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Airstream PNEG-343 Clothes Dryer User Manual

1. REAN ELECTRONIC MONITORING CONTROL SYSTEM D LOAD UNLOAD AUX 1 AUX 2 DELAYS OUT OF ee PROGRAM FAN OFF AUTO ON AUTO HEATER ON FAN RUNS ON EXCEPT CONTINUOUSLY DURING DURING BATCH DRY BATCH CYCLE ONLY UNLOAD HEATER OFF ON HEAT ER ON WHEN TAM RUNNING TOTAL BU UNLOAD 1 SPEED 2 SPEED STAGED CONTINUQUS BATCH SAFETY DIAGNOSTICS a AND HOLD DRYER POWER START Q OFF OFF STAGED CONT AUTO OUTSIDE LIGHT OFF AUTO ON BATCH FLOW Sen S SHUTDOWN D MANUAL AUTO ON AUTO AUTO ON AUTO FAN RUNS IFANRUNS HEATER ONT EXCEPT CONTINUOUSLY During DURING BATCH DRY BATCH CYCLE ONLY UNLOAD FAN RUNS Runs HEATER ON CONTINUOUSLY DURING DURING BATCH DAY BATCH CYCLE ONLY UNLOAD OFF ON HEATER ON WHEN RUNNING METERING ROLL SPEED ON HEATER ON WHEN TAM RUNNING Low SPEED HIGH SPEED 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 access information regarding dryer operation MOISTURE CONTROL to gauges and controls and the illumi MOISTURE CONTROL SWITCH nated switches provide a quick reference THERMOSTAT This switch turns the power on or for every operating function The pa
2. mm 32 1300 Series us nnns 33 Tro ble Arialysis Pioc edur uu aie 44 Quick Reference Guide d A 49 1300 SERIES DRYER OPERATION AND SERVICE Thank you for choosing stream Grain Dryer This dryer is one of the finest ever built It is designed to give excellent perfor mance and service for many years Grain Systems Inc warrants its products to be free of defects in ma terial and workmanship The only obligation of the manufacturer is to repair or replace components which have been submitted and found to be defective within 24 months after installation If so found to be defec tive the components will be repaired or replaced without charge this con stituting and entirely fulfilling the warranty obligation Grain Systems Inc assumes no liability for ex penses incurred without written au thorizations in no event shall liabil This manual describes the op eration and service for all standard production 1300 series three fan grain dryers These models are available for liquid propane WARRANTY ity include special or consequential damages or exceed the selling price of the product This warranty does not cover products or parts which have been damaged by negligent use misuse alteration or accident Electric mo tors tires and other components supplied by outside manufacturers have separate warran
3. 1300 SERIES WIRING DIAGRAMS 1300 SERIES WIRING DIAGRAMS INPUT OUTPUT BOARD TERMINAL IDENTIFICATION T F I ib E hu s Mid MA d Kr i L 1 1 Mut h 111117 TTT iin LL ul T H I TET mn FH TM 34 1300 SERIES WIRING DIAGRAMS 1300 SERIES WIRING TO CONTROL BOX U Fol EE EE L HILARI 15 h t 35 1300 SERIES WIRING DIAGRAMS 1300 SERIES CONTROL WIRING 1300 SERIES WIRING DIAGRAMS 1300 SERIES SAFETY WIRING DIAGRAM SAFETY DESCRIPTION J5 8 12 VOLTS DC FAN 3 HOUSING HIGH LIMIT MAY 26 1994 TERMINAL ON INPUT QUTPUT BOARD 2 7 3 VAPOR HIGH LIMIT 22 8 2 HOUSING HIGH LIMIT 2 VAPOR HIGH LIMIT J1 6 FAN 1 HOUSING HIGH LIMIT FAN 1 VAPOR HIGH LIMIT 1 5 PLENUM 3 HIGH LIMIT J2 11 PLENUM 2 HIGH LIMIT 41 12 PLENUM 1 HIGH LIMIT LOWER MODULE FIXED GRAIN HI LIMIT 41 18 REAR DISCHARGE SWITCH J5 5 LONER MODULE ADJ GRAIN HI LIMIT 44 18 MOTOR OVERLOADS J4 1
4. Possible Cause 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 Itmay 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 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 Check for proper burner alignment side to side Vibration during shipment may have caused misalignment Burner will not fire with fan operating Burner switch must be on 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 The blinking light indicates the flame sensor is not detecting flame 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 wil
5. BPH ENTER RPM TOTAL BU SAFETY DIAGNOSTICS PUSH AND HOLD Figure 2 The Airstream Electronic Monitoring Control System 11 DRYER CONTROL PANEL The Airstream Electronic Monitoring Control System showing several different LCD displays SETTING THE LOAD AND UNLOAD DELAYS The load delay is used to delay the starting of the load auger when the dryer is unloading to prevent the load auger from starting and stopping The unload delay is used to control the amount of time the unload au gerruns after the metering rolls stop to allow for auger cleanout Both the load and unload delays are set us ing the same procedure as the tim ers The aux 1 and aux 2 delays are presently not being used UTILIZING THE BUSHEL COUNTER When operating the dryer the LCD display will show the dryer mode of operation on the first line the bush els per hour or the metering roll rom on the second line and the total 12 bushels dried on the third line By pressing the bph rpm total bu but ton the second line will alternate between the metering roll rpm s or the bushel per hour rate The to tal bushels dried reading is the to tal since the bushel counter was last reset To reset the bushel counter press and hold the reset button for five seconds Press the enter button through the date and time settings and follow the in structions displayed on the LCD for resetting the counter In the batch mode the first line o
6. CHECK To check the staged batch opera tion turn the control power switch to the on position Tum the drying mode switch to the staged batch posi tion Press the reset button open the main fuel supply valve atthe tank on an LP dryer or valve in the fuel supply line on a natural gas dryer Turn on the electric shut off valve to allow fuel flow to the dryer if so equipped Turn the load switch to auto and unload switch to one speed Push the dryer power start button and the controller will se quentially start all dryer components in their proper order If any switches are not in their correct position for staged batch operation the dryer will indicate improper switch position and will not start until the switches are in the proper position After start ing all batch timers will time down in sequence When the unload cycle is complete the timers will automati cally reset to their original settings and start the dry timer again DRYER SHUTDOWN To shut down the dryer first close the fuel supply valve atthe tank or valve along the fuel line If the burner is operating let the dryer run outoffuel and itwill shutdown automatically due to loss of flame Close the fuel valve at the dryer and press the dryer power stop button Turn off the safety discon nect handle on the front of the power box and turn off the main power to the dryer EMERGENCY In case of emergency push the dryer power stop button The fan burn
7. INSPECTION ELECTRICAL POWER Turn on the electrical power supply to the dryer set all circuit breakers to on including the safety discon necthandle mounted on front of the dryer power panel CONTROL POWER SWITCH Turn the control power switch to on The switch will light up A copyright message model number total run ning time in hours and minutes cur rent date and time will appear Atthis point the controller will lock out all other dryer functions Once the date and time appear press reset and the dryer will perform its safety circuit check If a fault is found the cause will be displayed on the LCD If all are found safe the controller will sup ply power to the electronic fuel shut off valve if so equipped and the dry ing mode switch will light up indicat ing thatthe dryeris ready to be started The Maxon safety shut off valve POWER START BUTTON Push the dryer start button and all the selector switches on the control panel will be activated FUEL CHECK If using LP gas make sure the tank has plenty of fuel and that the tank does not have a regulator mounted to it If using natural gas make sure an adequate supply is available If using LP gas slowly open the main fuel supply valve at the tank If using natural gas turn on the valve along the supply line Then open the electronic shut off valve Maxon valve if so equipped or open the manual shut off valve on the dryer to allow f
8. TIMER SETTINGS Full Heat Fan amp Burner Switche s on Manual Dry Cool Burner s on Auto Fan s on Manual Initial Moisture 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Moisture Removed 2 pts 3 pts 4 pts 5 pts 6 pts 7 pts 8 pts 9 pts 10 pts 11 pts 12 pts 13 pts 14 pts 15 pts 16 pts 17 pts 18 pts 19 pts 20 pts Approx Dry Time 16 min 21 min 26 min 31 5 min 37 min 41 5 min 47 min 51 min 54 min 58 min 62 min 66 5 min 71 5 min 76 min 81 min 86 min 91 min 96 min 100 min Dry 6 min 11 min 16 min 21 5 min 27 min 31 5 min 37 min 47 min 44 min 48 min 52 min 56 5 min 61 5 min 66 min 71 min 76 min 81 min 86 min 90 min These are approximate starting points S et unload meter 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 2 presentunload time Example 13 75 11 800 1000 Cool 0 Unload 10 min 10 min 10 m
9. also show a notice able drop indicating that the hi fire solenoid is closed and the burner is being supplied with less gas through the low fire control valve At this time set the hi fire and lo a Use the pressure regulator for hi fire and the ball valve for lo fire The ther fire pressure settings mostat should cycle between high and low approximately 4 to 5 times per minute Approximate settings should be LP Gas Hi Fire 6 15 Ibs Lo F ire 2 6 Ibs Natural Gas Hi Fire 6 10 Ibs Lo Fire 1 3 Ibs If the burner remains on hi fire and does not cycle increase the regulator setting on the propane models or the supply valve on the natural gas models in order to reach the thermostat setting If the burner remains in lo fire and does not cycle The dryer fan and heater controls featuring 1 pressure regulator 2 lo fire control valve 3 high pressure solenoid 4 low pressure solenoid 5 hi lo fire thermostat 6 fuel supply line 7 LP solenoid or supply ball valve NG 8 air pressure switch and 9 liquid filled gauge DRYER PRE START CHECKS All dryer functions should be checked before operation each season slightly decease gas pressure with the lo fire control valve If the gas pressure is decreased too much a popping or fluttering sound will be heard Also anytime the high pres sure side is adjusted the low pres sure side needs to be checked Re peatthe testfor each fan heater unit STAGED BATCH
10. component Problem Possible Cause Control power switch light off 1 Check that main power and circuit breakers are turned on Check for tripped breaker Check for blown 5 amp fuses Monitor relay is defective 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 OQ Ui UN 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 board 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 devel oped a problem that requires its replacement No display on LCD screen Check for a defective power switch Check wiring between fuses and input output board Check for 120 volts AC between points J 9 3 and AC 1 The display may have a malfunction requiring its replacement Q N m Control power light is on drying mode light is on load auger fan heat
11. fuel shut off and gas purged from system proceed as follows a Disconnect the plumbing sup port brackets from the pipe train 30 b Disconnect gas solenoid valve coils Be sure to mark which one goes where c Lift pipe with orifice solenoid valve and other parts attached straightup and remove from fan heater housing Orifice and other parts can now be removed from pipe train if desired Reassemble To reassemble parts reverse the disassembly pro cedure and check the following a Make sure all parts are thoroughly cleaned and open b Use a dependable brand of high temperature pipe caulking compound when assembling gas connections Apply only a light coating onto male threaded end of fittings c Solenoid valves and gas regula tors are directional and must be properly installed Do notattempt to connect gas solenoid valve by applying force to the valve core stem as it may ruin the unit d Make sure all electrical wires are properly connected R eferto wiring diagrams This view of the dryer heater shows 1 high pressure gas solenoid 2 low pressure gas solenoid 3 gas solenoid valves 4 gas regulator and 5 vaporizer adjustment bracket The speed reducer gear box This dryer is equipped with SCR metering roll drive assembly The metering rolls are driven by a separate DC type electric motor The speed of the motor is vari able and is controlled by an electric SCR silicon cont
12. the current time and date To activate the controller press the reset button SETTING THE DRY COOL BATCH AND UNLOAD TIMERS These switches are used to setthe cycle times in the staged batch drying mode only The drying mode switch must be in the staged batch position The cur rentsetting on these three timers is dis played directly above each timer button To change the setting of these timers follow these instructions 1 Press the dry cool or unload timer button 2 Press the modify button 3 Pressthe increase or decrease button to adjustthe settings 4 Pressthe enter button During operation the remaining time on each timer is displayed on the screen If the power goes out or if the dryer is stopped these times are saved by the controller When the dryer is restarted the timers will continue timing down The timers will return to their initial setting if the reset button is pushed SETTING THE OUT OF GRAIN TIMER If the dryer runs out of grain while the load auger switch is in the auto posi tion the outof grain timerautomatically shuts offthe dryerafterthe period oftime preseton the timer When pressed the display will show the amount of time left on the timer and the percentage oftime used by the lastload A second screen will appear with the timer s setting and may be modified as described in the batch timer section REGA ELECTRONIC MONITORING CONTROL SYSTEM DRYER DIVISION OF GSD PROGRAM
13. the dry cool unload se quence by turning the fan switch to auto If the dryer is being operated in all heat turn the heater switch to on The burner will operate whenever the fan is operating If the dryer is being used in dry and cool turn the heater switch to auto and the burner will auto 21 11 12 DRYER START UP amp OPERATION matically shut down during the cooling and unloading cycles Turn the unload switch to the one speed position The bottom auger and metering rolls will start automatically during the unload cycle ofthe dry cool un load mode along with any grain handling equipment that is wired to the dryer The speed at which the metering rolls operate during the unload cycle is adjusted by using the high speed metering roll knob Turning the dial clockwise will in crease the grain discharge rate and counterclockwise will decrease the discharge rate To control the length of the dry cycle using only the dry time setting programmed into the system turn the moisture con trol setting to off To use the au tomatic moisture control so that the dry time is determined not only by the dry time setting but also by the moisture content of the drying grain turn the mois ture control switch to on and set dial to a beginning setting of 135 F 13 To start the drying operation push the dryer power start but ton The controller will start all the dryer components in their proper order I
14. 2 TO 5 SECOND HARDWARE TIMR 45 10 FLAME DETECTOR SHUTDOMN CIRCUIT 15 8 12 VOLTS DC 3 FLAME DETECTION 22 9 FAN 2 FLAME DETECTION _ J1 10 FAN 1 FLAME DETECTION J1 9 TO 40 SECOND HARDWARE TIMER 45 6 16 8 12 VOLTS DC USER SUPPLIED SAFETY J1 20 RHODES ALL CONNECTIONS MUST HAVE 12 VOLTS DC TO OPERATE SEPT 1993 37 1300 SERIES WIRING DIAGRAMS 1300 SERIES FRONT PANEL INTERNAL WIRING rus ER A Pr d nii 1300 SERIES WIRING DIAGRAMS 1300 SERIES FRONT PANEL EXTERNAL WIRING 1300 SERIES WIRING DIAGRAMS DRYER FAN CAN CONTROL WIRING MAY 26 1994 FLAME TIME C DELAY 2 51 o p 110 VOLTS AC 4 FENWAL NEUTRAL W 110 VOLTS AC BLK BURNER LIGHT BRN H9 L1 7 Ove 2 DO LIOUID Lom THERMOSTAT gt s W AN WHO W hea 12 VOLTS DC rm i i Bk HIGH VAPOR LIMIT N AN ry Men Ps VAPOR HOUSING LIMIT YEL N MN w M HoH Y H
15. 3 5 min 19 4 pts 26 min 5 5 min 0 3 5 min 30 min 15 min 3 min 3 5 min 20 5 pts 31 5 min 7 min 0 3 5 min 35 min 17 5 min 3 min 3 5 min 21 6 pts 37 min 9 min 0 3 5 min 40 min 20 min 3 min 3 5 min Amen 2 Fan on Manual 2 Burner on Manual 1 Fan on Auto 1 Burner on Auto 22 7 pts 41 5 min 10 5 min 0 3 5 min 45 min 5 min 18 min 3 5 min 23 8 pts 47 min 12 5 min 0 3 5 min 50 min 2 5 min 18 min 3 5 min 24 9 pts 51 min 13 5 min 0 3 5 min 55 min 4 min 18 min 3 5 min 2596 10 pts 54 min 14 5 min 0 3 5 min 60 min 5 5 min 18 min 3 5 min 26 11 pts 58 min 16 min 0 3 5 min 65 min 7 5 min 18 min 3 5 min 27 12 pts 62 min 17 5 min 0 3 5 min 70 min 9 min 18 min 3 5 min 28 13 pts 66 5 min 18 5 min 0 3 5 min 75 min 10 5 min 18 min 3 5 29 14 pts 71 5 min 20 5 min 0 3 5 min 80 min 12 5 min 18 min 3 5 min 3096 15 pts 76 min 22 min 0 3 5 min 85 min 14 min 18 min 3 5 min 3196 16 pts 81 min 23 5 min 0 3 5 min 90 min 15 5 min 18 min 3 5 min 32 17 pts 86 min 25 5 min 0 3 5 min 95 min 17 5 min 18 min 3 5 min 33 18 pts 91 min 27 min 0 3 5 min 100 min 19 min 18 min 3 5 min 34 19 pts 96 min 28 5 min 0 3 5 min 105 min 20 5 min 18 min 3 5 min 35 20 pts 100 min 30 min 0 3 5 min 110 22 5 min 18 min 3 5 min These are approximate starting points S et unload meter roll high speed setting to 999 If unload equipment cannot adequ
16. AIRSTREAM GRAIN CONDITIONING SYSTEMS 199 4 f 4 m JJ des Au m AUIRSTREAM It s really smart A Division of 650 1300 SERIES DRYER OPERATION AND SERVICE TABLE OF CONTENTS ee see 4 Safety 5 Safety Alert Decals cn ae ea ea rd 6 Safety P recautiors nn 7 Dryer Control Panel Featuring The Electronic Monitoring Control 8 Safety Circuit Shutdown 13 DryerP re Start Checks ten oo A 14 Pre Seasot InspectiOn m au aaa en 14 Dryer Start Up amp 1 022 202 2 0066 6166 emen emere 18 Continuous Flow And Continuous Batch Start Up 18 Continuous Flow Metering Roll Settings e 19 Fan amp Heater S witch Settings een 22 Batch Timer Settings 23 Staged Auto Batch Timer 5 5 2 2 24 1300 Series Dryer Service Guide sereine nnne 25 Seasonal Inspection And 26 Suggested L bricants ir itt 27 Fan Propellor Removal And Installation 28 Fan Motor Removal And Installation 29 Heater Parts Removal And Installation men 30 Metering Roll Servicing meme 31 How To Determine A Metering Roll P roblem
17. ECTED The flame sensor has failed to de tecta burner flame indicating that the burner has failed to light there is a problem with the flame sensing cir cuitry or the dryer is not getting burner fuel The message will dis tinguish between burner 1 and 2 FAN 1 2 OR 3 HOUSING HIGH TEMPERATURE The temperature high limit located on the fan burner housing has opened indicating an over tempera ture condition has occurred towards the rear of the fan heater housing This control is set at 200 F and must be manually reset The message will distinguish between fan 1 and 2 BURNER 1 2 OR 3 SHUT DOWN LOSS OF AIRFLOW The contacts in the air switch have opened due to insufficientairflow forthe bumerto operate The message will dis tinguish between burner 1 and 2 GRAIN DISCHARGE WARNING The lid on the grain discharge box has opened indicating that grain is not being taken away fast enough atthe discharge box LOWER ADJUSTABLE GRAIN HIGH TEMPERATURE An over temperature condition has oc curred in the right side left and right as viewed from behind the dryer grain col umn causing the control to shut down the dryer This control is adjustable from 80 to 220 F and automatically resets itself when cool LOWER FIXED GRAIN HIGH TEMPERATURE An over temperature condition has oc curred in the left side left and right as viewed from behind the dryer grain col umn causing the control to shutdown the dryer This co
18. OUSING AIR BLU AN AN N a u I bare BL T 12 VOLTS DC RED D ak jt RD sh B OR OR P ue OR lan N or Ee TER 1 5 12 VOLTS DC ALL WIRES COME FROM lo nn MAIN CONTROL BOX OR BRN E N N BRN W CSI zh ie SSL OD QAR N 4 OR RHODES JUNE 93 40 1300 SERIES WIRING DIAGRAMS 1300 SERIES 220 VOLT SINGLE PHASE CONTROL WIRING L ll F F l 1 1300 SERIES WIRING DIAGRAMS 1300 SERIES 220 VOLT 3 PHASE POWER WIRING TROUBLE ANALYSIS PROCEDURE A multimeter is required forsome of the following checkout procedures Before performing any tests check ifthe dryerpower supply is 1 phase 230 volt or 3 phase 230 or 460 volt burner circuit is 120 volts AC on all standard U S production models The control circuit to the motor starters is 120 AC volts The safety circuit is 12 volts DC When checking these circuits measure voltage between the cir cuit test location and to ground DC circuits should be measured between the test location and its respective DC ground Referto wiring diagrams and the parts list for identification of parts and the electrical terminals CAUTION When making high volt age tests with live circuits be ex tremely careful Follow established safety practices Turn power on for testing only Do notattemptto make the dryer operate by using a jumper wire to bypass a defective safety
19. UTDOWN A shutdown has occurred due to an auxiliary installed safety feature FAN 1 2 OR FAILURE NO AIRFLOW Contacts in the air switch have opened due to the fan nottuming orthe airswitch may need adjustment The message will distinguish between fan 1 and 2 FAN 1 20R 3 CANNOT START CHECK AIR SWITCH The air switch contacts have closed prior to the fan starting indicating a freewheeling blade or improper set ting of the air switch The message will distinguish between fan 1 and 2 13 DRYER PRE START CHECKS Before the dryer is filled thoroughly inspect the unit and check the op eration 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 ma terial that may cause possible jam ming of the metering rolls BEFORE ATTEMPTING TO OPERATE THE DRYERMAKE SURE ALL SAFETY SHIELDS ARE IN PLACE ALL BOTTOM CLEANOUT AND REAR ACCESSDOORSARE CLOSED AND ALL PERSONNEL ARE CLEAROF THE DRYER SET CONTROL SWITCHES Moisture Control S witch ON Moisture Control Thermostat MAXI MUM TEMPERATURE Load S witch OFF Unload Switch OFF Fan Switches OFF Burner Switches OFF Outof Grain Timer 8 MINUTE Load Delay 30 SECONDS Unload Delay 30 SECONDS Metering Roll Speed LOW AND HIGH SPEED SETTINGS PUT ON ZERO Dry Timer 60 MINUTE Cool timer 20 MINUTE Unload timer 10 SECONDS Mode Switch CONTINUOUS FLOW 14 PRE SEASON
20. aft 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 Checkthatthe mercury switch box is in the proper position Bottom auger will not start 1 Check that the bottom auger circuit breaker is on 2 Ifthe 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 ata time 2 3 days while not operating the dryer or during rainy weather The number in the warning message designates the fan burner or plenum where the problem is located All areas are numbered from the bottom up For example the bottom fan is number 1 and the top fan is number 3 46 TROUBLE ANALYSIS PROCEDURE Problem
21. ain backlash as a result of torsion build up in the system caused by the jam The auger discharge switch 32 The metering roll drive HOW TO CLEAR A JAMMED METERING ROLL noise when making this check Once Place a pipe wrench on the hub of the sprocket of the jammed meter ing roll and turn the roll First back ward and then forward several times in an attemptto dislodge the object and clear itthrough the roll If this is not successful have an assistant turn the metering roll and attempt to locate the jam by sound Shutdown the fan heater and eliminate any other the location is determined the roll can be reached from the outside by open ing the access doorto remove the for eign object causing the jam before opening doors see below The ser vice tool mustbe inserted before open ing doors First swing open the ple num bottom closure panel Insertthe service tool above the metering roll PLENUM BOTTOM CLOSURE PANEL METER ROLL ADJUST DAMPER COLUMN CUT OFF DAMPER GRAIN COLUMN METER ROLL ACCESS DOOR SERVICE TOOL This column cutoff damper is designed to insertthrough 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 inspec tion without unloading the dryer the plenum bottom closure panel and metering roll adjust damper must be removed prior to using service tool
22. arger motors On motors having grease drain plugs remove plug and operate motor for 20 minutes before replacing drain plug LUBRICATION INSTRUCTIONS FOR BALL BEARING MOTORS SUGGESTED LUBRICATION INTERVALS Hours of Service per Year 5000 Continuous Normal Applications Seasonal Service motor is idle for 6 months or more Continuous high ambient tempera tures dirty or moist locations high vibrations or when shaft end gets hot H P Range 1 8 to 7 1 2 10 to 40 50 to 150 1 8 to 7 1 2 10 to 40 50 to 150 All 1 8 to 40 50 to 150 Suggested Lube Interval 5 years 3 years 1 year 1 year 3 years 9 months 1 year beginning of season 6 months 3 months The bearings have been lubricated at the factory 26 thus no lubrication should be added before start up SERVICE SUGGESTED LUBRICANTS Insulation Class Consistency A amp B Medium A amp B Medium F amp H Medium Type Grease Frame Type Polyurea Shell Dolium R 215T amp Smaller Polyurea Shell Dolium R 254 amp Larger Polyurea Shell Dolium R All Note All of the auger and me 4 tering roll bearings are lifetime lu bricated and do not require service relubrication 1 Remove and clean the gas line 5 strainers Make certain gas valves are closed and that gas is purged from the system before attempting disassembly 2 Inspectthe collector plate at the top of the burner casting and the burner cup for any acc
23. ately 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 For additional cooling set 1 fan switch on manual If you need more time between dumps use batch mode New unload time calculation present unload time 24 Example 13 75 11 800 1000 new dial setting 1000 1300 SERIES SERVICE GUIDE SERVICE SEASONAL INSPECTION AND SERVICE The dryer is made of weather resis tant material and is designed to re quire a minimum of service How ever each season we recommend the following items be checked be fore the unit is used and any dam aged or questionable parts replaced These checks will help eliminate possible failures and assure de pendable operation of the equip ment 1 Shutoffelectrical power Open power box and control box and in spectfor moisture rodent damage or accumulated foreign material Remove any foreign material present Inspectand tighten any loose terminal connections Re place any damaged or deteriorated wiring 2 Checkeach propellorfor freedom of rotation and uniform tip clear ance They should also be in spected for dirtand grain dust es pecially inside the hub Any addi tional weight can seriously effect the balance and result in harmful vibrations and a shortbearing life 3 Check each propellor for free pla
24. atic mois ture control feature of the dryer is uti lized e Set the speed of the metering rolls during continuous flow operation when the moisture control is notused e Setthe rate of grain discharge from the dryer during the unload cycle of staged batch dryer operation DRYER POWER START SWITCH This switch starts and operates the dryer based on switch settings If other switch settings are in the off position individual dryer compo nents can be operated by turning the drying mode switch to continuous flow pressing the dryer power start button and then turning on the de sired dryer component DRYER POWER STOP SWITCH This switch stops all dryer func tions If an automatic dryer shut down occurs first determine and correct the cause of the shutdown Then press the dryer power stop button to reset the dryer before restarting The Airstream Dryer Control Panel mounted on the dryer 10 DRYER CONTROL PANEL ELECTRONIC MONITORING CONTROL SYSTEM The Electronic Monitoring Control System Figure 2 controls all tim ing functions and safety circuit checks It is designed to simplify dryer operation by providing printed messages and warnings on its liq uid crystal display LCD TURNING ON THE ELECTRONIC MONITORING CONTROL SYSTEM Turn the control power switch to on The monitor will display a copyright message and model number total running time in hours and minutes and
25. ay need adjustment Display shows FAN 1 2 OR 3 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 sh
26. but ton and turn on the computer NOVRAM will appearon the LCD dis play The year date time and min utes may be changed now and the shutdown history may also be Cleared Note Ifthe history is cleared the dryer model number must be reset or only the bottom fan will operate Dryer owner and Airstream associates check the Electronic Monitoring Control System 49 5 21 AIRSTREAM GRAIN CONDITIONING SYSTEMS AUIRSTREAM It s really smart A Division of 650 1004 E Illinois St Box 20 Assumption IL 62510 0020 phone 217 226 4421 fax 217 226 4420
27. components Use CAUTION in checking voltage or other procedures requiring power to be ON Check for gas leaks atall 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 Setpressure regulatorto avoid excessive gas pressure applied to burner during ignition and when burner is in operation See chartforoperat ing procedures Do notexceed maximum recommended drying tem perature Keep the dryerclean Do notallow fine material to accumulate in the ple num chamber Also occasionally clean the outside screens of the dryer Keep auger 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 Before attempting to remove and reinstall any propeller make certain to read the recommended procedure listed within the servicing section of the manual Be certain that capacities of auxiliary conveyors are matched to dryer auger capacities Clean grain is easierto dry Fine material increases resistance to airflow and requires removal of extra moisture READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE SAVE FOR FUTURE REFERENCE USE CAUTION IN THE OPERATION OF THIS EQUIPMENT The
28. 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 presenta hazard to personnel which can not be completely safeguarded against without interfering with effi cient operation and reasonable ac cess to components Use extreme caution in working around high speed fans gas fired heaters augers and auxiliary con veyors which may start without warning when the dryer is operating on automatic control KEEP THE DRYER CLEAN DO NOT ALLOW FINE MATERIAL TO ACCUMULATE IN THE PLENUM CHAMBER ORSURROUNDING THE OUTSDE 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 spectthe operation of the unitforany developing problems or unsafe con ditions Take special note of the safety precautions listed above before tempting to operate the dryer DRYER CONTROL PANEL MOISTURE CONTROL THERMOS TAT INCREASE TEMPERATURE TU DECREASE MOISTURE CONTENT EACH 5 DEGREE MARK EQUALS 1 POINT OF MOISTURE OFF ON S LIGHT ON WHEN DISCHARGE MOISTURE ABOVE SETPOINT DRYING MODE CONTROL POWER OFF ON S LOAD AUGER FAN RUNS DRYER DIVISION OF 80 TIMERS rim
29. down the moisture control thermostat As the setting is decreased the indica tor light should come on and the me tering rolls should stop operating The bottom auger will stop after the 30 second clean out delay provid ing that the dryer is still being held by the moisture control thermostat Rotate the moisture control thermo statup to its maximum setting The light should go off and the metering rolls should restart along with the bottom auger if it has stopped TWO SPEED OPERATION To check two speed operation move the switch to the two speed position set low speed on 200 and high speed on 600 Slowly turn the ther mostat until the moisture control switch light comes on The meter ing roll speed is now controlled by the low speed dial Turning the ther mostat the other way until the light goes outleaves the metering rolls con trolled by the high speed dial METERING ROLL OPERATION To check the metering roll operation turn eitherthe low speed orhigh speed knob clockwise and the metering roll speed should increase Turning ei ther knob counterclockwise will de 15 DRYER PRE START CHECKS crease the speed Make sure the drive chain tension is properly ad justed and all sections of the meter ing rolls rotate Turn the unload switch off after these checks are complete The bottom auger will continue to run for 30 seconds after the switch is turned off to allow for cleanout FAN SWITCHES Bump each fan sw
30. e atthe high speed metering roll potentiometer setting orturn off de pending on the control signal from the moisture controlthermostat The discharge auger will operate when ever the metering rolls are operating In both the 1 speed orthe 2 speed position if the moisture control switch is off and the drying mode switch is turned to cont flow the metering roll speed can be manu ally controlled by adjusting the high speed metering roll potenti ometer The discharge auger will operate continuously Ifthe drying mode switch is turned to staged batch the unload switch should be setto the 1 speed posi tion The discharge auger and metering rolls will only operate during the unload cycle of the staged batch operation and the speed of the metering rolls is ad justed using the high speed me tering roll potentiometer Note If the unload auxiliary motor overload relay is being uti lized in the dryer control panel this switch will also control the opera tion of the auxiliary equipment LOW SPEED METERING ROLL POTENTIOMETER This is used to adjustthe low speed ofthe metering roll when the 2 speed automatic moisture control feature of the dryer is in use DRYER CONTROL PANEL HIGH SPEED METERING ROLL POTENTIOMETER This is used to Setthe high speed of the metering roll when the two speed automatic mois ture control feature of the dryer is uti lized e Set the speed of the metering rolls when the one speed autom
31. ected aux unloading conveyors to continue operating for the pro grammed amountof time even after the metering rolls stop This feature permits the cleanout of grain within the unloading equipment at the end of all dis charge cycles Ifa foreign object becomes lodged in the metering rolls and jams the system the unloading auger will stay in motion However the metering roll drive will stop and the DC motor should stall out The Electronic Monitoring Control System will shut down the dryer after a two minute period If any one metering roll orsensor should malfunction the control will display a left or right metering roll failure warn ing 31 SERVICE HOW DETERMINE METERING ROLL PROBLEM To determine if the metering prob lem is from blockage perform the following test with the power off Remove the drive chain by loos ening the motor mounting bolts Refer to photo and place a pipe wrench on the hub ofthe roller chain sprocket on the left hand metering roll at the drive end of the dryer Apply up to 100 ft 165 of force and attempt to rotate the roll toward the inside of the dryer If the metering roll will turn then repeat for right hand side If the metering roll will turn it can be assumed that no blockage exists and the problem is from some other cause Check fora break in the power train chain drive key pin etc CAUTION Keep hands away from sprocket teeth to avoid injury from ch
32. er and all augers will stop immediately 17 DRYER START UP CONTINUOUS FLOW AND CONTINUOUS BATCH START UP PROCEDURE Atthe beginning of each harvest and before filling the dryer with grain make sure to inspect the dryer for rodent damage proper belt and chain tension and missing or dam aged safety shields Test operate the dryer using the prestart check procedures located on pages 14 17 l Before attempting to operate the dryer make sure that all safety shields are in place all plenum bottom closure panel doors are closed all rear access doors are closed and all personnel are Clear ofthe grain dryer and grain handling machinery 2 selector switches on the control panel to the off position 3 Turn on the electric power sup ply to the dryer and move the safety disconnecthandle mounted on the dryer s upper power box to on 4 Turn the control power switch to on The switch will light up A copyright message model num ber total running time in hours and minutes current date and time will appear Atthis pointthe controller will lock outall other dryer functions Once the date and time appear press reset and the dryer will perform its safety circuit checks If a fault is found the cause will be dis played on the LCD If all are found safe the controller will 18 allow the electronic fuel shutoff valve to be manually opened if so equipped and the dry ing mode switch will light up indica
33. er unload auger will not operate mn Press the dryer power start button 2 Referto the problem listed for load auger fan heater and unload auger in the following sections Display shows L1 VOLTAGE LOST message The left circuit breaker located on the input output board of the Electronic Monitoring Control S ystem has tripped or one ofthe 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 S ystem has tripped Display shows MOTOR OVERLOAD message 44 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 TROUBLE ANALYSIS PROCEDURE Problem Possible Cause Display shows BURNER 1 2 OR 3 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 read justed This control is a 200 F limit which automatically resets when it cools Display shows BURNER 1 2 OR 3 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 dry
34. er is not getting burner fuel Display shows FAN 1 2 OR 3 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 indicat ing that grain is backing up into the discharge box Display shows LOWER 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 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 Display shows OUT OF GRAIN message Display shows OUT OF GRAIN UNLOAD CLEANOUT message 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 restart ing inspect load equipment for possible damage or adjustment Display shows PLENUM 1 2 OR 3 HIGH TEMPERATURE me
35. f any of the se lected switches are improperly positioned for staged batch dry ing the display will indicate the proper switch position and will not allow the dryer to operate until 14 15 the position of the switch is cor rected To shutdown the dryer close the fuel supply valve at the fuel tank or fuel source If the burners are operating let the dryer run out of fuel causing an automatic shutdown due to a loss of flame Close the fuel valve at the dryer and press the dryer power stop button Turn off the dryer s main circuit breaker located on the front of the power panel Turn off the main power supply to the dryer In case of an emergency press the dryer powerstop button The burners fans and all augers will stop immediately STAGED BATCH FAN amp HEATER SWITCH SETTINGS Fan Setting Heater Setting Fan Function Heater Function Auto Auto Fans stay on during dry and cool Burners stay on during dry timer cycle cycle only only Auto On Fans stay on during dry and cool Burners stay on during dry and cool cycle only 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 22 DRYER START UP amp OPERATION 1300 SERIES BATCH
36. f motor by tempo rarily mounting fan blade on motor shaft Rotate fan blade by hand making the necessary adjustments so the tip clearance between blade and housing is uniform If re quired remove the fan blade and fully tighten all four motor mount bolts Note Make sure to install and tighten the propellor in accordance with previous instructions The position of the fan motor provides easy access for service 29 SERVICE HEATER PARTS REMOVAL AND INSTALLATION Most of the heater parts can be re moved by simply identifying any at tached wiring and then disconnect ing the obvious mounting parts 1 Flame sensor Disconnect the wire connector and unscrew the flame sensor out of its mount ing bracket 2 Gas Solenoid valve coil s Unsnap either the plastic cap or the metal clip on the gas valve and slide the housing and coil off the valve stem and body Do not energize the coil when itis removed as the coil may be come damaged due to exces sive current flow 3 Regulator and gas solenoid valve s The gas regulator and so lenoid valve s are directional and mustbe connected as indicated by the markings near the port open ings Make sure gas is shutoff and purged from the system before re moving parts Note When installing a liquid 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
37. f the LCD display tells which timer is being used and the second line switches between total batches unload rpm or total bushels The third line indicates total dry time and the fourth line is time remain ing on the timers DRYER SAFETY CIRCUIT The Electronic Monitoring Control System continuously checks all safety circuits on the dryer and will automatically shut the dryer down should a problem occur The cause of the dryer shutdown will be dis played on the LCD display and a beeper will sound on the controller To restart the dryer after a safety shutdown first correct the reason for the shutdown and then press the dryer power stop button to reset circuit Press the start button The Electronic Monitoring Control System stores in its memory the time date and cause for the last 25 dryer safety shutdowns To review this in formation hold the reset button in for five seconds The procedure for re viewing the safety circuitshutdown log will be displayed on the LCD display DRYER CONTROL PANEL SAFETY CIRCUIT SHUTDOWN MESSAGES BURNER 1 2OR 3 VAPOR HIGH TEMPERATURE The LP gas vapor temperature sensor located in the gas pipe train downstream from the vaporizer has opened indicat ing that the vaporizor is running too hot and mustbe readjusted This sensoris set at 200 F and automatically resets itself when cool The message will dis tinguish between burner 1 and 2 BURNER 1 2 OR 3 WARNING FLAME NOT DET
38. ice station An authorized service station is the only place that can provide possible mo tor warranty Motor service and re pair at other places will be at own ers expense If the service station determines motor failure is caused by faulty ma terial or workmanship within the warranty period repair will be cov ered under the warranty Motor fail ure caused by external sources will result in a charge to the owner for repair 1 Make certain power is shut off and locked out Remove fan guard and propellor 2 Remove cover from fan heatercon trol box and disconnect the motor lead wires from within the box Note Tag or otherwise identify wires for ease of reassembly 3 Remove motor mount bolts If there are shims between the motor and its base note their location so they can be properly installed during reassembly 4 Disconnect the upper end of the motor conduit then carefully pull the wires through the hole in the fan heater housing Remove motor from the fan heater unit with the conduit still attached If motor re quires service take itto an autho rized service station 5 reinstall motor slide onto mo torbase plate and replace shims if required between motor base and plate Reinstall motor mount bolts and washer but do not fully tighten atthis time 6 Reinstallconduitand wires through hole in fan heaterhousing and care fully connect all electrical wiring 7 Adjustposition o
39. in 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min new dial setting 1000 Approx Dry Time 18 min 24 min 30 min 35 min 40 min 45 min 50 min 55 min 60 min 65 min 70 min 75 min 80 min 85 min 90 min 95 min 100 min 105 min 110 min Dry 18 min 24 min 30 min 35 min 40 min 45 min 50 min 55 min 60 min 65 min 70 min 75 min 80 min 85 min 90 min 95 min 100 min 105 min 110 min Cool 18 min 18 min 18 min 18 min 18 min 18 min 18 min 18 min 18 min 18 min 18 min 18 min 18 min 18 min 18 min 18 min 18 min 18 min 18 min Unload 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 10 min 23 DRYER START UP amp OPERATION 1300 SERIES STAGED BATCH TIMER SETTINGS Full Heat C00 Fan amp Burner Switch s on Manual 2 Fan on Manual 2 Burner on Auto 1 Fan on Manual 1 Burner on Off Initial Moisture Approx Approx Moisture Removed Dry Time Dry Cool Unload Dry Time Dry Cool Unload 17 2 pts 16 min 2 min 0 3 5 min 18 min 9 min 3 min 3 5 min 18 3 pts 21 min 3 5 min 0 3 5 min 24 min 12 min 3 min
40. ired setting is reached Pressing the increase and decrease buttons simultaneously will access the following programming features Safety circuit shutdown log Dryer model number Fandelay BPH factor Metering roll monitor disabling feature Air switch disabling feature These features are accessed se quentially as listed above Press the increase or decrease buttons to change a setting Press the enter button to move from feature to fea ture Pressing and holding the reset but ton for five seconds will access the following programming features Calendar year setting Calendar month setting Calendar day setting Clock hour setting Clock minute setting e Bushel counter reset Batch counter reset These features are accessed sequen tially as listed above Press the in crease or decrease buttons to change a setting Press the enter but ton to move from feature to feature Change the marquee on the LCD dis play Press and hold the modify button while turning on the control power Tochange a character press the increase or decrease button move the cursor to the right press the unload button move the cursor to the left press the dry button To delete a character press the cool button Press enter when the desired marquee is displayed To reset the computer to the original default setting turn off the computer press and hold the green AUX 1
41. is being utilized in the dryer control panel this switch will also control the opera tion of the auxiliary equipment FAN SWITCHES Each fan is turned on or off with this switch The on position oper ates the fan continuously during staged batch and continuous flow modes The auto position operates the fan in staged batch during the dry and cool cycle The switch will light up whenever the airflow switch is sensing airflow and the dryer is full of grain HEATER SWITCHES Each burner is turned on or off with this switch The auto position op erates the burner in staged batch during the dry cycle The on posi tion will operate the burner only when the fan is running The switch will light up only when the flame sensor detects the flame UNLOAD SWITCH The unload switch turns the meter ing rolls and discharge auger on or off and selects the operation of the metering rolls Inthe 2 speed position ifthe moisture control switch is on and the drying mode switch is turned to cont flow the metering roll speed will alternate between the high speed metering roll potentiometer setting and the low speed metering roll potentiometer set ting depending on the control signal from the moisture control thermo stat The discharge auger will oper ate continuously Inthe 1 speed position if the mois ture control switch is on and the dry ing mode switch is turned to cont flow the metering roll speed will op erat
42. itch and observe the fan rotation The fan should run counterclockwise Sometimes on three phase models all motors will run backwards They can easily be reversed by interchanging two ofthe 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 fans or burners will notoperate The fans cannot create enough static pressure to engage the air switch You will receive a loss of airflow message BURNER SAFETY check the burner safety function first make sure the main gas valve is off Tum the fan switch on and allow the fan to start Then turn the heater switch on for that fan The dryer will shut down after 20 seconds The safety message Burner 1 waming flame not detected will appear Restartdryer and repeatfor each fan heater BURNER TEST FIRE Test fire each burner by starting the fan Then turn the burner switch to on Turn on the fuel supply and the burner should ignite after a short 16 purge delay of approximately 10 seconds Gas pressure should be shown on the gauge Atthis time adjust the burner hi lo fire thermo statto 200 F causing the burner to operate on hi fire This thermostat is located on the front left side ofthe dryer Observe the gas pressure on gauge and turn the thermostatto its minimum setting causing the burner to cycle into lo fire As the burner thermostat is turned down the gas pressure should
43. l not fire No gas pressure with fan operating at least 15 seconds gas supply or fan heater malfunction Check gas supply Also check gas filter and gas line for possible obstruction or closed valves Refill tank replace or repair parts as required 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 120 volts Check for proper voltage 120 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 Fenwal Ignition Board Check board for spark by removing ignition wire from board and holding aninsu lated 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 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 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 Check lo fire solenoid valve fo
44. n other metal parts 9 Make sure all dryer guards and warning decals are securely in Stalled Make certain guards do not interfere with moving parts If guards orwaming decals are missing con tact your dealer for a free replace ment 10 Testfire the dryer several weeks ahead ofthe drying season Check for possible gas leaks See page 16 for burner test fire 27 SERVICE FAN PROPELLOR REMOVAL AND INSTALLATION The fan propellor is secured to the motor shaft by the use of a taper lock bushing motor shaft key and three cap screws CAUTION Although the taper lock method of retaining the propellor onto the motor shaft is simple it is essentialthatthe following points be read carefully and fully understood Improper installation can cause a loose flying propellor and result in serious injury or death THREADED BUSHING HOLES The threaded holes within the bush ing are provided for disassembly purposes only Do notattemptto use these holes for reassembly They will not allow the parts to lock onto the shaftthereby causing a hazard ous operating condition CLEARANCE HOLES When reassembling parts the cap screws must be installed through the untapped clearance holes as shown This will cause the propellor to be pulled forward onto the tapered bushing thus locking the parts se curely onto the motor shaft When fan servicing requires re moval and installation of the propellor make sure the propellor i
45. natural gas Turn on the Maxon electric shut off valve ifso equipped oropen the manual shut off valve to allow fuel flow to the dryer 5 The dryer should already be filled with grain Turn the load auger switch to auto In both the auto and manual position the grain level switch will automati cally keep the dryer full of grain In the auto position the dryer will shut down after the preset time period on the out of grain timer or ifthe grain flow to the dryer is interrupted 10 Turn the fan switch to auto The fan will start and the switch will lightup when airflow is detected Start the burner by turning the heater switch to auto After purg ing for approximately 10 sec onds the burner will fire and the heater switch will light up indi cating that the flame sensing circuitis sensing burner flame Forinformation concerning burner adjustment see the pre start section of this manual To properly setthe correct dry cool and unload time for various moisture content grains S ee the charts on page 23 and 24 If the dryer is being operated in all heat turn the fan switch to on In this position the fan will run continuously during the dry cool and unload stages ofthe staged batch operation If the dryer is being operated in the dry and cool mode the preferred position for the fan switch is the on position so the fan will run con tinuously If desired the fan can be turned off during the unload cycle of
46. ntrol is set at 210 F and automatically resets itself when cool MOTOR OVERLOAD One ofthe thermal overloads on ei ther the fan load unload or auxil iary motors has opened indicating an overcurrent condition The over loads must be manually reset OUT OF GRAIN WARNING UNLOAD CLEANOUT The dryer has run low on grain and the out of grain timer has timed out shutting the dryer down The unload auger will clean out the dryer if it is in continuous flow operation 12 VOLT POWER SUPPLY WARNING The right circuit breaker on the input output board has tripped L1 VOLTAGE LOST The left circuit breaker located on the input output board of the Elec tronic Monitoring Control System has tripped or one of the hardware timers has shut down the dryer METERING ROLL DRIVE SYSTEM FAILURE The metering roll drive system has failed to turn A broken chain or jammed metering roll is a possibility RIGHT METERING ROLL FAILURE The right as viewed from behind the dryer metering roll has stopped tum ing or the sensor has been damaged LEFT METERING ROLL FAILURE The left as viewed from behind the dryer metering roll has stopped turn ing orthe sensor has been damaged PLENUM 1 2OR 3 HIGH TEMPERATURE An over temperature condition has occurred inside the dryer plenum This control is a 300 F limit and au tomatically resets itself when cool The message will distinguish be tween plenum 1 and 2 AUXILIARY SAFETY SH
47. ow ing safety decals are not displayed on your dryer or if they are dam aged contact Grain Systems Inc for replacement A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENT A DANGER ROTATING AUGER KEEP HANDS FEET HAIR AND CLOTHING AWAY FROM INTAKE DO NOT REMOVE OR MODIFY ANY GUARDS KEEP CHILDREN AWAY FAILURE TO DO SO WILL RESULT IN SERIOUS INJURY OR DEATH SAFETY ALERT DECALS 44 DANGER Automatically controlled belt drive can start at any time Keep hands clear Failure to do so could result in serious injury or death DC 386 44 DANGER Do not operate without shields in place Before removing any shield disconnect main power supply and allow all moving parts to stop Replace shields securely before restarting unit Failure to do so could result in serious injury or death 85 44 DANGER Automatic equipment can start at any time Do not enter until fuel is shut off and electrical power is locked in off position Failure to do so will result in serious injury death DC 384 Three decals displayed on all Airstream Dryers Belt drives chain driven meter rolls and combustible fuels must be treated with caution 10 11 12 13 SAFETY PRECAUTIONS Read and understand the operating manual before trying to operate the dryer Never operate the dryer while the guards are removed Power supply should be OFF for service of electrical
48. p period start the flow of grain out of the dryer Turn the unload switch to the two speed position The bot tom auger and metering roll will immediately start and the un load switch will light If additional grain handling equipmentis uti lizing the unload auxiliary over load supplied with the dryer this equipment will also imme diately start 13 To shutthe dryer down close the fuel supply valve atthe fuel tank orfuel source Letthe dryer run until the fuel supply lines drain and the dryer automati cally shuts down due to loss of flame Close the fuel valve atthe dryer Press the dryer power stop button Turn offthe dryer s safety disconnect handle Tum off the main power supply to the dryer 14 In case of emergency push the dryer stop button The fan burner and all augers will stop immediately Note The Electronic Monitor ing Control System can be used to automatically startthe dryer Place all the control panel selector switches in the proper position and open the electric fuel shut off valve before pressing the dryer power start button The controller will start all dryer components in their proper order STAGED BATCH OPERATION 1 Tumthe control powerswitch to on 2 Make sure the drying mode switch is tumed to staged batch 3 Afterthe date and time appear press the reset button 4 Open the main fuel supply valve on the tank if using LP gas or the valve in the fuel supply line if using
49. r proper operation 47 TROUBLE ANALYSIS PROCEDURE 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 Tempo rarily 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 insuffi cient 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 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 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 48 Burner operates But will not cycle from lo fire to hi fire Check for an excessive lo fire gas pressure setting Observe pressure setting shown on gauge and compare reading
50. rolled rectifier control within the main control box MAIN CONTROLS 1 SCRspeedcontrol The meter ing roll speed pots on the front of the control box regulate the speed ofthe DC motor which drives the metering rolls The markings on the scale from 0 to 999 represent the flow of grain past the metering rolls as a percent of the maximum grain discharge rate for the dryer The maximum setting of 999 provides a maximum 10096 discharge of 1960 BPH for 1314 2520 BPH for 1318 3080 BPH for 1322 model dryers Note When the control is set to the maximum discharge rate 999 the metering roll speed should be 17 5 RPM for 8 dis charge auger 2 DC electric motor The direct current DC motor provides the drive for the metering roll and is located on the front left hand side of standard model dryers The output shaft of the motor is connected directly to the gear box assembly The DC motor requires no operational SERVICE METERING ROLL SERVICING adjustment as it is completely controlled from the control box Speed reducer gear box The direct drive gear box provides the required speed reduction and transmits power to the me tering 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 Unload auger time delay The delay controls the bottom auger system and causes the unload auger and any conn
51. s 100 min 100 082 116 These are approximate starting points 19 DRYER START UP amp OPERATION CONTINUOUS FLOW METERING ROLL SETTINGS Dry Cool Initial Moisture Approx 2 Speed 2 Speed Moisture Removed Dry Time 1 Speed Low High 17 2 pts 18 min 363 187 650 18 3 pts 24 min 272 163 550 19 4 pts 30 min 218 145 450 20 5 pts 35 min 187 131 363 21 6 pts 40 min 163 119 272 22 7 pts 45 min 145 109 218 23 8 pts 50 min 131 101 187 24 9 pts 55 min 119 093 163 25 10 pts 60 min 109 087 145 26 11 pts 65 min 101 082 131 27 12 pts 70 min 093 077 119 28 13 pts 75 min 087 073 109 29 14 pts 80 min 082 069 101 30 15 pts 85 min 077 065 093 31 16 pts 90 min 073 061 087 32 17 pts 95 min 069 057 082 33 18 pts 100 min 065 053 077 34 19 pts 105 min 062 049 073 35 20 pts 110 min 059 045 069 These are approximate starting points 20 DRYER START UP 11 To move grain through the dryer turn the moisture control switch to on The switch will light up Note When the unload switch is in the 2 speed position and the moisture control thermostat switch is off the speed ofthe metering rolls can be manually adjusted by turn ing the high speed metering roll dial Turning the dial clockwise will in crease the grain discharge rate counterclockwise will decrease the discharge rate The numbers on the speed dials indicate the percentage of full speed 12 Atthe end ofthe startu
52. s removed and reinstalled properly 1 Lock outthe fan power supply and remove the fan guard and the venturi as required on some models 28 Key Remove the three cap screws from the clearance holes in the taper lock bushing Installtwo grade 5 cap screws into the threaded holes in bush ing and turn them by hand until they bottom againstthe front surface of the propellor Block propellor to prevent it from tuming and gradually tum the cap screws upto 1 4 tum ata time until the propellor breaks loose from the bushing and motor shaft Carefully Capscrews installed through threaded holes of bushing Fan Hub Split Taper Bushing Fan blade installation remove bushing and propellor With the propellorfree from the bushing a wheel can be used to pull the bushing off ofthe motor shaft R e attach bushing onto propellorto pre ventthe loss of parts Note During manufacture the propellor and bushing are balanced together and are marked with two small dots to identify their original alignment position Check the bush ing and propellor to make sure they have alignment marks Mark the alignment of the propellor and bush ing if necessary Capscrews installed through threaded holes of bushing Fan Hub Split Taper Bushing Fan blade removal SERVICE FAN MOTOR REMOVAL AND INSTALLATION In the event of motor failure remove the motor as described and take it to the nearest serv
53. sonal injury or death Grain S ystems Inc recommends thatyou contact your local power com pany and have a representative sur vey your dryer installation so your wir ing will be compatible with their sys tem and you will have adequate power supplied to your unit DANGER hi Do not operate with service door removed MAY CAUSE SERIOUS INJURY OR DEATH 1989 GRAIN SYSTEMS INC stand safe operating proceedures and some problems which may be encountered by the operator and other personnel As owner and or operator it is your responsibility to know what re quirements hazards and precau SAFETY ALERT SYMBOL tions exist and to inform all person nel associated with the equipment or who 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 dryer should read this manual manual mustbe delivered with equipment to its owner Failure to read this manual and its safety instructions is a misuse of the equipment WARNING BE ALERT Personnel operating or working around a This SAFETY ALERT DECALS A DANGER Disconnect electricity before inspecting or servicing Keep guards and screens on exposed areas MAY CAUSE SERIOUS INJURY OR DEATH 1992 GRAIN SYSTEMS INC Safety decals should be read and understood by all people in and around the dryer area If the foll
54. ssage An over temperature condition has occurred inside the dryer plenum This control is a 300 F limit which automati cally 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 5 8 and 1 20 terminals on the input output board Display shows BURNER 1 2 OR 3 SHUTDOWN LOSS OF AIRFLOW message The air switch contacts have opened indicating insufficient airflow for burner to operate The number in the warning message designates the fan burner or plenum where the problem is located All areas are numbered from the bottom up For example the bottom fan is number 1 and the top fan is number 3 45 TROUBLE ANALYSIS PROCEDURE Problem Possible Cause Display shows 1 2 OR 3 FAILURE NO AIRFLOW message The air switch contacts have opened indicating the fan may not be turning The air switch m
55. tent pending Electronic Monitoring Con trol System is a computerized con trol system that gives instant 8 This electronic thermostat controls the moisture level of discharged grain by sensing grain column tem perature off to the moisture control thermo stat It lights up when the grain col umn temperature is below the ther mostat set point DRYER CONTROL CONTROL POWER SWITCH The powerto the Electronic Moni toring Control System is turned on or off with this switch OUTSIDE LIGHT The dryer service light is turned on or off here It also may be set on auto which turns the light on while the dryer is running and off if a shutdown occurs DRYING MODE SWITCH This is used to select staged batch or continuous flow drying The switch will light only afterthe Elec tronic Monitoring Control System has been turned on the safety cir cuit is okay and the reset button on the control panel has been pressed LOAD AUGER SWITCH This is used to select the opera tion of the fill auger In both the auto and manual position the load auger will operate ifthe dryer is low on grain and will automatically shut off when the dryer is full In the auto position only the dryer will shut down after a preset period of time set on the out of grain timer or if grain flow is interrupted to the dryer The switch will light when ever the load auger is operating Note If the load auxiliary mo tor overload relay
56. the burner will fire and the heater switch will light up This indicates thatthe flame sensing circuitis sensing bumer flame For information concerning burner adjustment see the pre start section of this manual Operate the heaters to dry grain for 6 7 minutes per point of moisture to be removed with the plenum tem perature setat 180 F Example Shelled com starts with 2596 mois ture and the final moisture content is to be 1596 1096 removal Us ing the all heat dryeration process the estimated drying time is 60 min utes 10 x 6 While operating the dryeradjustthe metering roll dials to the recom mended settings Seethe charts on page 19 and 20 DRYER START UP amp OPERATION 1300 SERIES CONTINUOUS FLOW METERING ROLL SETTINGS Full Heat Initial Moisture Approx 2 Speed 2 Speed Moisture Removed Dry Time 1 Speed Low High 17 2 pts 16 min 625 317 875 18 3 pts 21 min 476 270 175 19 4 pts 26 min 385 241 675 20 5 pts 31 5 min 317 213 575 2196 6 pts 37 min 270 196 476 2296 7 pts 41 5 min 241 185 385 2396 8 pts 47 min 213 172 317 2496 9 pts 51 min 196 161 270 25 10 pts 54 min 185 150 241 26 11 pts 58 min 172 140 213 2196 12 pts 62 min 161 132 196 2896 13 pts 66 5 min 150 123 185 2996 14 pts 71 5 min 140 116 172 3096 15 pts 76 min 132 110 161 3196 16 pts 81 min 123 104 150 3296 17 pts 86 min 116 100 140 3396 18 pts 91 min 110 096 132 3496 19 pts 96 min 104 087 123 3596 20 pt
57. ties from those suppliers This warranty is ex clusive and in lieu of all other war ranties expressed or implied Grain Systems Inc reserves the right to make design or specification or natural gas fuel supply with either single phase 230 volt or three phase 220 or 440 volt elec trical power changes at any time without any contingentobligations to purchasers of products already sold All instructions shall be con strued as recommendation only Because of the many variable con ditions in actual installation Grain S ystems Inc assumes no liability for results arising from the use of such recommendations Any alter ation in design or operation of any Grain S ystems Inc product mustbe submitted and approved in writing by Grain Systems Inc before the al teration is made Airstream Service Technician checks the wiring on a single module grain dryer SAFETY FIRST Grain Systems Inc s principle con cern is your safety and the safety of others associated with grain han dling equipment This manual was written with thatthoughtin mind We want to keep you as a customer This manual is to help you under The symbol shown below is used to call your attention to instructions concerning your personal safety Watch for this symbol it points out important safety precautions It means ATTENTION WARNING CAUTION and DANGER Read the message that follows and be cautious to the possibility of per
58. ting thatthe dryer is ready to be started 5 Move the load auger switch to manual and push the dryer power startswitch The top au ger will immediately start and the load auger switch will light up If additional grain handling equipment is wired to the dryer it will also start immediately 6 When the dryer is full of grain the top auger will stop automatically and any grain handling equipment wired to the dryer will also stop CONTINUOUS FLOW OPERATION 1 Tum the control power switch to on 2 After the date and time appear on screen press the reset button p Pushthe dryer power startswitch 4 Open the main fuel supply valve on the tank if using LP gas or open the fuel supply line if us ing natural gas Turn on the Maxon electric shut off valve if so equipped oropenthe manual shut off valve to allow fuel flow to the dryer 5 Turn the drying mode switch to continuous flow 6 10 The dryer should already be filled with grain Turn the load auger switch to the auto posi tion In both the auto and manual positions the dryer grain level switch will automatically keep the dryer full of grain In the auto position the dryer will shutdown after a presettime period on the out of grain timer Turn the fan switch to on The fan will start and the switch will light up when airflow is detected Start the burner by turning the heater switch to on After purg ing for approximately 10 sec onds
59. uel flow to the dryer In spect all gas lines and connections for possible leaks Any gas leaks mustbe fixed immediately The metering roll access area LOAD AUGER With the grain supply shut off quickly bump the load auger switch to manual and see ifthe load auger rotates clockwise as viewed from the drive end or counterclockwise ifthe dryer is a frontload model Ifthe wet grain supply auxiliary is wired to the dryer itshould also rotate in the cor rect direction at this time Turn the load auger switch to the auto posi tion The top auger and wet grain supply auxiliary should run for one minute and then the dryer will shut down leaving the safety shutdown message outof grain warning dis played Press the dryer power stop button to resetthe panel then press the start button ONE SPEED OPERATION To check one speed operation place the unload switch in the one speed setting Turn up the high speed metering roll dial until the metering rolls start rotating The bottom auger should rotate coun terclockwise as viewed from the drive end The metering roll drive motor should rotate clockwise as viewed from the drive end ofthe gear box Ifthe dry grain take away auxil DRYER PRE START CHECKS iary is wired to the dryer itshould start and rotate in the proper direction MOISTURE CONTROL THERMOSTAT To check the moisture control ther mostat leave the unloading switch on one speed and slowly turn
60. umu lation of foreign material Clean Inspect flame sensors for pos sible damage or poor connec tions Flame sensor wires must be in good condition Inspectand manually rotate the top augerpaddle assembly The paddle unit mustrotate freely withoutany indication of sticking or binding Inspectthe top auger and bottom auger drive lines for proper adjust mentand condition R eadjustline tension as required Note All of the auger and me if required Foreign material in tering roll bearings are lifetime lu the burnercup orcasting willnot bricated and do not require service burn out and will impair burner relubrication operation 3 Ifrequired inspect ignitor plug and clean the electrodes Use an igni tion pointfile to remove carbon and rust between the electrode sur faces Ignitor gap should be about 1 8 inch Operate dryer clean out levers and check cleanouthatch mecha nism for proper operation With hatch open inspectand remove any accumulation of dirt fines and foreign material from the bottom auger trough area Bottom Auger Drive Note Do not allow high mois ture material to collect within the trough area It may adversely affect metal parts 8 Inspectentire dryer for loose worn or damaged parts Include check of auger flighting metering rolls and other intemal parts Check thattem perature sensors within air ple num chamber are secured within insulated clamps and do not chafe o
61. with recommended low pressure settings listed in this manual Readjust lo fire setting on flow control valve if necessary Check for improperly adjusted or defective hi lo fire thermostat control Temporarily increase the tempera ture 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 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 after turning on the control power press the reset button Setting the dry cool unload and out of grain timers Press the dry cool unload or out of grain button Press the modify button Press the increase or decrease button to get desired setting Press the enter button when desired setting is reached Setting the load and unload delays Press the load or unload button Press the modify button Press increase or decrease button to get desired setting Press the enter button when des
62. y Any side play is an indication of defective motor bearings which should be replaced to preventa complete motor failure Make sure motor mount bolts are tight 4 Motorbearings should be lubricated periodically depending on operat ing conditions Under normal usage itis desirable to have the motor cleaned checked and bearings re packed by an authorized service station every two to three seasons If the unit is operated continu ously through most of the year this service should be performed each year Note If on site bearing relubrication is to be performed see lubrication instructions for ball bear ing motors To keep motor bearings properly lubricated and dispel any accumulation of moisture within the windings the fan and auger motors should be operated for 15 to 30 min utes each month LUBE PROCEDURES If the motors are equipped with an alemite fitting clean the tip ofthe fit ting and grease with a grease gun Use 1 or 2 full strokes on motors in NEMA 215 frame and smaller Use 2 to 3 strokes on NEMA 254 through NEMA 365 frame Use 3 to 4 strokes on NEMA 404 frames and larger On motors having drain plugs remove drain plug and operate motor for 20 minutes before replacing drain plug On motors equipped with slotted head grease screw remove screw and apply grease tube to hole In sert 2 to 3 inch length of grease string into each hole on motors in NEMA frame and smaller Insert 3 to 5 inch length on l

Airstream PNEG-343 Clothes Dryer User Manual

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