Owners Operation Manual (CE) Sukup Manufacturing Company

AUTOMATIC GRAIN DRYER
Continuous Flow / Automatic Batch
Owners Operation Manual (CE)
Sukup Manufacturing Company
1555 - 255th Street P.O. Box 677
Sheffield, Iowa 50475
Phone 641 – 892 – 4222
Fax 641 – 892 – 4629
Manual # L14103DDC
2008/01
©Sukup Manufacturing Company
Table of Contents
Limited Warranty.............................................................................................................................. 2
Safety Section.................................................................................................................................. 3
Emergency Shutdown Locations ..................................................................................................... 9
Power Box Component Location ................................................................................................... 10
Control Box Components Location................................................................................................ 11
Dryer Installation............................................................................................................................ 12
Gas and Electric Hook-up.............................................................................................................. 12
Heater Operation ........................................................................................................................... 12
Air Proving Switch...................................................................................................................... 14
Low Temperature vs. High Temperature Kit ................................................................................. 14
Dry Fire Tests ................................................................................................................................ 15
Manual Control Operational Check ............................................................................................... 17
Maintenance and Service .............................................................................................................. 19
General Dryer Operation ............................................................................................................... 25
Continuous Flow ........................................................................................................................ 25
Automatic Batch ......................................................................................................................... 25
Grain Transfer ............................................................................................................................ 26
Manual ....................................................................................................................................... 26
Dryer Operation ............................................................................................................................. 29
Continuous Flow ............................................................................................................................ 30
Initial Dry .................................................................................................................................... 30
Restart With or Without Stabilization ......................................................................................... 34
Manual Control .............................................................................................................................. 40
Automatic Batch Control................................................................................................................ 45
Grain Transfer................................................................................................................................ 50
Functional Maintenance Requirements ......................................................................................... 51
Start of Drying Season requirements ............................................................................................ 51
Shutdown Faults ............................................................................................................................ 57
Appendix A – Auxiliary Motor Operation and Installation .............................................................. 63
Appendix B – Tonnes per Hour Information (Corn)....................................................................... 66
Appendix C – Dryer Startup Checklist........................................................................................... 67
Appendix D – Heater Operations (CE) .......................................................................................... 69
Appendix E – Dan-Corn Heater Troubleshooting Guide ............................................................... 72
Appendix F – Explanation of DanCorn Heater Box Components ................................................. 74
Appendix G – Ladder Diagrams…….……………...…………………………………………………...76
Single Fan…………...……….……………………………………………………………….... 76
Two Fan…………………………………………………………………………………………..97
NOTICE: The information contained herein is a confidential disclosure. All information contained
in this manual is property of Sukup Manufacturing Co., Sheffield, Iowa, USA and is provided on
the condition that it will not be used in any way detrimental to their interest. Reproduction of the
contents of this document is prohibited unless expressed written consent is given from Sukup
Manufacturing Co.
Limited Warranty
Congratulations on your purchase of a new Sukup Automatic Dryer! We’re pleased to add your
name to the growing list of Sukup Dryer customers. Your Sukup Automatic Dryer offers the most
advanced automatic operation of any dryer on today’s market. You can feel confident that you
have purchased your Dryer from a company committed to serving farmers for years to come.
Sukup Manufacturing is one of the few family-owned companies in an era of corporate mergers.
Our family has more than 40 years of grain drying and handling experience and an excellent
reputation for standing behind our products - we appreciate your purchase. You can look forward
to many years of superior performance from your Sukup Automatic Dryer!
Limited Warranty
SUKUP MANUFACTURING COMPANY (Sukup) warrants to original retail purchaser that within time limits set forth, new
equipment shall be free from defects in material and workmanship. A part will not be considered defective if it
substantially fulfills performance specifications. Should any part prove defective within the warranty period, the part will
be replaced without charge F.O.B. Sukup Mfg. Co., Sheffield, Iowa USA or Distribution Centers - Arcola, Illinois; Aurora,
Nebraska; Defiance, Ohio; Jonesboro, Arkansas; Cameron, Missouri; Watertown, South Dakota. To obtain warranty, a
copy of original invoice is required.
THE FOREGOING LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF
MERCHANTABILITY, FITNESS OR PURPOSE AND OF ANY OTHER TYPE, WHETHER EXPRESSED OR IMPLIED.
Sukup neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said part,
and will not be liable for incidental or consequential damages. THE REMEDIES STATED HEREIN SHALL BE THE
EXCLUSIVE REMEDIES AVAILABLE UNDER THIS LIMITED WARRANTY.
Sukup reserves the right to change specifications, add improvements or discontinue manufacture of any of its equipment
without notice or obligation to purchasers of its equipment. This warranty gives you specific legal rights. You may also
have other rights, which vary according to state or province.
WARRANTY EXCLUSIONS - Labor, transportation, or any cost related to a service call is not provided by Sukup. This
Limited Warranty does not apply to damage resulting from misuse, neglect, normal wear, accident or improper installation
or maintenance. ITEMS NOT MANUFACTURED BY SUKUP (i.e. Tires, Belts, Motors, etc.) ARE COVERED UNDER
WARRANTIES OF THEIR RESPECTIVE MANUFACTURERS AND ARE EXCLUDED FROM COVERAGE UNDER THE
SUKUP WARRANTY. Since the down augers are so critical to the successful operation of the stirring machine, Sukup
Mfg. will not warranty any machines unless they are equipped with Sukup down augers.
BASIC WARRANTY – All Sukup manufactured products are warranted for one year from date of purchase.
EXTENDED STIRRING MACHINE WARRANTY – Sukup warrants Stirring Machines for two years from date of purchase.
EXTENDED STIRRING AUGER WARRANTY – Stirring Augers are warranted for two years from date of purchase. Must
return top 18” of down auger to obtain credit.
EXTENDED FAN WARRANTY - Sukup warrants fans for two years from date of purchase.
EXTENDED GRAIN DRYER WARRANTY - Sukup warrants grain dryers for two years from date of purchase.
EXTENDED HEATER CIRCUIT BOARD WARRANTY - Sukup warrants heater circuit boards for three years from date of
purchase.
ELECTRIC MOTOR WARRANTY - The manufacturers of electric motors warranty their motors through authorized
service centers. Contact motor manufacturer for nearest location. If motor warranty is refused by a service center based
upon date of manufacture, use the following procedure: Have the motor repair shop fill out the warranty report form as if
they were providing warranty service. State on the report the reason for the refusal. Send the report, motor nameplate,
and proof of purchase date to Sukup. If electric motor warranty is not satisfactorily handled by motor service center,
contact Sukup for assistance. Warranty may also be obtained by returning motor to Sukup Mfg. Co. or Distribution
Centers with prior authorization.
NOTE: Sukup will not be responsible for unauthorized motor replacement or repair.
WARRANTY CERTIFICATION - Warranty registration card and the Start-up Checklist performed by your dealer upon
successful completion should be mailed to certify warranty coverage.
UNAPPROVED PARTS OR MODIFICATION - All obligations of Sukup under this warranty are terminated if: unapproved
parts such as stirring augers are used, or if equipment is modified or altered in any way not approved by Sukup.
1-2
Safety Section
GRAIN DRYER
Safety Section
TRANSPORT SAFETY WARNING:
TRUCKER/TRANSPORTER IS TO
PROVIDE APPROVED SAFETY CHAIN
WHEN TOWING DRYER.
WARNING: Transporting this
equipment on public roads may
result in serious injury or death. If road travel
is required it is essential that all the following
procedures be followed:
The above safety-alert means “ATTENTION!
Be Alert! Your personal safety is involved”
This symbol draws your attention to
important instructions concerning your
personal safety. Read the message carefully
to avoid personal injury or death.
1. Read and understand -- operator’s
manual.
2. Check and comply with state & local
regulations.
3. Use required emblems or lights.
4. Travel at a reasonable and safe speed.
Reduce speed and/or use lower gear on
rough ground or slopes.
5. Stop slowly.
6. Have extended rear angle mirrors on
vehicles.
7. Signal & check behind you when turning.
FOLLOW MACHINE SAFETY SIGN &
MESSAGES
Observe
safe
operating
practices.
Carefully read this
manual and all safety
signs
on
your
equipment. Safety sign
must be kept in good
condition.
Replace
missing or damaged safety decals; available
from Sukup Mfg. Co.; Box 677, Sheffield,
Iowa 50475 at no charge.
WARNING: Check for other
vehicles when turning. (2/3 of roadway
farm accidents occurs when turning.)
• Use mirrors
• Be sure to have clear visibility,
• Use signal lights
Learn how to use controls and operate
machine. Do not let anyone operate unit
(especially youth) without thorough training
of basic operating and safety procedures.
WARNING: do not transport unit
in areas of poor visibility -• Especially on hills,
• During poor weather conditions,
• Or at night
Failure to do so may cause serious injury or
death. Use good judgement when
transporting. Maintain complete control of
unit at all times. Comply with State and local
laws governing. Read safety regulations
when moving units. Always strive to prevent
accidents! Watch out for other vehicles.
Make no unauthorized modifications to
machine. Modifications may endanger
function and/or safety of unit. Keep unit in
good working condition.
EMERGENCIES - KNOW WHAT TO DO
Have emergency numbers near your
telephone:
For doctors:
Emergency medical squad:
Ambulance service:
Hospital:
Fire department:
Have written directions to your location.
1-3
Safety Section
Make sure location for decal is free from
grease, oil and dirt. Remove backing from
decal and place in proper position. To order
replacement decals (no charge) contact
Sukup Manufacturing Company, P.O. Box
677, Sheffield, Iowa 50475 Phone
641.892.4222 Please specify computer
number.
WARNING:
TO PREVENT EXPLOSION OR FIRE
•
•
•
•
•
•
Carefully review
operators
manual.
Clean
under
unit, as fines
may cause a bin fire.
Check for gas leaks, (spray soapy
solution on piping and joints.)
Run fan at least a half minute before
starting heater.
NEVER start heater if you smell gas or
hear a hissing sound.
NEVER run heater with inspection door
open.
1. WARNING-L0281-To Avoid serious injury
or death.
Failure to heed these warnings may cause
serious injury or death.
2. DANGER - L02741-98 - Keep away from
any electrical lines, especially when moving
unit.
WARNING:
KEEP CLEAR OF ALL MOVING
PARTS
Keep people (ESPECIALLY YOUTH) away
from
equipment,
particularly
during
operation. Keep away
from all moving parts. Entanglement can
cause serious injury or death. Keep inlet
guard in place and in good working
condition.
3. DANGER - L0237 - Door interlock switch.
Augers are dangerous.
Failure to follow the above precautions may
cause serious injury or death.
+++++++++++++++++++++++++++++++++
Mount safety decals when unit is
assembled. Please check that all decals are
in place according to the drawing/picture
and in good legible condition.
IMPORTANT!! If suggested locations are
not clearly visible, place safety decals in
more suitable area. Never cover up any
existing safety decals.
1-4
Safety Section
4. WARNING - L0166 - Guards & shields in
place.
Disconnect Electricity. Check fan blade.
7. CAUTION - L0285-98
Not intended for use on public roads.
If road travel is required:
8. WARNING - L02831
Lower & secure parking stands before
unhitching unit.
5. DANGER -L0271 - Shield missing, do not
operate.
6. WARNING - L0284-98
Keep away from all moving parts.
9. DANGER - L0301
Rotating augers are dangerous!
1-5
Safety Section
10. CAUTION - L0520
Failure to keep unit clean may cause fire
and serious injury or death.
12. WARNING - L0512
Use safety chain when towing unit to
eliminate detachment hazard.
11. WARNING - L0164
Metal is slippery when wet; Never carry
items when climbing; Have another person
present;
Use safety harness & safety line; etc
1-6
Safety Section
1-7
Safety Section
3. WARNING - L0166
Disconnect electricity; guards, shields in
place; Check fan blade tight.
SAFETY DECAL LOCATIONS FOR FAN &
HEATER
Safety decals and shields are mounted
whenever possible at factory. Please check
that all decals are in place according to
these drawings and in good legible
condition. To order replacement decals or
shields (NO CHARGE) contact your dealer
or Sukup Mfg. Co., 1555 - 255th Street P.O. Box 677 - Sheffield, Iowa 50475.
Please specify computer number.
IMPORTANT ! The following safety decals
should be mounted on your equipment as
shown below. If suggested locations are not
clearly visible, place safety decals in more
suitable area. Never cover up any existing
safety decals.
4. DANGER - L0204
Close service door.
Make sure location area for decal is free
from grease, oil and dirt. Remove backing
from decal and place in proper position.
1. WARNING - L0281
Safe operation decal.
The numbers on the drawings below refer to
the location of the safety decals listed
above.
2. WARNING - L0165
Disconnect Electricity; Bleed gas
1-8
Emergency Shutdown Locations
Emergency Shutdown Locations
The power distribution box is located at the front left of the dryer.
It contains all of the main power distribution components.
On the outside of the
power distribution box,
the front door has two
latches mounted to it.
The door lock handle
secures the door and
can be locked with a key.
The main disconnect
mechanism prevents the
opening of the power box while power is present in the system.
Caution:
Power is still present at the lower side of the main switch
when the power box is open.
The picture at right shows
the main disconnect in the
closed position, power is
present in the system.
Located on the side of the
power distribution box, is the
Emergency Stop switch.
During operation, the switch
is pulled out and is
illuminated red.
Pressing the Emergency
Stop Switch or turning off the
system control switch on the
control panel will shut down
control system. Main power
is still present to the system.
System Control Switch
1-9
Control Box Components Location
Power Box Component Location
The picture below displays the power box and identifies all of the
major components.
SCR
Control Transformer
Transformer
SCR
110V
Relays
Load
Unload
Fan
Power
Distribution
Block
Starter/Protectors
3A
Breakers
Contactors
Y/∆ Starter
Hour
Meter
Main
Switch
Terminal Strip
Important Note:
During initial setup or after relocation of the dryer, it is
highly recommended that ALL of the main power wiring
connections be inspected for security and tight
connections. The wires are tightened at the factory;
however the connections should be checked after transport.
Note
All power boxes are wired to prevent EMC conditions. Varistor
and Snubber networks are provided for extra protection against
electromagnetic charges. When installing and running the dryer,
do not remove any EMC protection.
1 - 10
Manual Control Operational Check
Control Box Components Location
LCD Display
Printer
System Switch
Keypad
Load Auger
Unload Auger
Control Switches
Work Light
Meter Roll Speed
Adjustment (for Manual
operation)
Heater Switches
Fan Switches
Power Supply
EMOD Board, I / O
Board, & Processor
(processor located
under I/O board, I/O
board located under
EMOD board)
EMI Filter
Control Relays
24VDC
Power Supply
Expansion Modules
PLC
(programmable
logic control)
Terminal Strip
Note
All power boxes are wired to prevent EMC conditions. Varistor
and Snubber networks are provided for extra protection against
electromagnetic charges. When installing and running the dryer,
do not remove any EMC protection.
1 - 11
Manual Control Operational Check
Dryer Installation
Gas and Electric Hook-up
Initial gas hookups should only be performed by qualified gas
service technicians in accordance with all applicable code
requirements. In conditions of a threaded pipe train, a regulator
must be installed on the gas tank and limit the pressure to 72 psi
(5 bars).
Initial electric hookups should only be performed by qualified
electrical service technicians in accordance with all applicable
code requirements.
Heater Operation
The heater and fan switches on the control box front panel must
be in either the “ON” or “AUTO” position. Power must be applied
to the fan before the dryer control box will apply power to the
heater(s).
Purge
After the heater is switched on, an automatic 30-second purge
cycle commences. During this cycle, with the fan operating, any
residual gas is cleared. The ignition board controls heater
startup sequences. The ignition board is located in the heater
control box.
Air Pressure Check
If operating in manual or automatic control, the dryer must be
filled with grain since without grain, insufficient air pressure will
develop and the dryer will shutdown in 5 seconds due to the low
static air pressure. If operating in the dry fire mode, the air
pressure sensor is disabled. No gas is being supplied during the
30-second purge cycle due to the gas solenoids being closed.
The static air pressure switch must sense the air pressure for the
control system to send a heater on signal. The differential air
switch is located in the heater box and must detect airflow to
allow the ignition sequence to begin.
Ignition
After the 30-second purge delay, the liquid and the vapor
solenoid is opened and a 4-second ignition attempt occurs.
Operation
The red power light on the heater box’s right side should be on at
this time. If a flame is not sensed within 5 seconds, the burner
will shutdown indicating that no flame was sensed.
1 - 12
Manual Control Operational Check
Plenum Temperature Adjustment
Liquid Propane systems
To adjust the plenum temperature, refer to the Dryer Operation
section of the Operators Manual
Heater Housing Over Temp
The heater housing
high
limit
switch
detects
excessive
temperatures
inside
the heater housing. It
is rated to open above
200°F (94°C). If this
trips, the dryer will
display a housing high
temp fault on the LCD.
Reset switch
The heater housing
high limit switch must
be manually reset.
Vaporizer Over-Temp
The heater’s vaporizer serves to
convert the liquid propane into
vapor propane by using the heat
from the burner. A vapor high limit
fault will shut the dryer down if
vapor fault exceeds 140°F (60°C).
The dryer will lock out the system
and
display
the
vapor
high temp alarm.
The limit
switch needs to be reset once the
vapor temperature drops, the
Control Box will latch the fault until
the operator acknowledges the
fault by pressing the control box
keypad “RESET”.
The vaporizer should be adjusted before operating. Normally,
the vaporizer outlet hose should be very warm to the touch but
not so hot that it can’t be held. To adjust the vaporizer, refer to
the next section, dry fire tests.
Caution
Vaporizer may be hot, use extreme caution when handling.
1 - 13
-
Manual Control Operational Check
Air Proving Switch
Velocity and pressure of the
airflow is measured by two tubes,
90° from each other. The air
proving switch then analyzes the
airflow. If airflow is not present,
the switch will turn off the
heater(s). This switch is located
inside the heater box. To adjust
the air-proving switch, turn the
end of the inner screws with a
flat head screwdriver.
To
decrease the amount of airflow detected, turn the screw counterclockwise. To increase the amount of airflow detected, turn the
screw clockwise.
Heater Operation at Low Plenum Temperatures
Operating the dryer at low temperatures (approximately less than
27°C above ambient temperature) requires low temperature
heater kit. This kit is automatically installed on all CE dryers. A
symptom of operating at temperatures with high temperature
equipment is a rumbling sound. This symptom occurs when the
gas pressure is low and the flame is burning back into the port
cup. Contact your Sukup dealer to purchase additional
equipment to reach lower temperatures.
Caution
Operating the dryer with too low of gas pressure will
damage the port cup. Contact dealer if symptoms occur.
Low Temperature vs. High Temperature Kit
Plenum Temp
Canola
Wheat
Corn
60°C (140°F)
80°C (176°F)
99°C (210°F)
Low Temp
Low Temp
NR
Low Temp
Low Temp
High Temp
Low Temp
High Temp
High Temp
At 10°C (50°F) ambient temperature
Heaters for Dan-Corn (Recommendations only)
Dryer
Fan Size
TE283
TE163
TE163,TE121
TE283
28”
28”
38”
44”
Dryer
TE283
TE163
TE163,TE121
TE283
Dryer Orifice Size
LP High Temp
LP Low Temp
Size (IN) Part # Size (IN) Part #
15/64
D7111
13/64
D7110
13/64
D7110
11/64
D7125
19/64
D7112
13/64
D7110
23/64
D7113
19/64
D7112
NG High Temp
Size (IN)
Part #
25/64
D71125
25/64
D71125
1/2
D71124
9/16
D71127
Dryer Port Cup Size
LP High Temp
LP Low Temp
NG High Temp
Size (IN) Part # Size (IN)
Part #
Size (IN) Part #
28”
9/16
D4027
3/8
D4025
9/16
D4027
28”
9/16
D4027
3/8
D4025
9/16
D4027
38”
3/4
D4044
9/16
D40443
3/4
D4044
44”
3/4
D4044
9/16
D40443
3/4
D4044
38” and 44” High Temp LP units also use flame deflector T16204
Fan Size
1 - 14
NG Low Temp
Size (IN)
Part #
19/64
D7112
19/64
D7112
23/64
D71131
7/16
D71129
NG Low Temp
Size (IN)
Part #
3/8
D4025
3/8
D4025
9/16
D40443
9/16
D40443
Manual Control Operational Check
Dry Fire Tests
Introduction
The “Dry Fire” mode of operation enables the operator a means
of running the dryer when there is no grain. Pre-season tests for
troubleshooting. Ensure that the power box main switch is ON.
Pull the red emergency stop button out. The emergency stop
button should illuminate red, indicating control power is available.
Dryer is NOT susceptible to EMI (electromagnetic interference)
due to being shielded by metal boxes.
Caution
While the dryer is running, excessive audible noise is present.
Hearing protection is strongly recommended.
At the control box, turn the system control switch to the
”COMPUTER” position. Place the fan and heater selector
switches to the “AUTO” position. The LCD display should show
“SYSTEM READY”, meaning the dryer is in the standby mode. If
any error messages are displayed, they must be corrected
before the dryer can be started. See faults section for isolation
of displayed system faults.
From the Control Panel, press “MODE” then “2” for the Dry Fire
Mode.
A screen will appear on the
LCD
prompting
the
operator as to which 1 of 4
Dry Fire Tests is to be
performed.
DRY FIRE OPTIONS
1 = FAN 2 = FAN + HEAT
3 = ROLLER RAMP TEST
9=ROLLER/SCR ADJUST
Fan Only
Selecting 1 at the prompt will energize the fan(s) only. The
static air pressure switch is disabled during this test. All other
monitored safeties are operational at this time.
If the LCD contrast is not to the operator’s liking, turn the R99
potentiometer on the I/O board (clockwise to darken, counterclockwise to lighten). Operator MUST be grounded with a
grounding strap while turning potentiometers on I/O board.
Fan and Heater
Selecting 2 for fan and heat will apply power to the fan and
heater. First the fan will come on, followed by the heater after a
30 second delay. As before, the static air pressure switch is
bypassed and the differential air switch is still used for burner
operation.
Selecting options 1 or 2 will commence a 10 minute timer
countdown followed by the fan and if selected, the heater
startup. At the end of the 10 minute period, the fan and heater
will turn off automatically and return the dryer to the standby
mode. The heater may not be started independent of the fan
being started.
Note
This screen (shown below) will appear if selecting the FAN or
FAN+HEAT option on dual fan systems. This allows the
operator to test each barrel independently if desired.
On Dual Fan systems, if selecting
fan and heater will start first,
followed by a short delay
before starting the lower fan
and heater.
1 - 15
“BOTH STAGES”, the upper
DRY FIRE OPTIONS
1 = UPPER STAGE
2 = LOWER STAGE
3 = BOTH STAGES
Manual Control Operational Check
Vaporizer Coil Adjustment (LP Models Only, Not Applicable to Natural Gas)
Adjusting the Heater: Vaporizer Coil.
Caution
If vaporizer is not adjusted correctly, piping could be hot!
Selecting the Dry Fire Mode Option 2 (fan and heater) is
required to operate the dryer’s
fan and heater when there is no
grain in the dryer. After the dryer
has been allowed to run and the
plenum
temperature
has
stabilized, the vaporizer outlet
(top) should be warm but not hot
to the touch. If the vapor side of
the pipe train is hot, or if the
dryer has shut down due to a
“VAPOR HIGH TEMP ALARM”,
the vaporizer may need to be
adjusted out (away from the
flame). To adjust the vaporizer
loosen the 2 pivot bolts (1 top, 1 bottom) of the vaporizer
adjustment bracket and then pivot the vaporizer either in or out
of the flame as necessary to regulate the temperature at the
vaporizer outlet. The U-Bolts mounting the vaporizer to the
adjustment bracket can also be loosened and vaporizer can be
moved in and out to adjust. Viewing hole is present to watch
vaporizer adjustment.
Meter Roll Ramp Test
WARNING
The Unload auger(s) will come on during the following
operations, as well as at any time the Meter Rolls are rotating to
avoid stuffing the unload auger.
Before performing either option 3 or option 9 of the Dry Fire
operations involving the Meter Rolls, the Control Panel
UNLOAD AUGER Switch must be turned to “AUTO”.
Selecting Dry Fire (Mode 2) then Option 3 (Roller Ramp Test)
will perform an automated voltage increase of the SCR drive
signal, which will cause an incremental step up of the Meter Roll
speed.
The speed will increase from 0 to 99% in 5% increments. The
display will show the current roll order in percent speed. The
whole process takes about 45 seconds. Pressing “RESET” will
stop the test and return the dryer to the standby mode.
Option 9 is only to be used by service technicians for calibration.
1 - 16
Manual Control Operational Check
Manual Control Operational Check
As part of an installation / pre-season operation checkout, only a
limited test may be made of the Manual Control System. This is
due to the fact that with no grain in the dryer, static air pressure
will be too low, which would
cause a fan shutdown and
not allow heater operation.
The following items may be
checked in manual with no
grain in the dryer.
1. Load Auger(s)
2. Unload Auger(s)
3. Meter Rolls
4. Work light (if added)
Note
In manual operation ALL safety interlock circuits are still
monitored by the PLC and should a fault occur, there would be a
safety shutdown.
To perform any operational
check in manual mode,
ensure that power is
applied to the power
distribution box and the Estop switch is illuminated.
All manual operations must be performed with the system control
switch in the “Manual” position.
1. Load Auger Test.
a. Position the load auger switch to “ON” position.
b. At this time the load auger should come on, and the light in
the load auger switch should illuminate.
Note
The load auger would run for 45 minutes if you were loading the
dryer before a loading time out shutdown would occur.
c. Position the load auger switch to “OFF”
d. The load auger should turn off, and the light in the load
auger switch should extinguish.
1 - 17
Manual Control Operational Check
2. Unload Auger Test
a. Position the unload auger switch to the “ON” position.
b. The unload auger should
come on and the light in the
unload auger switch should
illuminate.
c. Position the unload auger
switch to “OFF”. The unload
auger should turn off and
the light in the unload auger
switch should extinguish.
3. Meter Roller Test
Note
Unload Auger must be “ON” for the Meter rollers to operate.
a. Position the unload auger switch to “ON”
b. The unload auger should come on and the unload auger
light in the switch should illuminate.
c. Unlock Meter Roll Potentiometer by moving the lock lever
up.
d. Dial in any desired meter roll speed.
For example: If you desire 50% meter speed, set the dial to
indicate 50.0.
e. The meter rollers should be
rotating.
f. When complete, return Meter
Roll
Potentiometer to
000 and lock.
g. Turn the unload auger switch
to “OFF”.
Percent
Meter
Roll
Speed
Indicator
Adjust
Knob
Lock
4. Work Light Test (if added)
a. Position the work light to on, the work light on the dryer
should illuminate as well as the light in the switch. This light
will be on as long as power is applied to the dryer.
b. Position the work light
switch to “Auto”. The work
light on the dryer and in
the
switch
will
be
illuminated as long is there
is no fault condition. This
is true in either manual or
automatic control. Turn
work light switch off.
1 - 18
Maintenance and Service
Maintenance and Service
Preventative
Performing preventative maintenance on your dryer is very
important and can help to ensure that the dryer will perform well
throughout the drying season. The following guidelines are the
minimum recommended procedures to be performed.
When performing maintenance and using the ladder attached to
the dryer, make sure the ladder is dry before climbing. Ladder
may be slippery when wet.
Caution
All bolts used to keep enclosures locked MUST be tightened
beyond hand removal after opening to prevent undesired access.
Prior to Drying season
*Plan well in advance in case repairs or parts are needed! !
Warning
Lock out power before removing any safety shields
Note:
When working with the top section of the dryer, a walkway must
be installed that meets any applicable standards / codes.
Physical Inspection
1. Remove fan inlet screen. Check for foreign material on fan
blade. Check that the fan rotates freely and that all blade tip
clearances are the same. Check belts for wear.
2. Reinstall fan inlet screen. Check ventilation openings in
motor for any blockage.
3. Check wiring of fan and heater. Look for loose connections,
bare wires or rodent damage. Be sure to check ignition wire
and flame sensor wire for damage or short to ground.
4. Examine the flame rod for cracked porcelain insulation.
5. Examine
spark
plug for proper gap
and
clean
the
electrodes
if
Retaining Bolt
required. The gap
should be 1/8”
(3.175 mm). Spark
plug and flame rod
should
be
examined
periodically
through out the
drying season.
Flame Sense
6. Inspect the port
Flame Deflector
Rod
cup
for
any
accumulation
of
foreign material. Clean if required. Foreign material in the
port cup will not burn out, and will impair burner operation,
(Port cup located behind the deflector)
Inspect Vaporizer, Diffuser, Flame Deflector, and heater venture
supply pipe for damage and physical integrity.
1 - 19
Maintenance and Service
Caution
One drop of Liquid propane will expand 270 times as it
converts to Vapor. It is very dangerous to have the
Vaporizer coil develop a leak during heater operation. Be
sure to check the vaporizer coil yearly. The Vaporizer
should be replaced every 5 years.
7. Remove and clean the gas strainer.
8. Inspect all valve train components for physical integrity.
9. Inspect all valve train connections for tightness.
Liquid Propane
8
7
9
6
11
12
13
10
5
14
4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
3
2
1
NPT LP Inlet Fitting
Fuel Shutoff Valve
LP Gas Strainer
Vaporizer Inlet
Vapor Outlet and Pressure Relief Valve (not shown)
Pressure Regulator
Main (Upstream) Gas Valve and Actuator
Blocking (Downstream) Gas Valve and Actuator
Electronic Modulating Valve
High Pressure Gas Switch
Valve Proving Pressure Switch
Pressure Gauge
Valve Proving Pressure Gauge
Pressure Relief Valve (behind regulator)
Vapor Pressure Relief (not shown)
1 - 20
Maintenance and Service
Natural Gas
5
6
7
2
1
3
1.
2.
3.
4.
5.
6.
7.
4
Gas Inlet Street Fitting
Fuel Shutoff Valve
Main (Upstream) Gas Valve and Actuator
Blocking (Downstream) Gas Valve and Actuator
Electronic Modulating Valve
Pressure Gauge
High Pressure Switch
11. Open inner and outer unload auger clean out/access doors,
and inner and outer column clean out /access doors.
1 - 21
Maintenance and Service
12. Remove any accumulation of fines, dirt or foreign material
from the bottom auger trough area, meter rolls and lower
column.
13. Inspect unload auger, 1 ¼” (3.175 cm) auger end flange
bearings and wooden hanger bearing and flighting for
damage and security.
14. Inspect meter rolls for damage and security.
15. Inspect meter roll wood bearings for damage, hole
elongation (excessive play), and security.
Note
Auger end flange bearings are lifetime lubricated and do not
require service lubrication.
Auger wood hanger bearings are oil-impregnated and do not
require service lubrication.
Meter roll bearings are oil-impregnated wood and do not require
service lubrication.
1 - 22
Maintenance and Service
16. Refer to the pictures below when checking the unload auger
/ meter roll drive train.
Upper Meter Roller
Right
Left
Left Idler
Right Idler
Lower Meter Roller
Right
Left
Reduction
Gear Box
(behind
shield)
Unload
Auger
Belt
Unload
Auger
Pulley
Reduction
Gear Box
17. Inspect unload auger pulleys and meter roll sprockets for
wear or damage.
18. Inspect unload auger belts for cracks or breaks. Check belt
tension for proper adjustment. For proper belt tension test,
press on the belt mid-way between pulleys. Belt should not
deflect more than the distance of one belt width.
19. Inspect the chain belt links, and idler rolls for wear or
damage.
20. Check that the idlers are adjusted properly to remove slack
in drive chains.
21. Check that the reduction gearbox/DC motor is adjusted
outward enough to remove slack on lower drive chain
1 - 23
Maintenance and Service
22. Inspect reduction gearbox for damage / leakage. Check fluid
level.
23. Inspect unload auger motor, DC meter roll motor for damage
and security.
24. Reinstall unload auger/ meter roll drive train shield.
25. Remove cover from load auger motor drive and covers from
top of wet bin.
(see pictures below)
26. Inspect load auger drive pulleys for damage and security
27. Inspect load auger drive belts for cracks and breaks. Check
auger drive belts for proper tension. To test for proper
tension, press on each belt at the mid-way point between the
two pulleys. Belt should not deflect more than the distance of
one belt width. Adjust as necessary.
28. Inspect load auger end flange bearings and mid wood
hanger bearing for wear or damage.
29. Inspect flighting for wear or damage.
Note
The load auger bearings are lifetime lubricated and do not
require service lubrication.
30. Reinstall all covers and shield.
31. Perform overall inspection of the rest of the dryer looking for
loose, missing or damaged parts.
Operational Check
32. Perform pre-season operation test of dryer by performing the
Dry Fire Test. While the fan and heater are running, perform
a leak test of the heater gas train using a soapy water
solution.
1 - 24
General Dryer Operation
General Dryer Operation
Continuous Flow
Continuous Flow dryer operation requires creating a gradient of
moisture from the top to the bottom of the dryer and is
accomplished by three main functions; initial dry, stabilization,
and continuous flow. Before the first drying operation is started,
the user must enter the incoming moisture and the desired
output moisture into the control panel. These moistures are
used to calculate the time necessary to perform the initial dry at
160°F (71°C) temperature, during which no grain is unloaded
from the dryer. After initial dry is complete, the user will set the
desired drying plenum temperatures and the controller calculates
a meter roll speed corresponding to the plenum temperatures
entered. The dryer then performs a stabilization routine. During
stabilization, a gradient of moisture is established in the dryer by
drying and unloading one full load of grain without adjusting the
meter roll speed. After stabilization has completed, the dryer
enters continuous flow operation. During this operation, the
dryer adjusts the meter roll speed for variances seen in the
actual output moisture compared to the desired output moisture.
When the final dry of the season is achieved, the user simply
enters the final dry function and follows the simple instructions
listed on the screen of the control panel.
When continuing a drying operation after the dryer has run out of
grain or has been shut down, it is often desirable to run with the
settings as before the shut down. Therefore, quick methods of
restarting the dryer have been developed to meet this demand.
Restarting the dryer with or without stabilization, depending upon
the particular situation, can be accomplished by following a short
series of steps, explained on the control panel screen during
normal startup operation.
Automatic Batch
Automatic batch is a standard feature of the Sukup Continuous
Flow Grain Dryer. Batch operations enable operators to dry their
grain in a manner they have become accustomed to, enables
them to dry extremely wet grain, allows single fan dryers to be
operated in a heat cool manner, and makes it possible to dry
grains which require a low plenum temperature.
Two controlling operations of automatic batch have been
developed. The first method dries batches according to time
entries. The operator enters set times into the control panel
during which the dryer will heat, cool, and unload the grain.
During unload the dryer calculates the average moisture of each
batch and prints it. The user can then adjust the time entries
according to the desired output moisture. The second method of
operation requires purchasing the temperature control option.
The operator enters a desired dry temperature value into the
control panel.
When the kernel temperature in the column
reaches the set temperature, the dryer proceeds to cool the
grain, if necessary, and then unload the grain. The set variables
may be changed to the operator’s choosing at anytime during the
batch operation (The new settings take effect the next batch).
1 - 25
General Dryer Operation
Grain Transfer
Increasingly, operators require the dryer to transfer grain through
it to reach their storage facilities. A mode of grain transfer has
been developed to simplify this process. The control panel
display, steps the user through a simple process to begin and
end the procedure through normal startup operation.
Manual
Manual operation serves many purposes. When operators want
complete control of their dryer, manual operation fulfills this
need. Manual operation serves as a redundant control set,
allowing the user to operate their dryer while the dealer meets
any necessary service demands. Manual operation is a simple
procedure of manually turning on fans, heaters, loads, and
unloads. The dryer automatically loads the dryer during manual
operation while the user has control of the meter roll speeds.
1 - 26
General Dryer Operation
Grain Dryer Control System Menus
Quick Reference Guide V4.3A
[SET] Menu: Continuous Flow
1=CALIBRATE SENSORS
2=PLENUM TEMPERATURE
3=MOIST OUT 4=MST IN
5=CONFIGURATION
1 – Calibrate Moisture/Temperature Sensors
2 – Set Plenum Temperatures(s) and Options
3 – Set Output Moisture Setpoint
4 – Set Input Moisture
5 – Set Configuration Parameters
[SET] Menu: Autobatch
1=CALIBRATE SENSORS
2=PLENUM TEMPERATURE
3=DRY TIMES 4=COOL
-or3=DRY TEMPS 4=COOL
5=UNLOAD
6=CONFIG
1 – Calibrate Moisture/Temperature Sensors
2 – Set Plenum Temperature(s) and Options
3 – Set Dry Cycle Time of Dry Kernel Temperature
4 – Set Cool Cycle Time
5 – Set Unload Cycle Time
6 – Set Configuration Parameters
[1] Calibrate Sensors Menu:
1=OUTPUT MST 2=TEMP
3=PLENUM RTD TEMP
4=COLUMN RTD TEMP
5=INPUT MST 6=TEMP
1 – Calibrate Output Moisture
2 – Calibrate Output Temperature
3 – Calibrate Plenum RTD Temp(s) (if applicable)
4 – Calibrate Grain Column RTD Temp (if applicable)
5 – Calibrate Input Moisture (if applicable)
6 – Calibrate Input Temperature (if applicable)
[2] Plenum Temperature Menu:
1=PLENUM TEMPERATURE
-or (two fan)1=UPPER PLENUM TEMP
2=LOWER PLENUM TEMP
3=MIN TMP 4=MAX TMP
5=TMP ADJ INC 6=TIME
1 – Set Single/Upper Plenum Temperature Setpoint (if equipped)
2 – Set Lower Plenum Temperature Setpoint (if equipped)
3 – Set Minimum Plenum Temperature
4 – Set Maximum Plenum Temperature
5 – Set Temperature Adjustment Increment (if applicable)*
6 – Set Temperature Adjustment Time (if applicable)*
* Adjusts plenum temperature when meter roll speed is at a
min/max limit (if equipped with Electronic Mod Valve)
[5] (CF) of [6] (AB)
Configuration Menu:
1=TIME/DATE 2=LANG
3=ROLL SPD MIN 4=MAX
5=VALVE MIN 6=MAX
7=CLEANOUT8=FAN DELAY
1 – Set Time and Date
2 – Set Language Selection (if applicable)
3 – Set Minimum Allowed Meter Roll Speed
4 – Set Maximum Allowed Meter Roll Speed
5 – Set Minimum Allowed Electronic Mod Valve Opening (if
equipped)
7 – Set Unload Auger Cleanout Delay Time
8 – Set Fan Shutdown Delay Time
[MODE] Menu:
MODE = ?
1=VALVE
2=DRY FIRE
4=CAL/SETUP 5=SENSOR
6=SET PROC 7=UNITS
1 – Perform Electronic Mod Valve Diagnostics (if applicable)
2 – Perform Dryer Dry Fire Diagnostics
4 – Monitor Sensors
5 – Select Moisture Sensor
6 – Select Processor PCB Version
7 – Select Temperature Units (F or C)
1 - 27
General Dryer Operation
Before Loading or Starting the Dryer
Caution
Ensure that all safety shields are in place. Ensure that outside
access covers on both sides of Dryer are secured and latched.
Dryer Startup Preliminary Steps
1. Prior to starting the dryer, turn the Main Disconnect on the
front of the power box to “OFF”.
2. Open the front panel of the power box by turning the chrome
cabinet latch 1/4 turn. (See next page).
3. Ensure
that
all
starter/protectors in
the
power
box
(shown at right) are
turned ON for dryer
operation.
Starter/Protectors
4. Close the power box
front panel and latch
by
turning
the
chrome cabinet latch
1/4 turn.
5. Engage the main disconnect, by turning the lever 45°
clockwise indicating “ON”. The main disconnect lever must
appear as shown for dryer operation. On the left front side of
the power box, pull the red “Emergency Stop” button out.
The “Emergency Stop” button illuminates RED if pulled out
with the main disconnect “ON”.
1 - 28
General Dryer Operation
Dryer Operation
Four operations have been designed to operate the Sukup Grain
Dryer.
1.
2.
3.
4.
Continuous Flow
Automatic Batch
Manual Operation
Grain Transfer
To operate continuous flow, automatic batch, or grain transfer,
select the computer position of the system control switch on the
front panel and auto position for all others. Operating the dryer
in manual requires turning the system control switch to manual
and all other switches to on. In manual, when turning the other
switches to the on position, this will start the corresponding
device immediately.
Instructions for operation of the dryer are in the following
locations:
• Continuous Flow, next page
• Automatic Batch p. 45
• Manual p. 40
• Grain Transfer p. 50
1 - 29
General Dryer Operation
Continuous Flow
Three options exist to begin the operation of continuous flow:
Initial Dry, Restart with Stabilization, and Restart. The table
below details the starting scenarios to choose the correct method
to start the dryer.
Start/Restart scenario
Initial Dry w/
Stabilization
Restart w/
Stabilization
Restart
All wet grain, No gradient
established
Shutdown greater than 1 Hours,
gradient established, grain cool
Change of plenum temperature
more than 20°F.
Yes
No
No
No
Yes
No
No
Yes
No
Instructions for starting the dryer in continuous flow:
• Initial Dry, below
• Restart with Stabilization and Restart page 34
Initial Dry
During initial dry, two procedures are performed followed by
continuous flow operation. The first procedure is to perform an
initial dry. Initial dry dries the grain at a specific temperature, 71º
C, over a calculated period of time without unloading. The time
value is calculated based upon the input moisture entered into
the controller. The second procedure performed is stabilization.
Stabilization begins unloading the grain and does not adjust the
meter rolls until the dryer has completely turned over the grain in
the dryer. This meter roll speed is calculated off of the input
moisture given and the entered plenum temperatures. The time
for stabilization is calculated off of the determined meter roll
speed to completely turn the dryer over.
Press start to begin
automatic
operation,
ensuring all of the control
switches are turned to
the auto position.
From the display outlined
here, choose Continuous
Flow by pressing 1.
On the next screen,
select initial dry by
pressing 1.
1 - 30
** SYSTEM READY **
SET SWITCHES TO AUTO
THEN PRESS START
01/25/08
12:45PM
CONT. FLOW
AUTOBATCH
GRAIN TRANS.
FINAL DRY
1
2
3
4
OPERATION
PRESS
INITIAL DRY
1
STAB & RESTART
2
RESTART
3
General Dryer Operation
A series of menus is then displayed to enter the appropriate
settings for the date/time, input moisture, desired output
moisture, minimum meter roll speed, and maximum meter roll
speed. The previous recorded values will be displayed on these
menus, to accept these values press (+), to change these values
press (-).
After
setting
these
values, the screen will be
displayed as below.
**DRYER NOT FULL**
START TO BEGIN
OR RESET TO ABORT
OR 1 FOR FINAL DRY
Press start and the dryer will perform an initial fill if necessary,
followed by starting the heaters and fans for initial dry. Pressing
reset would take the operator to the start screen. Pressing 1
would allow the operator to perform the end of season final dry
procedure.
After pressing start, if the dryer requires filling, the fill will begin.
If the fill time exceeds 45 minutes, the fill will shutdown. Ensure
that the dryer is filling correctly and that sufficient grain is present
to fill the dryer. Press start for another load attempt if necessary.
Once the dryer is full, determined by the dryer’s paddle switch
assembly, the load auger(s) will turn off automatically.
Automated starting of the
fans and firing of the
STARTING FAN
heaters is now performed.
The upper or single fan is
turned on followed by the
corresponding heater. The LCD will display ‘Starting Fan…’ until
proper plenum air pressure is detected. If insufficient air
pressure is present, the dryer will shutdown with a static air
pressure fault. Refer to Shutdown Faults in Troubleshooting
Section.
HEATER PURGE IN
The dryer will then start the
heater. The fan will purge
PROGRESS FOR LOWER
for 30 seconds after which
HEATER PLEASE WAIT
ignition will occur.
The
flame sensor will then
attempt to detect a flame. If flame is not sensed within 5
seconds, the dryer will shutdown and display a Flame Timeout
Fault. Refer to Shutdown Faults.
On two fan dryers, the
same
procedure
is
followed for the second
fan and heater.
PLENUM TEMPERATURE
STABILIZING
PLEASE STAND BY
90 SECONDS REMAINING
The dryer will then
stabilize the plenum
temperature for 100 seconds. During this time, the plenum
temperature will exceed the set temperature, and then fall back
to the proper setting. This is typical operation of the modulation
value. Often, 100 seconds is not sufficient to stabilize the
plenum. The plenum temperature is indicated on the control box
and the front of the dryer in sight of the mod valve.
1 - 31
General Dryer Operation
If start is not pressed
within 10 minutes, the
dryer will shutdown due to
inactivity.
The
dryer
will
perform initial dry.
Dryer Stabilization
now
SYSTEM IDLE SHUTDOWN
OPERATOR INPUT REQ’D
PRESS ANY KEY
INITIAL DRY
TIME = 33:50 MINUTES
31:04 REMAINING
PLENUM TEMP = 71C
After initial dry is complete, the operator must enter the
stabilization period.
For two fan dryers,
SELECT OPERATION
select
whether
to
operate the dryer in full 1 = FULL HEAT,
heat mode or in heat 2 = TOP HEAT ONLY
cool mode. If operating 3 = BOTTOM HEAT ONLY
in heat/cool, the lower
heater will now be shut off.
Single fan units can only operate in heat/cool mode in automatic
batch operation.
1 - 32
General Dryer Operation
Next, set the operating
plenum
temperatures
PLENUM TEMPERATURE
within the operating
IS SET TO 220F
range of 140ºF (60°C)
and 220ºF (104°C).
OK(+) OR CHG(-)
The controller records
the last setting the operator had input.
The table below outlines approximate point removals based on
given plenum temperatures. Use it to establish the proper
plenum temperatures to maximize output and remain within
system output capacity limitations.
Approximate meter roll speed given the plenum temperature and points removal for a
single fan.
(This chart is to be used for CORN only)
Pts
Removed
15
10
5
3
Plenum
71°C
6.9%*
9.7%*
19.4%
32.3%
Plenum
77°C
7.1%*
10.7%
21.4%
35.7%
Plenum
82°C
7.8%*
11.7%
23.4%
39.0%
Plenum
88°C
8.5%*
12.7%
25.4%
42.3%
Plenum
93°C
9.1%*
13.7%
27.4%
45.7%
Plenum
99°C
9.8%*
14.7%
29.4%
49.0%
Plenum
104°C
10.5%
15.7%
31.4%
52.3%
*If it is necessary to run the meter rolls lower than 10%, Automatic Batch must be used.
Upon entering the plenum temperature, the controller calculates
the proper meter roll speed. Allowed meter roll speeds are 10%
to 99%. If the calculated speed exceeds the maximum meter roll
user setting or cannot reach the minimum meter roll speed, the
user will be prompted to adjust the plenum temperatures settings
or accept the setting with a warning. If the dryer requires
operation below 10% meter roll speed and the plenum
temperatures have been set to their maximum setting or set to
the operator’s desired maximum, the dryer must be run in
automatic batch operation. Proceed as necessary, press reset
to cancel start and begin automatic batch operation.
After setting the temperatures and accepting the calculated
meter roll speed, the stabilization countdown will occur.
Changing the meter roll speed from the calculated speed for
stabilization is not recommended.
When stabilization completes, the dryer will automatically
proceed to continuous flow operation. Refer to continuous flow
operation section.
1 - 33
General Dryer Operation
Restart With or Without Stabilization
Restart was created to simplify the process of restarting the
dryer with settings similar to those previously set.
When
restarting, the dryer will resume the same full heat or heat cool
operation as previously run. Changing between full heat and
heat cool requires running the initial dry operation.
When selecting restart without stabilization, it is necessary to
check whether the dryer must be re-stabilized. The control panel
display will show when the dryer was last shutdown. Use this
information, along with the chart on p. 33, to determine whether
or not it is necessary to restabilize the dryer. If it is necessary to
restablize the dryer, press (-), otherwise press (+).
Once it has been determined whether or not to run stabilization,
the display will prompt the operator to approve or change dryer
settings.
The display will show date/time, minimum and
maximum meter roll speeds, previous plenum temperature
settings, and last recorded meter roll speed. Upon changing any
of the plenum temperatures or the meter roll speed, the operator
will be prompted to reset all plenum temperatures and the meter
roll speed. This is necessary to prevent the dryer from running in
an undesirable manner. If resetting these values, the controller
will require the same parameters as those required when
entering plenum temperatures for initial dry.
After
accepting
or
**DRYER NOT FULL**
resetting the settings, the
PRESS START TO LOAD
operator is prompted to
OR RESET TO ABORT
press start to perform an
OR 1 FOR FINAL DRY
initial fill, if necessary,
followed
by
the
immediate starting of the fans and heaters. Pressing reset would
take the operator to the standby screen. Pressing 1 would allow
the operator to perform the end of season final dry procedure.
After pressing start, if the dryer required filling, the fill will begin.
If the fill time exceeds 45 minutes, the fill will shutdown. Ensure
that the dryer is filling correctly and that sufficient grain is present
to fill the dryer. Press start for another load attempt if necessary.
Once the dryer is full, determined by the dryer’s paddle switch
assembly, the load auger(s) will turn off automatically.
Automated starting of the
fans and firing of the
heaters is now performed.
STARTING FAN
The upper or single fan is
turned on followed by the
corresponding heater. The
LCD will display ‘Starting Fan…’ until proper plenum air pressure
is detected. If insufficient air pressure is present, the dryer will
shutdown with a static air pressure fault. Refer to Shutdown
faults section.
1 - 34
General Dryer Operation
The dryer will then start the
HEATER PURGE IN
heater.
The heater will
PROGRESS FOR LOWER
purge for 30 seconds after
which ignition will occur.
HEATER PLEASE WAIT
The flame sensor will then
attempt to detect a flame.
If flame is not sensed in 5 seconds, the dryer will shutdown and
display a Flame Timeout Fault. Refer to Shutdown faults section
On two fan dryers, the same procedure is followed for the
second fan and heater.
If start is not pressed
within 10 minutes, the
dryer will shutdown due to
inactivity.
SYSTEM IDLE SHUTDOWN
OPERATOR INPUT REQ’D
PRESS ANY KEY
Dryer Stabilization from restart
If stabilization is required, the dryer will immediately begin
stabilization, otherwise, refer below for continuous flow
operation.
When stabilization completes, the dryer will automatically
proceed to continuous flow operation.
Continuous Flow
During continuous flow, the dryer will begin sampling the grain
moisture and temperature. The plenum temp, current moisture,
grain temperature, and meter roll speed are displayed along with
three-minute temperature compensated average moisture.
The desired moisture will also be displayed alternately with the
current moisture value.
The meter rolls are adjusted, based upon a running three-minute
average, every 15 minutes. The meter rolls will not be adjusted
if the new moisture average is approaching the desired moisture
value or if the new meter roll speed is within 0.2% of the current
meter roll speed. The amount of adjustment made is based
upon the difference of the desired moisture value and the actual
three-minute average moisture value.
1 - 35
General Dryer Operation
Print-out Information
Once the dryer is running, discharged grain temperature, current
moisture, 3-minute moisture average as well as the current roll
order will be printed once every 15 minutes.
If a shutdown occurs, the date & time that the shutdown occurred
will be printed along with a brief description of the particular
shutdown.
SUKUP AUTO DRYER
** VERSION 4.3A **
Starting operation. Initial
Dry, Restart, or Restart with
Stabilization
Moisture setting
Maximum meter roll setting
Temperature sensor
calibration adjustment
indicator
Time Initial load started
Time Initial load ended
Time Initial Dry started
Time Initial Dry ended
Dryer stabilization
completed
Computer goes into full
automatic moisture control
Data is printed every 10
minutes and can be adjusted
to not print or to print every
10 minutes.
SINGLE FAN DRYER
CONTINUOUS FLOW OPERATION
INITIAL DRY
DATE: 2/01/06 TIME: 2:15PM
INPUT MOISTURE = 22.5%
OUTPUT MOISTURE SETPOINT= 16.5%
MAXIMUM ROLL = 50%
MINIMUM ROLL = 10%
MOISTURE CAL ADJ = 0.0%
TEMP. CAL ADJUST = 0
----------------------------------------------------------------2:15PM INITIAL LOAD STARTED
2:15 INITIAL LOAD COMPLETED
2:17PM INITIAL DRY STARTED – 30.0 MIN.
2:47PM INITIAL DRY COMPLETED
PLENUM TEMPERATURE = 220F
CALCULATED INIT. ROLL = 26%
2:48PM STABILIZATION STARTED-54.7 MIN.
3:43PM STABILIZATION COMPLETED
SAMPLING 10 MIN PRINTOUT
TIME OUT OUT
ROLL COL PLEN
TEMP MOIST SPEED TEMP TEMP
-----------------------------------------------------------3:43 125F 16.4% 39% 190F 220F
3:53 125F 16.5% 39% 191F 220F
4:03 125F 16.6% 39% 190F 220F
4:05PM USER SHUTDOWN
1 - 36
Program version number
Operation selected
Continuous Flow, Automatic
Batch, or Grain Transfer
User entered incoming
moisture content
Minimum meter roll setting
Moisture sensor calibration
adjustment indicator
Computer calculated time for
stabilization
Prints time, output
temperature, output
moisture, roll speed, column
temperature, and plenum
temperature.
Whenever the dryer shuts
down, it will print the time
and reason for shutdown
General Dryer Operation
Setting’s Adjustment During Continuous Flow
Pressing the set key
during continuous flow
operation allows the
user to change the
settings listed on the
display right.
1=CALIBRATE SENSORS
2=PLENUM TEMPERATURE
3=COL TEMP 4=MST IN
5=CONFIGURATION
Output Calibration Procedure During Continuous Flow
Once the dryer has begun sampling and the grain kernel
temperature has stabilized the output moisture sensor’s
accuracy should be verified.
1. At the display, note the current 3-minute moisture average
and the current temperature reading.
2. Immediately test the discharged grain from the sample spout
at the rear of the dryer.
3. Test the moisture and temperature of the sample. Using a
moisture tester that has been calibrated to the tester of the
location the grain will be sold at.
4. Compare the tested moisture value against the value noted
earlier by the dryer. Set the temperature before setting the
moisture.
5. Press set from the continuous flow operating screen, then
press 5 to set the temperature calibration
• Example:
The dryer read 120°F (49°C) kernel
temperature and the actual temperature was 110°F
(43°C). The difference between the recorded versus the
set temperature was -10 degrees. After pressing set,
the displayed temperature is 115°F (46°C). Update the
current temperature to read 105°F (41°C).
6. Allow 3 minutes for the temperature change to take effect.
7. Again, press set from
CURRENT MOISTURE
the continuous flow
VALUE IS 16.0%
operating screen, then
press 1 to set the
DESIRED INDICATED
moisture calibration.
VALUE ??.?%
• Example:
The
dryer read 16.5 % moisture and the actual moisture was
16.0 %. The difference between the recorded versus the
set moisture was –0.5 %. After pressing set, the
displayed moisture was 15.5 %. Update the current
moisture to read 15.0 %.
8. Sensor calibration is complete. Calibrate as necessary.
1 - 37
General Dryer Operation
Stopping of Automatic Moisture Control
Continuous flow operation can be stopped by any of the three
following methods:
1. User shutdown by pressing
the ‘Reset’ button.
OUT OF WET GRAIN
2. Automatic shutdown due to
PLC 10 MIN. TIMEOUT
an Out-of-Grain timeout
FOR RESTART PRESS 1
3. Automatic shutdown due to
PRESS 2
a fault.
Refer to Fault FINAL DRY
Shutdown section
Final Dry
The final dry procedure was designed to dry the remaining grain
in the dryer and empty the dryer. Since the dryer will not be
completely full, the static air switch will be bypassed.
When Final Dry has been
selected, the screen will
display the following:
LAST RECORDED INPUT
MOISTURE WAS 21.0%
OK(+) OR CHG(--)
At this point, the last input moisture entry is displayed. The user
may either accept this indication or change it by pressing “OK” or
“CHG”.
The fan and heater will start
in sequence, this is followed
by a 100 second Plenum
temperature
stabilization
period.
The amount of dry time is
calculated by the computer
based on 3.0 minutes per
point of moisture removal
comparing the incoming
moisture
content
with
desired moisture out.
PLENUM TEMPERATURE
STABILIZING.
PLEASE STAND BY.
95 SEC. REMAINING
RECOMMEND 60C DRY
TIME FOR 13.5 MIN.
OK(+) OR CHG(--)
At this point you can accept the computers recommendation or
change it anywhere between 5 minutes and 60 minutes.
Whether you accept the time
recommendation or change
it, the next screen to appear
will be:
At this point the Final Dry is
in progress.
At the end of the timed
sequence, the next screen
is listed here.
1 - 38
FINAL DRY 60C
TIME = 13.5 MINUTES
13.49 REMAINING
PLENUM TEMP = 60C
HEATER IS NOW OFF
PRESS ANY KEY TO
START FINAL UNLOAD
OR ‘RESET’ TO ABORT
General Dryer Operation
Press any key on the keypad to start Final Unload.
The meter rolls will be set
to the maximum speed.
* FINAL UNLOAD *
MOIST=16.5% TMP=33C
ROLL ORDER = 50%
REMAINING = 27:25
The third line displays time
remaining for Final Unload.
The fan is still on during Final Unload. It may be turned off by
turning the front panel fan selector switch to “OFF”.
After the calculated time is complete, the screen will display
“Final Dry Complete Press Any Key”. The Final Dry cycle should
now be complete and the last of the dried grain will have been
transferred. If there is still grain in the dryer, a manual unload
can be performed to empty it.
Press any key on the keypad to return to the main screen.
1 - 39
General Dryer Operation
Manual Control
Introduction
This mode of operation is provided primarily as a back up for
operating the dryer should there be a problem with the automatic
controller. However, the dryer may be run in manual at any time.
When operating in the manual mode, safety circuits are
monitored by the PLC, and a fault condition will cause a system
shut down. In the event of a fault, the switches must be turned to
the “off” position to reset the control system. If the computer
system is non-operational, turn switches to OFF and cycle
power.
Starting Dryer from Empty
To start the dryer in
the manual mode, turn
the
system
power
switch to manual. If the
computer
is
nonoperational, the screen
will not appear:
** SYSTEM READY **
** MANUAL CONTROL **
The dryer is now ready
START TO MONITOR
for manual operation.
8/22/05
12:45PM
Step 1. Load Dryer
Load the dryer, by turning
the load auger switch to
“ON”. At this time the dryer
will load. When the dryer is
full, the load auger will shut
off automatically. It is not
necessary to turn the load
auger off with the switch.
During manual operation,
the PLC will monitor the
dryer and control the load device to automatically fill the dryer
during operation.
If the computer is operational, and the operator desires to
monitor the moisture and
** MANUAL CONTROL **
temperature
of
the
output
grain,
press
NO AUTO CONTROL OR
“START”
and
the
SENSE OF METER ROLLS
following screen will
START TO CONTINUE
appear:
Press any key on keypad to continue to the monitoring function.
1 - 40
General Dryer Operation
Step 2. Starting Fans/Heaters
Next, start the fans and heaters by first turning the fan switch to
“ON” and then turning the heater switch to “ON”.
Note
The Heater will still have a 30-second purge before starting.
#1 Fan/Heater
Allow the plenum temperature to stabilize for approximately 100
seconds.
Step 3. Initial Dry Time
Manually adjust the heaters for a plenum temperature of 71°C
(160°F) as indicated on the digital temperature indicator by
pressing SET [2] for plenum temperature.
On dryers using the manually adjusting mod valve, turn the Thandle clockwise to increase the plenum temperature, and
counter-clockwise to decrease the plenum temperature.
On dryers using the electronic mod valve, open the inner door of
the control box and locate the electronic circuit board with the
digital temperature display. On this board, are there are small
slide switches labeled #1, #2, etc. Place the correct slide switch
into the manual position and adjust the corresponding
potentiometer (also marked #1, #2, etc.) to the correct
temperature.
The amount of time to keep the dryer in this condition is
determined by the incoming grain moisture and the desired
output moisture.
Use the formula below to determine the Initial Dry time.
(Incoming Moisture Content – Desired Moisture Content Out) x 5 Minutes = Initial Dry Time
Example
(21% Incoming – 16% Desired Out) x 5 Minutes = 5% x 5
Minutes = 25 Minute Initial Dry Time
After the Initial Dry time is complete, it is necessary to allow the
dryer to stabilize the moisture gradient. At this time, manually
increase the plenum temperature to 140-220°F (60°C-104°C) by
pressing SET [2] for plenum
temperature adjust.
Step 4. Dryer stabilization
After the initial dry time is
completed,
set
the
plenum
temperature to the operating
temperature.
Begin dryer stabilization by turning
the unload auger switch to “ON”.
1 - 41
General Dryer Operation
Next adjust the
Meter Roll Speed
to the desired
speed. To adjust
the
meter
roll
setting, move the
locking lever up,
and rotate the
knob
to
the
desired setting.
Percent
Meter
Roll
Speed
Indicator
Adjust
Knob
Lock
The speed setting is indicated by a 3-digit indicator in the center
of the knob. This value indicates 000 to 999. Example: If desired
speed is 25%, dial indicator to 250.
To determine the correct meter roll speed setting, follow the
chart below. If the speed settings require the dryer to run at less
than 10% meter roll speed, or a manual setting of 100, it is
necessary to dry the grain in the Automatic Batch mode, or
increase the plenum temperature.
Approximate meter roll speed given the plenum temperature and points removal for a
single fan. This chart is a starting point, adjust as necessary for each dry.
(This chart is to be used for CORN only)
Pts
Plenum
Plenum
Plenum
Plenum
Plenum
Plenum
Plenum
Removed
71C
77C
82C
88C
93C
94C
104C
065 *
071 *
078 *
085 *
091 *
098 *
105
15
097 *
107
117
127
137
147
157
10
194
214
234
254
274
294
314
5
323
357
390
423
457
490
523
3
*If it is necessary to run the meter rolls lower than 100 and more than 999, Automatic
Batch must be used.
Important
At this point it is very important to let the dryer stabilize. DO
NOT make any further Meter Roll adjustments until the dryer
has turned the grain over completely one time. To determine
the amount of time to turn the dryer over one time, refer to
the chart below.
Time to Clear Dryer at Given Meter Roll Settings (Approximate)
Roll
Setting
Minutes to
Unload
Roll
Setting
Minutes to
Unload
Roll
Setting
Minutes to
Unload
100
150
200
250
300
350
400
161
114
90.5
76.4
67.0
60.3
55.3
450
500
550
600
650
700
750
51.3
48.2
45.6
43.5
41.7
40.1
38.8
800
850
900
950
999
37.6
36.6
35.7
34.8
34.1
At this point a proper moisture gradient will have been
established if the roll speed was left alone.
1 - 42
General Dryer Operation
Step 5. Dryer Operating under Manual Meter Roll Control
At the end of the Dryer stabilization period as determined above,
monitor the discharge moisture content by either observing the
control box display (only if computer is operational) or by
performing a manual sample test using the sample spout.
Calibrate temperature and moisture readout as described on
page 37 if necessary.
SAMPLING…
OUTPUT TEMP = 35C
CURR. MOIST. = 16.0%
AVG. MOIST = 15.9%
This display, detailed here,
will show the output moisture
while running in manual.
If the discharge moisture content is not correct, adjust the meter
roll potentiometer according to Figure #1 if moisture content is
too high, or according to Figure #2 if moisture content is too low.
Deviation Above Set Point
Moisture 0.5% High
Moisture 1.0% High
Moisture 1.5% High
Moisture 2.0% High
Moisture 2.5% High
Moisture 3.0% High
Moisture 3.5% High
Moisture 4.0% High
Moisture 4.5% High
Decrease Meter Roll Setting
Decrease Dial setting 025
Decrease Dial setting 050
Decrease Dial setting 075
Decrease Dial setting 100
Decrease Dial setting 125
Decrease Dial setting 150
Decrease Dial setting 175
Decrease Dial setting 200
Decrease Dial setting 225
Figure 1
Deviation Below Set Point
Moisture 0.5% Low
Moisture 1.0% Low
Moisture 1.5% Low
Moisture 2.0% Low
Moisture 2.5% Low
Moisture 3.0% Low
Moisture 3.5% Low
Moisture 4.0% Low
Moisture 4.5% Low
Increase Meter Roll Setting
Increase Dial setting 025
Increase Dial setting 050
Increase Dial setting 075
Increase Dial setting 100
Increase Dial setting 125
Increase Dial setting 150
Increase Dial setting 175
Increase Dial setting 200
Increase Dial setting 225
Figure 2
Important
After adjusting the meter roll speed, allow at least 15 minutes of
operation before re-checking moisture and/or re-adjusting meter
speed again.
1 - 43
General Dryer Operation
Step 6. Dryer Shut Down
To shut the dryer down when in manual operation, perform the
following steps in sequence.
a. Set meter roll potentiometer to “000” and lock.
b. Turn the heater switch to “OFF”.
c.
Turn the load auger switch to “OFF”.
d. Turn the unload auger switch to “OFF”.
e. Turn the fan switch to “OFF”.
f.
Turn the system power switch to “OFF”.
Starting the Dryer after a Shut down
The following table is a guideline for restarting the dryer after a
shutdown.
Start/Restart scenario
Initial Dry w/
Stabilization
All wet grain, No gradient
established
Shutdown greater than 1 Hours,
gradient established, grain cool
Shutdown less than 1 Hour,
gradient established
Change of plenum temperature
more than -7°C.
Restart w/
Stabilization
Restart
Yes
No
No
No
Yes
No
No
No
Yes
No
Yes
No
The method used for restarting the dryer depends on how long
the dryer has been shut down.
1 - 44
General Dryer Operation
Automatic Batch Control
Note
Two-fan/heater operation is the same as a single fan/heater,
except for controlling and monitoring the second fan and
heater. Operator must set both plenums at the same
temperature.
To start the dryer, turn all
switches to ‘Auto’ and
press start.
Begin automatic batch by
pressing 2.
CONT. FLOW
AUTOBATCH
GRAIN TRANSFER
FINAL DRY
1
2
3
4
Set Date/Time
If the date and time are
correct, press OK (+). If
you wish to change the
date or time, press CHG (-)
and follow the screen
instructions.
01/14/08
02:37:47 PM
ARE THE DATE/TIME
OK(+) OR CHG(-)?
Set Input Moisture
Accept or change the
incoming grain moisture
content.
THE CURRENT INPUT
MOISTURE SET=20.5%
OK(+) OR CHG(-)?
Set Max Roll Speed
The Maximum Roll Speed
will now be displayed. If
MAXIMUM METER ROLL
the speed of the unload
IS SET TO = 50%
matches the capability of
the unload system, press
OK(+).
To change the
OK(+) OR CHG(-)?
maximum meter roll speed
setting press CHG(-) and
follow the screen instructions.
Full Heat or Heat Cool
Select full heat or heat/cool
operation.
The cool
FOR FULL HEAT –
operation
is
always
PRESS 1
controlled by a user
FOR HEAT/COOL –
settable
time
value.
PRESS 2
During full heat operation,
the heaters will remain on
continuously. When heat/cool is chosen, the heaters are turned
off during the cool cycle and the unload cycle.
Set Batch Number
Each batch is assigned
a batch number and
used on the printout.
Set the starting threedigit batch number.
1 - 45
PREVIOUSLY ASSIGNED
BATCH NUMBER = 1
RESUME FROM PREVIOUS?
OK(+)
CHG(-)
General Dryer Operation
Dryer Fill
After
accepting
or
**DRYER NOT FULL**
resetting the settings, the
PRESS
START TO LOAD
operator is prompted to
OR
RESET
TO ABORT
press start to perform an
OR ‘1’ FOR FINAL DRY
initial fill, if necessary,
followed
by
the
immediate starting of the fans and heaters. Pressing reset would
take the operator to the main standby screen.
After pressing start, if the dryer requires filling, the fill will begin.
If the fill time exceeds 45 minutes, the fill will shutdown. Ensure
that the dryer is filling correctly and that sufficient grain is present
to fill the dryer. Press start for another load attempt if necessary.
Once the dryer is full, determined by the dryer’s paddle switch
assembly, the load system will turn off automatically.
Fan and Heater Start-up
Automated starting of the
fans and firing of the
heaters is now performed.
STARTING FAN
The upper or single fan is
turned on followed by the
corresponding heater. The
LCD will display ‘Starting Fan…’ until proper plenum air pressure
is detected and if insufficient air pressure is present, the dryer
will shutdown with a static air pressure fault. Refer to Shutdown
faults section.
The dryer will then start the
HEATER PURGE IN
heater.
The heater will
PROGRESS FOR LOWER
purge for 30 seconds after
which ignition will occur.
HEATER PLEASE WAIT
The flame sensor will then
attempt to detect a flame.
If flame is not sensed in 5 seconds, the dryer will shutdown and
display a Flame Timeout Fault. Refer to Shutdown faults section
On two-fan dryers, the same procedure is followed for the
second fan and heater.
If start is not pressed within
10 minutes, the dryer will
shutdown due to inactivity.
SYSTEM IDLE SHUTDOWN
OPERATOR INPUT REQ’D
PRESS ANY KEY
1 - 46
General Dryer Operation
The following table provides suggested guidelines for various start/restart scenarios.
Start/Restart scenario
Change Dry Time
Dry Cycle
RESTART
All wet grain
Shutdown greater than 6
Hours, grain cool
Shutdown 1 to 6 Hours, grain
warm
Change of plenum
temperature more than -7°C.
Shutdown less than 1 Hour
No
Yes. Possibly lower dry time (Check printer tape).
Yes
Yes
Yes. Possibly lower dry time (Check printer tape).
Yes
No. (Check moisture of next batch)
No
Yes. Possibly lower dry time (Check printer tape).
Yes
The plenum should now
be adjusted to the
desired
drying
temperature.
Time and/or Temperature Selection
Choose the method of
operation for automatic
batch. If the dryer does
not have the temperature
option installed, the only
option given on this
screen will be the timed
batch option.
PLENUM TEMPERATURE
IS ISET TO 104C
OK(+) OR CHG(-)
GRAIN DISCHARGE BY –
TIME ONLY = ENTER 1
TEMP ONLY = ENTER 2
If TIME ONLY is selected, all functions, dry, cool and unload are
controlled by a time setting.
If TEMP ONLY is selected, the dry function is controlled by a set
temperature with a maximum four-hour batch limit. Upon failure
to reach the set temperature in four hours, the dryer is shut
down. The cool function, if selected, and unload function remain
time controlled.
1 - 47
General Dryer Operation
Set Batch Variables
For the time option,
the time to dry must
now be entered.
BATCH DRY TIME
IS SET TO __MIN.
OK(+) OR CHG(-)?
For the temp option
the
desired
dry
temperature
must
now be entered.
DESIRED GRAIN COLUMN
DRY DISCHARGE TEMP
IS SET TO 52C
OK(+) OR CHG(-)?
If heat cool has been
selected,
the
controller will prompt
the operator to enter
the desired cooling
time.
BATCH COOL TIME
IS SET TO __MIN.
The unload time
must now be set. A
recommended time
has been calculated
off of the maximum
meter roll speed.
BATCH UNLOAD TIME
IS SET TO = __ MIN
RECOMMENDED = __ MIN
OK(+) OR CHG(-)?
OK(+) OR CHG(-)?
After
beginning
operation, any of the
1=CALIBRATE SENSORS
settings listed below
2=PLENUM TEMPERATURE
can be altered by
3=DRY TIMES/TMP 4=COOL
pressing the set
5=UNLOAD 6=CONFIG
button.
Changing
time
values
will
affect the next time the operation is performed. Changing the
temperature value will immediately affect the output.
1.
2.
3.
4.
5.
6.
7.
Moisture Calibration Offset
Temperature Calibration Offset
Dry Time
Cool Time
Unload Time
Maximum Meter Roll Speed
Dry Temperature Setting
1 - 48
General Dryer Operation
Drying in Automatic Batch
As automatic batch operation begins drying, the remaining time
or current kernel temp will be displayed.
When the dry cycle is completed, the cool cycle, if running in
heat/cool, will begin. The remaining time will be displayed.
During
unload,
the
average moisture and
current temperature will
be displayed, as shown
here.
UNLOAD TIME = 30 MIN.
MOIST=15.5% TMP=33C
COLUMN TEMP. = 33C
29:59 AVG. MST = 15.2%
Unload Cycle
After unloading the first batch, a display informs the user the
batch is finished and begins the drying operation for the next
batch. A printout is then given showing average temperature
and moisture of the entire batch.
A screen displaying the
next batch number will
come up when the dryer
is ready to begin the next
batch.
Note
READY TO DRY BATCH
NUMBER 2
Please remember to refer back to the parameters printed out by
the printer for each batch number to determine if a change is
required for the next batches or if one of the following has
occured.
1.
2.
3.
4.
The input moisture of the grain changes.
The plenum temperature has been increased or decreased.
A shut down occurred due to a fault.
A drastic change in climate (ambient temperature, winds,
etc).
1 - 49
General Dryer Operation
Grain Transfer
Introduction
Increasingly, operators require the dryer to transfer grain through
it to reach their storage facilities. A mode of grain transfer has
been developed to simplify this process. During grain transfer
the dryer will not run the fans, heaters, or moisture sensing
equipment. All relevant safety circuits are monitored.
Starting Grain Transfer
Press “3” to continue
with the Grain Transfer
mode.
CONT. FLOW
AUTOBATCH
GRAIN TRANS.
FINAL DRY
1
2
3
4
Set the Maximum Meter
Roll Speed. This speed
will be used to transfer
grain as quickly as
possible.
MAXIMUM ROLL SPEED
IS SET TO 50%
The operator is then
prompted to press start
to perform an initial fill, if
necessary.
**DRYER NOT FULL**
PRESS START TO LOAD
OR RESET TO ABORT
OR '1' FOR FINAL DRY
OK(+) OR CHG(-)?
After pressing start, if the dryer requires filling, the fill will begin
(Completely filling the dryer is necessary in order to still monitor
safety functions by the PLC). If the fill time exceeds 45 minutes,
the fill will shut down. Ensure that the dryer is filling correctly
and that sufficient grain is present to fill the dryer. Press start for
another load attempt if necessary. Once the dryer is full,
determined by the dryer’s paddle switch assembly, the load
system will turn off automatically.
After the meter roll speed has been set, and the dryer filled, the
operator will be prompted to press start to begin transferring
grain.
The operator is asked whether the 30-minute “Out of Wet Grain”
timeout is to be used. If
selected, the load system
IS 30 MINUTE OUT
will automatically be shut
OF WET GRAIN
down after 30 minutes of
TIMEOUT DESIRED?
no grain being detected by
YES(+) OR NO(-) ?
the paddle switch. The
unload
system
will
continue to run for another 10 minutes to clean out.
The
grain
transfer
operating
screen
will
display the meter roll
speed, as shown here.
To end the Grain Transfer
mode, press “RESET”.
1 - 50
**GRAIN TRANSFER**
MOIST=16.5% TMP=19C
ROLL ORDER = 50%
TO EXIT PRESS RESET
Functional Maintenance Requirements
Functional Maintenance Requirements
Start of Drying Season requirements
At the start of every drying season, the Trantorque screw on
each fan(s) must be checked for proper torque. See Appendix A
in the Installation-Service part of the manual for more
information.
Daily Maintenance requirements
This assumes 24-hour day operation during harvest.
1. Clean foreign material from fan air inlet screen.
2. Sweep off top of exhaust slope where fines may have
accumulated on the outer perforated skins.
3. Visually inspect for an even grain movement along all
perforated panels of the lower outer grain column slope. If
grain in one section is not moving, or it is moving slowly,
check for obstructions in the flow gate area or columns. Pay
particular attention to the area directly under the wet grain
bin, where excessive amounts of fines and foreign material
can accumulate.
4. Perform plenum clean out where fines and foreign material
may have accumulated. Shut the Dryer down. Open rear
access door. Sweep all fines and debris from front of plenum
area to the rear plenum area. Close rear access door and
insert interlock key.
1 - 51
Functional Maintenance Requirements
5. Open rear clean out door
6. Operate the fan only by either running it in the Dry Fire mode
or in the manual mode. Continue running the fan until no
more fines / debris come out of the rear clean out.
7. Turn fan off.
8. Reinstall rear clean out door.
9. Sweep fines / debris of discharge chute screen.
1 - 52
Functional Maintenance Requirements
10. Remove discharge moisture sensor and clean sensor flag
and copper tube.
Reinstall moisture sensor.
11. Inspect plenum RTD temperature sensor. Clean if necessary.
The RTD is located on the side of the plenum. It is an
aluminum tube that runs the length of the dryer.
RTD Temp
Sensor Wire
12. Restart dryer operation per automatic control or per manual
control
1 - 53
Functional Maintenance Requirements
Semi-weekly Maintenance requirements
1. Perform all steps of daily maintenance requirements as
listed in previous section, except step 12, restarting dryer.
2. Open inner and outer unload auger clean out / access doors.
Inner Unload
Auger
Access/Cleanout
Door
3. Inspect unload auger area and meter roll area for
obstructions, fines, and debris. Clean as necessary. Close
inner and outer unload auger clean out / access doors
4. Restart dryer operation per automatic control or per manual
control.
1 - 54
Functional Maintenance Requirements
Weekly Maintenance requirements
1. Unload grain from dryer by performing Final Dry in automatic
2. Perform all steps from the Daily and Semi-weekly
requirements except for restarting dryer.
3. Thoroughly inspect grain columns for accumulation of trash
and fines, at peak of inner perforated grain walls, and above
meter roll flow gates.
4. Check tension of load and unload auger drive belts.
5. Restart the dryer per automatic control (Initial Load, Initial
Dry).
End of Season Maintenance requirements
1. After dryer is unloaded for the last time, open all access
doors and panels. Thoroughly clean the entire dryer by
sweeping and using compressed air. Ensure cleaning of the
wet bin trash pan.
Caution
Do not blow compressed air directly into static air pressure
switch.
2. Perform all steps listed in prior to season maintenance
inspection.
3. Reinstall all access panels and doors with one exception.
Leave the Unload Auger clean out doors open for water
drainage.
4. Lock out electrical power.
5. Install a cover on fan inlet screen to keep debris from
entering the fan and to keep the fan from windmilling.
6. Remove discharge moisture
sensor from grain discharge
chute and put into sensor
holder (sensor could be
covered in standing water if
left inside tube).
1 - 55
Functional Maintenance Requirements
Year-Round Maintenance requirements
1. Remove fan inlet cover and control box cover. Apply
electrical power.
2. Operate the fan, load auger, unload auger and meter rolls for
10 minutes using the Dry Fire mode (see page 15). This will
redistribute the grease in the motor bearings, auger
bearings, reduction gearbox and meter roll drive train.
3. Remove and lock out electrical power, reinstall covers.
4. Remove Wye strainer on the Liquid pipe train (see picture
below) and clean out all fines. Replace strainer.
1 - 56
Shutdown Faults
Shutdown Faults
Upon fault detection, whether in Automatic or Manual operation,
the LCD will display which fault and/or faults caused the
shutdown.
Warning
If necessary, when a fault occurs, power must be disconnected
from the dryer and gas must be turned off before correcting the
fault. If at all unsure, contact your Sukup dealer. Be cautious of
other people or objects around the dryer.
Upon shutdown, the dryer unload may be allowed to run an
additional period of time to clear the unload auger of grain. To
change this amount of time, see Out of Wet Grain Fault.
All fault messages are latched, meaning that they will remain on
screen until the operator acknowledges the message by pressing
the reset key. This is useful in the event of a nuisance trip that
may have otherwise reset by the time the operator realizes that
the dryer has shut down. A summary of all on-screen faults
follows:
Grain Discharge Chute / Unload Auger Warning
Possible Problems
Grain Discharge lid
opened
Grain overflow
discharge
DISCHARGE CHUTE OPEN
OR UNLOAD
AUGER STOPPED
PRESS ANY KEY
Possible Solutions
Return lid to a closed position
of
Slow maximum roll speed. (Grain may over dry)
Insure that take-away system is operating properly.
Lower plenum temperature, maximum roll speed was achieved.
Indicated by asterisk on screen.
Broken or jammed
unload auger
Check unload auger for broken flighting or foreign material.
Check motor and belts.
Rear Access Door Open
Possible Problems
Interlock key removed from rear door switch
REAR ACCESS DOOR IS
OPEN--CHECK DOOR AND
INTERLOCK SWITCH
PRESS ANY KEY
Possible Solutions
Replace Key
1 - 57
Shutdown Faults
Housing High Temperature Alarm
Possible Problems
Housing temperature has
exceeded 93°C
HOUSING HIGH TEMP
INSPECT HTR HOUSING
AND/OR TEMP SETTING
Possible Solutions
Manually reset switch in 5X5 box of proper heater after
temperature has gone down. Refer to heater operation
section.
Check for plugged fan grill.
Check for defective MOD valve.
Vaporizer High Temperature Alarm
Possible Problems
Vapor coil exceeded 60°C
VAPOR HIGH TEMP
ADJ. VAPORIZER COIL
AND CHK FUEL SUPPLY
Possible Solutions
Manually reset the O/T switch in the 2x4 box located on
the vaporizer pipe train.
Supply tank may be low. Fill tank
Vaporizer misadjusted, readjust, and refer to the heater
operation section.
Fan airflow obstructed. Check for obstructions.
Plenum High Temperature Alarm
Possible Problems
Plenum temperature
163°C
exceeded
PLENUM HIGH TEMP
INSPECT PLENUM AREA
AND/OR TEMP SETTING
Possible Solutions
Check plenum by placing back of hand near rear door,
checking for heat. If ok, remove interlock key and
assess problem.
Plenum temperature set too high (adjust setting)
COLUMN HIGH TEMP
POSSIBLE CLOG OR
TEMPERATURE SETTING
Grain Column High Temperature Alarms
Possible Problems
Column temperature
93°C (200°F)
exceeds
Possible Solutions
Check for stagnant column that has overheated.
Unplug if necessary.
Lower plenum temperature if no columns are plugged.
1 - 58
Shutdown Faults
Motor Thermal Overload Alarm
Possible Problems
Motor overload occurred for fan,
load or unload auger, or auxiliary
device.
MOTOR OVERLOAD ALARM
CHK THERM OVERLOADS
IN POWER DIST. BOX
Possible Solutions
Check overload devices in power and auxiliary box for
fault.
Check faulted device for possible
overheating conditions caused by an obstruction in
the auger or a bad bearing in the motor or auger.
Output Sensor Not Found
MOISTURE SENSOR
NOT FOUND SHUTDOWN
PRESS ANY KEY
Possible Problems
Current moisture or temperature
reading is outside the boundaries
of normal operation.
Possible Solutions
Check sensor calibration adjustments.
Check if motor is rotating.
Check if sensor is placed in operating position.
Meter Roller Failure
Possible Problems
Meter rolls have stopped turning
SYSTEM SHUTDOWN
METER ROLL FAILURE
CHECK PROX OR I/O
PRESS ANY KEY
Possible Solutions
Check for obstruction in meter rolls
Check chain linkage for broken chain
Low Static Air Pressure (located on dryer)
LOW STATIC PRESSURE.
CHECK FAN/AIR SWITCH
PRESS ANY KEY
Possible Problems
Internal plenum pressure could
not be reached upon start-up.
Possible Solutions
Dryer is not filling.
operation.
(Check load auger for proper
Internal plenum pressure was lost
during operation.
Wet bin has run out of grain and allowed inner plenum
to release air pressure before out of wet grain time
out occurs.
Air switch out of calibration
Contact your Sukup Dealer to adjust air switch.
1 - 59
Shutdown Faults
Out of Wet Grain
OUT OF WET GRAIN
PLC 10 MIN. TIMEOUT
FOR RESTART PRESS 1
FINAL DRY
PRESS 2
(Dryer is not full)
Possible Problems
Wet bin has been emptied
Possible Solutions
Run Final Dry if end of season
Fill device has failed
Check all fill devices
Dryer unloading faster than filling
Adjust load auger secondary fill time delay off. Refer to
instructions on below.
Unload Auger Time Delay Off and Secondary Auxiliary Time Delay Off Adjustment
If you desire to have your unload system have a timed delay off
function, (To clear augers so as not to heavily load them on
restart), this is provided. This feature is adjustable from 0 to 60
seconds of “Off Delay”.
If you desire to have your second fill auxiliary have a timed delay
off function, (To allow additional grain to unload from bin before
turning off secondary fill) this is also provided. This feature is
adjustable from 0 to 20 seconds of “Off Delay”.
Note
The unload and fill system will still shut off immediately under the
following fault conditions. 1.) Rear Door open. 2.) Grain
discharge chute open. 3.) Motor Overload.
1. Gain access to the inside of the control box by opening
the front door and the inner panel.
2. Locate the Programmable Logic Controller, (PLC), which
is on the middle of the back panel. Refer to component
location section.
3. Open the access door by lifting up on the right side
(hinged on left). (Refer to picture below)
4. There are two adjustable potentiometers located at the
top of opening (see picture below).
Timed Unload
Adjustment
0 to 60
seconds
Timed Load
Adjustment 0
to 20 seconds
1 - 60
Shutdown Faults
The potentiometer on the left side is the adjustment for
the timed unload, the right is for the adjustment of the
secondary fill auxiliary. Both are factory pre-set to 0.
To change the setting to a timed delay, rotate the potentiometer
clock-wise, (see the diagram above) to the desired amount of
“Delay Off” time.
5. Close the access door on the PLC.
6. Close control box inner door.
DRYER FILL SHUTDOWN
CORN NOT UNLOADING
15 Minute without Fill Timeout
(Dryer is full)
PRESS ANY KEY
Possible Problems
Dryer must fill at least every 15
minutes when unloading for
Continuous Flow or Automatic
Batch
Possible Solutions
Unload Auger is turned off
Broken unload or meter roll
SYSTEM SHUTDOWN
2 HR DRY LIMIT
2 Hour Maximum Batch Timeout
PRESS ANY KEY
Possible Problems
Batch temperature setting has not
been reached in 2 hour period
Possible Solutions
Heat set too low (Increase heat)
Temperature set too high (Decrease temperature)
Contact Dealer if problem continues
Defaults Set
Possible Problems
Battery backed data is corrupted
DEFAULTS SET
CURRENT VALUES
OUT OF RANGE.
PRESS ANY KEY
Possible Solutions
If displayed multiple times when starting the dryer,
contact your Dealer for battery backed data part
replacement.
1 - 61
Shutdown Faults
Air Timeout
This will occur when the
fan is started and static air
pressure is not detected
within 5 seconds.
Heater Fault
This will occur on upper
heater start if flame is not
sensed within 5 seconds
LOWER AIR TIMEOUT
(PLC) CHECK LOWER
FAN AND AIR SWITCH
PRESS ANY KEY
UPPER HEATER FAULT
PLC 45 SEC TIMEOUT
PRESS ANY KEY
Out of Grain timeout
This will occur on initial
dryer loading if dryer does
not fill within 45 minutes
1 - 62
LOADING TIMEOUT
EXCEEDED - DRYER IS
NOT FULL OF GRAIN
PRESS ANY KEY
Appendix A
Appendix A – Auxiliary Motor Operation and Installation
Auxiliary controls can be set up in a number of configurations.
Three control circuits exist, one for the auxiliary unload and two
for the auxiliary fill. For the unload, a single control circuit is
used to start an external unload device at the same time as the
unload of the dryer. The auxiliary fill operations have two control
circuits. When turning the fill of the dryer on, a delay of 5
seconds exists between the start of each motor, the dryer fill
motor, the first auxiliary load, and the second auxiliary load. The
fill paddle will send a signal to the controls that the dryer is nearly
full, a switch is triggered to turn the second auxiliary load off.
This operation can be delayed by up to 20 seconds with a simple
setting on the PLC, explained in detail on page 60. Upon
receiving the signal that the dryer is completely full, all auxiliary
motors are shut off. If the second auxiliary is within its delay
period, it will shut off when the dryer is full.
Caution
Auxiliary components should
not be installed in the power
box, only in auxiliary box
located above the power box.
Installing the components
When installing the components
into the box, the starter/protector
is mounted on the top DIN rail
and the contactor is mounted on
the middle DIN rail directly
below.
rter/Protectors
If the components kits are
purchased
from
Sukup
Manufacturing,
the
starter/protector and contactors will be pre-wired together.
Contactors
Wiring the components
trip
Three sets of wires must be installed for the auxiliaries:
1. Control wiring, including jumpers to terminal 3 across the
terminal strip
• Wire 5 – Auxiliary load one (nearest the dryer)
• Wire 9 – Auxiliary load two
• Wire 15 – Auxiliary unload
2. Fault protection wiring
• Wire 18 – Fed from terminal into first auxiliary N/O
contact
• All contacts are then wired in series
• Wire 49D – Taken from last contact to terminal strip
3. Power wiring
• Installed similar those located in power box
• Direct wire leaving space from transformer as the
transfer heats up slightly during operation.
Caution
If contacts installed are not purchased from Sukup
Manufacturing, fault protection must be installed. Contact
Sukup Manufacturing to purchase these components.
1 - 63
Appendix A
1 - 64
Appendix A
1 - 65
15
18
21
24
27
30
60% Meter
Roll
70% Meter
Roll
80% Meter
Roll
90% Meter
Roll
100% Meter
Roll
12
40% Meter
Roll
50% Meter
Roll
9
6
20% Meter
Roll
30% Meter
Roll
3
12 Foot
1 Module
10% Meter
Roll
Dryer
1 - 66
The above chart is an approximation only!
40.6
36.6
32.5
28
24
20
16
12
8
4
16 Foot
1 Module
51
45.7
40.6
35.6
30
25
20
15
10
5
20 Foot
1 Module
61
55
49
42.7
36.6
30
24
18
12
6
24 Foot
1 Module
71
64
57
50
42.7
35.6
28
21
14
7
28 Foot
1 Module
61
55
49
42.7
36.6
30
24
18
12
6
16 Foot
2 Module
76
68.6
61
53
45.7
38
30
23
15
7.6
20 Foot
2 Module
91
82
73
64
55
45.7
36.6
27
18
9
24 Foot
2 Module
76
68.6
61
53
45.7
38
30
23
15
7.6
20 Foot
3 Module
91
82
73
64
55
45.7
36.6
27
18
9
24 Foot
3 Module
Appendix B
Appendix B – Tonnes per Hour Information (Corn)
38
Approximate Tonnes per Hour Information for each Module
Appendix C
Appendix C – Dryer Startup Checklist
Following are the minimum operator actions required to successfully start the Dryer
Warning
Augers, fans, and heaters will start with out warning at the appropriate
times. Please use caution around dryer.
1. Open the power box and ensure that all internal breakers are turned
on. Close the door to the power box, close the latch and turn the
master disconnect “ON”.
2. On the power box, pull the Emergency Stop button out. It should
illuminate red.
3. On the control box front panel, turn system control switch to the
“COMPUTER” position. Turn all other front panel switches to
“AUTO”.
4. The Display should show “SYSTEM READY”. All faults must be
cleared before the dryer can start. Press “START” if there are no
faults.
5. The display will give the options of selecting Continuous Flow “1”,
Automatic Batch “2”, or Grain Transfer “3”. Press “RESET” to abort
dryer startup.
For Continuous Flow
Initial Dry
•
Operator must select Initial Dry, Restart & Stabilization, or Restart.
•
Date/Time, Input Moisture Set, Output Moisture Set, Maximum
Roller Speed, Minimum Roller Speed must be accepted or changed
A 71ºC plenum temperature is required for an Initial Dry
It is HIGHLY RECOMMENDED that the operator is at the dryer to
verify the grain moisture accuracy once sampling has started and
adjust if necessary.
If an output sensor moisture or temperature calibration adjustment
is necessary, while the dryer is sampling, press “SET” and select
OUTPUT MOIST to change the moisture or TEMP CAL ADJUST to
change the temperature. Once the required calibration adjust has
been entered, the dryer will recommence with the moisture
sampling. Allow 30 minutes for the dryer to stabilize before
repeating this procedure.
•
•
•
Restart & Stabilization
•
•
•
Restart
•
•
Date/Time, Input Moisture Set, Output Moisture Set, Maximum
Roller Speed, Minimum Roller Speed must be accepted or
changed.
Plenum temperatures and meter roll speed must be accepted or
changed.
Dryer will run through stabilization. This choice is recommended if
dryer has been off for longer than three (3) hours and the grain in
the dryer is partially dry.
If dryer has been off for less than three (3) hours, it is
recommended that this option be used.
If dryer is off for more than three (3) hours, the operator can choose
to use stabilization or can skip that option.
1 - 67
Appendix C
For Automatic Batch
•
•
•
•
For Grain Transfer
•
•
If user has the “Temperature Option”, the user must choose if the
dryer will run in Time Setting or Temperature Setting.
When the Time Option is chosen, user must decide the times for
heating and cooling of the grain.
If the Temperature Option is present and chosen, user must decide
the temperature for heating and time for cooling the grain.
When the dryer unloads the grain, the meter rolls will run at the
maximum meter roll setting given by the operator.
Dryer operator must decide the maximum meter roll speed for this
option.
Do not exceed unload system capability.
1 - 68
Appendix D
Appendix D – Heater Operations (CE)
3 Wire Air Switch without Low Pressure Switch
The following parts will be found on either the gas pipe train or in the
heater box.
•
•
•
•
•
•
•
•
•
•
•
Burner Operation
Automatic Valve Proving Control – LDU11 – heater box
Valve Proving Pressure Switch – low and high – between the
upstream and downstream valves on the pipe train
CE Gas Burner Control – LME21.350A1 – heater box
High Pressure Switch – pipe train – after downstream valve
Housing High Temperature Switch – 5 x 5 box on fan barrel
Differential Air Switch – heater box
Vapor Over-Temp Switch (on LP systems) – pipe train
Ignition Transformer – heater box
Main – Upstream Gas Valve – pipe train
Blocking – Downstream Gas Valve – pipe train
Electronic Modulating Gas Valve (EMOV) – pipe train
On heaters not requiring the LDU11 valve proving control (28” heater),
once the burner control relay is energized, 120VAC must flow through
the housing O/T, and the high-pressure switch, before being applied to
the CE heater control unit (LME21.350A1).
On heaters requiring the LDU11 (valve proving control), once the main
power is being supplied to the dryer, 120 VAC is supplied directly to the
LDU11.
The LDU11 valve proving control goes through two valve tests. During
TEST 1, the downstream valve is energized for 4 seconds, evacuating
all of the gas pressure between the upstream and the downstream
valves. This test is used to determine if an increase in pressure is
detected between the two valves by the valve proving pressure switch.
If an increase in pressure is detected, TEST 1 will FAIL, and lockout will
occur. The valve proving control can be reset by pressing the clear
plastic on top of the unit, or by pressing the reset button on the control
box keypad. During TEST 1, a voltage is output from terminal 15 of the
LDU11. If no leaks are present, pressure will remain low and the
voltage will pass through the N.C. contacts and be present on terminal
16 of the LDU11. If TEST 1 has not failed, TEST 2 will begin.
In TEST 2, the upstream valve is energized for 4 seconds, which
pressurizes the piping between the two valves. If a decrease in
pressure is detected by the valve-proving pressure switch, TEST 2 will
fail and lockout will occur. The valve proving control can be reset by
pressing the clear plastic on top of the unit, or by pressing the reset
button on the control box keypad. During TEST 2, a voltage is again
output from terminal 15 of the LDU11. If no leaks are present, pressure
will remain high and the voltage will be present on terminal 17 of the
LDU11. The valve-proving test will be initiated each time main power is
supplied to the dryer (not when turning the control system on and off, or
going between automatic and manual).
If both test 1 and 2 pass, 120 VAC is output from terminal # 6 of the
LDU11. If no faults have been detected by the dryer control system,
then, at the proper time, the control system will call for burner operation
1 - 69
Appendix D
by closing a set of N.O. contacts. This voltage must flow through the
housing high temperature switch, and the high-pressure gas switch.
This voltage is then supplied to terminal # 12 of the CE Burner Control
Unit (LME21.350A1).
Upon supplying voltage to the CEBC, the following ignition sequence
takes place.
Ignition Sequence
1. 120 VAC is supplied to terminal # 12 of the LME21.350A1 (CEBC).
2. A 2.5 second wait time begins.
3. The fan ON control signal is enabled. This voltage is output on
terminal # 3 of the LME21.350A1, which checks for this same
voltage on terminal # 6, which comes from a N.C. contact in the
differential air switch. This verifies that the fan is off and no airflow
is being detected.
4. Within 5 seconds of the fan ON signal being enabled, the differential
air switch must close a set of N.O. contacts, which applies this
same voltage to terminal # 11. This indicates that air movement
has been detected. If this signal is not detected, the unit will go into
a fault mode.
5. Upon receiving a voltage on terminal #11, the unit goes into a 30
second pre-purge time delay.
6. Following the purge time, the ignition transformer is energized.
After a 2 second pre-ignition time, the fuel valve is opened.
7. The ignition transformer remains energized for an additional 4
seconds. (total of 6 sec.)
8. Flame must be detected within 5 seconds, or the unit will go into a
fault mode.
9. The flame signal must be maintained for an additional 10 seconds
before opening other fuel valves.
Loss of flame will cause the CEBC to lockout. The unit may be reset by
pressing the small clear plastic button on the front of the unit for
approximately 2 seconds, or the reset button may be pressed on the
keypad located on the front of the control box. 3 attempts will be
allowed for burner ignition. On the 4th attempt, the unit will be locked
out and power must then be cycled to the unit before the ignition
sequence may be re-initiated.
The electronic modulating valve is in the low fire position for the ignition
sequence. After flame has been established, the main control system
on the dryer will send a control signal to the valve, which will open or
close the valve to maintain a desired temperature set point which is set
by the user.
Note
CEBC = CE Burner Control Unit
This is a general description of burner operation. For specific details of
the LME21.350A1, please refer to the Siemens bulletin # CC1N7101en.
A more detailed explanation of the above is as follows:
1. The Fan has been turned ON.
2. 120 VAC is sent to the heater board by energizing the respective control
relay.
• CR3 – Upper Heater
• CR6 – Lower Heater (Located in the Power Box)
1 - 70
Appendix D
3. A dry contact on each of the relays (CR3 & CR6), when closed, will
send a 24VDC signal to the PLC, indicating that 120VAC has been
applied to the heater board.
4. The 120VAC must pass through a 3 Amp circuit breaker located in the
Power Box.
• F9 – Upper Heater – Wire # 1D
• F10 – Lower Heater – Wire # 1I
NOTE: On dryers built in 2007 and after, the above wires were
switched. Wire # 1D – Lower Heater, Wire # 1I – Upper Heater
5. After 120 VAC is applied to the heater board, a 25 second purge time
begins. This purge time is designed into the heater board circuitry.
6. After the purge cycle is complete, 120 VAC is sent out by the heater
board on wire # 9, to energize the ignition transformer and on wire # 10
to energize the liquid solenoid valve, the vapor solenoid valve, and the
flame sense relay. The flame sense relay sends a signal to the PLC
indicating that the heater ignition sequence has started.
• 0CH10 – Upper Heater
• 1CH10 – Lower Heater
7. The RED light on the side of the Heater Box is ON during the ignition
process.
8. An external 60-second timer is also energized at this time (on pre –
2006 dryers).
9. The ignition transformer is energized for 6 seconds and then turned off.
If a flame has not been detected within 5 seconds, the gas valves are
shut OFF and the heater board goes into a lockout condition. The flame
sense relay is de-energized, losing the 24VDC signal to the PLC. The
dryer is then shut down with a flame failure fault.
10. On the electronically controlled modulation valve, the valve remains in
the low fire position for 20 seconds after the flame has been proven.
The valve then begins to slowly open until the programmed set point
has been reached.
11. At any time, if the flame sense signal is lost for 4 seconds, the heater
board will turn OFF the gas valves and go into a lockout condition. The
Flame Sense relay is also de-energized, interrupting the 24VDC signal
being sent to the PLC. This causes a flame failure fault to occur and
the dryer is shut down.
1 - 71
Appendix E
Appendix E – Dan-Corn Heater Troubleshooting Guide
38” / 44” – Fan / Heater
1. Turn on the main power. The LDU11 (valve proving) should begin
rotating.
2. Test 1 releases pressure between the upstream (main) valve and
the downstream (blocking) valve.
3. During test 1, the yellow light on the downstream (blocking) actuator
will turn on for 4 seconds.
If the test fails, the orange light on the front of the LDU11 will turn
on. The test failure is most likely due to a leak. If a leak is not
found, a pressure gauge may need to be installed to verify. After
being repaired, press the clear plastic window on the front of the
LDU11, or press reset on the keypad, and the next test will begin
after rotating to the test 1 starting position.
4. Test 2 pressurizes the piping between the upstream (main) and the
downstream (blocking) valve.
5. During test 2, the yellow light on the upstream (main) valve will turn
on for 4 seconds. The liquid valve will also be energized at this
time. If the test fails, the orange light on the front of the LDU11 will
turn on. The test failure is probably due to a leak. If a leak is not
found, a pressure gauge may need to be installed to verify. After
being repaired, press the clear plastic window on the front of the
LDU11, or press reset on the keypad, and the next test will begin
after rotating to the test 1 starting position.
6. If the valve proving test was successful, 120 VAC should now be
present on terminal # 6 of the valve proving unit. On the 38” / 44”
heaters, this wire number will be 1E. (28” heaters do not use the
valve proving unit)
All Burners
NOTE:
If this is a 38” / 44”, the LDU11 valve proving - test 1 & 2 - must have
been successfully completed before proceeding.
1. Wire numbers for both the 28” heater, and the 38” / 44” heater are
listed in the following paragraphs.
2. If the CE burner control unit (LME21) does not display an orange or
red light, measure for 120 VAC at the housing O/T switch on
terminal #1 (if 28”), or terminal # 1E (if 38” / 44”).
3. An orange light indicates the burner sequence has begun – red
indicates a fault condition. If 120 VAC is not present, measure both
sides of the housing O/T switch. Wires 1 and 1A (on 28”), 1E and
1F (on 38” / 44”). If voltage is present on one side of the housing
O/T switch, but not the other side, the housing O/T switch is tripped
out or defective. Try pushing the reset button and re-check for
voltage.
4. Once 120 VAC is present on both sides of the housing O/T switch,
measure wire # 1A (on 28”) or 1F (on 38” / 44”) at the high pressure
switch. If 120 VAC is not present, check the wiring between the
housing O/T switch and the high pressure switch. If 120 VAC is
1 - 72
Appendix E
present on wire # 1A (on 28”) or 1F (on 38” / 44”), measure wire 1B
(on 28”) or 1G (on 38” / 44”) for 120 VAC. If voltage is not present,
the high pressure switch is not adjusted properly or is defective.
(the contact remains closed, unless the gas pressure exceeds the
setting of the pressure switch)
5. If 120 VAC is measured on 1B (on 28”) or 1G (on 38” or 44”), but
not measured on wire # 1D (on 28”) or 1I (on 38” / 44”), go to the
power box and check the heater control relay (CR3 – Lower CR6 Upper) and the circuit breaker for 120 VAC through both
components. Be sure that the control system is calling for heat, and
the circuit breaker has not tripped.
6. If voltage is measured on terminal # 1D (on 28”), or 1I (on 38” / 44”),
the LED on the front of the CE burner control unit will turn on. If the
unit had not previously locked out, then the LED should be orange
in color. If the indicating light is red, press the clear plastic reset
button on the front of the unit (for 2 seconds) or press the reset
button on the keypad. The red light will go out for a few seconds
and come back on with an orange color.
7. The fan should be running at this time.
8. When the orange light comes ON, use a voltmeter to measure 120
VAC on terminal #3 (FO) of the LME21 burner control unit.
9. If 120 VAC is present on terminal # FO, both air switch solenoids
should energize. If the air switch solenoids do not energize, and the
light on the front of the LME21 burner control unit is orange, the
most likely cause would be the differential air switch contact not
being in the closed position when the air switch solenoids were first
energized.
10. Shortly after both air switch solenoids energize, the 120 VAC will
shift (on the air switch contacts) from terminal # 6 to terminal # 11.
After the air switch contact has closed, measure for 120 VAC on
terminal # 11. If no voltage is present and the fan is running, the
venturi is connected backwards, or the air switch needs to be
adjusted. (turn the adjustment screw all of the way out and turn
back in 1 full turn)
11. The yellow light will remain ON (steady) while waiting for the air
switch to activate. After approximately 20 seconds, the light will
change to red and will not attempt burner ignition. If the air switch
did close the contact, 120 VAC can be measured on terminal # 11.
12. After a short purge time (and after 120 VAC was measured on
terminal # 11), the yellow light will now begin to flash. At this time,
the ignition transformer will energize, followed by the gas valve.
Within 1 – 2 seconds, if flame is sensed, the LED will turn green
and remain ON.
13. If flame is not detected, check for ignition, and gas supply
to the burner. Also, a bad ground will prevent flame from
being detected.
1 - 73
Appendix F
Appendix F – Explanation of DanCorn Heater Box Components
Components:
1.
2.
3.
4.
5.
6.
7.
1 ea
1 ea
2 ea
3 ea
1 ea
1 ea
1 ea
LME.21 - CE BURNER CONTROL UNIT
LDU11 - CE VALVE PROVING UNIT
ASCO SOLENOIDS (2 ea - used with the differential air switch)
ICE CUBE RELAYS - RR, IR, FSR
CE DIFFERENTIAL AIR SWITCH - 3 – WIRE
IGNITION TRANSFORMER (controlled directly by the LME.21)
RED INDICATING LIGHT
Reset Relay – (RR) CONTACTS: RR1 & RR2
RR1 – Resets the LME.21 (heater control unit) - Terminal #8 (wire #57) is connected to
terminal #2).
RR2 - 28” (RR2A, RR2B) When the RESET button is pressed on the keypad, the liquid
valve opens to pressurize the pipe train in the event that a low pressure switch is included
on the pipe train.
RR2 - 38” / 44” - Resets the LDU11 (valve proving unit) by applying 120 VAC to terminal
#18 (wire #65).
Isolation Relay – (IR) CONTACTS: IR1, IR2, & IR3
IR1 – 28” IR1 is closed when the main and blocking gas valves are energized, allowing
the flame sense signal back to the dryer control system. The FSR interrupts the signal if
no flame is sensed.
IR1 - 38” / 44” Separates the LDU11 from the reset signal, if the valve proving unit test 1
and 2 were successful.
IR2 - Separates the LDU11 alarm output from the LME.21 alarm output.
IR3 – This contact is closed if the valve proving unit test 1 and 2 were successful. Closing
this contact allows a voltage to be sent back to the dryer control system indicating that no
burner faults exist. At this point, contact FSR will open if no flame is sensed.
Flame Sense Relay - (FSR) CONTACT: FSR1
FSR1 - If this N.C. contact opens (during burner operation), the flame sense signal is lost,
and a fault will be detected by the dryer control system and the dryer will be shut down
(the burner would already be shut down by the LME.21 Burner Control Unit).
Air Switch
The air switch has 3 colored wires attached to an internal set of contacts. BLUE, RED,
and BLACK.
The RED # 6 wire is connected to the N.C. contact.
The BLACK # 11 wire is connected to the N.O. contact.
The BLUE # FO wire is the common connection for the N.O. and N.C contacts.
Red Indicating Light
The RED indicating light will illuminate when the gas valves are energized.
ASCO Solenoid Valves (2 ea)
The solenoid valves are energized when the FAN ON signal is present on terminal #3,
(wire #FO) of the burner control unit (LME.21). The solenoid valves prevent the
differential air flow switch from sensing air flow, except, when the fan is turned on by the
LME.21 Burner Control Unit.
1 - 74
Notes
1 - 75
Appendix G
Single Fan Ladder Diagrams
MAIN DISCONNECT SWITCH
MAIN DISCONNECT
SW ITCH
1
2
3
POW ER DIST
BLOCK
FUSE F1
3 AMP
460 VOLTS
FUSE F1
3 AMP
FUSE F2
3 AMP
FUSE F2
3 AMP
H3 H2
H4
H1
H1
H3 H2
H4
4
CONTROL TRANSFORMER
PRI-230V / 1 PHASE
SEC-120V / 1 PHASE
CONTROL TRANSFORMER
PRI-460V / 1 PHASE
SEC-120V / 1 PHASE
X2
X1
2
2
X1
X2
FUSE F3
3 AMP
5
E-STOP
6
PLC COM
10CH02
1
PLC OUT
10CH02
10CH02
33
1
7
SYSTEM
CONTROL
MOC
1
8
SWITCHED
AC CR1
33
MOV
91.6(6)
22
22
OOX
F6 C.B.
.5 AMPS
23
POW ER
TO PLC
F7 C.B.
.5 AMPS EMI FILTER
25
9
+5 & +15VDC
POW ER SUPPLY
22
1
+24 VOLT DC
POW ER SUPPLY
XOO
25
26
1
10
SWITCHED
AC CR1
3
11
AUO/MAN CR2
26
XOO
NOTE #2
PLC COM
12CH00
12CH00
3
12
91.4(9)
91.10(8)(9)
91.10(10)(11)
MOV
24
XOO
91.1(7)
91.1(11)
91.9(7)(8)
LOAD SWITCH
MO A
PLC OUT
12CH00
32
LOAD M2
32
6
91.3(12)
91.4(3)
91.9(9)
91.11(1)(2)(3)
XOO
MOV
I/O K1 I/O F1
I/O J2
I/O J2
RELAY FUSE
PIN 1
PIN 2
86
13
OOX
NOTE 2
RC SNUBBER
1
3
2
24
Title:
PORTABLE DRYER: DAN-CORN SINGLE
FAN & HEAT: 120 VOLT CONTOL
Author: Sukup Mfg.
Date: 08/07
Revision: 1-10-08
Sheet: 91.1
1
3
UNLOAD
SWITCH
24
2
MO A
UNLOAD M3
10
1
91.3(12)
91.5(5)
91.9(10)
91.11(4)(5)
91.11(6)(7)
24 XOO
MOV
CR UNLOAD
91.2(12)
87
1
2
CR
UNLOAD
87
91.2(2)
10A
91.2(11)
91.9(17)(18)(19)
OOX
I/O J2
PIN 3
3
I/O K2 I/O FUSE
RELAY F2 .25A
3
NOTE 2
I/O J2
PIN 4
METER ROLL
CR5
91.9(4)(5)(6)
91.9(19)
91.10(3)(4)
FAN SWITCH
87
MO A
FAN M5
RC SNUBBER
11
24
4
91.2(4)
91.3(12)
91.11(8)
XOO
I/O J2
PIN 5
3
I/O K3 I/O FUSE
RELAY F3 3.15A
I/O J2
PIN 6
88
MOV
HOUR METER
88
5
OOX NOTE # 2
RC SNUBBER
HEATER
SWITCH
M OA
I/O J2
PIN 7
6
7
I/O K4 I/O FUSE
RELAY F4 3.15A
3
24
I/O J2
PIN 8
CR-M 5
OR M 5
12
91.2(8)
91.2(9)
91.9(1)
91.4(8)
NOTE #1
91.11(10)
XOO
89
HEATER CR3
13
89
RC SNUBBER
OOX
WIRE NUMBERS
B, C, D, FOR 28"
G, H, I, FOR 38"/44"
8
FROM THE HEATER
CONTROL BOX
HEATER
CR3
1C
1B
F9 C.B.
3 AMP
LOCATED IN POWER BOX
TO THE HEATER
CONTROL BOX
SEE DRAWING 91.12
WORK LIGHT
SWITCH
9
1D
WORK LIGHT
RELAY
CR11
MO A
1
19
XOO
10
3
3
PLC COM
10CH03
10CH03
11
1
12
OOX
NOTE 2
PLC OUT
10CH03
CR UNLOAD
31
31
91.6(7)
MAIN GAS SOLENOID
NOTE 3
1
91.2(2)
91.9(17)(18)(19)
3
3
(only on NG single fan)
Title:
2
PORTABLE DRYER: DAN-CORN SINGLE
FAN & HEAT: 120 VOLT CONTROL CONT.
Author: Sukup Mfg.
Date: 08/07
Revision: 1-10-08
Sheet: 91.2
+24 VDC
18
DC COMMON
95
INPUT 0CH
95
COM
REAR DOOR
0CH00
18
1
36
36
0CH01
2
SPARE
VAPOR HIGH LIMIT
18
3
0CH02
37
37
0CH03
CONNECT #18 TO INPUT IF NOT USING THE HOUSING HIGH LIMIT
4
18
18
PLENUM HIGH LIMIT
18
5
6
7
0CH04
39
39
RIGHT COLUMN HIGH LIMIT
18
40
40
LEFT COLUMN HIGH LIMIT
18
41
41
0CH05
0CH06
0CH07
GRAIN DISCHARGE CHUTE
18
42
8
42
STATIC AIR PRESSURE SWITCH
18
9
0CH08
43
43
LOWER PADDLE
18
10
0CH09
44
44
FLAME RELAY
18
11
0CH10
45
45
MOTOR OVERLOAD MOTOR OVERLOAD
LOAD M 2
UNLOAD M 3
49D
12
+
+
18
49
+
+
18
NOTE 4
49E
MOTOR OVERLOAD
FAN M 5
49F
0CH11
49
Title:
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T P L C IN P U T S
CHANNEL 0
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.3
+24 VDC
18
DC COMMON
95
INPUT 1CH
95
FAN ON
18
46
1
I/O J2
PIN 11
18
2
I/O K6 I/O FUSE
RELAY F6 .25A
1CH00
46
I/O J2
PIN 12
51
1CH01
DRYFIRE
LOAD ON M2
18
47
3
I/O J2
PIN 9
18
4
I/O K5 I/O FUSE
RELAY F5 3.15A
COM
51
1CH02
47
I/O J2
PIN 10
52
1CH03
RESET
52
1CH04
5
UPPER PADDLE
18
6
7
1CH05
53
53
HEAT ON
18
48
48
1CH06
AUTO/MAN
18
8
54
1CH07
54
1CH08
9
1CH09
10
1CH10
11
1CH11
12
18
Title:
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T P L C IN P U T S
CHANNEL 1
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.4
DC COMMON
95
+24 VDC
18
INPUT 2CH
18
1
COM
2CH00
2
2CH01
CONNECT #95 TO THE INPUT IF NOT USING THE AIR SWITCH
3
95
95
2CH02
4
UNLOAD ON M3
95
5
2CH03
94
94
92
92
93
93
96
96
LEFT METER ROLL
PROXIMITY SWITCH
2CH04
6
RIGHT METER ROLL
PROXIMITY SWITCH
2CH05
7
UNLOAD AUGER
PROXIMITY SWITCH
2CH06
8
2CH07
9
2CH08
10
2CH09
11
2CH10
12
LOAD SWITCH
UNLOAD SWITCH
95A
13
FAN SWITCH
95B
2CH11
95C
95
10
+
18
+
11
+
95
+
12
TO PLC
INPUT
BROWN
+24VDC
BLUE
DC COMMON
BLACK
SIGNAL
PROX SWITCH
Title:
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T P L C IN P U T S
CHANNEL 2
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.5
OUTPUT 10CH
1
2
3
4
5
6
7
3
COM
21
10CH00
COM
10CH01
MODEM (if used)
+ 55 +
56
MODEM (if used)
+ 56 +
33
10CH02
87
10CH03
HEATER TIMER SOLENOID
(older models only)
+
+
21
55
1
COM
(120 VAC)
SWITCHED AC
+ 3
+
+
120 VAC
1
+
SWITCHED AC
COIL CR1
2
TIMED UNLOAD
(OFF DELAY set by user)
+ 87 +
DC COMMON
8
95
COM
9
10CH04
10
10CH05
11
10CH06
12
10CH07
+
95
+
1A
1A
REAR DOOR
I/O J15 PIN 1
14A
14A
AUTO/MAN
I/O J15 PIN 14
3A
3A
VAPORIZER HIGH LIMIT
I/O J15 PIN 3
4A
4A
HEATER HOUSING HIGH
LIMIT I/O J15 PIN 4
Title:
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T P L C O U T P U T S
CHANNEL 10
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.6
OUTPUT 11CH
DC COMMON
1
95
COM
2
11CH00
3
11CH01
4
11CH02
11CH03
+
5A
PLENUM HIGH LIMIT
I/O J15 PIN 5
6A
6A
COLUMN HIGH LIMIT
I/O J15 PIN 6
7A
COLUMN HIGH LIMIT
I/O J15 PIN 7
2A
GRAIN DISCHARGE
CHUTE I/O J15 PIN 2
91
2A
95
COM
95
5A
Meter Roll Fault
5
6
+
I/O J1
PIN 5 & 7
91
DC COMMON
+ 95 +
7
11CH04
11A
11A
5 SECOND AIR FAULT
I/O J15 PIN 11
8
11CH05
13A
13A
10 MINUTE OUT OF WET
GRAIN I/O J15 PIN 13
9
11CH06
12A
12A
45 SECOND HEATER
FAULT I/O J15 PIN 12
10
11CH07
8A
8A
MOTOR OVERLOAD
I/O J15 PIN 8
Title:
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T P L C O U T P U T
CHANNEL 11
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.7
OUTPUT 12CH
1
2
3
4
5
7
COM
12CH01
COM
12CH02
7
12CH03
COM
9
12CH04
10
12CH05
11
12CH06
12
12CH07
+
32
12CH00
6
8
3
COM
3
+
32
+
SWITCHED AC
120 VOLTS
LOAD SWITCH
MANUAL
7
+
5
+
5
+
8
+
8
+
1ST AUX LOAD
(incline auger or leg)
NOTE: 6
2ND AUX LOAD
(wet bin)
NOTE: 6
9
+
95
DC COMMON
+ 95 +
9
+
15A
15A
AIR SENSE
I/O J15 PIN 15
16A
16A
FLAME SENSE
I/O J15 PIN16
9A
9A
LOWER PADDLE SWITCH
I/O J15 PIN 9
10A
10A
UPPER PADDLE SWITCH
I/O J15 PIN 10
Title:
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T P L C O U T P U T
CHANNEL 12
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.8
AUTO/MAN CR2
HEATER RELAY CR3
1
13
FROM CRM5
OR M5
A
B
2
AC COMMON
11
26
FROM COMP
MAN SWITCH
A
2
B
AC COMMON
91.1(10)
91.2(6)
17B
18
2
SCR REF.
12via THUMBWHEEL
4
7
48
1B
TO HEATER
BOX
9
6
C.B. F9
3 AMP
1C
1D
9
17
TO SCR
TERM SIG
95
TO SCR
TERM COM
91.10(9)
TO PLC 1CH06
91.4(7)
3
6
13 via PROCESSOR 17A
SCR REF
3
91.10(10)
TO HEATER
BOX
91.2(8)
14
DC COMMON
95
4
7
91.10(8)
15
DC COMMON
95
1
91.10(7)
METER ROLLS CR5
4
FROM CR
UNLOAD
10A
B
A
16 +24VDC
2
18
AC COMMON
54
8
5
91.4(8)
TO PLC
1CH07
91.2(2)
CR UNLOAD
L2
5
4
7
L2A
91.10(4)
L1
6
6
9
91.10(3)
TO SCR
TERM L2
C.B. F4
220VAC
3 AMP
L1B TO SCR
L1A
TERM L1
17
FROM PLC
31
OUTPUT
10CH03
18 110VAC
1
B
2
A
AC COMMON
91.2(11)
9
87
6
TO UNLOAD SW
MANUAL SIDE
91.2(2)
19
UNLOAD ON
SIGNAL
10
7
1
10A
TO CR5 COIL
METER ROLLS
91.2(2)
SWITCHED AC CR1
7
FROM
10CH02
33
A
B
2
AC COMMON
20
91.1(7)
8 120VAC
1
91.11(7)
TO TERMINAL
#15- POWER BOX
DRY CONTACTS THAT CAN BE USED TO TURN
ON AUX UNLOAD EQUIPMENT- SEE NOTE 9
91.1(11)
9
TO TERMINAL
#14-POWER BOX
AUX CONTACT
ON M3 (UNLOAD)
14
15
6
3
SWITCHED AC
TO TERM 3
FAN ON SIGNAL
AUX CONTACT
ON M5 (460V )
9
+24VDC
AUX CONTACT
ON M2 (LOAD ON)
47
18
+24VDC
18
21
46
TO PLC INPUT
1CH00
91.4(1)
TO PLC INPUT
1CH02
FAN - HEAT INTERLOCK
AUX CONTACT
ON M5 (460V)
10 -24VDC
AUX CONTACT
ON M3 (UNLOAD ON)
95
94
22
TO PLC INPUT
2CH03
FROM THE
HEAT ON SWITCH
Title:
13
12
TO HEAT ON
RELAY CR3
91.2(6)
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T R E L A Y
C O N T A C T W IR IN G
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.9
1
+
AC.B. F5 3AMP
A+
L1B
3
L1
4
L2
L2A
+
TO DC MOTOR
+
2
+
+
C.B. F4 3AMP METER ROLLS CR5
L1A
L1 POW ER FROM
DISTRIBUTION
BLOCK
230 VAC
L2
91.2(2)
5
F-
6
F+
AUTO/MAN CR2
7
91.1(10)
I1
95
8
95
91.1(10)
COM
17
9
10
DC COMMON
+ 95 +
95
95
METER ROLL
SPEED POT 10K
17B
SIG
91.9(15)
+15 VDC
85
+
+12
+
5K OHM RESISTOR
17
91.9(16)
17A
REF VOLTAGE
FROM PROCESSOR
CR2 IS ENERGIZED
WHEN IN MANUAL
Title:
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T S C R B O A R D
W IR IN G
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.10
L1
L2
L3
STARTER PROTECTOR
CB2
LOAD CONTACTOR
M2
1
LOAD
MOTOR
2
3
4
+24VDC
AUX CONTACT
18
47
TO PLC INPUT 1CH02
91.4(4)
STARTER PROTECTOR
CB3
UNLOAD CONTACTOR
M3
5
UNLOAD
MOTOR
6
7
AUX CONTACT
94
95
-24VDC
8
91.5(5)
AUX CONTACT
14
15
9
STARTER PROTECTOR
CB5
TO PLC
INPUT 2CH03
DRY CONTACTS FOR
AUXILIARY UNLOAD
FAN CONTACTOR
M5
10
FAN
MOTOR
11
12
See Drawing # 91.19 & 91.20
13
+24VDC
AUX CONTACT
18
46
TO PLC
INPUT 1CH00
91.4(2)
Title:
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T 3 P H P O W E R
W IR IN G
Author: Sukup Mfg.
Date: 01/04
Revision: 1-10-08
Sheet: 91.11_3ph
TO POWER BOX
GND 2
1 1I 18 37455216195
1G
2
TERMINAL STRIP
IN HEATER BOX
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
1G
1
2
1I
18
21
37
45
52
161
FO
95
GND
VAPOR OVER TEMP.
18
18
FSR1
IR3
RR2
1
13
67
15
62
62
17
63
IR1
66
64
19
FO
37
52
58
SPARK
TRANSFORMER
9
6
RED LIGHT
10
PRESSURE SWITCH FOR
VALVE PROVING CONTROL
(NO)
64
62
IR2
23
58
67
63
(NC)
LIQU ID SOLENOID
59
+
MAIN GAS VALVE
+
+
1E +
+
+
+
+
1 +
BLOCKING GAS VALVE
60
VALVE PROVING U N IT
1E
DC COMMON
18
61
AIR SWITCH
65
1
+
+
air
s w.
11
10 +
60 +
+24VDC
SPARK PLUG
FO - Blue
65
21
Black
Red
FSR
2
10 +
95
IR
1I
2
HOUSING
OVER TEMP
+
RR
E lectronic Mod Valve
+
+
+
+
+
+
+
+
+
+
+
+
12
11
10
9
8
7
6
5
4
3
2
1
AIR SW ITCH SOLENOID #2
45
BURNER CONTROL UNIT
12 1I +
11 11 +
10 58 +
RR1
+
9
+
57
8
9 +
7
6 +
6
+
5
10 +
4
FO +
3
+
2
+
1
FLAME ROD
1
AIR SW ITCH SOLENOID #1
TO HIGH PRESSURE SWITCH (see below)
+
+
+
BLACK 95
RED 18
WHITE 61
1F
1I (from the power box)
H IGH
PRESSURE
1G (to the pow er box)
1G
-1
- 23
-
NOTE: Pipe train components connect to a terminal strip
in the 5 x 5 junction box located on the front of the
dryer. From that terminal strip through a conduit to
the heater box terminal strip.
CONTROL SIGNAL
ELECTRONIC MOD VALVE
MOTOR-ON PIPE TRAIN
Title:
IR - ISOLATION RELAY
RR - RESET RELAY
FSR - FLAME SENSE RELAY
- INDICATES NO CONNECTION
PORTABLE DRYER: DAN-CORN SINGLE FAN & HEAT
HEATER CONTROL & FAULT WIRING - 38" OR 44"
HOUSING
Author: Sukup Mfg.
Date: 01/04
Revision: 1-10-08
Sheet: 91.12
95
85
SIG
1
2
3
PLENUM TEMP SIGNAL
+
71
TEMP DISPLAY
71
+
4
5
ELECTRONIC MOD VALVE CONTROL BOARD
7
DC COMMON
+ 95 +
8
+
9
10
11
+15VDC
85
95
85
61
61A
6
+
61A
REF VOLTAGE
FROM PROCESSOR
DC COMMON
+ 95 +
+
+24VDC
18
+
ELECTRONIC MOD VALVE
MOTOR- ON PIPE TRAIN
Black
Red
White
95
18
61
1
2
3
12
13
Title:
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T E L E C T R O N IC
M OD VALVE CONTRO L
Author: Sukup Mfg.
Date: 01/06
Revision: 1-10-08
Sheet: 91.13
82
61A
17A
+
82
TO ELECTRONIC MOD VALVE CONTROL BOARD
TO CR2 SCR REF VOLTAGE
01 23 4567
REMOTE
PRINTER
CONNECTOR
+
SMARTWATCH
GRAY
A to D CONNECTOR
DALLAS
LANGUAGE
CHIP
D to A CONNECTOR
EPROM
PINK
PLENUM TEMP
+ 71 +
71
70
+
70
+
COLUMN TEMP (if used)
.01uF
CAP
POWER PLUG
YELLOW HARNESS TO PLC
KEYPAD
HARNESS
+
+
95
85
+
+
+
84
+
0 +5 +15
POWER PLUG
LCD
HARNESS
OUTPUT SENSOR
PINK
RED
BROWN
BLUE
BLACK
WHITE
GREEN
SHIELD
51
DRYFIRE SIGNAL
89
18
52
TO HEATER SWITCH
+24VDC
RESET SIGNAL
88
TO FAN SWITCH
87
TO UNLOAD SWITCH
SWITCHED AC
TO LOAD SWITCH
3
86
INPUT SENSOR
GRAY
(if used)
CABLE TO
MOISTURE SENSOR
Title:
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T I/O &
P R O C E S S O R B O A R D W IR IN G
Author: Sukup Mfg.
Date: 01/07
Revision: 1-10-08
Sheet: 91.14
+5 VDC
+
841
+
841
+5 VDC
+
84
+
DC COM.
+
95
+
+
85
+
+
82
+
95
95
95
PRINTER POWER
HARNESS
SIGNAL FROM
PROCESSOR
PAPER ROLLER CONTROL BOARD
82
85
95
+15 VDC
84
82
FOR MANUAL
PUSH BUTTON
(if installed)
811
801
80
81
DC MOTOR AND PAPER ROLLER
Title:
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T P R IN T E R A N D
P A P E R R O L L E R W IR IN G
Author: Sukup Mfg.
Date: 01/07
Revision: 1-10-08
Sheet: 91.15
MINCO TRANSMITTER (DISCONTINUED IN 2007 - REPLACE WITH T17028)
POWER
1
2 3
RED
DC COMMON
95
1 2 3
SENSOR
+15VDC
85
BLACK
RED
SIGNAL BACK TO PROCESSOR
RED
YEL
WHITE
RTD'S & TRANSMITTERS ARE USED
TO SENSE PLENUM TEMPERATURE
AND ALSO WITH THE COLUMN TEMP OPTION.
TO RTD SENSOR
T17028 NEW AS OF 2007
SIGNAL BACK TO
PROCESSOR
FROM RTD SENSOR RED
1 2 3
FROM RTD SENSOR YEL
RED 85
+15VDC
DC COMMON BLACK 95
WHITE
1VDC - 5VDC
1 2 3
Title:
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T R T D
T R A N S M IT T E R W IR IN G
Author: Sukup Mfg.
Date: 01/07
Revision: 1-10-08
Sheet: 91.16
NT
1
EK
uC control
RESET
K1
FSV
K2/1
2
12
2
K2/2
10
3
K3
7
K4
4
5
9
11
6
8
1
ION
3
LP
AL
4
Pa
BV2
Z
EK
1D
5
3 AMP
C.B. F9
BV1
M
1C
6
CR3
1B
7
HIGH GAS
PRESSURE SW
1A
8
A
HEATER
HOUSI NG OT
B'
B
C
D
SB/R
12
W/GP
1
2
AL
10
M
3
Z
7
BV1
4
(LR)BV2
5
LP
6
FS
1
9
AL = Alarm
BV1 = Fuel Valve # 1
BV2 = Fuel Valve # 2
FS = Flame Signal
GP = Gas Pressure Switch
LP = Air Pressure Switch
LR = Load Controller
M = Fan Motor
R = Control Thermostat
SB = Safety Limit Thermostat
W = Limit Thermostat / Pressure S w.
tw t10
t1
t3
Title:
t3n
TSA
11
t4
PORTABLE DRYER:DAN-CORN SINGLE
FAN & HEAT: BURNER CONTROL
Author: Sukup Mfg.
Date: 08/07
Revision: 1-10-08
Sheet: 91.17
SINGLE FAN ELECTRICAL DRAWING NOTES
NOTE 1:
On 3 phase dryers the control voltage comes from an auxiliary contact on motor starter M5.
NOTE 2:
On all switches, XOO indicates that the switch is in the Manual or ON position. OOX
indicates that the switch is in the Computer or AUTO position.
NOTE 3:
CR Unload is an off delay timer, allowing the unload to clean out when a fault occurs.
NOTE 4:
Terminals found in the auxiliary box. If no auxiliary controls are installed, place a jumper
between terminal 18 and terminal 49.
NOTE 5:
For auxiliary wiring of 12CH01 and 12CH02, Refer to Appendix 1 in the Dryer Manual.
NOTE 6:
Drawing 91.12 covers both LP & NG heaters. If the heater is NG, then the vapor high limit
and the liquid solenoid valve are not used.
NOTE 7:
- indicates the screw terminal on the relay socket that the wire is attached to,
found in drawing 91.9.
NOTE 8:
The Differential Air Flow switch is only used on CE and CSA dryers. It is not used on the
domestic dryers.
NOTE 9:
Auxiliary contacts on M3 are a dry set of contacts that can be used for controlling extra
unload equipment when the dryer unload is running. If a Sukup Cyclone air system is used,
just connect between terminal #17 & #18 on the air system and terminals # 14 and # 15
on the dryer for automatic control.
NOTE:
There are different types of electrical noise protection installed throughout the dryer. These
components might not be shown.
L1
L2
1
L3
3
WIRE FOR Y-DELTA STARTER
J5225 AND J5226
5
KM2
1
3
5
1
3
5
KM3
2
4
6
KM1
2
4
6
2
4
6
14
U1
V1
W1
KM2
13
14
KM1
U2
V2
W2
13
TERM #11
55
67
KM2
TERM #12
14
56
68
22
22
KM3
KM3
KM1
21
21
13
A1
A1
TERM #12
KM1
KM3
A2
TERM #2
A1
KM2
A2
Term #12*
Term #11*
Term #2
Term #13*
Title:
Y-D E LT A W IR IN G
Author:
Date:
Sukup M fg.
1 1 /3 0 /0 5
Revision: 1-10-08
Sheet:
9 1 .1 9
A2
L1
L2
1
L3
3
5
1
KM2
3
1
5
3
5
KM3
2
4
U1
V1
6
KM1
2
4
6
2
6
4
14
W1
KM2
13
14
KM1
13
U2
V2
TERM #11*
W2
55
TERM #12*
67
KM2
KM2
68
56
14
22
21
KM3
13
KM3
A1
TERM #13*
KM1
21
KM1
A2
22
A1
KM2
A1
KM3
A2
A2
TERM #2
Term #1 2*
Term #1 1*
A1
A1
A2
A1
* WIRE NUMBERS MAY VARY DEPENDING IF IT IS ON
THE UPPER FAN OR THE LOWER FAN.
A2
A2
21
21
13
55
67
56
68
21
13
KM3
LOWER FAN
#11 FAN ON
#12 HEAT INTERLOCK
#13 HEAT INTERLOCK
13
UPPER FAN
#110 FAN ON
#109 HEAT INTERLOCK
#111 HEAT INTERLOCK
K M1
K M2
14
14
14
22
22
22
A2
A2
T erm # 2
T erm # 13 *
Title:
Y-D EL TA W IR IN G
Author: Sukup Mfg.
Date: 12/08/05
Revision: 1-10-08
Sheet:
9 1 .2 0
Appendix G
Two Fan Ladder Diagrams
MAIN DISCONNECT SWITCH
1
MAIN DISCONNECT
SW ITCH
POW ER DIST
BLOCK
2
480 VOLTS
3
FUSE F1
3 AMP
FUSE F1
3 AMP
FUSE F2
3 AMP
H1
H3 H2
H4
4
FUSE F2
3 AMP
H3 H2
H1
H4
CONTROL TRANSFORMER
PRI-230V / 1 PHASE
SEC-120V / 1 PHASE
X1
CONTROL TRANSFORMER
PRI-480V / 1 PHASE
SEC-120V / 1 PHASE
X2
2
X1
X2
FUSE F3
3 AMP
5
E-STOP
6
PLC COM
10CH02
1
1
7
1
92.8(6)
MOC
22
1
22
OOX
1
9
SWITCHED
AC CR1
33
92.1(11)
92.12(7)
MOV
33
SYSTEM
CONTROL
8
PLC OUT
10CH02
10CH02
F6 C.B.
.5 AMPS
F7 C.B.
.5 AMPS
23
POWER
TO PLC
25
+5 & +15VDC
POWER SUPPLY
EMI FILTER
22
+24 VOLT DC
POWERSUPPLY
XOO
1
10
26
26
AUO/MAN CR2
92.5(9)
92.12(15)
XOO
11
24
12
I/O J2 I/O K2
RELAY
PIN 3
MOV
87
CR
UNLOAD
OOX
I/O FUSE
I/O J2
F2 3A
3
13
3
METER
ROLL CR5
PIN 4
10A
87
2
RC SNUBBER
1
UNLOAD
AUGER M2
XOO
NOTE #2
CR UNLOAD
1
87
1
10
10
24
XOO
92.1(7)
MOV
UNLOAD
SWITCH
MO A
SWITCHED
AC CR1
1
3
24
Title:
PORTABLE DRYER: DAN-CORN TW O FAN
& HEAT: 120 VOLT CONTOL
Author: Sukup Mfg.
Date: 01/08
Revision: 1-10-08
Sheet: 92.1
1
3
LOWER HEAT
SWITCH
24
2
CR-M 5
OR M 5
MO A
1
I/O J2
PIN 15
I/O J2
PIN 16
I/O K 8 I/O FUSE
RELAY F8 3 A
12
24
XO O
LOWER HEAT
CR3
13
NOTE #1
89
2
89
RC SNUBBER
FROM LOWER
HEATER
BOX
3
LOWER
HEAT CR3
1B
LOCATED IN POWER BOX
PLC COM
13CH00
OO X
F9 C.B.
3A
1C
1D
( FOR 28")
TO LOWER
HEATER
BOX
SEE DRAWING # 92.16
LOWER FAN
SWITCH
PLC OUT
13CH00
13CH00
120
4
LOWER
FAN M5
MO A
11
120
XO O
I/O J2 I/O K7 I/O FUSE
RELAY F7 3A
PIN 13
5
I/O J2
PIN 14
MOV
88
88
OO X
UPPER HEAT
SWITCH
RC SNUBBER
MO A
6
CR-M 6
OR M 6
109
24
UPPER
HEAT CR6
111
XO O
NOTE #1
I/O J2
PIN 7
7
I/O K4 I/O FUSE
RELAY F4 3A
I/O J2
PIN 8
113
OO X
RC SNUBBER
FROM UPPER
HEATER
BOX
8
UPPER
HEAT CR6
1G
LOCATED IN POWER BOX
10CH00
1H
1I
( FOR 38" / 44" )
TO UPPER
HEATER
BOX
SEE DRAWING 92.15
UPPER FAN
SWITCH
MO A
9
PLC COM
10CH00
F10 C.B.
3 AMP
PLC OUT
10CH00
121
UPPER
FAN M6
110
XO O
10
I/O K3 I/O FUSE
I/O J2
F3 3A
I/O J2 RELAY
PIN 5
11
PIN 6
MOV
114
OO X
HOUR METER
3
RC SNUBBER
2
Title:
PORTABLE DRYER: DAN-CORN TW O
FAN & HEAT 120 VAC CONTROL
Author: Sukup Mfg.
Date: 1/08
Revision: 1-10-08
Sheet: 92.2
1
3
2
PLC OUT
10CH03
PLC COM
10CH03
10CH03
CR UNLOAD
31
31
1
MOV
PLC COM
12CH00 12CH00
LOAD
SWITCH
PLC OUT
12CH00
2
LOAD AUGER M2
MO A
32
6
XOO
I/O J2
PIN 1
3
I/O K1 I/O FUSE
RELAY F1 3A
I/O J2
PIN2
MOV
86
OOX
RC SNUBBER
WORK LIGHT
SWITCH
MO A
19
1
4
WORK LIGHT
19
2
1 XOO
5
3
OOX
MAIN GAS
VALVE
3
6
7
8
9
10
11
1
2
3
Title:
PORTABLE DAN-CORN DRYER: TW O FAN
& HEAT 120 VOLT CONTROL
Author: Sukup Mfg.
Date: 01/08
Revision: 1-10-08
Sheet:
92.3
+24 VDC
18
DC COMMON
95
1
INPUT 0CH
95
COM
REAR DOOR
0CH00
2
18
3
LOWER VAPOR
HIGH LIMIT
18
37
37
UPPER VAPOR
HIGH LIMIT
18
102
102
4
5
36
36
0CH01
0CH02
0CH03
CONNECT #18 TO THE INPUT IF NOT USING HOUSING HIGH LIMIT
18
6
UPPER PLENUM HIGH LIMIT
18
104
104
7
RIGHT COLUMN HIGH LIMIT
18
40
40
8
LEFT COLUMN HIGH LIMIT
41
18
41
9
GRAIN DISCHARGE CHUTE
42
18
42
10
UPPER STATIC AIR
PRESURE SWITCH
18
105
105
LOWER PADDLE
18
44
44
11
0CH04
0CH05
0CH06
0CH07
0CH08
0CH09
UPPER FLAME RELAY
18
12
LOAD M 2
49D
13
0CH10
106
106
UNLOAD M 3
49E
LOWER FAN M 5
49F
UPPER FAN M 6
49G
0CH11
49
18
+
+
18
49
+
+
NOTE 4
MOTOR OVERLOAD CIRCUIT
Title:
P O R T A B L E D R Y E R : D A N -C O R N T W O
F A N & H E A T P L C IN P U T S C H A N N E L 0
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10-08
Sheet: 92.4
+24 VDC
18
DC COMMON
95
1
INPUT 1CH
95
UPPER FAN ON
18
107
2
COM
1CH00
107
92.3(1)
I/O J2
PIN 11
3
I/O K6 I/O FUSE
RELAY F6 .25A
I/O J2
PIN 12
18
1CH01
51
51
DRYFIRE
4
1CH02
LOAD ON M2
47
18
I/O J2
PIN 9
5
47
I/O K5 I/O FUSE
RELAY F5 .25A
I/O J2
PIN 10
18
1CH03
52
52
RESET
6
1CH04
CONNECT #18 TO INPUT IF NOT USING THE HOUSING HIGH LIMIT
18
18
7
UPPER PADDLE
18
53
53
8
UPPER HEAT ON
108
18
108
1CH05
1CH06
92.1(11)
9
10
11
12
13
AUTO/MAN
18
54
LOWER PLENUM HIGH LIMIT
39
18
LOWER STATIC AIR
PRESSURE SWITCH
18
1CH07
54
1CH08
39
1CH09
43
43
LOW ER FLAME RELAY
18
45
45
LOWER FAN ON
18
46
46
1CH10
1CH11
Title:
P O R T A B L E D R Y E R : D A N -C O R N T W O
F A N & H E A T P L C IN P U T S C H A N N E L 1
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10-08
Sheet: 92.5
DC COMMON
95
+24 VDC
18
1
95
COM
2CH00
2
3
INPUT 2CH
50
LOWER HEAT CR3
18
48
2CH01
48
4
2CH02
5
2CH03
6
2CH04
7
2CH05
2CH06
8
2CH07
9
2CH08
10
2CH09
11
2CH10
12
2CH11
13
Title:
P O R T A B L E D R Y E R : D A N -C O R N T W O
F A N & H E A T P L C IN P U T S C H A N N E L 2
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10-08
Sheet: 92.6
+24 VDC
18
DC COMMON
95
INPUT 3CH
COM
1
95
PRIOR TO 2007 DIFFERENTIAL AIR SWITCH INPUT
- CONNECT TO #95 SO INPUT IS ALWAYS ON
95
95
PRIOR TO 2007 DIFFERENTIAL AIR SWITCH INPUT
- CONNECT TO #95 SO INPUT IS ALWAYS ON
95
3CH00
2
3
3CH01
3CH02
4
3CH03
UNLOAD ON M 3
95
5
94
94
LEFT METER ROLL
PROXIMITY SWITCH
95
6
3CH04
92
92
RIGHT METER ROLL
PROXIMITY SWITCH
95
7
3CH05
93
93
UNLOAD AUGER
PROXIMITY SWITCH
95
8
3CH06
96
96
3CH07
9
3CH08
10
3CH09
11
3CH10
12
LOAD SWITCH
95
13
95A
10
+
18
+
11
+
95
+
12
UNLOAD SWITCH
TO PLC
INPUT
LOWER FAN
SWITCH
95B
UPPER FAN
SWITCH
95C
3CH11
95D
BROWN
+24VDC
BLUE
DC COMMON
BLACK
SIGNAL
PROX SWITCH
Title:
PO RTAB LE DRYER : D AN=C O RN TW O
F A N & H E A T P L C IN P U T S C H A N N E L 3
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 92.7
OUTPUT 10CH
1
2
3
COM
10CH00
COM
(120 VAC)
SWITCHED AC
+ 3
+
3
121
UPPER FAN SWITCH
MODEM (if used)
+ 55 +
55
MUST CONNECT DIRECTLY TO THE PLC TERMINALS
4
5
10CH01
COM
56
1
MODEM (if used)
+ 56 +
+
120 VAC
1
+
SWITCHED AC
COIL CR1
6
7
8
9
10CH02
33
2
CR UNLOAD
10CH03
COM
10CH04
31
2
95
DC COMMON
+
95
+
1A
1A
REAR DOOR
I/O J15 PIN 1
14A
14A
AUTO/MAN
I/O J15 PIN 14
3A
3A
4A
4A
10
10CH05
11
10CH06
12
13
10CH07
Title:
UPPER VAPORIZER HIGH
LIMIT I/O J15 PIN 3
UPPER HEATER HOUSING
HIGH LIMIT I/O J15 PIN 4
PORTABLE DRYER: DAN-CORN TW O FAN
& HEAT PLC OUTPUTS CHANNEL 10
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10/08
Sheet: 92.8
OUTPUT 11CH
1
DC COMMON
+ 95 +
95
COM
2
5A
5A
6A
6A
11CH00
UPPER PLENUM HIGH
LIMIT I/O J15 PIN 5
3
11CH01
4
COLUMN HIGH LIMIT
I/O J15 PIN 6
I/O J1
PIN 5 & 7
11CH02
5
91
7A
COLUMN HIGH LIMIT
I/O J15 PIN 7
2A
GRAIN DISCHARGE
CHUTE I/O J15 PIN 2
METER ROLL FAULT
2A
11CH03
6
7
8
95
COM
9
11CH04
DC COMMON
+ 95 +
11A
11A
UPPER 5 SECOND AIR
FAULT I/O J15 PIN 11
13A
13A
10 MINUTE OUT OF WET
GRAIN I/O J15 PIN 13
12A
12A
UPPER 45 SECOND HEATER
FAULT I/O J15 PIN 12
8A
8A
10
11CH05
11
11CH06
12
13
11CH07
Title:
MOTOR OVERLOAD
I/O J15 PIN 8
P O R T A B L E D R Y E R : D A N -C O R N T W O
FAN & HEAT PLC O UTPUT CHAN NEL
11
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10/08
Sheet: 92.9
OUTPUT 12
1
2
COM
12CH00
3
32
SWITCHED AC
120 VOLTS
+ 3
+
LOAD SWITCH
MANUAL
92.1 (8)
3
4
5
6
7
8
9
COM
12CH01
COM
12CH02
7
+
7
+
1ST AUX LOAD
(incline auger or leg)
NOTE: 6
5
+
5
+
8
+
8
+
2ND AUX LOAD
(wet bin)
NOTE: 6
9
+
95
DC COMMON
+ 95 +
9
+
12CH03
COM
12CH04
15A
15A
16A
16A
9A
9A
LOWER PADDLE SWITCH
I/O J15 PIN 9
10A
10A
UPPER PADDLE SWITCH
I/O J15 PIN 10
UPPER AIR SENSE
I/O J15 PIN 15
10
12CH05
UPPER FLAME SENSE
I/O J15 PIN16
11
12CH06
12
13
12CH07
Title:
P O R T A B L E D R Y E R : D A N -C O R N T W O
FAN & HEAT PLC O UTPUT CHAN NEL
12
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10/08
Sheet: 92.10
OUTPUT 13CH
1
2
3
4
5
6
7
8
9
COM
13CH00
COM
13CH01
COM
13CH02
13CH03
COM
13CH04
3
120
95
SWITCHED AC
120 VOLTS
+
+3
LOW ER FAN
SWITCH MANUAL
DC COMMON
+ 95 +
5B
5B
LOW ER FLAME SENSE
I/O J16 PIN 5
3B
3B
LOWER VAPOR HIGH
LIMIT I/O J16 PIN 3
2B
2B
LOWER HOUSING HIGH
LIMIT I/O J16 PIN 2
1B
1B
LOWER PLENUM HIGH
LIMIT I/O J16 PIN 1
6B
6B
LOWER 5 SEC AIR
FAULT I/O J16 PIN 6
7B
7B
LOW ER 45 SEC FLAME
FAULT I/O J16 PIN 7
4B
4B
LOW ER AIR SENSE
I/O J16 PIN 4
95
95
DC COMMON
+ 95 +
DC COMMON
+ 95 +
10
13CH05
11
13CH06
12
13
13CH07
Title:
P O R T A B L E D R Y E R : D A N -C O R N T W O
FAN & HEAT PLC O UTPUT CHAN NEL
13
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10/08
Sheet: 92.11
LOWER HEAT RELAY CR3
1
13
FROM CRM5
OR M5
B
AUTO/MAN CR2
2
A
15
FROM COMP
MAN SWITCH
26
A
92.2(1)
18
2
1B
3
7
48
TO PLC 2CH01
C.B. F10
3 AMP
1C
6
1D TO HEATER
BOX
16
SCR REF.
via THUMBWHEEL
SCR REF
17 via PROCESSOR
17B
6
METER ROLLS CR5
FROM UNLOAD
2
A
B
SWITCH
10A
92.1(12)
L2
5
L1
6
7
17A
7
92.13(4)
C.B. F4
220VAC
3 AMP
L1B TO SCR
L1A
6
9
TERM L1
92.13(5)
FROM
10CH02
1
92.1(11)
6
9
SWITCHED AC
TO TERM 3
UPPER HEAT RELAY CR6
92.2(6)
FROM CRM6
2
111 B
OR M6
A
18
10
1G
11
7
9
DC COMMON
19
DC COMMON
20
12
B
18
+24VDC
13
14
10
9
6
7
1
TO SCR
TERM COM
1
5
8
54
TO PLC
1CH07
AUX CONTACT ON M2
47 TO PLC INPUT
18
+24VDC
1CH02
LOAD ON SIGNAL
AUX CONTACT ON M3
22
95
-24VDC
TO TERMINAL
#14 - POWER BOX
94 TO PLC INPUT
3CH03
UNLOAD ON SIGNAL
AUX CONTACT ON M3
15
14
TO TERMINAL
#15 - POWER BOX
AUX CONTACT ON M5
1I
TO HEATER
BOX
24
2
+24VDC
18
46
TO PLC INPUT
1CH11
LOWER FAN
ON SIGNAL
25
AUX CONTACT ON M6
18
107 TO PLC INPUT
+24 VDC
1CH00
92.3(1)
1
95
TO PLC 1CH06
1H
A
95
4
7
92.13(9)
92.5(9)
CR UNLOAD
31
95
92.13(8)
23
C.B. F9
3 AMP
6
18
DRY CONTACT THAT CAN BE USED TO TURN
ON AUX UNLOAD EQUIPMENT
92.5(8)
108
4
92.15
TO SCR
TERM SIG
92.13(11)
21
3
17
3
TO SCR
TERM L2
SWITCHED AC CR1
92.1(7)
2
33
A
B
8 120VAC
9
4
L2A
9
92.13(10)
92.16
4
2
92.1(10)
4
92.6(3)
9
B
UPPER FAN
ON SIGNAL
87
10A
Title:
P O R T A B L E D R Y E R : D A N -C O R N T W O
FAN & HEAT RELAY CO N TAC T
W IR IN G
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10/08
Sheet: 92.12
1
2
+
AC.B. F5 3AMP
+
3
A+
4
5
6
7
L1B
L1
L2
L2A
DC COMMON
I1
+
95
+
92.12(19)
COM
SIG
95
95
95
92.12(18)
17
17B
92.12(17)
17
METER ROLL
SPEED POT 10K
+15 VDC
+ 85
5K OHM RESISTOR
17A
92.12(16)
12
POWER FROM POWER
DISTRIBUTION BLOCK
230 VAC
AUTO/MAN CR2
F+
+12
11
+
F-
17
10
+
L2
95
9
+
METER ROLLS CR5
C.B. F4 3AMP
L1
L1A
95
8
-
TO DC MOTOR ARMATURE
+
REF VOLTAGE
FROM PROCESSOR
CR2 IS ENERGIZED
WHEN IN MANUAL
13
Title:
PORTABLE DRYER: TW O FAN & HEAT
SCR BOARD W IRING
Author: KWC
Date: 01/01
Revision: 01/04 , 01/07
Sheet: 92.13
L1 L2 L3
1
MAIN DISCONNECT SWITCH
CB2
M2
2
LOAD
MOTOR
3
4
AUX CONTACT ON M2
18
+24VDC
5
47
TO PLC INPUT 1CH02
M3
CB3
6
UNLOAD
MOTOR
7
8
AUX CONTACT ON M3
95
94
TO PLC INPUT 3CH03
-24VDC
9
AUX CONTACT ON M3
14
15
DRY CONTACT FOR
THE AUXILIARY UNLOAD
10
M5
CB5
LOWER FAN
MOTOR
11
12
NOTE: Please see Drawing 92.24 & 92.25
AUX CONTACT ON M5
18
46
TO PLC INPUT 1CH11
+24VDC
13
CB6
M6
14
UPPER FAN
MOTOR
15
16
17
+24VDC
AUX CONTACT ON M6
18
107
TO PLC INPUT 1CH00
Title:
P O R T A B L E D R Y E R : D A N -C O R N T W O
F A N & H E A T 3 P H P O W E R W IR IN G
Author: Sukup Mfg.
Date: 08/07
Revision: 1-10-08
Sheet: 92.14
TO POWER BOX
GND 2
1 1I 18 37455216195
1G
2
TERMINAL STRIP
IN HEATER BOX
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
1G
1
2
1I
18
21
37
45
52
161
FO
95
GND
VAPOR OVER TEMP.
18
18
FSR1
IR3
RR2
1
13
67
15
62
62
17
63
IR1
66
64
19
FO
37
E lectronic Mod Valve
SPARK
TRANSFORMER
9
6
FO - Blue
RED LIGHT
10
PRESSURE SWITCH FOR
VALVE PROVING CONTROL
(NO)
64
62
IR2
23
58
67
63
(NC)
LIQUID SOLENOID
59
+
MAIN GAS VALVE
+
+
1E +
+
+
+
+
1 +
BLOCKING GAS VALVE
60
VALVE PROVING UN IT
1E
DC COMMON
18
61
AIR SWITCH
65
1
+
+
air
s w.
11
10 +
60 +
+24VDC
SPARK PLUG
2
Black
Red
65
21
FSR
58
10 +
95
IR
1I
2
HOUSING
OVER TEMP
+
RR
52
+
+
+
+
+
+
+
+
+
+
+
+
12
11
10
9
8
7
6
5
4
3
2
1
AIR SWITCH SOLENOID #2
45
BURNER CONTROL UNIT
12 1I +
11 11 +
10 58 +
RR1
+
9
+
57
8
9 +
7
6 +
6
+
5
10 +
4
FO +
3
+
2
+
1
FLAME ROD
1
AIR SWITCH SOLENOID #1
TO HIGH PRESSURE SWITCH (see below)
+
+
+
BLACK 95
RED 18
WHITE 61
1F
1I (from the power box)
HIGH
PRESSURE
1G (to the power box)
1G
-1
- 23
-
NOTE: Pipe train components connect to a terminal
strip in a 5 x 5 box located on the front of the
dryer. From that terminal strip through a conduit
to the heater box terminal strip.
CONTROL SIGNAL
ELECTRONIC MOD VALVE
MOTOR-ON PIPE TRAIN
Title:
IR - ISOLATION RELAY
RR - RESET RELAY
FSR - FLAME SENSE RELAY
- INDICATES NO CONNECTION
PORTABLE DRYER: DAN-CORN TWO FAN & HEAT
UPPER HEATER CONTROL & FAULT - 38" OR 44"
HOUSING
Author: Sukup Mfg.
Date: 01/04
Revision: 1-10-08
Sheet: 92.15
TO POWER BOX
1
1D
37 52 95
18 45 61
2
1-10-08
2
1B
TERMINAL STRIP
IN HEATER BOX
+
+
+
+
+
+
+
+
+
+
+
+
+
1B
1
2
1D
18
21
37
45
52
61
FO
95
GND
+
+
+
+
+
+
+
+
+
+
+
+
+
18
18
FSR1
IR1
AIR SWITCH SOLENOID #2
37
45
RR
52
E lectronic Mod Valve
IR
10
SPARK
TRANSFORMER
SPARK PLUG
9
Black
Red
6
11
FO - Blue
air
s w.
AIR SWITCH
RED LIGHT
10
RR2A
1
FSR
58
BURNER CONTROL UNIT
12 1D +
11 11 +
10 58 +
RR1
+
9
57 +
8
9 +
7
6 +
6
+
5
10 +
4
FO +
3
+
2
+
1
FLAME ROD
1
AIR SWITCH SOLENOID #1
TO HIGH PRESSURE SWITCH (see below)
VAPOR OVER TEMP.
LIQUID SOLENOID
10A
10A
RR2B
MAIN GAS VALVE
BLOCKING GAS VALVE
10
2
HOUSING
OVER TEMP
1
1
DC COMMON
+
+
95
+24VDC
18
+
+
BLACK 95
RED 18
WHITE 61
1A
HIGH
PRESSURE
1B
-1
- 23
-
1B (to the power box)
NOTE: Pipe train components connect to a terminal
strip in a 5 x 5 box located on the front of the
dryer. From that terminal strip through a conduit
to the heater box terminal strip.
CONTROL SIGNAL
+
61
+
ELECTRONIC MOD VALVE
MOTOR-ON PIPE TRAIN
IR - ISOLATION RELAY
RR - RESET RELAY
FSR - FLAME SENSE RELAY
- INDICATES NO CONNECTION
Title:
PORTABLE DRYER: DAN-CORN TWO FAN & HEAT
LOWER HEATER CONTROL & FAULT - 28" HOUSING
Author: Sukup Mfg.
Date: 01/04
Revision: 1-10-08
Sheet: 92.16
95
85
SIG
1
2
UPPER PLENUM
TEMP SIGNAL
3
72
TEMP DISPLAY
+
+
71
4
71
72
+
+
LOWER PLENUM
TEMP SIGNAL
5
ELECTRONIC MOD VALVE CONTROL BOARD
DC COMMON
+
95
7
+
8
+
9
+15VDC
85
REF VOLTAGE
FROM PROCESSOR
95
85
61
61A
161
161A
6
+
DC COMMON
+ 95 +
ELECTRONIC MOD VALVE
MOTOR- ON UPPER PIPE TRAIN
61A
+
161A
+24VDC
18
+
BLACK 95
RED 18
WHITE 161
10
1
2
3
11
12
13
DC COMMON
+ 95 +
+
+24VDC
18
+
ELECTRONIC MOD VALVE
MOTOR- ON LOWER PIPE TRAIN
BLACK
RED
WHITE
Title:
95
18
61
1
2
3
P O R T A B L E D R Y E R : D A N -C O R N T W O
F A N & H E A T E L E C T R O N IC M O D
VALVE CO NTRO L
Author: Sukup Mfg.
Date: 01/06
Revision: 1-10-08
Sheet: 92.17
+
82
+
82
161A TO UPPER EMOV CONTROL BOARD
61A TO LOWER EMOV CONTROL BOARD
17A TO CR2 SCR REF VOLTAGE
01 23 4567
REMOTE
PRINTER
CONNECTOR
SMARTWATCH
GRAY
PINK
A to D CONNECTOR
DALLAS
LANGUAGE
CHIP
D to A CONNECTOR
EPROM
PLENUM TEMP
+
+
+
71
70
70
+
+
+
COLUMN TEMP
(if used)
.01uF
CAP
+
+
+
POWER PLUG
72
71
95
85
84
+
+
+
POWER PLUG
YELLOW HARNESS TO PLC
KEYPAD
HARNESS
BLUE HARNESS TO PLC
LCD
HARNESS
OUTPUT SENSOR
PINK
RED
BROWN
BLUE
BLACK
WHITE
GREEN
SHIELD
89
TO LOWER HEATER SWITCH
88
TO LOWER FAN SWITCH
51
DRYFIRE SIGNAL
113
18
52
+24VDC
RESET SIGNAL
TO UPPER HEATER SWITCH
114
TO UPPER FAN SWITCH
87
TO UNLOAD SWITCH
SWITCHED AC
TO LOAD SWITCH
3
86
GRAY
INPUT SENSOR
(if used)
Title:
CABLE TO
MOISTURE SENSOR
PORTABLE DRYER : DAN-CORN TW O FAN &
HEAT I/O & PRO C ESSO R B OARD W IRIN G
Author: Sukup Mfg.
Date: 01/07
Revision: 1-10-08
Sheet: 92.18
+5 VDC
+
841
+
841
+5 VDC
+
84
+
DC COM.
+
95
+
+
85
+
+
82
+
95
95
95
PRINTER POWER
HARNESS
SIGNAL FROM
PROCESSOR
PAPER ROLLER CONTROL BOARD
82
85
95
+15 VDC
84
82
FOR MANUAL
PUSH BUTTON
(if installed)
811
801
80
81
DC MOTOR AND PAPER ROLLER
Title:
PORTABLE DRYER : DAN-CORN TWO FAN & HEAT
PRINTER AND PAPER ROLLER WIRING
Author: Sukup Mfg.
Date: 01/07
Revision: 1-10-08
Sheet: 92.19
MINCO TRANSMITTER (DISCONTINUED IN 2007 - REPLACE WITH T17028)
POWER
95 DC COMMON BLACK
+15VDC
85
RED
SIGNAL BACK TO PROCESSOR
WHITE
YEL
RED
1
2 3
RED
1 2 3
SENSOR
RTD'S & TRANSMITTERS ARE USED
TO SENSE PLENUM TEMP AND ALSO
WITH THE COLUMN TEMP OPTION.
TO RTD SENSOR
T17028 NEW AS OF 2007
FROM RTD SENSOR RED
1 2 3
FROM RTD SENSOR YEL
BLACK 95
DC COMMON
RED 85
+15VDC
WHITE
1VDC - 5VDC
SIGNAL BACK TO PROCESSOR
1 2 3
Title:
PORTABLE DRYER : DANCORN TW O
F A N & H E A T R T D T R A N S M IT T E R
W IR IN G
Author: Sukup Mfg.
Date: 01/07
Revision: 1-10-08
Sheet: 92.20
TWO FAN ELECTRICAL DRAWING NOTES
NOTE 1: On 3 phase dryers, the control voltage comes from an Auxiliary contact on M5 & M6 starter.
NOTE 2: On all switches XOO indicates that the switch is in the Manual or ON position. OOX
indicates that the switch is in the Computer of AUTO position.
NOTE 3: CR Unload is a timed off delay, so that the unload will clean out when a fault occurs.
NOTE 4: Terminals found in the Auxiliary box. If no auxiliary controls are installed, place a jumper
between terminal 18 and terminal 49.
NOTE 5: For Auxiliary wiring of 12CH01 and 12CH02, Refer to Appendix 1 in the Dryer Manual.
NOTE 6: Drawing 91.12 covers both LP & NG heaters. If the heater is NG, then the vapor high limit
and the liquid solenoid valve are not used.
NOTE 7: - indicates the screw terminal on the relay socket that the wire is attached to,
found in drawing 91.9.
NOTE 8: Differential Air Flow switch is only used on CE and CSA dryers. It is not used on the
domestic dryers.
NOTE: There are different types of electrical noise protection that are installed throughout the dryer,
that might not be shown in these drawings.
NT
1
EK
uC control
RESET
K1
FSV
K2/1
2
12
2
10
K3
K2/2
3
7
K4
4
5
9
11
6
1
8
ION
3
LP
4
1I
AL
Z
Pa
BV2
EK
CR6
6
BV1
M
5
1H
3 AMP
C.B. F9
1G
7
HIGH GAS
PRESSURE SW
1F
8
HEATER
HOUSING OT
B
A
B'
C
D
SB/R
1E
12
W/GP
AL
10
NOTE: 1A COMES FROM TERMINAL M
#6 OF THE VALVE PROVING UNIT
3
Z
7
BV1
4
9
1E 2
AL = Alarm
BV1 = Fuel Valve # 1
BV2 = Fuel Valve # 2
(LR)BV2
FS = Flame Signal
GP = Gas Pressure Switch
LP = Air Pressure Switch
LP
LR = Load Controller
M = Fan Motor
R = Control Thermostat
FS
SB = Safety Limit Thermostat
W = Limit Thermostat / Pressure Sw.
5
6
11
1
tw t10
t1
t3
t3n
TSA
t4
Title: PORTABLE DRYER: DAN-CORN TW O FAN
& HEAT: UPPER BURNER CONTROLLER
Author: CSP
Date: 08/07
Revision: 1-10-08
Sheet: 92.22
NT
1
EK
uC control
RESET
K1
FSV
K2/1
2
12
2
10
3
K4
K3
K2/2
7
4
5
9
11
6
8
1
ION
3
LP
1D
4
AL
Z
Pa
BV2
EK
3 AMP
C.B. F9
5
6
BV1
M
1C
CR3
1B
7
HIGH GAS
PRESSURE SW
1A
8
B
A
HEATER
HOUSING OT
C
B'
D
SB/R
12
W/GP
9
1
AL
10
M
3
Z
7
BV1
4
2
AL = Alarm
BV1 = Fuel Valve # 1
BV2 = Fuel Valve # 2
(LR)BV2
FS = Flame Signal
GP = Gas Pressure Switch
LP = Air Pressure Switch
LP
LR = Load Controller
M = Fan Motor
R = Control Thermostat
FS
SB = Safety Limit Thermostat
W = Limit Thermostat / Pressure Sw.
5
6
11
1
tw t10
t1
t3
Title:
t3n
TSA
t4
PORTABLE DRYER: DAN-CORN LOW ER
FAN & HEAT: BURNER CONTROL
Author: Sukup Mfg.
Date: 08/07
Revision: 1-10-08
Sheet: 92.23
L1
L2
1
L3
3
WIRE FOR Y-DELTA STARTER
J5225 AND J5226
5
KM2
1
3
5
1
3
5
KM3
2
4
6
KM1
2
4
6
2
4
6
14
U1
V1
W1
KM2
13
14
KM1
U2
V2
W2
13
TERM #11
55
67
KM2
TERM #12
14
56
68
22
22
KM3
KM3
KM1
21
21
13
A1
A1
TERM #12
KM1
KM3
A2
TERM #2
A1
KM2
A2
Term #12*
Term #11*
Term #2
Term #13*
Title:
Y-D E LT A W IR IN G
Author:
Date:
Sukup M fg.
1 1 /3 0 /0 5
Revision: 1-10-08
Sheet:
9 2 .2 4
A2
L1
L2
1
L3
3
5
1
KM2
3
1
5
3
5
KM3
2
4
U1
V1
6
KM1
2
4
6
2
6
4
14
W1
KM2
13
14
KM1
13
U2
V2
TERM #11*
W2
55
TERM #12*
67
KM2
KM2
68
56
14
22
21
KM3
13
KM3
A1
TERM #13*
KM1
21
KM1
A2
22
A1
KM2
A1
KM3
A2
A2
TERM #2
Term #1 2*
Term #1 1*
A1
A1
A2
A1
* WIRE NUMBERS MAY VARY DEPENDING IF IT IS ON
THE UPPER FAN OR THE LOWER FAN.
A2
A2
21
21
13
55
67
56
68
21
13
KM3
LOWER FAN
#11 FAN ON
#12 HEAT INTERLOCK
#13 HEAT INTERLOCK
13
UPPER FAN
#110 FAN ON
#109 HEAT INTERLOCK
#111 HEAT INTERLOCK
K M1
K M2
14
14
14
22
22
22
A2
A2
T erm # 2
T erm # 13 *
Title:
Y-D EL TA W IR IN G
Author: Sukup Mfg.
Date: 12/08/05
Revision: 1-10-08
Sheet:
9 2 .2 5
AUTOMATIC GRAIN DRYER
Continuous Flow / Automatic Batch
Installation / Service Manual (CE)
Sukup Manufacturing Company
1555 - 255th Street P.O. Box 677
Sheffield, Iowa 50475
Phone 641 – 892 – 4222
Fax 641 – 892 – 4629
Manual # L14103CED - DC
2008/01
©Sukup Manufacturing Company
Installation Section
Table Of Contents
Installation and Pre-operational Check out ..................................................................................... 3
Dryer set up / supports................................................................................................................. 3
Cross support braces and Front stand ........................................................................................ 6
Lift Bracket Locations................................................................................................................... 7
Wet Bin assembly ...................................................................................................................... 10
Top Load Auger Motor and Shields ........................................................................................... 12
Dryer Hitch with 24” Extension................................................................................................... 15
Safety shields / Access doors and covers ................................................................................. 16
Control Box Stand Assembly ..................................................................................................... 21
Ground Rod Installation ............................................................................................................. 22
Service Manual .............................................................................................................................. 23
Sensor Installation and Removal Instructions............................................................................ 23
Component Calibration .............................................................................................................. 35
Heater operation at low plenum temperatures .............................................................................. 43
Appendix A – Fan Blade Replacement ......................................................................................... 47
Appendix B – Dryer Orifice and Port Cup Combinations............................................................... 50
2-2
Installation Section
Installation and Pre-operational Check out
Dryer set up / supports
Warning
The wheel transport kit is for transport only and is NOT to be used
when operating the dryer. The dryer MUST be mounted and
supported in an approved manner.
The dryer must be mounted a minimum of 40.64 cm above the
surface to allow for clean out.
Optional dryer supports are available from Sukup Mfg. in 0.61M,
0.91M, and 1.22M lengths. The support kits come with the
necessary hardware needed to attach the supports to the dryer
frame. The customer must supply the hardware necessary for
attachment to the concrete pad. (Recommend 1/2“ or 5/8”
hardware).
Ladder extensions are included with the 0.91M & 1.22M leg
extension kit. The same length of ladder extension is supplied
with the 1.22M kit as the 0.91M kit. For the 0.91M kit cut off
excess ladder length for your application.
Contact your Sukup Dealer to order either the supports and / or
extra ladder extensions.
The following five drawings show proper support leg locations for
8, 12, 16, 20, 24 and 28 foot dryers.
8 Foot Dryer
2-3
Installation Section
12 Foot Dryer
16 Foot Dryer
2-4
Installation Section
20 Foot Dryer
24 Foot Dryer
2-5
Installation Section
28 Foot Dryer
Cross support braces and Front stand
If the dryer is not mounted using Sukup Mfg supports, the
following guidelines must be followed:
•
•
•
Supports under grain columns must be at least every 6 feet
(1.83 meters).
Support under front hitch
Fasten dryer down to foundation using brackets or
turnbuckles
2-6
Installation Section
Lift Bracket Locations
8 Foot Dryer Lift Points
12 Foot Dryer Lift Points
2-7
Installation Section
16 Foot Dryer Lift Points
20 Foot Dryer Lift Points
2-8
Installation Section
24 Foot Dryer Lift Points
28 Foot Dryer Lift Point
2-9
Installation Section
Wet Bin assembly
Note:
When working with the top section of the dryer, a walk-way must
be installed that meets any applicable standards / codes.
1. Position the half of the wet bin without the auger into the
upright position first, then pivot the side with the auger into
the upright position. Bolt the wet bin together at the end plate
seams, side seams, pivot seams, and top hanger support.
2. Bolt the trash pan brackets into the wet bin on filling end of
dryer. Bolt the trash pan to the trash pan brackets. Refer to
Figure SPT0036.
Figure SPT0036
3. Attach the fill auger paddle switch assembly. Locate the
holes for the paddle switch in the wet bin on the end
opposite the filling end.
Note
Holes are pre-punched for mounting at either end. Remove
desired plastic plugs.
4. Slide a plastic bushing on each side of wet bin from inside
out. Slide the shaft with the mercury switch box through the
bushing on one side of the wet bin. Position the paddle
weldment inside of the wet bin, and slide the shaft through
the pipe of paddle weldment. Slide the shaft through the
bushing on the other side of the wet bin. Tighten set screws
of paddle weldment onto shaft, making sure the paddle and
box on shaft are square, and paddle can pivot freely.
Figure SPT0054
2 - 10
Installation Section
Wet Bin Assembly (Continued)
5. Bolt the top fill hopper to the top of the wet bin on the filling
end of the dryer. Place the cover plates on top and attach
with ¼” x 1” self drill screws. Refer to Figure SPT0039 for
Front fill and Figure SPT0041 for Rear fill dryers.
Figure SPT0039
Figure SPT0041
2 - 11
Installation Section
Top Load Auger Motor and Shields
1. Bolt the lower shield bracket to the end of the dryer, using
5/16 x 1” bolts and 5/16 nuts. Refer to Figure SPT0031.
Figure SPT0031
2. Hold the motor mount up to the holes on the side of the wet
holding bin. Slide a 1” conduit tube through the motor plate
holes of the dryer. Refer to Figure SPT0034.
Figure SPT0034
3. Slide the shaft collars on each side of the wet holding bin
plate. Refer to Figure SPT0035.
2 - 12
Installation Section
Motor
Hardware
(4 Pieces)
Turnbuckle
Hardware
Figure SPT0035
4. Tighten the shaft collars under the motor mount and on each
side of the wet holding bin plate. Make sure the motor mount
can pivot. Refer to picture below.
5. Bolt the turnbuckle plate to the side of the dryer. Refer to
Figure SPT0034.
6. Bolt the turnbuckle between the motor mount and the
turnbuckle plate using ½ x 1 ¾ “ bolts and ½” flat washers
and ½” lock nuts. Refer to Figure SPT0035.
7. Bolt the motor to the motor mount using 5/16” x 1” bolts and
5/16 nuts and washers. Refer to Figure SPT0034.
2 - 13
Installation Section
8. Bolt the inner shield to the upper and lower brackets using
5/16 bolts, washers, and nuts. Refer to Figure SPT0034.
9. Attach a 10.8 cm O.D. pulley to the motor shaft with a key
and attach the 40 cm O.D. pulley to the top load auger with a
taper lock bushing. Attach 2 B95 belts between the auger
pulley and the motor pulley. Tighten the turnbuckle to tighten
the belts Refer to Figure SPT0034.
10. The Final assembly should appear as below.
Figure SPT0033
11. Slide the outer shield around the outside of the inner shield
and attach with 6 – 5/16” x 1” bolts.
Refer to Figure SPT0034.
2 - 14
Installation Section
Dryer Hitch with 24” Extension
Dryers have an extension to compensate for the belt drive
distance for easier transport. See below for part descriptions of
this extension.
ITEM NO.
1
2
3
4
5
6
7
8
9
10
11
QTY.
1
1
1
1
1
5
5
4
2
2
2
PART NO.
T16310D
T43711
T16309D
T4372
J0822
J1220
J1051
J0813
J08361
J1222
J1059
2 - 15
DESCRIPTION
HITCH RECEIVER WELDMT, JACK
HITCH INSERT WELD, 24” EXT
TUBE, 4 ½ X 4 ½ SQ, 24” HITCH EXT
CLEVIS WELD
SCREW, ¾”-10 X 5” LG.
¾” LOCKWASHER
¾-10 HEX NUT
SCREW, ¾-10 X 5 ½” LG
BOLT, 7/8-9 X 6 ½” LG
7/8” LOCKWASHER
7/8-9 HEX NUT
Service Section
Safety shields / Access doors and covers
Warning
It is extremely important to operate the dryer with all safety
shields installed.
1. Safety Shields
The load auger safety shield is located on the top of the Dryer
and it functions to cover the load auger drive pulleys, motor, and
belts.
The unload auger and meter roll drive safety shield is located on
the front of the dryer and functions to cover the unload auger
motor, pulleys and belts. It also covers the meter roll sprockets
and drive chains.
2 - 16
Service Section
The non-driven end of the load auger has a safety shield and is
located at the rear of the dryer. The shield also serves as a
mount for the unload proximity junction box.
Auger
Non-driven
End
Shield
The fan inlet screen is located at the intake of the fan. It prevents
foreign material from being drawn into the fan. The fan inlet
screen MUST be in place when fan is running!
Fan Inlet
Screen
2 - 17
Service Section
The grain discharge chute door is located at the rear of the dryer,
on the top of the grain discharge chute. It prevents access to the
unload auger while dryer is in operation and opens on grain
overflow if the takeaway system fails.
Discharge
Chute Door
2. Access doors/covers
The heater access panel is located on the upper left side of the
heater and allows access to the inside of the heater barrel.
Heater
Access Panel
2 - 18
Service Section
The exterior grain column access and cleanout doors and the
exterior unload auger access and cleanout doors are located on
the bottom portion of the dryer.
The inner grain column access doors are located in the plenum
area on each column, both sides.
The
unload
auger
inner access panels
are located in the
plenum, on the floor.
Inner Unload
Auger
Access/Cleanout
Door
2 - 19
Service Section
The plenum access door is located at the rear of the dryer.
Caution
The clean out door is located at the rear of the dryer just below
the plenum access door. It is used to clean the plenum out. With
the fan running and standing to the side, lift the door and fines
and debris will be blown out.
Do not run heater when cleaning out plenum. Stand to the side
of the door, for fines will blow directly out of the dryer.
.
The rear viewing port is located in the plenum access door and is
used to view the interior of the dryer during operation.
2 - 20
Service Section
Control Box Stand Assembly
The optional control box stand will come disassembled and
packaged in the rear of
the Dryer.
Remove
the stand components,
which
include
the
following:
a. Stand Main frame
b. Left leg support
bracket
c. Right leg support
bracket
d. Hardware bag
Assembly Instructions:
1. Bolt the stand legs to the stand frame
with the 3/8” x 3” bolts, nuts, and
washers (See picture at right).
2. Slide the 4 - 3/8” x 3” bolts and the 4
flat washers through the 2 holes in
top and middle cross-braces of the
stand, with the bolt-heads on the side
of the stand with the shorter legs.
This is so that the control box will be
mounted on the stand with the longer
side of the legs under the control
box. Fasten the bolts to the stand
with flat washers and nuts. (See
Picture at right).
3. Unbolt the control box from the inside
of the fan support plate.
4. Bolt the control box to the stand
with the 3/8” nuts and washers.
5. Position the stand with the control
box where desired.
Caution
Anchor the stand to the concrete or
stake the stand to the ground to
prevent the stand from moving or
tipping over. The stand with control
box attached can be very unstable,
especially with windy conditions.
2 - 21
Service Section
Ground Rod Installation
A system ground rod and
clamp are supplied with
the dryer and can be found
in the rear of the dryer.
The rod is copper, 8 feet
(2.44 m) long, and ½ inch
diameter.
Ground
Rod
1. The installation of the
ground rod and ground
wire must conform to
National
Electrical
Code
Handbook
procedures.
2. Install the ground rod
within 8 feet (2.44 m)
of the dryer and attach
it
to
the
power
distribution box ground lug located in the lower right corner.
The ground rod located at the power pole will not provide
sufficient grounding for the dryer.
3. The proper grounding will provide added safety in case of
any short or lightening strike.
4. The ground rod MUST be installed for proper functionality of
the sensors on the dryer and to validate the warranty.
Dryer Installation
Gas and Electric Hook-up
Initial gas hookups should only be performed by qualified gas
service technicians in accordance with all applicable code
requirements. In conditions of a threaded pipe train, a regulator
must be installed on the gas tank and limit the pressure to 72
psi. (5 bars).
Initial electric hookups should only be performed by qualified
electrical service technicians in accordance with all applicable
code requirements.
2 - 22
Service Section
Service Manual
Sensor Installation and Removal Instructions
A. Discharge Moisture Sensor
This sensor is used to monitor the grain’s moisture as it exits the
dryer.
Removal:
1. Turn power off at the power box.
2. Locate the discharge moisture sensor on the bottom of the
grain discharge chute.
3. Disconnect the sensor ground strap connected to the dryer
with a locking nut.
4. Release the sensor retaining clamp and remove the sensor
from the discharge tube.
5. Remove the wire cable retaining clips fastening the wire to
the dryer all the way back to the junction box located at the
6. right rear of
the dryer.
7. Remove
the
junction
box
cover
by
removing the
four screws.
8. Disconnect the
sensor wires
from the dryer
wiring.
Installation:
1. Obtain a new moisture sensor and place it into the grain
discharge tube. Secure the sensor by tightening the holding
clamp.
2. Connect the
ground strap
to the dryer
frame, and
tighten the
lock nut.
3. Route
the
wire cable to
the junction
box
using
the
cable
clamps
to
secure the
cable to the dryer.
4. Connect the sensor wiring to the dryer wiring. Red to Red.
Brown to Brown. Blue to Blue. Black to Black. White to
White. Green to Green. Shield to Shield.
5. Install junction box cover by tightening four screws.
2 - 23
Service Section
B. Grain Discharge Chute Sensor
This sensor is used to detect a plugged take-away system.
Should the take-away system malfunction, the grain would push
up the discharge chute door, causing a fault condition.
Removal
1. Turn the power off at the power box.
2. Locate the grain discharge chute sensor junction box.
3. Remove the cover by removing the four screws.
4. Disconnect the two sensor wires from the dryer wiring.
5. Remove the switch.
Installation
1. Obtain a new sensor and insert the sensor onto dryer.
2. Connect the two sensor wires to the dryer wiring.
3. Reinstall cover when finished.
2 - 24
Service Section
C. Grain Level Sensor
Used to detect when the dryer is full of grain.
Removal
1. Turn power off at the power box.
2. Locate the grain level sensor junction box. Found on the
right side of the wet bin, opposite the fill end.
3. Remove the four screws holding the sensor to the dryer.
4. Disconnect the four wires (red, black, white, and green) from
the dryer wiring.
5. Remove the switch from the dryer by sliding it out of the wet
bin.
Installation
1. Obtain a new switch and insert into the wet bin.
2. Connect the wires in the following manner – Red to red,
black to black for power, white to white, and green to green
for ground.
3. When finished, reinstall the sensor by tightening the four
screws holding the sensor to the dryer.
2 - 25
Service Section
D. Unload Auger Sensor
This sensor monitors the rotation of the unload auger. Should
the unload auger stop turning for 5 seconds, a fault condition will
occur.
Removal
1. Turn power off at the power box.
2. Locate the unload auger sensor on the end of the grain
discharge chute.
3. Remove the cover by removing four screws.
4. Loosen and remove the inside lock nut and remove the
proximity switch from the box.
5. Follow the wiring to the junction box located on the side of
the grain discharge chute and remove the cover by removing
four screws.
6. Disconnect the sensor wires from the dryer wiring.
Installation
1. Obtain a new sensor and remove the first locknut. Slide the
sensor into the hole and secure with the locknut just
removed.
2. IMPORTANT: The gap between the tip of the rotating target
and the proximity sensor must be between 6.4 mm +/- 10%
inch.
3. Route the wiring in the same manner as before and connect
the sensor wires to the dryer wiring. Blue to #95 Black.
Brown to #18 Orange. Black to #96 Red.
4. Turn power on at the power box and turn the control box
selector switch to manual. Turn the unload auger switch to
on. Unload auger should now be turning. If installation was
NOT successful, a fault message will appear on the LCD
screen within 5 seconds and the unload auger will shut
down. See photo of Grain Discharge Chute Sensor (Section
B), page 24.
5. Reinstall the cover by tightening the four screws.
2 - 26
Service Section
E. Vaporizer Over-Temperature Sensor
This sensor monitors the vapor temperature as it exits the
vaporizer coil.
Should the temperature exceed a specific
temperature, the sensor opens the circuit, causing a fault
condition.
Removal
1. Turn the power off at the power box.
2. Locate the vaporizer over-temperature switch on the heater
pipe train, on the vaporizer coil.
3. Remove cover and screws.
4. Follow the wiring to the heater box and remove cover. See
photo in Section H, Heater High Limit.
5. Disconnect the red #18 wire attached to the housing high
limit switch. A new crimp terminal end should be used.
6. Disconnect the red #37 wire, which is also attached to a blue
#37 wire by removing the blue wire nut.
Vaporizer OverTemperature Sensor
Installation
1. Obtain a new over-temperature switch and position the new
switch in the same position as the old switch and secure by
screws and replace cover.
2. Route the new switch wiring to the heater control box.
3. Attach the red #18 wire to the housing high-temperature
switch where #18 blue connects.
4. Attach the red #37 wire to the blue #37 wire.
2 - 27
Service Section
F. Rear Door Interlock Switch
Should the interlock key be removed from the switch, a fault
condition will occur.
Removal
1. Turn the power off on the front of the power box.
2. Locate the rear door at the back of the dryer.
3. Pull the interlock key out of the switch.
4. Remove a small, gold colored Philips screw which will allow
the cover to open downward.
5. Loosen the two wire terminals and remove the wires.
6. Remove the two 5/16 mounting screws securing the switch
to the dryer.
7. Loosen the liquid tight strain relief collar and pull the wire
from the switch. Remove the switch from the dryer.
8. Remove the liquid tight fitting from the bottom of the switch.
Installation
1. Obtain a new switch and check the head for the proper
position.
2. If needed, rotate the head 90 degrees to match the old
switch position.
3. Install the liquid tight strain relief collar into the bottom of the
new switch.
4. Remove the small, gold Philips screw, which will allow the
cover to open downward.
5. Feed the wires through the liquid tight fitting and up into the
switch.
6. Attach the wires to the top two terminals. (N.C.)
7. Close the cover and secure with the Philips screw.
8. Attach the switch assembly to the dryer using the two 5/16
hold down screws.
9. Check the interlock key. The key may or may not require
changing depending on the key design.
10. Insert the interlock key into the switch.
2 - 28
Service Section
G. Grain column over temperature sensors
The removal and installation procedure is identical for both grain
column over temperature sensors. Refer to the photos below.
Removal:
1. Remove the junction box cover for the appropriate sensor.
2. Locate the sensor wires and remove the blue wire nuts
connecting the sensor to the dryer wiring.
3. Remove the sensor by removing the 5/16” nuts holding the
sensor to the junction box, see photo for details.
4. While removing the sensor, coil the small copper tube for
easy handling.
Grain Column
Over Temperature
Switch
Installation:
1. Install the new sensor by carefully uncoiling the small copper
tube into the conduit inside the junction box.
2. Using extreme care not to bend the copper tube. Attach the
switch to the back of the junction box using the 5/16” nuts.
3. Reconnect the wires. There should be orange #18 and blue
#40 or blue #41 depending upon side of the dryer.
4. Reinstall the junction box cover when completed.
2 - 29
Service Section
H. Heater Housing Hi-Limit Switch
The heater housing hi-limit switch is located inside the heater
box. The switch is mounted on the housing between the spark
transformer and the terminal block and monitors the temperature
of the heater housing.
Removal:
1. Open the heater box cover by removing four screws and
remove plastic cover.
2. Locate the housing high limit switch.
3. Remove the wires from the switch by pulling on the crimped
connectors.
4. Remove the two hold down screws.
5. Remove the switch.
Reset switch
Installation:
1. Insert the new switch into position and secure with two hold
down screws.
2. Attach the crimped connectors to the tabs on the switch.
There should be a blue #38 to one side and a red #18 and
blue #18 to the other side of the housing high limit switch.
3. Reinstall the heater box cover when complete.
2 - 30
Service Section
I.
Plenum RTD Temperature Sensor
This sensor monitors the temperature of the plenum area. If the
temperature exceeds a preset value, a fault condition will exist.
Removal:
1. Locate the sensor junction box mounted to the front of the
plenum area on the front of the dryer.
2. Open the junction box and disconnect the wires from the
transmitter attached to the cover.
3. Remove the two bolts on the two tabs holding the junction
box to the dryer.
4. Remove the conduit fittings from the ends of the junction
box.
5. Remove the clips holding the sensor tube to the inside wall
of the plenum area. Gently set aside the plenum over
temperature capillary.
6. Pull the sensor out leaving the grommet on the dryer and coil
the tube from the sensor for ease of removal.
Installation:
1. Uncoil the new sensor carefully. Any kinks will damage the
new sensor.
2. Feed the sensor tube through the junction box into the
plenum.
3. Attach the sensor tube to the inside wall of the plenum area
similar as removal.
4. Attach the junction box to the outside
of the dryer after reattaching the
conduit.
5. Reusing the clips from the inside of the
dryer install the new sensor tube to the
inside wall of the plenum area. During
installation of sensor tube, reinstall the
plenum over temperature capillary.
The over temperature capillary and the
plenum temperature sensor are
designed to be mounted to the same
clip inside the plenum area.
6. Wire the transmitter to the wires from the conduits and install
the junction box cover. Make sure to connect braided shield
wires together using wire nuts.
2 - 31
Service Section
J. Metering roll proximity switches:
The removal and installation procedure is identical for either the
left or right metering roll proximity switch. This sensor monitors
the rotation of the meter rolls. During operation the light on the
proximity switch and appropriate input on the PLC will flash
indicating rotation. Due to the slow rotation of the meter rolls,
the lights might flash slowly. If removal of the target is
necessary, install using fresh anti-seize compound.
Removal:
1. Remove the cover to the appropriate metering roll junction
box at the rear of the dryer.
2. Remove the inner lock nut on the proximity switch.
3. Remove the switch from the box.
4. Remove the hold-down clamps for the wires and remove the
cover to the right rear junction box.
5. Disconnect the wiring from the right rear junction box.
6. Loosen the liquid tight strain relief collar connector freeing
the wires
7. Remove the wires from the junction box.
Installation:
1. Installation of the new proximity switch is opposite to that of
removal.
2. Caution: Adjustment of the proximity switch is critical. The
gap from the tip of the switch to the rotating target MUST be
1.6mm +/- 10% (use a coin like a Kroner or a Euro for an
approximate distance), see the above photo.
3. Reinstall the covers.
2 - 32
Service Section
K. Static Air Pressure Sensor
The static air pressure sensor detects that, during operation,
there is enough static air pressure within the plenum area to dry
properly.
Removal:
1. Locate the junction box on the front plenum area.
2. Remove the cover and disconnect the orange and purple
wires from the switch by removing the blue wire nuts.
3. Remove the screen filter from the backside of the switch
from inside the plenum area of the dryer.
4. Remove the air switch.
Plenum Over
Temperature
Switch
Air Switch
Installation:
1. Reinstallation of the switch is opposite of assembly.
2. New switches should be pre-calibrated and ready for
installation.
3. After switch installation, reinstall wires, screen filter, and the
junction box cover.
2 - 33
Service Section
L. Plenum Over Temperature Sensor
The plenum over temperature sensor trips when the temperature
of the plenum area rises above a temperature determined by the
sensor. Removal of the plenum over temperature sensor is
similar to the removal of the plenum temperature indication
sensor.
Removal:
1. Locate the sensor junction box mounted to the front of the
plenum area on the front of the dryer.
2. Open the junction box and disconnect the blue and orange
wires from the sensor.
3. Remove the clips holding the sensor capillary to the inside
wall of the plenum area. Gently set aside the plenum
temperature indicator tube.
4. Pull the sensor free and coil the copper capillary from the
sensor for ease of removal.
Plenum Over
Temperature
Switch
Air Switch
Installation:
1. Uncoil the new sensor carefully. Kinks may damage the
sensor.
2. Feed the new copper capillary through the junction box into
the plenum.
3. Attach the sensor capillary to the inside wall of the plenum
area similar as removal.
4. Reusing the clips from the inside of the dryer install the new
sensor capillary to the inside wall of the plenum area.
During installation of the sensor capillary, reinstall the
plenum over temperature capillary. The over temperature
capillary and the plenum temperature sensor are designed to
be mounted to the same clip inside the plenum area.
5. Connect the blue and orange wires, using blue wire nuts, to
the sensor.
2 - 34
Service Section
Component Calibration
1. SCR Calibration Adjust
A+
A-
Left Potentiometer
Right Potentiometer
To calibrate the SCR board to factory standards:
a. With the E-Stop pushed in, disconnect wire #94 in
the power box from the Unload Auxiliary Contact.
This will disconnect the safety circuit.
b. Pull out the E-Stop and turn the System switch and
Unload switch on the control box to AUTO. On the
keypad, press MODE and “2” (Dry Fire Options).
Then press option “9” for the S.C.R. Adjust.
c.
Enter 10% initially and using a Digital Multimeter
(DMM) set to DC Volts, measure A+ and A- on the
SCR board (red lead on A+, black on A-). This
measurement should be approximately 18 VDC. If it
is not, adjust the left potentiometer on the SCR
board until it is approximately 18VDC.
d. Enter 99% and using the DMM, measure A+ and Aagain. This measurement should be approximately
180VDC. If it is not, adjust the right potentiometer
on the SCR board to approximately 180VDC.
e. When one potentiometer is adjusted, the other
adjusts also so steps c and d need to be repeated
until both 10% and 99% are accurate. Press
RESET when finished and turn the System switch
and Unload switch to OFF.
f.
With the E-Stop pushed in, reconnect wire #94 in
the power box to the Unload Auxiliary Contact.
Close the power box door and turn on power.
2 - 35
Service Section
2. I/O Board Meter Roll Adjustment
R68
LED’s
R64
To change the meter roll adjustment, do the following:
a. Locate R64 and R68 potentiometers on the upper
right of the I/O board. These will look like small blue
cubes with a screw out of the top. They will be to
the right of two small white chips.
b. With the System switch turned on, turn R64 and
R68 screws counter-clockwise until the LED (LED9
and LED10) located to the left of the white chip to
the left of the potentiometer is lit. Then turn the
potentiometer
screws
one
full
turn
counterclockwise further.
3. Moisture Sensor Calibration
See Output Calibration Procedure During Continuous
Flow Section in the Continuous Flow section of the
Operators Manual
2 - 36
Service Section
4. Air Switch Adjustment Calibration
Plenum Over
Temperature
Switch
Air Switch
It may become necessary to adjust the static air pressure switch.
Follow these instructions:
a. Find the switch located on the upper front plenum in a 4”
black circular junction box (see above).
b. The switch is adjustable between 0 to 3 inches of static
pressure. It is a normally open switch that closes when the
set pressure is reached.
c.
To increase the pressure set point, turn the adjustment
screw counter-clockwise (see below).
d. To decrease the pressure set point, turn the adjustment
screw clockwise (see below).
2 - 37
Service Section
5. Contrast Adjustment Calibration
Display
Contrast
Potentiometer
a. Locate the I/O board inside the control box on the upper right
corner of the panel.
b. Locate R99 potentiometer on the upper right of the I/O
board. The potentiometer will look like a small blue cube
with a screw out of the top.
c. To darken the display, turn the screw on the top of R99
clockwise. To make the display lighter, turn the screw
counter-clockwise.
2 - 38
Service Section
6. Unload Auger Time Delay Off Adjustment
Timed Unload
Adjustment
0 to 60
seconds
Access
Door
Open
The Unload Auger Time Delay Off Adjustment option is used
only in manual. This option shuts down the unload auger after
the selected amount of time and only after some faults. It will
not delay on a user shutdown.
To add a timed delay (up to 60 seconds) to the auxiliary unload,
follow these steps:
a. Gain access to the inside of the control box by opening the
inner panel.
b. Locate the Programmable Logic Controller (PLC), which is
on the middle of the back panel (see above).
c.
Open the access door by lifting up on the right side (hinged
on the left). See picture above.
d. Locate the two adjustable potentiometers located at the top
of the opening (see above). The potentiometer on the left
side is the adjustment for the timed unload. It is factory preset to 0.
e. To change the setting to the timed delay, rotate the
potentiometer clock-wise, (see diagram below) to desired
amount of delay time.
0 Seconds
f.
60 Seconds
Close the access door on the PLC and close the Control box
inner panel.
2 - 39
Service Section
7. Secondary Fill Adjustment Calibration
Timed Load
Adjustment
0 to 20
seconds
Access
Door
Open
The Secondary Fill Adjustment Calibration is provided to clean
out the incline auger from the wet bin to the dryer.
To add a secondary fill adjustment (up to 20 seconds) to the
auxiliary load, follow these steps:
a. Gain access to the inside of the control box by opening the
inner panel.
b. Locate the Programmable Logic Controller (PLC), which is
on the middle of the back panel (see above).
c.
Open the access door by lifting up on the right side (hinged
on the left). See picture above.
d. Locate the two adjustable potentiometers located at the top
of the opening (see above). The potentiometer on the right
side is the adjustment for the timed load. It is factory pre-set
to 0.
e. To change the setting to the timed delay, rotate the
potentiometer clock-wise, (see diagram below) to desired
amount of delay time.
f.
Close the access door on the PLC and close the Control box
inner panel.
2 - 40
Service Section
8. Proximity Switch Calibration
When calibrating the proximity switch, a tape measure will be
needed.
a. Locate the box at the end of the discharge chute on the
dryer. The proximity switch and rotating target will be
located inside this box. See below:
Proximity
Switch
Boxes
b. Once the box is opened, a green rotating target and the
proximity switch can be found inside.
c.
To calibrate the proximity switch, loosen the locking nut on
the switch.
Rotating
Target
Proximity
Switch
Gap Adjustment
1/16 inch (1.6mm)
d. Using a tape measure, shift the switch so that it is 1/16 of an
inch (1.6mm) from target (use a coin like a Kroner or a Euro
for an approximate distance). This measurement is very
important for accuracy. The switch must be this distance so
that it can read the target as it turns.
e. Once the switch is in place, tighten the locking nut and
replace the cover on the box.
2 - 41
Service Section
9. Rear Discharge Chute Switch Adjustment
When adjusting the Rear Discharge Chute switch, a 7/16 socket
wrench will be needed.
a. Locate the box on the discharge chute at the rear of the
dryer and open the discharge chute lid. See below:
Discharge
Chute Switch
Box
b. Attached to the lid of the discharge chute is a metal bracket
with the box fastened to it. Using a 7/16 socket wrench,
loosen the screw holding the box in place. See below:
Screw
Metal Bracket
c. Adjust the box so that the chute door will trip when the door
opens by sliding it along the metal plate slot. Once the
position has been found, tighten the screw to hold the box in
place.
2 - 42
Phone Modem Installation Kit Instructions
Heater operation at low plenum temperatures
If you are trying to operate the heater on your dryer at low
temperatures (at 140F/60C degrees or less), you may
experience some difficulty. If you hear rumbling sounds and / or
see the flames are burning yellow instead of blue, then the
pressure is too low and the flame is burning back into the port
cup. If you desire to operate at the lower temperature range, two
parts on the heater must be changed. See Appendix B of this
section or contact your Sukup dealer.
Caution
The following procedure is to be performed by qualified
service personnel only.
The following procedure is a modification of the heater that
involves changing the gas line orifice and the port cup.
Step 1. Operate the dryer fan and heater. While it is running turn
the fuel shutoff lever to the off position. (See figure below) Allow
heater to flame out (purge gas lines).
Step 2. Lock out all electrical power and gas lines
Step 3. Locate the orifice
pipe
train
assembly
(refer to picture at right)
Step 4. Loosen the union
located at the bottom of
the orifice pipe train
assembly
(refer
to
picture at right)
Step 5. Remove the
bracket located at the
top of the orifice pipe
train assembly.
(refer to picture at right)
2 - 43
Phone Modem Installation Kit Instructions
Step 6. Remove the
orifice
pipe
train
assembly by lifting out
and up at the bottom of
the
assembly,
and
pulling the top of the
assembly straight out of
the heater housing.
Step 7. With orifice pipe
train
removed
from
heater housing, locate
the
threaded
orifice
(refer to picture below).
Step 8. Remove the threaded orifice by rotating it CCW.
Step 9. From the table below select the appropriate orifice for
your dryer. Select from the column labeled “Low Temperature
Orifice”.
Heater Type
Standard Orifice & Part #
44” (1.118 m) 30 HP
44” (1.118 m) 15 HP
38” (0.97 m) 15 HP
28” (0.71 m) 15 HP
23 / 64” (9.128 mm) D7113
19 / 64” (7.54 mm) D7112
19 / 64” (7.54 mm) D7112
13 / 64” (5.159 mm) D7110
Low Temperature Orifice &
Part #
19 / 64” (7.54 mm) D7112
13 / 64” (5.159 mm) D7110
13 / 64” (5.159 mm) D7110
11 / 64” (4.366 mm) D7125
Step 10. Install new orifice into pipe train assembly.
Step 11. Re-install orifice pipe train assembly into heater housing
by reversing steps 4 through 6 above.
2 - 44
Phone Modem Installation Kit Instructions
Caution
Ensure that the union is re-tightened properly to prevent
gas leaks
Step 12. Access the dryer plenum area by entry through the rear
door. Locate the heater burner assembly. Remove the flame
deflector by removing the bolt located in the center of the
deflector.
(Refer to picture below)
Retaining Bolt
Flame Sense
Rod
Flame Deflector
Step 13. Note mounting position of flame sense rod (for reinstallation). Remove flame sense rod from it’s mount bracket.
Remove the two port cup retention bolts. Remove port cup.
(refer to picture above)
Step 14. From the table below select the appropriate port cup for
your dryer. Select from the column labeled “Low Temperature
Port Cup”
Heater Type
44”
44”
44”
38”
28”
40 HP
30 HP
15 HP
15 HP
15 HP
Standard Port Cup & Part #
3 / 4”
3 / 4”
3 / 4”
3 / 4”
9 / 16”
D4044
D4044
D4044
D4044
D4027
Low Temperature Port Cup
& Part #
5 / 8” D71128
3 / 8” D4041
3 / 8” D4041
3 / 8” D4041
3 / 8” D4025
Step 15. Install new port cup by reversing the items in Step 11.
Important
When re-installing the top bolt be sure to re-attach the heater
harness bracket, located at the rear of the burner assembly.
Important
When re-installing the flame sense rod, ensure that the rod is not
grounded out and that the rod is in the flame path.
(see picture below)
2 - 45
Phone Modem Installation Kit Instructions
Retaining Bolt
Flame Sense
Rod
Note
Flame Deflector
Do NOT re- install the flame deflector as it is not needed in
lower temperature applications.
Step 16. Restore electrical power to the dryer and open the fuel
valves.
Step 17. Start fan and heater. When heater turns on, inspect for
gas leaks around the union area using soapy water.
Step 18. Re-adjust mod valve and vaporizer coil as needed.
Step 19. Inspect heater flame. Look for nice clean flame, blue in
color. Minor yellow coloring at the tips of the flame is acceptable.
Dryer can now be restored to service.
2 - 46
Appendix A
Appendix A – Fan Blade Replacement
Fan torque specifications (For Trantorque specifications, see next page)
Follow these instructions when replacing the blade on the fan of the dryer and maintaining the
blade at the start of the drying season.
Failure to properly tighten blade may cause serious injury
or death:
•
•
•
•
•
USE TORQUE WRENCH with settings capable of
attaining the correct torque specifications.
There MUST be a gap between the bushing and the
blade to insure a tight fit.
DO NOT over-tighten. May cause hub to crack and
threads to strip.
NEVER run fan without screen guard installed.
DO NOT stand in front of fan when running.
Procedure to Install Axial Fan Blade with Taper-lock Bushing:
1. Put blade on motor shaft.
2. Position bushing on motor shaft and tighten setscrew (if applicable).
3. Insert bolts with lockwashers through the unthreaded holes in the bushing into the
threaded holes on the blade.
4. Tighten bolts evenly to draw the fan blade onto the bushing. Using a torque wrench,
tighten bolts to ¾ of the recommended torque, then continue to alternately tighten them
until they remain at their full torque rating specified below.
5. Install screen guard and run for a minute. DO NOT STAND IN FRONT OF FAN.
6. Recheck bolt torque. Continue this process until bolts maintain specified torque after fan
has been run.
PART #
J0426
J04265
J0424
J04286
J04285
J0432
FAN
SIZE
28”
28”
38”
44”
44”
44”
Fan Torque Specifications – Prior to 2006
BORE
BUSHING
HP
BUSHING
SIZE
BOLT
15
P1
1.125
5/16”
20
SDS
1.375
1/4"
10
P1
1.375
5/16”
15
SK
1.625
5/16”
30
SD
1.875
1/4"
40
SK
2.125
5/16”
2 - 47
TORQUE
FT-LBS
13
9
13
15
9
15
TORQUE
Nm
17.6
12.2
17.6
20.3
12.2
20.3
Appendix A
Trantorque specifications
A Trantorque GT Keyless Bushing offers flexible and easy installation while providing exceptional
holding power. To ensure a Trantorque GT unit performs as specified, it must be installed
properly.
WARNING: Do not lubricate the Trantorque GT bushing or shaft. The use of any
lubricant on the contact surfaces could result in bushing failure and will void all
warranties.
1. Insert the Trantorque GT unit into the component to be
mounted, making sure the mating hub is flush against the
shoulder at the hex flats.
2. Position the assembly at the desired location on the
shaft and hand-tighten the nut (clockwise), until the
assembly becomes snug on the shaft.
WARNING: Do not hammer or use any type of
impact to force the Trantorque GT assembly
along the shaft.
WARNING: The shaft must fully engage the
shaft gripping area of the Trantorque GT unit.
3. Using a torque wrench, tighten the nut to the proper
installation torque. The hex flats on the outer ring are
provided for counter-torque, elimination the need to hold
the component or shaft, while applying installation torque.
NOTE: At full installation torque, the assembly will have moved approximately 1.6 mm (1/16”)
axially along the shaft away from the nut. If axial position is critical, it may be necessary to loosen
the nut and reposition the assembly.
WARNING: Over-tightening the nut could damage the Trantorque GT unit and/or the
mounted component.
PART #
J0436
J0437
J0437
J0435
J0435
J0435
J04371
J04372
FAN
SIZE
28”
28”
38”
38”
38”
44”
44”
44”
HP
15
20
10
15
20
15
30
40
Trantorque Bushings
BORE
BUSHING
SIZE
TRANTORQUE
1.125
TRANTORQUE
1.375
TRANTORQUE
1.375
TRANTORQUE
1.625
TRANTORQUE
1.625
TRANTORQUE
1.625
TRANTORQUE
1.875
TRANTORQUE
2.125
2 - 48
NUT
SIZE
1.75”
2”
2”
2.25”
2.25”
2.25”
2.5”
2.75”
TORQUE
FT-LBS
165
190
190
230
230
230
400
440
TORQUE
Nm
224
258
258
312
312
312
542
597
Appendix A
Instructional Decal located on Fan
2 - 49
Appendix B
Appendix B – Dryer Orifice and Port Cup Combinations
Note: All dryers are shipped with High-Temp heater configuration.
High-Temp = Approx. 80-180°F Rise Above Ambient Air Temp
Intermediate = Approx. 60-160°F Rise Above Ambient Air Temp
Low-Temp = Approx. 40-80°F Rise Above Ambient Air Temp
Liquid Propane (LP)
High-Temp Orifice:
44" 40 HP
44" 30 HP
44" 15 HP
D71125 (25/64") D7113 (23/64") D7112 (19/64")
38" 10, 15, 20 HP
D7112 (19/64")
28" 15 HP
28" 20 HP
D7110 (13/64") D7106 (17/64")
High-Temp Port Cup:
D4044 (3/4")
D4044 (3/4")
D4044 (3/4")
D4044 (3/4")
D4027 (9/16")
D4027 (9/16")
Flame Deflector:
Yes
Yes
Yes
Yes
No
No
NA
NA
Intermediate Orifice:
D71125 (25/64") D7113 (23/64") D7112 (19/64")
D7112 (19/64")
Intermediate Port Cup:
D40443 (9/16") D40443 (9/16") D40443 (9/16")
D40443 (9/16")
Flame Deflector:
Low-Temp Orifice:
Yes or No
Yes or No
Yes or No
D7112 (19/64") D7112 (19/64") D7110 (13/64")
Yes or No
D7110 (13/64")
D7125 (11/64") D7125 (11/64")
Low-Temp Port Cup:
D4041 (3/8")
D4041 (3/8")
D4041 (3/8")
D4041 (3/8")
D4025 (3/8")
D4025 (3/8")
Flame Deflector:
No
No
No
No
No
No
Natural Gas (NG)
High-Temp Orifice:
44" 40 HP
44" 30 HP
44" 15 HP
38" 10, 15, 20 HP
28" 15 HP
28" 20 HP
D71128 (5/8") D71127 (9/16")
D71124 (1/2")
D71124 (1/2")
High-Temp Port Cup:
D4044 (3/4")
D4044 (3/4")
D4044 (3/4")
D4044 (3/4")
D4027 (9/16")
D4027 (9/16")
Flame Deflector:
No
No
No
No
No
No
D71124 (1/2")
D71124 (1/2")
NA
NA
Intermediate Port Cup: D40443 (9/16") D40443 (9/16") D40443 (9/16")
D40443 (9/16")
Intermediate Orifice:
Flame Deflector:
Low-Temp Orifice:
D71128 (5/8") D71127 (9/16")
No
No
No
D71125 (25/64") D71125 (25/64")
No
D7112 (19/64")
D7112 (19/64")
Low-Temp Port Cup:
D71129 (7/16") D71129 (7/16") D71131 (23/64") D71131 (23/64")
D4041 (3/8")
D4041 (3/8")
D4041 (3/8")
D4041 (3/8")
D4025 (3/8")
D4025 (3/8")
Flame Deflector:
No
No
No
No
No
No
2 - 50
AUTOMATIC GRAIN DRYER
Continuous Flow / Automatic Batch
Portable and Stack Dryers
Dryer Software Manual (DC)
Sukup Manufacturing Company
1555 - 255th Street P.O. Box 677
Sheffield, Iowa 50475
Phone 641 – 892 – 4222
Fax 641 – 892 – 4629
Manual # L141037 DC
1/2008
©Sukup Manufacturing Company
Table of Contents
1. Continuous Flow ......................................................................................................................... 5
A. Initial Dry................................................................................................................................. 5
1.
Set Date / Time.............................................................................................................. 5
2.
Set Input Moisture ......................................................................................................... 5
3.
Set Output Moisture....................................................................................................... 5
4.
Set Maximum Meter Roll Speed.................................................................................... 5
5.
Set Minimum Meter Roll Speed..................................................................................... 5
6.
Load Begin .................................................................................................................... 6
7.
Fan Start and Stabilization ............................................................................................ 6
8.
Full Heat, Top only, Bottom only ................................................................................... 7
9.
Enter Upper Plenum Temperature ................................................................................ 7
10.
Enter Lower Plenum Temperature ................................................................................ 7
11.
Enter Ambient Temperature .......................................................................................... 7
12.
Enter Meter Roll Speed ................................................................................................. 7
B.
Stabilization and Restart / Restart Only ............................................................................ 8
1.
Set Current Input Moisture ............................................................................................ 8
2.
Select Full Heat, Top Only, Bottom Only....................................................................... 8
3.
Enter Upper, Lower Plenum Temperature .................................................................... 8
4.
Set Warm Up Time ........................................................................................................ 8
2. AutoBatch ................................................................................................................................... 9
A.
Set Date/Time ................................................................................................................... 9
B.
Set Input Moisture ............................................................................................................. 9
C.
Set Maximum Meter Roll Speed ....................................................................................... 9
D.
Full Heat or Heat/Cool....................................................................................................... 9
E.
Set Batch Number............................................................................................................. 9
F.
Set Upper Lower Plenum Temperature ............................................................................ 9
G.
Set Batch Dry Time ........................................................................................................... 9
H.
Set Batch Cool Time ......................................................................................................... 9
I.
Set Batch Unload Time...................................................................................................... 9
3. Autobatch Set Menu ................................................................................................................. 10
A.
Calibrate Sensors............................................................................................................ 10
B.
Plenum Temperature ...................................................................................................... 10
C.
Dry Time.......................................................................................................................... 10
D.
Unload Time.................................................................................................................... 10
4. Grain Transfer........................................................................................................................... 11
A.
Set Maximum Roll Speed................................................................................................ 11
B.
Set Out of Wet Grain Timer............................................................................................. 11
5. Final Dry ..................................................................................................................................... 7
A.
Set Input Moisture ............................................................................................................. 7
B.
Fan Start and Stabilization ................................................................................................ 7
C.
Set Final Dry Time ............................................................................................................ 7
D.
Final Unload ...................................................................................................................... 8
6. Set Menu .................................................................................................................................. 12
A.
Calibrate Sensors............................................................................................................ 13
1.
Input Temperature ....................................................................................................... 13
2.
Input Moisture.............................................................................................................. 13
3.
Output Temperature .................................................................................................... 13
4.
Output Moisture ........................................................................................................... 13
5.
Plenum RTD Temperature .......................................................................................... 13
6.
Column RTD Temperature .......................................................................................... 13
7.
Input Moisture Sensor Enable/Disable ........................................................................ 13
B.
Plenum Temperature ...................................................................................................... 14
1.
Upper, Lower Plenum Temperature ............................................................................ 14
2.
Minimum Temperature ................................................................................................ 14
3-2
3.
Maximum Temperature ............................................................................................... 14
4.
Temperature Adjustment Increment............................................................................ 14
5.
Temperature Adjustment Time .................................................................................... 14
C.
Moisture Out.................................................................................................................... 15
1.
Set Desired Output Moisture ....................................................................................... 15
D.
Moisture In ...................................................................................................................... 15
1.
Set Desired Input Moisture .......................................................................................... 15
E.
Configuration................................................................................................................... 16
1.
Set the Time/Date........................................................................................................ 16
2.
Language Selection..................................................................................................... 16
3.
Set the Minimum Roll Speed ....................................................................................... 16
4.
Set the Maximum Roll Speed...................................................................................... 16
5.
Set the EMOV – Valve Minimum................................................................................. 16
6.
Set the EMOV – Valve Maximum................................................................................ 16
7.
Set Unload Clean Out Time ........................................................................................ 16
8.
Set Fan Shutdown Delay............................................................................................. 16
F.
Meter Rolls ...................................................................................................................... 17
1.
Control Adjustment Time ............................................................................................. 17
2.
Multiplier ...................................................................................................................... 17
3.
Print Time .................................................................................................................... 17
4.
Breakpoint ................................................................................................................... 17
5.
Linear Range ............................................................................................................... 17
6.
Data Log Time ............................................................................................................. 17
7. Mode......................................................................................................................................... 18
A.
Electronic Mod Valve Adjustment ................................................................................... 18
1.
Ramp Test ................................................................................................................... 18
2.
EMOV Valve Adjust ..................................................................................................... 18
B.
Dry Fire Options .............................................................................................................. 19
1.
Fan Only ...................................................................................................................... 19
2.
Fan and Heat............................................................................................................... 19
3.
Meter Roll Ramp Test.................................................................................................. 19
4.
Meter Roll/SCR Adjust................................................................................................. 19
C.
Sensor/Calibration/Setup ................................................................................................ 20
1.
Input, Output................................................................................................................ 20
D.
Sensor Selection ............................................................................................................. 20
1.
Black, Red, or None .................................................................................................... 20
E.
Units, Fahrenheit or Centigrade...................................................................................... 20
F.
Electronic Mod Valve ...................................................................................................... 22
1.
Multiplier ...................................................................................................................... 22
2.
Linear Range ............................................................................................................... 22
3.
Low Fire Position ......................................................................................................... 22
4.
Minimum Valve Opening ............................................................................................. 22
5.
Maximum Valve Opening ............................................................................................ 22
8.
Bushels Per Hour................................................................................................................ 24
A.
How to Turn On and Set Up............................................................................................ 24
B.
How to Turn Off............................................................................................................... 24
9.
Temperature Based Control ............................................................................................... 25
A.
Switching To.................................................................................................................... 25
B.
Control Parameters defined ............................................................................................ 25
10.
General Information ............................................................................................................ 27
A.
Dip Switch Settings ......................................................................................................... 27
B.
Reset Default Values ...................................................................................................... 29
C.
Resets default values...................................................................................................... 29
D.
15 minute fill timer shutdown enable / disable ................................................................ 29
E.
Print History..................................................................................................................... 29
F.
Enables / Disables data logging features........................................................................ 29
3-3
G.
H.
I.
J.
K.
L.
11.
A.
B.
C.
D.
E.
12.
A.
B.
C.
D.
E.
F.
13.
A.
B.
C.
D.
E.
14.
A.
15.
A.
B.
C.
Remote monitoring enable / disable ............................................................................... 30
Printer enable / disable ................................................................................................... 30
Electronic modulation valve control enable / disable....................................................... 30
Precision print enable / disable........................................................................................ 30
Input moisture sensor enable / disable ........................................................................... 30
Load Start Delay (0 to 240 seconds) .............................................................................. 30
Electronic Modulation Valve Control Parameters ............................................................... 31
Multiplier .......................................................................................................................... 31
Linear Control Range ...................................................................................................... 31
Valve Minimum................................................................................................................ 31
Valve Maximum............................................................................................................... 31
Adjustment Recommendations ....................................................................................... 32
Meter Roll Control Parameters ........................................................................................... 33
Control Adjustment Time................................................................................................. 33
Multiplier Factor............................................................................................................... 33
Print Time ........................................................................................................................ 33
Breakpoint ....................................................................................................................... 33
Linear Control Range ...................................................................................................... 33
Adjustment Recommendations ....................................................................................... 34
Remote Monitoring ............................................................................................................. 35
Parts Required ................................................................................................................ 35
Installation ....................................................................................................................... 35
Computer Setup .............................................................................................................. 35
Connecting ...................................................................................................................... 35
Settings ........................................................................................................................... 36
Data Logging ...................................................................................................................... 36
Setup ............................................................................................................................... 36
Remote Control................................................................................................................... 36
Enable/Disable ................................................................................................................ 36
Control Keys.................................................................................................................... 37
Troubleshooting .............................................................................................................. 37
3-4
1. Continuous Flow
A. Initial Dry
Press START then 1 on Keypad
1. Set Date / Time
2. Set Input Moisture
3. Set Output Moisture
4. Set Maximum Meter Roll Speed
5. Set Minimum Meter Roll Speed
3-5
Initial Dry continues from previous page (#3)
6. Load Begin
7. Fan Start and Stabilization
3-6
8.
9.
10.
11.
12.
Full Heat, Top only, Bottom only
Enter Upper Plenum Temperature
Enter Lower Plenum Temperature
Enter Ambient Temperature
Enter Meter Roll Speed
5. Final Dry
A. Set Input Moisture
B. Fan Start and Stabilization
C. Set Final Dry Time
3-7
B. Stabilization and Restart / Restart Only
1.
2.
3.
4.
Set Current Input Moisture
Select Full Heat, Top Only, Bottom Only
Enter Upper, Lower Plenum Temperature
Set Warm Up Time
D. Final Unload
3-8
2. AutoBatch
Press START then 2 on Keypad
A.
B.
C.
D.
E.
F.
G.
H.
I.
Set Date/Time
Set Input Moisture
Set Maximum Meter Roll Speed
Full Heat or Heat/Cool
Set Batch Number
Set Upper Lower Plenum Temperature
Set Batch Dry Time
Set Batch Cool Time
Set Batch Unload Time
3-9
3. Autobatch Set Menu
Press [SET] On The Keypad
Note: Must be in the autobatch mode to access this menu
A.
B.
C.
D.
Calibrate Sensors
Plenum Temperature
Dry Time
Unload Time
3 - 10
4. Grain Transfer
Press Start Then 3 On The Keypad
A. Set Maximum Roll Speed
B. Set Out of Wet Grain Timer
3 - 11
6. Set Menu
Press [SET] On Keypad
3 - 12
Set Menu – Continuous Flow
Press [SET] On Keypad and then [1] on Keypad
A. Calibrate Sensors
1.
2.
3.
4.
5.
6.
7.
Input Temperature
Input Moisture
Output Temperature
Output Moisture
Plenum RTD Temperature
Column RTD Temperature
Input Moisture Sensor Enable/Disable
3 - 13
Set Menu
Press [SET] And Then [2] On Keypad
B. Plenum Temperature
1.
2.
3.
4.
5.
Upper, Lower Plenum Temperature
Minimum Temperature
Maximum Temperature
Temperature Adjustment Increment
Temperature Adjustment Time
3 - 14
Set Menu
Press [SET] And Then [3] Or [4] On Keypad
C. Moisture Out
1. Set Desired Output Moisture
D. Moisture In
1. Set Desired Input Moisture
3 - 15
Set Menu – Press [SET and then [5] On Keypad
E. Configuration
1.
2.
3.
4.
5.
6.
7.
8.
Set the Time/Date
Language Selection
Set the Minimum Roll Speed
Set the Maximum Roll Speed
Set the EMOV – Valve Minimum
Set the EMOV – Valve Maximum
Set Unload Clean Out Time
Set Fan Shutdown Delay
3 - 16
Control Algorithm – Meter Rolls – Hidden Menu
Set 6 - Press [SET] and then [6] On Keypad
F. Meter Rolls
1.
2.
3.
4.
5.
6.
Control Adjustment Time
Multiplier
Print Time
Breakpoint
Linear Range
Data Log Time
3 - 17
7. Mode
Press [MODE] On Keypad
A. Electronic Mod Valve Adjustment
1. Ramp Test
2. EMOV Valve Adjust
3 - 18
B. Dry Fire Options
1.
2.
3.
4.
Fan Only
Fan and Heat
Meter Roll Ramp Test
Meter Roll/SCR Adjust
3 - 19
MODE – Press [MODE] On Keypad
C. Sensor/Calibration/Setup
1. Input, Output
D. Sensor Selection
1. Black, Red, or None
E. Units, Fahrenheit or Centigrade
3 - 20
3 - 21
Control Algorithm – Electronic MOD Valve – Hidden Menu
Set 9 – Press [SET] the [9] On Keypad
F. Electronic Mod Valve
1.
2.
3.
4.
5.
Multiplier
Linear Range
Low Fire Position
Minimum Valve Opening
Maximum Valve Opening
3 - 22
Control Algorithm (continued) – Electronic MOD Valve – Hidden Menu
Set 9 – Press [SET] the [9] On Keypad
3 - 23
8. Bushels Per Hour
Press [9] On Keypad (see #1)
A. How to Turn On and Set Up
1. Note: To access the BPH (Bushels Per Hour) screen, the dryer must be in the continuous
flow operation, unloading grain
2. While unloading, select [9] on the keypad. The following screen should be displayed:
CALIBRATE BUSHELS/HR
ENTER CURR. BPH
1
TIME SAMPLE
2?
TO EXIT PRESS RESET
3. Key [1] is selected if the BPH is known or calculated from the dryer size. For example, if
a 12 ft. dryer is unloading at 25%, multiply 1200
BPH x 0.25. The answer is 300 BPH. Enter the
300 BPH as the Current BPH by selecting [1] on
BUSHELS PER HOUR IS
the keypad. When this is done, the following
????
screens will be displayed. Once the BPH has been
entered, the BPH will be displayed on the screen.
4. Number 2 is selected if the actual BPH coming from
the dryer is to be measured. By pressing Key [2],
the following screen will be displayed:
BPH TIMER STARTED
PRESS 9 TO STOP TMR
5. Once key [2] has been pressed, a timer is started and the roll ordered will be averaged
and retained in memory until the timer is stopped.
6. Once a “sample” has been unloaded, whether it be
a truckload or enough grain to be accurately
weighed, press [9] again to stop the timer. The
following screen will be displayed:
7. The computer retains the time and average roll
order until the operator selects key [9] again, to
enter the bushels unloaded.
BPH TIMER STOPPED
PRESS 9 TO CALIBRATE
SAMPLING UNLOAD
TIME = 10.0 MINUTES
BUSHELS UNLOADED
????
8. In the case of a shutdown, the timer is paused until it is either stopped or unloading is
resumed. Note: the larger the sample, the more accurate the readout will be. Once
calibrated, the BPH will be displayed whenever the roll order is displayed.
B. How to Turn Off
9. To turn off the BPH display, press key [9] then key [1] during dryer operation and enter
0000 for the BPH.
3 - 24
9. Temperature Based Control
Press [SET] the [8] On Keypad
A. Switching To
If a grain column RTD sensor has been installed, the metering rolls can be controlled using grain
temperature as the controlling factor.
Note: The following screens will not appear if RTD sensor has not been installed.
1. To switch from moisture based control to grain temperature control, press [SET] then [8].
The following screen should be displayed: Press [1] to change to temperature based
control.
B. Control Parameters defined
How it works?
The meter rolls are being controlled internally by the software using temperature-based control
from the column RTD sensor. The initial temperature control setpoint is set to the column
temperature.
After stabilization has completed. This temperature setpoint will automatically vary in order to
maintain the desired output moisure.
Control parameters defined:
1. Tolerance – The column temperature must be at the setpoint or within the set +/- tolerance
before the software automatically makes an adjustment to the control temperature. If the
RTD indicates an overdrying/underdrying condition and the moisture sensor indicates the
opposite, a change will take place regardless of tolerance. Default is 3.
3 - 25
2. Control Adjustment Time – The minimum amount of time required between adjustments.
Note that tolerance must be met before the timer is started. Default is set to 5 minutes.
3. Roll Speed Compensation – The present meter roll speed can be used to compensate the
control adjustment time. For instance, if the control adjustment time is 5 minutes and the
meter roll speed is 33%, the roll speed compensation will then require a 15 minute time
between adjustments. Default is ON. (The higher the roll speed, the longer the time between
adjustments).
4. Temperature Adjustment Increment – The control temperature is adjusted by this increment
for every 1.0% variation from accrual moisture vs. desired moisture. For example, if the
desired moisture is 15.0%, actual moisture is 16.5%, and the temperature adjustment
increment is 5, then 7 degrees will be added to the control temperature. Default is 5 (5
degrees for the temperature adjustment increment and an extra 2 degrees for being an
additional 0.5% away from the desired set point).
Recommendations for Adjustments:
Caution should be taken when making adjustments and it is recommended that only one
parameter be changed at a time. After an adjustment, carefully monitor the input moisture
and note variations going through the dryer. If variations of the input grain are +/- 3.0% from
one sample to the next and that trend continues, these variations will be seen at the output
but will not cause any adjustments to be made to the meter roll speed (tolerance default is set
to 3).
If moisture control seems too slow or sluggish, first try adjusting the temperature adjustment
increment. A change from 5 to 7 may have a large impact. If control still seems sluggish, try
adjusting the control adjustment time from 5 minutes to 4. Roll speed compensation is
recommended.
If moisture control seems too fast and is causing oscillations, first try adjusting the temperature
adjustment increment. A change from 5 to 3 will have a large impact. If control still seems
too fast, try adjusting the control adjustment time from 5 to 6 minutes. Roll compensation is
recommended.
The tolerance factor should need little or no adjustment.
3 - 26
10.
General Information
A. Dip Switch Settings
DIP 1:
DIP 2:
DIP 3:
DIP 4:
DIP 5:
DIP 6:
Down is for 150:1 gear reduction, up is for 100:1 gear reduction.
Down indicates a 50/50 dryer, up indicates 2/3-1/3 dryer.
Down is for a 2-Fan dryer, up is for a single fan dryer.
Down if the dryer has proximity switches on the meter rolls, up if encoders.
Down if the meter roll fault needs to be bypassed, up if enabled.
Down will reset all of the defaults back to factor settings, (same as pressing 0,0)
Beginning with V4.2, indicates the dryer has electronic MOD valves.
DIP 7: Down causes the program to use the internal clock timing on the board, up causes the
real time clock (RTC) found in the smartwatch to be used.
1. When replacing a processor board, verify that the DIP switch settings are identical to the
board being removed. If any DIP switch is changed, the system power needs to be recycled
in order for the new setting to be recognized.
2. Upon startup, the checksum of saved variables (such as min / max meter roll speed) is
compared to the checksum saved upon the last change. Should they not match, the default
values are reset. This will commonly occur if the software (PROM) has been upgraded, or if
the Smartwatch IC is defective or not seated properly.
3. Initial Dry is typically performed with a temperature of 160F. If this is not desired, the min /
max plenum temperature can be adjusted accordingly through the [SET] - [ 2 ] menu. For
instance, when drying wheat seed, 125F may be the maximum desired drying temperature.
Assuming that the LOW TEMPERATURE KIT has been installed, a maximum temperature of
125F can be entered. The initial dry calculation will then be made using a drying temperature
of 125F. The same applies for Final Dry, except that Final Dry generally uses a temperature
setting of 140F.
4. During stabilization, moisture and temperature information are hidden from the operator, as
the information during this time might be off target. To view this information, press the
[MODE] key. Calibration can be performed by pressing the [SET] key. [RESET] will take you
out of stabilization and into the sampling mode.
5. At various stages during operation, IF an input moisture sensor has been installed, the input
moisture will be shown as the dryer is loading. If the dryer is not loading, the [MODE] key
can be pressed to view the incoming moisture.
6. During sampling, or continuous flow mode of operation, the moisture sensor must be
functioning properly for accurate moisture control. If the output moisture falls below 8.0%
(5% in V4.0 or higher), the message “ NO GRAIN DETECTED ” will be displayed and the
dryer will shut down after 3 minutes of this condition. If the output moisture falls below 1.0 %,
the message “ MOISTURE SENSOR NOT FOUND ” is displayed and the dryer will shut
down after 30 seconds.
7. While the system is pausing so that the displayed text can be read, pressing any key can
advance the screen. During data entry, the [MODE] key can be used to back up one step,
the [CHG] key will back up one digit, and the [OK] key accepts the current value. For
instance, if a three digit number is requested (???), pressing [1] then [OK] accepts “1” for the
value, similar to “001”.
3 - 27
8. The System Status printout has been streamlined to only include pertinent information.
Standard settings such as Black Moisture Sensor, Processor Version SukupF, etc., are no
longer printed. Nonstandard settings will be printed during Initial Dry or Autobatch modes of
operation.
9. Displayed moisture readings are a 5-sample average, with samples taken at least one
second apart. A sample consists of 60 A / D readings that are averaged. Moisture is
temperature compensated where every 20F above 80F constitutes a –1% offset, and every
20F below 80F constitutes a +1% offset. When in automatic, a small compensation factor is
also included based on meter roll speed. No offset is Included for 10% speed, a +0.6% linear
offset up to 40% and an additional +0.15% linear offset up to 100%.
3 - 28
B. Reset Default Values
1. Pressing key [0] at the start screen will display the program version currently in use.
2. Pressing key [0] and then [SET] will display the following menu:
0= DEF 1= FILL 2= HISTR
3= CLR HIST 4= DATA LG
5= REMOT 6= BAUD 7= PRT
8= VALV 9= PREC MD=INP
If any of the above information has been memorized, pressing [0] and then the number of the
feature desired, will take the user directly to that function, bypassing the above screen.
Pressing [0] and then any of the following will take the user to that feature:
C. Resets default values
Press [0]
DEFAULTS SET
D. 15 minute fill timer shutdown enable / disable
Press [1]
15 MIN FILL TIMER
ENABLED
E. Print History
Press [2]
Prints the last 150 lines of information – stored in memory
NO INFORMATION DISPLAYED
Clears the print history
Press [3]
NO INFORMATION DISPLAYED
F. Enables / Disables data logging features
Press [4]
DATA LOGGING
ENABLED
3 - 29
G. Remote monitoring enable / disable
Press [5]
REMOTE MONITORING
ENABLED
Selects RS-232 remote baud rate
Press [6]
While this screen is displayed, each time the [CHG] key
is pressed, a new baud rate is displayed.
(57600, 19200, 9600, 4800, 2400, 1200, 300) When the
correct rate is displayed, press [OK] to accept.
SERIAL BAUD RATE IS
57600
OK(+) OR CHG(-) ?
H. Printer enable / disable
Press [7]
PRINTER
ENABLED
I.
Electronic modulation valve control enable / disable
If enabled, press one of the following keys within 4
seconds to:
[1] = Will disable upper electronic mod valve
[2] = Will disable lower electronic mod valve
ELECTRONIC MOD VALVE
ENABLED
While this screen is displayed, pressing [1] or [2] will disable the respective valve. A message will
be displayed, indicating which valve was disabled.
J.
Precision print enable / disable
Press [9]
(Include the decimal point for the roll speed)
PRECISION PRINT
ENABLED
K. Input moisture sensor enable / disable
Press [MODE]
INPUT MOISTURE SENSOR
ENABLED
L. Load Start Delay (0 to 240 seconds)
Press [CHG]
LOAD START DLY TIME
IS SET TO 0 SECONDS
LOAD START DLY TIME
OK(+) OR CHG(-)
??? SECONDS
3 - 30
11.
Electronic Modulation Valve Control Parameters
To access the Control Parameters Menu, press [SET] then [9].
1= MULTIPLIER
2= LINEAR RANGE
3= LOW FIRE POSITION
5= VALVE MIN 6= MAX
A. Multiplier
The multiplier affects the size of the adjustment. A nonlinear scale is used to determine the
amount of adjustment. As the moisture approaches the target setpoint, the amount of adjustment
becomes significantly less. Increasing the multiplier will cause the control to adjust quicker, using
bigger steps, but may cause oscillation (swinging) problems. Decreasing the multiplier will cause
the control to adjust slower, which should be done to prevent oscillation problems.
Default for 38 / 44” fans =
0.20
Default for 28” fans =
0.24
Range =
0.01 to 9.99
B. Linear Control Range
Sets the point away from the target when the adjustment becomes linear. With a linear control of
16.0, once the temperature reaches + / - 16.0F of the target, a linear scale will be used to
determine the amount of the adjustment.
Default =
16.0F
Range =
0.0F to 25.5F
Low Fire Position
Sets the starting position of the valve. With a low fire position of 50 %, the processor will send a
5.0 VDC to the valve as soon as power is applied to the Control Box. Once ignited, the processor
will open the valve farther, if necessary, and start to control. If the angle % on the valve is set to
60 %, a 10 VDC signal will open the butterfly valve to 60 % of 95 degrees or 57 degrees.
Therefore, a 5.0 VDC signal will open the valve to (5.0 – 2) / (10 – 2) * 60 % * 95 degrees = 24.4
degrees.
Default for 38 / 44” fans =
50 %
Default for 28” fans =
40 %
Range =
Valve Min to Valve Max
C. Valve Minimum
Sets the minimum position of the valve. With a valve minimum of 44%, the processor will not
allow the control signal to fall below 4.4 VDC. Therefore, a 4.4 VDC signal will open the valve to:
(4.4 – 2) / (10 – 2) * 60 % * 95 degrees = 17.1 degrees.
Default for 38 / 44” fans =
44 %
Default for 28” fans =
26 %
Range =
10 % to Max – 2 %
D. Valve Maximum
Sets the maximum position of the valve. Typically, this is always set to 100 % to allow the
processor to reach the maximum output if needed, but this can be lowered to limit the maximum
output voltage being sent to the valve, by the processor. This may be desired if the plenum RTD
temperature were to fail, the valve would be limited as to how far it would open, keeping the
maximum temperature from climbing.
3 - 31
E. Adjustment Recommendations
Verify that capacitors have been installed on the inputs to the processor board. Without them,
electrical noise can impact the signal causing false readings, which will impact control.
Adjust the low fire (minimum) valve position as needed to achieve the proper pressure upon
startup. Ideally, there should be 2 – 3 PSI as the flame is lit.
Upon starting the heater for the first time, press the number of the plenum on the keypad to
observe control. An increase in temperature of approximately 1 degree each 1 – 2 seconds will
be observed. If the control overshoots the target by 8 degrees, try lowering the multiplier. If the
overshoot is less than 8 degrees, try lowering the linear range. If control is sluggish as the
temperature approaches the set point, try raising the multiplier. If the control is sluggish once the
temperature is within 8 – 10 degrees, try increasing the linear range.
Once the control point has been established, upon restarting the heaters, control will immediately
go to the last temperature entered, and will remain at that point until the 100-second stabilization
period has ended, unless the temperature overshoots. A change in plenum temperature changes
the control point.
Try to avoid changing multiple parameters at the same time, and making dramatic changes. The
default parameters are optimized for our control system and should require only slight
refinements, if any, to tune in the control.
To access the Plenum Temperature Setup Menu, press [SET] and then option [2]. The following
menu will be displayed:
See page 14 for screen progression.
1= UPPER PLENUM TEMP
2= LOWER PLENUM TEMP
3= MIN TMP 4= MAX TMP
5= TMP ADJ INC 6= TIME
Note, when the electronic mod valve is installed, options [5] and [6] allow for the plenum
temperature to be adjusted automatically when the meter roll speeds have reached a minimum or
maximum meter roll speed limitation. (Indicated by an asterisk ( * ) beside the roll order display)
Setting the Temperature Adjustment Increment to 5 and the Temperature Adjustment Time to 30
minutes would cause the Plenum Temperature to be increased 5 degrees after 30 minutes of
running at the minimum meter roll speed, or decreased by 5 degrees after 30 minutes of running
at maximum meter roll speed. The Plenum Temperature will remain within the Min / Max
boundaries established by options [3] and [4] . Note that the vaporizer, if equipped, may need
adjustment under extreme circumstances.
An asterisk ( * ) is shown to the left of the plenum temp (s) on the LCD screen to indicate that the
electronic mod valve has reached maximum opening or closing. An exclamation mark ( ! ) is
shown to the left of the Plenum Temp(s) to indicate that the actual temperature has been 15
degrees or more away from the Setpoint for more than a minute.
Note: After 10 minutes of being 15 degrees away from the setpoint, the dryer will be shut down.
After 5 minutes of being 30 degrees away from the setpoint, the dryer will also be shut down.
3 - 32
12.
Meter Roll Control Parameters
To access the meter roll control parameters, press [SET] then [6].
CONTROL PARAMETERS
1= ADJ TIME 2= MULT
3= PRT TIME 4= BREAKPT
5= LINEAR RANGE
A. Control Adjustment Time
Sets the frequency at which the software monitors the roll speed to see if an adjustment is
necessary. Note that all corrections are scaled over a 15-minute period such that the sum of all
corrections will be equivalent to one correction every 15 minutes.
Default =
0 (adjust every 6 seconds)
Range =
0 to 30 minutes
B. Multiplier Factor
Affects the size of an adjustment. A nonlinear scale is used to determine the amount of
adjustment. As the moisture approaches the target setpoint, the amount of adjustment becomes
significantly less. Increasing the multiplier will cause the control to adjust more quickly, using
bigger steps, but may cause oscillation (swinging) problems. Decreasing the multiplier will cause
the control to adjust more slowly, which should prevent oscillation problems.
Default for moisture control =
0.80
Default for temperature control =
0.16
Range =
0.01 to 9.99
C. Print Time
Sets the frequency (in minutes) at which the data is printed.
Default =
10 minutes
Range =
1 to 60 minutes, or 0 for OFF
D. Breakpoint
Sets the point away from the setpoint where control begins to slow down. With a breakpoint of
1.0 %, once the moisture reaches + / - 1.0 %, no adjustments will be made if the current moisture
reading is closer to the setpoint than the previous adjustment moisture reading. NOTE: When
using temperature control, a breakpoint set to 1.0 will cause the same effect when within 1.0
degree F of the setpoint.
Default for moisture control =
1.0 %
Default for temperature control =
5 degrees F
Range =
0 % to 25.5 % or 0 F to 25.5 degrees F
E. Linear Control Range
Sets the point away from the setpoint when the adjustment scale becomes linear. With a linear
control range of 1.0 %, once the moisture reaches + / - 1.0 % of the setpoint, a linear scale will be
used to determine the amount of adjustment (as the moisture moves closer to the setpoint, the
smaller the adjustment becomes).
Default for moisture control =
Default for temperature control =
Range =
3 - 33
1.0 %
5 degrees F
0 % to 25.5 % or 0 to 25.5 degrees F
F. Adjustment Recommendations
Verify that incoming moisture is somewhat stable. Keep in mind that as incoming moisture
varies, the variance will be seen at the output until the control system can “catch up” .
If control is “swinging” a couple of points on either side of the setpoint, try decreasing the
multiplier in small increments which will bring about smaller control adjustments. Note that a
small change in the multiplier will have a big impact on the control. Changing 0.80 to 0.70 is
sufficient. Another option is to increase the breakpoint from 1.0 % to 2.0 %. This will cause
adjustments to not be made, assuming that control adjustments are in the correct direction. If
control is sluggish and doesn’t seem to get to the setpoint fast enough, try increasing the
multiplier from 0.80 to 0.90.
If the control is within range, a 0.5 – 1 point of the setpoint, but seems sluggish in reaching the
target, try increasing the linear range from 1.0 % to 1.5 %. This will provide more of a boost when
getting close to the setpoint, and help prevent overshooting. If the control is oscillating between
.5 and 1 point from the setpoint, try decreasing the linear range from 1.0 % to 0.6 %. The
breakpoint feature can also be utilized here to fine-tune the control.
Try to avoid changing multiple parameters at the same time, and making dramatic changes to any
parameter. The default parameters are optimized for your control system and should require only
small adjustments to tune the system. Allow a half-hour or so to pass before making another
change. It is not recommended to make a change to the control adjustment time. Allowing the
control system to make small corrections more often is a better method than making larger
corrections less often.
3 - 34
13.
Remote Monitoring
A. Parts Required
1. Sukup RS-232 adapter cable – P/N J3293 installed on all dryers built after July 2005.
2. Grain Dryer Software V4.0 or higher – or – Stack Dryer Software V3.0 or higher – or – Tower
Dryer Software V1.3 or higher, also installed on all dryers built after July 2005.
3. Windows based PC ( personal computer ) with an RS232 9-pin serial connection.
4. Appropriate length serial communication extension cable and gender changer.
(Distances exceeding 1000 feet are not recommended!)
5. Assemble a Category – 5 cable using the following diagram:
2 >----------------------< 2
3 >----------------------< 3
5 >----------------------< 5
CAT – 5 cable and DB9 connectors and pins are readily available from most major
electronics suppliers.
B. Installation
1. Dryers built prior to July 2005, if necessary, remove the I/O board to gain access to the
processor board.
Verify that the software installed is V4.0 or greater for the Portable Dryer or V3.0 or greater for
Stack Dryers (refer to PROM replacement guide if replacing). Place the 10-pin stake
connector from the RS232 adapter cable into the processor board connector J1 (found directly
above the printer cable in the upper right hand corner of the PCB, next to the red DIP
switches). Reconnect the I/O board to the processor board.
2. Drill a hole in the bottom of the Control Box large enough to route the serial communications
cable. Plug the cable into the other end of the adapter cable. Use a grommet to prevent the
cable from being cut by the sharp edge of the drilled hole.
3. Route the serial communications cable to an open communications port on the back of the PC
or Laptop.
C. Computer Setup
1. From within Windows based PC, open Hyperterminal (commonly found under Start --Æ
Accessories -Æ Communications). If prompted, enter the connection name as “Sukup”. Choose
File -Æ Properties to select settings. Verify that the proper COM port is selected (typically COM
1). Select Configure. Set up communication for 57,600 bits per second, 8 data bits, no parity, 1
stop bit, and no flow control. Select OK twice to save settings.
D. Connecting
1. Open Sukup Hyperterminal session. Verify that communication is connected (lower left hand
corner of Hyperterminal). If not connected, click on the telephone icon to enable the connection.
2. Verify that the dryer control system is turned on. If communication is working properly, the
screen currently displayed on the dryer LCD will be echoed to Hyperterminal. If communication in
not working, Please refer to the troubleshooting section.
3 - 35
E. Settings
1. The four line LCD will be echoed to Hyperterminal and updated every second.
Remote monitoring is on by default. Simply connect a straight through RS232 cable to our
adapter cable (on the processor board) and the remote PC (personal computer) to monitor the
LCD status using Windows Based Hyperterminal. Set Hyperterminal for 57600 baud. If data
logging or graphing is desired, disable the remote monitoring by pressing [0] and then [5] .
Enable CSV by pressing [ 0 ] and then [ 4 ] . In HyperTerminal, select transfer, and then capture
text. Type in the file name followed by .CSV extension. Data will then be saved in comma
separated variable format which can be opened in Excel or other spreadsheet application. Go to
[SET] and then [6] then [6] again to set up CSV send frequency (1 minute by default).
14.
Data Logging
A. Setup
1. While the dryer is unloading, HyperTerminal can be used to log moisture and temperature
information. The information can be saved into a .CSV file for use with all spreadsheet
applications, which can then be used to create graphical trending information showing dryer
performance.
2. To save information into a .CSV file, from within HyperTerminal, select Transfer -Æ Capture
Text. Name and save the file to an appropriate location and use a .CSV extension. Type ‘ $ ‘
from HyperTerminal to toggle between remote monitoring and data logging modes. Current
mode will be displayed.
3. By default, information will be logged every 3 minutes. To change the log rate, type 0 to log
every six seconds or 1 – 9 to log every x # of minutes.
4. Data may be viewed but not altered while capturing is taking place. To close the capture file,
select Transfer Æ Capture Text Æ Stop.
5. Open the .CSV file in a text editor such as Notepad or Word. Condition the file for
spreadsheet use by deleting any non-logging information ( excluding the header ) as needed.
Save the file.
6. The file may then be opened using a spreadsheet application. Refer to the application
manual to create graphs of trending information.
15.
Remote Control
A. Enable/Disable
1. To gain access to the remote control features from within HyperTerminal, type ‘ # ‘, a
message will appear stating:
a. REMOTE CONTROL ENABLED
b. AUTOMATICALLY DISABLED AFTER
c. THREE MINUTES OF INACTIVITY
d. OR PRESS ‘ # ‘ AGAIN TO DISABLE
NOTE: AUTOMATIC DRYER STARTUP WILL NOT BE ALLOWED REMOTELY.
2. The remote control features can be used to do everything that the keypad at the control box
can do, except that it cannot be used to start the fans, heaters, or augers. If an attempt is
made to do so, a message will appear, stating that the “DRYER CANNOT BE STARTED
REMOTELY”, and the program will return to the start screen.
3 - 36
B. Control Keys
1. Once enabled, the following keys (all caps) can be used to control the dryer:
0 – 9 keys:
S:
R:
T:
M:
O, K, +, OR Y:
C, -, OR N:
same as the keypad
SET
RESET
START
MODE
OK
CHG
2. After 3 minutes of inactivity, remote features will be disabled and ‘ # ‘ must be typed again to
gain access.
3. If a key is pressed at the dryer, remote features will be locked out for the one minute. A
message will appear stating that “REMOTE CONTROL TEMPORARILY LOCKED OUT” if an
attempt is made.
C. Troubleshooting
1. PROBLEM: No communication between the dryer and the remote computer.
POSSIBLE SOLUTIONS:
a. Verify that the proper software is installed in the dryer control system and
that HyperTerminal is set up properly and connected.
b. Verify that all cabling connections are secure and properly pinned out.
c. Verify that the adapter cable is plugged into J1 and not J2.
d. Verify the baud rate of the dryer control system (press [0] then [6]) make sure
that the baud rate matches the setting within HyperTerminal.
e. Try lowering the baud rate of both the control system and HyperTerminal.
f. Close and restart HyperTerminal.
g. Verify that dryer control is in the remote monitoring mode and not the datalogging mode. Type ‘ $ ‘ from HyperTerminal to toggle modes, or [0] and
then [4] to toggle data logging and [0] and then [5] to toggle remote
monitoring.
h. Disconnect the serial communications cable from both ends. On the female
end, place a paper clip between pins 2 and 5. Measure the resistance
between pins 2 and 5 on the male end. If the resistance is much greater
than 7 ohms per 100 FT, thoroughly check cabling for kinks or breaks and
replace if necessary. Repeat for pins 3 and 5. If possible, try using another
computer or replace the adapter cable or the processor board in the dryer
control system.
2. PROBLEM: Garbled data appears on the HyperTerminal screen.
POSSIBLE SOLUTIONS:
a. Try lowering the baud rate settings for both the dryer control and
HyperTerminal.
b. Close and restart HyperTerminal.
c. Check or replace the serial communications cabling or re-crimp or solder
pins.
3 - 37
Notes
3 - 38
SUKUP DRYER CATALOG TECHNICAL DATA
TABLE OF CONTENTS
Dimensional Drawings ..........................................................................................................................2
Dryer Specifications ..............................................................................................................................4
Pre-Installation Requirements...............................................................................................................6
Electrical Load Requirements, Single Module Dryers ...........................................................................7
Fuel Information ..................................................................................................................................10
Dryer Installation Information ..............................................................................................................12
General Dryer Operation.....................................................................................................................15
Dan Corn Heater Wiring......................................................................................................................17
Continuous Flower Dryer Heater Orifice & Port Cup Configurations...................................................18
Appendix A: Estimated Tonnes Per Hour Information Per Module .....................................................19
4-1
Dimensional Drawings
4-2
4-3
Dryer Specifications
4-4
4-5
Pre-Installation Requirements
Location:
Location of the dryer is a very important decision to make. Numerous factors should be taken into
consideration when determining where to install the Dryer. Factors to consider when selecting your site
are:
1.
2.
3.
4.
5.
Wet grain supply
Dry grain discharge
Location of storage bins
Other grain handling equipment
Minimum of 3 feet (0.91 meter) clearance from other structures on the side of the Dryer and 5 feet
(1.53 meter) minimum clearance from other structures at the fan inlet.
6. Minimize handling distances of load and unload systems
7. Locate Dryer and storage bins in a well drained area
8. Electrical requirements
Warning: Do not install the dryer inside a building or any other area where fuel
installation regulations, and or electrical codes, and or insurance
requirements do not allow.
Warning: Do not operate the dryer in an area where combustible material can be
drawn into the Fan, or where load and unload augers can come in contact with
power lines.
Foundation:
A reinforced concrete pad is recommended for dryer stability.
The following table is a basic guideline for materials required for each size dryer pad.
Concrete Pad Size
12 Foot Dryer
16 Foot Dryer
20 Foot Dryer
24 Foot Dryer
28 Foot Dryer
1.12 m x 2 m (12’ x 22’)
1.12 m x 2.42 m (12’ x 26’)
1.12 m x 2.79 m (12’ x 30’)
1.12 m x 3.16 m (12’ x 34’)
1.12 m x 12 m (12’ x 38’)
Meters (Yards)
of Concrete
6.5 (7.1)
7.6 (8.3)
8.7 (9.5)
9.8 (10.7)
10.9 (11.9)
Quantities are approximate and requirements may vary due to site elevations
See the Installation and Pre-operational check out section in the Installation-Service part of
the manual for the proper support leg locations for 12, 16, 20, 24, and 28 foot dryers.
Foundation:
7.6 cm
46 cm 38 cm
23 cm 15 cm
7.6 cm
15 cm
3.66 m
4-6
Electrical Load Requirements, Single Module Dryers
Note: A Service Rated Disconnect needs to be installed leading into the Dryer
power distribution box. This disconnect is not included with the dryer and should be installed by a
qualified electrician.
The following charts provide information for the electrician wiring the Grain Dryer. It is
recommended that you contact your local Power Company and have a representative inspect the
installation to see that your wiring is compatible with their system and that sufficient power is
supplied to your dryer.
Caution: The only thing connected to the recommended service amps should be your
Grain Dryer.
Standard electrical safety practices and codes should be used. Refer to the National Electrical
Code Standard Handbook by the National Fire Protection Association.
Only a qualified electrician should make all electrical wiring installation.
Dryer Electrical Specifications:
SINGLE FAN MODELS
TE1211D - 12 Foot Dryer – Single Fan/Heater - 380 Volt – 3 Phase – 50HZ
Main Switch = 250 Amps
Fan
Minimum
Top Auger
Bottom Auger
38”
Amps
3 HP/#14
3HP/#14
10-15 HP/#10
38 Amps
Motor/Wire
5.0 FLA
5.0 FLA
28 FLA
** See Auxiliary Kits section for options
TE1211E - 12 Foot Dryer – Single Fan/Heater - 380 Volt – 3 Phase – 50 HZ
Main Switch = 250 Amps
Fan
Minimum
Top Auger
Bottom Auger
38”
Amps
3 HP/#14
3HP/#14
10-15 HP/#10
38 Amps
Motor/Wire
5.0 FLA
5.0 FLA
28 FLA
** See Auxiliary Kits section for options
TE1612E- 16 Foot Dryer – Single Fan/Heater - 380 Volt – 3 Phase – 50 HZ
Main Switch = 250 Amps
Fan
Minimum
Top Auger
Bottom Auger
38”
Amps
3 HP/#14
3HP/#14
10-15 HP/#10
38 Amps
Motor/Wire
5.0 FLA
5.0 FLA
28 FLA
** See Auxiliary Kits section for options
Maximum
Amps
250 Amps
Maximum
Amps
250 Amps
Maximum
Amps
250 Amps
TE1614E - 16 Foot Dryer – Single Fan/Heater - 380 Volt – 3 Phase – 50 HZ STREAMLINE
Main Switch = 250 Amps
Fan
Minimum
Maximum
Top Auger
Bottom Auger
38”
Amps
Amps
3 HP/#14
3HP/#14
10-15 HP/#10
42 Amps
250 Amps
Motor/Wire
6.5 FLA
6.5 FLA
28.5 FLA
** See Auxiliary Kits section for options
4-7
TWO FAN MODELS
TE1631D – 16 Foot Dryer – 2 Fan / Heater 2/3 – 1/3, 380V – 3 Phase, Natural Gas – 50 HZ
Main Switch = 250 Amps
Top
Bottom
Upper Fan
Lower Fan
Minimum Maximum
Auger
Auger
38”
28”
Amps
Amps
3 HP/#14 3HP/#14 10-17HP/#10 10-15HP/#10
202 Amps 250 Amps
Motor/Wire
5 FLA
5 FLA
28 FLA
28 FLA
** See Auxiliary Kits section for options
TE1631A – 16 Foot Dryer – 2 Fan / Heater 2/3 – 1/3, 380V – 3 Phase, Natural Gas – 50 HZ
Main Switch = 250 Amps
Top
Bottom
Upper Fan
Lower Fan
Minimum Maximum
Auger
Auger
38”
28”
Amps
Amps
3 HP/#14 3HP/#14 10-17HP/#10 10-15HP/#10
202 Amps 250 Amps
Motor/Wire
5 FLA
5 FLA
28 FLA
28 FLA
** See Auxiliary Kits section for options
TE2432E – 24 Foot Dryer – 2 Fan / Heater 2/3 – 1/3, 380V – 3 Phase, Natural Gas – 50 HZ
Main Switch = 250 Amps
Top
Bottom
Upper Fan
Lower Fan
Minimum
Maximum
44”
28”
Amps
Amps
Auger
Auger
3 HP/#14 3HP/#14
30 HP/#8
15HP/#10
96 Amps
250 Amps
Motor/Wire
6.5 FLA
6.5 FLA
55 FLA
28 FLA
** See Auxiliary Kits section for options
TE2831D – 28 Foot Dryer – 2 Fan / Heater 2/3 – 1/3, 380V – 3 Phase, Natural Gas – 50 HZ
Main Switch = 250 Amps
Top
Bottom
Upper Fan
Lower Fan
Minimum
Maximum
Auger
Auger
44”
28”
Amps
Amps
3 HP/#10 3HP/#10
30 HP/#3
20HP/#4
118 Amps
250 Amps
Motor/Wire
14 FLA
14 FLA
55 FLA
35 FLA
** See Auxiliary Kits section for options
TE2832D – 28 Foot Dryer – 2 Fan / Heater 2/3 – 1/3, 380V – 3 Phase, Natural Gas – 50 HZ
Main Switch = 250 Amps
Top
Bottom
Upper Fan
Lower Fan
Minimum
Maximum
Auger
Auger
44”
28”
Amps
Amps
3 HP/#10 3HP/#10
30 HP/#3
20HP/#4
118 Amps
250 Amps
Motor/Wire
14 FLA
14 FLA
55 FLA
35 FLA
** See Auxiliary Kits section for options
4-8
Auxiliary Load and Unload Kit Options:
** Dryers may be equipped with auxiliary load and or unload motor starters / overloads. These can either
be installed at the factory, or field installed. There are different numbers for these kits depending on if it is
field or factory installed.
Auxiliary Load and Unload kit specifications:
•
Dryers have been pre-configured to handle up to 2 (two) 10 HP kits on single module dryers.
****If additional auxiliaries are required, the Dealer is responsible to determine if the dryer can handle the
amperage load. If the dryer is not able to handle the extra load, the auxiliary must have it’s own power
source independent of the dryer.
Temperature Compensated Overloads, 3 Phase Units:
All Dryers manufactured as three phase units, are equipped with temperature compensated overloads. It
is recommended if auxiliary load and unload kits are installed and not purchased from Sukup
Manufacturing Company, that temperature compensated units be used.
4-9
Fuel Information
LIQUID PROPANE
Sukup dryers for liquid propane use must be connected to a supply tank to draw liquid from the
bottom of the tank. The tank should be 1,000 gallons or larger, and have a regulator mounted to it
with a maximum 5 bars (72 psi). The connection to the dryer should be with a flexible hose
designed for LP gas. Have your LP gas supplier make proper connections and safety controls to
meet local codes and National Fire Protection Association standards.
Do not use tanks that have previously been used for ammonia or fertilizer solutions. These
substances are extremely corrosive and can damage fuel supply and burner parts.
Water in the supply tank may freeze in the pipe train or controls, causing damage. To ensure the
tank is free of moisture, the best precaution is to purge with methanol. Check with the gas
supplier if this needs to be done. Do not use tanks with an accumulation of oil or heavy
hydrocarbons from long use on a vapor withdrawal system.
If more than one tank is needed to supply liquid propane to the dryer, the vapor sides of the tanks
must be connected together to equalize the pressure from each tank. Have your LP gas supplier
make proper connections and safety controls to meet local codes and National Fire Protection
Association standards.
FUEL SYSTEM RECOMMENDATIONS
LIQUID PROPRANE
DRYER SIZE
8 FT, SINGLE HEATER
12 FT, SINGLE HEATER
16 FT, SINGLE HEATER
16 FT, 2 MODULE
16 FT, 3 MODULE
20 FT, SINGLE HEATER
20 FT, DUAL HEATER
20 FT, 2 MODULE
20 FT, 3 MODULE
24 FT, DUAL HEATER
24 FT, 2 MODULE
24 FT, 3 MODULE
28 FT, DUAL HEATER
MAXIMUM
HEAT CAPACITY
(BTU/HR)
3,000,000
5,000,000
6,000,000
13,000,000
20,000,000
7,000,000
9,000,000
16,500,000
25,000,000
10,000,000
20,000,000
30,000,000
11,000,000
MAXIMUM
FUEL FLOW
L/HR (GAL/HR)
124.9 (33)
204.4 (54)
246 (65)
537.5 (142)
825 (218)
287.7 (76)
371 (98)
681.4 (180)
1030 (272)
412.6 (109)
825.2 (218)
1234 (326)
454.2 (120)
FUEL LINE SIZE
(MINIMUM UP TO 100’)
CM (IN)
3 / 8”
1.27 (1 / 2”)
1.27 (1 / 2”)
1.9 (3 / 4”)
2.54 (1”)
1.27 (1 / 2”)
1.9 (3 / 4”)
1.9 (3 / 4”)
2.54 (1”)
1.9 (3 / 4”)
2.54 (1”)
2.54 (1”)
1.9 (3 / 4”)
1. See
fuel
specification
chart
above
for
recommended line size.
2. Use a pressure regulator at the supply tank.
3. Open LP shut-off valves slowly to prevent
inadvertent closing of excess flow valves
Connection to liquid manifold on Dryer
4 - 10
NATURAL GAS
Sukup dryers for natural gas use are designed to function at a heat value of approximately 1000
BTU per cubic foot. A regulated pressure of 1 bar (15 PSI) must be provided for connection to the
dryer. Ensure also that sufficient volume is maintained for the correct operating pressure.
NATURAL GAS
DRYER SIZE
8 FT, SINGLE HEATER
12 FT, SINGLE HEATER
16 FT, SINGLE HEATER
16 FT, 2 MODULE
16 FT, 3 MODULE
20 FT, SINGLE HEATER
20 FT, DUAL HEATER
20 FT, 2 MODULE
20 FT, 3 MODULE
24 FT, DUAL HEATER
24 FT, 2 MODULE
24 FT, 3 MODULE
28 FT, 2 DUAL HEATER
MAXIMUM
HEAT CAPACITY
(BTU/HR)
3,000,000
5,000,000
6,000,000
13,000,000
20,000,000
7,000,000
9,000,000
16,500,000
25,000,000
10,000,000
20,000,000
30,000,000
11,000,000
MAXIMUM
FUEL FLOW
L/HR (CUBIC FEET/HR)
84,951 (3000)
141,584.2 (5000)
169,901.1 (6000)
368,119 (13,000)
566,336.9 (20,000)
198,218 (7000)
254,851.6 (9000)
467,228 (16,500)
707,921.2 (25,000)
283,168.5 (10,000)
566,336.9 (20,000)
849,505.4 (30,000)
311,485 (11,000)
FUEL LINE SIZE
(MINIMUM UP TO 100’)
CM (IN)
1 1 / 4”
3.81 (1 1 / 2”)
3.81 (1 1 / 2”)
6.35 (2 1 / 2”)
6.35 (2 1 / 2”)
5.08 (2”)
5.08 (2”)
6.35 (2 1 / 2”)
7.62 (3”)
5.08 (2”)
6.35 (2 1 / 2”)
7.62 (3”)
2”
1. See fuel specification chart above for recommended line
size.
Connection to natural gas manifold on dryer
2 fan/heater natural gas dryer
4 - 11
Dryer Installation Information
Dryer set up / supports:
Warning: The wheel transport kit is for transport only and is NOT to be used when operating the
dryer. The dryer MUST be mounted and supported in an approved manner.
The dryer must be mounted a minimum of 38.1 cm (16 in) above the surface to allow for clean out.
Optional dryer supports are available from Sukup Mfg. in 2-foot, 3-foot, and 4-foot lengths.
The support kits come with attaching hardware to attach the supports to the dryer frame. Customer must
supply hardware for attachment to concrete pad (Recommend 1/2“ or 5/8” hardware).
Optional Dryer ladder extensions are available from Sukup Mfg. in 2-foot, 3-foot and 4-foot lengths.
Contact your Sukup Dealer to order either the supports and / or ladder extensions.
See the Installation and Pre-operational check out section in the Installation-Service part of
the manual for the proper support leg locations for 12, 16, 20, and 24 foot dryers.
Cross support braces and Front stand
If the dryer is not mounted using Sukup Mfg supports, the following guidelines must be followed:
•
•
•
Supports under grain columns must be at least every 1.83 m (6 feet)
Support under front hitch
Tie down dryer to foundation
2.4 M
4.5 M
1.79 M
0.65 M
1.92 M
3.66 M
4 - 12
Installation of customer sign
A sign, showing customer name or farm name and / or dealer name, is provided at no additional
charge by Sukup Manufacturing. The dealer will order the sign, specifying the appropriate information to
be printed on it.
3/8”
4 Places
3/8”
4 places
Side of
Sign Bracket
Front of Sign bracket
The bracket pictured above can be mounted to the outside of the dryer, on any two-foot grain column
section. The sign is then mounted to the bracket.
4 - 13
Unload Auger Time Delay Off and Secondary Auxiliary Time Delay Off Adjustment
If you desire to have your unload system have a timed delay off function, (To clear augers so as not to
heavily load them on restart), this is provided. This feature is adjustable from 0 to 60 seconds of “Off
Delay”.
If you desire to have your second fill auxiliary have a timed delay off function, (To clear any
vertical augers so as not to heavily load them on restart) this is also provided. This feature is
adjustable from 0 to 20 seconds of “Off Delay”.
The function of the auxiliaries is detailed in the General Dryer Functions, located in the technical
data portion of the catalog.
The following steps will guide you through both procedures.
Note: The unload and fill system will still shut off immediately under the following conditions for
safety reasons. 1.) Rear Door open. 2.) Grain discharge chute open. 3.) Motor Overload.
Step 1. Gain access to the inside of the control box by opening the front door and the inner panel.
Step 2. Locate the Programmable Logic Controller, (PLC), which is on the middle of the back panel.
Step 3. Open the access door by lifting up on the right side (hinged on left). (Refer to picture above)
Step 4. There are two adjustable potentiometers located at the top of opening (see picture below).
Timed Unload
Adjustment
0 to 60
seconds
Timed Load
Adjustment 0
to 20 seconds
The potentiometer on the left side is the adjustment for timed unload, the right is for the adjustment of the
secondary fill auxiliary. Both are factory pre-set to 0.
To change the setting to a timed delay, rotate the potentiometer clock-wise, (see the diagram above) to
the desired amount of “Delay Off” time.
Step 5. Close the access door on the PLC.
Step 6. Close control box inner door.
4 - 14
General Dryer Operation
Continuous Flow:
Continuous Flow dryer operation requires creating a gradient of moisture
from the top to the bottom of the dryer and is accomplished by three main
functions; initial dry, stabilization, and continuous flow. Before the first drying
operation is started, the user must enter the incoming moisture and the desired
output moisture into the control panel. These moistures are used to calculate the
time necessary to perform the initial dry at a set temperature, during which no
grain is unloaded from the dryer. After initial dry is complete, the user will set the
desired drying plenum temperatures and the controller calculates a meter roll
speed corresponding to the input plenum temperatures. The dryer then performs
a stabilization routine. During stabilization, a gradient of moisture is established
in the dryer by drying and unloading one full load of corn without adjusting the
meter roll speed. After stabilization has completed, the dryer enters continuous
flow operation. During this operation, the dryer adjusts the meter roll speed for
variances seen in the actual output moisture compared to the desired output
moisture. When the final dry of the season is achieved, the user simply enters
the final dry function and follows the simple instructions listed on the screen of
the control panel.
When continuing a drying operation after the dryer has run out of grain or
has been shut down, it is often desirable to run with the settings as before the
shut down. Therefore, quick methods of restarting the dryer have been
developed to meet this demand.
Restarting the dryer with or without
stabilization, depending upon the particular situation, can be accomplished by
following a short series of steps, laid out on the control panel screen during
normal startup operation.
Automatic Batch:
Automatic batch is a standard feature of the Sukup Continuous Flow Grain
Dryer. Batch operations enable operators to dry their grain in a manner they
have become accustomed to, enables them to dry extremely wet grain, and
allows single fan dryers to be operated in a heat cool manner.
Two controlling operations of automatic batch have been developed. The
first method dries batches according to time entries. The operator enters set
times into the control panel during which the dryer will heat, cool, and unload the
grain. During unload the dryer calculates the average moisture of each batch
and prints it. The user can then adjust the time entries according to the desired
output moisture. The second method of operation requires purchasing the
temperature control option.
The operator enters a desired dry temperature value into the control panel.
When the kernel temperature in the column reaches the set temperature, the
dryer proceeds to the next operation.
The set variables may be changed to the operator’s choosing at anytime
during the batch operation.
4 - 15
Grain Transfer:
Increasingly, operators require the dryer to transfer grain through it to reach their
storage facilities. A mode of grain transfer has been developed to simplify this process.
The control panel display steps the user through a simple process to begin and end the
procedure through normal startup operation.
Manual:
Manual operation serves many purposes. When operators want complete
control of their dryer, manual operation fulfills this need. Manual operation serves as a
redundant control set, allowing the user to operate their dryer while the dealer meets
any necessary service demands. Manual operation is a simple procedure of manually
turning on fans, heaters, loads, and unloads. The dryer automatically loads the dryer
during manual operation while the user has control of the meter roll speeds.
Auxiliary Operation:
Auxiliary controls can be setup in a number of configurations. Three
control channels exist, one for the auxiliary unload and two for the auxiliary fill.
For the unload, a single control channel is used to start an external unload device
at the same time as the unload of the dryer. The auxiliary fill operations have two
control channels. When turning the fill of the dryer on, a delay of 5 seconds
exists between the start of each motor, the dryer fill motor, the first auxiliary load,
and the second auxiliary load. The fill paddle will send a signal to the controls
that the dryer is nearly full, a switch is triggered to turn the second auxiliary load
off. This operation can be delayed by up to 20 seconds with a simple setting on
the PLC, explained in detail in the manual. Upon the signal that the dryer is
completely full, all auxiliary motors are shut off. If the second auxiliary is within
its delay period, it will shut off when the dryer is full.
Time delay off:
A time delay off has been included with the dryer to allow up to a 60
second clean out of the dryer to be performed upon shut down. The instructions
to set-up this operation are listed in the manual.
Optional Phone Modem:
An optional phone modem, purchased separately, can be used to contact
the operator of the dryer upon shutdown.
4 - 16
Dan Corn Heater Wiring
4 - 17
Continuous Flower Dryer Heater Orifice & Port Cup Configurations
Note: All dryers are shipped with High-Temp heater configuration.
High-Temp = Approx. 80-180°F Rise Above Ambient Air Temp
Intermediate = Approx. 60-160°F Rise Above Ambient Air Temp
Low-Temp = Approx. 40-80°F Rise Above Ambient Air Temp
Liquid Propane (LP)
High-Temp Orifice:
44" 40 HP
44" 30 HP
44" 15 HP
D71125 (25/64") D7113 (23/64") D7112 (19/64")
38" 10, 15, 20 HP
D7112 (19/64")
28" 15 HP
28" 20 HP
D7110 (13/64") D7106 (17/64")
High-Temp Port Cup:
D4044 (3/4")
D4044 (3/4")
D4044 (3/4")
D4044 (3/4")
D4027 (9/16")
D4027 (9/16")
Flame Deflector:
Yes
Yes
Yes
Yes
No
No
D71125 (25/64") D7113 (23/64") D7112 (19/64")
D7112 (19/64")
NA
NA
Intermediate Port Cup: D40443 (9/16") D40443 (9/16") D40443 (9/16")
D40443 (9/16")
Intermediate Orifice:
Flame Deflector:
Low-Temp Orifice:
Yes or No
Yes or No
Yes or No
D7112 (19/64") D7112 (19/64") D7110 (13/64")
Yes or No
D7110 (13/64")
D7125 (11/64") D7125 (11/64")
Low-Temp Port Cup:
D4041 (3/8")
D4041 (3/8")
D4041 (3/8")
D4041 (3/8")
D4025 (3/8")
D4025 (3/8")
Flame Deflector:
No
No
No
No
No
No
28" 15 HP
28" 20 HP
Natural Gas (NG)
High-Temp Orifice:
44" 40 HP
44" 30 HP
44" 15 HP
38" 10, 15, 20 HP
D71128 (5/8") D71127 (9/16")
D71124 (1/2")
D71124 (1/2")
High-Temp Port Cup:
D4044 (3/4")
D4044 (3/4")
D4044 (3/4")
D4044 (3/4")
D4027 (9/16")
D4027 (9/16")
Flame Deflector:
No
No
No
No
No
No
D71124 (1/2")
D71124 (1/2")
NA
NA
Intermediate Port Cup: D40443 (9/16") D40443 (9/16") D40443 (9/16")
D40443 (9/16")
Intermediate Orifice:
Flame Deflector:
Low-Temp Orifice:
D71128 (5/8") D71127 (9/16")
No
No
No
D71125 (25/64") D71125 (25/64")
No
D7112 (19/64")
D7112 (19/64")
Low-Temp Port Cup:
D71129 (7/16") D71129 (7/16") D71131 (23/64") D71131 (23/64")
D4041 (3/8")
D4041 (3/8")
D4041 (3/8")
D4041 (3/8")
D4025 (3/8")
D4025 (3/8")
Flame Deflector:
No
No
No
No
No
No
4 - 18
12
14
16
18
20
70% Meter
Roll
80% Meter
Roll
90% Meter
Roll
100% Meter
Roll
8
40% Meter
Roll
60% Meter
Roll
6
30% Meter
Roll
10
6
4
20% Meter
Roll
50% Meter
Roll
3
2
10% Meter
Roll
‘
4 - 19
30.5
27
24
21
18
15
12
9
12 Foot
1 Module
8 Foot
1 Module
Dryer
40.6
36.6
32.5
28.5
24
20
16
12
8
4
16 Foot
1 Module
51
45.7
40.6
35.6
30.5
25
15
15
10
5
20 Foot
1 Module
61
55
49
42.7
36.6
30.5
24
18
12
6
24 Foot
1 Module
71
64
57
50
42.7
35.6
28.5
21
14
7
28 Foot
1 Module
Appendix A: Estimated Tonnes Per Hour Information Per Module
This chart is only an approximation!
NOTES
4 - 20
Parts Index
Parts Index
Table Of Contents
SWCB1.1.0.06 Control Box Front Panel – Single Fan Diagram ..................................................... 2
SWCB1.2.0.06 Control Box Front Panel (Rear) Diagram ............................................................... 3
SWCB1.3.0.06M Control Box Inside Panel Diagram ...................................................................... 4
SINGLE FAN / SINGLE & THREE PHASE PARTS – CONTROL BOX ...................................... 5
SWPB2.1.0.06 Power Box Door Diagram ....................................................................................... 6
SWPB2.4.0.06 Power Box Three Phase / Single Fan Diagram 380V ............................................ 7
SINGLE FAN / THREE PHASE 380 VOLT PARTS – POWER BOX .......................................... 8
SWCB1.1.1.06 Control Box Front Panel – Two Fan Diagram ........................................................ 9
SWCB1.2.1.06 Control Box Front Panel (Rear) – Two Fan Diagram ........................................... 10
SWCB1.3.1.06M Control Box Inside Panel – Two Fan Diagram .................................................. 11
TWO FAN / SINGLE & THREE PHASE PARTS – CONTROL BOX......................................... 12
SWPB2.4.1.06A Power Box Three Phase / Two Fan Diagram, 2-15HP, 380V ............................ 13
TWO FAN / THREE PHASE 380 VOLT, 2-15HP PARTS – POWER BOX............................... 14
SWPB2.4.1.06B Power Box Three Phase / Two Fan Diagram, 30HP/20HP, 380V ..................... 15
TWO FAN / THREE PHASE 380 VOLT, 30HP/20HP PARTS – POWER BOX........................ 16
5-1
Parts Index
SWCB1.1.0.06 Control Box Front Panel – Single Fan Diagram
5-2
Parts Index
SWCB1.2.0.06 Control Box Front Panel (Rear) Diagram
5-3
Parts Index
SWCB1.3.0.06M Control Box Inside Panel Diagram
5-4
Parts Index
SINGLE FAN / SINGLE & THREE PHASE PARTS – CONTROL BOX
Part Label
Number
1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
33
34
35
36
38
39
40
41
42
43
44
45
46
47
Drawing Number
Parts
Description
SWCB1.1.0.06 & SWCB1.2.0.06
SWCB1.1.0.06 & SWCB1.2.0.06
SWCB1.1.0.06 & SWCB1.2.0.06
SWCB1.1.0.06
SWCB1.1.0.06
SWCB1.1.0.06
SWCB1.1.0.06
SWCB1.1.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
F60679
J47331
J47602
J6772
J6774
J6773
J6775
J8812
T16474
J6768
T17993
J0982
J6777
J6792
J6734
J6771
F6068
F60672
J4751
J4603
J6383
J8818
QP23934
J6382
J8817
T7080
J6726
J6757
J46501
J4641
J6787
J4623
J8819
J6754
J48184
J6787
J67491*
J67504*
J67532*
J47901
J8816
J46308
F6090
J46505
LCD,W/CONNECTOR
PRINTER,CITIZEN,CBM920-RF
KEYPAD,84SY3326-70
AMBER 3 POS.ILLUM.OPERATOR
OPERATOR,CLEAR,3 POS.ILLUM.
BLUE 3 POS.ILLUM.OPERATOR
OPERATOR,GREEN,3 POS.ILLUM
ASSEMBLY,POTENTIOMETER
FRAME,DISPLAY
EXTRUS,TOP MARKING,TME 2
PAPER ROLLER, 2006
NUT,HEX,6-32,PLT,MS
SUPPLYLIGHT,DIRECT,W/2N.O
CONTACT,SUPLITE,2N.C
POTENTIOMETER,MULTI-TURN
CONTACT,SUPLITE,2N.0
POWER SUPPLY
PROCESSOR,COMPLETE
FILTER,CORCOM,1VB1
SMART WATCH,DS1243Y-120
SOCKET,11 PIN
CIRCUIT, ASSY, 10J MOV & RC
ADAPTOR,3 WAY (63V)
RELAY
CIRCUIT, ASSY, 100J MOV&RC
PROM, PROGRAM
OMRON PLC
EXPANDER MODULE
I/O BOARD POPULATED
4 TERMINAL PLUG
VARISTOR,100 JOULE
PLUG,6 TERMINAL
CIRCUIT, .1UF CAP & SHRINK
STOP,DIN END
½ AMP BREAKER
VARISTOR,100 JOULE
GROUND,TERMINAL
TERMINAL,FEED THRU
BARRIER,END
GROUND BAR,7 HOLE ALUM
CIRCUIT,ASSY,RC ONLY
SUPPLY,POWER,24VDC
DISPLAY,RTD TEMP
BOARD,E-MOD VALVE,1 FAN
*See page 16
5-5
Parts Index
SWPB2.1.0.06 Power Box Door Diagram
5-6
Parts Index
SWPB2.4.0.06 Power Box Three Phase / Single Fan Diagram 380V
5-7
Parts Index
SINGLE FAN / THREE PHASE 380 VOLT PARTS – POWER BOX
Part Label
Number
Drawing
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
20
21
22
23
24
28
29
30
33
34
35
36
38
39
40
41
42
44
45
46
47
49
50
51
52
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
Parts for Model
Numbers:
TE1211E, TE1212E,
& TE1612E
T18511
T18523
T16520
J0472
J0985
T18523
J0513
J0990
T16521
T18523
T16525
T16525
J47901
J6383
J6382
J5265
J5236
J4492
J6729
J5536
J6495
J6794
J4766
J52601
J52461
J6754
J67532*
J67504*
J67491*
J48185
J8817
J67421
J5274
J4048 & J1195
J5232
J5266
J6700
J5226
J5212
Part of T16525
J6496
J4767
*See page 16
5-8
Description
DOOR, POWER DIST
GUIDE, LATCH
SPACER, NYLN, GUIDE
SCREW,10-24 X 1
NUT, HEX,10-24,PLT,MS
ROD, 13” LONG
SCREW, 1/4-20,1.25,
NUT, HEX, 1/4-20,PLT
SPACER, NYLON, LTCH
ROD, 21” LONG
HANDLE & GASKET
SHORT BOLT
GROUND BAR, 7 HOLE ALUM
SOCKET, FINGER SAFE
RELAY, 11 PIN
AUX CONTACT
STARTER, PROTECTOR, 6-10 AMPS
OPERATOR, MUSHROOM, 2 POS.MAINT
DIRECT SUPPLYLIGHT MOD.W/N.C.
RESISTOR, 1/2 TO 1H,SCR BRD
TRANSFORMER, CONTROL, 380V-230V&115V
SCR, DC DRIVE
HOURMETER, 115V, 60HZ
AUX CONT, LAD8N20
CONT, 40A, LC1D40G7
STOP, DIN END
BARRIER, END
TERMINAL, FEED THRU
GROUND, TERMINAL
BREAKER, CIRCUIT, 3 AMP
CIRCUIT, ASSY, 100J MOV&RC
TERMINAL, FEED THRU, 70 AMP
OVERLOAD, 86 AMPS
LUG, COPPER TERMINAL & WASHER, LOCK
STARTER, PROTECTOR, 25-40 AMPS
AUX CONTACT (GV3A01)
BLOCK, POWER DISTRIBUTION 3 PH
STARTER, WYE-DELTA, 25KW, 50HZ
SWITCH, MAIN, 250 AMP 3 POLE
SHAFT, SWITCH DISCONNECT, W/OP
FUSE BLOCK L60030M3SQ
COVER, MAIN SWITCH, KCA1B
Parts Index
SWCB1.1.1.06 Control Box Front Panel – Two Fan Diagram
5-9
Parts Index
SWCB1.2.1.06 Control Box Front Panel (Rear) – Two Fan Diagram
5 - 10
Parts Index
SWCB1.3.1.06M Control Box Inside Panel – Two Fan Diagram
5 - 11
Parts Index
TWO FAN / SINGLE & THREE PHASE PARTS – CONTROL BOX
Part Label
Number
1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
33
34
35
36
38
39
40
41
42
43
44
45
46
47
Drawing Number
Parts
Description
SWCB1.1.0.06 & SWCB1.2.0.06
SWCB1.1.0.06 & SWCB1.2.0.06
SWCB1.1.0.06 & SWCB1.2.0.06
SWCB1.1.0.06
SWCB1.1.0.06
SWCB1.1.0.06
SWCB1.1.0.06
SWCB1.1.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.2.0.06
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
SWCB1.3.0.06M
F60679
J47331
J47602
J6772
J6774
J6773
J6775
J8812
T16474
J6768
T17993
J0982
J6777
J6792
J6734
J6771
F6068
F60672
J4751
J4603
J6383
J8818
QP23934
J6382
J8817
T7080
J6726
J6757
J46501
J4641
J6787
J4623
J8819
J6754
J48184
J6787
J67491*
J67504*
J67532*
J47901
J8816
J46308
F6090
J46504
LCD,W/CONNECTOR
PRINTER,CITIZEN,CBM920-RF
KEYPAD,84SY3326-70
AMBER 3 POS.ILLUM.OPERATOR
OPERATOR,CLEAR,3 POS.ILLUM.
BLUE 3 POS.ILLUM.OPERATOR
OPERATOR,GREEN,3 POS.ILLUM
ASSEMBLY,POTENTIOMETER
FRAME,DISPLAY
EXTRUS,TOP MARKING,TME 2
PAPER ROLLER, 2006
NUT,HEX,6-32,PLT,MS
SUPPLYLIGHT,DIRECT,W/2N.O
CONTACT,SUPLITE,2N.C
POTENTIOMETER,MULTI-TURN
CONTACT,SUPLITE,2N.0
POWER SUPPLY
PROCESSOR,COMPLETE
FILTER,CORCOM,1VB1
SMART WATCH,DS1243Y-120
SOCKET,11 PIN
CIRCUIT, ASSY, 10J MOV & RC
ADAPTOR,3 WAY (63V)
RELAY
CIRCUIT, ASSY, 100J MOV&RC
PROM, PROGRAM
OMRON PLC
EXPANDER MODULE
I/O BOARD POPULATED
4 TERMINAL PLUG
VARISTOR,100 JOULE
PLUG,6 TERMINAL
CIRCUIT, .1UF CAP & SHRINK
STOP,DIN END
½ AMP BREAKER
VARISTOR,100 JOULE
GROUND,TERMINAL
TERMINAL,FEED THRU
BARRIER,END
GROUND BAR,7 HOLE ALUM
CIRCUIT,ASSY,RC ONLY
SUPPLY,POWER,24VDC
DISPLAY,RTD TEMP
BOARD,E-MOD VALVE,2 FAN
*See page 16
5 - 12
Parts Index
SWPB2.4.1.06A Power Box Three Phase / Two Fan Diagram, 2-15HP, 380V
5 - 13
Parts Index
TWO FAN / THREE PHASE 380 VOLT, 2-15HP PARTS – POWER BOX
Part Label
Number
Drawing Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
20
21
22
23
24
28
29
30
33
34
35
36
38
39
40
41
42
44
45
46
47
49
50
51
52
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.1.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
SWPB2.4.0.06
Parts for Model
Numbers:
T1631A & T1632A
T18511
T18523
T16520
J0472
J0985
T18523
J0513
J0990
T16521
T18523
T16525
T16525
J47901
J6383
J6382
J5265
J5236
J4492
J6729
J5536
J6495
J6794
J4766
J52601
J52461
J6754
J67532*
J67504*
J67491*
J48185
J8817
J67421
J5274
J4048 & J1195
J5232
J5266
J6700
J5226
J5212
Part of T16525
J6496
J4767
Description
DOOR, POWER DIST
GUIDE, LATCH
SPACER, NYLN, GUIDE
SCREW,10-24 X 1
NUT, HEX,10-24,PLT,MS
ROD, 13” LONG
SCREW, 1/4-20,1.25,
NUT, HEX, 1/4-20,PLT
SPACER, NYLON, LTCH
ROD, 21” LONG
HANDLE & GASKET
SHORT BOLT
GROUND BAR, 7 HOLE ALUM
SOCKET, FINGER SAFE
RELAY, 11 PIN
AUX CONTACT
STARTER, PROTECTOR, 6-10 AMPS
OPERATOR, MUSHROOM, 2 POS. MAINT
DIRECT SUPPLYLIGHT MOD.W/N.C.
RESISTOR, 1/2 TO 1H,SCR BRD
TRANSFORMER, CONTROL, 380V-230V&115V
SCR, DC DRIVE
HOURMETER, 115V, 60HZ
AUX CONT, LAD8N20
CONT, 40A, LC1D40G7
STOP, DIN END
BARRIER, END
TERMINAL, FEED THRU
GROUND, TERMINAL
BREAKER, CIRCUIT, 3 AMP
CIRCUIT, ASSY, 100J MOV&RC
TERMINAL, FEED THRU, 70 AMP
OVERLOAD, 86 AMPS
LUG, COPPER TERMINAL & WASHER, LOCK
STARTER, PROTECTOR, 25-40 AMPS
AUX CONTACT (GV3A01)
BLOCK, POWER DISTRIBUTION 3 PH
STARTER, WYE-DELTA, 25KW, 50HZ
SWITCH, MAIN, 250 AMP 3 POLE
SHAFT, SWITCH DISCONNECT, W/OP
FUSE BLOCK L60030M3SQ
COVER, MAIN SWITCH, KCA1B
*See page 16
5 - 14
Parts Index
SWPB2.4.1.06B Power Box Three Phase / Two Fan Diagram, 30HP/20HP, 380V
5 - 15
Parts Index
TWO FAN / THREE PHASE 380 VOLT, 30HP/20HP PARTS – POWER BOX
Part
Label
Number
Drawing
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
20
21
22
23
24
25
28
29
30
33
34
35
36
37
38
39
40
44
45
47
48
50
SWPB2.1
SWPB2.1
SWPB2.1
SWPB2.1
SWPB2.1
SWPB2.1
SWPB2.1
SWPB2.1
SWPB2.1
SWPB2.1
SWPB2.1
SWPB2.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
SWPB2.3.1
Parts for Model
Numbers:
T2421B &
T2422B
T18511
T18523
T16520
J0472
J0985
T18523
J0513
J0990
T16521
T18523
T16525
T16525
J47901
J3881
J38802
J5265
J5243
J4492
J6729
J5536
J6490
J6794
J6787
J4766
J5260
J5246
J6754
J67532*
J67504*
J67491*
N/A
J48185
J8817
J67421
J5242
J5266
J5247
J5212
Part of T16525
Parts for Model
Numbers:
T2021B,T2022B,
T2031B,T2032B
T18511
T18523
T16520
J0472
J0985
T18523
J0513
J0990
T16521
T18523
T16525
T16525
J47901
J3881
J38802
J5265
J5242
J4492
J6729
J5536
J6490
J6794
J6787
J4766
J5260
J5246
J6754
J67532*
J67504*
J67491*
N/A
J48185
J8817
J67421
J5242
J5266
J5247
J5212
Part of T16525
Parts for Model
Numbers:
T1631B &
T1632B
T18511
T18523
T16520
J0472
J0985
T18523
J0513
J0990
T16521
T18523
T16525
T16525
J47901
J3881
J38802
J5265
J5236
J4492
J6729
J5536
J6490
J6794
J6787
J4766
J5260
J5246
J6754
J67532*
J67504*
J67491*
N/A
J48185
J8817
J67421
J5242
J5266
J5247
J5212
Part of T16525
Description:
DOOR, POWER DIST
GUIDE, LATCH
SPACER, NYLN, GUIDE
SCREW,10-24 X 1
NUT, HEX,10-24,PLT,MS
ROD, 13” LONG
SCREW, 1/4-20,1.25,
NUT, HEX, 1/4-20,PLT
SPACER, NYLON, LTCH
ROD, 21” LONG
HANDLE & GASKET
SHORT BOLT
GROUND BAR
11 PIN SOCKET
11 PIN RELAY
AUX CONTACT
STARTER PROTECTOR
MUSHRM OPERATOR
DIRECT SUPPLYLITE
RESISTOR
CNTRL TRANSFORMER
SCR DRIVE
100 JOULE VARISTOR
HOURMETER
AUX CONTACT
40A CONTACTOR
DIN END STOP
END BARRIER
FEED THRU TERMINAL
GROUND TERMINAL
N/A
3 AMP BREAKER
100J MOV&RC CIRCUIT
70A FEED THRU TERM
STARTER PROTECTOR
AUX CONTACT
CONTACTOR
MAIN SWITCH
PWR DISCON SHAFT
*If Dryer serial number is after #8696, Phoenix terminals replaced the previous Entrelec
terminals. The following numbers are their replacements:
J67532 – replaced with J6903
J67504 – replaced with J6900 (DC terminals) and J6901 (AC terminals)
J67491 – replaced with J6902
The AC Suppression board (J67831) is used in the Power Box to replace the AC terminals.
5 - 16
AUTOMATIC DRYER PARTS ASSEMBLIES (CE)
Sukup Manufacturing Company
1555 - 255th Street P.O. Box 677
Sheffield, Iowa 50475
Phone 641-892-4222
Fax 641-892-4629
Parts Assemblies - L1455 - DC
1/2008
© Sukup Manufacturing Company
Table of Contents
DRYER FAN PARTS ....................................................................................................................................................3
DRYER HEATER PARTS.............................................................................................................................................4
PIPE TRAIN, EL MOD VALVE 1/2”, 28” FAN-HEATER ...............................................................................................5
PIPE TRAIN, EL MOD VALVE 1/2”, 28” FAN-HEATER ...............................................................................................6
PIPE TRAIN, EL MOD VALVE 1/2”, 38” FAN-HEATER ...............................................................................................7
PIPE TRAIN, EL MOD VALVE 3/4”, 38” & 44” FAN-HEATER .....................................................................................8
12’ WET BIN ...............................................................................................................................................................10
16’ WET BIN ...............................................................................................................................................................12
20’ WET BIN ...............................................................................................................................................................14
24’ WET BIN ...............................................................................................................................................................16
28’ WET BIN ...............................................................................................................................................................18
DRIVE END OF DRYERS ..........................................................................................................................................20
DRIVE END OF DRYERS, SINGLE FAN - BACK END .............................................................................................22
SINGLE FAN - BACK END .........................................................................................................................................23
COLUMN PARTS .......................................................................................................................................................24
BACK METERING ROLLS .........................................................................................................................................25
12’ CAM LOCK ASSEMBLY .......................................................................................................................................26
16’ CAM LOCK ASSEMBLY .......................................................................................................................................27
20’ CAM LOCK ASSEMBLY .......................................................................................................................................28
24’ CAM LOCK ASSEMBLY .......................................................................................................................................29
28’ CAM LOCK ASSEMBLY .......................................................................................................................................30
FRAME FOR BOTH STANDARD & STACKED DRYERS .........................................................................................31
12’ BOTTOM AUGER .................................................................................................................................................32
16’ BOTTOM AUGER .................................................................................................................................................33
20’ BOTTOM AUGER .................................................................................................................................................34
24’ BOTTOM AUGER .................................................................................................................................................35
28’ BOTTOM AUGER .................................................................................................................................................36
DRYER HITCH WITH 24” EXTENSION .....................................................................................................................37
DRYER ASPIRATOR COMPONENT INSTRUCTIONS.............................................................................................38
DRYER ASPIRATOR COMPONENT ASSEMBLY (Optional)....................................................................................40
6-2
DRYER FAN PARTS
SWPD0029
Ref. #
1
2
3
4
5
Description
Housing
Motor
Blade
Venturi
Inlet Screen
28”
15HP
1hp
T28550
H5753
J3062
J3080
D3824
28”
15HP
3ph
T28550
H5758
J3962
J3080
D3824
38”
15HP
1ph
T12980
H5755
T12175
J3085
J3132
38”
15HP
3ph
T12981
H6275
T12175
J3085
J3132
6-3
38”
20HP
3ph
T12981
H6800
T121752
J3085
J3132
44”
15HP
1ph
T16980
H5755
J3070
J3090
J2957
44”
15HP
3ph
T16980
H6275
J3070
J3090
J2957
44”
30HP
3ph
T20980
H7125
J3067
J3090
J2957
44”
40PH
3ph
T24980
H7175
J3068
J3090
J2957
DRYER HEATER PARTS
REF. #
DESCRIPTION
28” LP
28” NG
38” LP
38” NG
1
2
3
4
5
6
7
8
9
10
Housing
Burner
Vaporizer
Flame Deflector
Port Cup
Flame Sensor
Spark Plug
Pipe Train
Orifice Pipe
Orifice
T28550
D4017
D70321
----D4027
J5747
J5739
T24173
D7119
D7110
T28550
D4017
--------D4027
J5747
J5739
T24172
D7119
D71125
T12990
T12196
T16194
T16204
D4044
J5747
J5739
T16193
D71281
D7112
T12990
T12196
-------D4044
J5747
J5739
T24193
D71191
D71124
15HP
15HP
11
Liquid Pipe Train
D4006
-----
T16187
-----
6-4
44” LP
15HP
T16990
T16201
T16194
T16204
D4044
J5747
J5739
T16193
D71281
D7112
44” NG
15HP
T16990
T16201
-------D4044
J5747
J5739
T20193
D71192
D71124
44” LP
30HP
T16990
T16201
T16194
T16204
D4044
J5747
J5739
T16193
D71281
D7113
44” NG
30HP
T16990
T16201
-------D4044
J5747
J5739
T25193
D71192
D71127
T16187
----
T16187
----
PIPE TRAIN, EL MOD VALVE 1/2”, 28” FAN-HEATER
LP MODEL – T20200D
REF. #
1
2
3
4
5
6
7
8
9
10
11
DESCRIPTION
EYEBOLT,PIPE TRAIN,5/8"COLLAR
NUT,HEX,3/8-16,PLT
NIPPLE,1/4X1 1/2,BLKPIPE,SCH80
NIPPLE,1/4 X CL,SCH 80
STRAINER,LIQ,1/4”
TEE,1/4X1/4X1/4,SCH 80
PLUG,3/8,PIPE,BLACK
ELBOW,3/8FLX1/4MIP,90DE,E1-6B
VALVE,1/4",RELIEF,3865-250
VALVE,1/4 ,LP BALL
CONDUIT,LIQ VLV ACT 28",ASSY
QTY
2
4
3
1
1
2
1
1
2
1
1
6-5
COMP. #
D71162
J1020
J2400
J24003
J5990
J2470
J2610
J2740
J6050
J6080
T17092
PIPE TRAIN, EL MOD VALVE 1/2”, 28” FAN-HEATER
LP MODEL – T18810D
REF. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
DESCRIPTION
REGULATOR,1/2"X1584MN,CGA ONLY
NIPPLE,1/2X2,SCH 40
ELBOW,1/2,90 DEGREE,SCH 40
VALVE,GAS,1/2",VGG10.154U
KIT,NEMA 4,AGA66
ACTUATOR,SKP15.001E1
NIPPLE,1/2 X CLOSE,SCH 40
TEE,1/2X1/2X1/2,SCH 40
BUSHING,REDUCING,1/2X1/4,MAL
NIPPLE,1/4 X CL,SCH 80
UNION,1/4",SCH 40
ELBOW,1/4 X 90,SCH 40
NIPPLE,1/4X3,SCH 40
SWITCH,HIGH PRESSURE,ASHCROFT
VALVE,BUTTERFLY L/ACTUATOR,1/2
TEE,REDUCING,3/4X1/2X1/2,SCH40
ELBOW,STREET,1/4,90 DEG,SCH 40
GAUGE,PRES,0-30,LIQ,1/4"BTM MT
NIPPLE,3/4 X CLOSE,SCH 40
QTY
1
3
1
2
2
2
4
1
1
3
1
2
1
1
1
1
2
1
1
COMP. #
J6110
J24061
J2522
J6235
J6241
J6240
J2405
J2471
J2569
J24003
J2703
J2526
J2411
J4432
J6125
J2481
J2517
J5960
J2410
6-6
REF. #
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
DESCRIPTION
UNION,3/4,BLACK,#150
NIPPLE, 3/4 X 10" SCH 80
ELBOW,3/4,90 DEGREE,SCH 40
NIPPLE,3/4 X 8,SCH 40
COUPLING,REDUCING,1/2X1/4,SC40
VALVE,1/4", RELIEF,A1325,H120
BRACKET,ELECTRONIC MOD VALVE
COVER,ELECTRONIC VALVE
SCREW,#10-16,3/4,PLT,SELFDRILL
EYEBOLT,PIPE TRAIN,7/8"COLLAR
NIPPLE,1/2X1 1/2,SCH 80
TEE,1/2X1/2X1/2,SCH 80
PLUG,1/2,SQ HD,BLACK PIPE
NIPPLE,1/2 X 6,SCH 80
ELBOW,1/2,90 DEGREE,SCH 80
UNION,1/2FLX1/2MIP,U1-8D
BUSHING,REDUCING,1/4X1/8
GAUGE,PRES,30PSI,01B XUC,PM
QTY
1
1
2
1
1
1
1
1
4
2
1
1
1
1
1
1
1
1
COMP. #
J2710
J2429
J2525
J2418
J2572
J6171
T161935
T26902
J0469
D71161
J2406
J2472
J2617
J24093
J2523
J2840
J2560
J5959
PIPE TRAIN, EL MOD VALVE 1/2”, 38” FAN-HEATER
LP MODEL – T161871D
REF. #
1
2
3
4
5
6
7
8
9
10
11
12
DESCRIPTION
TEE,1/2X1/2X1/2,SCH 80
NIPPLE,1/2X1 1/2,SCH 80
VALVE,1/2",BALL,ITT 1550
EYEBOLT,PIPE TRAIN,7/8"COLLAR
NUT,HEX,3/8-16,PLT
STRAINER,WYE,1/2",20 MESH
PLUG,3/8,PIPE,BLACK
VALVE,1/2",RELIEF,3129G,H135-2
RAIN CAP,7545-10
ELBOW,1/2FLX1/2MIP,90DE,E1-8D
ELBOW,STREET,1/2,90 DEG,SCH 80
SOLENOID ASSY,LIQ,1/2",38",D-C
6-7
QTY
2
4
1
2
4
1
1
2
2
1
1
1
COMP. #
J2472
J2406
J6082
D71161
J1020
J5992
J2610
J6170
J6200
J2745
J2519
T17029D
PIPE TRAIN, EL MOD VALVE 3/4”, 38” & 44” FAN-HEATER
LP MODEL – T18812D
REF. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
DESCRIPTION
VALVE,BUTTERFLY L/ACTUATOR,3/4
NIPPLE,3/4X2,SCH 40
NIPPLE,3/4 X CLOSE,SCH 40
TEE,3/4X3/4X3/4,SCH 40
SWITCH,HIGH PRESSURE,ASHCROFT
VALVE,GAS,3/4"SNGL,VGG10.204U
NIPPLE,1/4X1 1/2,SCH 40
ELBOW,1/4 X 90,SCH 40
UNION,1/4",SCH 40
NIPPLE,1/4 X CL,SCH 80
SWITCH,PRESSURE,ASHCROFT
KIT,NEMA 4,AGA66
ACTUATOR,SKP15.001E1
ELBOW,3/4,90 DEGREE,SCH 40
UNION,3/4,BLACK,#150
ELBOW,STREET,3/4,90 DEG,SCH 40
REGULATOR,3/4",DRILLED+TAPPED
QTY
1
5
6
2
1
2
4
5
2
5
1
2
2
3
2
1
1
COMP. #
J6126
J2420
J2410
J2485
J4432
J6236
J24001
J2526
J2703
J24003
J4433
J6241
J6240
J2525
J2710
J2530
T19015
6-8
REF. #
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
DESCRIPTION
EYEBOLT,PIPE TRAIN
NIPPLE, 3/4 X 6, SCH 80
TEE,3/4X3/4X3/4,SCH 80
PLUG,3/4
NIPPLE,3/4X6 1/2,BLACK,SCH 40
COUPLING,REDUCING,3/4X1/4,SC40
ELBOW,STREET,1/4,90 DEG,SCH 40
GAUGE,PRES,0-30,LIQ,1/4"BTM MT
COVER,ELECTRONIC VALVE
BRACKET,ELECTRONIC MOD VALVE
SCREW,#10-16,3/4,PLT,SELFDRILL
VALVE,1/4", RELIEF,A1325,H120
TEE,1/4X1/4X1/4,SCH 40
BUSHING,REDUCING,1/4X1/8
GAUGE,PRES,30PSI,01B XUC,PM
NIPPLE,1/4 X 2,SCH 40
QTY
1
1
1
1
1
2
2
1
1
1
2
1
1
1
1
1
COMP. #
T16224
J2428
J2491
J2620
J2427
J2574
J2517
J5960
T26902
T161935
J0469
J6171
J2469
J2560
J5959
J24004
NOTES
6-9
12’ WET BIN
12’ WET BIN
REF. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
DESCRIPTION
Trash Pan
Support, Trash Pan
Left Support Gusset
Right Support Gusset
RR Wet Bin End Plate
RF Wet Bin End Plate
LF Wet Bin End Plate
LR Wet Bin End Plate
Top 8’ Panel (RR & LF) 2000
Top 8’ Panel (LR & RF) 2000
Wet Bin Side Perforated (Stainless)
Wet Bin Side Perforated (Galvanized
LT Pivot Brace Wet Bin
RT Pivot Brace Wet Bin
Splice, Wet Bin Side
Bolt Down Lip 8’ 2000
Hopper Side
Hopper End
Top Auger Shield (Inner)
Top Auger Shield (Outer)
Plate, Turnbuckle, Connector
Top Motor Mount
Top Shield Brace
Bracket, LF Top auger Shield
Bracket, RF top Auger Shield
Bearing, 1.25, FLG, W/LC, HCFTS207-20
Splice Gusset Right
Splice Channel Short
Turnbuckle, 3/8” x 6”
Pivot, Motor Mount, Top
Collar, Shaft, 1-3/16”
Bushing, 1.25, SK
Pulley, 15.75 OD, DBL “B” Gr, SK
MTR, Auger 3HP, 1ph, TEFC,
MTR, Auger 3HP, 3ph, TEFC
Pulley, 3.5 OD, 1.25, DBL, B, Cast
Belt, B95
Key, 1/4 x 1/4 x 2”
Paddle, Assembly
Lid, Extension, wet Bin
Cover, Hopper
Splice Gusset Left
Crimp Plate
Hanger, Auger, T, 6CH2203
Splice Channel
Bushing, Wood, 1.25” ID
Spacer, T-Hanger, Top auger
Lid, Wet Holding Bin
Top auger
Stub Shaft
Bottom Auger Shaft
Auger Shaft, Top Front
Lid, Bin, Wet HLD. 12”
Bolt Down Lip, 4’
Side, Wet Bin 4’ (Galvanized)
Side, Wet Bin 4’ (Stainless)
Top 4’ Panel(LR) 12’
Top 4’ Panel (RR) 12’
4’ Rear, Top Auger
6 - 11
QTY
1
3
8
8
1
1
1
1
1
1
2
2
10
6
2
2
2
2
1
1
1
1
1
1
1
2
2
2
1
1
2
1
1
1
1
1
2
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
1
COMP. #
T16235
T16236
T16117
T16118
T17401
T17400
T17402
T17403
T17452
T17451
T17450S
T17450
T17410
T17411
T17412
T17453
T17935
T17936
T16256
T16255
T16283
T16277
T16258
T16861
T16860
J0010
T16145
T16146
J0904
T18150
J1338
J0410
J03992
T12590
H3345
J0317
J0252
F4499
T16262
T16159
T17937
T16144
T16142
J0097
T16143
J0096
T16096
T16158
T16428
F4720
G73291
T16436
T12519
T12524
T12525
T12525S
T12526
T12527
T12503
16’ WET BIN
6 - 12
16’ WET BIN
REF. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
DESCRIPTION
Trash Pan
Support, Trash Pan
Left Support Gusset
Right Support Gusset
RR Wet Bin End Plate
RF Wet Bin End Plate
LF Wet Bin End Plate
LR Wet Bin End Plate
Top 8’ Panel ( RR & LF) 2000
Top 8” Panel (LR & RF) 2000
Wet Bin Side Perf, (Stainless)
Wet Bin Side Perf, (Galvanized)
LT Pivot Brace Wet Bin
RT Pivot Brace Wet Bin
Splice, Wet Bin Side
Bolt Down Lip 8’, 2000
Hopper Side
Hopper End
Top Auger Shield (Inner)
Top Auger Shield (Outer)
Plate, Turnbuckle, Connector
Top Motor Mount
Top Shield Brace
Bracket, LF Top Auger Shield
Bracket, RF Top Auger Shield
Bearing, 1.25, FLG, W/LC, HCFTS207 - 20
Splice Gusset Right
Channel, Splice, Short
Turnbuckle, 3/8” x 6”
Pivot, Motor Mount, Top
Collar, Shaft, 1-3/16”
Bushing, 1.25 SK
Pulley, 15.75OD, Double “B” Gr. SK
Motor, Auger 3HP, 1ph, TEFC
Motor, Auger 3HP, 3ph, TEFC
Pulley, 3.5 OD, 1.25, Double, B, Cast
Belt, B95
Key, 1/4 x 1/4 x 2
Paddle, Assembly
Lid, Wet Holding Bin
Lid, 10.5”, Extension, Wet Bin
Cover, Hopper
Splice Gusset Left
Crimp Plate
Hanger, Auger, T, 6CH2203
Splice Channel
Bushing, Wood, 1.25” ID
Spacer, T-Hanger, Top auger
Lid, 92-1/2” Wet Holding Bin
Top Auger
Shaft, 8’ Hanger Bearing
Shaft, 1.25” x 9”
Shaft, Top Front, 12-3/4”
6 - 13
QTY
1
3
12
8
1
1
1
1
2
2
4
4
12
8
2
4
2
2
1
1
1
1
1
1
1
2
2
2
1
1
2
1
1
1
1
1
2
2
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
COMP. #
T16235
T16236
T16117
T16118
T17401
T17400
T17402
T17403
T17452
T17451
T17450S
T17450
T17410
T17411
T17412
T17453
T17935
T17936
T16256
T16255
T16283
T16277
T16258
T16861
T16860
J0010
T16145
T16146
J0904
T18150
J1338
J0410
J03992
T12590
H3345
J0317
J0252
F4499
T16262
T16157
T16159
T17937
T16144
T16142
J0097
T16143
J0096
T16096
T16158
T16428
F4720
G73291
T16436
20’ WET BIN
6 - 14
20’ WET BIN
REF. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
DESCRIPTION
Trash Pan
Support, Trash Pan
Left Support Gusset
Right Support Gusset
RR Wet Bin End Plate
RF Wet Bin End Plate
LF Wet Bin End Plate
LR Wet Bin End Plate
Top 8’ Panel ( RR & LF) 2000
Top 8” Panel (LR & RF) 2000
Wet Bin Side Perf, (Stainless)
Wet Bin Side Perf, (Galvanized)
LT Pivot Brace Wet Bin
RT Pivot Brace Wet Bin
Splice, Wet Bin Side
Bolt Down Lip 8’, 2000
Hopper Side
Hopper End
Top Auger Shield (Inner)
Top Auger Shield (Outer)
Plate, Turnbuckle, Connector
Top Motor Mount
Top Shield Brace
Bracket, LF Top Auger Shield
Bracket, RF Top Auger Shield
Bearing, 1.25, FLG, W/LC, HCFTS207 - 20
Splice Gusset Right
Channel, Splice, Short
Turnbuckle, 3/8” x 6”
Pivot, Motor Mount, Top
Collar, Shaft, 1-3/16”
Bushing, 1.25 SK
Pulley, 15.75OD, Double “B” Gr. SK
Motor, Auger 5HP, 1ph, TEFC
Motor, Auger 5HP, 3ph, TEFC
Pulley, 3.5 OD, 1.25, Double, B, Cast
Belt, B95
Key, 1/4 x 1/4 x 2
Paddle, Assembly
Lid, Wet Holding Bin
Lid, 10.5”, Extension, Wet Bin
Cover, Hopper
Splice Gusset Left
Crimp Plate
Hanger, Auger, T, 6CH2203
Splice Channel
Bushing, Wood, 1.25” ID
Spacer, T-Hanger, Top auger
Lid, 92-1/2” Wet Holding Bin
Top Auger
Shaft, 8’ Hanger Bearing
Shaft, 1.25” x 9”
Shaft, Top Front, 12-3/4”
Side, Wet Bin, 4’, 2000
Top 4’ Panel (LR) 12’
Bolt Down Lip, 4’
Top Middle Auger 20’
Lid, Wet Holding Bin 20’
6 - 15
QTY
1
3
16
10
1
1
1
1
2
2
4
4
12
8
2
4
2
2
1
1
1
1
1
1
1
2
2
2
1
1
2
1
1
1
1
1
2
2
1
1
1
1
2
1
1
1
1
1
1
2
2
1
1
2
2
2
1
1
COMP. #
T16235
T16236
T16117
T16118
T17401
T17400
T17402
T17403
T17452
T17451
T17450S
T17450
T17410
T17411
T17412
T17453
T17935
T17936
T16256
T16255
T16283
T16277
T16258
T16861
T16860
J0010
T16145
T16146
J0904
T18150
J1338
J0410
J03992
T20590
H4190
J0317
J0252
F4499
T16262
T16157
T16159
T17937
T16144
T16142
J0097
T16143
J0096
T16096
T16158
T16428
F4720
G73291
T16436
T12525
T20526
T12524
T16427
T20158
24’ WET BIN
6 - 16
24’ WET BIN
REF. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
DESCRIPTION
Trash Pan
Support, Trash Pan
Left Support Gusset
Right Support Gusset
RR Wet Bin End Plate
RF Wet Bin End Plate
LF Wet Bin End Plate
LR Wet Bin End Plate
Top 8’ Panel ( RR & LF) 2000
Top 8” Panel (LR & RF) 2000
Wet Bin Side Perf, (Stainless)
Wet Bin Side Perf, (Galvanized)
LT Pivot Brace Wet Bin
RT Pivot Brace Wet Bin
Splice, Wet Bin Side
Bolt Down Lip 8’, 2000
Hopper Side
Hopper End
Top Auger Shield (Inner)
Top Auger Shield (Outer)
Plate, Turnbuckle, Connector
Top Motor Mount
Top Shield Brace
Bracket, LF Top Auger Shield
Bracket, RF Top Auger Shield
Bearing, 1.25, FLG, W/LC, HCFTS207 - 20
Splice Gusset Right
Channel, Splice, Short
Turnbuckle, 3/8” x 6”
Pivot, Motor Mount, Top
Collar, Shaft, 1-3/16”
Bushing, 1.25 SK
Pulley, 15.75OD, Double “B” Gr. SK
Motor, Auger 5HP, 1ph, TEFC
Motor, Auger 5HP, 3ph, TEFC
Pulley, 3.5 OD, 1.25, Double, B, Cast
Belt, B95
Key, 1/4 x 1/4 x 2
Paddle, Assembly
Lid, Wet Holding Bin
Lid, 10.5”, Extension, Wet Bin
Cover, Hopper
Splice Gusset Left
Crimp Plate
Hanger, Auger, T, 6CH2203
Splice Channel
Bushing, Wood, 1.25” ID
Spacer, T-Hanger, Top auger
Lid, 92-1/2” Wet Holding Bin
Top Auger
Shaft, 8’ Hanger Bearing
Shaft, 1.25” x 9”
Shaft, Top Front, 12-3/4”
Auger, Bottom Front, 93-1/2”
Top 8’ Panel (LR&RF) 2000
6 - 17
QTY
1
3
18
12
1
1
1
1
2
2
6
6
17
13
4
6
2
2
1
1
1
1
1
1
1
2
4
4
1
1
2
1
1
1
1
1
2
2
1
1
1
1
4
2
2
2
2
2
2
2
2
1
1
1
2
COMP. #
T16235
T16236
T16117
T16118
T17401
T17400
T17402
T17403
T17452
T17451
T17450S
T17450
T17410
T17411
T17412
T17453
T17935
T17936
T16256
T16255
T16283
T16277
T16258
T16861
T16860
J0010
T16145
T16146
J0904
T18150
J1338
J0410
J03992
T20590
H4190
J0317
J0252
F4499
T16262
T16157
T16159
T17937
T16144
T16142
J0097
T16143
J0096
T16096
T16158
T16428
F4720
G73291
T16436
T16430
T24451
28’ WET BIN
6 - 18
28’ WET BIN
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
DESCRIPTION
TRASH PAN
SUPPORT, TRASH PAN
LEFT SUPPORT GUSSET
RIGHT SUPPORT GUSSET
RR WET BIN END PLATE
RF WET BIN END PLATE
LF WET BIN END PLATE
LR WET BIN END PLATE
TOP 8’ PANEL (RR&LF) 2000
TOP 8’ PANEL (LR&RF) 2000
WET BIN SIDE PERF, 2000
LT PIVOR BRACE WET BIN
RT PIVOR BRACE WET BIN
SPLICE, WET BIN SIDE
BOLT DOWN LIP 8’ 2000
HOPPER SIDE
HOPPER END
TOP AUGER SHIELD (INNER)
TOP AUGER SHIELD (OUTER)
PLATE, TURNBUCKEL, MTR MNT
TOP SHIELD BRACE
BRACKET, LF TOP AUGER SHIELD
BRACKET, LF TOP AUGER SHIELD
BRACKET, RF TOP AUGER SHIELD
SPLICE GUSSET RIGHT
CHANNEL, SPLICE, SHORT
TURNBUCKLE, 3/8” X 6”
PIVOT, MOTOR MOUNT, TOP
COLLAR, SHAFT, 1 3/16”
BUSHING, 1 ¼” SK
PULLEY, 15.75OD, DBL “B” GR, SK
MTR, AUGER
PULLEY, 3.5 OD, 1.25, DBL, B, CAST
BELT, B95
KEY, ¼ X ¼ X 2
SWITCH ASSY, WET BIN, D-C
LID, WET HOLDING BIN
LID, 10.5”, EXTENSION, WET BIN
COVER, HOPPER
SPLICE GUSSET LEFT
CRIMP PLATE
HANGER, AUGER, T, 6CH2203
SPLICE CHANNEL
BUSHING, WOOD, 1.25” I.D.
SPACER, T-HANGER, TOP AUGER
LID 92 ½” WET HOLDING BIN
TOP AUGER
SHAFT, 8” HANGER BEARING
SHAFT, 1.25” X 9”
SHAFT, TOP FRONT, 12 ¾”
AUGER, BOTTOM FRONT, 93 ½”
TOP 8’ PANEL
MOTOR MOUNT, TOP LOAD
PLATE, COVER RF GARNER END
TOP MIDDLE AUGER (20 FT)
BOLT DOWN LIP, 4 FT 2000
SIDE, WET BIN, 4FT 2000
PLATE, SHORT SPLICE
LID, WET HOLD BIN 20 FT.
TOP 4’ PANEL (LR) 12FT 2000
6 - 19
QTY
1
3
20
16
1
1
1
1
2
2
6
20
16
6
6
2
2
1
1
11
1
1
1
2
6
6
1
1
2
1
1
1
1
2
2
1
1
1
1
6
3
3
3
3
3
2
2
3
1
1
1
2
1
1
1
2
2
6
1
2
COMP #
T16235
T16236
T16117
T16118
T17401
T17400
T17402
T17403
T17452
T17451
T17450S
T17410
T17411
T17412
T1745.
T17935
T17936
T16256
T16255
T16283
T16258
T16861
T16860
J0010
T16145
T16146
J0904
T18150
J1338
J0410
J03992
H4190
J0317
J0252
F4499
T18262E
T16157
T16159
T17937
T16144
T16142
J0097
T16143
J0096
T16096
T16158
T16428
F4720
G73291
T16436
T16430
T24451
T16277
T17415
T16427
T12524
T12525
T16141
T20158
T20526
DRIVE END OF DRYERS
DRIVE END OF DRYERS
REF. #
1
2
3
4
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
DESCRIPTION
Motor, 3HP, 1ph
Motor, 3HP, 3ph
Motor, 5HP, 1ph
Motor, 5HP, 3ph
Flangette, 3 hole for 205 Bearing
Sprocket, 40B20, 1” Bore
Meter Plate
Sprocket, 50B12, 1” Bore
Sprocket, 40B30, 1” Bore
Shaft, Front, Meter Roll
Screw, 1/2-13, 3, PLTD, Gr. 5, HHCS
Sprocket, Idler, 50-13
Spacer, Sprocket, Continuous
Nut, Hex, 1/2-13, PLT, Gr. 5
Washer, Lock, 1/2, PLT, Split
Washer, Flat, 1/2, PLT
Bearing, 1.25, FLG, W/LC, HCFTS207-20
Pulley, 3.5 OD, 1.125, DBL, B, Cast
Pulley, 15.75OD, DBL “B” Gr., SK
Bushing, 1.25, SK
Sprocket, 50B12, 1.125” Bore
Reducer, Speed, 150: 1, 6003869
Motor, 1HP, 180V DC, 1750 RPM, TEFC
Chain, #50 157 Links
Chain, #40 73 Links
Chain Link, #50 Connector
Chain Link, #40 Connector
Chain Link, #40 Offset 1/2 Link
Belt, BX 72
6 - 21
QTY
1
1
1
1
8
2
4
2
2
4
2
2
2
2
2
2
1
1
2
2
1
1
1
1
2
1
2
2
2
COMP. #
T12590
H3345
T20590
H4190
J0098
J16487
T17920
J1678
J1649
T16266
J0750
J1685
T16282
J1040
J1215
J1125
J0010
J0317
J03992
J0410
J16612
J3682
H1140
T16803
T16800
J1760
J1745
J1750
J0246
DRIVE END OF DRYERS, SINGLE FAN - BACK END
SINGLE FAN - BACK END
COMP. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
DESCRIPTION
Edging Top & Bottom, Door
Edging Sides, Back Door
Back End Plate
Access Door
Top Hinge, Access Door
Bottom Hinge, Access Door
Catch, Rear Access Door
Bottom Back Auger
Bottom Angle Splice
Side End Plate
Side Rail, Blowout Door
Blowout Door
Hinge Bracket
Handle, Locking, #GD303
Bearing, 1.25, Flange, W/LC, HCFTS207-20
Bottom Auger Shaft,1, 1.25” x 10”
Back Bottom End Plate
Bearing Shim Plate
Brace for Unload Auger
Mercury Switch Plate
Gate, Sample Spout
Spacer, Sample Spout
Sample Spout Angle
Spout, Sample
Cover, Sample Spout, (Unload)
Strap, Moisture Sensor - Back
Hinge, Moisture Sensor- Back
Latch, 3-10 LL, 2-57-1625-07-00
Cover, Tube, Rear Discharge
Ring, 10” Flange
Tube, Discharge
Step, Unload Tub
Lid, Sump Box
Hinge, Sump Box
Front-Sides, Sump box
Back Plate, Sump Box
Bottom, Sump Box
Lid Hinge Side, Sump Box
Bracket, Prox. Switch, Unload Auger
Box, Prox. Switch, Unload Auger
Seal, 2” OD, 1-1/4” ID, CR #12481
Target, Prox. Switch, Unload Auger
6 - 23
QTY
2
2
1
1
1
1
1
1
1
2
4
1
2
1
1
1
1
1
2
1
1
2
2
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
COMP. #
T16136
T16137
T17916
T16147
T16149
T16150
T16151
T16431
T17925
T16101
T16154
T17658
T16148
J2313
J0010
T17251
T25521
T25682
T25681
T16358
T17652
T17653
T17651
T17655
T17663
T17850
T17851
J2310
T25679
J6610
T25677
T25678
T25672
T25676
T25670
T25671
T25674
T25675
T17252
T17263
J7023
T17256
COLUMN PARTS
REF #
DESCRIPTION
1
2
3
Side Divider
Upper Divider
Outer Top Perforated Panel (Stainless)
Outer Top Perf Panel (Galvanized)
Outside Middle Perf Panel (Stainless)
Outside Middle Perf Panel (Galv.)
Top Inner Perforated Panel
Bottom Flow Control Gate
Column Separator
Top Flow Control Gate
Rigid Adjustment Plate
Bottom Rigid Door
Latch
Support Latch Strap
Outer Cleanout Door
Bottom Outer Perf Panel (Stainless)
Bottom Outer Perforated Panel (Galv.)
Inner Side Perforated Panel
Lower Divider
Side Rail, Inner Access
Bottom Rail, Inner Access
Inner Access Door
Door Latch Bracket
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
QTY
10
10
12
12
12
12
6
12
12
12
12
12
12
12
12
12
12
12
10
24
12
12
12
12’
COMP#
T16110
T16111
T16105S
T16105
T16104S
T16104
T16114
T17900
T17901
T17902
T17903
T17904
T17906
T17907
T17908
T17909S
T17909
T17910
T17924
T16219
T16220
T16221
T17657
QTY
14
14
16
16
16
16
8
16
16
16
16
16
16
16
16
16
16
16
14
32
16
16
16
16’
COMP#
T16110
T16111
T16105S
T16105
T16104S
T16104
T16114
T17900
T17901
T17902
T17903
T17904
T17906
T17907
T17908
T17909S
T17909
T17910
T17924
T16219
T16220
T16221
T17657
6 - 24
QTY
18
18
20
20
20
20
10
20
20
20
20
20
20
20
20
20
20
20
18
40
20
20
20
20’
COMP#
T16110
T16111
T16105S
T16105
T16104S
T16104
T16114
T17900
T17901
T17902
T17903
T17904
T17906
T17907
T17908
T17909S
T17909
T17910
T17924
T16219
T16220
T16221
T17657
QTY
22
22
24
24
24
24
12
24
24
24
24
24
24
24
24
24
24
24
22
48
24
24
24
24’
COMP#
T16110
T16111
T16105S
T16105
T16104S
T16104
T16114
T17900
T17901
T17902
T17903
T17904
T17906
T17907
T17908
T17909S
T17909
T17910
T17924
T16219
T16220
T16221
T17657
QTY
26
26
28
28
28
28
14
28
28
28
28
28
28
28
28
28
28
28
28
56
28
28
28
28’
COMP#
T16110
T16111
T16105S
T16105
T16104S
T16104
T16114
T17900
T17901
T17902
T17903
T17904
T17906
T17907
T17908
T17909S
T17909
T17910
T17924
T16219
T16220
T16221
T17657
BACK METERING ROLLS
SWPD0027
REF. #
1
2
3
4
5
6
7
8
9
10
11
DESCRIPTION
Metering Roll Assembly, 8'
Metering Roll Assembly, 4'
Connecting Shaft, Meter Roll
Bushing, Wooden, Octagon, 1” ID
Flangette, for 205 Bearing
Encoder Bracket
Meter plate
Top Back Shaft, Meter Roll
Bearing, 1”, Center, FH205-16, W/L CLR
Bottom Back Shaft, Meter Roll
Pin, Picker, 3/8, 1-1/2, PLT
Pin, Cotter, 1/8, 1, PLT
6 - 25
COMP. #
T16297
T16298
T16269
J1245
J0098
T17921
T17920
T16267
J0005
T16268
J15431
J1420
12’ CAM LOCK ASSEMBLY
REF. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
DESCRIPTION
Pivot Bracket
Hinge, Bottom Door, Cam Lock
Handle
Extension Arm, Cam Lock
Seal Plate, End, Cam Lock
Seal Plate, Mid, Cam Lock
8’ Angle, Cam Lock
8’ Door Support, Cam Lock
8’ Door, Cam Lock
Shaft, 49-3/4”, Cam Lock
Gusset, Rear, Cam Lock
Pivot Arm Weldment, Cam Lock
Gusset, Front, Cam Lock
Shaft, 74”, Cam Lock
Angle, Cam Lock, 4’
Door Support, Cam Lock, 4’
Door, Cam Lock, 4”
Pin, Cotter, 1/8, 1, PLT
6 - 26
QTY
5
5
5
5
2
1
2
1
1
1
1
5
6
1
2
1
1
4
COMP. #
T16393
T16387
T16382
T16386
T16386
T16390
T17456
T17454
T17455
T16400
T16381
T16383
T16380
T12516
T12529
T12530
T12528
J1420
16’ CAM LOCK ASSEMBLY
REF. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DESCRIPTION
8’ Door Support, Cam Lock
8’ Angle, Cam Lock
8’ Door, Cam Lock
Pivot Bracket
Hinge, Bottom Door, Cam Lock
Handle, Cam Lock
Extension Arm, Cam Lock
Seal Plate, End, Cam Lock
Seal Plate, Mid, Cam Lock
Shaft, 49.75”, Cam Lock
Gusset, Front, Cam Lock
Gusset, Rear, Cam Lock
Pivot Arm Weldment, Cam Lock
Shaft, 25”, Cam Lock
Shaft, Cam Lock, 74”
Pin, Cotter, 1/8”, 1, PLT
6 - 27
QTY
2
4
2
6
6
6
6
2
1
1
8
1
6
1
1
6
COMP. #
T17454
T17456
T17455
T16393
T16387
T16382
T16386
T16398
T16390
T16400
T16380
T16381
T16383
T20401
T12516
J1420
20’ CAM LOCK ASSEMBLY
REF. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
DESCRIPTION
Right Frame Angle
Wide Vertical Support
Narrow Vertical Support
Pivot Bracket
Hinge Bottom Door Cam Lock
Handle Cam Lock
Extension Arm, Cam Lock
Seal Plate, End, Cam Lock
Seal Plate, Mid, Cam Lock
8’ Angle, Cam Lock
8’ Door Support, Cam Lock
8’ Door, Cam Lock
Shaft, 49.75”, Cam Lock
Gusset, Rear, Cam Lock
Pivot Arm Weldment, Cam Lock
Gusset, Front, Cam Lock
Angle, Cam Lock 4’
Door Support, Cam Lock 4’
Door, Cam Lock 4’
Shaft, 25”, Cam Lock
Shaft, Cam Lock, 74”
Connector, Shaft
Pin, Cotter, 1/8, 1, PLT
6 - 28
QTY
1
6
5
8
8
8
8
2
2
4
2
2
2
1
8
10
2
1
1
1
1
1
8
COMP. #
T20319
T16322
T16323
T16393
T16387
T16382
T16386
T16398
T16390
T17456
T17454
T17455
T16400
T16381
T16383
T16380
T12529
T12530
T12528
T20401
T12516
T20403
J1420
24’ CAM LOCK ASSEMBLY
REF. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
DESCRIPTION
Right Frame Angle
Wide Vertical Support
Narrow Vertical Support
Pivot Bracket
Hinge, Bottom Door, Cam Lock
Handle, Cam Lock
Extension Arm, Cam Lock
Seal Plate, Mid, Cam Lock
8’Angle, Cam Lock
8’ Door Support
8’ Door, Cam Lock
Seal Plate, End, Cam Lock
Shaft, Cam Lock, 49.75”
Gusset, Rear
Pivot Arm Weldment
Gusset, Front
Shaft, Cam Lock, 74”
Shaft, Cam Lock, 25”
Pin, Cotter, 1/8, 1, PLT
6 - 29
QTY
1
7
8
9
9
9
9
2
6
3
3
2
1
1
9
12
2
1
8
COMP. #
T24319
T16322
T16323
T16393
T16387
T16382
T16386
T16390
T17456
T17454
T17455
T16398
T16400
T16381
T16383
T16380
T12516
T20401
J1420
28’ CAM LOCK ASSEMBLY
REF. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
DESCRIPTION
RIGHT FRAME ANGLE WELD
WIDE VERTICAL SUPPORT
PLATE, MAIN CONNECTOR, BOX, CONDUIT
NARROW VERTICAL SUPPORT
MAIN CONNECTOR PLATE
GUSSET, FRONT, CAM LOCK
GUSSET, REAR CAM LOCK
SHAFT, LONG CAN-LOCK
HANDLE, CAM-LOCK
PIVOT ARM WELD, CAM-LOCK
EXTENSION ARM, CAM LOCK
COVER, PLASTIC, HANGLE, 1 1.2 X 4 LG
SCREW, 3/8 –16 X 1, JS500, GD 5
NUT, WHIZLOCK, 3/8-16
NUT, HEX, 3/8-16, PLT LOCK
HINGE, BOTTOM DOOR, CAM LOCK
BOLT, 5/16-18 X ¾” GR 5, HEX WASHER HD, JS500
NUT, LOCK, 5/16-18, PLT
SHAFT, CAM-LOCK, LONG, 12’ ‘99
SHAFT, SHORT, CAM LOCK
CONNECTOR, SHAFT
8’ DOOR, CAM-LOCK 2000
DOOR, CAM-LOCK 4’ 2000
6 - 30
QTY
1
8
2
7
13
14
1
2
11
11
11
11
33
22
11
11
9
11
2
1
1
3
1
COMP. #
T28318
T16322
T16331
T16323
T16324
T16380
T16381
T16400
T16382
T16383
T16386
J23182
J06063
B5962
J1025
T16387
J0536
J1010
T12516
T20401
T20403
T17455
T12528
FRAME FOR BOTH STANDARD & STACKED DRYERS
12’, 16’, 20’, 24’, & 28’
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
DESCRIPTION
Hitch Receiver Weldment
Left Frame Angle
Connector Plate
Angle (Fan Support)
Right Frame Angle
Tightener Angle
DC Motor Brace
Front Cross Channel
Cross Channel
Main Connector Plate
Narrow Vertical Support
Wide Vertical Support
Channel Brace, Frame
12’
QTY
1
1
2
1
1
1
2
1
3
14
6
8
2
PT #
T16310
T12518
T16321
T16176
T12517
T16329
T16328
T16326
T16325
T16324
T16323
T16322
T12327
16’
QTY
1
1
2
1
1
1
2
1
3
18
8
10
2
PT #
T16310
T16319
T16321
T16176
T16320
T16329
T16328
T16326
T16325
T16324
T16323
T16322
T12327
6 - 31
20’
QTY
1
1
2
1
1
1
2
1
5
22
8
12
2
PT #
T16310
T20320
T16321
T16176
T20319
T16329
T16328
T16326
T16325
T16324
T16323
T16322
T12327
24’
QTY
1
1
2
1
1
1
2
1
5
26
12
14
2
PT #
T16310
T24320
T16321
T16176
T24319
T16329
T16328
T16326
T16325
T16324
T16323
T16322
T12327
28’
QTY
1
1
2
1
1
1
2
1
7
28
14
16
2
PT #
T16310
T28320
T16321
T16176
T28319
T16329
T16328
T16326
T16325
T16324
T16323
T16322
T12327
12’ BOTTOM AUGER
REF. #
1
2
3
4
5
6
7
8
9
10
DESCRIPTION
Bearing, 1.25, Flange, W/LC, HCFTS207-20
Shaft, Top Front, 12-3/4”
Auger, Bottom Front, 93-1/2”
Shaft, 8”, Hanger Bearing
Bushing, Wood, 1.25”, I.D.
Hanger, Auger, T, 6CH2203
Bottom Rear Auger
Shaft, 1, 1.25” x 10”
Screw, 7/16-14, 2, PLT
Nut, Lock, 7/16”-14, PLT
QTY
2
1
1
1
1
1
1
1
8
8
COMP. #
J0010
T16436
T16430
F4720
J0096
J0097
T12490
T17251
J0718
J1034
16’ BOTTOM AUGER
REF. #
1
2
3
4
5
6
7
8
9
10
11
DESCRIPTION
Bearing, 1.25, Flange, W/LC, HCFTS207-20
Shaft, Top Front, 12-3/4”
Auger, Bottom Front, 93-1/2”
Shaft, 8”, Hanger Bearing
Bushing, Wood, 1.25”, I.D.
Hanger, Auger, T, 6CH2203
Shaft, 1.25” x 10”
Screw, 7/16-14, 2, PLT
Nut, Lock, 7/16-14, PLT
Auger, Bottom Middle, 69-1/2”
Bottom Rear Auger, 1
6 - 33
QTY
2
1
1
2
2
2
1
12
12
1
1
COMP. #
J0010
T16436
T16430
F4720
J0096
J0097
T17251
J0718
J1034
T16432
T16433
20’ BOTTOM AUGER
REF. #
1
2
3
4
5
6
7
8
9
10
DESCRIPTION
Bearing, 1.25, Flange W/LC, HCFTS207-20
Shaft, Top Front, 12-3/4”
Auger, Bottom Front, 93-1/2”
Shaft, 8” Hanger Bearing
Bushing, Wood, 1.25” I.D.
Hanger, Auger, T, 6CH2203
Shaft, 1.25” x 10”
Screw, 7/16-14, 2, PLT
Nut, Lock, 7/16-14, PLT
Bottom Rear Auger
6 - 34
QTY
2
1
2
2
2
2
1
12
12
1
COMP. #
J0010
T16436
T16430
F4720
J0096
J0097
T17251
J0718
J1034
T12490
24’ BOTTOM AUGER
REF. #
1
2
3
4
5
6
7
8
9
10
11
DESCRIPTION
Bearing, 1.25, Flange, W/LC, HCFTS207-20
Shaft, Top Front, 12-3/4”
Auger, Bottom Front, 93-1/2”
Shaft, 8” Hanger Bearing
Bushing, Wood, 1.25” I.D.
Hanger Auger, T, 6CH2203
Shaft, 1.25” x 10”
Screw, 7/16-14, 2, PLT
Nut, Lock, 7/16-14, PLT
Auger, Bottom middle, 69-1/2”
Bottom Rear Auger
6 - 35
QTY
2
1
2
3
3
3
1
16
16
1
1
COMP. #
J0010
T16436
T16430
F4720
J0096
J0097
T17251
J0718
J1034
T16432
T16433
28’ BOTTOM AUGER
REF #
1
2
3
4
5
6
7
8
9
10
DESCRIPTION
BRG, 1.25, FLG, W/LC, HCFTS207-20
SHAFT, TOP FRONT, 12 ¾”
AUGER, BOTTOM FRONT, 93 ½”
SHAFT, 8” HANGER BEARING
BUSHING, WOOD 1.25” I.D.
HANGER, AUGER, T, 6CH2203
SHAFT, 1.25 X 10, BOTTOM AUGER
SCREW, 7/16-14, 2, PLT
NUT, LOCK, 7/16-14, PLT
BOTTOM REAR AUGER
6 - 36
QTY
2
1
3
3
3
3
1
16
16
1
COMP. #
J0010
T16436
T16430
F4720
J0096
J0097
T17251
J0718
J1034
T12490
DRYER HITCH WITH 24” EXTENSION
ITEM NO.
1
2
3
4
5
6
7
8
9
10
11
QTY.
1
1
1
1
1
5
5
4
2
2
2
PART NO.
T16310D
T43711
T16309D
T4372
J0822
J1220
J1051
J0813
J08361
J1222
J1059
DESCRIPTION
HITCH RECEIVER WELDMT, JACK
HITCH INSERT WELD, 24” EXT
TUBE, 4 ½ X 4 ½ SQ, 24” HITCH EXT
CLEVIS WELD
SCREW, ¾”-10 X 5” LG.
¾” LOCKWASHER
¾-10 HEX NUT
SCREW, ¾-10 X 5 ½” LG
BOLT, 7/8-9 X 6 ½” LG
7/8” LOCKWASHER
7/8-9 HEX NUT
6 - 37
DRYER ASPIRATOR COMPONENT INSTRUCTIONS
ASSEMBLY:
1. Attach the aspirator base assembly to the side of the dryer discharge housing. Mark and cut
a 3 ¾” x 7 ¼” hole (about 2 inches from the top) in the side of dryer discharge housing and
drill (6) ⅜” mounting holes using the base flange as a template. Mount the deflector with
these same holes on the inside face of the dryer discharge housing.
2. Assemble the C-face motor to the aspirator fan housing using the hex-head ⅜ -16 x ¾”
screws and lock-washers that are provided in the housing (discard the ⅜ nuts). Attach the
fan wheel to the motor shaft with a ⅞” split tapered bushing (J0409). Position the bushing so
it is flush with the end of the motor shaft and tighten the ¼” screws evenly to a torque of 95
inch-pounds.
3. Wire the motor so the fan wheel rotates in a clockwise direction when viewed from the top.
(see exploded view on page 2)
4. The fan may be assembled directly on top of the aspirator base, or extended with a length of
6” tube. Use 6” compression couplers to fasten the extension tube.
5. Assemble the cyclone to the fan in the same manner using a 6” extension tube if desired.
The 6” to 160mm tube adapter and clamp ring are used to secure the cyclone.
6. Use standard 6” tube supports and brackets (not shown in exploded view) to secure the
aspirator assembly to the dryer or other convenient structure.
OPERATION:
1. Remove the clean-up plate (Item 2b) from the aspirator base when the unit is to be used to
clean light material from discharged grain. Adjust the restrictor plates up or down to vary the
amount of air pulling chaff from the grain.
2. The aspirator base may also be used to clean up around the dryer. Remove the 3” cap (Item
2a) and attach a 3” flexible hose (Item 15), slide the clean-up plate back into the base and
use it to regulate the amount of air required to pull material up the 6” tube to the fan.
6 - 38
DRYER ASPIRATOR COMPONENT ASSEMBLY (Optional)
6 - 39
DRYER ASPIRATOR COMPONENT ASSEMBLY (Optional)
6 - 40
Sukup Automatic Grain Dryer
Troubleshooting Guide (CE)
L14106 - DC
1/2008 Rev.1
Table of Contents
Safety Section.......................................................................................................3
Fault Troubleshooting ...........................................................................................9
Grain Discharge Chute Sensor ..........................................................................9
Grain Level Sensor ..........................................................................................11
Unload Auger Proximity Sensor .......................................................................13
Unload Auger Proximity Sensor (continued) ....................................................14
Vapor Over-Temperature Sensor.....................................................................15
Grain Column Over-Temperature Sensor ........................................................21
Heater Housing Hi-Limit Switch .......................................................................25
Metering Roll Proximity Switch.........................................................................27
Static Air Pressure Sensor...............................................................................31
Plenum Over-Temperature Sensor ..................................................................35
Device Troubleshooting ......................................................................................39
Discharge Moisture Sensor..............................................................................39
SCR Drive ........................................................................................................42
Plenum Temperature Sensor (RTD) ................................................................43
Plenum Temperature Display ..........................................................................45
Burner Operations............................................................................................47
Electronic MOD Valve......................................................................................50
Wire Numbers and their uses .............................................................................56
DanCorn Conduit Wiring .....................................................................................61
Auxiliary Load and Unload Terminals .................................................................63
I/O Board Map.....................................................................................................64
7-2
Safety Section
GRAIN DRYER
Safety Section
•
•
•
The above safety-alert means “ATTENTION! Be Alert!
Your personal safety is involved” This symbol draws
your attention to important instructions concerning your
personal safety. Read the message carefully to avoid
personal injury or death.
WARNING: Check for other vehicles when
turning. (2/3 of roadway farm accidents
occurs when turning.)
Use mirrors
Be sure to have clear visibility,
Use signal lights
WARNING: do not transport unit in areas
of poor visibility -•
Especially on hills,
•
During poor weather conditions,
•
Or at night
Failure to do so may cause serious injury or death. Use
good judgement when transporting. Maintain complete
control of unit at all times. Comply with State and local
laws governing. Read safety regulations when moving
units. Always strive to prevent accidents! Watch out for
other vehicles.
FOLLOW MACHINE SAFETY SIGN &
MESSAGES
Observe
safe
operating
practices. Carefully read this
manual and all safety signs
on your equipment. Safety
sign must be kept in good
condition. Replace missing
or damaged safety decals;
available from Sukup Mfg.
Co.; Box 677, Sheffield,
Iowa 50475 at no charge.
WARNING:
TO PREVENT EXPLOSION OR FIRE
•
•
Learn how to use controls and operate machine. Do not
let anyone operate unit (especially youth) without
thorough training of basic operating and safety
procedures.
•
Make no unauthorized modifications to machine.
Modifications may endanger function and/or safety of
unit. Keep unit in good working condition.
•
•
•
EMERGENCIES - KNOW WHAT TO DO
Have emergency numbers near your telephone:
Carefully
review
operators manual.
Clean under unit, as
fines may cause a
bin fire.
Check for gas leaks,
(spray soapy solution
on piping and joints.)
Run fan at least a half minute before starting
heater.
NEVER start heater if you smell gas or hear a
hissing sound.
NEVER run heater with inspection door open.
Failure to heed these warnings may cause serious
injury or death.
For doctors:
Emergency medical squad:
Ambulance service:
Hospital:
Fire department:
Have written directions to your location.
WARNING:
KEEP CLEAR OF ALL MOVING PARTS
TRANSPORT SAFETY WARNING:
TRUCKER/TRANSPORTER IS TO PROVIDE
APPROVED SAFETY CHAIN WHEN TOWING
DRYER.
WARNING: Transporting this equipment
on public roads may result in serious injury
or death. If road travel is required it is essential that all
the following procedures be followed:
Keep people (ESPECIALLY YOUTH) away from
equipment, particularly during operation. Keep away
from all moving parts. Entanglement can cause serious
injury or death. Keep inlet guard in place and in good
working condition.
1. Read and understand -- operator’s manual.
2. Check and comply with state & local regulations.
3. Use required emblems or lights.
4. Travel at a reasonable and safe speed. Reduce
speed and/or use lower gear on rough ground or
slopes.
5. Stop slowly.
6. Have extended rear angle mirrors on vehicles.
7. Signal & check behind you when turning.
Failure to follow the above precautions may cause
serious injury or death.
+++++++++++++++++++++++++++++++++
7-3
Safety Section
Mount safety decals when unit is assembled. Please
check that all decals are in place according to the
drawing/picture and in good legible condition.
4. WARNING - L0166 - Guards & shields in place.
Disconnect Electricity. Check fan blade.
IMPORTANT!! If suggested locations are not clearly
visible, place safety decals in more suitable area. Never
cover up any existing safety decals.
Make sure location for decal is free from grease, oil and
dirt. Remove backing from decal and place in proper
position. To order replacement decals (no charge)
contact Sukup Manufacturing Company, P.O. Box 677,
Sheffield, Iowa 50475 Phone 641.892.4222 Please
specify computer number.
1. WARNING-L0281-To Avoid serious injury or death.
5. DANGER -L0271 - Shield missing, do not operate.
2. DANGER - L02741-98 - Keep away from any
electrical lines, especially when moving unit.
6. WARNING - L0284-98
Keep away from all moving parts.
3. DANGER - L0237 - Door interlock switch. Augers are
dangerous.
7-4
Safety Section
7. CAUTION - L0285-98
Not intended for use on public roads.
If road travel is required:
11. WARNING - L0164
Metal is slippery when wet; Never carry items when
climbing; Have another person present;
Use safety harness & safety line; etc
8. WARNING - L02831
Lower & secure parking stands before unhitching unit.
12. WARNING - L0512
Use safety chain when towing unit to eliminate
detachment hazard.
9. DANGER - L0301
Rotating augers are dangerous!
10. CAUTION - L0520
Failure to keep unit clean may cause fire and serious
injury or death.
7-5
Safety Section
7-6
Safety Section
SAFETY DECAL LOCATIONS FOR FAN & HEATER
3. WARNING - L0166
Disconnect electricity; guards, shields in place; Check
fan blade tight.
Safety decals and shields are mounted whenever
possible at factory. Please check that all decals are in
place according to these drawings and in good legible
condition. To order replacement decals or shields (NO
CHARGE) contact your dealer or Sukup Mfg. Co.,
1555 - 255th Street - P.O. Box 677 - Sheffield, Iowa
50475. Please specify computer number.
IMPORTANT ! The following safety decals should be
mounted on your equipment as shown below. If
suggested locations are not clearly visible, place safety
decals in more suitable area. Never cover up any
existing safety decals.
Make sure location area for decal is free from grease,
oil and dirt. Remove backing from decal and place in
proper position.
1. WARNING - L0281
Safe operation decal.
4. DANGER - L0204
Close service door.
2. WARNING - L0165
Disconnect Electricity; Bleed gas
The numbers on the drawings below refer to the
location of the safety decals listed above.
7-7
Safety Section
This page intentionally left blank
7-8
Fault Troubleshooting
Fault Troubleshooting
Grain Discharge Chute Sensor
The Grain Discharge Chute Sensor is present on
the dryer to detect the Discharge Chute opening
during operation. This fault usually indicates a
problem with the take-away system.
DISCHARGE CHUTE OPEN
OR UNLOAD
AUGER STOPPED
PRESS ANY KEY
Figure 1.1b: Grain Discharge Chute Sensor
Figure 1.1a: Grain Discharge Chute Fault
Model
1 Fan Portable Dryer
2 Fan Portable Dryer
2 Module Stack Dryer
3 Module Stack Dryer
Input
0CH07
0CH07
0CH02
0CH02
Wire #
42
42
42
42
Output
11CH03
11CH03
N/A
N/A
Wire #
2
2
N/A
N/A
1. Is the Discharge Chute open?
a. Determine the cause of the door being opened and return the door to the closed position.
2. Is the sensor out of adjustment?
a. This can be determined by watching the input light on the PLC. Adjust the angle of the
switch after placing the door at the height you wish the fault to occur. The PLC input light
is out when a fault occurs.
3. If unable to adjust the sensor and turn on the PLC input light, a voltmeter will be used to
determine if the sensor is malfunctioning.
4. At the Discharge Chute, find the junction box fastened to the lid. This box contains the sensor.
a. Remove the cover and locate the two wires coming from the sensor. One of the wires
should be labeled # 18. Measure for 24VDC from wire #18 to ground. (On older dryers,
a jumper may need to be installed in the control box from wire # 95, found on the PLC, to
the ground bar at the bottom of the control box).
5. If 24VDC is measured on wire # 18, check for voltage on wire # 42. If 24VDC is not present,
tilting the sensor may be necessary to allow the mercury to make contact with the switch
contacts. If unable to measure 24VDC on wire # 42, the sensor is bad and must be replaced.
6. If 24VDC is present on wire # 42, but the PLC input light is still off, proceed to the Power Box and
measure terminal # 42 for 24VDC. If unable to measure 24VDC on terminal # 42, check
connections between the Discharge Chute Sensor and the Power Box.
7. If 24VDC was measured on terminal # 42 in the Power Box, proceed to the control box and
measure terminal # 42 for 24VDC. If unable to measure 24VDC, check connections between the
Power Box and the Control Box.
8. If 24VDC was measured on terminal # 42 in the control box, measure for 24VDC at the PLC
input. If unable to measure 24VDC on the PLC input, check the connections between the control
box terminal strip and the PLC.
9. If 24VDC is now measured on the PLC input, but the input light is not on, the PLC may be
malfunctioning.
10. If the PLC input light is on but the PLC output light (on portable dryers) is not on, the PLC may be
malfunctioning.
11. If the PLC input light is now on, try clearing the fault by pressing reset on the keypad and
determine if the fault is now cleared.
7-9
Fault Troubleshooting
Grain Discharge
Chute Sensor
Figure 1.1c: Placement of sensor on dryer
7 - 10
Fault Troubleshooting
Grain Level Sensor
The Grain Level sensor is located on the side of the
dryer connected to the paddle switch. This sensor is
used to indicate when the dryer is running low or out of
grain. A fault will be displayed when this occurs.
OUT OF WET GRAIN
PLC 10 MIN. TIMEOUT
FOR RESTART PRESS 1
FINAL DRY
PRESS 2
Figure 1.2a: Fault Display
Figure 1.2b: Grain Level Sensor
Model
1 Fan Portable Dryer
2 Fan Portable Dryer
2 Module Stack Dryer
3 Module Stack Dryer
Input
0CH09
0CH09
0CH03
3CH03
Wire #
44
44
44
44
Output
12CH06
12CH06
N/A
N/A
Wire #
9
10
N/A
N/A
1. Is the wet bin out of grain?
a. If this is the last load for the season, press 2 for Final Dry.
2. Has an auxiliary load malfunctioned?
a. Repair the cause of the load failure and press RESET.
3. If wet grain is available and the load auxiliaries are functioning, is the paddle switch bound up?
a. If so, free the paddle switch and repair the cause.
4. Are both PLC input lights off? (both lights should be off when the dryer is calling for grain – paddle
down)
Are both PLC input lights on? (both lights should be on when the dryer is full. – paddle up)
a. If not, remove the cover from the junction box
on the paddle switch assembly and visually
check sensors for proper placement in their
respective holders. Refer to Fig. 1.2c
5. Observe the upper and lower PLC input lights
while someone moves the paddle switch from the
down position to the up position.
a. If either PLC input light does not turn on,
measure for 24VDC on wire #18 to ground.
(touch the black probe from the meter to the
dryer frame. It may be necessary to connect
a jumper to wire #95 on the PLC to the
ground bar in the Control Box.)
6. If 24VDC is measured on wire #18, measure for
24VDC on the other wire going to the sensor.
a. With the paddle switch in the up position,
Figure 1.2C: Grain Level Sensor Installed
24VDC should be measured on wire #44 and
#53.
b. If not, replace the respective sensor and recheck for voltage.
7. If the paddle switch is in the up position and 24VDC is present on both sensors, but one or both of the
PLC input lights are off, voltage will need to be measured on the respective terminal on the Power
Box terminal strip.
a. If 24VDC is not measured on the respective terminal, check the wiring connections between the
Paddle Switch junction box and the Power Box terminal strip.
7 - 11
Fault Troubleshooting
8. If 24VDC is measured at the Power Box terminal strip and the PLC input lights are not on, measure
for 24VDC on the terminal strip in the control box.
9. If unable to measure 24VDC on the control box terminal, check wiring connections between the
Power Box and the Control Box terminal strips.
10. If 24VDC is measured on the Control Box terminal strip but the PLC input lights are not on, measure
for 24VDC at the PLC inputs.
a. If 24VDC is measured on the PLC inputs but the light is off, the PLC could be malfunctioning.
b. If 24VDC is not measured on the PLC inputs, check the wiring connections from the Control Box
terminal to the PLC inputs.
Grain Level Sensor
Figure 1.2d: Grain Level Sensor Installed on Dryer (wet bin down)
7 - 12
Fault Troubleshooting
Unload Auger Proximity Sensor
The Unload Auger sensor is located on the
discharge bin on the end of the unload auger. This
sensor monitors the unload auger and will give a
fault and stop the dryer if the unload auger stops
turning.
DISCHARGE CHUTE OPEN
OR UNLOAD
AUGER STOPPED
PRESS ANY KEY
Figure 1.3a: Fault Display
*This sensor uses NEGATIVE switching
Figure 1.3b: Unload Auger Proximity Sensor
Model
1 Fan Portable Dryer
2 Fan Portable Dryer
2 Module Stack Dryer
3 Module Stack Dryer
Input
2CH06
3CH06
3CH02
4CH02
Wire #
96
96
96
95
Output
11CH03
11CH03
N/A
N/A
Wire #
2
2
N/A
N/A
1. Visually inspect the load auger for a problem.
a. Are the belts tight and in good condition?
b. Does the motor smell of feel hot?
c. Is a Motor Overload fault being displayed along with the Unload Auger fault? If so, do not restart
the Unload motor until a definite cause for the overload has been determined. After repairing the
cause of the fault, reset the motor overload. Then press RESET on the keypad.
2. If no fault is being displayed, go to Manual and turn on the Unload and check for rotation.
a. While the auger is rotating, check the PLC Input light, this light should be flashing at a regular
rate, indicating rotation.
b. If the PLC Input light is not flashing, check auger for rotation. If the auger is not rotating, find the
cause and repair.
3. If rotating, look at the back of the sensor itself. A small, orange light should be visible and flashing on
and off.
4. If the orange light on the back of the sensor is not flashing, find the junction box attached to the
discharge chute and remove the cover.
a. Locate the Brown, Black, and Blue wires coming from the Unload Auger Sensor. Measure for
24VDC on wire # 18 (brown), with respect to wire # 95 (blue).
b. If 24VDC is not measured on wire # 18, go to the Power Box terminal strip and measure for
24VDC on the bottom terminal strip.
c. If 24VDC is not measured on wire # 18 in the Power Box, go to the Control Box and measure for
24VDC on the terminal strip.
d. If 24VDC is not measured on wire # 18 in the control box, go to the PLC and measure for 24VDC
on the topside of the PLC.
5. If possible, position the flag over the sensor so that the sensor will be in the ON condition.
NOTE: This sensor is a negative switching device. This means that when the sensor is in the on
condition, the voltage on the output wire (black) will be 0VDC.
7 - 13
Fault Troubleshooting
Unload Auger Proximity Sensor (continued)
a. With the sensor in the ON condition, the light on the back of the sensor should be on. Measure
for 0VDC on the output wire (black).
If the light is on but 0VDC is not measured on the output (black) sensor wire, the sensor is
malfunctioning.
b. If 0VDC is measured on the output (black) sensor wire, go to the PLC in the Control Box and
check the PLC Input light. This light should be on when the sensor is in the ON condition.
c. If 0VDC is measured on the output (black) sensor wire but the
PLC input light is not on, measure for 0VDC on the Power Box terminal strip. If 0VDC is not
measured, in the Power Box, check wiring connections between the junction box and the Power
Box.
d. If 0VDC is measured in the Power Box, go to the Control Box and measure or 0VDC on the
terminal strip.
e. If 0VDC is not measured in the Control Box, check wiring connections between the Power Box
and the Control Box.
f. If 0VDC is measured in the Control Box, go to the PLC and measure for 0VDC on the PLC input
terminal.
g. If 0VDC is not measured at the PLC input, check wiring connections between the terminal strip
and the PLC input.
Unload Auger Sensor
7 - 14
Figure 1.3c: Unload Auger Proximity Sensor Installed on Dryer
Fault Troubleshooting
Vapor Over-Temperature Sensor
The Vapor Over-Temperature Sensor is located on the pipe train for the heater(s). It is provided to
prevent the gas from over heating the vaporizer and causing vapor to vaporize.
VAPORIZER HIGH TEMP
ADJ. VAPORIZER COIL
AND CHK FUEL SUPPLY
Figure 1.4a: Fault Display
Figure 1.4b: Vapor Over-Temperature Sensor
Model
1 Fan Portable Dryer
2 Fan Portable Dryer (Lower)
2 Fan Portable Dryer (Upper)
2 Module Stack Dryer (#1)
2 Module Stack Dryer (#2)
2 Module Stack Dryer (#3)
2 Module Stack Dryer (#4)
3 Module Stack Dryer (#1)
3 Module Stack Dryer (#2)
3 Module Stack Dryer (#3)
3 Module Stack Dryer (#4)
3 Module Stack Dryer (#5)
3 Module Stack Dryer (#6)
Input
0CH02
0CH01
0CH02
0CH08
0CH09
0CH10
0CH11
2CH00
2CH01
2CH02
2CH03
2CH04
2CH05
Wire #
37
102
37
37
102
202
302
37
102
202
302
402
502
Output
11CH03
10CH06
10CH06
N/A
N/A
N/A
N/A
N/A
Wire #
3
3
3
N/A
N/A
N/A
N/A
N/A
1. This fault indicates when the output of the vaporizer coil has become too hot (above 60 C.)
a. The tubing near the fault device should be fairly warm to the touch but not hot.
b. Check the fuel supply - is the tank low on fuel?
c. Air inlet obstruction – clean debris from the fan grill.
d. Vaporizer coil is too close to the flame. – Adjust vaporizer coil.
2. Has the Vaporizer Coil had sufficient time to cool down?
a. This device must be manually reset after the device has cooled down.
3. Is the PLC Input light on?
a. After the device has cooled down and reset, the PLC Input light should now be ON.
b. If not, follow the wiring from the coil to the heater box and measure for 24VDC on wire # 18.
4. If 24VDC is not measured on wire # 18, go to the Power Box and measure 24VDC on the terminal
strip.
a. If 24VDC is measured on wire # 18 on the Power Box terminal strip, check the wiring connections
from the Heater Box to the Power Box.
b. If 24VDC is not measured on wire # 18 on the Power Box terminal strip, go to the Control Box
and check for 24VDC on wire # 18 on the terminal strip.
5. If 24VDC is not measured on wire # 18 on the Control Box terminal strip, go to the PLC and measure
for 24VDC on the power supply output.
a. If unable to measure 24VDC on the power supply output at the PLC, remove all of the wires from
the terminal and check for 24VDC. If
24VDC is not measured, the PLC 24VDC power supply is bad.
b. If, after removing all wires from the terminal, 24VDC can be measured, one of the wires
connected to that terminal is shorted and will have to be isolated and the short corrected.
7 - 15
Fault Troubleshooting
Vapor Over-Temperature Sensor (continued)
6. With 24VDC now being measured on wire # 18 on one wire of the vaporizer O/T switch, and the
device has cooled down to ambient temperature, measure for 24VDC on the other wire (not # 18)
coming from the O/T switch.
a. If 24VDC is NOT measured on the other wire, the O/T switch is bad.
b. If 24VDC is measured on the other wire coming from the O/T switch, take note of the wire number
and go to the Power Box and measure for 24VDC on the terminal strip.
c. If 24VDC is NOT measured on the Power Box terminal strip, check the wiring connections
between the Power Box and the Heater Box.
d. If 24VDC is measured on the Power Box terminal strip, go to the Control Box and measure for
24VDC on the terminal strip. (same wire number)
e. If 24VDC is NOT measured on the terminal strip, check the wiring connections between the
Power Box and the Control Box.
f. If 24VDC is measured on the Control Box terminal strip, go to the PLC Input terminal for that wire
# and measure for 24VDC.
g. If 24VDC is NOT measured, check the wiring connections between the Control Box terminal strip
and the PLC Input terminal.
h. If 24VDC is measured on the Input terminal, and the Input light is NOT on, and the fault message
is still being displayed (after pressing RESET), the PLC is malfunctioning.
7 - 16
Fault Troubleshooting
Vapor OverTemp Sensor
Figure 1.4c: Vapor Over-Temperature Sensor Installed on Dryer
7 - 17
Fault Troubleshooting
This page intentionally left blank
7 - 18
Fault Troubleshooting
Rear Door Interlock Switch
The Rear Door Interlock Switch is located to the left of
each rear door on the dryer. This device is used to
keep the dryer from running when the rear door is open
and a person may be in the plenum of the dryer.
REAR ACCESS DOOR IS
OPEN--CHECK DOOR AND
INTERLOCK SWITCH
PRESS ANY KEY
Figure 1.5a: Fault Display
Figure 1.5b: Rear Door Interlock Switch
Model
1 Fan Portable Dryer
2 Fan Portable Dryer
2 Module Stack Dryer
3 Module Stack Dryer
Input
0CH00
0CH00
0CH02
3CH02
Wire #
36
36
36A-D
36
Output
10CH04
10CH04
N/A
N/A
Wire #
1
1
N/A
N/A
1. Check the rear door or doors to be sure that the doors are closed and the keys are inserted into the
switch. If a key is found out of a switch, make sure you check inside the plenum for personnel who
may be working on the dryer.
2. If all keys are inserted, but you still have a fault, check that the PLC input light is ON.
a. If the light is not ON, go to the junction box on the back of the dryer containing the wire from the
key switches. Remove the cover and locate and measure 24VDC on input wire.
NOTE: On the single module dryers, wire # 18 feeds into the key switch and out of the key switch.
If more than one plenum, the switches are connected in series and then routes back to
the PLC input.
NOTE: On the 2 and 3 module dryers, the Discharge Chute and the Rear Door switches are
connected in series. This means that Wire # 18 feeds 24VDC to the Discharge Chute
sensor and then becomes wire # 36 which is then fed to the Rear Door key switches,
which are all in series.
3. If 24VDC is not present on input wire, check (ON STACKS - make sure the Discharge Chute door is
closed) that 24VDC is measured on wire #18.
a. If 24VDC is present on input wire, but the PLC input light is not ON, check for 24VDC returning
from the key switches. Generally, each additional key switch adds a letter to the wire number
after coming out each successive key switch. 36 – 36A – 36B – etc.
b. If 24VDC is not returned from the key switches, a voltage check on the wire coming from each
key switch may be required. (Rear Door key switches are in SERIES)
4. If 24VDC is being returned from the last key switch, measure for 24VDC on the appropriate wire on
the Power Box terminal strip.
a. If 24VDC is not measured on the Power Box terminal strip, check the wiring connections between
the junction box and the Power Box.
b. If 24VDC is measured on the Power Box terminal strip, go to the Control Box and measure the
appropriate wire for 24VDC.
c. If 24VDC is not measured on the Control Box terminal strip, check wiring connections between
the Power Box and the Control Box.
d. If 24VDC is measured on the Control Box terminal strip, measure for 24VDC at the PLC input
terminal.
e. If 24VDC is measured an the terminal strip in the Control Box but not at the PLC input, check
wiring from the terminal strip to the PLC input terminal.
5. If 24VDC is measured on the PLC input terminal but the input light is not on, and you have a Rear
Door fault on the LCD screen, the PLC is malfunctioning.
7 - 19
Fault Troubleshooting
Rear Door
Interlock Switch
Figure 1.5c: Rear Door Interlock Switch Installed on Dryer
7 - 20
Fault Troubleshooting
Grain Column Over-Temperature Sensor
The Grain Column Over-Temp sensor is located in
conduit running through the grain columns
horizontally. This device is used to monitor the
temperature of the columns and will turn the dryer
off if the columns reach 149°C.
COLUMN HIGH TEMP
POSSIBLE CLOG OR
TEMPERATURE SETTING
Figure 1.6a: Fault Display
Figure 1.6b: Grain Column Over-Temperature Sensor
Model
1 Fan Portable Dryer (Right)
1 Fan Portable Dryer (Left)
2 Fan Portable Dryer (Right)
2 Fan Portable Dryer (Left)
2 Module Stack Dryer (Right)
2 Module Stack Dryer (Left)
3 Module Stack Dryer (Right)
3 Module Stack Dryer (Left)
Input
0CH05
0CH06
0CH05
0CH06
0CH00
0CH01
3CH00
3CH01
Wire #
40
41
40
41
40
41
40
41
Output
11CH01
Wire #
6
11CH01
6
N/A
N/A
N/A
N/A
1. Check all of the grain columns for an obstruction, which would prevent the grain from flowing through
the grain column.
a. If an obstruction is found, do not restart the dryer until the obstruction has been cleared.
2. If no obstruction is found and grain is flowing freely through each column, the plenum temperature
may need to be reduced.
NOTE: To check for an obstruction, go to manual and turn the Load to OFF and turn the Unload to
ON. Run the Unload long enough for the grain level in the columns to drop at least 1 foot. Stand
back from the dryer and look through the screens to notice the grain level in each column. Any
column, which has an obstruction, will be readily visible.
3. If the column temperature has cooled down and the RESET button has been pressed on the keypad,
and the fault message is still being displayed, remove the junction box cover and measure for 24VDC
on wire # 18.
4. If 24VDC is NOT measured on wire # 18 go to the Power Box terminal strip and measure for 24VDC
on the terminal strip.
a. If 24VDC is measured on the Power Box terminal strip, check the wiring connections between the
junction box and the Power Box.
b. If 24VDC is NOT measured on the Power Box terminal strip, go to the Control Box and measure
for 24VDC on the terminal strip.
c. If 24VDC is measured on the Control Box terminal strip, check the wiring connections between
the Power Box and the Control Box.
d. If 24VDC is NOT measured on the Control Box terminal strip, go to the PLC and measure for
24VDC coming from the PLC 24VDC power supply.
e. If 24VDC is not measured coming from the power supply, remove all Wires from the terminal and
measure again for 24VDC.
f. If the 24VDC returns, one of the wires has a short to ground and will need to be isolated and
corrected.
g. If unable to measure 24VDC coming from the PLC power supply, the PLC is defective.
7 - 21
Fault Troubleshooting
Grain Column Over-Temperature Sensor (continued)
5. At this point, 24VDC should be measured on wire # 18 at the O/T sensor.
Measure for 24VDC on the other wire (not # 18) coming from the sensor.
a. If 24VDC is NOT measured, the O/T sensor is defective.
b. If 24VDC is measured on the wire coming from the O/T sensor but
The PLC Input light is NOT on, note the wire number and go to
The Power Box and measure for 24VDC on the terminal strip.
c. If 24VDC is NOT measured on the terminal strip in the Power Box, check the wiring connections
between the junction box and the Power Box.
d. If 24VDC is measured on the terminal strip in the Power Box, go to the
Control Box and measure for 24VDC on the terminal strip.
e. If 24VDC is NOT measured on the Control Box terminal strip, check the wiring connections
between the Power Box and the Control Box.
f. If 24VDC is measured on the Control Box terminal strip, go to the PLC and measure for 24VDC
on the Input terminal.
g. If 24VDC is NOT measured on the Input terminal, check the wiring connections between the
Control Box terminal strip and the PLC Input terminal.
h. If 24VDC is measured on the Input terminal but the Input light is not on, but the fault message is
still being presented (after pressing RESET), the PLC is defective.
7 - 22
Fault Troubleshooting
Grain Column Over-Temp Sensor
7 - 23
Fault Troubleshooting
Grain Column Over-Temp Sensor
7 - 24
Fault Troubleshooting
Heater Housing Hi-Limit Switch
Heater Housing Hi-Limit switch is the reset button
located in the 5x5 box mounted on the top side of the
fan barrel. This switch trips when the heater reaches a
temperature of 93°C.
HOUSING HIGH TEMP
INSPECT HTR HOUSING
AND/OR TEMP SETTING
Figure 1.7a: Fault Display
Figure 1.7b: Heater Housing Hi-Limit Switch
Model
1 Fan Portable Dryer
2 Fan Portable Dryer (Upper)
2 Fan Portable Dryer (Lower)
2 Module Stack Dryer (#1)
2 Module Stack Dryer (#2)
2 Module Stack Dryer (#3)
2 Module Stack Dryer (#4)
3 Module Stack Dryer (#)
3 Module Stack Dryer (#)
3 Module Stack Dryer (#)
3 Module Stack Dryer (#)
3 Module Stack Dryer (#)
3 Module Stack Dryer (#)
Input
0CH03
0CH03
1CH04
1CH00
1CH01
1CH02
1CH03
2CH06
2CH07
2CH08
2CH09
2CH10
2CH11
Wire #
38
38
103
38
103
203
303
38
103
203
303
403
503
Output
10CH07
10CH07
Wire #
4
4
N/A
N/A
N/A
N/A
1. Check for proper fan operation and airflow.
a. Check the ignition harness for burned wires. Replace is necessary.
b. Check for a plugged fan grill and remove any debris.
c. Remove the cover from the faulted Heater Box and push the RED reset button located at the
center of the Heater Box.
d. Go to manual and turn on the fan. Insure that the fan is running at the proper speed.
e. Turn the burner switch to ON and observe the burner for proper operation.
2. After allowing time enough to cool, the RED reset button on the hi-limit switch should push in and
latch.
a. If the reset button will not latch, the hi-limit switch is defective.
b. If the reset button will latch but the fault remains after RESET is pressed, voltage measurements
will need to be taken.
3. Locate the two wires plugged on to the hi-limit switch. Measure for 24VDC on wire # 18.
a. If 24VDC is not present on wire # 18, go to the Power Box and check for 24VDC on the terminal
strip.
b. If 24VDC is measured on the terminal strip, check wiring connections between the Heater Box
and the Power Box.
c. If 24VDC is NOT measured on the terminal strip, go to the Control
Box and check for 24VDC on wire # 18 on the terminal strip.
d. If 24VDC is measured on the terminal strip, check wiring connections between the Power Box
and the Control Box.
e. If 24VDC is NOT measured on the terminal strip, go to the PLC and
Measure for 24VDC coming from the 24VDC Power Supply.
7 - 25
Fault Troubleshooting
Heater Housing Hi-Limit Switch (continued)
f.
If 24VDC is not measured at the Power Supply + terminal (wire # 18), remove all of the wires
from the terminal and measure for 24VDC,
If 24VDC has returned, one of the wires is shorted. This wire must be isolated and the short
corrected.
4. At this point, 24VDC should be measured on wire # 18 at the hi-limit switch in the Heater Box.
a. Measure for 24VDC on the other wire connected to the hi-limit switch. With the RED reset button
latched in, 24VDC should be present.
b. If 24VDC is NOT measured, the hi-limit switch is defective.
c. If 24VDC is measured but the PLC Input light is not ON, take note of the wire number and go to
the Power Box and measure for 24VDC on the terminal strip.
d. If 24VDC is NOT measured on the terminal strip, check the wiring connections between the
Heater Box and the Power Box.
e. If 24VDC is measured on the Power Box terminal strip, go to the
Control Box terminal strip and measure for 24VDC.
f. If 24VDC is NOT measured on the terminal strip, check the wiring connections between the
Power Box and the Control Box.
g. If 24VDC is measured on the terminal strip, go to the PLC Input terminal and measure for 24VDC.
h. If 24VDC is NOT measured on the input terminal, check the wiring connections from the Control
Box terminal strip to the PLC Input terminal.
i. If 24VDC is measured on the input terminal on the PLC but the input light is NOT on, but the fault
message is still being displayed after pressing RESET on the keypad, the PLC is defective.
7 - 26
Fault Troubleshooting
Metering Roll Proximity Switch
The Metering Roll Proximity Switches are located in
junction boxes at the back of the dryer. This device is used
to monitor the metering rolls for rotation. If the rolls cease to
turn, the fault will be displayed and the dryer will shut down.
METER ROLL
** FAILURE **
CHECK PROX OR I/O
PRESS ANY KEY
Figure 1.8a: Fault Display
Figure 1.8b: Metering Roll Proximity Switch
Model
1 Fan Portable Dryer (Left)
1 Fan Portable Dryer (Right)
2 Fan Portable Dryer (Left)
2 Fan Portable Dryer (Right)
2 Module Stack Dryer (Right)
2 Module Stack Dryer (Left)
3 Module Stack Dryer (Right)
3 Module Stack Dryer (Left)
Input
2CH04
2CH05
3CH04
3CH05
3CH04
3CH05
4CH04
4CH05
Wire #
92
93
92
93
92
93
92
93
Output
11CH02
Wire #
91
11CH02
4
N/A
N/A
N/A
N/A
1.
2.
3.
4.
5.
Turn the Control Panel switches to OFF.
Turn the manual Meter Roll Speed control to 150 (15%).
Turn the control system from off to manual.
Turn the Unload switch to ON.
Observe the chain on the Meter Rolls DC Motor for movement.
a. If the chain is moving than check to see if the Meter Rolls are turning.
b. If the Meter Rolls are not turning, check for a broken chain.
6. If the mechanical operation of the Meter Rolls drive train appears to be ok, but the Meter Rolls motor
is not turning, voltage measurements will need to be taken at the SCR Drive Unit in the Power Box.
NOTE: Because these measurements are taken inside the Power Box, qualified electrical service
personnel should do this work. HIGH VOLTAGE IS PRESENT IN THIS BOX REFER TO THE
SCR DRIVE TROUBLE SHOOTING SHEET.
7. If the Meter Rolls are turning, go to the back of the dryer and look at the back of the Meter Roll sensor
for the orange light turning on and off.
a. Check both PLC Inputs for the Input lights turning on and off.
b. After determining which Meter Roll Input signal is missing, go to that Meter Roll box which houses
the proximity switch and remove the cover. Make sure that the flag is within 1/8” of the sensor
head when passing over the sensor. If not, this adjustment will need to be made before
proceeding. Turn the Unload OFF at a point where the Meter Roll flag is positioned above the
proximity sensor. The orange light on the back of the proximity sensor should now be on.
a. If the orange light is not on, follow the wire from the proximity sensor to the junction box.
Remove the junction box cover.
b. Measure for 24VDC on wire # 18.
c. If 24VDC is not measured on wire # 18 go to the Power Box and measure for 24VDC on the
terminal strip.
7 - 27
Fault Troubleshooting
Metering Roll Proximity Switch (continued)
d. If 24VDC is measured on the Power Box terminal strip, check the wiring connections between
the junction box and the Power box.
e. If 24VDC is not measured on the Power Box terminal strip, go to the Control Box terminal
strip and measure for 24VDC on wire #18 on the terminal strip.
f. If 24VDC is measured on the Control Box terminal strip, check the wiring from the Power Box
to the Control Box.
g. If 24VDC is not measured on wire # 18 on the Control Box terminal strip, go to the PLC and
measure for 24VDC coming from the 24VDC Power Supply terminals.
h. If 24VDC is not measured on the 24VDC Power Supply, remove all of the wires on the output
terminal. (# 18 wires) and measure again for 24VDC. If 24VDC is now measured on the
terminal, one of the # 18 wires is causing a short and must be isolated and corrected.
i. If 24VDC is still NOT measured on the Power Supply output terminal, the PLC is defective.
8. At this point, 24VDC should be present on wire # 18 in the junction box on the back of the dryer
(brown sensor wire). This voltage is referenced to ground (blue sensor wire).
NOTE: This sensor is a negative switching device. This means that when the sensor is in the on
condition, the voltage on the output wire (black sensor wire) will be 0 VDC.
9. Make sure the flag is over the proximity sensor head and adjusted to 1/8th inch or less.
10. The light on the back of the proximity sensor should be on, and 0VDC should be measured on the
output (black sensor wire). If not, the sensor is defective.
11. If 0 VDC is measured on the output (black) wire, go to the Control Box and check the PLC Input light.
The input light should be ON when the sensor is in the ON condition.
a. If 0 VDC is measured on the black sensor wire but the PLC Input light is not ON, take note of the
wire number and go to the Power Box terminal strip and measure for 0 VDC.
b. If 0 VDC is NOT measured on the Power Box terminal strip, check the wiring connections
between the junction box and the Power Box.
c. If 0 VDC is measured on the Power Box terminal strip, go to the
Control Box and measure for 0 VDC on the terminal strip.
d. If 0 VDC is NOT measured on the Control Box terminal strip, check the wiring connections
between the Power Box and the Control Box.
e. If 0 VDC is measured on the Control Box terminal strip, go to the
PLC and measure for 0 VDC on the PLC Input terminal.
f. If 0 VDC is measured on the PLC Input terminal but the light is NOT
ON, the PLC may be defective.
g. If 0 VDC is NOT measured on the input terminal, check the wiring between the Control Box
terminal strip and the PLC Input terminal.
7 - 28
Fault Troubleshooting
Metering Roll
Proximity Switches
Figure 1.8c: Metering Roll Proximity Switches Installed on Dryer
7 - 29
Fault Troubleshooting
This page intentionally left blank
7 - 30
Fault Troubleshooting
Static Air Pressure Sensor
The Static Air Pressure sensor is located
in the junction box with the air switch
(see below). It monitors the amount of
static pressure in the plenum and will
shut down the dryer if there is not enough
present.
Dryer must be full of grain!!!
Figure 1.9b: Static Air Pressure Sensor Apart
Model
1 Fan Portable Dryer
2 Fan Portable Dryer (Upper)
2 Fan Portable Dryer (Lower)
2 Module Stack Dryer (#1)
2 Module Stack Dryer (#2)
2 Module Stack Dryer (#3)
2 Module Stack Dryer (#4)
3 Module Stack Dryer (#1)
3 Module Stack Dryer (#2)
3 Module Stack Dryer (#3)
3 Module Stack Dryer (#4)
3 Module Stack Dryer (#5)
3 Module Stack Dryer (#6)
Input
0CH08
0CH08
1CH09
1CH08
1CH09
1CH10
1CH11
0CH01
0CH03
0CH05
0CH07
0CH09
0CH11
Wire #
43
43
105
43
105
205
305
43
105
205
305
405
505
Output
11CH04
11CH04
13CH05
N/A
Wire #
11
11
6B
N/A
N/A
N/A
1. To develop static air pressure in the plenum, the dryer must
LOW STATIC PRESSURE
be full of grain. Check the grain level in the columns.
CHECK FAN/AIR SWITCH
a. If columns are not full, check for the out of wet grain cause,
and correct.
PRESS ANY KEY
2. Place the Main System switch to Manual and turn the fan
Figure 1.9a: Fault Display
switch to ON.
a. Check the fan for proper operation and airflow.
3. If a fault message is displayed on the LCD screen, the air switch may not be adjusted correctly.
a. Remove the junction box cover containing the air switch.
b. With the dryer full of grain, and the fan switch turned to ON, check the PLC Input light. The input
light should be ON at this time.
c. If the input light is NOT on, using a small tipped screwdriver, turn the adjustment screw counterclockwise until the input light turns on.
d. Once the input light is on, turn the fan off and observe the PLC Input light. The light should turn
OFF as the fan slows down.
e. If the light remains ON after the fan has slowed, turn the adjustment screw clockwise very slowly
until the input light turns off.
f. While watching the PLC Input, turn the fan ON and then OFF, making sure that the input light is
turning on and off with the fan.
4. If, after going through the above procedure, the PLC Input light remains in either the on or the off
position without changing, voltage measurements will be necessary.
a. Locate wire # 18 in the junction box and measure for 24VDC.
b. If 24VDC is NOT measured, go to the Power Box and measure for 24VDC on the terminal strip.
c. If 24VDC is measured on the terminal strip, check the wiring connections between the junction
box and the Control Box.
d. If 24VDC is NOT measured on the Power Box terminal strip, go to the Control Box and measure
for 24VDC on wire # 18 on the terminal strip.
e. If 24VDC is measured on the terminal strip, check the wiring connections between the Power Box
and the Control Box.
f. If 24VDC is NOT measured on the terminal strip, go to the PLC and measure for 24VDC on the
24VDC Power Supply terminals.
7 - 31
Fault Troubleshooting
Static Air Pressure Sensor (continued)
g. If 24VDC is measured at the ( + ) terminal, check the wiring connections between the Control Box
terminal strip and the PLC Power Supply terminals.
h. If 24VDC is NOT measured on the ( + ) terminal, remove all of the wires from the terminal and
again measure for 24VDC.
i. If 24VDC has returned, one of the wires has a short and will need to be isolated and the short
corrected.
5. At this point, 24VDC should now be measured on wire # 18 at the air switch.
6. Measure for 24VDC on the other wire coming from the Air Switch.
a. If 24VDC is measured on this wire, use a small screwdriver and turn the adjustment clockwise
until the 24VDC is no longer present.
b. If turning the adjustment screw clockwise fails to turn OFF the Air Switch, the switch is defective.
c. If 24VDC is NOT measured on the wire coming from the Air Switch, use a small screwdriver and
turn the adjustment screw counter-clockwise until 24VDC is measured.
d. If turning the adjustment screw counter-clockwise fails to turn ON the Air Switch, the switch is
defective.
7. After replacing the Air Switch, follow the previous instructions on switch adjustment for proper
operation.
a. If the PLC Input light is not turning on when the Air Switch is on, voltage measurements will need
to be taken.
b. Adjust the Air Switch to the ON position. Measure for 24VDC on the wire coming from the Air
Switch.
c. Take note of the wire number and go to the Power Box and measure for 24VDC on the terminal
strip.
d. If 24VDC is NOT measured on the terminal strip, check the wiring connections between the
junction box and the Power Box terminal strip.
e. If 24VDC IS measured on the terminal strip, go to the Control Box and measure for 24VDC on the
terminal strip.
f. If 24VDC is NOT measured on the terminal strip, check the wiring connections between the
Power Box and the Control Box.
g. If 24VDC is measured on the terminal strip, go to the PLC Input terminal and measure for
24VDC.
h. If 24VDC is NOT measured on the input terminal, check wiring connections between the terminal
strip and the PLC.
i. If 24VDC is measured on the PLC Input terminal but the input light is not on, but the fault
message is still being displayed on the LCD screen after pressing RESET, the PLC is defective.
7 - 32
Fault Troubleshooting
Static Air Pressure Sensors
Figure 1.9c: Static Air Pressure Sensors Installed on Dryer
7 - 33
Fault Troubleshooting
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7 - 34
Fault Troubleshooting
Plenum Over-Temperature
Sensor
The Plenum Over-Temperature
Sensor is located inside the
plenum of the dryer. It is provided
to protect from the plenum over
heating.
PLENUM HIGH TEMP
POSSIBLE CLOG OR
TEMPERATURE SETTING
Figure 1.10a: Fault Display
Model
1 Fan Portable Dryer
2 Fan Portable Dryer (Upper)
2 Fan Portable Dryer (Lower)
2 Module Stack Dryer (#1)
2 Module Stack Dryer (#2)
2 Module Stack Dryer (#3)
2 Module Stack Dryer (#4)
3 Module Stack Dryer (#1)
3 Module Stack Dryer (#2)
3 Module Stack Dryer (#3)
3 Module Stack Dryer (#4)
3 Module Stack Dryer (#5)
3 Module Stack Dryer (#6)
1.
2.
3.
4.
5.
Figure 1.10b: Plenum Over-Temperature Sensor Old and New (Left to Right)
Input
0CH04
0CH04
1CH08
1CH04
1CH05
1CH06
1CH07
4CH06
4CH07
4CH08
4CH09
4CH10
4CH11
Wire #
39
39
104
39
104
204
304
39
104
204
304
404
504
Output
11CH00
11CH00
13CH04
N/A
Wire #
5
5
1B
N/A
N/A
N/A
Check the fan grill for obstruction and remove any accumulated debris.
With the dryer shut down, remove the key from the key-lock switch at the plenum access door. Open
the door and inspect the plenum for any problems.
After the plenum has cooled down, press the RESET key on the keypad. The fault should be cleared
from the display.
If the fault has not cleared, remove the cover from the junction box containing the Plenum O/T
sensor and measure for 24VDC on wire # 18.
a. If 24VDC is NOT measured on wire # 18, go to the Power Box and measure for 24VDC on wire #
18 on the terminal strip.
b. If 24VDC is measured on wire # 18 in the Power Box, check the wiring connections between the
junction box and the Power Box.
c. If 24VDC is NOT measured on the terminal strip, go to the Control Box and measure for 24VDC
on the terminal strip.
d. If 24VDC is measured on wire # 18 on the terminal strip, check the wiring connections between
the Power Box and the Control Box.
e. If 24VDC is NOT measured on the terminal strip go to the PLC
24VDC Power Supply and measure for 24VDC.
f. If 24VDC is measured on the ( + ) terminal of the Power Supply, check the wiring connections
between the terminal strip and the PLC Power Supply.
g. If 24VDC is NOT measured on the ( + ) terminal of the PLC Power Supply, remove all of the
wires from the terminal and measure for 24VDC. If the voltage has returned, one of the wires is
shorted and will have to be isolated and the short corrected.
At this point, 24VDC should be measured on wire # 18 on the Plenum O/T switch.
7 - 35
Fault Troubleshooting
Plenum Over-Temperature Sensor (continued)
6.
Measure for 24VDC on the other side of the switch.
a. If the O/T switch is cooled down and 24VDC is NOT measured on the other wire, the sensor is
defective.
b. If 24VDC is measured on the other wire coming from the sensor, Go to the PLC and check the
input light. If the input light is ON, press RESET on the keypad and the fault should clear.
c. If the input light is not ON, take note of the wire number coming out of the O/T sensor and go to
the Power Box and measure for 24VDC on the terminal strip.
d. If 24VDC is NOT measured on the Power Box terminal strip, check the wiring connections
between the junction box and the Power Box.
e. If 24VDC is measured on the Power Box terminal strip, go to the Control Box and measure for
24VDC on the terminal strip.
f. If 24VDC is NOT measured on the terminal strip, check the wiring between the Power Box and
the Control Box.
g. If 24VDC is measured on the Control Box terminal strip, measure for 24VDC on the PLC Input
terminal.
h. If 24VDC is measured on this terminal, and the input light is OFF, but the fault message is still
being displayed, the PLC is defective.
i. If 24VDC is NOT measured on the PLC Input terminal, check the wiring connections between the
Control Box terminal strip and the PLC Input terminal.
7 - 36
Fault Troubleshooting
Plenum Over-Temp Sensors
Figure 1.9c: Plenum Over-Temperature Sensors Installed on Dryer
7 - 37
Fault Troubleshooting
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7 - 38
Fault Troubleshooting
Device Troubleshooting
Discharge Moisture Sensor
The Discharge Moisture sensor is found under the
discharge chute at the rear of the dryer. If is used to
calculate the moisture and temperature of the grain
as it is discharged from the dryer.
MOISTURE SENSOR
NOT FOUND SHUTDOWN
PRESS ANY KEY
Figure 2.1b: Discharge Moisture Sensor
Figure 2.1a: Fault Display
If the moisture sensor is in question, please make the following checks before taking any voltage
measurements.
1. Turn the main system switch to Computer.
2. Go to Mode 4 from the start screen (this screen will show the information coming back from the
moisture sensor).
3. With the moisture sensor hanging from the dryer (from the ground strap), the screen should read
ambient temperature and 0.0 for moisture.
4. With the moisture sensor flag grounded, the screen should still show ambient temperature with a
moisture reading of approximately 48% – 50%.
5. If these readings are not close to the above information, go to Mode 5 and select the moisture
sensor, which is currently in use on the dryer.
6. If, after going through the above procedures, the information displayed is incorrect, voltage
measurements will be required.
7. In the Control Box, locate the I/O Board. On the bottom right hand side of the board, find the sixwire plug with the gray cable attached.
8. The colors of the wires in this connector are from left to right, red, brown, blue, black white, green
& shield.
9. Take voltage measurements from the green wire to all of the other wires and compare to the
following readings.
4 – Wire Sensor
Red = 15VDC
White = 0 – 5VDC
Black = .300 – 5VDC
Green = Ground
Sensor w/ Black Shrink
Red = 15VDC
Brown = 15VDC
Blue = 0 – 5VDC
Black = .300 – 5VDC
White = 8.5VDC
Sensor w/ Red Shrink
Red = 15VDC
Brown = 15VDC
Blue = .250 - .350VDC
Black = .300 – 5VDC
White = 8.5VDC
Sensor w/ NO Shrink
Red = 15VDC
Brown = 15VDC
Blue = .250 -.350VDC
Black = 5.25 –7.50VDC
White = 8.5VDC
10. Taking voltage measurements at the I/O board would be the first step.
11. If the readings are incorrect, voltage readings should be taken at the junction box located near
the discharge chute.
12. If the readings obtained in the junction box are the same as those obtained at the I/O board plugin, the sensor is probably defective.
13. If the readings are different, the strong possibility exists that a wiring connection is loose. In that
case, take readings on the wires coming back from the moisture sensor to the terminal strip in the
junction box.
14. Go to the Power Box and take the same readings and compare these readings.
15. To those taken in the junction box. If the readings are different, check the wiring connections
from the junction box to the Power Box.
16. If the readings are the same, go to the Control Box and recheck the voltage readings at the I/O
board plug-in connector.
17. If the readings are different from those taken at the I/O board, check the wiring connections
between the Power Box and the I/O board.
7 - 39
Fault Troubleshooting
Discharge Moisture Sensor
Figure 2.1c: Discharge Moisture Sensor Installed on Dryer
7 - 40
Fault Troubleshooting
Printer Paper Roller
Figure 2.2a: Paper Roller
Figure 2.2b: Paper Roller Installed
1. Although not essential to dryer operation, there are a few checks that can be made if the paper roll
fails to operate.
a. Measure for 15VDC on terminals # 83 & # 85.
b. This voltage comes from the power supply. If 15VDC is not measured on these terminals, check
wiring connections between the terminal strip and the Power Supply.
c. Wire # 82 is connected to the same terminal strip as wires # 83 & # 85.
This signal would be difficult to measure accurately with a voltmeter, but if the Printer is working,
and the wiring connections to the terminal strip are tight, then the Paper Roll board is receiving a
signal to turn on each time the printer starts printing.
NOTE: A small electronic circuit board is connected to the Paper Roll motor. This electronic
circuit is constantly checking the Data Line for information being sent to the printer. Each time
information is detected, the Paper Roll is turned on for approximately 10 seconds.
d. Near the Paper Roll motor are two BROWN wires. The dryer is shipped with these wires tied
near the motor but not connected.
These wires may be connected to a pushbutton switch if the owner wishes to manually energize
the Paper Roll motor.
e. Another test would be to momentarily short the two BROWN wires together which will cause the
motor to turn on.
f. If the Paper Roll motor still does not turn, short the two brown wires and check for 15VDC on the
two motor terminals.
g. If 15VDC is measured at the motor terminals, the motor is defective, or a wire connection is
loose.
7 - 41
Fault Troubleshooting
SCR Drive
MAIN POWER - 220VAC - LI & L2
If the dryer is a 460VAC, the 220VAC is
supplied from a step-down transformer
located in the Power Box, through fuse 3A
(10 AMP).
If the dryer is a 230VAC dryer, the
220VAC is supplied directly from the
distribution block.
The 220VAC then routes through two
N.O. contacts on relay CR5, through fuse F4
(3 AMP), to the L1 and L2 terminals on the
SCR Drive Unit.
Relay CR5 is energized at the same time
the Unload Coil - M3 is energized (in
Automatic or Manual).
Figure 2.4a: SCR Board
1. If the meter rolls are turning in Manual or
Automatic, the SCR Drive Unit is OK. If the meter rolls are not turning in either Automatic or Manual,
voltage measurements will need to be taken. The SCR Drive Unit is located in the Power Box.
NOTE: Measurements will need to be taken in the Power Box with power turned on. This work
should be performed by electrically qualified personnel only. HIGH VOLTAGE IS PRESENT!
2. With power on, locate relay CR5 and measure for 220VAC on the two wires located on the topside of
the ice cube relay. If 220VAC is NOT measured, check fuse F4.
a. If fuse F4 is OK, and the dryer is 460 VAC, check fuse F3A (located on the transformer).
b. If fuse F4 is OK, and the dryer is a 230VAC dryer, go to the distribution block and measure for
230VAC.
c. If 220VAC is not measured at the distribution block, check to make sure the main power switch is
turned on.
d. If 220VAC is measured at the distribution block but not on the top of relay CR5, check the wiring
connections between the distribution block and the CR5 terminals.
3. At this point, 230VAC should now be measured on the two wires on the top of CR5. Turn the Main
System switch to the Manual position and the Unload switch to the ON position. CR5 should now be
energized.
a. Measure for 230VAC on the two wires on the bottom of relay CR5.
b. If 230VAC is NOT measured, measure for 120VAC on the two coil wires. If 120VAC is measured
and relay appears to be energized, relay is defective.
c. If 120VAC is NOT measured on the coil wires, check the Unload motor Starter M3. The coil
should be energized. If this coil is not energized, make sure the Unload switch is turned to ON
and the Main System switch is turned to Manual.
d. 120VAC should now be measured on terminals L1 and L2 (3rd and 4th terminals from the top).
4. Before the SCR Drive Unit will feed DC voltage to the motor, a reference voltage must be present on
the SIG and COM terminals of the drive unit. The voltage measured will be from 1.0VDC – 9.5VDC
depending on the percentage of meter roll speed selected. (2nd and 3rd terminals from the bottom).
a. With the Unload turned on and 220VAC measured on L1 and L2, measure for DC voltage on the
SIG and COM terminals at the drive unit.
b. If DC voltage is NOT measured, go to the Control Box and locate relay CR2 (ice cube relay).
c. Measure for DC voltage on the two wires on the bottom of the relay next to the back panel
(labeled #16 and #17).
NOTE: In Manual, the voltage is supplied by the manual potentiometer. In Automatic, the voltage is
supplied by the processor board.
7 - 42
Fault Troubleshooting
Plenum Temperature Sensor (RTD)
Averaging RTD – Resistive Temperature
Device
The averaging RTD is a device, which
measures the average resistance over the
length of the tube. The dryer commonly uses
16ft. and 24ft. lengths.
The RTD is used in conjunction with a
transmitter which converts the resistance into
a 1.0VDC – 5.0VDC signal.
This voltage is then fed into the Plenum
Temperature Display, which will be located
Figure 2.7a: Plenum Temperature Sensor
on the Control Panel and near the pipe train
of each heater.
If the RTD is in question, a voltage and resistance comparison can be made to determine if the unit is
defective.
1. Begin by locating the junction box containing the RTD transmitter. This is a rectangular box
approximately 4in. by 2 1/2in. The transmitter is attached to the cover.
2. A white label should be attached to the transmitter. Also, two terminal strips, each with three
terminals will be located on the top of the transmitter.
3. Next to the terminal strips is a small adjustment screw. NEVER adjust either of these screws. These
are calibration adjustments and once moved, the transmitter will not work correctly until a factory
calibration is performed.
4. Locate the terminal strip with the
output, +, and – connections.
Measure for 15VDC on terminal
#2 and #3.
5. If 15VDC is not present, note the
wire numbers and go to the
Power Box and check for voltage
on the terminal strip.
6. With 15VDC present at the
transmitter, measure the output
voltage (#1 and #3). A voltage
between 1.0VDC and 5.0VDC
should be measured.
7. With
15VDC
present
on
terminals #2 and #3 but no
voltage is measured between
terminals #1 and #3, the
transmitter is defective.
8. If a voltage is measured, use the
chart on the next page to
Figure 2.7b: Plenum Temperature Sensor Installed
determine if the voltage is
reasonable.
9. If a voltage is measured between terminals #1 and #3, go to the other terminal strip and remove the
two wires coming from the RTD (red and yellow).
10. A jumper should be connected between terminals #2 and #3.
11. Take a resistance reading with the meter. The resistance of the RTD is directly related to the
temperature of the RTD.
NOTE: This reading should be taken with the dryer cooled down and at ambient temperature.
7 - 43
Fault Troubleshooting
Plenum Temperature Sensor (RTD) (continued)
12. If the reading shows infinite (open) resistance, the RTD is defective. Compare the resistance reading
to the following table to determine if the resistance is reasonable.
Temperature
10F (-12C)
15F (-9C)
20F (-7C)
25F (-4C)
30F (-1C)
35F (2C)
40F (4C)
45F (7C)
50F (10C)
55F (13C)
60F (16C)
65F (18C)
70F (21C)
75F (24C)
80F (27C)
85F (29C)
90F (32C)
95F (35C)
100F (38C)
105F (41C)
110F (43C)
115F (46C)
120F (49C)
125F (52C)
130F (54C)
135F (57C)
140F (60C)
145F (63C)
150F (66C)
Resistance
952
963
973
984
995
1006
1017
1028
1039
1049
1060
1071
1082
1093
1103
1114
1125
1136
1146
1157
1168
1178
1189
1200
1211
1221
1232
1243
1253
Voltage
1.16
1.24
1.32
1.40
1.48
1.56
1.64
1.72
1.80
1.88
1.96
2.04
2.12
2.20
2.28
2.36
2.44
2.52
2.60
2.68
2.76
2.84
2.92
3.00
3.08
3.16
3.24
3.32
3.40
13. If the resistance compares to the ambient temperature around the dryer, and the voltage on the
output wire is close to the ambient temperature, then the transmitter and the RTD are functioning
correctly.
Go to the Plenum Temperature Display trouble-shooting sheet to continue.
7 - 44
Fault Troubleshooting
Plenum Temperature Display
1. If the display reading is incorrect by only a few degrees, please
look at the diagram below to locate the adjustment potentiometer.
2. While watching the display, use a small screwdriver and turn the
screw clockwise or counter-clockwise until the correct
temperature is being displayed. Check the other display (one
display is located on the Control Panel and the other display is
located on the dryer) each should read within + or – a few
degrees of each other.
3. If the display is dark and appears to be without power, measure
for voltage on the white plug on the RTD Amplifier board. 15VDC
Figure 2.6a: Plenum Temp Display
should be measured.
4. If 15VDC is not measured, go to the control box, and measure for
voltage on the terminal strip located in the middle-right of the box (wire #83 and #85).
5. If 15VDC is measured, check the wiring connections between the Control Box and the Plenum
Temperature Display.
6. If 15VDC is now measured on the white plug at the display, measure between the wire marked #83
and the wire attached to the green connector (signal voltage from the RTD).
7. If a voltage (1.0 VDC – 5.0 VDC) is not measured on the wire connected to the green connector,
refer to the RTD trouble-shooting section.
8. Using the chart found under the RTD trouble-shooting section, compare the measured voltage to the
temperature. If this voltage is correct, and the display cannot be adjusted (refer to the diagram on the
following page for display adjustment) to the correct temperature, the display is defective.
Figure 2.6b: Plenum Temp Display
Figure 2.6c: Plenum Temp Display Rear Right
Display Adjustment
Signal (Green Contact)
7 - 45
Fault Troubleshooting
This page intentionally left blank
7 - 46
Fault Troubleshooting
Burner Operations
3 Wire Air Switch without Low Pressure Switch
The following parts will be found on either the gas pipe train or in the
heater box.
•
•
•
•
•
•
•
•
•
•
•
Burner Operation
Automatic Valve Proving Control – LDU11 – heater box
Valve Proving Pressure Switch – low and high – between the
upstream and downstream valves on the pipe train
CE Gas Burner Control – LME21.350A1 – heater box
High Pressure Switch – pipe train – after downstream valve
Housing High Temperature Switch – 5 x 5 box on fan barrel
Differential Air Switch – heater box
Vapor Over-Temp Switch (on LP systems) – pipe train
Ignition Transformer – heater box
Main – Upstream Gas Valve – pipe train
Blocking – Downstream Gas Valve – pipe train
Electronic Modulating Gas Valve (EMOV) – pipe train
On heaters not requiring the LDU11 valve proving control (28” heater),
once the burner control relay is energized, 120VAC must flow through
the housing O/T, and the high-pressure switch, before being applied to
the CE heater control unit (LME21.350A1).
On heaters requiring the LDU11 (valve proving control), once the main
power is being supplied to the dryer, 120 VAC is supplied directly to the
LDU11.
The LDU11 valve proving control goes through two valve tests. During
TEST 1, the downstream valve is energized for 4 seconds, evacuating
all of the gas pressure between the upstream and the downstream
valves. This test is used to determine if an increase in pressure is
detected between the two valves by the valve proving pressure switch. If
an increase in pressure is detected, TEST 1 will FAIL, and lockout will
occur. The valve proving control can be reset by pressing the clear
plastic on top of the unit, or by pressing the reset button on the control
box keypad. During TEST 1, a voltage is output from terminal 15 of the
LDU11. If no leaks are present, pressure will remain low and the voltage
will pass through the N.C. contacts and be present on terminal 16 of the
LDU11. If TEST 1 has not failed, TEST 2 will begin.
In TEST 2, the upstream valve is energized for 4 seconds, which
pressurizes the piping between the two valves. If a decrease in pressure
is detected by the valve-proving pressure switch, TEST 2 will fail and
lockout will occur. The valve proving control can be reset by pressing the
clear plastic on top of the unit, or by pressing the reset button on the
control box keypad. During TEST 2, a voltage is again output from
terminal 15 of the LDU11. If no leaks are present, pressure will remain
high and the voltage will be present on terminal 17 of the LDU11. The
valve-proving test will be initiated each time main power is supplied to
the dryer (not when turning the control system on and off, or going
between automatic and manual).
If both test 1 and 2 pass, 120 VAC is output from terminal # 6 of the
LDU11. If no faults have been detected by the dryer control system,
then, at the proper time, the control system will call for burner operation
by closing a set of N.O. contacts. This voltage must flow through the
housing high temperature switch, and the high-pressure gas switch.
7 - 47
Fault Troubleshooting
This voltage is then supplied to terminal # 12 of the CE Burner Control
Unit (LME21.350A1).
Upon supplying voltage to the CEBC, the following ignition sequence
takes place.
Ignition Sequence
1. 120 VAC is supplied to terminal # 12 of the LME21.350A1 (CEBC).
2. A 2.5 second wait time begins.
3. The fan ON control signal is enabled. This voltage is output on
terminal # 3 of the LME21.350A1, which checks for this same
voltage on terminal # 6, which comes from a N.C. contact in the
differential air switch. This verifies that the fan is off and no airflow is
being detected.
4. Within 5 seconds of the fan ON signal being enabled, the differential
air switch must close a set of N.O. contacts, which applies this same
voltage to terminal # 11. This indicates that air movement has been
detected. If this signal is not detected, the unit will go into a fault
mode.
5. Upon receiving a voltage on terminal #11, the unit goes into a 30
second pre-purge time delay.
6. Following the purge time, the ignition transformer is energized. After
a 2 second pre-ignition time, the fuel valve is opened.
7. The ignition transformer remains energized for an additional 4
seconds. (total of 6 sec.)
8. Flame must be detected within 5 seconds, or the unit will go into a
fault mode.
9. The flame signal must be maintained for an additional 10 seconds
before opening other fuel valves.
Loss of flame will cause the CEBC to lockout. The unit may be reset by
pressing the small clear plastic button on the front of the unit for
approximately 2 seconds, or the reset button may be pressed on the
keypad located on the front of the control box. 3 attempts will be allowed
for burner ignition. On the 4th attempt, the unit will be locked out and
power must then be cycled to the unit before the ignition sequence may
be re-initiated.
The electronic modulating valve is in the low fire position for the ignition
sequence. After flame has been established, the main control system on
the dryer will send a control signal to the valve, which will open or close
the valve to maintain a desired temperature set point which is set by the
user.
Note
CEBC = CE Burner Control Unit
This is a general description of burner operation. For specific details of
the LME21.350A1, please refer to the Siemens bulletin # CC1N7101en.
7 - 48
Fault Troubleshooting
5
6
7
4
3
2
1
Burner Control Panel for a 38”/44” heater. Components for a 28” heater are the same minus the
LDU11 flame proving unit.
1.
2.
3.
4.
5.
6.
7.
CE Burner Control Unit – LME21
Flame Safe Relay – FSR
Reset Relay – RR
Isolation Relay – IR
Air Switch Solenoid
3 – Wire Air Switch
Ignition Transformer
7 - 49
Fault Troubleshooting
Electronic MOD Valve
General Information
1. A plenum RTD and Transmitter are required. The transmitter requires a 15 VDC
power source which generates a 0 – 5 VDC signal which is sent to the processor
board and the EMOV board.
2. A new 24 VDC power supply is installed. This power supply replaces the current 24
VDC power supply built into the PLC. (# 95 – Gnd, #18 - +24 VDC)
3. A Belimo actuator is connected to a butterfly valve, which opens or closes to control
the temperature of the plenum. The Belimo actuator requires a 24 VDC power
source and accepts a 0 – 10 VDC control signal. This signal comes from the
processor board. (via the EMOV board )
4. An Electronic Mod Valve board (EMOV) is mounted on top of the I/O board. This
board has a dual function. A slide switch is provided for each valve, which, when
switched to the Manual position, allows the user to set a 0 – 10 VDC signal to be
sent to the Belimo actuator for Manual control. Also, each plenum may be selected
and the temperature displayed.
5. Trouble shooting the Belimo valve requires a familiarity with the software being used
to control the valve. The following covers software information:
QUICK REFERENCE:
a. Press 0 and then 8 to enable or disable the EMOV.
b. DRY FIRE OPERATION:
1. Press MODE 2 for Dry Fire Operation. Select the option calling for Fan(s) and
heater(s). Fan(s) will be started, followed by the heater(s).
2. Upon heater ignition, verify that each heater is operating at a pressure of 4 – 5
PSI. If the pressure is less than 4 PSI, or exceeds 5 PSI, loosen the nuts on the
u-bolt that connect the actuator to the butterfly valve shaft and rotate the valve
shaft until the gas pressure is reading between 4 – 5 PSI.
3. Press SET 2 to select the plenum temperature menu. Set the plenum
temperatures to a minimum value. Verify that the valve is controlling to the
desired temperature. To monitor valve status, press the number of the heater
desired on the keypad.
4. Press RESET to return to the start screen.
7 - 50
Fault Troubleshooting
MODE – PRESS [MODE] ON KEYPAD
M ODE = ?
1= VALVE
2= DRY FIRE
4= CAL/SETUP 5= SENSOR
6= PROCESSOR 7= UNITS
NOTE: IF EM OV ENABLED
PROCESSOR - M ODE 6
M ODE 1
MOD VALVE OPTIONS
1 = RAM P TEST
2 = VALVE ADJUST
PROCESSOR BOARD VER.
SELECTED IS SUKUPF
NOTE: TO CHANGE, PRESS CHG
RAM P TEST - M ODE 1,1
VALVE ADJUST - MODE 1,2
SELECT PLENUM
1 = UPPER PLENUM
2 - LOWER PLENUM
SELECT PLENUM
1 = UPPER PLENUM
2 - LOWER PLENUM
VALVE RAM P
UP - REST
DRIVE POS = ??.?
DRIVE POS = 20%
CHANGE TO ??%
TO EXIT PRESS RESET
7 - 51
Fault Troubleshooting
CONTROL ALGORITHM – ELECTRONIC MOD VALVE – HIDDEN MENU
SET 9 – PRESS [SET] THE [9] ON KEYPAD
1= M ULTIPLIER
2= LINEAR RANGE
3= LOW FIRE POSITION
5= VALVE M IN 6= M AX
M ULTIPLIER - SET 9,1
LINEAR RANGE - SET 9,2
LOW FIRE POS. - SET 9,3
SELECT PLENUM
1 = UPPER
2 = LOWER
?
SELECT PLENUM
1 = UPPER PLENUM
2 = LOWER PLENUM
?
SELECT PLENUM
1 = UPPER PLENUM
2 = LOWER PLENUM
?
M ULTIPLIER IS SET TO
0.20
LINEAR RANGE SET TO
16.0
LOW FIRE POSITION
IS SET TO 40%
OK(+) OR CHG(-) ?
OK(+) OR CHG(-) ?
OK(+) OR CHG(-) ?
CHG
CHG
IF
UPPER
PLENUM
CHG
SET M ULTIPLIER
SET LINEAR RANGE
LOW FIRE POSITION
(37% - 100%)
??.?
??.?
??%
BACK TO START SCREEN
BACK TO START SCREEN
LOW FIRE POSITION
(26% - 100%)
IF
LOWER
PLENUM
??%
SET 9, 5
VALVE M IN
VALVE M AX
SELECT PLENUM
1 = UPPER PLENUM
2 = LOWER PLENUM
?
M IN. VALUE OPENING
IS SET TO 40%
M AX. VALUE OPENING
IS SET TO 75%
OK(+) OR CHG(-) ?
OK(+) OR CHG(-) ?
CHG
UPPER
AND
LOWER
SET 9, 6
SELECT PLENUM
1 = UPPER PLENUM
2 = LOWER PLENUM
?
CHG
M IN. VALVE OPENING
(10% - 98%)
M IN. VALVE OPENING
(42% - 100%)
??
??
BACK TO START SCREEN
7 - 52
UPPER
42-100%
LOWER
28-100%
Fault Troubleshooting
1. The first step in trouble shooting an EMOV problem is to determine whether or not the
problem is with just one heater or with all of the heaters.
2. If the problem is with all of the heaters, check for 24 VDC coming from the power supply.
This is the supply voltage to all of the Belimo actuators.
3. If the 24 VDC is present, check for a voltage on each actuator’s signal wire. If these voltages
are not present, the processor board may be the cause.
4. If the problem has been isolated to one heater, locate the Auto/Manual slide switch on the
EMOV board located on top of the I/O board in the Control Box). With power applied to the
control box, place the slide switch for that heater in the Manual position. (fan(s) and
heater(s) are off during testing).
5. While measuring the DC voltage on the EMOV board, (between GND - #95) and the signal
wire going to that actuator (61, 161, 261, 361, 461, or 561). With the manual potentiometer
turned fully clockwise, a voltage of approximately 10 VDC should be measured. As you
slowly turn the potentiometer counter-clockwise, the voltage will decrease until 0 VDC is
read. With the potentiometer set to read 10 VDC on the voltmeter, go to the heater pipe
train and check the butterfly valve shaft for a fully open position (the slot on the end of the
shaft should be at 60° to the pipe train). With the potentiometer set to read 0 VDC on the
volt meter, the slot on the end of the butterfly valve shaft should be perpendicular to the pipe
train.
6. If a voltage is measured at the EMOV board, but not at the valve, check for a loose wiring
connection between the EMOV board and the actuator.
7. If voltage is measured at the valve, but the valve did not open or close, re-confirm the
presence of 24 VDC to the valve. If 24 VDC is present, the valve is probably defective, or
the u-bolt, which mechanically connects the valve to the butterfly shaft is loose and needs to
be tightened.
8. The above tests will test the wiring from the EMOV board to the actuator and the actuator
itself.
9. If voltage is not measured at the EMOV board on the wires going out to the Belimo actuator,
# 61, 161, 261, 361, 461, or 561, check the voltage on the wires coming in from the
processor board (61A, 161A, 261A, 361A, 461A, or 561A). If voltage is not measured on
the wires coming in from the processor board, check the wiring harness that plugs into the
processor board or replace the processor board itself.
7 - 53
Fault Troubleshooting
BLUE TERM INAL STRIP
#10
TEM PERATURE
#9
M OISTURE
#8
N/C
#7
N/C
#6
N/C
#5
71
SINGLE FAN
#4
CAP
71
CAP
72
#3
GROUND
#2
GROUND
#1
SINGLE AND TWO FAN PROCESSOR BOARD
BLUE TERM INAL STRIP
#10
TEM PERATURE
#9
M OISTURE
#8
#7
#6
#5
#4
#3
76
CAP
75
CAP
74
CAP
73
72
CAP
CAP
71
GROUND
#2
GROUND
#1
STACK PROCESSOR BOARD
7 - 54
CAP
TWO FAN
Fault Troubleshooting
Electronic MOD Valve Board
76 Plenum #6 Temp. IN
75 Plenum #5 Temp. IN
74 Plenum #4 Temp. IN
73 Plenum #3 Temp. IN
72 Plenum #2 Temp. IN
71 Plenum #1 Temp. IN
N/C
561A VALVE #6 D/A IN
561 VALVE #6 Sig. OUT
461A VALVE #5 D/A IN
461 VALVE #5 Sig. OUT
361A VALVE #4 D/A IN
361 VALVE #4 Sig. OUT
261A VALVE #3 D/A IN
261 VALVE #3 Sig. OUT
161A VALVE #2 D/A IN
161 VALVE #2 Sig. OUT
61A VALVE #1 D/A IN
61 VALVE #1 Sig. OUT
85 +15 VDC
95 0 VDC
7 - 55
Fault Troubleshooting
Wire Numbers and their uses
Wire
Number
0
1
2
Description
Use
110V supply from transformer
110V supply after E-Stop
Neutral Wire
3
System switched 110V supply
4
110V Upper heater power on
5
110V 5 second auxiliary
6
110V load contactor
110V 5 second load auxiliary supply (common
to wire #5)
110V 10 second load auxiliary supply
(common to wire #9)
Conductor between transformer and E-Stop
Emergency Switched Control Supply
Provides Return for 110V circuits
110V present when Main System Switch is in
manual or computer
110V present upper heater circuit will begin firing
sequence
110V present energizes 5 second auxiliary
contactor (where applicable)
110V present energizes load contactor
Provides switched 110V from system to auxiliary
controls
Provides switched 110V from system to auxiliary
controls
110V present energizes 10 second auxiliary
contactor (where applicable)
110V present energizes unload contactor
CR5 relay, when energized provides 230V power
to SCR board
110V present energizes upper fan (pos. #1)
contactor
110V present; power available for upper heater
pending upon fan on/off
110V present energizes CR3 relay, system calls
for upper heat. Wired to aux. Contact or relay to
provide protection due to fan not running while
contactor energized
Provides switched 110V from system to auxiliary
controls
110V present energizes unload auxiliary
contactor (where applicable)
0 to 10 volt reference for SCR board,
1V=10% meter roll, 10V=99% meter roll
0 to 10 volt reference for SCR board from
processor for computer control of meter roll.
1V=10% meter roll, 10V=99% meter roll
0 to 10 volt reference for SCR board,
1V=10% meter roll, 10V=99% meter roll;
potentiometer fed from 15V source, using inline
resistor to drop voltage
Powered from PLC DC supply, provides voltage
for sensors
Provides switched 110V for worklight (110V
present, worklight on)
Spare
Provides 110V power for PLC and DC power
supply via fuses F6 and F7
Provides 110V power for PLC from fuse F6
Provides 110V power to unload and heaters
while in manual control
Provides DC power supply with 110V
Provides CR2 relay with 110V in manual mode
7
8
9
110V 10 second auxiliary
10
110V unload power on
10A
110V powers CR5 relay
11
110V upper fan power on
12
110V upper heater switch leg
13
110V powers CR3 relay (upper) heat turn on
safety due to fan failure
14
110V unload auxiliary supply
15
110V unload auxiliary
16
17
Meter roll reference voltage (neg.)
Meter roll reference voltage (pos.)
17A
Processor meter roll reference
17B
Manual control reference from front panel
18
24V supply
19
110V switch leg for worklight
21
Not used
22
110V supply for system power up
23
110V supply for PLC
Main control switched 110V power for unload
and heaters, manual mode
110V supply for DC power supply
110V supply for CR2 relay (Auto/Manual)
24
25
26
7 - 56
Fault Troubleshooting
31
Control from PLC for CR Unload
32
Control from PLC for Load in manual mode
33
Control from PLC for switched AC for system,
switches terminal #3
36
Rear door signal wire
37
Upper vapor high limit switch
38
Upper housing high limit switch
39
Upper plenum over temperature switch
40
Right grain column over-temperature
41
Left grain column over-temperature
42
Grain discharge chute
43
Upper plenum static air switch
44
Grain paddle switch (Lower)
45
Upper heater flame sense
46
PLC upper fan on input
47
PLC load on input
48
Heater on relay signal to PLC 24V = On
49&19A49L
Motor overload switches
51
PLC, status from I/O board for dryfire
52
PLC, status from I/O board
52A-52C
Manual mode fail to safety circuit
53
Grain paddle switch
54
PLC auto/manual status
55
Modem alarm contact
56
Modem Alarm contact
70
Automatic batch RTD signal wire
71
RTD signal wire lowest fan
72
RTD Signal wire fan pos. #2
73
RTD Signal wire fan pos. #3
7 - 57
Provides control to the PLC for the unload auger;
control is through the CR unload relay, energized
when fault occurs turning off meter rolls
Provides load circuit with PLC controlled 110V
while in manual mode
Provides control for system switched 110V
control, PLC controls switched power due to fault
possibilities
24V present = Door closed, provides voltage at
PLC for rear door status
24V present = Status ok, provides voltage at
PLC for upper vaporizer high temperature status
24V present = status ok, provides voltage at PLC
for upper heater housing high temperature status
24V present = status ok, provides voltage at PLC
for upper plenum high temperature status
24V present = status ok, provides voltage at PLC
for upper plenum high temperature status
24V present = status ok, provides voltage at PLC
for upper plenum high temperature status
24V present = status ok, provides voltage back
to PLC for grain discharge chute status
24V present = status ok, provides voltage back
to PLC for upper static air status
24V present = status grain not empty, lower grain
switch
24V present = status upper heater flame present;
flame detected
24V present = fan on, provides PLC with status
of upper fan operation
24V present = load auger on, provides PLC with
status of load operation (on or off)
24V present = on, Tells the PLC the system is
calling for the heater to turn on
24V present = status ok, provides voltage back
to PLC for overload status
Provides PLC with input for dryfire status (True
or False)
Provides PLC input to the status of the processor
through the I/O board
Old version on dryers prior to 2004, provided
information to the PLC for switch placement
when clearing a fault, see wire 95A – 95C on
2004 dryers.
24V present = Status dryer not full
Provides PLC with current status weather
auto/manual
Modem supplies a signal to 55 and during fault
status 55 and 56 connect, modem receives
signal back through 56. N/O switch
Provides signal to processor for autobatch
temperature drying, 0 – 5 volt DC reference
Provides control panel with 0 – 5 volt DC
reference for plenum temperature indication
Provides control panel with 0 – 5 volt DC
reference for plenum temperature indication
Provides control panel with 0 – 5 volt DC
reference for plenum temperature indication
Fault Troubleshooting
74
RTD Signal wire fan pos. #4
75
RTD Signal wire fan pos. #5
76
RTD Signal wire fan pos. #6
81
80
Pos. power wire for paper roller
Neg. common wire for paper roller
Gray 22ga., serial connection to the printer
from the processor
82
83
Black w/white, 22ga. power supply common
84
Red w/white, 22ga. 5V from power supply
85
Blue, 15V DC supply 22ga.
86
Load 110V supply while in computer mode
87
Unload 110V supply while in computer mode
88
89
Upper fan 110V supply while in computer
mode
Upper heater 110V supply while in computer
mode
91
Meter roll fault from the PLC
92
Right meter roll proximity signal wire
93
Left meter roll proximity signal wire
94
24V unload contactor auxiliary signal
95A-95C
Manual mode fail to safety circuit
95
Common reference on PLC for 24V supply
96
Unload auger proximity signal wire
1A
2A
3A
4A
5A
6A
7A
8A
9A
10A
11A
24V signal to the I/O board for a rear door
fault
24V signal to the I/O board for a grain
discharge chute fault
24V signal to the I/O board for a upper
vaporizer high limit fault
24V signal to the I/O board for a upper heater
housing high limit fault
24V signal to the I/O board for a upper
plenum hi limit fault
24V signal to the I/O board for a right grain
column high limit
24V signal to the I/O board for a left grain
column high limit
24V signal to the I/O board for a motor
overload fault
24V signal to the I/O board for a lower paddle
tilt switch activation
24V signal to the I/O board for a upper paddle
tilt switch activation
24V signal to the I/O board for a 5 second
upper static air timeout fault
7 - 58
Provides control panel with 0 – 5 volt DC
reference for plenum temperature indication
Provides control panel with 0 – 5 volt DC
reference for plenum temperature indication
Provides control panel with 0 – 5 volt DC
reference for plenum temperature indication
Provides 15VDC to the motor for the paper roller
Provides common return for the paper roller
(To J2 on the processor) signal to the printer for
printing
Supply for RTD sensor transmitter (neg.); power
supply common
5V supply, printer and I/O board
Supply for RTD sensor transmitters (pos.); power
supply voltage
Provides 110V to front panel load switch for
computer; I/O relay controlled
Provides 110V to front panel unload switch for
computer; I/O relay controlled
Provides 110V to front panel upper fan switch for
computer; I/O relay controlled
Provides 110V to front panel heater switch for
computer; I/O relay controlled
Provides the processor with signal after there is a
meter roll fault, loss of signal = fault
Provides PLC with square wave oscillating
signal, designating rotation
Provides PLC with square wave oscillating
signal, designating rotation
Provides PLC with signal for unload on/off status;
status = on when unload connected to common
Provides control over status of switches upon
startup. PLC requires switches to off. Stated ‘04
All items referenced to this terminal
Provides PLC with square wave oscillating
signal, designating rotation
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Fault Troubleshooting
12A
13A
14A
15A
16A
1B
2B
3B
4B
5B
6B
7B
D1
D2
24V signal to the I/O board for a 45 second
upper heater timeout fault
24V signal to the I/O board for a 45 minute
grain fault
24V signal to the I/O board for a manual/auto
mode
24V signal to the I/O board for a upper static
air sense switch
24V signal to the I/O board for a upper flame
sense switch
24V signal to the I/O board for a lower flame
sense switch
24V signal to the I/O board for a lower static
air sense switch
24V signal to the I/O board for a lower
vaporizer high limit fault
24V signal to the I/O board for a lower plenum
hi limit fault
24V signal to the I/O board for a lower heater
housing high limit fault
24V signal to the I/O board for a 5 second
lower static air time out fault
24V signal to the I/O board for a 45 second
lower heater timeout fault
Moisture sensor red, 15V moisture sensor
circuit supply
Moisture sensor brown, 15V temperature
sensor circuit supply
D3
Moisture sensor blue, 1.5V to 3.5V
temperature signal to the processor
D4
Moisture sensor black, 0 to 5V moisture signal
to the processor
D5
D6
D7
Moisture sensor white, 8.5V reference voltage
to the processor
Moisture sensor green, ground
Moisture sensor grounding braid (shielded
ground)
102
Lower vapor high limit
103
Lower housing high limit switch
104
Lower plenum over temp. switch
105
Lower plenum static air switch
106
Lower heater flame sense
107
PLC lower fan on input
108
PLC lower heat on input
109
110V lower heater switch leg
110
110V lower fan power on
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Provides signal to the processor through the I/O
board for fault occurrence
Supply voltage for the moisture sensor circuit
Supply voltage for the temperature sensor circuit
Provides the processor with a voltage signal
corresponding to temperature (Older models
used a 0.25 to 0.35V signal)
Provides the processor with a voltage signal
corresponding to moisture (Older models used a
5.5 to 7.5V signal)
Prior to 2004, dryers, this signal was used for a
reference. Later models do NOT use this ref.
Ground
Grounds the shielding for noise purposes
24V = status ok, provides voltage at PLC for
lower vaporizer high temperature status
24V = status ok, provides voltage at PLC for
lower heater housing high temperature
24V = status ok, provides voltage at PLC for
lower plenum high temperature status
24V present = status ok, provides voltage back
to PLC for lower static air status
24V present = status upper heater flame present;
flame detected
24V present = fan on, provides PLC with status
of lower fan operation
24V present = on, tells the PLC the system is
calling for the heater to turn on
110V present; power available for lower heater
pending upon fan on/off
110V present energizes lower fan (pos #2)
contactor
7 - 59
Fault Troubleshooting
111
110V power CR6 relay (lower) heat turn on
safety due to fan failure
112
110V lower heater power on
113
114
Lower heater 110V supply while in computer
mode
Lower fan 110V supply while in computer
mode
120
Lower fan PLC controlled turn on
121
Upper fan PLC controlled turn on
831
832
841
851
Black w/white, 22ga. isolated power supply
common
Black w/white, 22ga. isolated power supply
common
Red w/white, 22ga. 5V supply from the power
supply
Blue, 22ga. 15V supply from the power supply
Pink to
Proc
Moisture sensor signal to processor
Gray to
Proc
Temperature sensor signal to processor
7 - 60
110V present energizes CR3 relay, system calls
for upper heat. Wired to aux. contact or relay to
provide protection due to fan not running while
contactor energized
110V present lower heater circuit will begin firing
sequence
Provides 110V to front panel heater switch for
computer; I/O relay controlled
Provides 110V to front panel lower fan switch for
computer; I/O relay controlled
Allows control over the lower fan by the PLC for
manual mode
Allows control over the upper fan by the PLC for
manual mode
Printer
Printer
Printer
Plenum Temperature Indicator
Provides the processor with a voltage signal
corresponding to moisture (Older models used a
5.5 to 7.5V signal and did not connect directly to
the processor. There was calibration and signal
conditioning done by the I/O board)
Provides the processor with a voltage signal
corresponding to temperature (Older models
used a 0.25 to 0.35V signal and did not connect
directly to the processor. There was calibration
and signal conditioning done by the I/O board)
Fault Troubleshooting
DanCorn Conduit Wiring
7 - 61
Notes
7 - 62
Auxiliary Load and Unload Terminals
Note: Terminals A through F can be used as either
dry contacts or switched 115VAC by using
Terminals 2 (Neutral) and 3 (115VAC)
2
Neutral
3
115VAC
5
7
1ST Aux Load
5 Sec. Delay On
8
9
2ND Aux Load
10 Sec. Delay On
7 - 63
14
15
Aux Unload
18
49
D
Motor Overload
Safety Circuit
16 Pin Header Faults and Inputs From the Dryer
Two Fan Dryer
Header on
Back Side
of Board
From PLC in
Control Box For
Meter Roll
Sensing
To LCD Display
on Front Panel
of Control Box
From Keypad on
Front Panel of
Control Box
LOAD
UNLOAD
FAN1
HEAT1
DRY
FIRE
PLC
RESET
FAN2
Green & Shield
Blue (See Note 1)
HEAT2
24VDC
To Heater2
PLC
To Load
To Fan
From
Switch
Auger Switch
Switch
Reset
PLC
To Fan2 If used
(auto)
(auto)
To Heater
To Unload
Switch (auto)
Switched AC
To PLC
Switch
Auger Switch
If used
from CR3 in
Dry Fire
(auto)
(auto)
(auto)
Control Box
Mode
NOTE1: Original Moisture Sensor
RED Moisture Sensor
BLACK Moisture Sensor
Brown 15 VDC
Red 15 VDC
Temperature
Moisture
White 8.25 VDC
Single Fan Dryer
Black (See Note 1)
I/O Board Map
Moisture Sensor
From Rear of Dryer
6CON Shield Cable
Blue wire = 0.25VDC – 0.35VDC Black = 5.5VDC – 7.5VDC
Blue wire = 0.25VDC – 0.35VDC Black = 0.3VDC – 5.0VDC
Blue wire = 1.00VDC – 5.00VDC Black = 0.3VDC – 5.0VDC
7 - 64
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