CE Approved T-Series Tower Dryer Operation Manual PNEG-1797 Date: 06-11-12 PNEG-1797
PNEG-1797CE CE Approved T-Series Tower Dryer
PNEG-1797CE CE Approved T-Series Tower Dryer 3
Tower Dryer Gas Train Commissioning Check List and Sign-Off Function Component Set Point Pass/Fail/NA Check Fuel Supply Shut Off Valve Check Main Fuel Supply Pressure Set/Test Main Gas Regulator Pressure Set/Test Over Pressure Shut Off (OPSO) Pressure Set/Test Pressure Relief Valve Set/Test Maximum Gas Pressure Switch Set/Test Minimum Gas Pressure Switch Set Pilot Burner Pressure Set Burner High Flame Pressure Set Burner Low Flame Pressure Test Pilot Line Manual Shut Off Valve Test Main Gas Manual Shut Of
Table of Contents Contents Chapter 1 Safety .....................................................................................................................................................7 Safety Guidelines .................................................................................................................................. 7 Tower Dryer Operations and Service .................................................................................................... 8 Safety Precautions ........
Table of Contents Chapter 12 Error Messages ................................................................................................................................69 Safety Circuit Shut Down Messages ................................................................................................. 69 Input/Output Generated Errors .......................................................................................................... 70 Master Display Generated Errors .............................
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 Tower Dryer Operations and Service This manual contains important information that all owners/operators must understand, relating to: 1. Personal safety. 2. Preventing equipment problems. The owner/operator must inform anyone operating or working around this equipment of these safety guidelines. Failure to read this manual and it’s safety instructions is a misuse of the equipment and may lead to serious injury or death. Safety Precautions 1. Read the operating manual. 2.
1. Safety Working at Heights Whilst the equipment has been designed to operate primarily at ground level, at some stages during the life cycle it will be necessary to operate at heights. For this reason the equipment has been provided with access ladders, platforms and walkways. These have been designed to recognized safety standards to minimize the risk to health and safety to operators and technicians working on them. In addition attention should be paid to the following safety requirements. 1.
1. Safety 7. NEVER attach lifting equipment to ladders or platforms. 8. When working on the equipment, NEVER go outside the safety rails provided. 9. NEVER walk on the roof of the equipment. 10. Do not work at heights during high winds, heavy rain, snow, ice or storm. The majority of routine cleaning and service can be carried out from the service platforms provided. However in exceptional circumstances it may be necessary to access other parts of the equipment.
1. Safety Figure 1C 9. You may also need to lock out any associated equipment attached to the dryer. 10. Shut OFF, lock and tag the fuel supply at the main incoming valve. (See Figure 1D,) Figure 1D 11. Never work alone, it is recommended to work in teams of at least three (3) so help is immediately available in the event of emergency. 12. On completion of the work, check all team members are out of the dryer and all work tools have been recovered. 13. Close and lock all dryer accesses. 14.
1. Safety Precautions to Reduce Risk of Fire Whilst the dryer has been designed to minimize the risk of ignition of combustible dust and dirt, this can only be ensured by regular inspection and cleaning. At least every five (5) days. 1. Refer to Page 10 for required precautions before entering the dryer. The dryer must be locked out and tagged at the main power and fuel supply before entering. 2. Open the dryer access hatches and check for any significant build-up of dust or particles of grain. 3.
2. Decals Safety decals must be read and understood by all people in and around the dryer area. If any safety decals are not displayed on the dryer or if they are damaged, contact The GSI Group, Inc. for replacement: International Decals International, translated versions of the decals fitted to the equipment are available as part of the Language Pack that was supplied with the product. If you need further copies or a different language, please contact GSI or you dealer.
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2. Decals DC-2164 Automatic Machinery Background: White Colors: Black, ANSI Yellow and ANSI Blue Size: 3.940" x 1.970" Do not operate with guards removed Isolate and lock from power before removing guards Replace all guards before reconnection to power DC-2164 DC-2165 DC-2165 is located on the heat section inner and outer access hatches.
2. Decals DC-2214 Automatic conveying equipment below DC-2214 is located on the grain sampling access hatch.
2. Decals DC-2217 DC-2217 is located adjacent to the electrical lock out handle on the main power panel. Quantity: 1 Electrical Lockout SWITCH OFF, LOCK and TAG BEFORE working on or in the dryer to prevent accidental start-up DC-2217 DC-2230 Auto equipment can start at any time Rotating auger will crush and cut Background: White Colors: Black, ANSI Yellow and ANSI Blue Size: 6.000" x 3.
2. Decals DC-2232 Slip and fall hazard Can cause severe injuries DC-2232 is located on roof panels adjacent to roof steps. Quantity: 4 Do NOT step or stand in this area DC-2232 DC-2233 Electric shock and fire hazard DC-2233 is located on inside main power panel door.
2. Decals DC-2235 High Voltage Failure to observe practice below may result in severe injury, death, and/or equipment damage DC-2235 is located on inside and outside main power panel door. Quantity: 2 Insure that the incoming AC power and all separate power sources are turned off and locked before working on this equipment DC-2235 DC-2236 All maintenance procedures must be performed by qualified personnel who are familiar with the operation of this equipment.
3. Specifications Dryer Specifications Models 1050 1260 1575 1875 20100 24100 Blower Size 43" Axial 43" Axial 8490 8542 8542 8600 Blower RPM 1750 1750 1035 856 981 818 Blower kW 37.50 45.00 56.25 56.25 75.00 75.00 Metering kW 0.75 0.75 0.75 0.75 0.75 0.75 Drying m3/s 19.98 22.86 36.42 38.63 46.57 51.15 Cooling m3/s 6.85 8.27 18.21 19.32 23.28 25.58 Grain Column 324 mm 324 mm 324 mm 324 mm 324 mm 324 mm Tower Diameter 3.65 m 3.65 m 3.65 m 3.65 m 3.
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4. Dryer Installation Dryer Layout System Layout When considering dryer location make allowance for: 1. Grain handling systems. 2. Location of storage bins. 3. Wet grain supply. 4. Prevailing wind direction. 5. Fuel and power supply. 6. Noise. 7. Control panel location. Site Location Do not locate the dryer: 1. Inside a building. 2. Adjacent to combustible material which may be sucked in. 3. Within 2.0 m of other structures. Refer to specifications on Pages 20-22 and dimensions on Pages 23-25.
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4. Dryer Installation Fuel Connections LPG Dryers with Internal Vaporizers The dryer is designed to operate on liquid LPG with gross calorific value of 93.8 MJ/m3. The fuel supplier should provide liquid fuel from the tank to intake point at the strainer on the dryer pipe train. Natural Gas (NG) Dryers The dryer is designed to operate on natural gas with gross calorific value of 39.0 MJ/m3. The dryer is equipped with a natural gas supply pipe system connected to the heater solenoid valves.
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 roll speed Figure 5A WARNING Switches on the vision panel are for control purposes only. For servicing and maintenance switch OFF and lock at the main disconnect. Vision controls are used on several GSI drying products. It can operate any dryer in either a batch or a continuous flow mode.
5. Operating Controls 1. CONTROL POWER switch turns ON/OFF power to the control. 2. FAN switch starts/stops the fan. AUTO position is not used on T-Series and F-Series dryers. 3. HEATER switch turns the heater ON/OFF. AUTO position is not used on T-Series and F-Series dryers. 4. LOAD AUGER switch selects operating mode wet fill conveyor. In AUTO and MANUAL, the wet fill conveyor operates to keep the dryer full. In AUTO only the dryer shuts down if it is low on grain for a pre-set period. 5.
6. Vision Touch Screen Display Boot screen appears when the control power is switch ON. (See Figure 6A.) These two (2) buttons are used to update software. (See PNEG-1506 vision programming manual.) Figure 6A Default operation screen opens when START DRYER is pressed.
6. Vision Touch Screen Display 1. Dryer operation animation shows the status of the fan/heaters, load and unload augers and meter rolls. Also grain temperature, moisture content, M/C set point and tones counter. 2. Dryer status indicates if the dryer is stopped, started, loading or unloading. 3. Dryer status chart shows the grain temperature, moisture in/out, temperature out and metering roll speed. Over a period of time. 4.
6. Vision Touch Screen Display Optional Operation Screen Press View button give four (4) options. (See Figure 6D.) Figure 6D 1. Table view: Default operation screen view. (See Figure 6B on Page 32.) 2. Graph view: a. Press then b. Press any of c. Press . to select which data is graphed. to select time period. 3. Owner’s manual: See Page 40. 4. History: See Page 41.
6. Vision Touch Screen Display Setting the Timers Press to open the timers screen. (See Figure 6E.) Modifying timer set point Operation screen for setting timers Figure 6E 1. Press to set the load system delay during unload. Reduces load motor cycling. 2. Press to set the dryer shut down delay after the OUT OF GRAIN switch opens. Set to the maximum time for the dryer to refill during drying (this is displayed during loading on the screen). 3.
6. Vision Touch Screen Display 5. Use 6. Press when setting timers. Note default values may be entered. then to return to the operation screen. (See Figure 6B on Page 32.) Setting the Temperatures 1. Press to display temperature setup screen. (See Figure 6F.) Figure 6F 2. Press then use key pad to alter plenum temperature. 3. Press then use key pad to alter grain temperature. Note default units are °F. This can be changed to °C in SETUP. 4. Press 36 then to return to the operation screen.
6. Vision Touch Screen Display The Setup Screen Press adjust other dryer settings. Figure 6G 1. select continuous flow or staged batch drying modes. 2. adjust time and date settings. 3. select correct dryer model an details, as follow: a. Number fan/heaters = 1 b. Load system = end c. Dryer length (ft.) = 22 (Models 1875, 20100 and 24100) 18 (Models 1050, 1260 and 1575) d. Number modules = 1 e. Fuel = LP 4. See Page 57 for detailed setup.
6. Vision Touch Screen Display 5. changes between SI and American units. 6. see service section on Page 65. 7. burner mode should be ALL HIGH/LOW. (See Figure 6H.) Figure 6H 8. to adjust the switching range of the burner. (See Figure 6I on Page 39.) Default is 3°F (1°C). Tower dryers have just 1 plenum.
6. Vision Touch Screen Display Figure 6I 9. allows the dryer throughput meter to be calibrated on Figure 6J.
6. Vision Touch Screen Display Viewing the Owner’s Manuals on the Display Screen Press then the Owner’s Manual button. (See Figure 6K.) At the explorer screen, double press the manual and wait for it to open on screen. Figure 6K Use the scroll bar to navigate the manual. (See Figure 6L.
6. Vision Touch Screen Display Viewing the Dryer Shut Down History Press and then history. (See Figure 6M.) Figure 6M The shut down history is displayed and can be copied to a flash disc for viewing on another computer.
7. Dryer Start-Up WARNING BEFORE STARTING THE DRYER. All safety guards must be in place. All personnel must away from the dryer. All access doors must be closed. Dryer Commissioning Electrical 1. Carry out earth bonding test per EN60204 and/or local electrical laws and regulations. 2. Check adequate power supply. (Refer to table on Page 22.) 3. Voltage at phases must be within 5% of rated voltage. 4. Voltage drop must not exceed 5% when under full load. 5. Check overload settings for each motor circuit.
7. Dryer Start-Up 4. Set over pressure shut off (OPSO) per table on Page 20. a. Apply air pressure via main solenoid inlet flange. b. Increase/decrease spring pressure in OPSO. c. Valve should shut at 45 kPa maximum. 5. Set operational pressure per table on Page 22. a. Open main gas valve. b. Adjust pressure at regulator. 6. Set pilot flow rate. a. Close pilot line manual shut off valve. (See Figure 7G on Page 51.) b. Close ‘firing valve’ on main gas line. (See Figure 7I on Page 52.) c. Start blowers. d.
7. Dryer Start-Up 7. Checking pilot flame current. a. The minimum flame signal, measured at the burner control, should be 1.25 VDC. b. Flame signal can be checked at the Honeywell burner control, located in the main power panel, as shown in Figure 7C on Page 45. c. Flame rod may be re-positioned or gently bent to get better contact with the flame. Ensure rod is well clear of burner to prevent grounding when hot. Be careful not to damage ceramic insulator surrounding flame rod. (See Figure 7B.) d.
7. Dryer Start-Up Negative (-) meter lead Positive (+) meter lead One mega ohm/volt meter Flame simulator test jack Figure 7C Honeywell Test Flame 8. Set burner high-fire pressure. a. Re-open main gas ‘firing valve’. (See Figure 7I on Page 52.) b. Note required high-fire pressure from table on Page 22. c. Set plenum temperature to approximately 100°C above ambient. d. Light burners. e. Check modulating valve has driven fully open. f. Read pressure at burner gauge. (See Figure 7I on Page 52.) g.
7. Dryer Start-Up Pre-Season Checks 1. Inspect the accutrol metering system. a. Open the two (2) access doors and inspect the sweep metering system to ensure that the system is able to move freely. 2. Gas train a. Check for any leaks by pressurizing the line with air and using gas leak disclosing solution or by doing pressure loss tests. b. Leaks must be rectified by opening and resealing the joint. 3. Wiring a.
7. Dryer Start-Up 6. START switch a. Check all selector switches are OFF. b. Push the DRYER START switch. c. Selector switches be activated. 7. Fuel check a. Open the gas supply to the dryer. b. Check correct supply pressure. (See Table on Page 22.) 8. Load auger. With grain supply OFF. a. Start and stop load auger to check correct operation and rotation. b. Turn the load auger to AUTO and allow to run for 8 minutes. c. Dryer should stop and display OUT OF GRAIN error message. d.
7. Dryer Start-Up 13. Burner test fire a. Turn fuel ON. b. Set plenum temperature to 60°C. c. Start the fan. d. Turn HEATER switch to ON. e. After purge the burner should light. f. Adjust the pressure regulator to required burner pressure. (See Table on Page 22.) g. Lock the regulator. h. When the plenum reaches set point, adjust the MINIMUM setting on the modulating valve (See Figure 7I on Page 52) to the required setting. (See Table on Page 22.) i.
PNEG-1797CE CE Approved T-Series Tower Dryer Inlet section (See Page 50.) Regulator section (See Page 50.) Pilot section (See Page 51.) Safety shut off section (See Page 51.) Modular section (See Page 52.) 7.
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8. Dryer Start-Up and Operation Drying Temperatures Drying temperatures differ from crop to crop. Please check the drying temperature does not risk damage to the crop before proceeding. 1. Shelled corn moisture content of 20%-30% (93°C-104°C). 2. Small grain (wheat, oats, barley, milo), 65°C-90°C. 3. Soybeans 50°C-60°C. Initial Setup Parameters With the control power ON and the dryer control screen visible. 1. Timer and delay settings: Follow procedures in Setting the Timers on Page 35 to set. a.
8. Dryer Start-Up and Operation Continuous Flow Drying Mode Using Advanced Moisture Control 7. Press 8. Press and set dryer to CONTINUOUS FLOW. Press . . 1. Select this option 2. Press to open setup window 4. Select ON 3. Set unload maximum/ minimum 5.
8. Dryer Start-Up and Operation 9. Set minimum unload rate to 10% and maximum to suit the unload equipment. 10. Set plenum temperature management ON to reduce risk of over-drying when unload rates are limited by a low maximum unloading rate. 11. Return to Moisture Control window and set grain type. Optional printer may also be setup. 6. Set grain type. Bin # is for reference only. 7. Accept Figure 8B 12. Turn UNLOAD switch OFF. 13. Open fuel supply. 14. Turn LOAD AUGER switch to AUTO. 15.
8. Dryer Start-Up and Operation Figure 8C 20. Take three (3) samples with an accurate moisture meter and calculate the average moisture. Calibrate the wet and dry grain sensors until the on screen reading agrees with the average. To do this: a. Press . b. Press . c. Calculate difference between actual moisture reading an that on screen. d. Increase or decrease the on screen reading by the calculated difference. Example: Actual = 17%; On screen = 18.3%. Difference = Actual - On screen = -1.3% Enter -1.
8. Dryer Start-Up and Operation Calibrate sensors by touching the arrows buttons. Figure 8D 21. Turn UNLOAD to AUTO. Advanced moisture control is now active. Press and set target moisture content Figure 8E 22. Set the target moisture and let the dryer run. Make no more changes to allow the system to stabilize. 23. The dryer runs in MANUAL for 30 minutes being switched to AUTO to ensure grain is flowing evenly. The screen displays a timer to show remaining time to full AUTO control.
8. Dryer Start-Up and Operation How the Advanced Moisture Control Works 1. Wet and dry moisture and grain temperature are continually monitored. 2. Control action is mainly based on the dry sensor. 3. Grain flow is increased or decreased to maintain the required dry moisture. 4. The wet sensor and the column grain temperature sensor are intended to detect moisture spikes coming into the dryer so that the moisture controller can react ahead of time.
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10. Service WARNING BEFORE SERVICING THE DRYER. Turn OFF and LOCK electrical power at the MAIN DISCONNECT. Turn off fuel supply. Pre-Seasonal Inspection and Service 1. Inspect control panels for loose wires, rodent damage and accumulated foreign material. Clean and repair as required. 2. Lubricate the blowers, motors and metering system as per lubrication table on Page 68. 3. Check blower belts tension. 4. Inspect and clean the burner. Check that holes in the stainless steel air mixing plates are clear.
10. Service In Case of Fire 1. Hit emergency stop. 2. Shut off power. 3. Shut off fuel. 4. Do not try to cool a fire by running fan(s). 5. Never run grain from the dryer into the elevator or storage if a fire is known or suspected. 6. Locate the area of the fire. 7. If safe to do so, tackle the fire with a suitable extinguisher. Check for secondary fires. 8.
10. Service Pre-Season Service Check List ___ Lubricate blower bearings. ___ Lubricate blower motor bearings, if needed. ___ Check blower belts and adjust if necessary. ___ Clean burner ports. ___ Inspect flame rod and spark ignitor. ___ Check oil levels in gearboxes. ___ Inspect divider hopper between heat and cooling section. Clean if necessary. ___ Inspect bindicator grain level switches. ___ Inspect metering system access door cover seals.
11. Lubrication Location Instructions Type of Lubrication Lubrication Interval Accutrol (sweep unload) top and bottom drive bearings. Lubricate slowly until lube shows through seal. Wipe clean. High quality, grade #2 lithium based grease. Beginning of season (annually). Accutrol (sweep unload) coupling hub. Remove the two (2) lube plugs from the cover. Lubricate slowly until grease begins seeping through relief plug. High quality, grade #2 lithium based grease. Beginning of season (annually).
12. Error Messages Safety Circuit Shut Down Messages Shut down warning window: Touch the Help button to display the shut down help window. (See Figure 12A.) Shut down warning window: Touch the Help button to display the shut down help window. Figure 12A Fan/Heater Generated Errors Air Switch Stuck Switch is stuck closed when fan is OFF. Fan Loss of Airflow Air switch has stopped sensing air pressure during fan operation. Fan No Airflow Air switch is not sensing air pressure after fan start-up.
12. Error Messages Housing High-Limit Heater housing has exceeded 93°C and burner has locked out. This must be manually re-set once the cause has been removed. Ignition Failure Burner failed to light. Burner control will lock-out and must be re-set. Check flame sensor. Illegal Flame Burner control is seeing flame when burner is OFF. Check for leaking safety valve. Check for fire. Motor Overload Motor thermal overload has opened load on one or other motor. Must be manually re-set.
12. Error Messages Unload Motor Overload The motor overload has tripped on the unload motor overload located in the upper control box. User Safety On CE dryers this safety indicates that the valve proving system has failed to prove the main safety valves. Valves may need to be replaced or be re-seated. Master Display Generated Errors Cont-Batch Mode Chng Dryer was switch from continuous flow to batch or vice versa whilst running.
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NOTES 84 PNEG-1797CE CE Approved T-Series Tower Dryer
15. 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.
