Tower Dryer 12', 18', 24' and 30' Diameter Dryer Models Operation and Service Manual - 2011 PNEG-526 Date: 02-28-11 PNEG-526
THIS PRODUCT IS PROTECTED UNDER ONE OR MORE OF THE FOLLOWING U.S.
Tower Dryer Operations & Service TABLE OF CONTENTS DRYER OPERATION SafetyFirst .......................................................................................................... 7 SafetyPrecautions .............................................................................................9 Installation Requirements ...............................................................................10 Dryer Control Panel..................................................................................
DRYER OPERATIONS 5
Tower Dryer Operations & Service SAFETY FIRST SAFETY GUIDELINES This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protectingpersonal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidlines.T o help you recognize this information, we use the symbols that are defined below .
SAFETY FIRST The GSI Group Inc.'s principle concern is your safety and the safety of others associated with grain handling equipment. This manual was written with that thought in mind. We want to keep you as a customer by helping you understand Tower Dryer Operations & Service safe operating procedures, and some of the problems that may be encountered by the dryer operator or other personnel.
Tower Dryer Operations & Service READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE SAFETY PRECAUTIONS Use Caution In The Operation Of This Equipment 4. Check for gas leaks at all gas pipe connections. If any leaks are detected, do not operate dryer. Shut down and repair before further operation. The design and manufacture of this dryer is directed toward operator safety.
INSTALLATION REQUIREMENTS Electrical The dryer can be furnished to operate off of 240, 480, or 575 volt, 60 Hz power or 380 volt, 50 cycle power. The dryer is furnished with a power panel equipped with a main circuit breaker disconnect and motor starters and branch breakers for the individual blower motors. Standard blower motor starting is across-the-line starting. When necessary, the dryer can be equipped with optional soft-start motor starting equipment.
Tower Dryer Operations & Service DRYER CONTROL PANEL 1 2 3 4 C D E F 7 11 5 13 14 6 8 9 Figure 1: 10 12 The grain dryer control panel with full color touch screen control.
DRYER CONTROL PANEL Dryer Control Panel Featuring The Allen-Bradley PLC Control System 1. Full Color Graphical Display provides continuous visual feedback on the current dryer status as well as a convenient means of setting operating parameters and options. Most set points and status screens are accessed by simply touching an on-screen object. 2. Message Center displays current dryer conditions and alarm messages with toubleshooting tips in easy to read language. 3.
Tower Dryer Operations & Service DRYER START UP dryer. (ie. wet legs, conveyors, etc.) 1. Prepare dryer for start up Perform preseason inspection and service as outlined in the Maintenance Section before attempting to operate the dryer. The dryer must have all Pre-Season and Post-Season maintenance to ensure reliable operation Make sure all discharge doors, grain exchanger cleanout doors, heat section door, louvered cooling section doors, etc. are closed.
Tower Dryer Operations & Service DRYER START UP 5.1 8 10 11 14 14 5.2 9 15 NOTE: 8 PRESS TO ENTER NEW TEMP.
Tower Dryer Operations & Service 11. Start the burner by turning the BURNER selector switch to the "ON" position. The dryer automatically goes through a 30 second purge period once the blowers are started. The amount of time remaining on the purge cycle will be displayed on the LCD display screen. After the purge period the burner pilot will automatically light. Once the flame control circuit on the dryer senses flame, the light in the BURNER selector switch will illuminate.
Tower Dryer Operations & Service DRYER START UP 17.1 17.2 17.2 17.
Tower Dryer Operations & Service 18. Shutdown dryer. The dryer will likely have to be shutdown from time to time. The steps used to shut it down will depend upon the duration of the shutdown. If the dryer will be shutdown for 4 hours or less, follow the Short Shutdown procedure. For longer shutdowns, such as overnight, follow the Extended Shutdown procedure Short Shutdowns - Less than 4 hours For short shutdown periods, the dryer can be shutdown by pushing the DRYER POWER STOP button.
TRI-POINT MOISTURE CONTROLLER Tower Dryer Operations & Service Optional Tri-Point Moisture Controller Operation Manual 12 18
Tower Dryer Operations & Service TRI-POINT MOISTURE CONTROLLER I. Main Screen 9 8 7 6 5 1 2 3 4 1. Two-hour moisture history chart green line for incoming moisture; yellow line for outgoing moisture; and the red line is the target moisture. 6. Moisture target - To change the moisture target, press within the rectangular area and key in the new target from the pop-up keypad. 2. Moisture Control button - to access the Moisture Control Set-up screen. 7. Current moisture coming out of the dryer. 3.
TRI-POINT MOISTURE CONTROLLER Tower Dryer Operations & Service II. Set-Up of the Controller *Press the “MOIST CONTROL” button from the main screen to access the moisture set-up screen: 1 6 2 4 5 1. Unload upper limit - the maximum unloading rate (%) in which dryer can be run without plugging any unloading conveyors. 2. Current column grain temperature - measured from the RTD sensor at the end of the drying section (it is not the temperatureof the grain coming out of the dryer). 3.
Tower Dryer Operations & Service TRI-POINT MOISTURE CONTROLLER III. Operation Procedure 1. Start the dryer; set the dryer unload at a desired speed from the dryer control panel. 2. Let the dryer run under manual mode for warming up until the column grain temperature has stabilized and the moisture coming out of the dryer is within ± 2% of the target moisture. 3.
TRI-POINT MOISTURE CONTROLLER Tower Dryer Operations & Service The sensor should be calibrated 2-3 times a day. At the same time check and clean the sensor and sensor sampling box to make sure that there is no debris blocking the grain flow around the sensor. 4. Check or change the target moisture from the main screen. 5. Press “MOIST CONTROL” to access the moisture control set-up screen. Check upper/lower unloading limits and change them if needed. 6.
Tower Dryer Operations & Service TRI-POINT MOISTURE CONTROLLER V. Alarms The controller checks the sensors and control status regularly. If abnormal conditions are detected, a corresponding alarm will go off, an alarm message will come up on the main screen and the dryer will be shut down. ALARM CAUSES SOLUTION Moisture out of range the moisture coming out of the dryer was 2.
TRI-POINT MOISTURE CONTROLLER Tower Dryer Operations & Service VI. Access Drying History 1. Press the “DATA LOG” button from the main screen to open the moisture history screen. The controller logs quarterly data up to 120 records (i.e. 30 hours) into the archive. 2. Press the browse buttons to browse the record.
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MAINTENANCE 29
MAINTENANCE Tower Dryer Operations & 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.
MAINTENANCE Tower Dryer Operations & Service SEASONAL INSPECTION AND SERVICE 1. 2. 3. 4. 5. 6. 7. Important! The covers to the metering system access door(s) 4. must be in place at all times when the dryer is in operation. Before turning blowers always make sure this door is clamped 5. into position. Follow lubrication guides as outlined in the Lubrication Table. 6. Do not let grain fines and dust accumulate inside the cooling section of the dryer.
MAINTENANCE LOCATION Tower Dryer Operations & Service LUBRICATION TABLE INSTRUCTIONS TYPE OF LUBRICATION LUBRICATION INTERVAL Metering drum drive shaft bearing (On GSI hopper bottom dryers only). Accutrol (sweep unload) top and bottom drive bearings. (On Zimmerman flat bottom dryers only). Lubricate slowly until lube shows through seal. Wipe clean. High quality; grade #2 lithium based grease. Beginning of season (annually). Lubricate slowly until lube shows through seal. Wipe clean.
MAINTENANCE 26 Tower Dryer Operations & Service 34
MAINTENANCE Tower Dryer Operations & Service PRE-SEASON SERVICE CHECKLIST _____ 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.
MAINTENANCE Tower Dryer Operations & Service 36 2
TROUBLE SHOOTING 37
TROUBLESHOOTING Tower Dryer Operations & Service The GSI & Zimmerman Tower dryers are designed to be self diagnosing. Most electrical or operating problems are displayed on the screen of the operator interface and the problem area is graphically high lighted. Always insure that either 240 or 480 volt 3 phase power is being provided to the dryer. All motor starters coils and the burner circuitry operate at 120v AC. All of the safety circuit on the dryer operates at 24v DC.
Tower Dryer Operations & Service Problem Pilot will not light. (Continued) TROUBLESHOOTING What to do - If pilot still doesn’t light, check pilot area on burner. Clean if necessary. - If pilot area is hot indicating that the pilot was lighting, replace flame rod. - If pilot area is cold, replace spark plug. - If pilot still doesn’t light, check the Protectofier components in the control box. Pilot lights but main burner will not light - Check for water in gas train by opening drain valve.
TROUBLESHOOTING Tower Dryer Operations & Service Problem What to do Dryer shuts down, red light lights and horn sounds, display shows: “OVERHEAT AT _________” “POSSIBLE FIRE” - Check for possible fire in dryer at location indicated in message. - Check for a plugged or slow moving grain column. - Check for a plugged grain turner. - Check to insure that the dryer is full of grain and is continually being kept full. - Check for a defective high limit sensor.
Tower Dryer Operations & Service TROUBLESHOOTING Message What to do AUXILIARY STUCK CLOSED BLOWER 3 STARTER Check Term 203 AUXILIARY STUCK CLOSED BLOWER 4 STARTER AUX. CONTACT FAILED TO CLOSE TRI-STARTER Check Term. 204 Check Term. 200 AUX. CONTACT FAILED TO CLOSE BLOWER 1 STARTER AUX. CONTACT FAILED TO CLOSE BLOWER 2 STARTER Check Term. 201 Check Term. 202 AUX. CONTACT FAILED TO CLOSE BLOWER 3 STARTER AUX. CONTACT FAILED TO CLOSE BLOWER 4 STARTER Check Term. 203 Check Term.
TROUBLESHOOTING Tower Dryer Operations & Service Message What to do AUXILIARY STUCK CLOSED TOP WET CONVEYOR Check Term. 213 CONTACT FAILED TO CLOSE DRY CONVEYOR CONTACT FAILED TO CLOSE AUX. DRY CONVEYOR Check Term. 209 Check Term. 210 CONTACT FAILED TO CLOSE DRY LEG CONTACT FAILED TO CLOSE TOP DRY CONVEYOR Check Term. 211 Check Term. 212 CONTACT FAILED TO CLOSE AUX. WET CONVEYOR CONTACT FAILED TO CLOSE WET LEG Check Term. 215 Check Term.
Tower Dryer Operations & Service TROUBLESHOOTING Message What to do INTERLOCKED START TOP DRY CONVEYOR FIRST Check Term. 112 INTERLOCKED START AUX.
Tower Dryer Operations & Service PARTS LIST COMMERCIAL TOWER DRYER COMMON SERVICE PARTS Part # Description Where Used Bindicator GT3-0036 Bindicator RA4 Low Grain Indicator Located on Upper Sidewall of Dryer 815-1700-5 Bindicator RA6 High Grain Indicator Located on Dryer Roof 756-1150-9 Bindicator Micro-Switch Replacement Switch for Either Bindicator 769-1225-2 Bindicator Paddle Replacement Paddle for Either Bindicator 756-1148-3 Bindicator Motor A-H9A-K-HD Replacement Motor for Either Bi
Tower Dryer Operations & Service PARTS LIST COMMERCIAL TOWER DRYER COMMON SERVICE PARTS (CONTINUED) Part # Description Where Used Burner Control/Maintenance 756-1009-7 Flame Rod Senses Flame in Burner (Natural Gas or LP) GT3-0091 Ignitor I-31-1 Spark Spark Plug for Burner (Natural Gas or LP) WR-7MM Wire, 7mm Silicone Ignitor Wire for Spark Plug - Sold per Foot GT3-0609 Ignitor Plug Oil (Maxon GP18110/Auburn I-101) Spark Plug for Burner (Fuel Oil Only) 756-1484-2 Connector, Flame Rod and Ig
Tower Dryer Operations & Service PARTS LIST COMMERCIAL TOWER DRYER COMMON SERVICE PARTS (CONTINUED) Part # Description Where Used Manual Shut-Off Valves GT3-0014 Valve, DeZurich 2" Used at Beginning of Gas Train - Size Specific GT3-0198 Valve, DeZurich 3" Used at Beginning of Gas Train - Size Specific 707-1141-1 O-Ring 2" Dezurich Replacem ent Part for 2" DeZurich Valve 707-1140-3 O-Ring 3" Dezurich Replacem ent Part for 3" DeZurich Valve D02-0084 Brass Ball Valve 1/4 Used in Return Line
Tower Dryer Operations & Service PARTS LIST COMMERCIAL TOWER DRYER COMMON SERVICE PARTS (CONTINUED) Part # Description Where Used Single Switch GT3-0620 GT3-0623 Switch Set VCS-1 (SOV) Maxon VOS-1 #14-23433 Switch Set VCS-1 (VOS-1) Maxon #14-18428 Double Switch Maxon Switch 3" Valve and Up Maxon Switch 2" Valve and Below GT3-0619 GT3-0622 KD-PVA0005 769-1028-0 Switch Set VCS-2 (SOV) Maxon VOS-2 (STO) #14-23434 Double Maxon Switch 3" Valve and up Switch Set VCS-2 (VOS-2) Maxon #14-18429 Double Maxon
Tower Dryer Operations & Service PARTS LIST COMMERCIAL TOWER DRYER COMMON SERVICE PARTS (CONTINUED) Part # Description Where Used Inverters and Line Reactors Inverters GT3-0955 Allen Bradley Inverter, VFD AB PF4 2HP/230V Variable Speed Drive for Unload - Size and Voltage Specific GT3-0954 Allen Bradley Inverter, VFD AB PF4 2HP/460V Variable Speed Drive for Unload - Size and Voltage Specific GT3-0953 Allen Bradley Inverter, VFD AB PF4 5HP/230V Variable Speed Drive for Unload - Size and Voltage S
Tower Dryer Operations & Service PARTS LIST COMMERCIAL TOWER DRYER SIDEWALL SHEETS Part # Description Where Used GSI and ZIMMERMAN Inside Galvanized Sheets Inside 12' Diameter Dryer GT1-0405 Sheet, Wall Inside Top 12' Top Ring GT1-0406 Sheet, Wall Inside Heat 12' Heat Section GT1-0407 Sheet, Wall Inside Cleanout 12' Inside at Grain Inveter GT1-0408 Sheet, Wall Inside Cool 12' Cooling Section GT1-0409 Sheet, Wall Inside Bottom 12' Bottom Ring Inside 18' Diameter Dryer GT1-0195 Sheet, Wal
Tower Dryer Operations & Service PARTS LIST COMMERCIAL TOWER DRYER SIDEWALL SHEETS (CONTINUED) Part # Description Where Used Outside 24' Diameter Dryer GT1-0590-24 Sheet, Wall Punched Blank Solid Top Rings, Ring Below Grain Inverter, Ring Above Bottom Ring GT1-0591-24 Sheet, Wall Punched Blank .078 Above Grain Inverter and In Cooling Section GT1-0592-24 Sheet, Wall Punched Blank .
ELECTRICAL DIAGRAMS 52
C DS1 N.O. 000 I:4.0/00 ACK: DOOR SWITCH 1 LOC: POWER PANEL C DS2 N.O. 001 I:4.0/01 ACK: DOOR SWITCH 2 LOC: POWER PANEL LIMITS UNLESS OTHERWISE SPECIFIED .0= ±.0625 .00= ±.0312 .000= ±.0156 ANGLES= ±1° PART NO. THE GSI GROUP TERMINALS IN POWER PANEL FIELD WIRING 1004 E. ILLINOIS ST. ASSUMPTION, IL 62510 TITLE TOWER DRYER CONTROL PANEL WIRING DIAGRAM P/N MAT'L DESC. DWG BY DATE SCALE SHEET HF DWG NO.
COMPONENT MANUALS
Tower Dryer Operations & Service COMPONENTS COMPONENT MANUALS I. II. III. IV. V. VI. VII. VIII. IX.
Tower Dryer Operations & Service COMPONENTS I COMPONENT MANUALS AC FREQUENCY DRIVE
Quick Start PowerFlex 4 Adjustable Frequency AC Drive FRN 3.xx This Quick Start guide summarizes the basic steps needed to install, start-up and program the PowerFlex 4 Adjustable Frequency AC Drive. The information provided Does Not replace the User Manual and is intended for qualified drive service personnel only.
English-2 Mounting Considerations • Mount the drive upright on a flat, vertical and level surface. – Install on 35 mm DIN Rail. or – Install with screws. Minimum Panel Thickness 1.9 mm (0.0747 in.) • • • Screw Size M4 (#8-32) Mounting Torque 1.56-1.96 N-m (14-17 lb.-in.) Protect the cooling fan by avoiding dust or metallic particles. Do not expose to a corrosive atmosphere. Protect from moisture and direct sunlight. Minimum Mounting Clearances See page 12 for mounting dimensions. 25 mm (1.0 in.
English-3 Specifications, Fuses and Circuit Breakers Drive Ratings Voltage kW (HP) Amps Range kVA Amps Fuses 100 - 120V AC (±10%) – 1-Phase Input, 0 - 230V 3-Phase Output 140M Motor Protectors (2) Power Dissipation IP20 Open Contactors Watts 22A-V1P5N104 22A-V2P3N104 22A-V4P5N104 22A-V6P0N104 140M-C2E-C10 140M-C2E-C16 140M-D8E-C20 140M-D8E-C25 100-C09 100-C12 100-C23 100-C37 25 30 50 70 140M-C2E-B40 140M-C2E-B63 140M-C2E-C16 140M-C2E-C16 140M-D8E-C25 100-C09 100-C09 100-C12 100-C16 100-C23 25 30
English-4 Power Wiring Power Wire Rating Recommended Copper Wire Unshielded 600V, 75°C (167°F) THHN/THWN 15 Mils insulated, dry location Shielded 600V, 75°C or 90°C (167°F or 194°F) RHH/RHW-2 Belden 29501-29507 or equivalent Shielded Tray rated 600V, 75°C or 90°C (167°F or 194°F) RHH/RHW-2 Shawflex 2ACD/3ACD or equivalent Power Terminal Block (A Frame Shown) Terminal R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 Description R/L1, S/L2 1-Phase Input R/L1, S/L2, T/L3 3-Phase Input U/T1 To Motor U/T1 V/T2 T
English-5 Control Terminal Block (1) Important: I/O Terminal 01 is always a coast to stop input except when P036 [Start Source] is set to “3-Wire” control. In three wire control, I/O Terminal 01 is controlled by P037 [Stop Mode]. All other stop sources are controlled by P037 [Stop Mode]. P036 [Start Source] Keypad Per P037 Coast 3-Wire Per P037 Per P037 2-Wire Per P037 Coast RS485 Port Per P037 Coast Important: The drive is shipped with a jumper installed between I/O Terminals 01 and 11.
English-6 Prepare For Drive Start-Up ! ATTENTION: Power must be applied to the drive to perform the following start-up procedures. Some of the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, only qualified service personnel should perform the following procedure. Thoroughly read and understand the procedure before beginning. If an event does not occur while performing this procedure, Do Not Proceed .
English-7 Integral Keypad ➋ ➊ ➌ RUN FWD REV PROGRAM ➍ ➏ Menu VOLTS AMPS HERTZ FAULT ➎ Basic Program Group Consists of most commonly used programmable functions. ➑ ➐ Description Display Group (View Only) Consists of commonly viewed drive operating conditions. ➒ Advanced Program Group Consists of remaining programmable functions. Fault Designator Consists of list of codes for specific fault conditions. Displayed only when fault is present. No.
English-8 Viewing and Editing Parameters The last user-selected Display Group parameter is saved when power is removed and is displayed by default when power is reapplied. The following is an example of basic integral keypad and display functions. This example provides basic navigation instructions and illustrates how to program the first Program Group parameter. Step Key(s) Example Displays 1.
English-9 See the PowerFlex 4 User Manual on CD for more information on parameters. Display Group Parameters No. Parameter Min/Max Display/Options d001 d002 d003 d004 d005 d006 [Output Freq] [Commanded Freq] [Output Current] [Output Voltage] [DC Bus Voltage] [Drive Status] 0.0/[Maximum Freq] 0.0/[Maximum Freq] 0.00/(Drive Amps × 2) 0/Drive Rated Volts Based on Drive Rating 0/1 (1 = Condition True) 0.1 Hz 0.1 Hz 0.
English-10 See the PowerFlex 4 User Manual on CD for more information on parameters. Advanced Group Parameters No.
English-11 See the PowerFlex 4 User Manual on CD for more information on parameters. No. Parameter Min/Max 0/FFFF A102 [Testpoint Sel] A103 [Comm Data Rate](3) 0/5 Display/Options Default 400 3 A106 [Comm Loss Time] A107 [Comm Format](3) 0.1/60.0 0/5 A110 [Anlg In 0-10V Lo] 0.0/100.0% 1 Hex 0 = “1200” 1 = “2400” 2 = “4800” 1 0 = “Fault” 1 = “Coast to Stop” 0.1 0 = “RTU 8-N-1” 1 = “RTU 8-E-1” 2 = “RTU 8-O-1” 0.1% A111 [Anlg In 0-10V Hi] 0.0/100.0% 0.1% 100.0% A112 [Anlg In4-20mA Lo] 0.
Tower Dryer Operations & Service COMPONENTS II COMPONENT MANUALS MAXON BURNER
Bulletin 5550 Series NP-LE AIRFLO® Burners • Designed for direct-fired make-up air and process applications • Improved emissions performance over Maxon's standard NP AIRFLO® Burner, with significantly lower levels of CO and NO2 • Higher capacity - up to 1,000,000 Btu/hr/ft • Shorter flame length • Easily meets ANSI/CSA standards • Available in low pressure version and corrosion-resistant materials m CORPORATION 201 East 18th Street, P.O. Box 2068, Muncie, Indiana, 47307-0068. Phone: (765) 284-3304.
Page 5552 Design and Application Details Specifications Input Rating Up to 1,000,000 Btu/hr/ft Airstream Profile Differential Pressure 0.3 to 1.
Page 5553 Typical Applications for Maxon Series NP-LE AIRFLO® Burners Packaged Make-up Air Systems with 100% Outside Air Packaged Make-up Air Systems with Partially Recirculated Air NP-LE AIRFLO® Burner NP-LE AIRFLO® Burner Fan Fan Fresh Air Fresh Air Return Air Supply Air Supply Air Single-stage Burner Heated Paint Spray Booths with Re-heat Option Humidity Controlled, 2-stage Burner Heated Paint Spray Booths Air Intake Air Intake Preheat NP-LE AIRFLO® Burner Reheat NP-LE AIRFLO® Burner (If Req
Page 5554 Design and Application Details System components normally used in conjunction with a Maxon NP-LE AIRFLO® Burner application Intake Louvers Profile Plate NP-LE AIRFLO® Burner 1 Duct Walls 2 4 3 10 Bl oc k& Bl ee dM ain n Ga sT rai ot Pil n s Ga i Tra 7 8 5 6 9 Main Volume Fan Legend: Item Number m CORPORATION Description 1 Outside ther mostat 2 Intake high temperature limit switch 3 Control valve 4 Vent valve 5 Strainer 6 Dr ip leg 7 Differential air switch
Page 5550-S-1 Series NP-LE AIRFLO® Burners Installation Instructions General Important: Do not discard packing material until all loose items are accounted for. Avoid bending or damaging the steel mixing plates of your Series NP-LE AIRFLO® Burner during uncrating and installation. These burners are used for the heating of fresh air in motion. Mount the burners so they fire parallel to and in the same direction as the movement of the air (see sketch 1 at right).
Series NP-LE AIRFLO® Burners Page 5550-S-2 Installation Instructions (cont'd.) Gas Train See piping layout below to identify various typical system components. Pipe size of gas line must be large enough to assure ample fuel pressure at maximum system capacity. Burner capacity is totally dependent on fuel differential being maintained. (See capacity/specification data for the actual fuel pressure required at the burner to achieve its rated capacity.
Series NP-LE AIRFLO® Burners Page 5550-S-3 Start-Up Instructions Read complete instructions before proceeding, and familiarize yourself with all the system's equipment components. Verify that your equipment has been installed in accordance with the original manufacturer's current instructions.
Series NP-LE AIRFLO® Burners Page 5550-S-4 Start-Up Instructions (cont'd.) A good minimum fire should provide uniform flame across the entire burner face, contained within the zipper flame channel at the base of burner mixing plates. Any thin spots or gaps indicate uneven air velocity over the burner which must be corrected or a higher minimum fire established by continuing to turn in on the minimum stop screw. (See drawing on page 5550-S-2.
Series NP-LE AIRFLO® Burners Page 5550-S-5 Start-Up Instructions (cont'd.) The desired maximum capacity may be achieved with less than full control valve opening. Mark with a pencil or scribe the point on valve crank arm where the desired maximum is obtained, then return crank arm to low position and shut system off. 10.
Series NP-LE AIRFLO® Burners Page 5550-S-6 Maintenance and Component Identification/Spare Parts NP-1-LE 6 4 2 8 3 9 10 see note below see 7 note below 5 1 17 see 7 note below 5 11 1 To order replacement parts: 1. 2. 3. 4. See burner nameplate and indicate burner type. Sketch burner arrangement (as viewed from casting side). Specify replacement items required from diagrams above. Specify quantity of each and assembly numbers from table below: Item No.
Series NP-LE AIRFLO® Burners Page 5550-S-7 Maintenance and Component Identification/Spare Parts NP-1-LE-AL 6 4 2 8 3 9 10 see note below see 7 note below 5 1 17 11 see 7 note below 5 1 To order replacement parts: 1. 2. 3. 4. See burner nameplate and indicate burner type. Sketch burner arrangement (as viewed from casting side). Specify replacement items required from diagrams above. Specify quantity of each and assembly numbers from table below: Item No.
Series NP-LE AIRFLO® Burners Page 5550-S-8 Maintenance and Component Identification/Spare Parts NP-1-LE-AL-SS 6 4 8 2 3 9 10 7 5 see note below see note below 17 12 1 see 7 note below 11 1 To order replacement parts: 1. 2. 3. 4. See burner nameplate and indicate burner type. Sketch burner arrangement (as viewed from casting side). Specify replacement items required from diagrams above. Specify quantity of each and assembly numbers from table below: Item No.
Series NP-LE AIRFLO® Burners Page 5550-S-9 Maintenance and Component Identification/Spare Parts NP-2-LE 6 4 2 8 3 9 10 see note below see 7 note below 5 1 17 see 7 note below 5 11 1 To order replacement parts: 1. 2. 3. 4. See burner nameplate and indicate burner type. Sketch burner arrangement (as viewed from casting side). Specify replacement items required from diagrams above. Specify quantity of each and assembly numbers from table below: Item No.
Series NP-LE AIRFLO® Burners Page 5550-S-10 Maintenance and Component Identification/Spare Parts Fastener Kits End Plate Fastener Kit Body to Body Fastener Kit End Plate Gasket Shim Gasket Shim Gasket M5 x 10 Hex Head Screw M5 Nut M5 x 20 Hex Head Screw M5 Lock Washer (SS only) M5 Lock Washer (SS only) M5 K-Nut M10 x 1.5 Hex Nut M10 x 1.
Series NP-LE AIRFLO® Burners Page 5550-S-11 Maintenance Instructions Periodic maintenance will insure continued troublefree operation of your Series NP-LE AIRFLO® Burner system. At least a yearly inspection is recommended for make-up air heating installations and more frequently for process applications in year-round operation. Your own experience is the best guide in determining frequency of inspection. As a minimum, the following procedure should be followed: 1. Shut the system down totally.
Series NP-LE AIRFLO® Burners Page 5550-S-12 Inspection and Maintenance of Gas Ports – Conduct initial inspection within the first month after commissioning. Visually check the gas ports of new burner assemblies for any piping scale or debris. Use Pin Vise with drill bit to remove. – Annual inspections are normally adequate once the initial piping debris is removed. The operating conditions of the burner will determine how frequently maintenance is actually required.
Tower Dryer Operations & Service COMPONENTS III COMPONENT MANUALS GAS CONTROL VALVE
Page 7002 Flow Control Valves Series “Q” Gas Control Valves provide the high capacity and low pressure drop benefits of a butterfly valve construction, plus an adjustable gradient feature for accurate fuel flow control. They are used independently for throttling of fuel gases and with PREMIX® Blower Mixers and AIRFLO® Mixers for stand-by fuel systems, where they allow change-over to alternate fuels without readjustment.
Flow Control Valves Page 7000-S-1 Installation Instructions – Support weight of piping independently. Do not place any Maxon Flow Control Valve in a piping bind. Provide pipe hangers and/or special support for related manifolds. – Maxon connecting base and linkage assemblies are designed to locate and/or position the control operator for its interaction with the Flow Control Valve assembly. They are not intended to support the weight of the control motor.
Page 7000-S-2 Flow Control Valves Adjusting Instructions Notice: Only generalized instructions can be provided here. Detailed adjusting instructions are provided with each individual Maxon burner and/or mixer system. General Instructions Important: Do not discard packing materials until all loose items are accounted for. To prevent damage in transit, some connecting base and linkage components may be packed separately and shipped loose with your new Maxon Flow Control Valve.
Tower Dryer Operations & Service COMPONENTS IV COMPONENT MANUALS GAS SHUT-OFF VALVE
Page 6102 Normally open or normally closed valves 4" Series 5000-SCP position “L” 1.
Electro-Mechanical Valves Page 6100-S-1 Installation Instructions 1. Read complete instructions before proceeding and do not discard packing materials until any/all loose items are located. Also, make sure that the installation of the Maxon valves will be in compliance with all applicable governmental, insurance and/or agency requirements or codes, such as NFPA-70, National Electric Code, CSA C22.1, Canadian Electric Code, etc. 2. General considerations: A.
Page 6100-S-2 Electro-Mechanical Valves Installation Instructions (cont'd.) orientations are acceptable, subject to the above limitations. The top assemblies of all Maxon valves are field rotatable to allow installations involving conflicts with these mounting restrictions. F. Main system shut-off should always use a manual leak-tight upstream fuel cock. G. Time lag between valve action and fluid flow (or flame response) is reduced if valve is located near the burner (or outlet). 4.
Electro-Mechanical Valves Page 6100-S-3 Installation Instructions (cont'd.) Top Assembly Rotation 1 1 2 2 2 5 5 5 1 4 4 4 3 Series 5000-CP Series 808 Maxon valves can and should be ordered in a configuration compatible with planned piping, but if open/ shut indicator window is not visible and/or valve orientation is not proper, the top assembly can be rotated in 90° increments around the valve body centerline axis by the following procedure: 1.
Page 6100-S-4 Electro-Mechanical Valves Installation Instructions (cont'd.) Top Assembly Rotation (cont'd.) 7. Remove the two body bolts [4] screwed up from the bottom (were partially unscrewed in step 5). 8. Carefully rotate top assembly to the desired position in a plane parallel to the top of the valve body casting. Rotate the top housing about 30° beyond this position, and then rotate it back. Reposition the top housing back down onto the valve body casting.
Electro-Mechanical Valves Page 6100-S-5 Operating Instructions Refer to appropriate catalog bulletin and specification page for operating sequence applying to your specific valve. Never operate valve until all essential allied equipment is operative and any necessary purges completed. Failure of electro-mechanically operated valve to operate normally indicates that it is not powered. Check this first! Then check internal holding solenoid and/or motor operator.
Page 6100-S-6 Electro-Mechanical Valves Maintenance Instructions Maxon valves are endurance tested far in excess of the most stringent requirements of the various approval agencies. They are designed for long life even if frequently cycled, and to be as maintenance-free and trouble-free as possible. Every Maxon valve is operationally tested and meets the requirements of ANSI B16.104 Class VI Seat Leakage when it leaves our plant.
Electro-Mechanical Valves Page 6100-S-7 Auxiliary Signal Switches Field Installation Instructions NOTE: Instructions below are written for normally closed valves. For normally open versions (STOM, STO-A, Fig. 1 & 2), reverse switch nomenclature. (VOS becomes VCS and vice versa.) General: Shut off fuel supply upstream of valve, then de-energize valve electrically. – Remove top or side cover to provide access, being careful not to damage gasket.
Page 6100-S-8 Electro-Mechanical Valves Electrical Data Normally Closed Valves Manual Reset Series: .375" – 3" Series 808, 818 (-S); 1" – 1.25" Series 730, 760, 790 (-S); 1" – 1.25" Series 33790 (-S): 2.5" – 4" Series 808-CP (-S); 818-CP (-S); 6" Series 808, 818 (-S) Automatic Reset Series: .375" – 3" Series 5000, 5100 (-S); 1" – 1.25" Series 4730, 4760, 4790 (-S); 1" – 1.25" Series 33479; 2.5" – 4" Series 5000-CP(-S); 5100-CP(-S) 4" – 6" Series 7000, 7100 (-S) .375" – .
Electro-Mechanical Valves Page 6100-S-9 Electrical Data Normally Open Valves .75" – 2" Series STO-M and STO-A (-S) 2.5" – 4" Series STO-MCP and STO-ACP (-S) 1/99 Maxon practices a policy of continuous product improvement. It reserves the right to alter specifications without prior notice.
Page 6100-S-10 Electro-Mechanical Valves Tandem Arrangements (for simultaneous opening of main and blocking valves) Installation Instructions Review and comply with all general valve installation instructions provided separately. (See sketch below.) 1. Mount both valves in fuel line with center to center spacing as originally specified, and blocking valve (without handle) downstream of main valve (with handle). 2. Check valve alignment to be certain that operating wheels lie in the same plane. 3.
Electro-Mechanical Valves Page 6100-S-11 Overhead Wheel & Chain Assembly Overhead wheel and chain assembly allows operation of a manual reset valve in an otherwise inaccessible overhead location. A wheel is mounted onto the handle of the valve. The attached chain is weighted on one end and has a paddle handgrip on the other. Once the valve is electrically energized, pulling down on the paddle will open normally closed versions or close normally open versions.
Page 6100-S-12 Electro-Mechanical Valves Maintenance Instructions CAUTION: Valve leak testing should be undertaken only by trained and experienced personnel. Instructions provided by the company and/or individuals responsible for the manufacture and/or overall installation of complete system incorporating Maxon valves take precedence over these provided by Maxon. If Maxon instructions conflict with any codes or regulations, contact Maxon Corporation before attempting this procedure.
Electro-Mechanical Valves Page 6100-S-13 Maintenance Instructions Suggested leak test procedure for double-blocking shut-off valves (without vent line) - continued (h) Secure test apparatus on valve #1. (i) Remove the 1/4” pipe plug from downstream side of shut-off valve #2. Install leak test apparatus. (j) With an auxiliary power supply connected to valve #1, open test apparatus and test valve for leakage. As a guideline, valve should be tested for 2 minutes per inch of pipe diameter.
Tower Dryer Operations & Service COMPONENTS V COMPONENT MANUALS GEARBOXES All GSI Hopper Bottom Dryers — Nord #SK5382 All Zimmerman 12’ Diameter Dryers — Sumitomo #6145DB All Zimmerman 18’ Diameter Dryers — Sumitomo #6185DB All Zimmerman 24’ Diameter Dryers — Sumitomo #6195DB
UNICASE® Shaft Mount Gearboxes BIM 1020 Installation and Maintenance Instructions USA Retain These Safety Instructions For Future Use CDN INSPECTION OF UNIT Thoroughly inspect the equipment for any shipping and handling damage before accepting shipment from the freight company.
INSTALLATION OF UNIT To ensure Iong service and dependabIe performance, an encIosed gear drive must be rigidIy supported and the shafts accurateIy aIigned. The foIIowing describes the minimum precautions required to accompIish this end. ! 50 d 80 = +0.000/-0.019 ! 80 d 120 = +0.000/-0.022 ! 120 d 180 = +0.000/-0.025 FOUNDATION The responsibiIity for the design and construction of the foundation Iies with the user.
AXIAL RETENTION Each drive shaft must be retained in place relative to the gear reducer. Or each gear reducer must be retained in place relative to the drive shaft. Either way NORD recommends the use of shaft shoulders, locking collars or FIXING ELEMENTS to axially retain the shaft or gear reducer in position. Output and Input shaft Diameter toIerance Metric (mm) d 18 = +0.012/+0.001 ! 18 d 30 = +0.015/+0.002 ! 30 d 50 = +0.018/+0.002 ! 50 d 80 = +0.030/+0.011 ! 80 d 120 = +0.035/+0.
COUPLING ALIGNMENT Shaft coupIings shouId be instaIIed according to the coupIing manufacturer’s recommendations for gap, anguIar and paraIIeI aIignment. In many instaIIations, it is necessary to aIIow for thermaI and mechanicaI shaft movement when determining shaft aIignment. The coupIing manufacturer’s recommendations shouId be foIIowed.
FILL LEVEL & DRAIN PLUGS The drain plugs are metric socket head cap screws. They will be located at the lowest part of the gearbox for ease of draining. The fill level plug is a hex head cap screw. It will be located between the Autovent and drain plug. Both types of plugs will have gaskets included to prevent oil from leaking. LUBRICANT AII NORD reducers are shipped from the factory properIy fiIIed with Iubricant and all plugs are installed according to the mounting position given on the reducer nametag.
MAINTENANCE Mineral lubricant should be changed every 10,000 service hours or after two years. For synthetic oils, the lube should be changed every 20,000 service hours or after four years. In case of extreme operating (e.g. high humidity, aggressive environment or large temperature variations), shorter intervals between changes are recommended. OIL SPECIFICATIONS NORD supplies aII reducers fiIIed with oiI from the factory.
LUBRICANT CAPACITY Each reducer has the oil level and oil quantity adjusted according to the mounting position shown in the tables. When replacing the oil, consult the tables below to determine the proper amount of oil to be installed according to the reducer size and mounting position. Note that this is approximate and the final level will be adjusted when the reducer is installed. Acceptable oil fill level is within ½ inch of the bottom of the fill plug threads.
PARTS LIST 5 27 28 29 30 SK 1382 - SK 5382 45 46 48 52 53 54 55 56 57 58 59 60 61 62 63 203 204 206 207 208 223 229 234 235 244 245 246 247 248 249 250 254 SK 6382 - SK 11382 BIM 1020/2005/03 9 Driving gear Hexagon screw Seal Supporting disc Third reduction gearcase Ball bearing Key Ball bearing Circlip Key Circlip Intermediate shaft, plain Intermediate shaft, gearcut Circlip Circlip Shim Circlip Circlip Drain plug Seal Driving gea Pinion shaft SK 6382 - SK 9382 Driving pinion Output shaft Key Locking
TROUBLE SHOOTING PROBLEM WITH THE REDUCER Overloading POSSIBLE CAUSES Load exceeds the capacity of the reducer Insufficient lubrication Runs Hot Improper lubrication Excessive lubrication Wrong lubrication Loose foundation bolts Runs Noisy Worn RV Disc Failure of Bearings Insufficient Lubricant Output Shaft Does Not Turn Internal parts are broken Weak mounting structure Loose hold down bolts Overloading unit may result in damage to disc May be due to lack of lubricant Overload Level of lubricant in
SM-CYCLOB SPEED REDUCERS
SECTION A CONTENTS Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 . General Construction . . . . . . . . . . . . . . . . . . . .A-3,4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5-10 Grease Units . . . . . . . . . . . . . . . . . . . . . . . . .A-7,8 Designated Greases .................. A-7 Grease Replenishment & Change . . . . . . .A-7 Quantities of Grease . . . . . . . . . . . . . . . .A-7,8 Oil Units . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL CONSTRUCTION Fig. A-1 Speed Reducer - Horizontal Foot Mount, Single Reduction Fig. A-2 Speed Reducer - Vertical Base Mount, Single Reduction Note: For details of oil seals, bearings or gaskets, refer to A-1 1 - 13. tRefer to Table A-I6 on Pg. A-9 for units which require a positive displacement pump. 'Pt. No. 58 -frame sizes 6195-6275 only; Pt. No. 5 9 -frame sizes 6205-6275 only. "See Fig. A-3, Page A-4; See Fig. A-4, Page A-4. + Table A-1.
GENERAL CONSTRUCTION Fig. A-3 Speed ReducerlSingleDisc Type (Frame Size 6060-6095) Speed Reducer - Single Disc SM-CYCLOasingle reduction, Models No. 6060-6095, employ the use of a single planetary gear (Cycloid Disc) and a balance weight. Fig. A-4 Speed Reducermouble Reduction Multiple Reduction Reducers Multiple reduction SM-CYCLP Reducers are a combination of standard reduction mechanism assemblies connected using an intermediate shafl (Part No. 5-01) and intermediate cover (Part No. 55) between them.
LUBRICATION Standard Type Mounted Reducer (Slow Speed Shaft Horizontal)wl Table A-3. Horizontal Mounted Single Reduction Reducers Table A-4. Horizontal Mounted Double Reduction Reducers .-, . . . . . -.i..E--.~--,.--I,r .. ,.,; . . .. .? . . ..ii... .r....ry. ..yr,:7; ..... .. . . .s . . . ... .i,.', ... *, ; ;; : r " .. aa. , , : - .., , ' , : , . : . ". ' . ; :, , , ,,;-: .........". ........... : , .. .. \ ....;.y,..:. . .:.-~'.'. . . . . +.,.>'r... , .. : . . .;'.:-'-.:. ,:;:;* 6:. .,..A .... 2.:. .
LUBRICATION Standard Vertical Mounted Reducer (Slow Speed Shaft Table A-5. Vertical Mounted Single Reduction Reducer Fr:n:ed O!! iubr'cnt~on(Pi Table A-6. Vertical Mounted Double Reduction Reducer Notes: [I]Please consult the factory for applications where the slow speed shaft is up. [Z]Tables A-5 and A-6 show the standard lubrication method when the Cyclo drive is driven at the standard input speed. [3]Ratios shown in white in Tables A-5 and A-6 are unavailable for the given unit sizes.
Lubricants Table A-7. Standard Greases[lI Grease Lubricated Models - Those models listed in Tables A-3 A-6 as grease lubricated are filled with grease before shipment to the customer and are ready for use. Table A-8. Grease Replenishment and Change Interval I I I Slngle and Double Reducbon Mahtenance Free Type I ''-r'-'''-''' '- ..- . ..---. .-- '.
LUBRICATION Table A-10. Double Reduction Grease Quantities - oz. fa.) .-. Mechanism (1st Stage) ~echanism(2nd Stage) Slow Speed Shaft Bearing (2nd Stage) I (750) 10.6 (300) (1100) 21.2 (600) (1000) 17.6 (500) (1500) 24.7 (700) Oil Lubricated Models Oil Fill Procedure 011 lubricated models are not filled with oil prior to shipping. Before start-up, remove the oil fill plug (See Pg. A-3, Fig. A-2, Part #28) and fill the reducer with recommended oil.
Table A-12. Oil Fill Quantities[ll ( )with tmchoid pump Table A-13. Allowable 011 Viscositv Table A-14. Oil Change Interval Forced Lubrication For Vertical Units Table A-15. Plunger Pump Type Plunger Pump Lubrication The plunger pump (Fig. A-2, Part #42) is automatically operated by a cam (Fig. A-2, Part #40) fitted on the slow speed shaft (Fig. A-2, Palt #I-01). The number of pumping cam teeth required is in direct relation to the reduction ratio and frame size.
BEARINGS, OIL SEALS, GASKETS Fig. A-9 18 1-02 1-03 Slow Speed Shafi Table A-20. Slow Speed Shaft Bearing Table A-21.
BEARINGS, OIL SEALS, GASKETS Fig. A-10 -Retaining Slow Speed Shaft Table A-22. Eccentric Bearing Intermediate Shaft (For Double Reduction Units) Ring High Speed Shaft Fip.
Table A-23. Intermediate Shaft Bearing 120x.155~16 Note: [I]D indicates lip (dust proof and seal lip) type.
Disassembly SM-CYCLOmReducers aredesigned to provide maximum ease when disassembing and reassembling; they require no special maintenance skills. 1. Remove the complete SM-CYCLO' Reducer with adaptor (motorized type) from the driven machine. 2. Remove the plug at the bottom of the oil gauge to drain all oil from the unit. 3. Remove the cooling fan cover and fan from those Speed Reducers (not motorized) equipped with a cooling fan, and stand the unit on a solid base with its high speed shaft side down.
, & Fig. A-12 i I I I Flg. A-16 - . rl ; I I kv e . -, 4 ! Note: number examInsen Ifadng Wm opposedto slowdspeed discnumber with side. v b. Apply grease to the raceway of the eccentric on the disc. Fix the rollers and set disc in place. c. Insert the spacer ring and set second disc in such a way that mark is 180' opposed to mark on the bottom disc. Eccentric Bearing Replacement Pre~autlonS The eccentric bearings are specially designed for'installation on SM-CYCLO. Reducers.
DAILY INSPECTION fluctuation is small. If temperature rises rapidly from a stable condition, add the recommended oil or grease (Tables A-7 and A-1 1). A rapid temperature rise may be caused from a lack of lubrication. 1. Visually check the oil level gauge on the vertical unit, forced-lubricated type. Check lubrication flow by viewing piping set and oil signal (Part No. 41). Faulty operation is caused by a lack of lubrication oil, damage to the plunger pump (Part No.
TROUBLESHOOTING AND REPAIR This troubleshooting guide is to help you identify and overcome common problems of reducers. If you have a problem not listed below, please consult factory. nsufficient lubrication. Loose hold do disc.
Tower Dryer Operations & Service COMPONENTS VI COMPONENT MANUALS MODUTROL MOTOR
Series 72 Modutrol IV™ Motors PRODUCT DATA FEATURES • Replaces M744S,T,Y and M745S,T,Y Motors. • M7261, M7274, M7281, M7284, and M7294 are non-spring return motors; M7272, M7282, M7285, and M7286 are spring return motors. • Oil immersed motor and gear train for reliable performance and long life. • Wiring box provides NEMA 3 weather protection. • Actuator motor and circuitry operate from 24 Vac. Models available with factory installed transformer or an internal transformer can be field added.
SERIES 72 MODUTROL IV™ MOTORS SPECIFICATIONS Models: TRADELINE models are selected and packaged to provide ease of stocking, ease of handling and maximum replacement value. TRADELINE model specifications are the same as those of standard models unless specified otherwise. TRADELINE models have auxiliary switch cams. NOTE: Auxiliary switches can only be added to motors that include auxiliary switch cams. (These cams cannot be field-added.
SERIES 72 MODUTROL IV™ MOTORS TOP VIEW TOP VIEW OF BRACKET 4-7/8 (124) 4-1/4 (107) 4-5/8 (116) 5-13/16 (148) 5-1/2 (140) 2-5/16 (58) 11/16 (17) 1/4 (7) POWER END 13/16 (20) 3 4-1/16 (103) 1/4 (7) 1-1/2 (37) 4 5 4-7/8 (124) 4-1/16 (103) 5-9/16 (141) 4-1/16 (103) 1-1/2 (37) WIRING BOX 3/4 (19) MOTOR 6-7/16 (164) 1 AUXILARY END POWER END 5-3/8 (137) 2-9/16 (66) 9/16 (15) 2 SPRING RETURN MODEL SHOWN 1 SOME MODELS DO NOT HAVE AN AUXILIARY SHAFT. ALL OTHER DIMENSIONS ARE THE SAME.
SERIES 72 MODUTROL IV™ MOTORS Auxiliary Switch Ratings (in Amps): See Table 3. Table 3. Auxiliary Switch Ratings (in Amps). One Contact Ratinga 120V 240V Full Load 7.2 3.6 Locked Rotor 43.2 21.6 a 40 VA pilot duty, 120/240 Vac on opposite contact. Stroke: Fixed 90° or 160° models available. Other models available with field adjustable strokes from 90° to 160°. Stroke adjusted by means of cams located in the wiring compartment.
SERIES 72 MODUTROL IV™ MOTORS INSTALLATION When Installing this Product... 1. 2. 3. 4. Mounting Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition. Check the ratings given in the instructions and on the product to make sure the product is suitable for your application. Installer must be a trained, experienced service technician. After installation is complete, check out product operation as provided in these instructions.
SERIES 72 MODUTROL IV™ MOTORS Adapter Bracket Damper Linkages The 220738A Adapter Bracket, positioned between the motor and the equipment, raises motor shaft height by 0.75 in. (19 mm) to match that of previous Modutrol® Motor models. The motor does not include a crank arm. Order the crank arm separately (see Accessories in the Specifications section). For detailed instructions on the assembly of specific linkages, refer to the Installation Instructions packed with the linkage.
SERIES 72 MODUTROL IV™ MOTORS STANDARD BOLTS (4) BOLTS PROVIDED (4) 1 WIRING BOX MOTOR ND RE WE PO ADAPTER BRACKET ND RE WE PO ND RE WE PO EQUIPMENT BASE 1 No. 12 OR 1/4 in. ZINC PLATED MACHINE SCREWS OR BOLTS NON-SPRING RETURN M452E SPRING RETURN Fig. 3. Mounting the motor with an adapter bracket. WIRING BOX POWER END OF MOTOR MOTOR Q5001 VALVE LINKAGE VALVE 1/4-20 UNC 1 in. LONG MOUNTING BOLTS M17092 Fig. 4. Mounting the motor on a Q5001 Valve Linkage.
SERIES 72 MODUTROL IV™ MOTORS Wiring 3. CAUTION 4. Electrical Shock or Equipment Damage Hazard. Can shock individuals or short equipment circuitry. Disconnect all power supplies before installation. Motors with auxiliary switches can have more than one disconnect. IMPORTANT All wiring must agree with applicable codes, ordinances and regulations. 1. 2. Ensure that the voltage and frequency stamped on the motor correspond with the power supply characteristics.
SERIES 72 MODUTROL IV™ MOTORS + – F MOTOR T2 BRAKE CIRCUITRY ELECTRONIC CIRCUIT TRIAC SWITCHING L1 (HOT) T1 CONTROLLER 3 1 4 L1 (HOT) T2 - - + + L2 TRIAC SWITCHING 1 L2 24V 2 F T1 1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQURED. 2 CONNECTING F TO – WILL DRIVE MOTOR TO FULLY OPEN. FEEDBACK POTENTIOMETER M5778 Fig. 7. Typical system wiring.
SERIES 72 MODUTROL IV™ MOTORS SETTINGS AND ADJUSTMENTS Zero and Span Adjustment for M7284Q and M7285Q Motors (Fig. 5.) 1. 2. 3. 4. 5. 6. 7. 8. Auxiliary Switches Adjust the start potentiometer fully clockwise (maximum zero) and the span potentiometer fully counterclockwise (minimum span). Set the controller current to the value required to drive the motor to the closed position. Turn the start potentiometer slowly counterclockwise until the motor begins to open.
SERIES 72 MODUTROL IV™ MOTORS Auxiliary Switch Adjustment IMPORTANT When adjusting the auxiliary switch cams use the following procedure: 1.Insert 1/8 in. screwdriver blade into a slot on cam and move the screwdriver top as far as possible in the required direction. See Fig. 10. 2.Repeat step 1 in successive cam slots until the cam is in the required position. Use the following procedure to obtain the desired auxiliary switch settings: 1.
SERIES 72 MODUTROL IV™ MOTORS OPERATION AND CHECKOUT Operation The motor feedback potentiometer and control current input circuit form a bridge circuit. As long as the final control element remains at the position proportional to the input current from the controller, the circuit is balanced, and the motor does not run.
Tower Dryer Operations & Service COMPONENTS VII COMPONENT MANUALS GAS REGULATORS
RM-1328 Rev. 9 Regulator Installation and Maintenance Instructions Model 121 Regulators Introduction Start-Up Streamlined body passages provide large capacity. An external control line is required from lower case to control piping. The 121 has a fast speed of response, yet is stable in operation. Soft seats assure positive tight shutoff. Orifices are replaceable. Springs are color coded. B. Note the set-point (set-point is the outlet pressure the regulator is adjusted to deliver).
Set Point Adjustment A. The 121 is factory adjusted as specified on the order. To change the set-point, readjust as follows: 1. Remove the top cap 1. 2. Adjust set-point with adjustment button 3, 3a or 6. Turn clockwise to increase and counterclockwise to decrease the outlet pressure. NOTE: a. Only make this adjustment when gas is actually flowing through the regulator. The flow should be small (approximately 1000 SCFH). Do not adjust when the regulator is closed and there is no flow. b.
Outlet Pressure Ranges and Springs OUTLET PRESSURE RANGE SIZE 11/2" to 31/2" w.c. 3 /4", 1" and 1 /4"** Model 121-8 1 /4", 1" and 11/4"** Model 121-8HP 3 11/2" to 12" w.c. 11/2", 2" and 21/2" Model 121-12 11/2", 2" and 21/2" Model 121-8 11/2", 2" and 21/2" Model 121-8HP 3" and 4" Model 121-16 3" and 4" Model 121-12 Green-Black Black-Red Cadmium* White Red – 31/2" to 61/2" w.c. 5" to 81/2" w.c. 6" to 14" w.c. 12" to 28" w.c.
Differential Regulator 3 SIZE DIFFERENTIAL PRESSURE RANGE SPRING COLOR SPRING PART NUMBER MAXIMUM BODY PRESSURE Red-Black Blue-Black Green-Black Green Orange (2" O.D.) 143-82-021-00 143-82-021-01 143-82-021-02 143-16-021-05 143-16-021-06 MAXIMUM DIAPHRAGM CASE PRESSURE /4", 1" and 11/4" 121-8** 31/2" to 61/2" w.c. 5" to 81/2" w.c. 6" to 14" w.c. 12" to 28" w.c.
11/2", 2" and 21/2" Model 121 Standard, Differential, Atmospheric or Zero Governors 1" NPT Vent connection 1" NPT Vent connection 1/ 4" NPT Vent connection 1/4" NPT Control line connection 121-8 (Standard) } PIPE SIZES (inlet x outlet) 11/2" x 11/2" 11/2" x 2" Screwed, NPT 2" x 2" 21/2" x 21/2" 2" x 2" Flanged ANSI 125 lb. FF 121-12 (Standard) 1" NPT Vent connection Fig.
Condensed Parts List 11/2", 2" and 21/2" ILL. NO. 1 1a 2 2a 3 3a 4 5 7a 7b 9 11 11 11 12 DESCRIPTION Seal Cap Seal Cap Tetraseal (or O-Ring) 21/4" x 23/8" Tetraseal (or O-Ring) 11/2" x 15/8" Adjustment Spring Button Spring Adjusting Screw Hex Steel Nut Housing Cover Top Spring Button Thrust Bearing, stainless ball, 3 /8" diameter Spring, see table “Spring Ranges” 121-12 Diaphragm Assembly (31/2" w.c.
Servicing – General Instructions To Service Orifice (19) 2. Carefully note location and position of all disassembled parts to be certain reassembly is correct. Inspect each one carefully and replace those that are worn or damaged or otherwise unsatisfactory. 2. Remove main diaphragm assembly 11 per steps 1 through 4 “To Service Main Diaphragm (11d)”. 1. Make sure the regulator is entirely depressured before servicing. 3.
3" and 4" Model 121 Standard 1" NPT Vent connection 1" NPT Vent connection 1/2" NPT Control line connection 1/4" NPT Control line connection 121-12 PIPE SIZES (inlet x outlet) 3" x 3" 4" x 4" } Flanged ANSI 125 lb.
138-02-005-01 143-16-005-00 120-08-066-00 905241 143-16-009-00 141-10-160-01 908561 121-62-022-50 121-62-017-50 121-62-150-50 121-62-150-52 121-10-178-50 121-16-058-52 121-16-550-51 903955 121-10-022-50 121-16-017-50 121-16-150-53 121-16-150-55 121-10-178-50 121-16-058-52 934007 902418 905481 904448 1190647 121-22-130-51 902922 902698 904085 904079 121-60-598-50 121-20-598-50 121-62-598-50 121-22-598-50 FOR BACK PRESSURE MODELS 14 Item 14 above, Wave Washer - substitute Poly-U Disk Retainer ILL. NO.
Servicing – General Instructions To Service Orifice (19) To Service Valve (15) 2. Remove seal diaphragm assembly 12 per step 2 under “To Service Seal Diaphragm (12b)”. Same general instructions as listed on Page 6. 1. Remove bolts 38 and remove bottom cap 37. 2. Remove retaining ring 16a. Use Truarc 0400 pliers, Invensys Part No. 1190647. 3. Remove both halves of valve holder 16b. 4. Remove valve 15, and wing 15a or spacer (wave washer 14 will probably also come off...do not lose it).
TOC RM-1399 Rev. 6 General Safety Instructions for Gas Regulators Keep this sheet for future reference.
-I TOC 8. Check the regulator "set-point" and "lock-up" pressure. (Setpoint is the outlet pressure the regulator is adjusted to deliver. Lock-up is the pressure where tight shutoff is achieved). IMPORTANT: During start-up, a pressure gauge must be connected to the outlet piping between the regulator outlet and the downstream shutoff valve to closely monitor the outlet pressure. When checking the regulator for set-point and lock-up, provision must be made to PERMIT FREE FLOW of gas beyond the outlet valve.
Tower Dryer Operations & Service COMPONENTS VIII COMPONENT MANUALS ASCO PILOT VALVE
Installation & Maintenance Instructions SERIES 2-WAY INTERNAL PILOT-OPERATED SOLENOID VALVES 8215 NORMALLY CLOSED OPERATION - 3/8I, 1/2I, OR 3/4I NPT IMPORTANT: See separate solenoid installation and maintenance instructions for information on: Wiring, Solenoid Temperature, Causes of Improper Operation, Coil, or Solenoid Replacement. Form No.
3. Replace valve bonnet and bonnet screw on valve body. Hand thread screws a few turns into valve body, then torque bonnet screws in a crisscross manner to 70 ± 8 in-lbs [8,0 ± 0,9 Nm]. 4. Install solenoid base gasket and solenoid base sub-assembly. Compress rider ring slightly to prevent damage when installing solenoid base sub-assembly. Torque solenoid base sub-assembly to 175 ± 25 in-lbs [19,8 ± 2,8 Nm]. 5. Install solenoid, see separate instructions and make electrical hookup.
Installation & Maintenance Instructions SERIES 8003G 8202G OPEN-FRAME, GENERAL PURPOSE, WATERTIGHT/EXPLOSIONPROOF SOLENOIDS INSTALLATION Ċ SERVICE NOTICE Ċ ASCO solenoid valves with design change letter G" or H" in the catalog number (ex. 8210G 1) have an epoxy encapsulated ASCO Red Hat II solenoid. This solenoid replaces some of the solenoids with metal enclosures and open-frame constructions. Follow these installation and maintenance instructions if your valve or operator uses this solenoid.
facilitate wiring, the solenoid may be rotated 360 . For the watertight and explosionproof solenoid, electrical fittings must be approved for use in the approved hazardous locations. CAUTION: Cryogenic Applications - Solenoid lead wire insulation should not be subjected to cryogenic temperatures. Adequate lead wire protection and routing must be provided. Additional Wiring Instructions For Optional Features: Open-Frame solenoid with 1/4 spade terminals.
Torque Chart Part Name solenoid base sub-assembly & adapter pipe adapter Torque Value Inch-Pounds 175 ± 25 90 maximum Remove red cap and push solenoid down. Then pry here to lift nameplate/retainer and push to remove. Remove red cap and push solenoid down. Then pry here to lift nameplate/retainer and push to remove. red cap nameplate/ retainer grounding wire green or green with yellow stripes solenoid with 1/2 NPT finger washer .062 to .
Torque Chart Part Name terminal block screws socket head screw center screw Torque Value in Inch-Pounds 10 ± 2 15 - 20 5±1 Open-Frame Solenoid with Screw Terminals. Socket head screw is used for grounding. Open-Frame Solenoid with 1/4 Spade Terminals See torque chart above Open-Frame Solenoid with DIN Terminals screw terminal adapter Indicates parts supplied in Termination Module Kit No.
Tower Dryer Operations & Service COMPONENTS IX COMPONENT MANUALS PROTECTOFIER
OPERATING SEQUENCE 42-VA uwuuwummum COMBUSTION SAFEOUARD Form 6642 VA Single Burner Supervision, Manual Pushbutton Ignition, Plug-in SSlOOA FLAME -PAK, Plug-in Control Relays Power on PROTECTOFIER terminals LI and L2 provides power to electronic network. Terminal L I must be powered before terminal 12. Power on PROTECTOFIER terminal 12 (thru permissive safety limits circuit) permits manual pushbutton ignition. I 3) N.O."F' contact in main valve circuit closes to energize main valve (thru N.O.
d-- ~-115~~-60~2. FU StO POWER SUPPLY. W H E N FLCIMZ IS €BTk8L\SWED A N D QtTEfTLD. O l h G R A M BELOW. MANUAL O P E R A T I O N C - C H E C K RELAY F-F L A M E RELAY S I N G L E BURNER PROTECTOFIER (FORMbb42VA GROUP M Z i O l a ) NO CONNECTION. I \NTLRNAL WIRtNb. - -- - E X T E R N A L W I R I N G . --------------A L A R M WORM - SFUEL AFETY INTLK.SLRiLS C I R C U I T . AND AIRPRESS.SWS., V€NT.FANS, ETC. A S REP'O. SINGLE BURNER PROTLCTOlrIER ( F o R M ~ ~Y A~ Z GROUPMZIO~.> lISV~-bOMZ.
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.
