TM-Series Tower Dryer Operation Manual PNEG-1707 Date: 12-28-09 PNEG-1707
All information, illustrations, photos, and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.
Table of Contents Contents Chapter 1 Safety .................................................................................................................................................. 5 Safety Guidelines ............................................................................................................................... 5 Dryer Operation ..................................................................................................................................
Table of Contents Chapter 7 Test Firing ........................................................................................................................................ 34 Dryer Checks .................................................................................................................................... 34 Inspect the Accutrol Metering System .............................................................................................. 34 Electrical Power ...............................
1. Safety Safety Guidelines This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections.
1. Safety Dryer Operation Thank you for choosing a GSI product. It is designed to give excellent performance and service for many years. This manual describes the operation for all standard production model dryers. These dryers are available with liquid propane or natural gas fuel supply and 3 phase 230, 380, 460, or 575 volts (50 Hz or 60 Hz) electrical power. Our foremost concern is your safety and the safety of others associated with this equipment. We want to keep you as a customer.
1. Safety Operating Precautions READ THESE INSTRUCTIONS BEFORE INSTALLATION AND OPERATION SAVE FOR FUTURE REFERENCE 1. Read and understand the operations manual before attempting to operate the unit. 2. Keep ALL guards, safety decals, and safety devices in place. NEVER operate dryer while guards are removed. 3. Keep visitors, children and untrained personnel away from dryer at all times. 4. Never attempt to operate the dryer by jumping or otherwise bypassing any safety devices on the unit. 5.
1. Safety Prepare for Emergencies Be prepared if fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone. Keep Emergency Equipment Quickly Accessible Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job. Eye Protection Remove all jewelry. Long hair should be tied up and back.
2. Safety Decals Contact the local power company to have a representative survey the installation to assure the wiring is compatible with their system and adequate power is supplied to the unit. Safety decals should be read and understood by all people in the grain handling area. Inspect all decals and replace any that are illegible, worn, or missing. Contact your dealer or the factory to order replacement decals. If a decal is damaged or is missing, contact: GSI Decals 1004 E. Illinois St. Assumption, IL.
2. Safety Decals WARNING! DO NOT STAND ON DRUM! Rotating drum will cause serious injury or death. Disconnect power before servicing. DC-1062 Decal: DC-1062 Flame and pressure beyond door. May cause serious injury. Do not enter when dryer is running. Decal DC-1062 is located inside the cooling section of the dryer on the two access doors to the metering section. DC-1061 Decal: DC-1061 Decal DC-1061 is located on the outside of the heat section door. WARNING! Airborne particles during operation.
3. Specifications Modular Tower Dryer Specifications Models TM-1008 TM-1010 TM-1012 TM-1015 Blower Size 43" Axial 43" Axial 43" Axial 48" Axial Blower RPM 1775 1775 1775 1775 Blower HP 40 50 60 75 Metering HP 1 1 1 1 Drying CFM 38000 45000 52000 66000 Cooling CFM 19500 22500 26000 33000 Burner Capacity (mBtu)2 8.2 9.7 11.2 14.3 Average Heat Use (mBtu) 5.1 6.1 7.0 8.
3. Specifications Dimensions M-1008T - Five (5) sections total usually ships on two (2) trucks all five (5) sections are 10'-10" in diameter. Figure 3A M-1008T 12 M-1010T - Six (6) sections total usually ships on two (2) trucks all six (6) sections are 10'-10" in diameter.
3. Specifications Dimensions (Continued) M-1012T - Seven (7) sections total usually ships on three (3) trucks all seven (7) sections are 10'-10" in diameter. M-1015T - Eight (8) sections total usually ships on three (3) trucks all eight (8) sections are 10'-10" in diameter.
4. Dryer Installation Dryer Layout System Layout Consider the grain handling system and location of storage bins and existing conveyors when selecting dryer site, to facilitate wet grain supply and dry grain discharge to conveyors. Other considerations are prevailing wind direction, fuel and power supply locations, noise and convenience of control location.
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4. Dryer Installation Fuel Supply NOTE: See table on Page 19 for recommended line size. Figure 4D Liquid Propane (LP) Fuel Supply Connection to natural gas manifold on dryer NOTE: See table on Page 19 for recommended line size. Natural gas meter and regulator.
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4. Dryer Installation Power Supply Disconnect All dryers are equipped with a power disconnect switch in the power box to permit total power shut down before opening the power box door, as required for inspection and service. The power disconnect switch is located on the power box door for quick shut down. See table on electrical requirements below for sizing the electrical service to the dryer. Electrical Requirements Dryer Model HP Motor Full Load Amps 40 94 1 - DC 5 Unload Auger 3 8.
4. Dryer Installation Machine to Earth Grounding It is very important that a machine to earth ground rod be installed at the dryer. Place the ground rod that comes standard, within eight feet (8') of the dryer and attach it to the dryer control panel with at least a #6 solid, bare, copper ground wire and the clamp provided. The grounding rod located at the power pole will not provide adequate grounding for the dryer.
5. Operating Controls Vision Control Panel Layout Touch screen Heater switch Fan switch Load auger switch Unload auger switch Operator light switch Control power switch Stop switch Start switch Meter system speed Figure 5A The vision control system is a state of the art dryer controller used on several GSI drying products. The vision control can operate any dryer in either a batch or a continuous flow mode.
5. Operating Controls Heater Switch The burner is turned ON or OFF with this switch. Turning the switch to the ON position will start the burner ignition sequence if the fan is also running. Turning the switch to the OFF position turns the burner OFF. The light inside of the switch will illuminate only when the flame sensor detects the burner flame. (NOTE: The heater AUTO position is not used for continuous flow operation.
6. Vision Touch Screen Display Boot Screen Turning the Power switch in the ON position, will start the Vision computer. The first screen to appear will be the Boot screen. (See Figure 6A.) Notice that there are four (4) “buttons” on the Boot screen. Install Dryer Software and Get Program From USB Flash buttons are only used for program updates that may be released at a later date. Touching the Start Dryer button will display the Default Operation screen.
6. Vision Touch Screen Display Figure 6B Setting the Timers Setting the timers for the dryer is a simple procedure. To set the timers, touch the button at the bottom of Operation screen. A new screen will appear called the Select Timers to Modify screen. (See Figure 6C on Page 26.) As you can see there are five (5) timers that you can modify: 1. Load delay: This delay is used to delay the starting of the load conveyor when the dryer is unloading to prevent the load conveyor from cycling to often. 2.
6. Vision Touch Screen Display Modifying timer set point Operation screen for setting timers Figure 6C To setup a timer touch the button of the timer you wish to modify. The Modify Timer Set Point screen will then be displayed. (See Figure 6C.) Note that there are two (2) number pads on this modify screen. The left number pad is used to modify the minutes and the right number pad will modify the seconds.
6. Vision Touch Screen Display Figure 6D The plenum temperature set point range is 80°F-250°F, and the current temperature set point for each plenum is displayed next to the corresponding Plenum button. The grain temperature set point range is 80°F-150°F, and the current temperature set point for the grain temperature is displayed next to the Grain Temperature button. The grain temperature set point is used for the temperature based moisture control only.
6. Vision Touch Screen Display The Setup Screen The Setup screen will allow you to setup other parameters of the dryer. To use the Setup screen touch the button. The Select Hardware Setup Parameter to Modify screen will now be displayed. As you can see there several different parameters that can be modified on this screen: Figure 6E 1. Drying mode: Touching the Drying Mode button will display the select Drying Mode window. Continuous flow will be the only option for Tower Dryers. 2.
6. Vision Touch Screen Display 4. Plenum temperature manager: The plenum temperature manager is used by the automatic moisture control to automatically lower drying temperatures if the maximum dryer unload rate is exceeded. Touching the Plenum Temperature Manager will display a Configuration screen that will allow you to turn this feature ON or OFF. Also, a configuration section is presented so that the user can edit the behavior of this option. Figure 6G 5.
6. Vision Touch Screen Display 6. Calibrate moisture sensor: Touching this button will display the Configuration screen to adjust the offset for wet and dry moisture and temperature. Figure 6I 7. Extended setup: Touching this button will display a setup menu with extended features and options.
6. Vision Touch Screen Display 1. Diagnostics: The Diagnostics operations are described in greater detail in the service section on Page 49 of this manual. 2. Differential: Touching the Differential button will display the Modify Burner Differential Settings screen. (See Figure 6K.) Adjusting the burner differential settings allows the operator to keep the plenum temperature within a certain range.
6. Vision Touch Screen Display 4. BPH calibration: Touching the BPH Calibration button will display the Unload Bushels Setup screen. (See Figure 6M.) As you can see the bushel counter can be cleared by touching the Clear button. However if the bushel counter is out of calibration it can be calibrated by touching the Increase and Decrease buttons.
6. Vision Touch Screen Display 6. Temp scale: Touch the Temp Scale button to choose either English units or SI units temperature scales. Depending what temperature scale you now operating in touching this button will display a Pop-up window asking if you want to switch to SI (celsius, metric tons, etc.,) or English units (fahrenheit, bushels, etc.). 7. Dryer model: Touching the Dryer Model button will display the Dryer Hardware Setup window.
7. Test Firing Dryer Checks This section gives a series of checks to be carried out on the dryer before starting for the first time in the drying season. If any of the checks fail to produce the stated result, you should consult your dealer. You should not attempt to use the dryer unless all the pre-start checks have been successfully completed. Before attempting to operate the dryer make sure all safety shields are in place, all access doors are closed and all personnel are clear of the dryer.
7. Test Firing Unload Auto Operation To check auto operation place the Unload switch in the AUTO setting. Check unload equipment for proper rotation. Unload Manual Operation To check manual operation move the Unload switch to the MANUAL position. Check unload equipment for proper rotation. Accutrol Sweep Metering System Operation To check the metering operation turn the knob clockwise, and the metering speed should increase. The metering system should be turning clockwise when viewed from above.
7. Test Firing Dryer Shut Down To shut down the dryer, 1. Close the fuel supply valve at the tank or valve along the fuel line. 2. If the burner is operating, let the dryer run out of fuel, and it will shut down automatically due to loss of flame. 3. Close the fuel valve at the dryer, and press the Dryer Power Stop button. 4. Turn OFF the control power. 5. Turn OFF the safety disconnect handle on the front of the power box, and turn OFF the main power to the dryer.
8. Dryer Operation Dryer Start-up 1. Before attempting to operate the dryer, make sure all safety shields are in place, the burner is uncovered, all column clean-out doors are closed, the four (4) metering access doors are closed, the drain valve in the fuel train is closed and all personnel are clear of the dryer and grain handling machinery. 2. Turn all selector switches on the control panel to the OFF position. 3.
8. Dryer Operation Figure 8A 12. It is important to remember that adjustments in the metering roll speed takes 1-2 hours for the full impact of the adjustment to be realized on exiting grain moisture levels. Continue to operate the dryer’s metering speed manually making small hourly changes either up or down to adjust for the desired final moisture content. 13.
8. Dryer Operation Moisture Control Setup 1. To setup the moisture control, first press the Setup button on the dryer touch screen. (See Figure 8B.) Figure 8B 2. Press the M/C Setup button on the Setup screen. (See Figure 8C.) A screen entitled Continuous Flow Setup will appear. (See Figure 8D on Page 40.
8. Dryer Operation 3. The dryer can be operated using a grain temperature only based moisture control or a moisture based control utilizing the moisture sensors on the dryer. Most operators choose to operate the dryer using the moisture based moisture controller. To set the moisture controller to the moisture based system, press the Moisture button. (See Figure 8D.) The Moisture box should have a check mark. 4. Two (2) options exist for the moisture based moisture control, either “Variable” or “5 Speed”.
8. Dryer Operation 6. The centering point about which the unload rate will vary, is determined by the manual unload rate at the time that the dryer is placed into automatic operation. When using the “5 Speed” option, the dryer will automatically adjust this centering point throughout the day if the Auto Centering button is pressed on the Continuous Flow Setup screen. (See Figure 8D on Page 40.
8. Dryer Operation 9. To avoid overloading dry conveyors taking grain away from the dryer when the dryer unload is operating in the automatic mode, it may be necessary to limit the maximum and minimum unload rate on the dryer’s metering system. To accomplish this, press the Unload Parameters button on the Setup screen. (See Figure 8C on Page 39.) The following screen will appear. (See Figure 8H.) Set the appropriate limits if necessary.
9. Drying Time Tables Drying Time Table……..
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9. Drying Time Tables Drying Time Table……..
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10. Service Pre-seasonal Inspection and Service The dryer is made of weather-resistant material, and is designed to require minimum service. However, each season we recommend the following items be checked before the unit is used, and any damaged or questionable parts replaced. These checks will help eliminate possible failures, and assure dependable operation of the equipment. 1. Shut off electrical power.
10. Service 6. When drying dirty corn in high humidity conditions, sludge may build up in the upper outside sheets of the dryer. This build up can be removed by either washing the sheets down with a high pressure water hose, or by shutting incoming grain, dropping the grain level to below the plugged area, and then running the fans and burner to dry the affected area. Tapping or sweeping the sheets will dislodge debris.
10. Service Pre-season Service Check List ___ Lubricate blower motor bearings, if needed. ___ Clean burner ports. ___ Inspect flame rod and spark ignitor. ___ Inspect divider hopper between heat and cooling section. Clean if necessary. ___ Inspect bindicator grain level switches. ___ Check gas pressure gauges. ___ Clean control and power panels, tighten loose connections, and check for leaks. ___ Inspect metering systems. Clean accumulated stalks and old grain.
10. Service Lubrication Table Location Instructions Type of Lubrication Lubrication Interval Accutrol (sweep unload) bottom shaft bearing. Lubricate slowly until lube shows through seal. Wipe clean. High quality, grade #2 lithium based grease. Beginning of season (annually). Blower motor bearings. See motor lubrication procedure below. High quality, grade #2 lithium based grease. Every 2 years (Normal operation, ever 8-10 months continuous operation). Metering variable speed drive motor.
11. Safety Circuit Shut Down Messages Shut down warning window: Touch the Help button to display the shut down help window. Figure 11A Fan/Heater Generated Errors The following is a list of errors that are generated with the fan/heater controller. Each fan/heater has there own set of safeties which are listed below. You will need to inspect the controller associated with the error. Example: If you get this error, it is telling you the problem is with housing 1 (bottom most fan) High-Limit.
11. Safety Circuit Shut Down Messages Grain Temp Short This error indicates there is a shorted condition with one of the grain temperature sensors located inside the left or right grain columns. This could be a shorted sensor or the sensor wires could be shorted. Grain Overheat An over temperature condition has occurred in one of the grain columns causing the control to shut down the dryer. This control is set at 210°F (99°C) and automatically resets itself when cool.
11. Safety Circuit Shut Down Messages Input/Output Generated Errors The following is a list of errors that are generated with the Input/Output board located in the upper control box. Air System Failure A shut down has occurred due to a air system that was installed with an integral Safety switch that was in the unit. The air system safety connections are located in the upper control box on the terminal strip. This can occur if this safety looses 12 VDC to terminal J1-10 on the Input/Output board.
11. Safety Circuit Shut Down Messages Unload Motor Overload The motor overload has tripped on the unload motor overload located in the upper control box. This indicates that 12 VDC has been lost to terminal J1-02 on the Input/Output board. Push the Red button on the overload to reset this error. This is caused from the motor operating with to much of a work load, which in turn uses more current (amperage). If the problem reoccurs then check the motor to make sure it is not being overworked.
11. Safety Circuit Shut Down Messages Figure 11B Plenum Temp Open This error indicates there is a open condition with the plenum temperature sensor located inside the plenum chamber. This could be a open sensor or the sensor wires could have a open connection. Plenum Temp Short This error indicates there is a shorted condition with the plenum temperature sensor located inside the plenum chamber. This could be a shorted sensor or the sensor wires could be shorted.
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13. Warranty GSI Group, LLC Limited Warranty The GSI Group, LLC (“GSI”) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier.
This equipment shall be installed in accordance with the current installation codes and applicable regulations which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made. GSI Group 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.gsiag.
