Airstream Clothes Dryer PNEG 339 User Manual

I R S T R E A M

R A I N

O N D I T I O N I N G

Y S T E M S

1 9 9 7

DRYER OPERATION

A N D S E R V I C E M A N U A L

PNEG-339

1100 SERIES SINGLE FAN

PORTABLE DRYER

MODELS

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1100 SERIES DRYER OPERATION AND SERVICE

TABLE OF CONTENTS

Warranty.......................................................................................................................4

Safety First...................................................................................................................5

Safety Alert Decals.......................................................................................................6

Safety Precautions.......................................................................................................7

Dryer Control Panel Featuring The Electronic Monitoring Control System.......................8

Safety Circuit Shutdown Messages......................................................................13

Dryer Pre Start Checks...............................................................................................14

Pre Season Inspection..........................................................................................14

Dryer Start Up...................................................................................................................18

Continuous Flow And Continuous Batch Start Up Procedure..............................18

Continuous Flow Metering Roll Settings...............................................................19

Continuous Batch Metering Roll And Timer Settings................................................22

1100 Series Dryer Service Guide.....................................................................................23

Seasonal Inspection And Service.........................................................................24

Suggested Lubricants..........................................................................................25

Fan Propellor Removal And Installation...............................................................26

Fan Motor Removal And Installation....................................................................27

Heater Parts Removal And Installation................................................................28

Metering Roll Servicing........................................................................................29

How To Determine A Metering Roll Problem........................................................30

Wiring Diagrams...................................................................................................31

Trouble Analysis Procedure...................................................................................41

Quick Reference Guide........................................................................................46

Notes...................................................................................................................47

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WARRANTY

THE GSI GROUP, INC. ("GSI") WARRANTS ALL PRODUCTS MANUFACTURED BY GSI TO BE FREE OF

DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDITIONS FOR A PE-

RIOD OF TWENTY-FOUR MONTHS AFTER RETAIL SALE TO THE ORIGINAL END USER OF SUCH PROD-

UCTS. GSI'S ONLY OBLIGATION IS, AND PURCHASER'S SOLE REMEDY SHALL BE FOR GSI, TO RE-

PAIR OR REPLACE, AT GSI'S OPTION AND EXPENSE, PRODUCTS THAT, IN GSI'S SOLE JUDGMENT,

CONTAIN A MATERIAL DEFECT DUE TO MATERIALS OR WORKMANSHIP. ALL DELIVERY AND SHIP-

MENT CHARGES TO AND FROM GSI'S FACTORY WILL BE PURCHASER'S RESPONSIBILITY. EXPENSES

INCURRED BY OR ON BEHALF OF THE PURCHASER WITHOUT PRIOR WRITTEN AUTHORIZATION

FROM AN AUTHORIZED EMPLOYEE OF GSI SHALL BE THE SOLE RESPONSIBILITY OF THE PURCHASER.

EXCEPT FOR THE ABOVE STATED EXPRESS LIMITED WARRANTIES, GSI MAKES NO WARRANTY OF

ANY KIND, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MER-

CHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN CONNECTION WITH (i) PROD-

UCT MANUFACTURED OR SOLD BY GSI OR (ii) ANY ADVICE, INSTRUCTION, RECOMMENDATION OR

SUGGESTION PROVIDED BY AN AGENT, REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR

RELATED TO THE CONFIGURATION, INSTALLATION, LAYOUT, SUITABILITY FOR A PARTICULAR PUR-

POSE, OR DESIGN OF SUCH PRODUCT OR PRODUCTS.

IN NO EVENT SHALL GSI BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL OR CONSEQUEN-

TIAL DAMAGES, INCLUDING, WITHOUT LIMITATION, LOSS OF ANTICIPATED PROFITS OR BENEFITS.

PURCHASER'S SOLE AND EXCLUSIVE REMEDY SHALL BE LIMITED TO THAT STATED ABOVE, WHICH

SHALL NOT EXCEED THE AMOUNT PAID FOR THE PRODUCT PURCHASED. THIS WARRANTY IS NOT

TRANSFERABLE AND APPLIES ONLY TO THE ORIGINAL PURCHASER. GSI SHALL HAVE NO OBLIGA-

TION OR RESPONSIBILITY FOR ANY REPRESENTATIVE OR WARRANTIES MADE BY OR ON BEHALF

OF ANY DEALER, AGENT OR DISTRIBUTOR OF GSI.

GSI ASSUMES NO RESPONSIBILITY FOR FIELD MODIFICATIONS OR ERECTION DEFECTS WHICH

CREATE STRUCTURAL OR STORAGE QUALITY PROBLEMS. MODIFICATIONS TO THE PRODUCT NOT

SPECIFICALLY COVERED BY THE CONTENTS OF THIS MANUAL WILL NULLIFY ANY PRODUCT WAR-

RANTY THAT MIGHT HAVE BEEN OTHERWISE AVAILABLE.

THE FOREGOING WARRANTY SHALL NOT COVER PRODUCTS OR PARTS WHICH HAVE BEEN

DAMAGED BY NEGLIGENT USE, MISUSE, ALTERATION OR ACCIDENT. THIS WARRANTY COVERS

ONLY PRODUCTS MANUFACTURED BY GSI. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL

OTHER WARRANTIES EXPRESS OR IMPLIED. GSI RESERVES THE RIGHT TO MAKE DESIGN OR SPECI-

FICATION CHANGES AT ANY TIME.

PRIOR TO INSTALLATION, PURCHASER HAS THE RESPONSIBILITY TO RESEARCH AND COM-

PLY WITH ALL FEDERAL, STATE AND LOCAL CODES WHICH MAY APPLY TO THE LOCATION AND

INSTALLATION.

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ROOF WARNING, OPERATION & SAFETY

ROOF DAMAGE WARNING AND DISCLAIMER

GSI DOES NOT WARRANT ANY ROOF DAMAGE CAUSED

BY EXCESSIVE VACUUM OR INTERNAL PRESSURE FROM

FANS OR OTHER AIR MOVING SYSTEMS. ADEQUATE

VENTILATION AND/OR "MAKEUP AIR" DEVICES SHOULD

BE PROVIDED FOR ALL POWERED AIR HANDLING SYS-

TEMS. GSI DOES NOT RECOMMEND THE USE OF DOWN-

WARD FLOW SYSTEMS (SUCTION). SEVERE ROOF DAM-

AGE CAN RESULT FROM ANY BLOCKAGE OF AIR PAS-

SAGES. RUNNING FANS DURING HIGH HUMIDITY/COLD

WEATHER CONDITIONS CAN CAUSE AIR EXHAUST OR

INTAKE PORTS TO FREEZE.

DRYER OPERATION

As owner and/or operator, it is

your responsibility to know what

requirements, hazards and pre-

cautions exist, and to inform all

personnel associated with the

equipment, or who are in the dryer

area. Avoid any alterations to the

equipment. Such alterations may

produce a very dangerous situa-

tion, where serious injury or death

may occur.

Thank you for choosing a GSI/

Airstream product. It is designed

to give excellent performance

and service for many years.

This manual describes the

operation and service for all stan-

dard 1100 Series one fan grain

dryers. These models are avail-

able for liquid propane or natu-

ral gas fuel supply, with either

single phase 230

volt, or three phase 220 or 440

volt electrical power.

The principal concern of the GSI

Group, Inc. ("GSI") is your safety and

the safety of others associated with

grain handling equipment. This

manual is written to help you under-

stand safe operating procedures,

and some of the problems that may

be encountered by the operator or

other personnel.

SAFETY ALERT SYMBOL

The symbol shown is used to call

your attention to instructions con-

cerning your personal safety. Watch

for this symbol; it points out impor-

tant safety precautions. It means

"ATTENTION", "WARNING", "CAU-

TION", and "DANGER". Read the

message and be cautious to the

possibility of personal injury or

death.

WARNING! BE ALERT!

Personnel operating or working around

electric fans should read this manual.

This manual must be delivered with the

equipment to its owner. Failure to read

this manual and its safety instructions is

a misuse of the equipment.

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SAFETY ALERT DECALS

Three decals displayed on all Airstream Dryers. Belt drives, chain driven meter rolls

and combustible fuels must be treated with caution.

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SAFETY PRECAUTIONS

1. Read and understand the operating manual before trying to operate the

dryer.

USE CAUTION

IN THE OPERATION

OF THIS EQUIPMENT

2. Never operate the dryer while the guards are removed.

The design and manufacture of this

dryer is directed toward operator

safety. However, the very nature of

a grain dryer having a gas burner,

high voltage electrical equipment

and high speed rotating parts, does

present a hazard to personnel,

which can not be completely safe-

guarded against, without interfering

with efficient operation and reason-

able access to components.

3. Power supply should be OFF for service of electrical components.

Use CAUTION in checking voltage or other procedures requiring power

to be ON.

4. Check for gas leaks at all gas pipe connections. If any leaks are

detected, do not operate dryer. Shut down and repair before fur-

ther operation.

5. Never attempt to operate the dryer by jumping or otherwise bypassing

any safety devices on the unit.

Use extreme caution in working

around high speed fans, gas-fired

heaters, augers and auxiliary con-

veyors, which may start without

warning when the dryer is operating

on automatic control.

6. Set pressure regulator to avoid excessive gas pressure applied to

burner during ignition and when burner is in operation. See chart for

operating procedures. Do not exceed maximum recommended dry-

ing temperature.

7. Keep the dryer clean. Do not allow fine material to accumulate in

the plenum chamber.

KEEP THE DRYER CLEAN

DO NOT ALLOW FINE

8. Keep auger drive belts tight enough to prevent slippage.

MATERIAL TO ACCUMULATE

IN THE PLENUM CHAMBER

OR SURROUNDING THE

OUTSIDE OF THE DRYER

9. Use CAUTION in working around high speed fans, gas burners,

augers and auxiliary conveyors which START AUTOMATICALLY.

10. Donotoperateinanyareawherecombustiblematerialwillbedrawninto

the fan.

Continued safe, dependable opera-

tion of automatic equipment de-

pends, to a great degree, upon the

owner. For a safe and dependable

drying system, follow the recom-

mendations within this manual, and

make it a practice to regularly in-

spect the operation of the unit for any

developing problems or unsafe con-

ditions.

11. Before attempting to remove and reinstall any propellor, make certain

to read the recommended procedure listed within the servicing section

of the manual.

12. Be certain that capacities of auxiliary conveyors are matched to dryer

auger capacities.

13. Clean grain is easier to dry. Fine material increases resistance to airflow

and requires removal of extra moisture.

READ THESE INSTRUCTIONS

BEFORE OPERATION AND SERVICE

Take special note of the safety

precautions listed above before at-

SAVE FOR FUTURE REFERENCE

tempting to operate the dryer.

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DRYER CONTROL PANEL

Figure 1: The grain dryer control panel with the Electronic Monitoring Control System in the upper right panel.

DRYER CONTROL PANEL FEATURING

THE ELECTRONIC MONITORING CONTROL SYSTEM

information about dryer operation.

The control panel provides easy ac-

cess to gauges and controls, and the

ILLUMINATED SWITCHES are a

quick reference for every operating

function. The patent pending Elec-

tronic Monitoring Control System

is computerized and gives instant

MOISTURE CONTROL

SWITCH (2)

MOISTURE CONTROL

THERMOSTAT (1)

This electronic thermostat con-

This switch turns the power ON or

OFF to the moisture control ther-

mostat. It lights up when the grain

column temperature is below the

thermostat set point.

trols the moisture level of dis-

charged grain by sensing grain

column temperature.

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DRYER CONTROL PANEL

CONTROL POWER

SWITCH (3)

FAN SWITCH (7)

• In the 1 SPEED position, if the

MOISTURE CONTROL switch is

ON, and the DRYING MODE

switch is turned to CONTINUOUS

FLOW, the METERING ROLL

SPEED will operate at the HIGH

speed metering roll potentiometer

setting or turn OFF depending on

the control signal from the MOIS-

TURE CONTROL THERMO-

STAT. The discharge auger will

operate whenever the metering

rolls are operating.

The fan is turned ON or OFF with

this switch. The ON position oper-

ates the fan continuously during

STAGED BATCH and CONTINU-

OUS FLOW modes. The AUTO po-

sition operates the fan in STAGED

BATCH during the dry and cool

cycle. The switch will light up when-

ever the airflow switch is sensing

airflow and the dryer is full of grain.

The power to the Electronic Moni-

toring Control System is turned

ON or OFF with this switch.

OUTSIDE LIGHT (4)

The dryer service light is turned

ON or OFF here. It also may be

set on AUTO, which turns the light

on while the dryer is running, and

off if a shutdown occurs.

HEATER SWITCH (8)

DRYING MODE SWITCH (5)

This switch is used to turn the

burner ON or OFF. The AUTO po-

sition operates the burner in

STAGED BATCH during the dry

cycle. The ON position will operate

the burner only when the fan is run-

ning. The switch will light up when

the flame sensor detects the flame.

This is used to select STAGED

BATCH or CONTINUOUS FLOW

drying. The switch will light only af-

ter the Electronic Monitoring Con-

trol System has been turned ON,

the safety circuit is okay and the

RESET button has been pressed.

• In both the 1 SPEED or the 2

SPEED position, if the MOIS-

TURE CONTROL THERMOSTAT

is OFF, and the DRYING MODE

switch is turned to CONTINUOUS

FLOW, the METERING ROLL

SPEED can be manually con-

trolled by adjusting the HIGH

speed metering roll potentiometer.

The discharge auger will operate

continuously.

UNLOAD SWITCH (9)

LOAD AUGER SWITCH (6)

This is used to select the opera-

tion of the load auger. In both the

AUTO and MANUAL position the

load auger will operate if the dryer

is low on grain, and will automati-

cally shut off when the dryer is full.

In the AUTO position only, the

dryer will shut down after a prede-

termined period of time set on the

OUT OF GRAIN TIMER, or if grain

flow is interrupted to the dryer. The

switch will light whenever the load

auger is operating.

The UNLOAD switch turns the me-

tering rolls and discharge auger

ON or OFF, and selects the opera-

tion of the metering rolls.

• If the DRYING MODE switch is

turned to STAGED BATCH, the

UNLOAD switch should be set to

the 1 SPEED position. The dis-

charge auger and metering rolls

will only operate during the unload

cycle of the staged batch opera-

tion, and the METERING ROLL

SPEED is adjusted using the

HIGH speed metering roll potenti-

ometer.

• In the 2 SPEED position if the

MOISTURE CONTROL switch is

ON, and the DRYING MODE

switch is turned to CONTINUOUS

FLOW, the METERING ROLL

SPEED will alternate between the

HIGH speed metering roll potenti-

ometer setting and the LOW

speed metering roll potentiometer

setting depending on the control

signal from the MOISTURE CON-

TROL THERMOSTAT. The dis-

charge auger will operate con-

tinuously.

Note: When this switch is set

to AUTO or MANUAL it also con-

trols the operation of any auxiliary

load equipment being utilized,

such as an auxiliary auger or con-

veyor.

Note: When this switch is set to

AUTO or MANUAL it also controls

the operation of any auxiliary load

equipment being utilized, such as

an auxiliary auger or conveyor.

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DRYER CONTROL PANEL

LOW SPEED METERING

ROLL POTENTIOMETER (10)

matic moisture control feature of

the dryer is utilized.

nents can be operated by turning the

DRYING MODE switch to CON-

TINUOUS FLOW, pressing the

DRYER POWER START button and

then turning ON the desired dryer

component.

This is used to adjust the LOW

speed of the metering roll when the

2 SPEED and MOISTURE CON-

TROL THERMOSTAT are in use.

• Set the speed of the metering

rolls during continuous flow op-

eration when the moisture control

is not used.

• Set the rate of grain discharge from

the dryer during the unload cycle of

staged batch dryer operation.

DRYER POWER

STOP SWITCH (13)

HIGH SPEED METERING

ROLL POTENTIOMETER (11)

This is used to:

This switch stops all dryer func-

tions. If an automatic dryer shut-

down occurs, first determine and

correct the cause of the shutdown.

Then, press the DRYER POWER

STOP button to reset the dryer be-

fore restarting.

• Set the HIGH speed of the meter-

ing roll when the 2 SPEED auto-

matic moisture control feature of

the dryer is utilized.

DRYER POWER

START SWITCH (12)

This switch starts and operates the

dryer based on switch settings. If

other switch settings are in the OFF

position, individual dryer compo-

• Set the speed of the metering

rolls when the 1 SPEED auto-

The Airstream Dryer Control Panel.

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DRYER CONTROL PANEL

SETTING THE DRY (16),

COOL (17) AND UNLOAD

(18) BATCH TIMERS

if the dryer is stopped, these times

are saved by the controller. When

the dryer is restarted the TIMERS

will continue timing down. The TIM-

ERS will return to their initial settings

by pressing the RESET button.

ELECTRONIC

MONITORING CONTROL

SYSTEM (14)

The Electronic Monitoring Control

System (Figure 2) controls all tim-

ing functions and safety circuit

checks. It is designed to simplify

dryer operation by providing printed

messages and warnings on its liq-

uid crystal display (LCD).

These switches are used to set the

cycle times in the STAGED BATCH

DRYING MODE only. The DRYING

MODE switch must be in the

STAGED BATCH position. The cur-

rent settings on these three TIMERS

are displayed directly above each

TIMER button. To change the set-

ting of these TIMERS follow these

instructions:

SETTING THE OUT OF

GRAIN TIMER (19)

If the dryer runs out of grain while

the LOAD AUGER switch is in the

AUTO position, the OUT OF GRAIN

TIMER automatically shuts OFF the

dryer after the period of time preset

on the TIMER. When pressed, the

display will show the amount of time

left on the TIMER and the percent-

age of time the last load expended.

A second screen will appear show-

ing the TIMER'S setting and will al-

low the operator to modify it as de-

scribed for setting the BATCH TIM-

ERS.

TURNING ON THE

ELECTRONIC

MONITORING CONTROL

SYSTEM USING THE

RESET BUTTON (15)

1. Press the DRY, COOL or UN-

LOAD TIMER button.

2. Press the MODIFY button.

3. Press the INCREASE or DE-

CREASE button to adjust the

settings.

Turn the CONTROL POWER switch

to ON. The monitor will display a

ber, total running time in hours and

minutes and the current time and

date. To activate the controller press

the RESET button.

4. Press the ENTER button.

During operation the remaining

time on each TIMER is displayed on

the screen. If the power goes out or

Figure 2: The Airtream Electronic Monitoring Control System

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DRYER CONTROL PANEL

The Airstream Electronic Monitoring Control System showing different LCD displays.

DRYER SAFETY CIRCUIT

on the third line. By pressing the

BPH/RPM/TOTAL BU button the

second line will alternate between

the METERING ROLL RPM's or the

BUSHEL PER HOUR rate. The TO-

TAL BUSHELS DRIED reading is

the total since the bushel counter

was last reset. To reset the

BUSHEL COUNTER, press and

hold the RESET button for five sec-

onds. Press the ENTER button

through the date and time settings

and then follow the instructions dis-

played on the LCD for resetting the

counter.

SETTING THE LOAD (20)

AND UNLOAD (21) DELAYS

The Electronic Monitoring Control

System continuously checks all

safety circuits on the dryer, and will

automatically shut the dryer down

should a problem occur. The cause

of the dryer shutdown will be dis-

played on the LCD display, and a

beeper will sound on the controller.

To restart the dryer after a safety

shutdown, first correct the reason for

the shutdown, and then press the

DRYER POWER STOP button to re-

set the circuit. Press the START

button.

The LOAD DELAY is used to delay

the starting of the load auger when

the dryer is unloading to prevent the

load auger from starting and stop-

ping. The UNLOAD DELAY is used

to control the amount of time the un-

load auger runs after the metering

rolls stop to allow for auger

cleanout. Both the LOAD and UN-

LOAD DELAYS are set using the

same procedure as the TIMERS.

The AUX1 and AUX 2 DELAYS are

presently not being used.

The Electronic Monitoring

Control System stores in its

memory the time, date and cause for

the last 25 dryer safety shutdowns.

To review this information hold the

RESET button in for five seconds.

The procedure for reviewing the

safety circuit shutdown log will be

displayed on the LCD display.

In the STAGED BATCH DRY-

ING MODE the first line of the LCD

display tells which TIMER is being

used, and the second line switches

between TOTAL BATCHES, UN-

LOAD RPM or TOTAL BUSHELS.

The third line indicates TOTAL DRY

TIME and the fourth line is TIME

REMAINING on the TIMERS.

UTILIZING THE

BUSHEL COUNTER (22)

When operating the dryer the LCD

display will show the DRYER MODE

OF OPERATION on the first line, the

BUSHELS PER HOUR or the ME-

TERING ROLL RPM on the second

line and the TOTAL BUSHELS dried

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DRYER CONTROL PANEL

SAFETY CIRCUIT SHUTDOWN MESSAGES

BURNER VAPOR HIGH

TEMPERATURE

The LP gas vapor temperature sen-

LOWER ADJUSTABLE

GRAIN HIGH

TEMPERATURE

METERING ROLL DRIVE

SYSTEM FAILURE

The metering roll drive system has

failed to turn. A broken chain or

jammed metering roll is a possibility.

sor located in the gas pipe train

downstream from the vaporizer, has

opened indicating that the vaporizor

is running too hot and must be re-

adjusted. This sensor is set at 200°F

and automatically resets itself when

cool.

An over temperature condition has

occurred in the right side (left and

right as viewed from behind the

dryer) grain column causing the

control to shut down the dryer. This

control is set at 210°F and automati-

cally resets itself when cool.

RIGHT METERING ROLL

FAILURE

The right (as viewed from behind the

dryer) metering roll has stopped turn-

ing, or the sensor has been damaged.

LEFT METERING ROLL

FAILURE

The left (as viewed from behind the

LOWER FIXED GRAIN

HIGH TEMPERATURE

BURNER WARNING FLAME

NOT DETECTED

An over temperature condition has

occurred in the left side (left and

right as viewed from behind the

dryer) grain column causing the

control to shutdown the dryer. This

control is set at 210°F and automati-

cally resets itself when cool.

The flame sensor has failed to de-

tect a burner flame indicating that the

burner has failed to light, there is a

problem with the flame sensing cir-

cuitry or the dryer is not getting

burner fuel.

dryer) metering rollhas stopped turn-

ing, or the sensor has been damaged.

12 VOLT POWER

SUPPLY WARNING

The right circuit breaker on the in-

put/output board has tripped.

FAN HOUSING HIGH

TEMPERATURE

AUXILIARY SAFETY

SHUTDOWN

MOTOR OVERLOAD

The temperature high limit located

One of the thermal overloads on

either the fan, load, unload or aux-

iliary motors has opened, indicat-

ing an overcurrent condition. The

overloads must be manually reset.

A shutdown has occurred due to an

auxiliary installed safety feature.

on the fan/burner housing has

opened, indicating an over tempera-

ture condition has occurred towards

the rear of the fan/heater housing.

This control is set at 200°F and must

be manually reset.

BURNER SHUTDOWN

LOSS OF AIRFLOW

The contacts in the air switch have

opened due to insufficient airflow for

the burner to operate.

OUT OF GRAIN

WARNING/UNLOAD

CLEANOUT

GRAIN DISCHARGE

WARNING

The lid on the grain discharge box

The dryer has run low on grain, and

FAN FAILURE

NO AIRFLOW

The contacts in the air switch have

the OUT OF GRAIN TIMER has

timed out, shutting the dryer down.

The unload auger will clean out the

dryer if in continuous flow operation.

has opened, indicating that grain is

not being taken away fast enough

at the discharge box.

opened due to the fan not turning, or

the air switch may need adjustment.

FAN CANNOT START

CHECK AIR SWITCH

L1 VOLTAGE LOST

PLENUM HIGH

TEMPERATURE

The left circuit breaker located on

the input/output board of the Elec-

tronic Monitoring Control System

has tripped, or one of the hardware

timers has shut down the dryer.

An over temperature condition has

occurred inside the dryer plenum.

This control is a 300°F limit and au-

tomatically resets itself when cool.

The air switch contacts have closed

prior to the fan starting, indicating a

freewheeling blade or improper set-

ting of the air switch.

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DRYER PRE START CHECKS

PRE SEASON INSPECTION

Before the dryer is filled, thoroughly

inspect the unit and check the op-

eration of the dryer as follows.

INSPECT THE METERING

ROLLS

Open all metering roll access

doors and inspect each compart-

ment for any bolts, nuts or other for-

eign material, that may cause pos-

sible jamming of the metering rolls.

BEFORE ATTEMPTING TO

OPERATE THE DRYER MAKE

SURE ALL SAFETY SHIELDS

ARE IN PLACE, ALL BOTTOM

CLEANOUT AND REAR

The Maxon safety shut off valve.

ELECTRICAL POWER

Turn ON the electrical power sup-

ply to the dryer, set all circuit break-

ers to ON, including the safety dis-

connect handle mounted on front

of the dryer's power panel.

POWER START BUTTON

Push the DRYER START button,

and all the selector switches on the

control panel will be activated.

ACCESS DOORS ARE CLOSED

AND ALL PERSONNEL ARE

CLEAR OF THE DRYER

FUEL CHECK

If using LP gas, make sure the tank

has plenty of fuel and that the tank

does not have a regulator mounted

to it. If using natural gas, make sure

an adequate supply is available.

If using LP gas, slowly OPEN

CONTROL POWER

SWITCH

SET CONTROL SWITCHES

Moisture Control Switch-ON

Moisture Control Thermostat-MAXI-

MUM TEMPERATURE

Load Switch-OFF

Turn the CONTROL POWER switch

to ON. The switch will light up. A

total running time in hours and min-

utes, current date and time will ap-

pear. At this point the controller will

lock out all other dryer functions.

Once the date and time appear,

press RESET and the dryer will per-

form its safety circuit check. If a fault

is found, the cause will be displayed

on the LCD. If all are found safe, the

controller will supply power to the

electronic fuel shut- off valve (if

so equipped) and the DRYING

MODE switch will light up, indicating

that the dryer is ready to be started.

Unload Switch-OFF

the main fuel supply valve at the

tank. If using natural, gas turn ON

the valve along the supply line.

Then, OPEN the electronic shut off

valve (Maxon valve), if so equipped,

or OPEN the manual shut off valve

on the dryer to allow fuel flow to the

dryer. Inspect all gas lines and con-

nections for possible leaks.

Fan Switch-OFF

Burner Switch-OFF

Out of Grain Timer-8 MINUTE

Load Delay-30 SECONDS

Unload Delay-30 SECONDS

Metering Roll Speed-LOW AND

HIGH SPEED SETTINGS PUT

ON ZERO

Dry Timer-60 MINUTE

Cool timer-20 MINUTE

Unload timer-10 SECONDS

Mode Switch-CONTINUOUS FLOW

Any gas leaks need to be

fixed immediately!

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DRYER PRE START CHECKS

gear box. If the dry grain take away

auxiliary is wired to the dryer, it

should start and rotate in the proper

direction.

MOISTURE CONTROL

THERMOSTAT

To check the MOISTURE CON-

TROL THERMOSTAT leave the

UNLOADING switch on 1 SPEED,

and slowly turn down the MOIS-

TURE CONTROL THERMOSTAT.

As the setting is decreased, the in-

dicator light should come on and the

metering rolls should stop operat-

ing. The bottom auger will stop af-

ter the 30 second clean out delay,

providing that the dryer is still being

held by the MOISTURE CONTROL

THERMOSTAT. Rotate the MOIS-

TURE CONTROL THERMOSTAT

up to its maximum setting. The light

should go off, and the metering

rolls should restart along with the

bottom auger if it has stopped.

To check 2 SPEED operation

The metering roll access area.

move the switch to the 2 SPEED po-

sition, set LOW speed on 200 and

HIGH speed on 600. Slowly turn the

thermostat until the MOISTURE

CONTROL switch light comes ON.

The METERING ROLL SPEED is

now controlled by the LOW speed

dial. Turning the THERMOSTAT the

other way until the light goes out now

leaves the metering rolls controlled

by the HIGH SPEED DIAL.

message (out of grain warning) dis-

played. Press the DRYER POWER

STOP button to reset the panel, then

press the START button.

LOAD AUGER

With the grain supply SHUT OFF,

quickly bump the LOAD AUGER

switch to MANUAL, and see if the

load auger rotates clockwise as

viewed from the drive end, or coun-

terclockwise if the dryer is a front

load model. If the wet grain supply

auxiliary is wired to the dryer it

should also rotate in the correct di-

rection at this time. Turn the LOAD

AUGER switch to the AUTO posi-

tion. The top auger and wet grain

supply auxiliary should run for one

minute, and then the dryer will shut

down leaving the safety shutdown

ONE SPEED OPERATION

To check 1 speed operation place

the UNLOAD switch in the 1 SPEED

setting. Turn up the HIGH SPEED

METERING ROLL DIAL until the

metering rolls start rotating. The

bottom auger should rotate coun-

terclockwise as viewed from the

drive end. The metering roll drive

motor should rotate clockwise as

viewed from the drive end of the

METERING ROLL

OPERATION

To check the metering rolloperation

turn either the LOW speed or HIGH

speed knob clockwise, and the ME-

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DRYER PRE START CHECKS

TERING ROLL SPEED should in-

crease. Turning either knob coun-

terclockwise will decrease the

speed. Make sure the drive chain

tension is properly adjusted and all

sections of the metering rolls ro-

tate. Turn the UNLOAD switch OFF

after these checks are complete.

The bottom auger will continue to

run for 30 seconds after the switch

is turned OFF to allow for cleanout.

ignite after a short purge delay of ap-

proximately 10 seconds. Gas pres-

sure should be shown on the gauge.

At this time adjust the BURNER

HIGH-LOW FIRE THERMOSTAT to

200°F, causing the burner to oper-

ate on high-fire. The thermostat is

fire and low-fire pressure settings.

Use the PRESSURE REGULATOR

for high-fire and the BALL VALVE

for low-fire. The thermostat should

cycle between high and low, ap-

proximately 4 to 5 times per minute.

Approximate settings should be:

located on the front left side of the

dryer. Observe the gas pressure on

gauge, and turn the thermostat to

its MINIMUM SETTING, causing the

burner to cycle into low-fire. As the

burner thermostat is turned down

the gas pressure should also show

a noticeable drop, indicating that the

high-fire solenoid is closed and the

burner is being supplied with less

gas through the low-fire control

valve. At this time set the high-

LP Gas

High-Fire 6-15 lbs.

Low-Fire 2-6 lbs.

High-Fire 6-10 lbs.

Low-Fire 1-3 lbs.

Natural Gas

If the burner remains on high-

fire and does not cycle, INCREASE

the regulator setting on the propane

models, or the supply valve on the

natural gas models in order to reach

the thermostat setting. If the

burner remains in low-fire and does

not cycle, slightly DECREASE gas

FAN SWITCH

Bump the FAN switch and observe

the fan rotation. The fan should run

counterclockwise. Sometimes on

three phase models all motors will

run backwards. They can easily be

reversed by interchanging the two

of three power supply wires. Re-

verse the two outside wires, L1 and

L3, and leave the middle one in the

same position.

Note: If the dryer is empty, the

burner will not operate. The fans

cannot create enough static pres-

sure to engage the air switch. You

will receive a loss ofairflow message.

BURNER SAFETY

To check the burner safety function,

first make sure the main GAS

VALVE is OFF. Turn the FAN switch

ON and allow the fan to start. Then,

turn the HEATER switch ON. The

dryer will shut down after 20 seconds.

The safety message, "Burner 1 warn-

ing flame not detected" will appear.

BURNER TEST FIRE

START the fan, and then turn the

HEATER switch to ON. Turn ON the

fuel supply, and the burner should

The dryer fan and heater controls featuring: 1-pressure regulator, 2-low-fire

control valve, 3-high pressure solenoid, 4-low pressure solenoid, 5-high-

low fire thermostat (assembly includes thermometer), 6-fuel supply line, 7-

LP solenoid or supply ball valve(NG) and 8-air pressure switch.

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DRYER PRE START CHECKS

All dryer functions should be checked before operation each season.

pressure with the LOW-FIRE CON-

TROL VALVE. If the gas pressure

is decreased too much a popping or

fluttering sound will be heard. Also,

anytime the high pressure side is

adjusted the low pressure side

needs to be checked.

VALVE to allow fuel flow to the

dryer, if so equipped. Turn the

LOAD switch to AUTO and UN-

LOAD switch to 1 SPEED. Push

the DRYER POWER START but-

ton and the controller will sequen-

tially start all dryer components in

their proper order. If any switches

are not in their correct position for

staged batch operation, the dryer

will indicate improper switch posi-

tion, and will not start until the

switches are in the proper position.

After starting, all batch timers will

time down in sequence. When the

unload cycle is complete the tim-

ers will automatically reset to their

original settings, and start the dry

timer again.

DRYER SHUTDOWN

To shutdown the dryer, first CLOSE

the FUEL SUPPLY VALVE at the

tank or valve along the fuel line. If

the burner is operating, let the dryer

run out of fuel, and it will shutdown

automatically due to loss of flame.

CLOSE the FUEL VALVE at the

dryer, and press the DRYER

POWER STOP button. Turn OFF

the safety disconnect handle on

the front of the power box, and turn

OFF the main POWER to the dryer.

STAGED BATCH CHECK

To check the staged batch opera-

tion, turn the CONTROL POWER

switch to the ON position. Press the

RESET button, OPEN the main

FUEL SUPPLY VALVE at the tank

on an LP dryer or valve in the fuel

supply line on a natural gas dryer.

Turn the DRYING MODE switch to

the STAGED BATCH position.Turn

ON the electric SHUT OFF

EMERGENCY

In case of emergency push the dryer

POWER STOP button. The fan,

burner and all augers will stop im-

mediately.

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DRYER START UP

CONTINUOUS FLOW AND CONTINUOUS BATCH START UP PROCEDURE

At the beginning of each harvest and

before filling the dryer with grain

make sure to inspect the dryer for

rodent damage, proper belt and

chain tension and missing or dam-

aged safety shields. Test operate

the dryer using the prestart check

procedures located on pages 14-17.

be displayed on the LCD. If all

are found safe the controller will

allow the electronic FUEL SHUT

OFF valve to be manually

Turn ON the electric SHUTOFF,

Maxon valve (if so equipped), or

OPEN the manual SHUTOFF

valve to allow fuel flow to the

dryer.

OPENED (if so equipped), and

the DRYING MODE switch will

light up, indicating that the dryer

is ready to be started.

5. Turn the DRYING MODE switch

to CONTINUOUS FLOW.

1. Before attempting to operate the

dryer make sure that all safety

shields are in place, all plenum

bottom closure panel doors

are closed, all rear access

doors are closed and all per-

sonnel are clear of the grain

dryer and grain handling ma-

chinery.

5. Move the LOAD AUGER switch

to MANUAL, and push the dryer

POWER START switch. The

top auger will immediately start,

and the LOAD AUGER switch

will light up. If additional grain

handling equipment is wired to

the dryer it will also start imme-

diately.

6. The dryer should already be

filled with grain. Turn the

LOAD AUGER switch to the

AUTO position. In both the auto

and manual positions the dryer

grain level switch will automati-

cally keep the dryer full of grain.

In the auto position the dryer will

shut down after a preset time

period on the out of grain timer.

2. Turn all SELECTOR switches

on the control panel to the OFF

position.

6. When the dryer is full of grain

the top auger will stop auto-

matically, and any grain han-

dling equipment wired to the

dryer will also stop.

7. Turn the FAN switch to ON. The

fan will start, and the switch will

light up when airflow is detected.

3. Turn ON the electric POWER

supply to the dryer, and move

the safety disconnect handle

mounted on the dryer's upper

power box to ON.

8. Start the burner by turning the

HEATER switch to ON. After

purging for approximately 10

seconds the burner will fire, and

the heater switch will light up.

This indicates that the flame

sensing circuit is sensing burner

flame. For information concern-

ing burner adjustment see the

pre start section of this manual.

CONTINUOUS FLOW

OPERATION

1. Turn the CONTROL POWER

switch to ON.

4. Turn the CONTROL POWER

switch to ON. The switch will

light up. A copyright message,

model number, total running

time in hours and minutes, cur-

rent date and time will appear.

At this point the controller will

lock out all other dryer functions.

Once the date and time appear,

press RESET, and the dryer will

perform its safety circuit checks.

If a fault is found the cause will

2. After the date and time appear

on screen, press the RESET

button.

3. Push the dryer POWER START

switch.

9. Operate the heaters to dry grain

for 6-7 minutes per point of

moisture to be removed with the

plenum temperature set at

4. OPEN the main FUEL SUPPLY

VALVE on the tank if using LP

gas, or OPEN the FUEL SUP

PLY LINE if using natural gas.

180°F. Example: Shelled corn

starts with 25% moisture and

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DRYER START UP

the final moisture content is to

be 15% (10% removal). Using

the all heat dryeration process,

the estimated drying time is 60

minutes (10 x 6).

13. To shut the dryer down, CLOSE

the FUEL SUPPLY VALVE at

the fuel tank or fuel source. Let

the dryer run until the fuel sup-

ply lines drain, and the dryer

automatically shuts down due to

loss of flame. CLOSE the FUEL

valve at the dryer. Press the

DRYER POWER STOP button.

Turn OFF the dryer's SAFETY

DISCONNECT handle. Turn

OFF the MAIN POWER supply

to the dryer.

gas or the valve in the FUEL

SUPPLY LINE if using natural

gas. Turn ON the ELECTRIC

SHUT OFF, Maxon valve (if so

equipped), or OPEN the manual

SHUT OFF valve to allow fuel

flow to the dryer.

10. While operating the dryer adjust

the METERING ROLL dials to

the recommended settings. See

the chart on page 00.

5. The dryer should already be

filled with grain. Turn the LOAD

AUGER switch to AUTO. In both

the auto and manual position,

the grain level switch will auto-

matically keep the dryer full of

grain. In the auto position, the

dryer will shut down after the

preset time period on the OUT

OF GRAIN TIMER, or if the

grain flow to the dryer is inter-

rupted.

11. To move grain through the dryer

turn the MOISTURE CONTROL

switch to ON. The switch will

light up.

14. In case of emergency push the

dryer STOP button. The fan,

Note: When the UNLOAD switch is

in the 2 SPEED position, and the

MOISTURE CONTROL THERMO-

STAT switch is OFF, the speed of

the metering rolls can be manually

adjusted by turning the HIGH

SPEED METERING ROLL dial.

Turning the dial clockwise will IN-

CREASE the grain discharge rate,

counterclockwise will DECREASE

the discharge rate. (The numbers on

the speed dials indicate the percent-

age of full speed.)

burner and all augers will stop

immediately.

Note: The Electronic Monitoring

Control System can be used to au-

tomatically start the dryer. Place all

the control panel SELECTOR

switches in the PROPER POSI-

TION, and OPEN the electric FUEL

SHUT OFF valve before PRESSING

the DRYER POWER START button.

The controller will start all dryer com-

ponents in their proper order.

6. Turn the FAN switch to AUTO.

The fan will start, and the switch

will light up when airflow is de-

tected.

7. Start the burner by turning the

HEATER switch to AUTO. Af-

ter purging for approximately

10 seconds the burner will fire,

and the heater switch will light

up indicating that the flame

sensing circuit is sensing

burner flame. For information

concerning burner adjustment

see the pre start section of this

manual.

STAGED BATCH

OPERATION

12. At the end of the start-up pe-

riod, start the flow of grain out

of the dryer. Turn the UNLOAD

switch to the 2 SPEED posi-

tion. The bottom auger and

metering roll will immediately

start, and the unload switch will

light. If additional grain han-

dling equipment is utilizing the

unload auxiliary overload sup-

plied with the dryer, this equip-

ment will also immediately

start.

1. Turn the CONTROL POWER

switch to ON.

2. Make sure the DRYING MODE

switch is turned to STAGED BATCH.

3. After the date and time appear,

PRESS the RESET button.

8. To properly set the correct dry,

cool and unload time for various

moisture content grains. See the

chart on page 00.

4. OPEN the main FUEL SUPPLY

VALVE on the tank if using LP

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DRYER START UP

9. If the dryer is being operated in

all heat, turn the FAN switch to

ON. In this position the fan will

run continuously during the dry,

cool and unload stages of the

staged batch operation. If the

dryer is being operated in the

dry and cool mode, the preferred

position for the FAN switch is the

ON position, so the fan will run

continuously. If desired, the fan

can be turned off during the un-

load cycle of the dry-cool-unload

sequence by turning the FAN

switch to AUTO.

start automatically during the

unload cycle of the dry-cool-

unload mode, along with any

grain handling equipment that

is wired to the dryer. The

button. The controller will start

all the dryer components in their

proper order. If any of the se-

lected switches are improperly

positioned for staged batch dry-

ing, the display will indicate the

proper switch position, and will

not allow the dryer to operate

until the position of the switch is

corrected.

speed at which the metering

rolls operate during the unload

cycle is adjusted by using the

HIGH SPEED METERING roll

dial. Turning the dial clockwise

will INCREASE the grain dis-

charge rate, and counterclock

wise will DECREASE the dis-

charge rate.

14. To shutdown the dryer, CLOSE

the FUEL SUPPLY valve at the

fuel tank or fuel source. If the

burner is operating, let the dryer

run out of fuel causing an auto-

matic shutdown due to a loss of

flame. CLOSE the FUEL VALVE

at the dryer, and press the dryer

POWER STOP button. Turn

OFF the dryer's main CIRCUIT

BREAKER located on the front

of the power panel. Turn OFF

the MAIN main POWER SUP-

PLY to the dryer.

12. To control the length of the dry

cycle using only the dry time

setting programmed into the

system, turn the MOISTURE

CONTROL setting to OFF. To

use the automatic moisture con-

trol so that the dry time is deter-

mined, not only by the dry time

setting, but also by the moisture

content of the drying grain, turn

the MOISTURE CONTROL

switch to ON.

10. If the dryer is being operated in

all heat, turn the HEATER

switch to ON. The burner will

operate whenever the fan is

operating. If the dryer is being

used in dry and cool, turn the

HEATER switch to AUTO and

the burner will automatically

shutdown during the cooling and

unloading cycles.

15. In case of an emergency press

the dryer POWER STOP button.

The burner, fan and all augers

will stop immediately.

11. Turn the UNLOAD switch to the

1 SPEED position. The bottom

auger and metering rolls will

13. To start the drying operation

push the dryer POWER START

FAN & HEATER SWITCH SETTINGS

Fan Function

Fan Setting

Heater Setting

Heater Function

Fans stay on during dry and cool

cycle only

Auto

Burners stay on during dry timer cycle

only

Fans stay on during dry and cool

cycle only

Auto

Burners stay on during dry and cool

Burners are on continuously

Fans are on continuously

Auto

Burners shut down at the end of the

dry cycle

At the end of the dry cycle in staged batch, the fans and heaters will continue running if in the Auto-Auto setting, until the preset tempera-

ture on the moisture control thermostat is reached.

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DRYER START UP

1100 SERIES BATCH TIMER SETTINGS

Dry & Cool

Full Heat

Fan & Burner Switches on Manual

Fans on Manual

Burners on Auto

Initial

Moisture

Moisture Approx.

Removed Dry Time

Approx.

Dry Time

Dry

Cool

Unload*

10 min.

Dry

Cool

Unload*

10 min.

17%

18%

19%

20%

21%

22%

23%

24%

25%

26%

27%

28%

29%

30%

31%

32%

33%

34%

35%

2 pts.

3 pts.

16 min.

21 min.

26 min

6 min.

18 min.

24 min.

30 min

18 min.

24 min.

30 min

18 min.

18 min

18 min.

11 min.

16 min

4 pts.

5 pts.

31.5 min.

37 min.

41.5 min.

47 min.

51 min.

54 min.

58 min.

62 min.

66.5 min.

71.5 min.

76 min.

81 min.

86 min.

91 min.

96 min.

100 min.

21.5 min.

27 min.

31.5 min.

37 min.

47 min.

44 min.

48 min.

52 min.

56.5 min.

61.5 min.

66 min.

71 min.

76 min.

81 min.

86 min.

90 min.

35 min.

40 min.

45 min.

50 min.

55 min.

60 min.

65 min.

70 min.

75 min.

80 min.

85 min.

90 min.

95 min.

100 min.

105 min.

110 min.

35 min.

40 min.

45 min.

50 min.

55 min.

60 min.

65 min.

70 min.

75 min.

80 min.

85 min.

90 min.

95 min.

100 min.

105 min.

110 min.

6 pts.

7 pts.

8 pts.

9 pts.

10 pts.

11 pts.

12 pts.

13 pts.

14 pts.

15 pts.

16 pts.

17 pts.

18 pts.

19 pts.

20 pts.

These are approximate starting points.

*Set unload metering roll high speed setting to 999. If unload equipment cannot adequately keep up, lower the speed

setting and add time to the unload timer setting to completely unload the batch. In full heat mode, the time added to the

unload timer will need to be substracted from the dry timer. If fan is on auto and does not run during unload, set cool timer

to 25 minutes.

New unload time calculation = present unload time

new dial setting

1000

Example

13.75 = 11 ÷ 800

1000

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QUICK START UP PROCEDURE

FULL START UP CHECK

Standard electrical safety practices

and codes should be used when

working with a dryer. Refer to the

National Electric Code Standard

Handbook by the National Fire Pro-

tection Association. A qualified elec-

trician should make all wiring instal-

lations.

This start up procedure assumes the following:

1. That you have read and understand the dryer operation and service

manual.

2. That you have taken special note of all safety precautions.

3. That all safety shields are in place.

4. That all metering roll access doors have been opened and all foreign

objects have been removed.

5. That you have done a pre start up check out.

6. That all motors have been checked for proper rotation.

7. That all heaters have been test fired.

8. That the fuel has been turned ON at the tank.

9. That the electric power has been turned ON.

10. That the main DISCONNECT switch on the dryer is ON.

11. That you have wet grain in the wet holding bin.

12. That you know the incoming grain moisture.

13. That you have the dry grain take away equipment in place.

14. That you have the grain going to the proper bin.

15. That all SWITCHES have been set to the OFF position.

16. That the load mercury switch box is installed with the side stamped

up, in the up position.

ALWAYS DISCONNECT

AND LOCK OUT POWER

BEFORE WORKING ON OR

AROUND DRYER

FILLING THE DRYER

1. Turn the green CONTROL POWER switch to ON. It should light up, go

through 4 screens and end with the time and date.

2. Turn the DRYING MODE switch to CONTINUOUS FLOW.

3. Push the RESET on the computer key pad to activate the computer.

4. Make sure the UNLOAD switch is in the OFF position.

5. Push the DRYER POWER start switch, it should light up.

6. Turn the LOAD AUGER switch to the MANUAL position to fill the dryer.

The load auger should start and run until the dryer is full, then shut off

automatically. (If the switch is set to the auto position the dryer will

shut down each time the out of grain timer times out, and will have to be

restarted.)

7. When the dryer has filled, turn the LOAD AUGER switch to the AUTO

position.

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QUICK START UP PROCEDURE

STARTING THE DRYER

This start up procedure is for a cold start on wet grain for continuous flow

operation.

1. Set the MAXON or FAST ACTION HAND VALVE on the incoming fuel

line to the ON position.

2. Make sure the MOISTURE CONTROL switch is in the OFF position.

3. Turn the FAN switch (or switches if a multi-fan dryer) to the ON posi-

tion. The light in the switch should light when the fan comes up to

about half speed.

4. Adjust the PLENUM AIR PRESSURE switch if necessary. Use a flat

blade screwdriver counterclockwise to make it more sensitive (taking

less pressure to activate it), or clockwise for the opposite effect.

5. Turn the HEATER switch (or switches if a multi-fan dryer) to the ON

position. The heater will purge for about 10 seconds then ignite. The

light in the heater switch will come on during ignition and will stay on if

the heater ignites. If the heater does not ignite, the light will go out after

trial for ignition and the dryer will shut down, indicating that it did not

light. If this happens check gas supply, and all valves in the fuel line to

make sure they are on.

ADJUSTING THE TEMPERATURE

1. Set the HIGH-LOW FIRE PLENUM THERMOSTAT on the left side of

the dryer to the drying temperature that you want to run (180° to 200°).

On multiple module dryers set the plenum chambers 30° to 60° apart.

Hottest at the top, most cool at the bottom.

How much gas pressure do I

use? See step number two in

the Adjusting The Temperature

section.

2. On LP gas models adjust the PRESSURE REGULATOR (high fire) on

the burner fuel line, so that burner will reach the thermostat setting

andswitch to (low fire) (pressures may be required up to 25 lbs.). Natu-

ral gas does not have a regulator, but uses a LARGE BALL VALVE

close to the vertical supply line for adjustment (pressures may be re-

quired up to 18 lbs.).

How often should my burner

cycle? See step number three

in the Adjusting The Temperature

section.

On LP gas models adjust the small RED HANDLED BALL VALVE

(low fire) so that the burner maintains flame then switches back to (high

fire). Natural gas has a BALL VALVE close to the burner control box,

for low fire adjustment.

3. Adjust the burner pressure so that the burners cycles 4 times per

minute (approx. 10 sec. on high--approx. 5 sec. on low). When on

high fire increasing the pressure with the PRESSURE REGULATOR

DECREASES the time spent on high fire. When on low fire increasing

the low fire pressure with the RED BALL VALVE INCREASES the time

spent on low fire.

4. On LP gas models adjust the VAPORIZER so the fuel pipes going to

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QUICK START UP PROCEDURE

the burner from the regulator are warm to the touch (not hot and cold).

The vaporizer can be adjusted two ways:

•Loosen the bolt in the hinging mechanism and swing it to a

hotter or cooler position, or

•Loosen the two bolts in the hinge pipe and slide the vaporizer

in or out to a cooler or hotter position.

Either one or both methods may have to be used to get the vaporizer to

the proper temperature. Natural gas does not use a vaporizer.

FULL HEAT-CONTINUOUS FLOW OPERATION

How often do I make speed

1. Check the Continuous Flow Metering Roll Settings-Full Heat on page

25. Pick the line that has your initial starting moisture. These are the

settings we will be referring to during this start up procedure.

2. Make sure the UNLOAD switch is OFF.

adjustment? See step number

ten in the Full Heat-Continuous

Flow Operation section.

3. Make sure the MOISTURE CONTROL switch is OFF.

4. Run the fan(s) and heater(s) for about 10% longer than the approxi-

mate drying time required for the moisture you are trying to dry.

5. Example: 10% removal would be about 54 minutes, 15% removal would

be about 76 minutes and 20% removal would be about 100 minutes.

Add 10 minutes to insure that the grain is dry.

6. After the time in step 4 turn the UNLOAD to 1 SPEED and set the

METERING ROLL SPEED, HIGH SPEED potentiometer to the setting

for 1 SPEED operation. Grain should begin to run at this time. Run time

for this is about 10% longer than the approximate drying time required

for the moisture you are trying to dry, as shown in the example #5 above.

This allows the moisture in the dryer to reach an even gradient top to

bottom without having any highs or lows in it. It will, however, overdry

some of the corn a little.

7. Increase the drying temperature to 190° for single fans or for multiple

fan dryers set the heat chambers 30° to 60° apart. Hottest at the top,

most cool at the bottom.

8. DO NOT TRY TO ADJUST THE DRYER FOR MOISTURE DURING

THIS PROCESS OR YOU WILL ESTABLISH HIGH AND LOW

SWINGS IN THE MOISTURE CONTROL. IT WILL TAKE SEVERAL

HOURS TO WORK ITSELF OUT.

9. After the run time in step 6 you are ready to set up the moisture control.

Now turn the MOISTURE CONTROL to the ON position. Set the tem-

perature to about 100°.

10. Turn the UNLOAD to 2 SPEED. Set the METERING ROLL SPEED,

LOW SPEED and HIGH SPEED potentiometer to the settings listed for

them. Let the dryer run on these settings as shown in the example #5

before trying to adjust moisture or meter roll settings. These settings

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QUICK START UP PROCEDURE

will not have your grain moisture adjusted exactly where you want it, but

will be a good place to start initially. A little different moisture at the

bottom of the storage bin is not usually a problem as long as you have

full floor aeration.

11. After the run time in step 10 you are ready to adjust the moisture con-

trol,and the meter roll speeds if required. Each time you make an

adjustment to the moisture control, it will take the approximate time shown

in example #5 to see the results.

1100 SERIES CONTINUOUS FLOW METERING ROLL SETTINGS

Full Heat

Initial

Moisture

2 Speed

High

Moisture

Removed

Approx.

Dry Time

2 Speed

Low

1 Speed

625

476

385

317

270

241

213

196

185

172

161

150

140

132

123

116

110

104

100

17%

18%

19%

20%

21%

22%

23%

24%

25%

26%

27%

28%

29%

30%

31%

32%

33%

34%

35%

875

775

675

575

476

385

317

270

241

213

196

185

172

161

150

140

132

123

116

2 pts.

3 pts.

16 min.

21 min.

26 min

317

270

241

213

196

185

172

161

150

140

132

123

116

110

104

100

096

087

082

4 pts.

5 pts.

31.5 min.

37 min.

41.5 min.

47 min.

51 min.

54 min.

58 min.

62 min.

66.5 min.

71.5 min.

76 min.

81 min.

86 min.

91 min.

96 min.

100 min.

6 pts.

7 pts.

8 pts.

9 pts.

10 pts.

11 pts.

12 pts.

13 pts.

14 pts.

15 pts.

16 pts.

17 pts.

18 pts.

19 pts.

20 pts.

These are approximate starting points.

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QUICK START UP PROCEDURE

ADJUSTING THE MOISTURE CONTROL

How do I set my moisture

control? See step number one

in the Adjusting The Moisture

Control section.

1. Each 5° on the MOISTURE CONTROL changes the output moisture by

about 1%. Example: 100° is set, producing 16% corn out, however,

17% corn out is needed. Reduce the MOISTURE CONTROL tempera-

ture by 5° to 95°. This should change the moisture out to about 17%. To

make the corn come out dryer, raise the temperature on the MOISTURE

CONTROL.

2. There are 4 sensors that are averaged together for sensing MOIS-

TURE CONTROL temperature, 1 on each side of the dryer in the front,

and 1 on each side of the dryer in the back. They are located about

⁄3 of the way up the grain column from the bottom, and in from the

side about 4 inches.

3. The small lights behind the temperatures on the MOISTURE CON-

TROL indicate the temperature of the grain at this sample point.

4. The 2 lights in the center are green, the lights to the right or to the left of

these are red.

5. When the grain temperature has the dryer cycling HIGH and LOW speed

on the green lights the moisture setting is being maintained correctly.

6. Set the METERING ROLL SPEED in relation to the small red lights

behind the temperatures on the MOISTURE CONTROL.

7. Red lights to the left indicate that the grain at the sample point is too

cool or wetter than desired. With this condition turn the LOW SPEED

left potentiometer to a lower number. This will slow down the metering

rolls and dry the grain longer, warming it up.

8. Red lights to the right indicate that the grain at the sample point is too

hot or dryer than desired. With this condition turn the HIGH SPEED

right potentiometer to a higher number. This will speed up the metering

rolls and remove the grain quicker, cooling it down.

9. If the MOISTURE CONTROL switches to LOW and only stays on low

for a minute or two and switches back to HIGH, speed up the LOW

SPEED left potentiometer. It is set too slow.

10. If the MOISTURE CONTROL switches to HIGH and only stays on high

for a minute or two and switches back to LOW, slow down the HIGH

SPEED right potentiometer. It is set too fast.

11. The MOISTURE CONTROL should stay on HIGH about 50% of the

time and on LOW about 50%, give or take 25%. There is a broad range

that will work. It should be switching low to high and back to maintain

the desired moisture. A control that does not switch, will not maintain

an evenly dried grain moisture, when the incoming wet grain moisture

is varying.

12. When adjusting the metering roll speeds it is better not to change the

speed more than 20 points at a time.

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QUICK START UP PROCEDURE

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1100 SERIES SERVICE GUIDE

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SERVICE

SEASONAL INSPECTION AND SERVICE

The dryer is made of weather resis-

effect the balance, and result in-

harmful vibrations and a short

bearing life.

To keep motor bearings properly lu-

tant material, and is designed to re-

quire a minimum of service. However,

each season we recommend the fol-

lowing 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 op-

eration of the equipment.

bricated, and dispel any accumula-

tion of moisture within the windings,

the fan and auger motors should

be operated for 15 to 30 minutes

each month.

3. CHECK propellor for free play.

Any side play is an indication of

defective motor bearings,

which should be replaced to pre-

vent a complete motor failure.

Make sure motor mount bolts

are tight.

LUBE PROCEDURES

If the motor is equipped with an

alemite fitting, CLEAN the tip of the

fitting and apply grease gun. Use 1

or 2 full strokes on motors in NEMA

215 frame and smaller. Use 2 to 3

strokes on NEMA 254 through

NEMA 365 frame. Use 3 to 4 strokes

on NEMA 404 frames and larger.

On motors equipped with slot-

ted head grease screw, remove

screw and apply grease tube to hole.

Insert 2 to 3 inch length of grease

string into each hole on motors in

NEMA frame and smaller. Insert 3

to 5 inch length on larger motors. On

motors having grease drain plugs,

remove plug and operate motor for

20 minutes before replacing drain

plug.

1. SHUTOFF electrical power.

OPEN power box and control

box, and inspect for moisture,

rodent damage or accumulated

foreign material. Remove any

foreign material present. Inspect

and tighten any loose terminal

connections. Replace any dam-

aged or deteriorated wiring.

4. Motor bearings should be LU-

BRICATED periodically, de-

pending on operating condi-

tions. Under normal usage it is

desirable to have the motor

cleaned, checked and bearings

repacked by an authorized ser-

vice station every two to three

seasons. If the unit is operated

continuously through most of the

year, this service should be per-

formed each year.

2. CHECK propellor for freedom

of rotation and uniform tip clear-

ance. It should also be in-

spected for dirt and grain dust,

especially inside the hub. Any

additional weight can seriously

Note: If on site bearing relubrication

is to be performed, see lubrication

instructions for ball bearing motors.

LUBRICATION INSTRUCTIONS FOR BALL BEARING MOTORS

SUGGESTED LUBRICATION INTERVALS*

Hours of Service per Year

H. P. Range

Suggested Lube Interval

5000

1/8 to 7 1/2

10 to 40

50 to 150

5 years

3 years

1 year

Continuous Normal Applications

1/8 to 7 1/2

10 to 40

50 to 150

1 year

3 years

9 months

Seasonal Service (motor is idle for 6

months or more)

All

1 year-beginning of season

Continuous high ambient tempera-

tures, dirty or moist locations, high

vibrations or when shaft end gets hot

1/8 to 40

50 to 150

6 months

3 months

* The bearings have been lubricated at the factory, thus no lubrication should be added before start up.

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SERVICE

SUGGESTED LUBRICANTS

Insulation Class

Consistency

Type

Grease

Frame Type

A & B

F & H

Medium

Polyurea

Shell Dolium R

215T & Smaller

254 & Larger

All

Note: All of the auger and meter-

ing roll bearings are lifetime lubri-

cated and do not require service

relubrication.

carbonand rust between the

electrode surfaces. Ignitor gap

shouldbeabout1/8inch.

7. OPERATE dryer clean out le-

vers, and CHECK clean-out

hatchmechanism for proper op-

eration. With hatch open, in-

spect and remove any accumu-

lation of dirt, fines and foreign

material from the bottom au-

ger trough area.

4. Inspect flame sensor for pos-

sible damage or poor connec-

tions. Flame sensor wire must

be in good condition.

1. Remove and CLEAN the gas

line strainers. Make certain gas

valves are CLOSED and that

gas is purged from the system

before attempting disassembly.

Note: Do not allow high moisture

material to collect within the trough

area. It may adversely affect metal

parts.

5. Inspect and manually ROTATE

the top auger paddle assem-

bly. The paddle unit must rotate

freely without any indication of

sticking or binding.

2. Inspect the collector plate (at

the top of the burner casting)

and the burner cup for any ac-

cumulation of foreign material.

CLEAN if required. Foreign ma-

terial in the burner cup or cast-

ing will not burn out and will im-

pair burner operation.

8. Inspect entire dryer for loose,

worn or damaged parts. Include

CHECK of auger flighting, me-

tering rolls and other internal

parts. CHECK that temperature

sensors within air plenum cham-

ber are secured within insulated

clamps, and do not chafe on

other metal parts.

6. Inspect the top auger and bot-

tom auger drive linesfor proper

adjustment and condition. Read-

just line tension as required.

Note: All of the auger and meter-

ing roll bearings are lifetime lubri-

cated and do not require service

relubrication.

3. If required, inspect ignitor plug

and CLEAN the electrodes.

Use an ignitionpointfiletoremove

9. Make sure all dryer guards and

warning decals are securely in-

stalled. Guards should not inter-

fere with moving parts. If guards

or warning decals are missing,

contact your dealer for a free re-

placement.

10. TEST FIRE the dryer several

weeks ahead of the drying sea-

son. CHECK for possible gas

leaks. (See page 16 for burner

test fire.)

Remove the Blue Burn Optimizer Cone. Inspect 1-collector plate, 2-burner

cup, 3-ignitor plug and electrodes and 4-flame sensor on the heater.

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SERVICE

FAN PROPELLOR REMOVAL AND INSTALLATION

Capscrews installed

through threaded

holes of bushing

The fan propellor is secured to the

motor shaft by the use of a taper-

lock bushing, motor shaft key and

three cap screws.

Fan Hub

Key

CAUTION: Although the taper-lock

method of retaining the propellor

onto the motor shaft is simple, it is

essential that the following points be

read carefully and fully understood.

Improper installation can cause a

loose flying propellor, and result in

serious injury or death.

Split Taper Bushing

Fan blade

installation

2. REMOVE the three cap screws

from the clearance holes in the

taper-lock bushing.

ingonto propellor to prevent the

loss of parts.

Note: During manufacture the

propellor and bushing on the 26" and

28" solid aluminum blades are bal-

anced together, and are marked with

two small dots to identify their origi-

nal alignment position. CHECK the

bushing and propellor to make

sure they have alignment marks.

MARK the alignment of the propellor

and bushing, if necessary.

THREADED BUSHING

HOLES

3. INSTALL two grade 5 cap

screws into the threaded holes

in bushing. TURN caps by hand

until they bottom against the

front surface of the propellor.

The threaded holes within the bush-

ing are provided for disassembly

purposes only. Do not attempt to use

these holes for reassembly. They

will not allow the parts to lock onto

the shaft thereby causing a hazard-

ous operating condition.

4. BLOCK propellor to prevent it

from turning, and gradually TURN

the cap screws (up to 1/4 turn

at a time) until the propellor

breaks loose from the bushing

and motor shaft. Carefully RE-

MOVE bushing and propellor.

With the propellor free from the

bushing, a wheel can be used

to PULL the bushing off of the

motor shaft. REATTACH bush-

Crowley blades have a keyway

to prevent any misalignment of the

propellor and bushing. Alignment

marks are on the back of the fan hub

assembly. To replace one of the

blade fins, alignment would be nec-

essary, however, this is not recom-

mended. In most cases, the com-

plete propellor should be changed.

CLEARANCE HOLES

When reassembling parts, the cap

screws must be installed through

the untapped clearance holes as

shown. This will cause the propellor

to be pulled forward onto the ta-

pered bushing, thus locking the

parts securely onto the motor shaft.

When fan servicing requires re-

Capscrews installed

through threaded

holes of bushing

moval and installation of the

propellor, make sure the propellor

is removed and reinstalled properly.

Fan Hub

1. LOCK OUT the fan power

supply, and REMOVE the fan

guard and the venturi, as re-

quired on some models.

Split Taper Bushing

Fan blade

removal

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SERVICE

FAN MOTOR REMOVAL AND INSTALLATION

In the event of motor failure, remove

the motor lead wires from

within the box.

shims (if required) between mo-

the motor as described, and take it

to the nearest service station. An

authorized service station is the only

place that can provide possible mo-

tor warranty. Motor service and re-

pair at other places will be at own-

ers expense.

tor base and plate. REINSTALL

motor mount bolts and washer.

Do not fully tighten at this time.

Note: Tag or otherwise identify wires

for ease of reassembly.

3. REMOVE motor mount bolts.

If there are shims between the

motor and its base, note their

location so they can be properly

installed during reassembly.

6. REINSTALL conduit and wires

through hole in fan/heater

housing and carefully CON-

NECT all electrical wiring.

If the service station determines

motor failure is caused by faulty ma-

terial or workmanship within the

warranty period, repair will be cov-

ered under the warranty. Motor fail-

ure caused by external sources will

result in a charge to the owner for

repair.

7. ADJUST position of motor.

Temporarily MOUNT fan blade

on motor shaft. ROTATE fan

blade by hand, making the nec-

essary adjustments, so the tip

clearance between blade and

housing is uniform. If required,

REMOVE the fan blade and

fully TIGHTEN all four motor

mount bolts.

4. DISCONNECT the upper end of

the motor conduit, and care-

fully PULL the wires through the

hole in the fan/heater housing.

REMOVE motor from the fan/

heater unit with the conduit still

attached. If motor requires ser-

vice, take it to an authorized ser-

vice station.

1. Make certain power is SHUT-

OFF and locked out. REMOVE

fan guard and propellor.

Note: Make sure to INSTALL and

TIGHTEN the propellor in accor-

dance with previous instructions.

2. REMOVE cover from fan/heater

control box, and DISCONNECT

5. To reinstall motor, SLIDE onto

motor base plate and REPLACE

The position of the fan motor provides easy access for service.

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SERVICE

HEATER PARTS REMOVAL AND INSTALLATION

Most heater parts can be removed

b. Disconnect gas solenoid valve

coils. Be sure to mark which one

goeswhere.

b. Use a dependable brand of

by simply identifying any attached

wiring. Then DISCONNECT the ob-

vious mounting parts.

high temperature pipe caulking

compound when assembling gas

connections. Apply only a light

coating onto male threaded end

of fittings.

c. Lift pipe (with orifice, solenoid

valve and other parts attached),

straight up and remove from fan

heater housing. Orifice and other

parts can now be removed from

pipe train, if desired.

1. Flame sensor: DISCONNECT

the wire connector. UNSCREW

the flame sensor out of its

mounting bracket.

c. Solenoid valves and gas regula-

tors are directional and must be

properly installed. Do not attempt

to connect gas solenoid valve by

applying force to the valve core

stem as it may ruin the unit.

2. Gas Solenoid valve coil: UN-

SNAP either the plastic cap, or

the metal clip on the gas valve,

and SLIDE the housing and coil off

the valve stem and body. Do

not energize the coil when it is

removed, as the coil may be-

come damaged due to exces-

sive current flow.

5. Reassemble: To reassemble

parts, reversethedisassemblypro-

cedureandcheckthefollowing:

d. Make sure all electrical wires are

properlyconnected. Refertowiring

diagrams.

a.Makesureallpartsarethoroughly

cleanedandopen.

3. Regulator and gas solenoid

valve(s):Thegasregulatorandso-

lenoid valve(s) are directional and

mustbeconnectedasindicatedby

the markings near the port open-

ings. Make sure gas is shut off and

purged from the system before re-

movingparts.

Note: When installing a liquid

gas solenoid valve on LP models,

do not over tighten the connection

into the inlet side, as the inlet orifice

may become partially blocked.

4. Main Gas Orifice: With fuel shut

off and gas purged from system,

proceedasfollows:

a. Disconnect the plumbing sup-

port brackets from the pipe train.

This view of the dryer heater shows 1-gas solenoid valve coils and 2-gas

regulator and 3-gas solenoid valves.

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SERVICE

METERING ROLL SERVICING

tional adjustment as it is completely

controlled from the control box.

3. Speed reducer gear box: The

direct drive gear box provides

the required speed reduction,

and transmits power to the me-

tering rolls through a drive chain

arrangement. The gear box does

not require adjustment. The drive

chain should also be periodically

lubricated and retensioned as

necessary.

4. Unload auger time delay: The

delay controls the bottom auger

system and causes the unload

auger (and any connected aux-

iliary unloading conveyors) to

continue operating for the pro-

grammed amount of time, even

after the metering rolls stop.

This feature permits the cleanout

of grain within the unloading

equipment at the end of all dis-

charge cycles.

The speed reducer gear box.

This dryer is equipped with SCR

metering roll drive assembly. The

metering rolls are driven by a sepa-

rate DC type electric motor. The

speed of the motor is variable and

is controlled by an electric SCR (sili-

con controlled rectifier) control within

the main control box.

charge of 1120 BPH for 1108, 1400

BPH for 1110, 1680 BPH for 1112,

1960 BPH for 1114, 2240 BPH for

1116, 2520 BPH for 1118, 2800 BPH

for 1120, 3080 BPH for 1122 and

3640 BPH for 1126 model dryers.

Note: When the control is set to

the maximum discharge rate (999),

the metering roll speed should be

9.75 RPM for 6" discharge and 17.5

RPM for 8" discharge auger.

5. Ifaforeignobjectbecomes lodged

in the metering rolls and jams

the system, the following events

will occur. The unloading auger

will stay in motion. However,

the metering roll drive will stop

and the DC motor should stall

out. The Electronic Monitor-

ing Control System will shut

down the dryer after a two minute

period. If any one metering roll or

sensor should malfunction the

control will display a left or right

metering roll failure warning.

MAIN CONTROLS

1. SCR speed control: The control

unit dial on the front of the control

box regulates the speed of the DC

motor which drives the meter-

ing rolls.

2. DC electric motor: The direct

current (DC) motor provides the

drive for the metering roll, and

is located on the front left hand

side of standard model dryers.

The output shaft of the motor

is connected directly to the gear

box assembly.

The markings on the scale from 0 to

999 represent the flow of grain past

the metering rolls as a percent of the

maximum grain discharge rate for

the dryer. The maximum setting of

999 provides a maximum 100% dis-

The DC motor requires no opera-

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SERVICE

HOW TO DETERMINE A METERING ROLL PROBLEM

To determine if the metering prob-

lem is from blockage, perform the

following test with the power off.

Remove the drive chain by loosen-

ing the motor mounting bolts. Refer

to photo, and place a pipe wrench

on the hub of the roller chain

sprocket, on the left hand metering

roll at the drive end of the dryer.

Apply up to 100 ft. lbs. of force, and

attempt to rotate the roll toward the

inside of the dryer. If the metering

roll will turn, then repeat for right

hand side. If metering roll will turn,

it can be assumed that no blockage

exists, and the problem is from some

other cause. Check for a break in

the power train, chain, drive key, pin,

etc.

The metering roll drive.

HOW TO CLEAR A JAMMED METERING ROLL

Place a pipe wrench on the hub of

the sprocket of the jammed meter-

ing roll and turn the roll. First back-

ward, and then forward several times

in an attempt to dislodge the object,

and clear it through the roll. If this is

not successful, have an assistant

turn the metering roll, and attempt to

locate the jam by sound. Shut down

the fan heater and eliminate any other

noise when making this check. Once

the location is determined, the roll can

be reached from the outside by open-

ing the access door to remove the for-

eign object causing the jam (before

opening doors see below). The ser-

vice tool must be inserted before open-

ing doors. First, swing open the ple-

num bottom closure panel. Insert

service tool above metering roll.

CAUTION: Keep hands away from

sprocket teeth to avoid injury

from chain backlash, as a result

of torsion build up in the system

caused by the jam.

SERVICE TOOL

This column cutoff damper is designed to insert through the grain column

(from the inside of the dryer) immediately above the metering roll. This

permits opening of the metering roll access door. For service or inspec-

tion without unloading the dryer, the plenum bottom closure panel and

metering roll adjust damper must be removed prior to using service tool.

The auger discharge switch.

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SERVICE

TROUBLE ANALYSIS PROCEDURE

• The safety circuit is 12 volts D. C.

• When checking these circuits, mea-

sure voltage between the circuit test

locationandtoground.

CAUTION: When making high voltage

tests with "live" circuits, be extremely

careful. Follow established safety prac-

tices. Turnpoweronfortestingonly. Do

not attempt to make the dryer operate

by using a jumper wire to bypass a de-

fectivesafetycomponent.

A multimeter is required for some of

the following check-out procedures.

Before performing any tests, make

certain if the dryer power supply is

1 phase, 230 volt, or 3 phase, 230

or 460 volt.

• D. C. circuits should be measured

between the test location and its re-

spective D. C. ground.

• The burner circuit is 120 volts AC

on all standard U. S. production

models.

Refer to wiring diagrams and the

parts list for identification of parts and

the electrical terminals.

• The control circuit to the motor start-

ers is 120 volts AC.

Problem

Possible Cause

Control power switch light off.

1. Check that main power and circuit breakers are

turned on. Check for tripped breaker.

2. Check for blown 5 amp fuses.

3. Monitor relay is defective.

4. Defective transformer or wiring.

5. Check for a defective power switch.

6. Check wiring between fuses and input/output board.

Refer to wiring diagram for test locations.

Control power light is on, reset button has been pressed,

drying mode light off.

1. Power interruption: Incoming power to the dryer has

been interrupted. The display screen will show the date

and time if this has occured, once power has returned.

2. Display not finished initial setup: The monitor will

display a copyright message and model number, total

running time in hours and minutes and then the current

date and time. To activate the controller press the reset

button.

This indicates control power is present at input/output

board, but no power is being transferred through the I/O

board.

3. Input/output board: The input/output board has devel-

oped a problem that requires its replacement.

No display on LCD screen.

1. Check for a defective power switch.

2. Check wiring between fuses and input/output board.

3. Check for 120 volts A. C. between points J9-3 and AC-1.

4. The display may have a malfunction requiring its replacement.

Control power light is on, drying mode light is on--load

auger, fan, heater, unload auger will not operate.

1. Press the dryer power start button.

2. Refer to the problem listed for load auger, fan heater and

unload auger in the following sections.

Display shows "L1 VOLTAGE LOST" message.

The left circuit breaker located on the input/output board of the

Electronic Monitoring Control System has tripped, or one of the

hardware timers on the Electronic Monitoring Control System has

shut down the dryer.

Display shows "12 VOLT POWER SUPPLY WARNING"

message.

The right circuit breaker located on the input/output board of the

Electronic Monitoring Control System has tripped.

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SERVICE

Problem

Possible Cause

Display shows "MOTOR OVERLOAD" message.

The thermal overload on the fan motor, load motor, unload

motor or an auxiliary motor has opened indicating an

overloaded motor. (The overloads must be manually reset).

Display shows "BURNER 1 VAPOR HIGH

TEMPERATURE" message.

The LP gas vapor temperature sensor located in the gas

train downstream from the vaporizor has opened, indicating

that the vaporizer is running too hot and must be read-

justed. (This control is a 200°F limit which automatically

resets when it cools).

Display shows "BURNER 1 WARNING FLAME NOT

DETECTED" message.

The flame sensor has failed to detect a burner flame,

indicating that the burner has failed to light, there is a

problem with the flame sensing circuitry or the dryer is not

getting burner fuel.

Display shows "FAN 1 HOUSING HIGH

TEMPERATURE" message.

The temperature high limit located on the fan/burner

housing has opened, indicating an over temperature

condition has occurred towards the rear of the fan/heater

housing. (This control is a 200°F limit control that must be

manually reset).

Display shows "GRAIN DISCHARGE WARNING" message.

The cover on the grain discharge box has opened, indicat-

ing that grain is backing up into the discharge box.

Display shows "LOWER ADJ. GRAIN HIGH

TEMPERATURE" message.

An over temperature condition has occurred inside the left

side grain column. (This control is a 210°F limit which

automatically resets when it cools).

Display shows "LOWER FIXED GRAIN HIGH TEMPERA-

TURE" message.

An over temperature condition has occurred inside the right

side grain column. (This control is a 210°F limit which

automatically resets when it cools).

Display shows "OUT OF GRAIN" message.

The dryer has run low on grain, and the out of grain timer

has timed out shutting the dryer down. The unload auger

will then clean out the dryer, if the unload switch is on

during continuous flow operation. Check the out of grain

timer setting, and if necessary adjust. Also, before restart-

ing, inspect load equipment for possible damage or

adjustment.

Display shows "OUT OF GRAIN-UNLOAD CLEANOUT.."

message.

Display shows "PLENUM 1 HIGH TEMPERATURE"

message.

An over temperature condition has occurred inside the

dryer plenum. (This control is a 300°F limit which automati-

cally resets when it cools).

Display shows "METER ROLL DRIVE SYSTEM FAILURE"

message.

The metering roll drive system has failed to turn within two

minutes. A faulty D. C. motor, broken chain or jammed roll

is a possible cause of this message.

Display shows "RIGHT METERING ROLL FAILURE"

message.

The right metering roll has stopped rotating, or the sensor

has been damaged.

Display shows "LEFT METERING ROLL FAILURE"

message.

The left metering roll has stopped rotating, or the sensor

has been damaged.

Display shows "AUXILIARY SAFETY SHUTDOWN"

message.

A shutdown has occurred due to a user installed safety

feature. This circuit is located between J5-9 and J1-20

terminals on the input/output board.

Display shows "BURNER 1 SHUTDOWN LOSS OF

AIRFLOW" message.

The air switch contacts have opened, indicating insufficient

airflow for burner to operate.

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SERVICE

Problem

Possible Cause

Display shows "FAN 1 FAILURE-NO AIRFLOW" message.

The air switch contacts have opened, indicating the fan

may not be turning. The air switch may need adjustment.

Display shows "FAN 1 CANNOT START-CHECK AIR

SWITCH" message.

The air switch contacts have closed prior to the fan

starting, indicating a freewheeling blade or improper setting

of air switch.

Fan motor will not start.

1. Check that the fan circuit breaker and the fan switch are

on. Also, check for defective switch or bad wiring connections.

2. If lighted switch does not light, the air switch needs

adjustment, or the bulb may be burned out.

3. Verify closing of fan motor contactor. Check voltage on

load side of contactor. See appropriate power wiring

circuit diagram for terminal numbers. Inspect contactor

for defective points or a burned out coil.

4. Inspect connections, and check voltage applied to the

motor leads in the fan heater box to determine if the

motor is defective.

5. Check capacitors on single phase motors, and replace if

defective. If motor starts slowly, check for low voltage

during starting due to excessive voltage drop in power

supply wiring.

Top auger will not start.

1. Check that the top auger circuit breaker and the load

auger switch are turned on.

2. If lighted switch does not light, the output power to the

contactor is missing. Check connections, or if the bulb is

burned out.

3. Check position of the upper auger paddle switch. It

must be down to start auger.

4. Inspect for secure mounting and wiring of mercury

switch in the terminal box on the top auger paddle

switch shaft. Include check for a defective mercury switch.

5. Verify closing of the top auger contactor. Check voltage on

load side of contactor. Inspect contactor for defective

points, or a burned out coil.

6. Inspect connections, and check voltage applied to motor

leads in motor junction box to determine if motor is defective.

7. Check that the mercury switch box is in the proper position.

Bottom auger will not start.

1. Check that the bottom auger circuit breaker is on.

2. If the lighted switch does not light, the output power to

the contractor is missing. Check connections, and

check to see if the bulb is burned out.

3. Check that the unload switch is on (1 or 2 speed).

4. Verify closing of bottom auger contactor; check voltage

on load side of contactor.

5. If using the moisture control, check for proper setting, or

defective operation of the control.

6. Check for any loose wire connections in unload auger

and moisture control thermostat circuits.

Grain not moving through columns.

1. Check the dryer for fine material buildup inside the

columns.

2. Avoid leaving the dryer columns full for long periods at a

time (2-3 days) while not operating the dryer, or during

rainy weather.

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SERVICE

Problem

Possible Cause

Grain not moving through columns.

1. Check the dryer for fine material buildup inside the

columns.

2. Avoid leaving the dryer columns full for long periods at a

time (2-3 days) while not operating the dryer or during

rainy weather.

3. Empty the dryer. Keep the dryer clean! Do not allow

fine material to gather in the plenum chamber.

4. It may be necessary to open the strike off plates in the

affected columns in half inch intervals.

Uneven drying-Some kernels appear brown while others

are under dried.

1. Check plenum thermostat temperature setting. Some

varieties of grain are more sensitive to higher operating

temperatures. It may be necessary to lower the plenum

operating temperature to accommodate this.

Uneven heat exiting from dryer columns.

Burner will not fire with fan operating.

2. Check for proper burner alignment (side to side).

Vibration during shipment may have caused misalignment.

1. Burner switch must be on.

2. Check for power to ignition board.

Heater switch light and gas solenoids go on and off

erratically-The light blinks on and off while the solenoids

"chatter".

1. The blinking light indicates the flame sensor is not

detecting flame.

2. The "chattering" solenoids are caused by the loss of

flame detection, and the thermostat and Fenwal ignition

board trying to reestablish a flame. Check for loose

wires on flame sensor; replace or repair wires or sensor.

Burner will not fire-No gas pressure with fan operating at

least 15 seconds (gas supply or fan heater malfunction).

1. Check gas supply. Also, check gas filter and gas line for

possible obstruction or closed valves. Refill tank;

replace or repair parts, as required.

2. Inspect gas solenoid valves (including liquid valve on

LP units) for defective coils or improper wiring. Replace

valve or coil if valve will not open with proper voltage

applied (115 volts).

3. Check for proper voltage. 115 volts across L1 and L2

incoming voltage to the Fenwal Ignition Board, and 115

volts outgoing across V1 and V2 to the solenoids.

Burner will not fire-But gauge shows gas pressure.

1. Fenwal Ignition Board: Check board for spark by

removing ignition wire from board, and holding aninsu-

lated screwdriver against the output terminal and 1/4"

away from the control box casing. There should be a

strong spark. Check board wire connections. Replace

the Fenwal board, if necessary.

2. Ignitor: Check that the ignitor is properly gapped to 1/8"

and that it has a strong spark. Inspect the porcelain and

electrodes for damage or cracking. Replace or clean if

necessary.

Burner maintains desired drying temperature-but cycles

from hi-fire to off (without going to lo-fire).

1. Make sure the low flow control valve is not completely

closed. Valve must be adjusted open to provide the

proper lo-fire gas pressure listed in this manual.

2. Check lo-fire solenoid valve for proper operation.

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SERVICE

Problem

Burner operates-But will not cycle from hi-fire to lo-fire.

Possible Cause

1. Check the gas pressure reading on the gauge. Problem

may be due to insufficient gas regulator setting. Tempo-

rarily decrease the hi-lo fire thermostat setting to verify

that the thermostat will function and cause the burner to

cycle. If burner will cycle at the reduced thermostat

setting, it indicates that the problem was due to insuffi-

cient heat to satisfy the original setting. Increase the

gas regulator setting for additional heat output. Do not

exceed the maximum pressure listed in this manual.

2. Hi-lo fire thermostat control may be defective. If the

burner still will not cycle to lo-fire after decreasing the

thermostat, the problem may be due to a broken or

kinked thermostat sensor tube. Observe reading on the

thermometer. Replace control assembly if it cannot be

set to cause its switch to go to the open circuit position

with normally hot air plenum temperatures.

3. If the burner continues to operate on hi-fire, check the

hi-fire gas solenoid valve for a stuck or blocked open

condition, or for reversed gas pipe connections. The

solenoid valve must not allow gas flow when its coil is

not energized.

Burner operates-But will not cycle from lo-fire to hi-fire.

1. Check for an excessive lo-fire gas pressure setting.

Observe pressure setting shown on gauge, and

compare reading with recommended low pressure

settings listed in this manual. Readjust lo-fire setting on

flow control valve, if necessary.

2. Check for improperly adjusted or defective hi-lo fire

thermostat control. Temporarily increase the tempera-

ture setting. If the heater will still not cycle, check for

problem in the control wire connections. The control

wires should be connected to terminals R and B of the

thermostat, so the switch will open upon temperature

rise. If the burner will cycle with these two wires

connected together, the thermostat is faulty.

3. Check for improperly connected or faulty hi-fire gas

vapor solenoid valve. Correct any poor connections or

defective wiring. If wiring appears proper, problem may

be caused by a burned out valve coil or defective valve.

Replace hi-fire solenoid valve, or its coil, if defective.

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QUICK REFERENCE GUIDE

ELECTRONIC MONITORING CONTROL SYSTEM

ton to move from feature to feature.

To change the marquee on the

LCD display:

•

BPH factor

Important! To activate the controller

after turning on the control power,

press the reset button.

Fill auger options:

a. Center fill auger

b. End fill auger

•

Press and hold the modify button

whileturningonthecontrolpower

Press the increase or decrease

button to change a character

Press the unloadbutton to move

the cursor to the right

•

Metering roll monitor disabling

feature

To set the dry, cool, unload and out

of grain timers:

Air switch disabling feature

•

Press the dry, cool, unload or

out of grain button

These features are accessed se-

quentially as listed above. Press the

increase or decrease buttons to

change a setting. Press the enter

button to move from feature to fea-

ture.

•

Press the modify button

Press the increase or decrease

button to get desired setting

Press the enter button when

desired setting is reached

Press the dry button to move the

cursor to the left

Press the cool button to delete

a character

•

Press enter when the desired

marquee is displayed

Pressing and holding the reset but-

ton for five seconds will access the

following programming features:

To set the load and unload delays:

•

Press the load or unload button

Press the modify button

To reset the computer to the original

default setting, turn off the computer,

press and hold the green AUX 1 but-

ton and turn on the computer.

NOVRAM will appear on the LCD dis-

play. The year, date, time and min-

utes may be changed now, and the

shutdown history may also becleared.

Note: If the history is cleared the

dryer model number must be reset or

only the bottom fan will operate (if so

equipped).

•

Calendar year setting

Calendar month setting

Calendar day setting

Clock hour setting

Press increase or decrease

button to get desired setting

Press the enter button when

desired setting is reached

•

Clock minute setting

Bushel counter reset

Batch counter reset

Pressing the increase and decrease

buttons simultaneously will access

the following programming features:

These features are accessed sequen-

tially as listed above. Press the in-

crease or decrease buttons to

change a setting. Press the enterbut-

•

Safety circuit shutdown log

Dryer model number

Fan delay

Dryer owner and Airstream associates check the Electronic Monitoring Control System.

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NOTES

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