Airstream PNEG-339 Clothes Dryer User Manual

AIRSTREAM GRAIN CONDITIONING SYSTEMS
DRYER OPERATION
1 9 9 7
AND SERVICE MANUAL
PNEG-339
1100 SERIES SINGLE FAN
PORTABLE DRYER
MODELS
1
2
1100 SERIES DRYER OPERATION AND SERVICE
TABLE OF CONTENTS
Warranty.......................................................................................................................4
Safety First...................................................................................................................5
Safety Alert Decals.......................................................................................................6
Safety Precautions.......................................................................................................7
Dryer Control Panel Featuring The Electronic Monitoring Control System.......................8
Safety Circuit Shutdown Messages......................................................................13
Dryer Pre Start Checks...............................................................................................14
Pre Season Inspection..........................................................................................14
Dryer Start Up...................................................................................................................18
Continuous Flow And Continuous Batch Start Up Procedure..............................18
Continuous Flow Metering Roll Settings...............................................................19
Continuous Batch Metering Roll And Timer Settings................................................22
1100 Series Dryer Service Guide.....................................................................................23
Seasonal Inspection And Service.........................................................................24
Suggested Lubricants..........................................................................................25
Fan Propellor Removal And Installation...............................................................26
Fan Motor Removal And Installation....................................................................27
Heater Parts Removal And Installation................................................................28
Metering Roll Servicing........................................................................................29
How To Determine A Metering Roll Problem........................................................30
Wiring Diagrams...................................................................................................31
Trouble Analysis Procedure...................................................................................41
Quick Reference Guide........................................................................................46
Notes...................................................................................................................47
3
WARRANTY
THE GSI GROUP, INC. ("GSI") WARRANTS ALL PRODUCTS MANUFACTURED BY GSI TO BE FREE OF
DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDITIONS FOR A PERIOD OF TWENTY-FOUR MONTHS AFTER RETAIL SALE TO THE ORIGINAL END USER OF SUCH PRODUCTS. GSI'S ONLY OBLIGATION IS, AND PURCHASER'S SOLE REMEDY SHALL BE FOR GSI, TO REPAIR OR REPLACE, AT GSI'S OPTION AND EXPENSE, PRODUCTS THAT, IN GSI'S SOLE JUDGMENT,
CONTAIN A MATERIAL DEFECT DUE TO MATERIALS OR WORKMANSHIP. ALL DELIVERY AND SHIPMENT CHARGES TO AND FROM GSI'S FACTORY WILL BE PURCHASER'S RESPONSIBILITY. EXPENSES
INCURRED BY OR ON BEHALF OF THE PURCHASER WITHOUT PRIOR WRITTEN AUTHORIZATION
FROM AN AUTHORIZED EMPLOYEE OF GSI SHALL BE THE SOLE RESPONSIBILITY OF THE PURCHASER.
EXCEPT FOR THE ABOVE STATED EXPRESS LIMITED WARRANTIES, GSI MAKES NO WARRANTY OF
ANY KIND, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN CONNECTION WITH (i) PRODUCT MANUFACTURED OR SOLD BY GSI OR (ii) ANY ADVICE, INSTRUCTION, RECOMMENDATION OR
SUGGESTION PROVIDED BY AN AGENT, REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR
RELATED TO THE CONFIGURATION, INSTALLATION, LAYOUT, SUITABILITY FOR A PARTICULAR PURPOSE, OR DESIGN OF SUCH PRODUCT OR PRODUCTS.
IN NO EVENT SHALL GSI BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING, WITHOUT LIMITATION, LOSS OF ANTICIPATED PROFITS OR BENEFITS.
PURCHASER'S SOLE AND EXCLUSIVE REMEDY SHALL BE LIMITED TO THAT STATED ABOVE, WHICH
SHALL NOT EXCEED THE AMOUNT PAID FOR THE PRODUCT PURCHASED. THIS WARRANTY IS NOT
TRANSFERABLE AND APPLIES ONLY TO THE ORIGINAL PURCHASER. GSI SHALL HAVE NO OBLIGATION OR RESPONSIBILITY FOR ANY REPRESENTATIVE OR WARRANTIES MADE BY OR ON BEHALF
OF ANY DEALER, AGENT OR DISTRIBUTOR OF GSI.
GSI ASSUMES NO RESPONSIBILITY FOR FIELD MODIFICATIONS OR ERECTION DEFECTS WHICH
CREATE STRUCTURAL OR STORAGE QUALITY PROBLEMS. MODIFICATIONS TO THE PRODUCT NOT
SPECIFICALLY COVERED BY THE CONTENTS OF THIS MANUAL WILL NULLIFY ANY PRODUCT WARRANTY THAT MIGHT HAVE BEEN OTHERWISE AVAILABLE.
THE FOREGOING WARRANTY SHALL NOT COVER PRODUCTS OR PARTS WHICH HAVE BEEN
DAMAGED BY NEGLIGENT USE, MISUSE, ALTERATION OR ACCIDENT. THIS WARRANTY COVERS
ONLY PRODUCTS MANUFACTURED BY GSI. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL
OTHER WARRANTIES EXPRESS OR IMPLIED. GSI RESERVES THE RIGHT TO MAKE DESIGN OR SPECIFICATION CHANGES AT ANY TIME.
PRIOR TO INSTALLATION, PURCHASER HAS THE RESPONSIBILITY TO RESEARCH AND COMPLY WITH ALL FEDERAL, STATE AND LOCAL CODES WHICH MAY APPLY TO THE LOCATION AND
INSTALLATION.
4
ROOF WARNING, OPERATION & SAFETY
ROOF DAMAGE WARNING AND DISCLAIMER
GSI DOES NOT WARRANT ANY ROOF DAMAGE CAUSED
BY EXCESSIVE VACUUM OR INTERNAL PRESSURE FROM
FANS OR OTHER AIR MOVING SYSTEMS. ADEQUATE
VENTILATION AND/OR "MAKEUP AIR" DEVICES SHOULD
BE PROVIDED FOR ALL POWERED AIR HANDLING SYSTEMS. GSI DOES NOT RECOMMEND THE USE OF DOWNWARD FLOW SYSTEMS (SUCTION). SEVERE ROOF DAMAGE CAN RESULT FROM ANY BLOCKAGE OF AIR PASSAGES. RUNNING FANS DURING HIGH HUMIDITY/COLD
WEATHER CONDITIONS CAN CAUSE AIR EXHAUST OR
INTAKE PORTS TO FREEZE.
DRYER OPERATION
Thank you for choosing a GSI/
volt, or three phase 220 or 440
Airstream product. It is designed
volt electrical power.
As owner and/or operator, it is
your responsibility to know what
The principal concern of the GSI
requirements, hazards and pre-
Group, Inc. ("GSI") is your safety and
cautions exist, and to inform all
This manual describes the
the safety of others associated with
personnel associated with the
operation and service for all stan-
grain handling equipment. This
equipment, or who are in the dryer
dard 1100 Series one fan grain
manual is written to help you under-
area. Avoid any alterations to the
dryers. These models are avail-
stand safe operating procedures,
equipment. Such alterations may
able for liquid propane or natu-
and some of the problems that may
produce a very dangerous situa-
ral gas fuel supply, with either
be encountered by the operator or
tion, where serious injury or death
single phase 230
other personnel.
may occur.
to give excellent performance
and service for many years.
SAFETY ALERT SYMBOL
The symbol shown is used to call
your attention to instructions con-
WARNING! BE ALERT!
cerning your personal safety. Watch
Personnel operating or working around
for this symbol; it points out impor-
electric fans should read this manual.
tant safety precautions. It means
This manual must be delivered with the
"ATTENTION", "WARNING", "CAU-
equipment to its owner. Failure to read
TION", and "DANGER". Read the
this manual and its safety instructions is
message and be cautious to the
a misuse of the equipment.
possibility of personal injury or
death.
5
SAFETY ALERT DECALS
Three decals displayed on all Airstream Dryers. Belt drives, chain driven meter rolls
and combustible fuels must be treated with caution.
6
SAFETY PRECAUTIONS
1. Read and understand the operating manual before trying to operate the
dryer.
2. Never operate the dryer while the guards are removed.
3. Power supply should be OFF for service of electrical components.
Use CAUTION in checking voltage or other procedures requiring power
to be ON.
USE CAUTION
IN THE OPERATION
OF THIS EQUIPMENT
The design and manufacture of this
dryer is directed toward operator
safety. However, the very nature of
a grain dryer having a gas burner,
high voltage electrical equipment
4. Check for gas leaks at all gas pipe connections. If any leaks are
detected, do not operate dryer. Shut down and repair before further operation.
and high speed rotating parts, does
present a hazard to personnel,
which can not be completely safeguarded against, without interfering
5. Never attempt to operate the dryer by jumping or otherwise bypassing
any safety devices on the unit.
with efficient operation and reasonable access to components.
Use extreme caution in working
6. Set pressure regulator to avoid excessive gas pressure applied to
burner during ignition and when burner is in operation. See chart for
operating procedures. Do not exceed maximum recommended drying temperature.
7. Keep the dryer clean. Do not allow fine material to accumulate in
the plenum chamber.
around high speed fans, gas-fired
heaters, augers and auxiliary conveyors, which may start without
warning when the dryer is operating
on automatic control.
KEEP THE DRYER CLEAN
8. Keep auger drive belts tight enough to prevent slippage.
9. Use CAUTION in working around high speed fans, gas burners,
augers and auxiliary conveyors which START AUTOMATICALLY.
DO NOT ALLOW FINE
MATERIAL TO ACCUMULATE
IN THE PLENUM CHAMBER
OR SURROUNDING THE
10. Do not operate in any area where combustible material will be drawn into
the fan.
11. Before attempting to remove and reinstall any propellor, make certain
to read the recommended procedure listed within the servicing section
of the manual.
OUTSIDE OF THE DRYER
Continued safe, dependable operation of automatic equipment depends, to a great degree, upon the
owner. For a safe and dependable
12. Be certain that capacities of auxiliary conveyors are matched to dryer
auger capacities.
drying system, follow the recommendations within this manual, and
make it a practice to regularly in-
13. Clean grain is easier to dry. Fine material increases resistance to airflow
and requires removal of extra moisture.
READ THESE INSTRUCTIONS
BEFORE OPERATION AND SERVICE
spect the operation of the unit for any
developing problems or unsafe conditions.
Take special note of the safety
precautions listed above before at-
SAVE FOR FUTURE REFERENCE
tempting to operate the dryer.
7
DRYER CONTROL PANEL
Figure 1: The grain dryer control panel with the Electronic Monitoring Control System in the upper right panel.
DRYER CONTROL PANEL FEATURING
THE ELECTRONIC MONITORING CONTROL SYSTEM
The control panel provides easy ac-
information about dryer operation.
cess to gauges and controls, and the
ILLUMINATED SWITCHES are a
MOISTURE CONTROL
THERMOSTAT (1)
This switch turns the power ON or
quick reference for every operating
This electronic thermostat con-
OFF to the moisture control ther-
function. The patent pending Elec-
trols the moisture level of dis-
mostat. It lights up when the grain
tronic Monitoring Control System
charged grain by sensing grain
column temperature is below the
is computerized and gives instant
column temperature.
thermostat set point.
8
MOISTURE CONTROL
SWITCH (2)
DRYER CONTROL PANEL
FAN SWITCH (7)
CONTROL POWER
SWITCH (3)
The fan is turned ON or OFF with
MOISTURE CONTROL switch is
The power to the Electronic Moni-
this switch. The ON position oper-
ON, and the DRYING MODE
toring Control System is turned
ates the fan continuously during
switch is turned to CONTINUOUS
ON or OFF with this switch.
STAGED BATCH and CONTINU-
FLOW, the METERING ROLL
• In the 1 SPEED position, if the
OUS FLOW modes. The AUTO po-
SPEED will operate at the HIGH
OUTSIDE LIGHT (4)
sition operates the fan in STAGED
speed metering roll potentiometer
The dryer service light is turned
BATCH during the dry and cool
setting or turn OFF depending on
ON or OFF here. It also may be
cycle. The switch will light up when-
the control signal from the MOIS-
set on AUTO, which turns the light
ever the airflow switch is sensing
TURE CONTROL THERMO-
on while the dryer is running, and
airflow and the dryer is full of grain.
STAT. The discharge auger will
operate whenever the metering
off if a shutdown occurs.
HEATER SWITCH (8)
rolls are operating.
DRYING MODE SWITCH (5)
This switch is used to turn the
This is used to select STAGED
burner ON or OFF. The AUTO po-
• In both the 1 SPEED or the 2
BATCH or CONTINUOUS FLOW
sition operates the burner in
SPEED position, if the MOIS-
drying. The switch will light only af-
STAGED BATCH during the dry
TURE CONTROL THERMOSTAT
ter the Electronic Monitoring Con-
cycle. The ON position will operate
is OFF, and the DRYING MODE
trol System has been turned ON,
the burner only when the fan is run-
switch is turned to CONTINUOUS
the safety circuit is okay and the
ning. The switch will light up when
FLOW, the METERING ROLL
RESET button has been pressed.
the flame sensor detects the flame.
SPEED can be manually controlled by adjusting the HIGH
LOAD AUGER SWITCH (6)
UNLOAD SWITCH (9)
speed metering roll potentiometer.
This is used to select the opera-
The UNLOAD switch turns the me-
The discharge auger will operate
tion of the load auger. In both the
tering rolls and discharge auger
continuously.
AUTO and MANUAL position the
ON or OFF, and selects the opera-
load auger will operate if the dryer
tion of the metering rolls.
turned to STAGED BATCH, the
is low on grain, and will automatically shut off when the dryer is full.
• If the DRYING MODE switch is
• In the 2 SPEED position if the
UNLOAD switch should be set to
In the AUTO position only, the
MOISTURE CONTROL switch is
the 1 SPEED position. The dis-
dryer will shut down after a prede-
ON, and the DRYING MODE
charge auger and metering rolls
termined period of time set on the
switch is turned to CONTINUOUS
will only operate during the unload
OUT OF GRAIN TIMER, or if grain
FLOW, the METERING ROLL
cycle of the staged batch opera-
flow is interrupted to the dryer. The
SPEED will alternate between the
tion, and the METERING ROLL
switch will light whenever the load
HIGH speed metering roll potenti-
SPEED is adjusted using the
auger is operating.
ometer setting and the LOW
HIGH speed metering roll potenti-
speed metering roll potentiometer
ometer.
Note: When this switch is set
Note: When this switch is set to
to AUTO or MANUAL it also con-
setting depending on the control
trols the operation of any auxiliary
signal from the MOISTURE CON-
AUTO or MANUAL it also controls
load equipment being utilized,
TROL THERMOSTAT. The dis-
the operation of any auxiliary load
such as an auxiliary auger or con-
charge auger will operate con-
equipment being utilized, such as
veyor.
tinuously.
an auxiliary auger or conveyor.
9
DRYER CONTROL PANEL
LOW SPEED METERING
ROLL POTENTIOMETER (10)
This is used to adjust the LOW
matic moisture control feature of
nents can be operated by turning the
the dryer is utilized.
DRYING MODE switch to CON-
• Set the speed of the metering
TINUOUS FLOW, pressing the
speed of the metering roll when the
rolls during continuous flow op-
DRYER POWER START button and
2 SPEED and MOISTURE CON-
eration when the moisture control
then turning ON the desired dryer
TROL THERMOSTAT are in use.
is not used.
component.
• Set the rate of grain discharge from
HIGH SPEED METERING
ROLL POTENTIOMETER (11)
the dryer during the unload cycle of
staged batch dryer operation.
This is used to:
• Set the HIGH speed of the meter-
DRYER POWER
STOP SWITCH (13)
This switch stops all dryer functions. If an automatic dryer shut-
ing roll when the 2 SPEED auto-
DRYER POWER
START SWITCH (12)
matic moisture control feature of
This switch starts and operates the
correct the cause of the shutdown.
the dryer is utilized.
dryer based on switch settings. If
Then, press the DRYER POWER
• Set the speed of the metering
other switch settings are in the OFF
STOP button to reset the dryer be-
rolls when the 1 SPEED auto-
position, individual dryer compo-
fore restarting.
The Airstream Dryer Control Panel.
10
down occurs, first determine and
DRYER CONTROL PANEL
ELECTRONIC
MONITORING CONTROL
SYSTEM (14)
SETTING THE DRY (16),
COOL (17) AND UNLOAD
(18) BATCH TIMERS
if the dryer is stopped, these times
The Electronic Monitoring Control
These switches are used to set the
will continue timing down. The TIM-
System (Figure 2) controls all tim-
cycle times in the STAGED BATCH
ERS will return to their initial settings
ing functions and safety circuit
DRYING MODE only. The DRYING
by pressing the RESET button.
checks. It is designed to simplify
MODE switch must be in the
dryer operation by providing printed
STAGED BATCH position. The cur-
messages and warnings on its liq-
rent settings on these three TIMERS
SETTING THE OUT OF
GRAIN TIMER (19)
uid crystal display (LCD).
are displayed directly above each
If the dryer runs out of grain while
TIMER button. To change the set-
the LOAD AUGER switch is in the
ting of these TIMERS follow these
AUTO position, the OUT OF GRAIN
instructions:
TIMER automatically shuts OFF the
1. Press the DRY, COOL or UN-
dryer after the period of time preset
TURNING ON THE
ELECTRONIC
MONITORING CONTROL
SYSTEM USING THE
RESET BUTTON (15)
are saved by the controller. When
the dryer is restarted the TIMERS
LOAD TIMER button.
on the TIMER. When pressed, the
2. Press the MODIFY button.
display will show the amount of time
Turn the CONTROL POWER switch
3. Press the INCREASE or DE-
left on the TIMER and the percent-
to ON. The monitor will display a
CREASE button to adjust the
age of time the last load expended.
copyright message and model num-
settings.
A second screen will appear show-
ber, total running time in hours and
4. Press the ENTER button.
ing the TIMER'S setting and will al-
minutes and the current time and
During operation the remaining
low the operator to modify it as de-
date. To activate the controller press
time on each TIMER is displayed on
scribed for setting the BATCH TIM-
the RESET button.
the screen. If the power goes out or
ERS.
Figure 2: The Airtream Electronic Monitoring Control System
11
DRYER CONTROL PANEL
The Airstream Electronic Monitoring Control System showing different LCD displays.
SETTING THE LOAD (20)
AND UNLOAD (21) DELAYS
on the third line. By pressing the
DRYER SAFETY CIRCUIT
BPH/RPM/TOTAL BU button the
The Electronic Monitoring Control
The LOAD DELAY is used to delay
second line will alternate between
System continuously checks all
the starting of the load auger when
the METERING ROLL RPM's or the
safety circuits on the dryer, and will
the dryer is unloading to prevent the
BUSHEL PER HOUR rate. The TO-
automatically shut the dryer down
load auger from starting and stop-
TAL BUSHELS DRIED reading is
should a problem occur. The cause
ping. The UNLOAD DELAY is used
the total since the bushel counter
of the dryer shutdown will be dis-
to control the amount of time the un-
was last reset.
To reset the
played on the LCD display, and a
load auger runs after the metering
BUSHEL COUNTER, press and
beeper will sound on the controller.
rolls stop to allow for auger
hold the RESET button for five sec-
To restart the dryer after a safety
cleanout. Both the LOAD and UN-
onds. Press the ENTER button
shutdown, first correct the reason for
LOAD DELAYS are set using the
through the date and time settings
the shutdown, and then press the
same procedure as the TIMERS.
and then follow the instructions dis-
DRYER POWER STOP button to re-
The AUX1 and AUX 2 DELAYS are
played on the LCD for resetting the
set the circuit. Press the START
presently not being used.
counter.
button.
In the STAGED BATCH DRY-
The Electronic Monitoring
UTILIZING THE
BUSHEL COUNTER (22)
ING MODE the first line of the LCD
Control System stores in its
display tells which TIMER is being
memory the time, date and cause for
When operating the dryer the LCD
used, and the second line switches
the last 25 dryer safety shutdowns.
display will show the DRYER MODE
between TOTAL BATCHES, UN-
To review this information hold the
OF OPERATION on the first line, the
LOAD RPM or TOTAL BUSHELS.
RESET button in for five seconds.
BUSHELS PER HOUR or the ME-
The third line indicates TOTAL DRY
The procedure for reviewing the
TERING ROLL RPM on the second
TIME and the fourth line is TIME
safety circuit shutdown log will be
line and the TOTAL BUSHELS dried
REMAINING on the TIMERS.
displayed on the LCD display.
12
DRYER CONTROL PANEL
SAFETY CIRCUIT SHUTDOWN MESSAGES
BURNER VAPOR HIGH
TEMPERATURE
The LP gas vapor temperature sen-
LOWER ADJUSTABLE
GRAIN HIGH
TEMPERATURE
METERING ROLL DRIVE
SYSTEM FAILURE
The metering roll drive system has
sor located in the gas pipe train
An over temperature condition has
failed to turn. A broken chain or
downstream from the vaporizer, has
occurred in the right side (left and
jammed metering roll is a possibility.
opened indicating that the vaporizor
right as viewed from behind the
is running too hot and must be re-
dryer) grain column causing the
RIGHT METERING ROLL
FAILURE
adjusted. This sensor is set at 200°F
control to shut down the dryer. This
The right (as viewed from behind the
and automatically resets itself when
control is set at 210°F and automati-
dryer) metering roll has stopped turn-
cool.
cally resets itself when cool.
ing, or the sensor has been damaged.
BURNER WARNING FLAME
NOT DETECTED
LOWER FIXED GRAIN
HIGH TEMPERATURE
LEFT METERING ROLL
FAILURE
The flame sensor has failed to de-
An over temperature condition has
The left (as viewed from behind the
tect a burner flame indicating that the
occurred in the left side (left and
dryer) metering roll has stopped turn-
burner has failed to light, there is a
right as viewed from behind the
ing, or the sensor has been damaged.
problem with the flame sensing cir-
dryer) grain column causing the
cuitry or the dryer is not getting
control to shutdown the dryer. This
12 VOLT POWER
SUPPLY WARNING
burner fuel.
control is set at 210°F and automati-
The right circuit breaker on the in-
cally resets itself when cool.
put/output board has tripped.
FAN HOUSING HIGH
TEMPERATURE
The temperature high limit located
on the fan/burner housing has
opened, indicating an over temperature condition has occurred towards
the rear of the fan/heater housing.
MOTOR OVERLOAD
One of the thermal overloads on
either the fan, load, unload or auxiliary motors has opened, indicating an overcurrent condition. The
overloads must be manually reset.
This control is set at 200°F and must
be manually reset.
AUXILIARY SAFETY
SHUTDOWN
A shutdown has occurred due to an
auxiliary installed safety feature.
BURNER SHUTDOWN
LOSS OF AIRFLOW
The contacts in the air switch have
OUT OF GRAIN
WARNING/UNLOAD
CLEANOUT
opened due to insufficient airflow for
the burner to operate.
GRAIN DISCHARGE
WARNING
The dryer has run low on grain, and
The lid on the grain discharge box
the OUT OF GRAIN TIMER has
FAN FAILURE
NO AIRFLOW
has opened, indicating that grain is
timed out, shutting the dryer down.
The contacts in the air switch have
not being taken away fast enough
The unload auger will clean out the
opened due to the fan not turning, or
at the discharge box.
dryer if in continuous flow operation.
the air switch may need adjustment.
The left circuit breaker located on
PLENUM HIGH
TEMPERATURE
FAN CANNOT START
CHECK AIR SWITCH
the input/output board of the Elec-
An over temperature condition has
The air switch contacts have closed
tronic Monitoring Control System
occurred inside the dryer plenum.
prior to the fan starting, indicating a
has tripped, or one of the hardware
This control is a 300°F limit and au-
freewheeling blade or improper set-
timers has shut down the dryer.
tomatically resets itself when cool.
ting of the air switch.
L1 VOLTAGE LOST
13
DRYER PRE START CHECKS
PRE SEASON INSPECTION
Before the dryer is filled, thoroughly
inspect the unit and check the operation of the dryer as follows.
INSPECT THE METERING
ROLLS
Open all metering roll access
doors and inspect each compartment for any bolts, nuts or other foreign material, that may cause possible jamming of the metering rolls.
BEFORE ATTEMPTING TO
OPERATE THE DRYER MAKE
The Maxon safety shut off valve.
SURE ALL SAFETY SHIELDS
ARE IN PLACE, ALL BOTTOM
CLEANOUT AND REAR
ELECTRICAL POWER
POWER START BUTTON
Turn ON the electrical power sup-
Push the DRYER START button,
ply to the dryer, set all circuit break-
and all the selector switches on the
ACCESS DOORS ARE CLOSED
ers to ON, including the safety dis-
control panel will be activated.
AND ALL PERSONNEL ARE
connect handle mounted on front
CLEAR OF THE DRYER
of the dryer's power panel.
FUEL CHECK
CONTROL POWER
SWITCH
If using LP gas, make sure the tank
Moisture Control Switch-ON
Turn the CONTROL POWER switch
does not have a regulator mounted
Moisture Control Thermostat-MAXI-
to ON. The switch will light up. A
to it. If using natural gas, make sure
copyright message, model number,
an adequate supply is available.
SET CONTROL SWITCHES
MUM TEMPERATURE
has plenty of fuel and that the tank
If using LP gas, slowly OPEN
Load Switch-OFF
total running time in hours and min-
Unload Switch-OFF
utes, current date and time will ap-
the main fuel supply valve at the
Fan Switch-OFF
pear. At this point the controller will
tank. If using natural, gas turn ON
Burner Switch-OFF
lock out all other dryer functions.
the valve along the supply line.
Out of Grain Timer-8 MINUTE
Once the date and time appear,
Then, OPEN the electronic shut off
Load Delay-30 SECONDS
press RESET and the dryer will per-
valve (Maxon valve), if so equipped,
Unload Delay-30 SECONDS
form its safety circuit check. If a fault
or OPEN the manual shut off valve
Metering Roll Speed-LOW AND
is found, the cause will be displayed
on the dryer to allow fuel flow to the
HIGH SPEED SETTINGS PUT
on the LCD. If all are found safe, the
dryer. Inspect all gas lines and con-
ON ZERO
controller will supply power to the
nections for possible leaks.
Dry Timer-60 MINUTE
electronic fuel shut- off valve (if
Cool timer-20 MINUTE
so equipped) and the DRYING
Unload timer-10 SECONDS
MODE switch will light up, indicating
Mode Switch-CONTINUOUS FLOW
that the dryer is ready to be started.
14
Any gas leaks need to be
fixed immediately!
DRYER PRE START CHECKS
gear box. If the dry grain take away
auxiliary is wired to the dryer, it
should start and rotate in the proper
direction.
MOISTURE CONTROL
THERMOSTAT
To check the MOISTURE CONTROL THERMOSTAT leave the
UNLOADING switch on 1 SPEED,
and slowly turn down the MOISTURE CONTROL THERMOSTAT.
As the setting is decreased, the indicator light should come on and the
metering rolls should stop operating. The bottom auger will stop after the 30 second clean out delay,
providing that the dryer is still being
held by the MOISTURE CONTROL
THERMOSTAT. Rotate the MOISTURE CONTROL THERMOSTAT
up to its maximum setting. The light
should go off, and the metering
rolls should restart along with the
bottom auger if it has stopped.
The metering roll access area.
To check 2 SPEED operation
move the switch to the 2 SPEED po-
LOAD AUGER
message (out of grain warning) dis-
sition, set LOW speed on 200 and
With the grain supply SHUT OFF,
played. Press the DRYER POWER
HIGH speed on 600. Slowly turn the
quickly bump the LOAD AUGER
STOP button to reset the panel, then
thermostat until the MOISTURE
switch to MANUAL, and see if the
press the START button.
CONTROL switch light comes ON.
load auger rotates clockwise as
The METERING ROLL SPEED is
viewed from the drive end, or coun-
ONE SPEED OPERATION
now controlled by the LOW speed
terclockwise if the dryer is a front
To check 1 speed operation place
dial. Turning the THERMOSTAT the
load model. If the wet grain supply
the UNLOAD switch in the 1 SPEED
other way until the light goes out now
auxiliary is wired to the dryer it
setting. Turn up the HIGH SPEED
leaves the metering rolls controlled
should also rotate in the correct di-
METERING ROLL DIAL until the
by the HIGH SPEED DIAL.
rection at this time. Turn the LOAD
metering rolls start rotating. The
AUGER switch to the AUTO posi-
bottom auger should rotate coun-
tion. The top auger and wet grain
terclockwise as viewed from the
METERING ROLL
OPERATION
supply auxiliary should run for one
drive end. The metering roll drive
To check the metering roll operation
minute, and then the dryer will shut
motor should rotate clockwise as
turn either the LOW speed or HIGH
down leaving the safety shutdown
viewed from the drive end of the
speed knob clockwise, and the ME15
DRYER PRE START CHECKS
TERING ROLL SPEED should in-
ignite after a short purge delay of ap-
fire and low-fire pressure settings.
crease. Turning either knob coun-
proximately 10 seconds. Gas pres-
Use the PRESSURE REGULATOR
terclockwise will decrease the
sure should be shown on the gauge.
for high-fire and the BALL VALVE
speed. Make sure the drive chain
At this time adjust the BURNER
for low-fire. The thermostat should
tension is properly adjusted and all
HIGH-LOW FIRE THERMOSTAT to
cycle between high and low, ap-
sections of the metering rolls ro-
200°F, causing the burner to oper-
proximately 4 to 5 times per minute.
tate. Turn the UNLOAD switch OFF
ate on high-fire. The thermostat is
Approximate settings should be:
after these checks are complete.
located on the front left side of the
The bottom auger will continue to
dryer. Observe the gas pressure on
run for 30 seconds after the switch
gauge, and turn the thermostat to
is turned OFF to allow for cleanout.
its MINIMUM SETTING, causing the
LP Gas
High-Fire 6-15 lbs.
Low-Fire 2-6 lbs.
Natural Gas
High-Fire 6-10 lbs.
Low-Fire 1-3 lbs.
burner to cycle into low-fire. As the
If the burner remains on high-
FAN SWITCH
burner thermostat is turned down
fire and does not cycle, INCREASE
Bump the FAN switch and observe
the gas pressure should also show
the regulator setting on the propane
the fan rotation. The fan should run
a noticeable drop, indicating that the
models, or the supply valve on the
counterclockwise. Sometimes on
high-fire solenoid is closed and the
natural gas models in order to reach
three phase models all motors will
burner is being supplied with less
the thermostat setting. If the
run backwards. They can easily be
gas through the low-fire control
burner remains in low-fire and does
reversed by interchanging the two
valve. At this time set the high-
not cycle, slightly DECREASE gas
of three power supply wires. Reverse the two outside wires, L1 and
L3, and leave the middle one in the
same position.
Note: If the dryer is empty, the
burner will not operate. The fans
7
cannot create enough static pressure to engage the air switch. You
5
will receive a loss of airflow message.
3
BURNER SAFETY
To check the burner safety function,
first make sure the main GAS
VALVE is OFF. Turn the FAN switch
ON and allow the fan to start. Then,
turn the HEATER switch ON. The
dryer will shut down after 20 seconds.
The safety message, "Burner 1 warn-
4
2
1
8
6
ing flame not detected" will appear.
BURNER TEST FIRE
START the fan, and then turn the
HEATER switch to ON. Turn ON the
fuel supply, and the burner should
16
The dryer fan and heater controls featuring: 1-pressure regulator, 2-low-fire
control valve, 3-high pressure solenoid, 4-low pressure solenoid, 5-highlow fire thermostat (assembly includes thermometer), 6-fuel supply line, 7LP solenoid or supply ball valve(NG) and 8-air pressure switch.
DRYER PRE START CHECKS
All dryer functions should be checked before operation each season.
pressure with the LOW-FIRE CON-
VALVE to allow fuel flow to the
DRYER SHUTDOWN
TROL VALVE. If the gas pressure
dryer, if so equipped. Turn the
To shutdown the dryer, first CLOSE
is decreased too much a popping or
LOAD switch to AUTO and UN-
the FUEL SUPPLY VALVE at the
fluttering sound will be heard. Also,
LOAD switch to 1 SPEED. Push
tank or valve along the fuel line. If
anytime the high pressure side is
the DRYER POWER START but-
the burner is operating, let the dryer
adjusted the low pressure side
ton and the controller will sequen-
run out of fuel, and it will shutdown
needs to be checked.
tially start all dryer components in
automatically due to loss of flame.
their proper order. If any switches
CLOSE the FUEL VALVE at the
STAGED BATCH CHECK
are not in their correct position for
dryer, and press the DRYER
To check the staged batch opera-
staged batch operation, the dryer
POWER STOP button. Turn OFF
tion, turn the CONTROL POWER
will indicate improper switch posi-
the safety disconnect handle on
switch to the ON position. Press the
tion, and will not start until the
the front of the power box, and turn
RESET button, OPEN the main
switches are in the proper position.
OFF the main POWER to the dryer.
FUEL SUPPLY VALVE at the tank
After starting, all batch timers will
on an LP dryer or valve in the fuel
time down in sequence. When the
EMERGENCY
supply line on a natural gas dryer.
unload cycle is complete the tim-
In case of emergency push the dryer
Turn the DRYING MODE switch to
ers will automatically reset to their
POWER STOP button. The fan,
the STAGED BATCH position.Turn
original settings, and start the dry
burner and all augers will stop im-
ON the electric SHUT OFF
timer again.
mediately.
17
DRYER START UP
CONTINUOUS FLOW AND CONTINUOUS BATCH START UP PROCEDURE
At the beginning of each harvest and
be displayed on the LCD. If all
Turn ON the electric SHUTOFF,
before filling the dryer with grain
are found safe the controller will
Maxon valve (if so equipped), or
make sure to inspect the dryer for
allow the electronic FUEL SHUT
OPEN the manual SHUTOFF
rodent damage, proper belt and
OFF valve to be manually
valve to allow fuel flow to the
chain tension and missing or dam-
OPENED (if so equipped), and
dryer.
aged safety shields. Test operate
the DRYING MODE switch will
the dryer using the prestart check
light up, indicating that the dryer
procedures located on pages 14-17.
is ready to be started.
5. Turn the DRYING MODE switch
to CONTINUOUS FLOW.
1. Before attempting to operate the
5. Move the LOAD AUGER switch
6. The dryer should already be
dryer make sure that all safety
to MANUAL, and push the dryer
filled with grain. Turn the
shields are in place, all plenum
POWER START switch. The
LOAD AUGER switch to the
bottom closure panel doors
top auger will immediately start,
AUTO position. In both the auto
are closed, all rear access
and the LOAD AUGER switch
and manual positions the dryer
doors are closed and all per-
will light up. If additional grain
grain level switch will automati-
sonnel are clear of the grain
handling equipment is wired to
cally keep the dryer full of grain.
dryer and grain handling ma-
the dryer it will also start imme-
In the auto position the dryer will
chinery.
diately.
shut down after a preset time
period on the out of grain timer.
2. Turn all SELECTOR switches
6. When the dryer is full of grain
on the control panel to the OFF
the top auger will stop auto-
7. Turn the FAN switch to ON. The
position.
matically, and any grain han-
fan will start, and the switch will
dling equipment wired to the
light up when airflow is detected.
3. Turn ON the electric POWER
dryer will also stop.
supply to the dryer, and move
the safety disconnect handle
mounted on the dryer's upper
power box to ON.
8. Start the burner by turning the
CONTINUOUS FLOW
OPERATION
1. Turn the CONTROL POWER
switch to ON.
4. Turn the CONTROL POWER
switch to ON. The switch will
purging for approximately 10
seconds the burner will fire, and
the heater switch will light up.
This indicates that the flame
2. After the date and time appear
sensing circuit is sensing burner
light up. A copyright message,
on screen, press the RESET
flame. For information concern-
model number, total running
button.
ing burner adjustment see the
time in hours and minutes, current date and time will appear.
At this point the controller will
pre start section of this manual.
3. Push the dryer POWER START
switch.
lock out all other dryer functions.
Once the date and time appear,
18
HEATER switch to ON. After
9. Operate the heaters to dry grain
for 6-7 minutes per point of
4. OPEN the main FUEL SUPPLY
moisture to be removed with the
press RESET, and the dryer will
VALVE on the tank if using LP
plenum temperature set at
perform its safety circuit checks.
gas, or OPEN the FUEL SUP
180°F. Example: Shelled corn
If a fault is found the cause will
PLY LINE if using natural gas.
starts with 25% moisture and
DRYER START UP
the final moisture content is to
13. To shut the dryer down, CLOSE
gas or the valve in the FUEL
be 15% (10% removal). Using
the FUEL SUPPLY VALVE at
SUPPLY LINE if using natural
the all heat dryeration process,
the fuel tank or fuel source. Let
gas. Turn ON the ELECTRIC
the estimated drying time is 60
the dryer run until the fuel sup-
SHUT OFF, Maxon valve (if so
minutes (10 x 6).
ply lines drain, and the dryer
equipped), or OPEN the manual
automatically shuts down due to
SHUT OFF valve to allow fuel
loss of flame. CLOSE the FUEL
flow to the dryer.
10. While operating the dryer adjust
the METERING ROLL dials to
valve at the dryer. Press the
the recommended settings. See
DRYER POWER STOP button.
the chart on page 00.
Turn OFF the dryer's SAFETY
filled with grain. Turn the LOAD
DISCONNECT handle. Turn
AUGER switch to AUTO. In both
OFF the MAIN POWER supply
the auto and manual position,
to the dryer.
the grain level switch will auto-
11. To move grain through the dryer
turn the MOISTURE CONTROL
switch to ON. The switch will
light up.
5. The dryer should already be
matically keep the dryer full of
14. In case of emergency push the
grain. In the auto position, the
Note: When the UNLOAD switch is
dryer STOP button. The fan,
dryer will shut down after the
in the 2 SPEED position, and the
burner and all augers will stop
preset time period on the OUT
MOISTURE CONTROL THERMO-
immediately.
OF GRAIN TIMER, or if the
STAT switch is OFF, the speed of
Note: The Electronic Monitoring
grain flow to the dryer is inter-
the metering rolls can be manually
Control System can be used to au-
rupted.
adjusted by turning the HIGH
tomatically start the dryer. Place all
SPEED METERING ROLL dial.
the control panel SELECTOR
6. Turn the FAN switch to AUTO.
Turning the dial clockwise will IN-
switches in the PROPER POSI-
The fan will start, and the switch
CREASE the grain discharge rate,
TION, and OPEN the electric FUEL
will light up when airflow is de-
counterclockwise will DECREASE
SHUT OFF valve before PRESSING
tected.
the discharge rate. (The numbers on
the DRYER POWER START button.
the speed dials indicate the percent-
The controller will start all dryer com-
age of full speed.)
ponents in their proper order.
7. Start the burner by turning the
HEATER switch to AUTO. After purging for approximately
12. At the end of the start-up period, start the flow of grain out
of the dryer. Turn the UNLOAD
switch to the 2 SPEED posi-
STAGED BATCH
OPERATION
1. Turn the CONTROL POWER
switch to ON.
tion. The bottom auger and
10 seconds the burner will fire,
and the heater switch will light
up indicating that the flame
sensing circuit is sensing
burner flame. For information
metering roll will immediately
2. Make sure the DRYING MODE
concerning burner adjustment
start, and the unload switch will
switch is turned to STAGED BATCH.
see the pre start section of this
light. If additional grain han-
manual.
dling equipment is utilizing the
3. After the date and time appear,
unload auxiliary overload sup-
PRESS the RESET button.
plied with the dryer, this equipment will also immediately
start.
8. To properly set the correct dry,
cool and unload time for various
4. OPEN the main FUEL SUPPLY
VALVE on the tank if using LP
moisture content grains. See the
chart on page 00.
19
DRYER START UP
9. If the dryer is being operated in
start automatically during the
button. The controller will start
all heat, turn the FAN switch to
unload cycle of the dry-cool-
all the dryer components in their
ON. In this position the fan will
unload mode, along with any
proper order. If any of the se-
run continuously during the dry,
grain handling equipment that
lected switches are improperly
cool and unload stages of the
is wired to the dryer. The
positioned for staged batch dry-
staged batch operation. If the
speed at which the metering
ing, the display will indicate the
dryer is being operated in the
rolls operate during the unload
proper switch position, and will
dry and cool mode, the preferred
cycle is adjusted by using the
not allow the dryer to operate
position for the FAN switch is the
HIGH SPEED METERING roll
until the position of the switch is
ON position, so the fan will run
dial. Turning the dial clockwise
corrected.
continuously. If desired, the fan
will INCREASE the grain dis-
can be turned off during the un-
charge rate, and counterclock
14. To shutdown the dryer, CLOSE
load cycle of the dry-cool-unload
wise will DECREASE the dis-
the FUEL SUPPLY valve at the
sequence by turning the FAN
charge rate.
fuel tank or fuel source. If the
switch to AUTO.
burner is operating, let the dryer
12. To control the length of the dry
run out of fuel causing an auto-
10. If the dryer is being operated in
cycle using only the dry time
matic shutdown due to a loss of
all heat, turn the HEATER
setting programmed into the
flame. CLOSE the FUEL VALVE
switch to ON. The burner will
system, turn the MOISTURE
at the dryer, and press the dryer
operate whenever the fan is
CONTROL setting to OFF. To
POWER STOP button. Turn
operating. If the dryer is being
use the automatic moisture con-
OFF the dryer's main CIRCUIT
used in dry and cool, turn the
trol so that the dry time is deter-
BREAKER located on the front
HEATER switch to AUTO and
mined, not only by the dry time
of the power panel. Turn OFF
the burner will automatically
setting, but also by the moisture
the MAIN main POWER SUP-
shutdown during the cooling and
content of the drying grain, turn
PLY to the dryer.
unloading cycles.
the MOISTURE CONTROL
switch to ON.
11. Turn the UNLOAD switch to the
1 SPEED position. The bottom
auger and metering rolls will
15. In case of an emergency press
the dryer POWER STOP button.
13. To start the drying operation
push the dryer POWER START
The burner, fan and all augers
will stop immediately.
FAN & HEATER SWITCH SETTINGS
Fan Setting
Heater Setting
Fan Function
Heater Function
Auto
Auto
Fans stay on during dry and cool
cycle only
Burners stay on during dry timer cycle
only
Auto
On
Fans stay on during dry and cool
cycle only
Burners stay on during dry and cool
On
On
Fans are on continuously
Burners are on continuously
On
Auto
Fans are on continuously
Burners shut down at the end of the
dry cycle
At the end of the dry cycle in staged batch, the fans and heaters will continue running if in the Auto-Auto setting, until the preset temperature on the moisture control thermostat is reached.
20
DRYER START UP
1100 SERIES BATCH TIMER SETTINGS
Dry & Cool
Full Heat
Fan & Burner Switches on Manual
Fans on Manual
Burners on Auto
Initial
Moisture
Moisture
Removed
Approx.
Dry Time
Dry
Cool
Unload*
Approx.
Dry Time
Dry
Cool
Unload*
17%
2 pts.
16 min.
6 min.
0
10 min.
18 min.
18 min.
18 min.
10 min.
18%
3 pts.
21 min.
11 min.
0
10 min.
24 min.
24 min.
18 min.
10 min.
19%
4 pts.
26 min
16 min
0
10 min.
30 min
30 min
18 min
10 min.
20%
5 pts.
31.5 min.
21.5 min.
0
10 min.
35 min.
35 min.
18 min.
10 min.
21%
6 pts.
37 min.
27 min.
0
10 min.
40 min.
40 min.
18 min.
10 min.
22%
7 pts.
41.5 min.
31.5 min.
0
10 min.
45 min.
45 min.
18 min.
10 min.
23%
8 pts.
47 min.
37 min.
0
10 min.
50 min.
50 min.
18 min.
10 min.
24%
9 pts.
51 min.
47 min.
0
10 min.
55 min.
55 min.
18 min.
10 min.
25%
10 pts.
54 min.
44 min.
0
10 min.
60 min.
60 min.
18 min.
10 min.
26%
11 pts.
58 min.
48 min.
0
10 min.
65 min.
65 min.
18 min.
10 min.
27%
12 pts.
62 min.
52 min.
0
10 min.
70 min.
70 min.
18 min.
10 min.
28%
13 pts.
66.5 min.
56.5 min.
0
10 min.
75 min.
75 min.
18 min.
10 min.
29%
14 pts.
71.5 min.
61.5 min.
0
10 min.
80 min.
80 min.
18 min.
10 min.
30%
15 pts.
76 min.
66 min.
0
10 min.
85 min.
85 min.
18 min.
10 min.
31%
16 pts.
81 min.
71 min.
0
10 min.
90 min.
90 min.
18 min.
10 min.
32%
17 pts.
86 min.
76 min.
0
10 min.
95 min.
95 min.
18 min.
10 min.
33%
18 pts.
91 min.
81 min.
0
10 min.
100 min.
100 min.
18 min.
10 min.
34%
19 pts.
96 min.
86 min.
0
10 min.
105 min.
105 min.
18 min.
10 min.
35%
20 pts.
100 min.
90 min.
0
10 min.
110 min.
110 min.
18 min.
10 min.
These are approximate starting points.
*Set unload metering roll high speed setting to 999. If unload equipment cannot adequately keep up, lower the speed
setting and add time to the unload timer setting to completely unload the batch. In full heat mode, the time added to the
unload timer will need to be substracted from the dry timer. If fan is on auto and does not run during unload, set cool timer
to 25 minutes.
New unload time calculation = present unload time
new dial setting
1000
Example
13.75 = 11 ÷ 800
1000
21
QUICK START UP PROCEDURE
FULL START UP CHECK
Standard electrical safety practices
and codes should be used when
This start up procedure assumes the following:
working with a dryer. Refer to the
1. That you have read and understand the dryer operation and service
National Electric Code Standard
manual.
Handbook by the National Fire Pro-
2. That you have taken special note of all safety precautions.
tection Association. A qualified elec-
3. That all safety shields are in place.
trician should make all wiring instal-
4. That all metering roll access doors have been opened and all foreign
lations.
objects have been removed.
5. That you have done a pre start up check out.
6. That all motors have been checked for proper rotation.
7. That all heaters have been test fired.
8. That the fuel has been turned ON at the tank.
9. That the electric power has been turned ON.
10. That the main DISCONNECT switch on the dryer is ON.
11. That you have wet grain in the wet holding bin.
ALWAYS DISCONNECT
AND LOCK OUT POWER
BEFORE WORKING ON OR
AROUND DRYER
12. That you know the incoming grain moisture.
13. That you have the dry grain take away equipment in place.
14. That you have the grain going to the proper bin.
15. That all SWITCHES have been set to the OFF position.
16. That the load mercury switch box is installed with the side stamped
up, in the up position.
FILLING THE DRYER
1. Turn the green CONTROL POWER switch to ON. It should light up, go
through 4 screens and end with the time and date.
2. Turn the DRYING MODE switch to CONTINUOUS FLOW.
3. Push the RESET on the computer key pad to activate the computer.
4. Make sure the UNLOAD switch is in the OFF position.
5. Push the DRYER POWER start switch, it should light up.
6. Turn the LOAD AUGER switch to the MANUAL position to fill the dryer.
The load auger should start and run until the dryer is full, then shut off
automatically. (If the switch is set to the auto position the dryer will
shut down each time the out of grain timer times out, and will have to be
restarted.)
7. When the dryer has filled, turn the LOAD AUGER switch to the AUTO
position.
22
QUICK START UP PROCEDURE
STARTING THE DRYER
This start up procedure is for a cold start on wet grain for continuous flow
operation.
1. Set the MAXON or FAST ACTION HAND VALVE on the incoming fuel
line to the ON position.
2. Make sure the MOISTURE CONTROL switch is in the OFF position.
3. Turn the FAN switch (or switches if a multi-fan dryer) to the ON position. The light in the switch should light when the fan comes up to
about half speed.
4. Adjust the PLENUM AIR PRESSURE switch if necessary. Use a flat
blade screwdriver counterclockwise to make it more sensitive (taking
less pressure to activate it), or clockwise for the opposite effect.
5. Turn the HEATER switch (or switches if a multi-fan dryer) to the ON
position. The heater will purge for about 10 seconds then ignite. The
light in the heater switch will come on during ignition and will stay on if
the heater ignites. If the heater does not ignite, the light will go out after
trial for ignition and the dryer will shut down, indicating that it did not
light. If this happens check gas supply, and all valves in the fuel line to
make sure they are on.
ADJUSTING THE TEMPERATURE
1. Set the HIGH-LOW FIRE PLENUM THERMOSTAT on the left side of
the dryer to the drying temperature that you want to run (180° to 200°).
On multiple module dryers set the plenum chambers 30° to 60° apart.
Hottest at the top, most cool at the bottom.
How much gas pressure do I
use? See step number two in
the Adjusting The Temperature
section.
2. On LP gas models adjust the PRESSURE REGULATOR (high fire) on
the burner fuel line, so that burner will reach the thermostat setting
and switch to (low fire) (pressures may be required up to 25 lbs.). Natural gas does not have a regulator, but uses a LARGE BALL VALVE
close to the vertical supply line for adjustment (pressures may be required up to 18 lbs.).
On LP gas models adjust the small RED HANDLED BALL VALVE
(low fire) so that the burner maintains flame then switches back to (high
fire). Natural gas has a BALL VALVE close to the burner control box,
How often should my burner
cycle? See step number three
in the Adjusting The Temperature
section.
for low fire adjustment.
3. Adjust the burner pressure so that the burners cycles 4 times per
minute (approx. 10 sec. on high--approx. 5 sec. on low). When on
high fire increasing the pressure with the PRESSURE REGULATOR
DECREASES the time spent on high fire. When on low fire increasing
the low fire pressure with the RED BALL VALVE INCREASES the time
spent on low fire.
4. On LP gas models adjust the VAPORIZER so the fuel pipes going to
23
QUICK START UP PROCEDURE
the burner from the regulator are warm to the touch (not hot and cold).
The vaporizer can be adjusted two ways:
•Loosen the bolt in the hinging mechanism and swing it to a
hotter or cooler position, or
•Loosen the two bolts in the hinge pipe and slide the vaporizer
in or out to a cooler or hotter position.
Either one or both methods may have to be used to get the vaporizer to
the proper temperature. Natural gas does not use a vaporizer.
FULL HEAT-CONTINUOUS FLOW OPERATION
How often do I make speed
adjustment? See step number
ten in the Full Heat-Continuous
Flow Operation section.
1. Check the Continuous Flow Metering Roll Settings-Full Heat on page
25. Pick the line that has your initial starting moisture. These are the
settings we will be referring to during this start up procedure.
2. Make sure the UNLOAD switch is OFF.
3. Make sure the MOISTURE CONTROL switch is OFF.
4. Run the fan(s) and heater(s) for about 10% longer than the approximate drying time required for the moisture you are trying to dry.
5. Example: 10% removal would be about 54 minutes, 15% removal would
be about 76 minutes and 20% removal would be about 100 minutes.
Add 10 minutes to insure that the grain is dry.
6. After the time in step 4 turn the UNLOAD to 1 SPEED and set the
METERING ROLL SPEED, HIGH SPEED potentiometer to the setting
for 1 SPEED operation. Grain should begin to run at this time. Run time
for this is about 10% longer than the approximate drying time required
for the moisture you are trying to dry, as shown in the example #5 above.
This allows the moisture in the dryer to reach an even gradient top to
bottom without having any highs or lows in it. It will, however, overdry
some of the corn a little.
7. Increase the drying temperature to 190° for single fans or for multiple
fan dryers set the heat chambers 30° to 60° apart. Hottest at the top,
most cool at the bottom.
8. DO NOT TRY TO ADJUST THE DRYER FOR MOISTURE DURING
THIS PROCESS OR YOU WILL ESTABLISH HIGH AND LOW
SWINGS IN THE MOISTURE CONTROL. IT WILL TAKE SEVERAL
HOURS TO WORK ITSELF OUT.
9. After the run time in step 6 you are ready to set up the moisture control.
Now turn the MOISTURE CONTROL to the ON position. Set the temperature to about 100°.
10. Turn the UNLOAD to 2 SPEED. Set the METERING ROLL SPEED,
LOW SPEED and HIGH SPEED potentiometer to the settings listed for
them. Let the dryer run on these settings as shown in the example #5
before trying to adjust moisture or meter roll settings. These settings
24
QUICK START UP PROCEDURE
will not have your grain moisture adjusted exactly where you want it, but
will be a good place to start initially. A little different moisture at the
bottom of the storage bin is not usually a problem as long as you have
full floor aeration.
11. After the run time in step 10 you are ready to adjust the moisture control, and the meter roll speeds if required. Each time you make an
adjustment to the moisture control, it will take the approximate time shown
in example #5 to see the results.
1100 SERIES CONTINUOUS FLOW METERING ROLL SETTINGS
Full Heat
Initial
Moisture
Moisture
Removed
Approx.
Dry Time
1 Speed
2 Speed
Low
2 Speed
High
17%
2 pts.
16 min.
625
317
875
18%
3 pts.
21 min.
476
270
775
19%
4 pts.
26 min
385
241
675
20%
5 pts.
31.5 min.
317
213
575
21%
6 pts.
37 min.
270
196
476
22%
7 pts.
41.5 min.
241
185
385
23%
8 pts.
47 min.
213
172
317
24%
9 pts.
51 min.
196
161
270
25%
10 pts.
54 min.
185
150
241
26%
11 pts.
58 min.
172
140
213
27%
12 pts.
62 min.
161
132
196
28%
13 pts.
66.5 min.
150
123
185
29%
14 pts.
71.5 min.
140
116
172
30%
15 pts.
76 min.
132
110
161
31%
16 pts.
81 min.
123
104
150
32%
17 pts.
86 min.
116
100
140
33%
18 pts.
91 min.
110
096
132
34%
19 pts.
96 min.
104
087
123
35%
20 pts.
100 min.
100
082
116
These are approximate starting points.
25
QUICK START UP PROCEDURE
ADJUSTING THE MOISTURE CONTROL
How do I set my moisture
control? See step number one
in the Adjusting The Moisture
Control section.
1. Each 5° on the MOISTURE CONTROL changes the output moisture by
about 1%. Example: 100° is set, producing 16% corn out, however,
17% corn out is needed. Reduce the MOISTURE CONTROL temperature by 5° to 95°. This should change the moisture out to about 17%. To
make the corn come out dryer, raise the temperature on the MOISTURE
CONTROL.
2. There are 4 sensors that are averaged together for sensing MOISTURE CONTROL temperature, 1 on each side of the dryer in the front,
and 1 on each side of the dryer in the back. They are located about
⁄ of the way up the grain column from the bottom, and in from the
13
side about 4 inches.
3. The small lights behind the temperatures on the MOISTURE CONTROL indicate the temperature of the grain at this sample point.
4. The 2 lights in the center are green, the lights to the right or to the left of
these are red.
5. When the grain temperature has the dryer cycling HIGH and LOW speed
on the green lights the moisture setting is being maintained correctly.
6. Set the METERING ROLL SPEED in relation to the small red lights
behind the temperatures on the MOISTURE CONTROL.
7. Red lights to the left indicate that the grain at the sample point is too
cool or wetter than desired. With this condition turn the LOW SPEED
left potentiometer to a lower number. This will slow down the metering
rolls and dry the grain longer, warming it up.
8. Red lights to the right indicate that the grain at the sample point is too
hot or dryer than desired. With this condition turn the HIGH SPEED
right potentiometer to a higher number. This will speed up the metering
rolls and remove the grain quicker, cooling it down.
9. If the MOISTURE CONTROL switches to LOW and only stays on low
for a minute or two and switches back to HIGH, speed up the LOW
SPEED left potentiometer. It is set too slow.
10. If the MOISTURE CONTROL switches to HIGH and only stays on high
for a minute or two and switches back to LOW, slow down the HIGH
SPEED right potentiometer. It is set too fast.
11. The MOISTURE CONTROL should stay on HIGH about 50% of the
time and on LOW about 50%, give or take 25%. There is a broad range
that will work. It should be switching low to high and back to maintain
the desired moisture. A control that does not switch, will not maintain
an evenly dried grain moisture, when the incoming wet grain moisture
is varying.
12. When adjusting the metering roll speeds it is better not to change the
speed more than 20 points at a time.
26
QUICK START UP PROCEDURE
27
1100 SERIES SERVICE GUIDE
28
SERVICE
SEASONAL INSPECTION AND SERVICE
The dryer is made of weather resis-
effect the balance, and result in-
To keep motor bearings properly lu-
tant material, and is designed to re-
harmful vibrations and a short
bricated, and dispel any accumula-
quire a minimum of service. However,
bearing life.
tion of moisture within the windings,
each season we recommend the fol-
the fan and auger motors should
lowing items be checked before the
3. CHECK propellor for free play.
unit is used, and any damaged or
Any side play is an indication of
questionable parts replaced. These
defective motor bearings,
checks will help eliminate possible
which should be replaced to pre-
LUBE PROCEDURES
failures, and assure dependable op-
vent a complete motor failure.
If the motor is equipped with an
eration of the equipment.
Make sure motor mount bolts
alemite fitting, CLEAN the tip of the
are tight.
fitting and apply grease gun. Use 1
1. SHUTOFF electrical power.
be operated for 15 to 30 minutes
each month.
or 2 full strokes on motors in NEMA
OPEN power box and control
4. Motor bearings should be LU-
215 frame and smaller. Use 2 to 3
box, and inspect for moisture,
BRICATED periodically, de-
strokes on NEMA 254 through
rodent damage or accumulated
pending on operating condi-
NEMA 365 frame. Use 3 to 4 strokes
foreign material. Remove any
tions. Under normal usage it is
on NEMA 404 frames and larger.
foreign material present. Inspect
desirable to have the motor
and tighten any loose terminal
cleaned, checked and bearings
ted head grease screw, remove
connections. Replace any dam-
repacked by an authorized ser-
screw and apply grease tube to hole.
aged or deteriorated wiring.
vice station every two to three
Insert 2 to 3 inch length of grease
seasons. If the unit is operated
string into each hole on motors in
2. CHECK propellor for freedom
continuously through most of the
NEMA frame and smaller. Insert 3
of rotation and uniform tip clear-
year, this service should be per-
to 5 inch length on larger motors. On
ance. It should also be in-
formed each year.
motors having grease drain plugs,
On motors equipped with slot-
spected for dirt and grain dust,
Note: If on site bearing relubrication
remove plug and operate motor for
especially inside the hub. Any
is to be performed, see lubrication
20 minutes before replacing drain
additional weight can seriously
instructions for ball bearing motors.
plug.
LUBRICATION INSTRUCTIONS FOR BALL BEARING MOTORS
SUGGESTED LUBRICATION INTERVALS*
Hours of Service per Year
H. P. Range
Suggested Lube Interval
5000
1/8 to 7 1/2
10 to 40
50 to 150
5 years
3 years
1 year
Continuous Normal Applications
1/8 to 7 1/2
10 to 40
50 to 150
1 year
3 years
9 months
Seasonal Service (motor is idle for 6
months or more)
All
1 year-beginning of season
Continuous high ambient temperatures, dirty or moist locations, high
vibrations or when shaft end gets hot
1/8 to 40
50 to 150
6 months
3 months
* The bearings have been lubricated at the factory, thus no lubrication should be added before start up.
29
SERVICE
SUGGESTED LUBRICANTS
Insulation Class
Consistency
Type
Grease
Frame Type
A&B
A&B
F&H
Medium
Medium
Medium
Polyurea
Polyurea
Polyurea
Shell Dolium R
Shell Dolium R
Shell Dolium R
215T & Smaller
254 & Larger
All
Note: All of the auger and meter-
carbon and rust between the
ing roll bearings are lifetime lubri-
electrode surfaces. Ignitor gap
vers, and CHECK clean-out
cated and do not require service
should be about 1/8 inch.
hatch mechanism for proper op-
OPERATE dryer clean out le-
eration. With hatch open, in-
relubrication.
4. Inspect flame sensor for pos-
spect and remove any accumu-
sible damage or poor connec-
lation of dirt, fines and foreign
line strainers. Make certain gas
tions. Flame sensor wire must
material from the bottom au-
valves are CLOSED and that
be in good condition.
ger trough area.
1. Remove and CLEAN the gas
Note: Do not allow high moisture
gas is purged from the system
before attempting disassembly.
2.
7.
5. Inspect and manually ROTATE
material to collect within the trough
the top auger paddle assem-
area. It may adversely affect metal
Inspect the collector plate (at
bly. The paddle unit must rotate
parts.
the top of the burner casting)
freely without any indication of
and the burner cup for any ac-
sticking or binding.
8. Inspect entire dryer for loose,
worn or damaged parts. Include
cumulation of foreign material.
CLEAN if required. Foreign ma-
6. Inspect the top auger and bot-
terial in the burner cup or cast-
tom auger drive lines for proper
tering rolls and other internal
ing will not burn out and will im-
adjustment and condition. Read-
parts. CHECK that temperature
pair burner operation.
just line tension as required.
sensors within air plenum cham-
Note: All of the auger and meter-
ber are secured within insulated
3. If required, inspect ignitor plug
ing roll bearings are lifetime lubri-
clamps, and do not chafe on
and CLEAN the electrodes.
cated and do not require service
other metal parts.
Use an ignition point file to remove
relubrication.
CHECK of auger flighting, me-
9. Make sure all dryer guards and
1
warning decals are securely installed. Guards should not interfere with moving parts. If guards
or warning decals are missing,
contact your dealer for a free replacement.
3
10. TEST FIRE the dryer several
4
weeks ahead of the drying sea2
son. CHECK for possible gas
leaks. (See page 16 for burner
Remove the Blue Burn Optimizer Cone. Inspect 1-collector plate, 2-burner
cup, 3-ignitor plug and electrodes and 4-flame sensor on the heater.
30
test fire.)
SERVICE
FAN PROPELLOR REMOVAL AND INSTALLATION
Capscrews installed
through threaded
holes of bushing
The fan propellor is secured to the
motor shaft by the use of a taperlock bushing, motor shaft key and
three cap screws.
CAUTION: Although the taper-lock
Fan Hub
Key
Split Taper Bushing
method of retaining the propellor
onto the motor shaft is simple, it is
Fan blade
installation
essential that the following points be
read carefully and fully understood.
Improper installation can cause a
2. REMOVE the three cap screws
loose flying propellor, and result in
from the clearance holes in the
serious injury or death.
taper-lock bushing.
ing onto propellor to prevent the
loss of parts.
Note: During manufacture the
propellor and bushing on the 26" and
THREADED BUSHING
HOLES
3. INSTALL two grade 5 cap
28" solid aluminum blades are bal-
screws into the threaded holes
anced together, and are marked with
The threaded holes within the bush-
in bushing. TURN caps by hand
two small dots to identify their origi-
ing are provided for disassembly
until they bottom against the
nal alignment position. CHECK the
purposes only. Do not attempt to use
front surface of the propellor.
bushing and propellor to make
these holes for reassembly. They
sure they have alignment marks.
will not allow the parts to lock onto
4. BLOCK propellor to prevent it
the shaft thereby causing a hazard-
from turning, and gradually TURN
ous operating condition.
the cap screws (up to 1/4 turn
MARK the alignment of the propellor
and bushing, if necessary.
Crowley blades have a keyway
at a time) until the propellor
to prevent any misalignment of the
CLEARANCE HOLES
breaks loose from the bushing
propellor and bushing. Alignment
When reassembling parts, the cap
and motor shaft. Carefully RE-
marks are on the back of the fan hub
screws must be installed through
MOVE bushing and propellor.
assembly. To replace one of the
the untapped clearance holes as
With the propellor free from the
blade fins, alignment would be nec-
shown. This will cause the propellor
bushing, a wheel can be used
essary, however, this is not recom-
to be pulled forward onto the ta-
to PULL the bushing off of the
mended. In most cases, the com-
pered bushing, thus locking the
motor shaft. REATTACH bush-
plete propellor should be changed.
parts securely onto the motor shaft.
When fan servicing requires removal and installation of the
Capscrews installed
through threaded
holes of bushing
propellor, make sure the propellor
is removed and reinstalled properly.
Fan Hub
1. LOCK OUT the fan power
supply, and REMOVE the fan
guard and the venturi, as required on some models.
Split Taper Bushing
Fan blade
removal
31
SERVICE
FAN MOTOR REMOVAL AND INSTALLATION
In the event of motor failure, remove
the motor lead wires from
shims (if required) between mo-
the motor as described, and take it
within the box.
tor base and plate. REINSTALL
to the nearest service station. An
Note: Tag or otherwise identify wires
motor mount bolts and washer.
authorized service station is the only
for ease of reassembly.
Do not fully tighten at this time.
place that can provide possible motor warranty. Motor service and re-
3.
REMOVE motor mount bolts.
6. REINSTALL conduit and wires
pair at other places will be at own-
If there are shims between the
through hole in fan/heater
ers expense.
motor and its base, note their
housing and carefully CON-
location so they can be properly
NECT all electrical wiring.
If the service station determines
motor failure is caused by faulty ma-
installed during reassembly.
terial or workmanship within the
warranty period, repair will be cov-
7. ADJUST position of motor.
4. DISCONNECT the upper end of
Temporarily MOUNT fan blade
ered under the warranty. Motor fail-
the motor conduit, and care-
on motor shaft. ROTATE fan
ure caused by external sources will
fully PULL the wires through the
blade by hand, making the nec-
result in a charge to the owner for
hole in the fan/heater housing.
essary adjustments, so the tip
repair.
REMOVE motor from the fan/
clearance between blade and
heater unit with the conduit still
housing is uniform. If required,
attached. If motor requires ser-
REMOVE the fan blade and
OFF and locked out. REMOVE
vice, take it to an authorized ser-
fully TIGHTEN all four motor
fan guard and propellor.
vice station.
mount bolts.
1. Make certain power is SHUT-
Note: Make sure to INSTALL and
2. REMOVE cover from fan/heater
5. To reinstall motor, SLIDE onto
control box, and DISCONNECT
motor base plate and REPLACE
TIGHTEN the propellor in accordance with previous instructions.
The position of the fan motor provides easy access for service.
32
SERVICE
HEATER PARTS REMOVAL AND INSTALLATION
Most heater parts can be removed
b. Disconnect gas solenoid valve
b. Use a dependable brand of
by simply identifying any attached
coils. Be sure to mark which one
high temperature pipe caulking
wiring. Then DISCONNECT the ob-
goes where.
compound when assembling gas
connections. Apply only a light
vious mounting parts.
c. Lift pipe (with orifice, solenoid
coating onto male threaded end
1. Flame sensor: DISCONNECT
valve and other parts attached),
of fittings.
the wire connector. UNSCREW
straight up and remove from fan
the flame sensor out of its
heater housing. Orifice and other
c. Solenoid valves and gas regula-
mounting bracket.
parts can now be removed from
tors are directional and must be
pipe train, if desired.
properly installed. Do not attempt
to connect gas solenoid valve by
2. Gas Solenoid valve coil: UNReassemble: To reassemble
applying force to the valve core
the metal clip on the gas valve,
parts, reverse the disassembly pro-
stem as it may ruin the unit.
and SLIDE the housing and coil off
cedure and check the following:
SNAP either the plastic cap, or
5.
d. Make sure all electrical wires are
the valve stem and body. Do
not energize the coil when it is
a. Make sure all parts are thoroughly
properly connected. Refer to wiring
removed, as the coil may be-
cleaned and open.
diagrams.
come damaged due to excessive current flow.
3. Regulator and gas solenoid
1
valve(s): The gas regulator and solenoid valve(s) are directional and
must be connected as indicated by
3
the markings near the port openings. Make sure gas is shut off and
1
purged from the system before removing parts.
Note: When installing a liquid
3
2
gas solenoid valve on LP models,
do not over tighten the connection
into the inlet side, as the inlet orifice
may become partially blocked.
4. Main Gas Orifice: With fuel shut
off and gas purged from system,
proceed as follows:
a. Disconnect the plumbing support brackets from the pipe train.
This view of the dryer heater shows 1-gas solenoid valve coils and 2-gas
regulator and 3-gas solenoid valves.
33
SERVICE
METERING ROLL SERVICING
tional adjustment as it is completely
controlled from the control box.
3. Speed reducer gear box: The
direct drive gear box provides
the required speed reduction,
and transmits power to the metering rolls through a drive chain
arrangement. The gear box does
not require adjustment. The drive
chain should also be periodically
lubricated and retensioned as
necessary.
4. Unload auger time delay: The
delay controls the bottom auger
system and causes the unload
The speed reducer gear box.
auger (and any connected auxiliary unloading conveyors) to
This dryer is equipped with SCR
charge of 1120 BPH for 1108, 1400
continue operating for the pro-
metering roll drive assembly. The
BPH for 1110, 1680 BPH for 1112,
grammed amount of time, even
metering rolls are driven by a sepa-
1960 BPH for 1114, 2240 BPH for
after the metering rolls stop.
rate DC type electric motor. The
1116, 2520 BPH for 1118, 2800 BPH
This feature permits the cleanout
speed of the motor is variable and
for 1120, 3080 BPH for 1122 and
of grain within the unloading
is controlled by an electric SCR (sili-
3640 BPH for 1126 model dryers.
equipment at the end of all dis-
con controlled rectifier) control within
the main control box.
charge cycles.
Note: When the control is set to
the maximum discharge rate (999),
5. If a foreign object becomes lodged
MAIN CONTROLS
the metering roll speed should be
in the metering rolls and jams
1. SCR speed control: The control
9.75 RPM for 6" discharge and 17.5
the system, the following events
RPM for 8" discharge auger.
will occur. The unloading auger
unit dial on the front of the control
box regulates the speed of the DC
motor which drives the meter-
will stay in motion. However,
2. DC electric motor: The direct
the metering roll drive will stop
current (DC) motor provides the
and the DC motor should stall
drive for the metering roll, and
out. The Electronic Monitor-
The markings on the scale from 0 to
is located on the front left hand
ing Control System will shut
999 represent the flow of grain past
side of standard model dryers.
down the dryer after a two minute
the metering rolls as a percent of the
The output shaft of the motor
period. If any one metering roll or
maximum grain discharge rate for
is connected directly to the gear
sensor should malfunction the
the dryer. The maximum setting of
box assembly.
control will display a left or right
ing rolls.
999 provides a maximum 100% dis34
The DC motor requires no opera-
metering roll failure warning.
SERVICE
HOW TO DETERMINE A METERING ROLL PROBLEM
To determine if the metering problem is from blockage, perform the
following test with the power off.
Remove the drive chain by loosening the motor mounting bolts. Refer
to photo, and place a pipe wrench
on the hub of the roller chain
sprocket, on the left hand metering
roll at the drive end of the dryer.
Apply up to 100 ft. lbs. of force, and
attempt to rotate the roll toward the
inside of the dryer. If the metering
The metering roll drive.
HOW TO CLEAR A JAMMED METERING ROLL
roll will turn, then repeat for right
Place a pipe wrench on the hub of
noise when making this check. Once
hand side. If metering roll will turn,
the sprocket of the jammed meter-
the location is determined, the roll can
it can be assumed that no blockage
ing roll and turn the roll. First back-
be reached from the outside by open-
exists, and the problem is from some
ward, and then forward several times
ing the access door to remove the for-
other cause. Check for a break in
in an attempt to dislodge the object,
eign object causing the jam (before
the power train, chain, drive key, pin,
and clear it through the roll. If this is
opening doors see below). The ser-
etc.
not successful, have an assistant
vice tool must be inserted before open-
turn the metering roll, and attempt to
ing doors. First, swing open the ple-
CAUTION: Keep hands away from
locate the jam by sound. Shut down
num bottom closure panel. Insert
sprocket teeth to avoid injury
the fan heater and eliminate any other
service tool above metering roll.
from chain backlash, as a result
of torsion build up in the system
caused by the jam.
SERVICE TOOL
This column cutoff damper is designed to insert through the grain column
(from the inside of the dryer) immediately above the metering roll. This
permits opening of the metering roll access door. For service or inspection without unloading the dryer, the plenum bottom closure panel and
The auger discharge switch.
metering roll adjust damper must be removed prior to using service tool.
35
SERVICE
TROUBLE ANALYSIS PROCEDURE
A multimeter is required for some of
• The safety circuit is 12 volts D. C.
CAUTION: When making high voltage
the following check-out procedures.
• When checking these circuits, mea-
tests with "live" circuits, be extremely
Before performing any tests, make
sure voltage between the circuit test
careful. Follow established safety prac-
certain if the dryer power supply is
location and to ground.
tices. Turn power on for testing only. Do
• D. C. circuits should be measured
not attempt to make the dryer operate
or 460 volt.
between the test location and its re-
by using a jumper wire to bypass a de-
• The burner circuit is 120 volts AC
spective D. C. ground.
fective safety component.
1 phase, 230 volt, or 3 phase, 230
Refer to wiring diagrams and the
on all standard U. S. production
parts list for identification of parts and
models.
• The control circuit to the motor start-
the electrical terminals.
ers is 120 volts AC.
Possible Cause
Problem
Control power switch light off.
Control power light is on, reset button has been pressed,
drying mode light off.
This indicates control power is present at input/output
board, but no power is being transferred through the I/O
board.
No display on LCD screen.
Control power light is on, drying mode light is on--load
auger, fan, heater, unload auger will not operate.
Display shows "L1 VOLTAGE LOST" message.
Display shows "12 VOLT POWER SUPPLY WARNING"
message.
46
1. Check that main power and circuit breakers are
turned on. Check for tripped breaker.
2. Check for blown 5 amp fuses.
3. Monitor relay is defective.
4. Defective transformer or wiring.
5. Check for a defective power switch.
6. Check wiring between fuses and input/output board.
Refer to wiring diagram for test locations.
1. Power interruption: Incoming power to the dryer has
been interrupted. The display screen will show the date
and time if this has occured, once power has returned.
2. Display not finished initial setup: The monitor will
display a copyright message and model number, total
running time in hours and minutes and then the current
date and time. To activate the controller press the reset
button.
3. Input/output board: The input/output board has developed a problem that requires its replacement.
1.
2.
3.
4.
Check for a defective power switch.
Check wiring between fuses and input/output board.
Check for 120 volts A. C. between points J9-3 and AC-1.
The display may have a malfunction requiring its replacement.
1. Press the dryer power start button.
2. Refer to the problem listed for load auger, fan heater and
unload auger in the following sections.
The left circuit breaker located on the input/output board of the
Electronic Monitoring Control System has tripped, or one of the
hardware timers on the Electronic Monitoring Control System has
shut down the dryer.
The right circuit breaker located on the input/output board of the
Electronic Monitoring Control System has tripped.
SERVICE
Problem
Possible Cause
Display shows "MOTOR OVERLOAD" message.
The thermal overload on the fan motor, load motor, unload
motor or an auxiliary motor has opened indicating an
overloaded motor. (The overloads must be manually reset).
Display shows "BURNER 1 VAPOR HIGH
TEMPERATURE" message.
The LP gas vapor temperature sensor located in the gas
train downstream from the vaporizor has opened, indicating
that the vaporizer is running too hot and must be readjusted. (This control is a 200°F limit which automatically
resets when it cools).
Display shows "BURNER 1 WARNING FLAME NOT
DETECTED" message.
The flame sensor has failed to detect a burner flame,
indicating that the burner has failed to light, there is a
problem with the flame sensing circuitry or the dryer is not
getting burner fuel.
Display shows "FAN 1 HOUSING HIGH
TEMPERATURE" message.
The temperature high limit located on the fan/burner
housing has opened, indicating an over temperature
condition has occurred towards the rear of the fan/heater
housing. (This control is a 200°F limit control that must be
manually reset).
Display shows "GRAIN DISCHARGE WARNING" message.
The cover on the grain discharge box has opened, indicating that grain is backing up into the discharge box.
Display shows "LOWER ADJ. GRAIN HIGH
TEMPERATURE" message.
An over temperature condition has occurred inside the left
side grain column. (This control is a 210°F limit which
automatically resets when it cools).
Display shows "LOWER FIXED GRAIN HIGH TEMPERATURE" message.
Display shows "OUT OF GRAIN" message.
Display shows "OUT OF GRAIN-UNLOAD CLEANOUT.."
message.
An over temperature condition has occurred inside the right
side grain column. (This control is a 210°F limit which
automatically resets when it cools).
The dryer has run low on grain, and the out of grain timer
has timed out shutting the dryer down. The unload auger
will then clean out the dryer, if the unload switch is on
during continuous flow operation. Check the out of grain
timer setting, and if necessary adjust. Also, before restarting, inspect load equipment for possible damage or
adjustment.
Display shows "PLENUM 1 HIGH TEMPERATURE"
message.
An over temperature condition has occurred inside the
dryer plenum. (This control is a 300°F limit which automatically resets when it cools).
Display shows "METER ROLL DRIVE SYSTEM FAILURE"
message.
The metering roll drive system has failed to turn within two
minutes. A faulty D. C. motor, broken chain or jammed roll
is a possible cause of this message.
Display shows "RIGHT METERING ROLL FAILURE"
message.
The right metering roll has stopped rotating, or the sensor
has been damaged.
Display shows "LEFT METERING ROLL FAILURE"
message.
The left metering roll has stopped rotating, or the sensor
has been damaged.
Display shows "AUXILIARY SAFETY SHUTDOWN"
message.
A shutdown has occurred due to a user installed safety
feature. This circuit is located between J5-9 and J1-20
terminals on the input/output board.
Display shows "BURNER 1 SHUTDOWN LOSS OF
AIRFLOW" message.
The air switch contacts have opened, indicating insufficient
airflow for burner to operate.
47
SERVICE
Problem
Display shows "FAN 1 FAILURE-NO AIRFLOW" message.
48
Possible Cause
The air switch contacts have opened, indicating the fan
may not be turning. The air switch may need adjustment.
Display shows "FAN 1 CANNOT START-CHECK AIR
SWITCH" message.
The air switch contacts have closed prior to the fan
starting, indicating a freewheeling blade or improper setting
of air switch.
Fan motor will not start.
1. Check that the fan circuit breaker and the fan switch are
on. Also, check for defective switch or bad wiring connections.
2. If lighted switch does not light, the air switch needs
adjustment, or the bulb may be burned out.
3. Verify closing of fan motor contactor. Check voltage on
load side of contactor. See appropriate power wiring
circuit diagram for terminal numbers. Inspect contactor
for defective points or a burned out coil.
4. Inspect connections, and check voltage applied to the
motor leads in the fan heater box to determine if the
motor is defective.
5. Check capacitors on single phase motors, and replace if
defective. If motor starts slowly, check for low voltage
during starting due to excessive voltage drop in power
supply wiring.
Top auger will not start.
1. Check that the top auger circuit breaker and the load
auger switch are turned on.
2. If lighted switch does not light, the output power to the
contactor is missing. Check connections, or if the bulb is
burned out.
3. Check position of the upper auger paddle switch. It
must be down to start auger.
4. Inspect for secure mounting and wiring of mercury
switch in the terminal box on the top auger paddle
switch shaft. Include check for a defective mercury switch.
5. Verify closing of the top auger contactor. Check voltage on
load side of contactor. Inspect contactor for defective
points, or a burned out coil.
6. Inspect connections, and check voltage applied to motor
leads in motor junction box to determine if motor is defective.
7. Check that the mercury switch box is in the proper position.
Bottom auger will not start.
1. Check that the bottom auger circuit breaker is on.
2. If the lighted switch does not light, the output power to
the contractor is missing. Check connections, and
check to see if the bulb is burned out.
3. Check that the unload switch is on (1 or 2 speed).
4. Verify closing of bottom auger contactor; check voltage
on load side of contactor.
5. If using the moisture control, check for proper setting, or
defective operation of the control.
6. Check for any loose wire connections in unload auger
and moisture control thermostat circuits.
Grain not moving through columns.
1. Check the dryer for fine material buildup inside the
columns.
2. Avoid leaving the dryer columns full for long periods at a
time (2-3 days) while not operating the dryer, or during
rainy weather.
SERVICE
Problem
Possible Cause
Grain not moving through columns.
1. Check the dryer for fine material buildup inside the
columns.
2. Avoid leaving the dryer columns full for long periods at a
time (2-3 days) while not operating the dryer or during
rainy weather.
3. Empty the dryer. Keep the dryer clean! Do not allow
fine material to gather in the plenum chamber.
4. It may be necessary to open the strike off plates in the
affected columns in half inch intervals.
Uneven drying-Some kernels appear brown while others
are under dried.
1. Check plenum thermostat temperature setting. Some
varieties of grain are more sensitive to higher operating
temperatures. It may be necessary to lower the plenum
operating temperature to accommodate this.
2. Check for proper burner alignment (side to side).
Vibration during shipment may have caused misalignment.
Uneven heat exiting from dryer columns.
Burner will not fire with fan operating.
1. Burner switch must be on.
2. Check for power to ignition board.
Heater switch light and gas solenoids go on and off
erratically-The light blinks on and off while the solenoids
"chatter".
1. The blinking light indicates the flame sensor is not
detecting flame.
2. The "chattering" solenoids are caused by the loss of
flame detection, and the thermostat and Fenwal ignition
board trying to reestablish a flame. Check for loose
wires on flame sensor; replace or repair wires or sensor.
Burner will not fire-No gas pressure with fan operating at
least 15 seconds (gas supply or fan heater malfunction).
1. Check gas supply. Also, check gas filter and gas line for
possible obstruction or closed valves. Refill tank;
replace or repair parts, as required.
2. Inspect gas solenoid valves (including liquid valve on
LP units) for defective coils or improper wiring. Replace
valve or coil if valve will not open with proper voltage
applied (115 volts).
3. Check for proper voltage. 115 volts across L1 and L2
incoming voltage to the Fenwal Ignition Board, and 115
volts outgoing across V1 and V2 to the solenoids.
Burner will not fire-But gauge shows gas pressure.
1. Fenwal Ignition Board: Check board for spark by
removing ignition wire from board, and holding aninsulated screwdriver against the output terminal and 1/4"
away from the control box casing. There should be a
strong spark. Check board wire connections. Replace
the Fenwal board, if necessary.
2. Ignitor: Check that the ignitor is properly gapped to 1/8"
and that it has a strong spark. Inspect the porcelain and
electrodes for damage or cracking. Replace or clean if
necessary.
Burner maintains desired drying temperature-but cycles
from hi-fire to off (without going to lo-fire).
1. Make sure the low flow control valve is not completely
closed. Valve must be adjusted open to provide the
proper lo-fire gas pressure listed in this manual.
2. Check lo-fire solenoid valve for proper operation.
49
SERVICE
50
Problem
Possible Cause
Burner operates-But will not cycle from hi-fire to lo-fire.
1. Check the gas pressure reading on the gauge. Problem
may be due to insufficient gas regulator setting. Temporarily decrease the hi-lo fire thermostat setting to verify
that the thermostat will function and cause the burner to
cycle. If burner will cycle at the reduced thermostat
setting, it indicates that the problem was due to insufficient heat to satisfy the original setting. Increase the
gas regulator setting for additional heat output. Do not
exceed the maximum pressure listed in this manual.
2. Hi-lo fire thermostat control may be defective. If the
burner still will not cycle to lo-fire after decreasing the
thermostat, the problem may be due to a broken or
kinked thermostat sensor tube. Observe reading on the
thermometer. Replace control assembly if it cannot be
set to cause its switch to go to the open circuit position
with normally hot air plenum temperatures.
3. If the burner continues to operate on hi-fire, check the
hi-fire gas solenoid valve for a stuck or blocked open
condition, or for reversed gas pipe connections. The
solenoid valve must not allow gas flow when its coil is
not energized.
Burner operates-But will not cycle from lo-fire to hi-fire.
1. Check for an excessive lo-fire gas pressure setting.
Observe pressure setting shown on gauge, and
compare reading with recommended low pressure
settings listed in this manual. Readjust lo-fire setting on
flow control valve, if necessary.
2. Check for improperly adjusted or defective hi-lo fire
thermostat control. Temporarily increase the temperature setting. If the heater will still not cycle, check for
problem in the control wire connections. The control
wires should be connected to terminals R and B of the
thermostat, so the switch will open upon temperature
rise. If the burner will cycle with these two wires
connected together, the thermostat is faulty.
3. Check for improperly connected or faulty hi-fire gas
vapor solenoid valve. Correct any poor connections or
defective wiring. If wiring appears proper, problem may
be caused by a burned out valve coil or defective valve.
Replace hi-fire solenoid valve, or its coil, if defective.
QUICK REFERENCE GUIDE
ELECTRONIC MONITORING CONTROL SYSTEM
Important! To activate the controller
•
BPH factor
after turning on the control power,
•
Fill auger options:
press the reset button.
To set the dry, cool, unload and out
•
LCD display:
b. End fill auger
•
•
out of grain button
These features are accessed se-
•
Press the modify button
quentially as listed above. Press the
•
Press the increase or decrease
increase or decrease buttons to
button to get desired setting
change a setting. Press the enter
Press the enter button when
button to move from feature to fea-
desired setting is reached
ture.
•
Press and hold the modify button
while turning on the control power
Metering roll monitor disabling
Press the dry, cool, unload or
•
To change the marquee on the
a. Center fill auger
feature
of grain timers:
ton to move from feature to feature.
•
Press the increase or decrease
button to change a character
Air switch disabling feature
•
Press the unload button to move
the cursor to the right
•
Press the dry button to move the
cursor to the left
•
Press the cool button to delete
a character
•
Press enter when the desired
marquee is displayed
To set the load and unload delays:
Pressing and holding the reset but-
•
Press the load or unload button
ton for five seconds will access the
•
Press the modify button
following programming features:
To reset the computer to the original
•
Press increase or decrease
•
Calendar year setting
default setting, turn off the computer,
button to get desired setting
•
Calendar month setting
press and hold the green AUX 1 but-
Press the enter button when
•
Calendar day setting
ton and turn on the computer.
desired setting is reached
•
Clock hour setting
NOVRAM will appear on the LCD dis-
•
Clock minute setting
play. The year, date, time and min-
Pressing the increase and decrease
•
Bushel counter reset
utes may be changed now, and the
buttons simultaneously will access
•
Batch counter reset
shutdown history may also be cleared.
the following programming features:
These features are accessed sequen-
Note: If the history is cleared the
•
Safety circuit shutdown log
tially as listed above. Press the in-
dryer model number must be reset or
•
Dryer model number
crease or decrease buttons to
only the bottom fan will operate (if so
•
Fan delay
change a setting. Press the enter but-
equipped).
•
Dryer owner and Airstream associates check the Electronic Monitoring Control System.
51
NOTES
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53
AIRSTREAM GRAIN CONDITIONING SYSTEMS
1004 E. Illinois St., Box 20
Assumption, IL 62510-0020
phone: 217-226-4421
fax: 217-226-4498
November 1997
54