AIRSTREAM GRAIN CONDITIONING SYSTEMS DRYER OPERATION 1 9 9 4 AND SERVICE MANUAL PNEG-343 1300 SERIES THREE FAN PORTABLE DRYER MODELS 1
1300 SERIES DRYER OPERATION AND SERVICE TABLE OF CONTENTS Warranty.......................................................................................................................4 Safety First...................................................................................................................5 Safety Alert Decals.......................................................................................................6 Safety Precautions.....................................................
1300 SERIES DRYER OPERATION AND SERVICE Thank you for choosing an Air- This manual describes the op- or natural gas fuel supply, with stream Grain Dryer. This dryer is eration and service for all standard either single phase 230 volt, or one of the finest ever built. It is production 1300 series three fan three phase 220 or 440 volt elec- designed to give excellent perfor- grain dryers. These models are trical power. mance and service for many years.
SAFETY FIRST Grain Systems, Inc.'s principle con- stand safe operating proceedures tions exist, and to inform all person- cern is your safety and the safety of and some problems which may be nel associated with the equipment others associated with grain han- encountered by the operator and or who are in the dryer area. Avoid dling equipment. This manual was other personnel. any alterations to the equipment. written with that thought in mind.
SAFETY ALERT DECALS Three decals displayed on all Airstream Dryers. Belt drives, chain driven meter rolls and combustible fuels must be treated with caution.
SAFETY PRECAUTIONS 1. Read and understand the operating manual before trying to operate the dryer. 2. Never operate the dryer while the guards are removed. 3. Power supply should be OFF for service of electrical components. Use CAUTION in checking voltage or other procedures requiring power 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, to be ON.
DRYER CONTROL PANEL Figure 1: The grain dryer control panel with the Electronic Monitoring Control System in the upper right panel. DRYER CONTROL PANEL FEATURING THE ELECTRONIC MONITORING CONTROL SYSTEM MOISTURE CONTROL SWITCH The control panel provides easy access information regarding dryer operation. to gauges and controls, and the illuminated switches provide a quick reference MOISTURE CONTROL THERMOSTAT This switch turns the power on or for every operating function.
DRYER CONTROL PANEL CONTROL POWER SWITCH FAN SWITCHES ture control switch is on, and the dry Each fan is turned on or off with ing mode switch is turned to cont. The power to the Electronic Moni- this switch. The on position oper- flow, the metering roll speed will op- toring Control System is turned on ates the fan continuously during erate at the high speed metering roll or off with this switch. staged batch and continuous flow potentiometer setting or turn off de- modes.
DRYER CONTROL PANEL HIGH SPEED METERING ROLL POTENTIOMETER when the moisture control is not used. flow, pressing the dryer power start • Set the rate of grain discharge from button and then turning on the de- This is used to: the dryer during the unload cycle of • Set the high speed of the metering roll staged batch dryer operation. sired dryer component.
DRYER CONTROL PANEL ELECTRONIC MONITORING CONTROL SYSTEM SETTING THE DRY, COOL, BATCH AND UNLOAD TIMERS if the dryer is stopped, these times The Electronic Monitoring Control These switches are used to set the cycle continue timing down. The timers System (Figure 2) controls all tim- times in the staged batch drying mode will return to their initial setting if ing functions and safety circuit only. The drying mode switch must be the reset button is pushed. checks.
DRYER CONTROL PANEL The Airstream Electronic Monitoring Control System showing several different LCD displays. SETTING THE LOAD AND UNLOAD DELAYS bushels dried on the third line.
DRYER CONTROL PANEL SAFETY CIRCUIT SHUTDOWN MESSAGES The LP gas vapor temperature sensor LOWER ADJUSTABLE GRAIN HIGH TEMPERATURE The metering roll drive system has located in the gas pipe train downstream An over temperature condition has oc- failed to turn. A broken chain or from the vaporizer, has opened indicat- curred in the right side (left and right as jammed metering roll is a possibility.
DRYER PRE START CHECKS PRE SEASON INSPECTION Before the dryer is filled, thoroughly inspect the unit and check the operation of the dryer as follows. INSPECT THE METERING ROLLS Open all metering roll access doors and inspect each compartment for any bolts, nuts or other foreign material, that may cause possible jamming of the metering rolls. BEFORE ATTEMPTING TO OPERATE THE DRYER MAKE SURE ALL SAFETY SHIELDS The Maxon safety shut off valve.
DRYER PRE START CHECKS iary is wired to the dryer, it should start and rotate in the proper direction. MOISTURE CONTROL THERMOSTAT To check the moisture control thermostat leave the unloading switch on one speed, and slowly turn down the moisture control thermostat. As the setting is decreased, the indicator light should come on and the metering rolls should stop operating.
DRYER PRE START CHECKS crease the speed. Make sure the purge delay of approximately 10 fire pressure settings. Use the drive chain tension is properly ad- seconds. Gas pressure should be pressure regulator for hi-fire and justed and all sections of the meter- shown on the gauge. At this time the ball valve for lo-fire. The ther- ing rolls rotate. Turn the unload switch adjust the burner hi-lo fire thermo- mostat should cycle between high off after these checks are complete.
DRYER PRE START CHECKS All dryer functions should be checked before operation each season. slightly decease gas pressure with Turn on the electric shut off valve to DRYER SHUTDOWN the lo-fire control valve. If the gas allow fuel flow to the dryer, if so To shut down the dryer, first close pressure is decreased too much a equipped. Turn the load switch to the fuel supply valve at the tank or popping or fluttering sound will be auto and unload switch to one valve along the fuel line.
DRYER START UP CONTINUOUS FLOW AND CONTINUOUS BATCH START UP PROCEDURE At the beginning of each harvest and allow the electronic fuel shutoff 6. The dryer should already be before filling the dryer with grain valve to be manually opened filled with grain. Turn the load make sure to inspect the dryer for (if so equipped), and the dry- auger switch to the auto posi- rodent damage, proper belt and ing mode switch will light up, tion.
DRYER START UP & OPERATION 1300 SERIES CONTINUOUS FLOW METERING ROLL SETTINGS Full Heat Initial Moisture Moisture Removed Approx. Dry Time 1 Speed 2 Speed Low 2 Speed High 17% 2 pts. 16 min. 625 317 875 18% 3 pts. 21 min. 476 270 775 19% 4 pts. 26 min 385 241 675 20% 5 pts. 31.5 min. 317 213 575 21% 6 pts. 37 min. 270 196 476 22% 7 pts. 41.5 min. 241 185 385 23% 8 pts. 47 min. 213 172 317 24% 9 pts. 51 min. 196 161 270 25% 10 pts. 54 min.
DRYER START UP & OPERATION CONTINUOUS FLOW METERING ROLL SETTINGS* Dry & Cool Initial Moisture Moisture Removed Approx. Dry Time 1 Speed 2 Speed Low 2 Speed 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.
DRYER START UP 11. To move grain through the dryer burner and all augers will stop 6. Turn the fan switch to auto. The turn the moisture control switch immediately. fan will start, and the switch will to on. The switch will light up. Note: The Electronic Monitor- light up when airflow is detected. Note: When the unload switch ing Control System can be used to is in the 2 speed position, and the automatically start the dryer. Place 7.
DRYER START UP & OPERATION matically shut down during the setting programmed into the the position of the switch is cor- cooling and unloading cycles. system, turn the moisture con- rected. trol setting to off. To use the au11. Turn the unload switch to the tomatic moisture control so that 14. To shutdown the dryer, close the one speed position.
DRYER START UP & OPERATION 1300 SERIES BATCH TIMER SETTINGS Dry & Cool Full Heat Fan & Burner Switche(s) on Manual Fan(s) on Manual Burner(s) on Auto Initial Moisture Moisture Removed Approx. Dry Time Dry Cool Unload* Approx. Dry Time Dry Cool Unload* 17% 2 pts. 16 min. 6 min. 0 10 min. 18 min. 18 min. 18 min. 10 min. 18% 3 pts. 21 min. 11 min. 0 10 min. 24 min. 24 min. 18 min. 10 min. 19% 4 pts. 26 min 16 min 0 10 min. 30 min 30 min 18 min 10 min. 20% 5 pts.
DRYER START UP & OPERATION 1300 SERIES STAGED BATCH TIMER SETTINGS Dry & Cool Full Heat Fan & Burner Switch(s) on Manual #2 Fan on Manual #2 Burner on Auto #1 Fan on Manual #1 Burner on Off Initial Moisture Moisture Removed Approx. Dry Time Dry Cool Unload* Approx. 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. 3.5 min. 19% 4 pts. 26 min 5.5 min 0 3.5 min.
1300 SERIES SERVICE GUIDE 25
SERVICE SEASONAL INSPECTION AND SERVICE The dryer is made of weather resis- tional weight can seriously effect accumulation of moisture within the tant material, and is designed to re- the balance, and result in harmful windings, the fan and auger motors quire a minimum of service. How- vibrations and a short bearing life. should be operated for 15 to 30 min- ever, each season we recommend the following items be checked be- utes each month. 3. Check each propellor for free play.
SERVICE SUGGESTED LUBRICANTS Insulation Class Consistency Type Grease Frame Type A&B A&B F&H Medium Medium Medium Polyurea Polyurea Polyurea Shell Dolium R Shell Dolium R Shell Dolium R 215T & Smaller 254 & Larger All Inspect flame sensors for pos- Note: Do not allow high mois- tering roll bearings are lifetime lu- sible damage or poor connec- ture material to collect within the bricated and do not require service tions. Flame sensor wires must trough area.
SERVICE FAN PROPELLOR REMOVAL AND INSTALLATION Capscrews installed through threaded holes of bushing The fan propellor is secured to the motor shaft by the use of a taperlock bushing, motor shaft key and three cap screws. CAUTION: Although the taper-lock method of retaining the propellor onto the motor shaft is simple, it is Fan Hub Key essential that the following points be Split Taper Bushing read carefully and fully understood.
SERVICE FAN MOTOR REMOVAL AND INSTALLATION In the event of motor failure, remove trol box, and disconnect the motor if required, between motor base the motor as described, and take it lead wires from within the box. and plate. Reinstall motor mount to the nearest service station. An Note: Tag or otherwise identify bolts and washer, but do not fully authorized service station is the only wires for ease of reassembly. tighten at this time.
SERVICE HEATER PARTS REMOVAL AND INSTALLATION Most of the heater parts can be re- b. Disconnect gas solenoid valve b. Use a dependable brand of moved by simply identifying any at- coils. Be sure to mark which one high temperature pipe caulking tached wiring, and then disconnect- goes where. compound when assembling gas ing the obvious mounting parts. connections. Apply only a light c. Lift pipe (with orifice, solenoid coating onto male threaded end 1.
SERVICE METERING ROLL SERVICING adjustment as it is completely controlled from the control box. 3. Speed reducer gear box: The direct drive gear box provides the required speed reduction, and transmits power to the metering rolls through a drive chain arrangement. The gear box does not require adjustment. The drive chain should also be periodically lubricated and retensioned as necessary. 4.
SERVICE HOW TO DETERMINE A METERING ROLL PROBLEM To determine if the metering problem is from blockage, perform the following test with the power off. Remove the drive chain by loosening the motor mounting bolts. Refer to photo, and place a pipe wrench on the hub of the roller chain sprocket, on the left hand metering roll at the drive end of the dryer. Apply up to 100 ft. lbs. of force, and The metering roll drive.
1300 SERIES WIRING DIAGRAMS 33
1300 SERIES WIRING DIAGRAMS INPUT/OUTPUT BOARD TERMINAL IDENTIFICATION 34
1300 SERIES WIRING DIAGRAMS 1300 SERIES WIRING TO CONTROL BOX 35
1300 SERIES WIRING DIAGRAMS 1300 SERIES CONTROL WIRING 36
1300 SERIES WIRING DIAGRAMS 1300 SERIES SAFETY WIRING DIAGRAM 37
1300 SERIES WIRING DIAGRAMS 1300 SERIES FRONT PANEL INTERNAL WIRING 38
1300 SERIES WIRING DIAGRAMS 1300 SERIES FRONT PANEL EXTERNAL WIRING 39
1300 SERIES WIRING DIAGRAMS DRYER FAN CAN CONTROL WIRING 40
1300 SERIES WIRING DIAGRAMS 1300 SERIES 220 VOLT SINGLE PHASE CONTROL WIRING 41
1300 SERIES WIRING DIAGRAMS 1300 SERIES 220 VOLT 3 PHASE POWER WIRING 42
1300 SERIES WIRING DIAGRAMS 1300 SERIES 440 VOLT 3 PHASE POWER WIRING 43
TROUBLE ANALYSIS PROCEDURE A multimeter is required for some of • The safety circuit is 12 volts DC CAUTION: When making high volt- the following checkout procedures. • When checking these circuits, age tests with "live" circuits, be ex- Before performing any tests, check measure voltage between the cir tremely careful. Follow established if the dryer power supply is 1 phase, cuit test location and to ground. safety practices. Turn power on for 230 volt, or 3 phase, 230 or 460 volt.
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 readjusted. (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.
TROUBLE ANALYSIS PROCEDURE Problem Possible Cause Display shows "FAN 1, 2 OR 3 FAILURE-NO AIRFLOW" message.* The air switch contacts have opened, indicating the fan may not be turning. The air switch may 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.
TROUBLE ANALYSIS PROCEDURE Problem Possible Cause Grain not moving through columns. 1. Check the dryer for fine material buildup inside the columns. 2. Avoid leaving the dryer columns full for long periods at a time (2-3 days) while not operating the dryer or during rainy weather. 3. Empty the dryer. Keep the dryer clean! Do not allow fine material to gather in the plenum chamber. 4. It may be necessary to open the strike off plates in the affected columns in half inch intervals.
TROUBLE ANALYSIS PROCEDURE 48 Problem Possible Cause Burner operates-But will not cycle from hi-fire to lo-fire. 1. Check the gas pressure reading on the gauge. Problem may be due to insufficient gas regulator setting. Temporarily decrease the hi-lo fire thermostat setting to verify that the thermostat will function and cause the burner to cycle. If burner will cycle at the reduced thermostat setting, it indicates that the problem was due to insufficient heat to satisfy the original setting.
QUICK REFERENCE GUIDE ELECTRONIC MONITORING CONTROL SYSTEM Important! To activate the controller • Fan delay Change the marquee on the LCD dis- after turning on the control power, • BPH factor play: press the reset button. • Metering roll monitor disabling • while turning on the control power feature Setting the dry, cool, unload and out • of grain timers: These features are accessed se- • Press the dry, cool, unload or quentially as listed above.
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AIRSTREAM GRAIN CONDITIONING SYSTEMS 1004 E. Illinois St.