making adjustments, cleaning,
or maintaining equipment.
ST-0027–2
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
Stay Clear of Hoisted Equipment
• Always use proper lifting or hoisting equipment when assem-
bling or disassembling equipment
• Do not walk or stand under hoisted equipment.
• Always use sturdy and stable supports when needed for
installation. Not following these safety precautions creates
the risk of falling equipment, which can crush personnel and
cause serious injury or death.
ST-0047–1
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Chapter 1: Safety Precautions
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 suppli-
er’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 main-
tenance can cause property damage, injury or death. Read
the installation, operating and maintenance instructions thor-
oughly before installing or servicing this equipment. Installa-
tion and service must be performed by a qualified installer,
service agency or the gas supplier.
ST-0024–1
Install and Operate Gas-Fired Equipment Properly
• Gas-fired equipment should be installed by a qualified pipe
fitter and must conform with local codes.
• For Canada: The equipment shall be installed in accordance
with the Natural Gas and Propane Installation Code, CSA
B149.1, or the Propane Storage and Handling Code, CSA
B149.2, or applicable provincial regulations, which should be
carefully followed in all cases. Authorities having jurisdiction
should be consulted before installations are made.
• For the United States: The equipment shall be installed in
accordance with the National Fuel Gas Code ANSI Z223.1/
NFPA 54.
ST-0016–2
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Chapter 1: Safety Precautions
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 pressure applied to the burner during ignition and opera-
tion. Do not exceed maximum recommended drying
temperatures.
• Equipment has sharp edges that can 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-0029–2
Store Bin Sheets Properly
• 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.
ST-0058–1
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Chapter 1: Safety Precautions
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 equip-
ment 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 operate for 20 minutes with the burner off to
purge products of combustion and to cool the components
before entering.
• 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.
ST-0030–2
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, con-
tact GSI for the recommended procedure.
ST-0031–2
Do Not Overfill TopDry
• Do not overfill TopDry. Stored grain must be no higher than
the heater duct opening.
• Filling the bin above this point will cause a blockage of the
ducts.
ST-0062–1
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Chapter 1: Safety Precautions
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 crush-
ing), 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
Rotating Auger Hazard
• Keep clear of rotating augers and
moving parts.
• Do not remove or modify guards or
covers.
• Lock-out power source before making
adjustments, cleaning, or maintaining
equipment.
• Failure to follow these precautions will
result in serious injury or death.
ST-0037–1
14 PNEG–4936 TopDry Autoflow

Chapter 1: Safety Precautions
Confined Space Hazards and Entry Procedures
• Note that the interior of this equipment is considered a con-
fined 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 con-
fined 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 hazard-
ous products or gases. Check the atmosphere for harm-
ful 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 equip-
ment and tools have been recovered once work is
complete.
ST-0055–1
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Chapter 1: Safety Precautions
Fall Hazard
• Ladders, stairways and platforms are for use by competent
and trained personnel only. Do not allow children or other
unauthorized persons to have access to the equipment.
• Access to the equipment must be restricted by the use of
security fencing and lockable gates.
• Lower sections of ladders must be fitted with a lockable
safety gate to prevent unauthorized access.
• Make sure that hot surfaces have had adequate time to cool
before working on or in the equipment.
• Lock out and tag out power supplies and fuel supplies to all
equipment.
• Do not attach lifting equipment to ladders or platforms.
• Do not go outside of the safety rails provided on elevated
platforms.
• Do not work at heights during high winds, rain, snow, or ice
storms.
ST-0056–1
Prevent Roof Damage Due to Vacuum Pressure
• Roof damage can result from excessive vacuum or internal
pressure from fans or other air moving systems. The manu-
facturer does not warrant this type of roof damage.
• Adequate ventilation or “makeup air” devices must be pro-
vided for all powered air handling systems.
• The manufacturer does not recommend the use of down-
ward flow systems (suction).
• Severe roof damage can result from any blockage of air
passages.
• Operating fans during high humidity or cold weather condi-
tions can cause air exhaust or intake ports to freeze.
ST-0028–2
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Chapter 1: Safety Precautions
Safety 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.
Location Decal No. Decal Description
Control Box DC-889 Danger: High Voltage
Chute Control
(Autoflow Only) DC-1945 Warning: Moving Parts
Chute Control
(Autoflow Only) DC-1948 Danger: High Voltage
Above access
door on heater
housing.
DC-1718 Caution: Grain Damage
Above access
door on heater
housing.
DC-1702 Notice: Use Thermostat
Above access
door on heater
housing.
DC-1559
Warning: Sharp Edges
Warning: Flame and
Pressure
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Chapter 1: Safety Precautions
Location Decal No. Decal Description
Control Box DC-1224 Danger: High Voltage
Control Box DC-1165 Danger: High Voltage
Located on duct
access doors. DC-973 Danger: Automatic
Equipment
Located next to
aeration system. DC-969 Caution: Vacuum Pressure
18 PNEG–4936 TopDry Autoflow

Chapter 1: Safety Precautions
Location Decal No. Decal Description
On bin door
covers. DC-GBC-1A Danger: Keep Clear of
Augers
On bin door
covers. DC-GBC-2A Warning: Unload
Instructions
To replace a damaged or missing decal, contact us to receive a free replacement.
GSI Decals
1004 E. Illinois St.
Assumption, IL 62510
Tel: [phone]
PNEG–4936 TopDry Autoflow 19

Chapter 1: Safety Precautions
Safety Sign-off Sheet
Below is a sign-off sheet that can 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
20 PNEG–4936 TopDry Autoflow