TOWER DRYER - GSI Group, LLC
Contents
1. 6 When drying dirty corn in high humidity condi tions sludge may build up in the upper outside sheets of the dryer This buildup can be removed by either washing the sheets down with a high pressure water hose or by shutting incoming grain dropping the grain level to below the plugged area and then running the fans and burner to dry the affected area Tapping or sweeping the sheets will dislodge debris Attempting to sweep off the sheet build up while it is still wet will usually plug the sheet more In Case of Fire 1 When you first detect a fire the entire drying operation should be shut down including grain flow into and out of the dryer The emergency controls may have already done this Also shut off the electrical and fuel supply to the dryer 2 Do not try to cool a fire by running the fan s 3 Never run grain from the dryer into the elevator or storage if a fire is known or suspected MAINTENANCE 4 Locate the area of the fire 5 Ifthe fire can be extinguished with a fire extin guisher water hose or by removing the burning material this should be done right away Watch the dryer closely for another fire after one has occurred 6 Emergency discharge slide gates at the bottom of each column as well as easy access gates located near the hopper discharge area permit fast dumping of each individual grain column 7 A fire extinguisher should be located at or near the dryer if a fire seems to be getting ou2. The burner circuit is 120 volts AC on all standard U S production D C circuits should be measured models Problem sure voltage between the circuit test location and to ground between the test location and its re spective D C ground CAUTION When making high voltage tests with live circuits be extremely careful Follow established safety prac tices Tum power on for testing only Do not attempt to make the dryer operate by using a jumper wire to bypass a de fective safety component Possible Cause Remedy Control power switch light off Check that main power and circuit breakers are turned on Check for tripped breaker Check for blown 5 amp fuses Defective transformer or wiring Check for a defective power switch Check wiring between fuses and input output board Refer to wiring diagram for test locations No display on LCD screen 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 Boom Control power light is on drying mode light is on load fan burner unload will not operate Press the dryer power start button Refer to the problem listed for load auger fan heater and unload auger in the following sections N Display shows L1 VOLTAGE LOST message The left circuit breaker located
3. Inspect the inside of the dryer heat sec tion and cooling section after operation to insure against the possibility of hot spots or fires Dryer Initiated Safety Shutdowns The Electronic Monitoring Control System con tinuously monitors all safety circuits on the dryer and automatically shuts the dryer down if a problem occurs The cause of the dryer shutdown will immediately be displayed on the LCD and an audible horn on the dryer will sound To silence the horn turn the CONTROL POWER switch to the OFF position To restart the dryer after a safety shutdown first correct the reason for the shutdown and then turn the CONTROL POWER switch to the ON position The dryer can be restarted by pressing the DRYER POWER START button Shutdown Error Messages All of the possible dryer safety shutdown mes sages that appear on the LCD display of the Electronic Monitoring Control System are listed in the TROUBLESHOOTING section of this manual Dryer Safety Shutdown Log Press the INCREASE and DECREASE buttons simultaneously to display a log of the past 25 dryer safety shutdowns on the LCD screen Follow the instructions displayed on the screen ELECTRONIC MONITORING CONTROL screen The screen will revert back to its original mode after a few seconds Setting the Out Of Grain Timer The OUT OF GRAIN timer automatically shuts down the dryer if it remains low on grain for a user set period of time This function is only enabled du
4. dryer The dryer must have all Pre Season and Post Season maintenance to ensure reliable operation Make sure all discharge doors grain ex changer cleanout doors heat section door louvered cooling section doors etc are closed Make sure that all personnel are clear of the dryer and any grain handling machinery 2 Open main gas valve to dryer 3 Switch on main breaker to provide electrical power to the dryer by placing the main circuit breaker handle located on the dryer power panel to the ON position 4 Switch on the control panel by turning the CONTROL POWER selector switch to the ON position The switch will illuminate indicating that the control panel has power The LCD display screen on the Electronic Monitoring Control System will light up and display a copyright message followed a few seconds later by a second display screen giving the date and time 5 Press the RESET button on the Electronic Monitoring Control System touch panel VW The RESET button MUST ALWAYS be pressed anytime the Electronic Control System is initially powered up Once the RESET button is pressed the Elec tronic Monitoring Control System performs a dryer safety check Ifa fault is found the cause of the fault will be displayed on the LCD screen Refer to the Troubleshooting Section for error diagnosis If no faults are Tower Dryer Ops amp Service found the dryer can be started and the LCD wi
5. kept full of grain Particulate matter has built up on the outside of the dryer and the dryer needs to be cleaned Grain not moving through columns Check the dryer for fine material buildup inside the columns Avoid leaving the dryer columns full for long periods at a time 2 3 days while not operating the dryer or during rainy weather Empty the dryer Keep the dryer clean Do not allow fine material to gather in the plenum chamber It may be necessary to open the strike in the affected columns in half inch intervals Uneven drying Some kernels appear brown while others are under dried Uneven heat exiting from dryer columns 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 19 NOTES Tower Dryer Ops Service 20 Tower Dryer Ops amp Service 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 12 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 GSTS SOLE JUDGMENT CONTAI
6. lower display indicates the set point desired drying temperature To Tower Dryer Ops Service 10 11 12 change the drying temperature press the up or down keys then press the reset key on the controller Recommended Drying Temperatures COMMS eec dene 180 to 210 F 5 5 140 to 160 Wisin 140 to 160 MIO escote 160 to 180 F prete 140 to 160 ios 140 to 160 F Start the blower s by turning the FAN S selector switch to the ON position The blower s will automatically start On multiblower units the Electronic Monitoring Control System will automatically start the blowers sequentially Once the blower s are up to speed Start the burner by turning the BURNER selector switch to the ON position The dryer will automatically go through a 60 second purge period The amount of time remaining on the purge cycle will be displayed on the LCD display screen After the purge period the burner pilot will automatically light Once the flame sensing circuit on the dryer senses flame the light in the BURNER selector switch will illuminate If the pilot fails to light in 60 seconds the dryer will shut down Cock and open the Maxon valves After the pilot is ignited the main burner can be lit by cocking and opening the two Maxon gas shutoff valves The main burner will light and the dryer s plenum temperature will be auto matically controlled by the mod
7. of the dryer The MANUAL position initially fills the dryer The OFF position turns the conveyor off shuts the slide gate The AUTO position enables automatic fill control and the OUT OF GRAIN TIMER On dryers filled on demand with a conveyor In the MANUAL or AUTO position the fill conveyor turns on when the dryer is low on grain and off when the dryer is full In the AUTO position only the dryer will automatically shut down when the dryer is low on grain and the OUT OF GRAIN TIMER expires On dryers filled on demand with a slide gate In the MANUAL and AUTO position the fill slide gate opens when the dryer is low on grain and shuts when the dryer is full In the AUTO position only the dryer will automatically shut down when the dryer is low on grain and the OUT OF GRAIN TIMER expires DRYER CONTROL PANEL On choke filled dryers In the AUTO position only the dryer will automatically shut down when the dryer is low on grain and the OUT OF GRAIN TIMER expires In the MANUAL or OFF position the OUT OF GRAIN TIMER is disabled The LOAD switch is illuminated whenever the lower grain level indicator senses grain 9 Fan s Switch turns the blower s on or off On multifan dryers the blower run through a staggered startup The switch is illuminated when all of the blower airflow switches close indicating that the blowers are operating correctly 10 Burner Switch turns the burner on or off When the
8. of the valve opposite the handle The solenoid should energize when a pilot is established If it does not check for faulty electrical connections or a faulty solenoid 2 Check for water in the gas line by opening drain valve 3 Check the hand valve in feed back line to the main gas regulator It should be partially open 4 Check for a broken or stuck butterfly in the gas butterfly valve Dryer will not reach operating temperature or it reaches it slowly 1 Low gas pressure Increase gas pressure on main gas regulator 2 Check for water in gas train by opening drain valve 3 Make sure dryer is completely full of grain by entering the heat plenum and looking for daylight in one of the grain columns 4 Gas parts in burner need to be cleaned Clean by drilling with a 47 drill bit 5 Make sure that the gas butterfly valve is being driven wide open by the modulating motor If not check motor or motor linkage 17 TROUBLESHOOTING Tower Dryer Ops Service Problem Possible Cause Display shows OUT OF GRAIN message The dryer has run low on grain and the out of grain timer has timed out shutting the dryer down 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 HIGH TEMP message Check that columns are flowing An over temperature condition has occurred inside the dr
9. switch is turned on the dryer automatically goes through a 60 second purge cycle followed by the automatic lighting of the burner pilot The switch illuminates when flame is sensed at the pilot After the pilot flame is established the Maxon shut off valves are energized and must be openned manually to supply gas to the main burner 11 Unload Dry Grain Conveyor Switch turns the unload conveyor on or off The switch illuminates when the conveyor is operating 12 Metering Drum Switch turns the metering drum on or off in forward or reverse The drum will not run forward unless the unload conveyor is on The switch illuminates when the metering drum is discharging grain 13 Dryer Power Start Button initiates automatic operation of the dryer When depressed the dryer begins the startup cycle and operates based on the positions of the selector switches on the control panel To control the operation of individual components first depress the DRYER POWER START button then turn on the individual dryer components as desired 14 Dryer Power Stop Switch manually stops all dryer functions and automatic equipment Important In case of an automatic dryer shutdown the DRYER POWER STOP button must be depressed to reset the dryer control circuit before the dryer can be restarted DRYER START UP 1 Prepare dryer for start up Perform preseason inspection and service as outlined in the Maintenance Section before attempting to operate the
10. N A MA TERIAL DEFECT DUE TO MATERIALS OR WORKMANSHIP ALL DELIVERY AND SHIP MENT CHARGES TO AND FROM GSI S FACTORY WILL BE PURCHASER S RESPONSI BILITY 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 LIMI TATION WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PUR POSE OR USE IN CONNECTION WITH 1 PRODUCT MANUFACTURED OR SOLD BY GSI OR 11 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 PARTICU LAR 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 AN TICIPATED 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 TRANSFER ABLE AND APPLIES ONLY TO THE ORIGINAL PURCHASER GSI SHALL HAVE NO OBLI GATION 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 MODIFICATI
11. ONS OR ERECTION DE FECTS WHICH CREATE STRUCTURAL OR STORAGE QUALITY PROBLEMS MODIFICA TIONS TO THE PRODUCT NOT SPECIFICALLY COVERED BY THE CONTENTS OF THIS MANUAL WILL NULLIFY ANY PRODUCT WARRANTY THAT MIGHT HAVE BEEN OTH ERWISE 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 WAR RANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IM PLIED 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 21 Tower Dryer Ops Service GSD a division of THE GSI GROUP 1004 E Illinois St Box 20 Assumption IL 62510 0020 phone 217 226 4421 fax 1 800 800 5329 www grainsystems com August 1998 23
12. OSS OF FLAME message The flame sensor has failed to detect a pilot flame indicat ing that the burner has failed to light there is a problem with the flame sensing circuitry or the dryer is not getting burner fuel Burner pilot lights but goes out before Maxon Valves are 1 Operator is waiting too long to cock Maxon Valve to cocked light main burner Maxons must be cocked within 60 seconds after establishing a pilot 2 Pilot regulator pressure needs to be adjusted to achieve a more stable pilot flame Display shows FAN INTERLOCK message Check contactor wiring on interlock The contacts on the side of the specified fan contactor have failed to close when the fan was turned on This may indicate a problem with the contactor Display shows NO AIRFLOW BLOWER___ message Indicates the specified blower has failed to show airflow during the preset period of time 1 Check airflow switch and tubes 2 Check wiring to airflow switches 3 Check belts on blowers and blower wiring and motors Display shows LOSS OF AIRFLOW message The airflow switch contacts have opened indicating insufficient airflow for burner to operate Pilot lights Cocked and opened the main gas valve but main burner will not come on 1 The handle on the Maxon main gas shutoff valves should offer some resistance when they are opened If they don t check the latching solenoid inside the valve by removing the cover from the side
13. P1 series burners provide even heat and efficient combus tion from either natural gas or LP vapor fuel oil burners are optional Divider hopper separates the heating and cooling sections while preventing build up of particu late matter Internally mounted tubular centrifugal blowers deliver high volumetric airflow to the pressure heat and suction cool sections Internal mounting provides the added benefit of ultra quiet operation as the surrounding grain creates a natural noise barrier Patented Electronic Monitoring Control System provides the most advanced and reliable dryer control on the market Weather proof NEMA IV cabinets and NEMA rated electrical compo nents ensure safe and reliable operation in all conditions DRYER CONTROL PANEL Tower Dryer Ops amp Service MRS PRESA ELECTRONIC MONITORING CONTROL SYSTEM DRYER DIVISION OF GBD tide EM AUTO RUN TUNE HOLD MOISTURE CONTROL THERMOSTAT MOISTURE CONTROL METERING DRUM SPEED MANUAL AUTO CONTROL POWER OFF ON OFF MANUAL AUTO USEFOR TIMED INITIAL FILL SHUTDOWN OUTSIDE LIGHT OFF LIGHT ON WHEN GRAN LEVEL IN DRYER IS FULL adivision of THE GST GROUP AUX 1 AUX 2 DELAYS SAFETY DIAGNOSTICS TOTAL BU PUSH AND HOLD m u AUTO TUNE PLENUM TEMPERATU
14. RE CONTROL TO CHANGE PLENUM TEMPERATURE PRESS DISPLAY TO VIEW PRESENT SET POINT TEMPERATURE PRESS TO CHANGE TEMPERATURE PRESS RESET BURNER UNLOAD DRYER POWER DRY GRAIN CONVEYOR START OFF ON METERING DRUM OFF REVERSE FORWARD ADANGER High voltage Will cause serious injury or death Lockout power before servicing Figure 1 The grain dryer control panel with the Electronic Monitoring Control System in the upper panel Tower Dryer Ops Service Dryer Control Panel Featuring The Electronic Monitoring Control System 1 Electronic Monitoring Control System controls all the dryer s timing functions and safety circuit checks It provides messages and warnings on its liquid crystal display LCD 2 Plenum Temperature Control controls and indicates drying temperature 3 Moisture Control Thermostat controls the metering drum discharge speed automatically when the MOISTURE CONTROL switch is set to AUTO 4 Moisture Control Switch selects automatic or manual control of the metering drum speed 5 Metering Drum Speed controls the metering drum discharge speed when the MOISTURE CON TROL switch is set to MANUAL 6 Control Power Switch energizes the control panel and the Electronic Monitoring Control System 7 Outside Light Switch turns the dryer service light on or off On AUTO the light turns on when the dryer is running and off when a shutdown occurs 8 Load Switch controls the filling
15. RLOCK message 1 Auxiliary contacts on side of unload contact failed to close when the contactor engaged Contactor isn t getting power or has malfunctioned Display shows GATE FAILED TO OPEN message Check limit switch on close side of gate for malfunction Check gate motor for loss of power Check for something stuck in gate The gate may have taken too long to close Po ot Display shows GATE FAILED TO CLOSE Check limit switch on open side for malfunction Check gate motor for loss of power Check for something stuck in gate The Gate may have taken too long to open mom Dryer starts losing during capacity 18 1 Dryer not being kept full of grain 2 Particulate matter has built up on the outside of the dryer and the dryer needs to be cleaned Tower Dryer Ops Service TROUBLESHOOTING Problem Possible Cause Grain not moving through cloumns Check that the load breaker and the load auger switch are turned on If switch does not light the output power to the contactor is missing Check connections or if the bulb is burned out Verify closing of the wet conveyor contactor Check volt age on load side of contactor Inspect contactor for defective points or a burned out coil Inspect connections and check voltage applied to motor leads in motor junction box to determine if motor is defective Dryer starts losing drying capacity Dryer not being
16. SS LE RA LN SY Sd da Mos i 9 90 9 OWER DRYER oe re Ei ESL ci AA PNEG 526 12 18 24 30 DIAMETER DRYER MODELS LE 5 mE e ree lee b Bea division of THE GSI GROUP Tower Dryer Ops amp Service TABLE OF CONTENTS DRYER OPERATION Safety a ati 4 Safety Fertilidad 5 Safety Precautionsa eee ob ta eq S re E rae ree Pr eoa 6 GSI Tower Dryer bereitet ee 7 Installation Requirements eene ener 8 Elec 8 O A A etti reget 8 Dryer Control Panel iaa 9 Dryer Start Up it ee dada 11 Dryer tpe 13 Electronic Monitoring Control 14 Turning On The Electronic Monitoring Control 14 The Electronic Monitoring Control System Display 14 Setting The Out Of Grain 15 Setting The Load And Unload Delays seen 15 Utilizing The Bushel Counter sess 15 Modifying The Bushel Per Hour Factor 15 Displaying The Dryer Hour Meter 15 Dryer Safety Circut i Rien eeu tee abad ades 15 Displaying The Dryer Safety Shutdown Log eee 15 Electronic Monitoring Control System 15 MAINTENANCE Pre Seasonal Inspection And Ser
17. ent or who are in the dryer area Avoid any alterations to the equipment Such alterations may produce a very dangerous situation where serious injury or death may occur DANGER Airborne particles during operation May impair vision and breathing Do not enter when dryer is running High speed belt drive operating overhead Can cause serious injury Keep head and hands clear Do not enter when Disconnect electricity before inspecting ot servicing Keep guards and screens on exposed areas dryer is running d A DANGER MAY CAUSE SERIOUS INJURY OR DEATH 1992 GRAIN SYSTEMS INC Flame and pressure beyond door May cause serious injury Do not enter when dryer is running The GSI Group Inc recommends you contact your local power company and have a representative Rotating drum below Will cause serious injury or death Lockout power before entering or servicing survey your dryer installation so your wiring will be compatible with their system and you will have ad A equate power supplied to your unit Safety decals should be read and understood by all people in and around the dryer area Ifthe follow ing safety decals are not displayed on your dryer or if A DANGER DO NOT STAND ON DRUM Rotating drum will cause serious injury or death Disconnect power before servicing they are damaged contact The GSI Group Inc for replacement The GSI Group Inc 1004 E Ill
18. est weight and unload system settings the correction factor may need to be calibrated so that the calculated and actual grain flow rates agree The bushel per hour factor is normally set at 1 0 If for example the actual grain flow rate is 5 percent higher than displayed change the bushel per hour factor to 1 05 To adjust the correction factor press the BPH RPM TOTAL BU button and follow the on screen instructions MAINTENANCE Tower Dryer Ops Service Pre Seasonal Inspection and Service 3 Check blower belts for proper tension The dryer is made of weather resistant material and is designed to require minimum service However each season we recommend the follow ing items be checked before the unit is used and any damaged or questionable parts replaced These checks will help eliminate possible failures and assure dependable operation of the equipment 4 Inspect and clean the burner Visually check that no holes in the stainless steel air mixing plates are plugged If burner ports are plugged clear them with a piece of wire or a drill bit After a period of several years it may become necessary to drill out the burner ports to clear away accumu lated rust Use a 47 drill bit to return burner ports to their original diameter 1 Shut off electrical power Open power box and control box and inspect for moisture rodent damage or accumu lated foreign material present Inspect and tighten any loose term
19. ginning of season Change every 2 years 1Lubrication of motors Operate motors for 20 minutes Clean grease fitting Remove grease relief plug and using a low pressure grease gun pump in the required grease After relubricating allow motor to run for 10 minutes before replacing relief hardware Do not overgrease 14 Tower Dryer Ops Service Seasonal Inspection and Service 1 The hopper access door must be in place at all times when the dryer is in operation Before turning blowers always make sure this door is clamped into position 2 Follow lubrication guides as outlined in the Lubrication Table 3 Do not let grain fines and dust accumulate inside the dryer Bi weekly 1f drying most products or daily 1f drying milo clean the cooling chamber floor of fines and dust Sweep down the cooling section sheets if necessary Fines can be swept into the hopper Make sure that the hopper divider that separates the heat section from the cooling section remains clean and open 4 When cleaning dryer check the grain discharge area around the metering drum to insure that grain is flowing freely from each column and that there is no trash build up Also sweep accumulated dust off of the metering drum drive motor and gearbox 5 If undried grain is left in the dryer for more than a week during the drying season inspect the plenum roof to make sure that there is not wet grain sticking to the roof that could restrict grain flow
20. ikely have to be shutdown from time to time The steps used to shut it down will depend upon the du ration of the shutdown If the dryer will be shutdown for 4 hours or less follow the Short Tower Dryer Ops amp Service Shutdown procedure For longer shutdowns such as overnight follow the Extended Shut down procedure Short Shutdowns less than 4 hours For short shutdown periods the dryer can be shutdown by pushing the DRYER POWER STOP button To restart the dryer push the DRYER POWER START button The Elec tronic Monitoring Control System will restart the dryer automatically based on selector switch settings Extended Shutdowns 4 hours or more 1 Shut off the burner Turn the BURNER selector switch to the OFF position All gas valves will immediately close and the burner will extinguish 2 Cool down grain Continue to operate blowers for approximately 10 minutes to cool grain To avoid overdried grain upon restarting the dryer continue to move grain through the dryer during the cooling off period 3 Shut off unload equipment Turn ME TERING DRUM and UNLOAD CON VEYOR selector switches to OFF posi tion 4 Shut off blowers Turn FAN S selector switches to OFF position 5 Shut off control panel Turn the CON TROL POWER selector switch to the OFF position 6 Turn off main circuit breaker located on the power panel 7 Close main gas valve to the dryer Tower Dryer Ops Service 8
21. inal connec 5 tions Replace any damaged or deterio rated wiring Check electrical connections at both the flame rod and spark plug Clean spark ignitor 2 Lubricate the blowers and metering 6 Lubricate linkage on gas modulating system as outlined in the Lubrication valve Make sure drain valve in the Table below fuel train is open at all times except when the dryer is operational LUBRICATION TABLE INSTRUCTIONS LUBRICATION INTERVAL LOCATION TYPE OF LUBRICATION Beginning of season an nually Metering drum drive shaft bearing Lubricate slowly until lub shows through seal Wipe clean High quality grade 2 lithium based grease Lubricate bottom bearing slowly counting the grease gun pumps until lub shows through the seal Wipe clean Use same number of grease gun pumps for top bearing High quality grade 2 lithium based grease Every 4 weeks of dryer operation Blower shaft bearings Blower motor bearings See motor lubrication proce High quality grade 2 Every 2 years Normal dure below lithium based grease operation every 8 10 months continuous operaton Every 2 years Normal Metering drum drive mo tor Metering drum gearbox See motor lubrication proce dure below Fill to check plug High quality grade 2 lithium based grease EP Gear Oil Amoco Permagear R EP 220 or equivalent operation every 8 10 months continuous operaton Be
22. inois St Assumption Illinois 62510 phone 217 226 4421 fax 800 800 5329 DC 1062 SAFETY PRECAUTIONS 10 11 12 13 Read and understand the operating manual before trying to operate the dryer Never operate the dryer while any guards are removed Power supply should be OFF for service of electrical compo nents Use CAUTION in checking voltage or other procedures requir ing power to be ON Check for gas leaks at all gas pipe connections If any leaks are detected do not operate dryer Shut down and repair before fur ther operation Never attempt to operate the dryer by jumping or otherwise bypassing any safety devices on the unit Do not exceed maximum recommended drying temperatures Keep the dryer clean Do not allow fine material to accumulate in the plenum chamber Keep blower drive belts tight enough to prevent slippage Use CAUTION in working around high speed fans gas burners augers and auxiliary conveyors which START AUTOMATICALLY Do notoperate in any area where combustible material will be drawn into the fan Be certain that capacities of auxiliary conveyors are matched to dryer metering capacities Clean grain is easier to dry Fine material increases resistance to airflow and requires removal of extra moisture Do not adjust any moving part on the dryer while it is running READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE SAVE FOR FUTURE REFERENCE T
23. ll display dryer status 6 Press the DRYER POWER START button to activate the LOAD FAN S BURNER UNLOAD and METERING DRUM selector switches on the control panel 7 Start auxiliary equipment needed for filling dryer ie wet legs conveyors etc The burner should be covered before filling the dryer to prevent accumulation of foreign material on the Ignitor Flame Sensor and Burner Ports Foreign material may interfere with burner operation 8 Fill the dryer by turning the LOAD selector switch to the MANUAL position On a demand fill dryer the wet conveyor will turn on slide gate will open and the dryer will start filling with grain Once the dryer is full a horn will sound and the wet conveyor will stop slide gate will shut Turn the LOAD selector switch to the AUTO position to silence the alarm and begin normal dryer operation In the AUTO position the dryer automatically controls the conveyor slide gate and the OUT OF GRAIN TIMER is enabled allowing automatic shutdown if the dryer remains low on grain after a preset period of time See Electronic Monitoring Control Section to modify OUT OF GRAIN TIMER The LOAD selector switch illumi nates whenever the grain level in the dryer reaches the lower Bindicator indicating that the dryer is at operating level 9 Set drying plenum temperature on the PLENUM TEMPERATURE CONTROL The upper display indicates the actual plenum temperature and the
24. mum of ground space Inside and outside safety ladders cages and catwalks provide safe and easy access to all areas of the dryer Reducer cone equalizes air velocity past burners for optimum combustion and provides step in access to burner assembly Walk in heat section provides easy access for interior cleaning Recycling heat from the cooling grain results in significant fuel savings Walk in cool section provides easy access to blowers and metering system Patented discharge system provides simple uniform metering and quick dryer clean out Industrial quality components includ ing Maxon valves and burners ensure years of reliable service 12 wide grain columns and long grain retention times result in high quality efficiently dried grain Grain turners in each column ensure even drying In line Maxon N
25. 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 Display shows 12 VOLT POWER SUPPLY WARNING message The right circuit breaker located on the input output board of the Electronic Monitoring Control System has tripped Display shows OVERLOAD or MOTOR OVL message Indicating either a fan unload or load motor overload is tripped 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 Blower motor s will not start 16 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 an 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 to determine if the motor is defective 5 If motor starts slowly check for low voltage during starting due to excessive voltage drop in power supply wiring Tower Dryer Ops Service TROUBLESHOOTING Problem Possible Cause Display shows L
26. ower Dryer Ops amp Service 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 and high speed rotating parts does present a hazard to personnel which can not be completely safeguarded against without interfering with ef ficient operation and reasonable ac cess to components Use extreme caution in working around high speed fans gas fired heaters augers and auxiliary con veyors KEEP THE DRYER CLEAN DO NOT ALLOW FINE MATERIAL TO ACCUMULATE IN THE PLENUM CHAMBER OR SURROUNDING THE OUTSIDE OF THE DRYER Continued safe dependable opera tion of automatic equipment de pends to a great degree upon the owner For a safe and dependable drying system follow the recom mendations within this manual and make it a practice to regularly in spect the operation of the unit for any developing problems or unsafe conditions Take special note of the safety precautions listed above before at tempting to operate the dryer Tower Dryer Ops Service GSI TOWER DRYER CUTAWAY Large wet holding garner bin is sealed to help retain grain dust and bees wings Stainless steel roll formed exterior sheeting promotes long dryer life and improved dryer appearance Heavy duty overall construction results in an extra rigid structure in a mini
27. ring dryer operation if the LOAD switch on the control panel is in the AUTO position Follow the instructions displayed on the screen To change the setting of this timer 1 Press the OUT OF GRAIN button 2 Press the MODIFY button 3 Press the INCREASE or DECREASE buttons to change the value 4 Press the ENTER button to accept the new value Setting the Load and Unload Delays The LOAD delay is used to delay the starting of a load conveyor or the opening of a slide gate when the lower Bindicator indicates a low grain level The UNLOAD delay is used to delay the stopping of the unload conveyor after the metering drum stops to allow the unload conveyor to empty out Both the LOAD and UNLOAD delays are set using the same procedure as the OUT OF GRAIN timer Changing BPH RPM Total BU Display By pressing the BPH RPM TOTAL BU button the third line of the display will toggle between showing either the metering drum RPM s give the bushel per hour rate that the metering drum is currently removing grain from the dryer at or give the total bushels dried since the bushel counter was last reset Displaying the Dryer Hour Meter By pressing the INCREASE button the total hours of dryer operation are displayed on the LCD Modifying the Bushel Per Hour Factor The bushel per hour reading given by the Elec tronic Monitoring Control System is a calculated value based on metering drum speed Due to variations in grain t
28. s injury or death This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently hazardous situation G ER which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation A WARN which if not avoided could result death or serious injury CAUTION indicates a potentially hazardous situation CAUTION CAUTION if avoided may result in minor or moderate CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTE indicates information about the equipment that you N OTE should pay special attention to db Tower Dryer Ops Service SAFETY FIRST The GSI Group Inc s principle concern is your safety and the safety of others associated with grain han dling equipment This manual was written with that thought in mind We want to keep you as a customer by helping you understand CAUTION safeoperating proceedures and some of the problems that may be encountered by the dryer operator or other personnel As owner and or operator it is your responsibility to know what re quirements hazards and precau WARNING tions exist and to inform all per sonnel associated with the equipm
29. t of control call the fire department End of Season Service 1 Empty the dryer at the end of the drying season The dryer should not be used for grain storage Grain left in there for an extended period of time can become wet swell and spoil Chunks of spoiled grain can plug the metering system and swelled grain places undue stress on the interior and exterior sheeting of the dryer 2 Clean out the plenum roof grain cushion and remove any grain that may be hanging up on the plenum roof 3 Make sure the grain exchangers are clean 4 Clean out the hopper that divides the heat section from the cooling section 5 Clean the cooling chamber floor 6 Remove all grain and trash from the metering drum floor This grain can be raked out by hand by opening the slide gates located in the hopper bottom of the dryer 7 Make sure gas supply is shut off to the dryer 8 Open the gas train drain valve located on the bottom of the gas train 9 It is a good practice to cover the burner with a tarpaulin or plastic to insure a clean burner TROUBLESHOOTING Tower Dryer Ops Service Trouble Analysis Procedure A multimeter is required for some The control circuit to the motor starters is 120 volts AC dures Before performing any tests The safety circuit is 12 volts D C make certain if the dryer power sup When checking these circuits mea of the following check out proce ply is 3 phase 230 or 460 volt
30. ulating motor and maintained at the selected temperature 12 1 Open firing valve Canadian dryers only DRYER START UP 13 Let plenum come up to temperature and begin drying Depending upon ambient conditions the dryer may take 10 20 minutes to reach the drying temperature 14 Start unload system Before discharging grain from the dryer first make sure all dry legs and conveyors are operating ahead of the dryer On dryers using the Proof of Auxiliary Un load Running terminal the unload conveyor will not operate unless the auxiliary equipment is run ning Turn the UNLOAD DRY GRAIN CON VEYOR selector switch to the ON position to operate the conveyor leading from the dryer The metering drum will not run forward un less the unload conveyor is running but will run backward whenever the selector switch is set to BACKWARD Turn the METERING DRUM selector switch to the FORWARD position to start discharging grain from the dryer 15 Set grain discharge rate Moisture Control Temperature manually With the MOIS TURE CONTROL selector switch in the MANUAL position adjust the grain dis charge rate using the METERING DRUM SPEED dial The LCD displays the current metering drum RPM or bushels per hour by pressing the BPH RPM TOTAL BU button 16 Check discharge moisture content after 10 minutes Take five small samples from the discharge and mix before taking a moisture reading 17 S
31. vice essen 16 Lubrication Tables cut t ra teet ote oer eee veers rre 16 Seasonal Inspection And Service sss 17 In Case O o ee 17 End Of Season Service eee eese E nena anten 17 TROUBLE SHOOTING Trouble Analysis Procedure sess eee 18 Ren Pere Eo E re penis 23 ELECTRICAL DIAGRAMS COMPONENT MANUALS Toshiba Compact Inverter Maxon Series NP amp RG AIRFLO Burners Protectofier Service Manual Honeywell Modutrol IV Motors Rockwell 121 Regulator Hansen Transmissions Service Manual Geared Motors And Gear Units ASCO Solenoid Valves FISHER Single And Second Stage LP Gas Regulators Honeywell UDC2000 Mini Pro Universal Digital Controller Product Manual Troubleshooting Service Section SAFETY FIRST Tower Dryer Ops Service SAFETY GUIDELINES This manual contains information that is important for you the owner operator to know and understand This information relates to protecting personal safety and preventing equipment problems It is the responsibility of the owner operator to inform anyone operating or working in the area of this equipment of these safety guidlines To help you recognize this information we use the symbols that are defined below Please read the manual and pay attention to these sections Failure to read this manual and it s safety instructions is a misuse of the equipment and may lead to seriou
32. witch over to Automatic Moisture Con trol When the discharge moisture content has stabilized at the desired amount for 20 to 30 DRYER SHUTDOWN minutes the dryer may be switched over to Automatic Moisture Control 17 1 Note the grain temperature indicated on the MOISTURE CONTROL THERMOSTAT typically 100 F to 120 F Adjust the set point on the MOISTURE CONTROL THERMO STAT to this value using the up or down keys on the thermostat then press RESET to lock in the new set point temperature 17 2 Turn the MOISTURE CONTROL selector switch to the AUTO position The MOIS TURE CONTROL THERMOSTAT will automatically adjust the metering drum speed to maintain the same grain temperature and grain moisture content If the discharge moisture content in consistently too high or too low adjust the set point temperature on the MOISTURE CON TROL THERMOSTAT as follows 5 F increase moisture point decrease 5 decrease 1 moisture point increase Allow 30 minutes between adjustments After the Automatic Moisture control is initially set up using the above steps future setups will not be required Following an extended shutdown manually operate the discharge rate from the dryer until the grain temperature has warmed to the set point temperature indicated on the thermostat Then turn the MOISTURE CONTROL selector switch to the AUTO position for automatic operation 18 Shutdown dryer The dryer will l
33. yer plenum This is an adjustable high limit with the controls mounted in the cooling section Display shows HIGH message indicating the upper middle lower or inside high limits have tripped causing a dryer shutdown Check for plugged column dryer is low on grain or a column hot spot Display shows FAN INTERLOCK message Indicates the specified blower has failed to show airflow during the preset period of time 1 Check airflow switch and tubes 2 Check wiring to airflow switches 3 Check belts on blowers and blower wiring and motors Display shows USER UNLOAD IS OFF message 1 The user supplied unload that the user has wired to the dryer component has stopped This will shutdown the dryer after 10 minutes Check auxiliary user supplied unload equipment Dry conveyor will not start 1 Check that the dry conveyor circuit breaker is on 2 If the 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 dry conveyor switch is on 4 Verify closing of dry conveyor contactor check voltage on load side of contactor 5 Check for any loose wire connections in dry conveyor circuits Display shows UNLOAD MOT INTERLOCK message 1 Auxiliary contacts on side of unload contact failed to close when the contactor engaged Contactor isn t getting power or has malfunctioned Display shows LOAD MOT INTE
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