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Commercial Tower Dryer Operator`s Manual

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4. ees CONTROL PANEL 222 P m 2
5. e e 99 O IEZ e 2310 880 e BES eo a FMES B ub 10008230 V 6 8 85 ET 565 1000 460V 6 3 3 B B rue 3 100085 75V 150082 30V 128 m 15008380V 67878 mE 15008460V 6 6 64 Em 15000575V 6 6 6 hes 2000e230V 67157154 b 20000460V 6 8 8 ET a eno eeN 508 a E Hc
6. PART ND DESCRIPTIDN ASSY NE WURK XXX XXXX X NETWORKS FOR 2004 CONTROL X JOB THIS PANEL X ITEM PART ND DESCRIPTION QTY DXXX XXXX X 747 AIC ISOLATED LINK COUPLER PON PON N 1 756 2159 9 746 410 RACK 10 SLOT tis 2 756 1795 1 746 P4 PWR SUPPLY 21 oem SE SAI 3 756 1796 9 747 1532 CPU W OS302 7 OR LATER E Ta 4 756 1797 7 747 M11 EEPROM zs sielelelelelelsieleleleilelel el 5 756 1799 3 746 NID4I LOG 2x2 IU 6 756 8161 5 746 NR4 PLC AB RTD MODULE uo ae PTT Eee 7 756 1807 4 746 N2 SLOT COVER S 8 756 1807 4 746 2 SLOT COVER Mo 552 xk E E 9 GT3 0810 746 1816 PLC AB DIX16VDC 3 3 Saree PANELVIEW PLUS 1000 756 1801 7 746 OW16 PLC AB 00 16 120VAC O i 1 GT3 XXX X
7. TU ESI MieroLogix 1200 gt x C PUWER SW Al N 4 eieleleleleieieieieieieiel pum 2 THE CP m ECONDARY tLe eelelelele lelelelel CB 04 03 em 7 4 4 1 2 pia AN FEES GET ES Ir VIEW PLUS 1000 PLUG INI HE LESE WER SUPPLY 24 Loles O CEET O ES 24VDC PW CONTROL PANEL EY C9 E IE GSI GROUP Xx 27 2 M ILLINOIS ST ASSUMPTION IL 62510 GND DCC 5 8 SS Dock SCIES DU E P N A
8. GAS TRAIN LT ESL INPUT RB NM POWER LNO DMH NO7 DM NONE A DRIVE GRAM INI WMH 931 VOLT Jee EQUENC ia XTUM a A COM OVDC owerr lex 734 3 MIN FREQ gt UTO 4 P035 75 MAX FREQ 2 010 7205 i 0 10V 2037 0 CRAMP TOP UT1 2038 3 4 20 INPUT SNK POSS 10 i i 0 20 ss 23 4 5 6 9 nn DDADOOODD 2041 0 READY n 112 4 lt PT CURR a ike ae S 12 13 14 15 16 17 18 19 DIP Sw1 D 202 DOD DID QD DIP SW2 SRC vol 208 508 506 50 DRV DRV ANALUG INPUT UUTPUI RMINALS lr PANE GSI ILLINOIS ST ASSU GROUP MPTION
9. FLEX 4 40 500 SE 9 0 6 ura O LOW CURRENT BLOWER CONTACTOR 5 206 s four e COIL CONTACTOR 3LC LOC POWER PANEL er ern RE 3 907 GRN za SNS O3 LOW CURRENT BLOWER CONTACTOR COIL CONTACTOR LOC POWER PANEL 1 208 GRN lan 901 An kV BLOWER 01 STARTER COIL MOTOR CONTACTOR C POWER P UA C 502 BLUWER e INS BLOWER 02 STARTER COIL MOTOR CONTACTOR LOC POWER PANEL 2192 503 BLOWER 3 x BLOWER 03 STARTER COIL MOTOR CONTACTOR LOC POWER PANEL ian 2 504 4 x Q BLOWER 04 STARTER COIL MOTOR CONTACTOR C POWER PANEL 9 0 5 PMS 05 SH pania ze ABLE PILOT SOLENOID FNOID ee NR ME P WE ANE PART NO 5 V a 5 IN P W x PANEL IHE Gol WIRING MAT L DESC P N DWG BY DATE DWG NO 04 10 0 mr TR ese
10. 13 WIRES sb ao PILOT FLAME R D PROTECTOFIER 4 f GAS a BURNER FLAME ROD V BURNER E 1 Bs 10 SEC TIMER RELAY W 600V CONTACT 1 2 NO JUMPER 7 3 N N S N N Soe me pus MVS L 2 MVS 5 MS Sieh eee CM CM PLC 111 PLC 112 SE ux L 1 217 E oyu C2 da x DUE AR la le MAXON VALVE 1 AXON VALVE 2 aes ET MAIN GAS AUXC7 9 CLOSE VENT MAIN GAS AUXC7 9 HONEY WEL HPS IRING VALVE Es VALS ENABLE WITH VALVE Reon ENABLE WITH VALVE M7284A 1012 LIMIT SWITCH LENBID PARTIALLY OPEN LENDID PARTIALLY OPEN MODUTROL MOTOR LIMITS UNLESS OTHERWISE SPECIFIED 0 0312 000 0156 ANGLES 1 Gol GROUP ILLINOIS ST ASSUMPTION IL 62510 WER DRYER CONTROL WIRING DIAGRAM P N
11. x VH 84 VL 2 DGT 5 Y SUPPLY SEN IK OHM gt DMC SENSOR Y GND O VDC LK HM eed 1 0 SW VDCQ RIN i JUM E HAS 3 A gt SIC D L 2 Pn T n OVDC m u j COM 54 5 92 1 co c DUT JUMPER WML WGT GND 4 GT Qe GND Q V D C LIMITS UNLESS OTHERWISE SPECIFIED cs ac 0 0312 000 0156 ANGLES 1 Tem 12VDC 1 45 1141 IE GSI GROUP VDC R D D E ILLINOIS ST ASSUMPTION IL 62510 IND lt TERMINALS IN POWER PANEL FIELD WIRING c m PEUT FIELD WIRING 7 WIRES 4 WIRES FLAME ELECTRODE ASSEMBLY OVERHEAT OVERHEAT 1 OUTSIDE INSIDE BURNER 7 Q GAS PILOT plos PEE Po ag
12. 2 W L A N R RSS TAR OCG DOR blo NE ER TE OO 1 FE m e c e e 112 N LI REV IgG 113 i 1000e230V 6 8 8A AT 56 10006420V 3 B FUe 3 1 2 10008575 V 6 3 35 2 15008230V 6 12 12 Ae Scu Kcu 15008380 V 6 8 8 55425 men 15000460 6 6 6A 15000575V 6 6 6 en ur 2000e230V eo 8 1 20000460V 6 8 8 35 O gt Erg cem GND GND GND 4LS ne aet x D D i i i n AMI Ul E SMITI i 3M 2 4 GND GND b e e 3LC E e 2 lt 5 _ van j AMI 3 x AN ET rwr Er Mt R 220V LIMITS UNLESS OTHERWISE SPECIFIED D G N E ND EU X A 00 0312 000 0156 ANGLES 31 Bm GNDY yy THE GSI GROUP ae Lec ac g 2 1004 ILLINOIS ST ASSUMPTION IL 62510 ore Sf TITLE TOWER
13. DH 485 S DITE ES O SLC 5703 CPU ouTPuT INPUT INPUT INPUT INPUT INPUT DUTPUT DUTPUT mers u odi sse ses 2 N INTFC 21 2 21 ua 50 2 121 06 04 21 7 W E x ri TERM WAHRE eses MODULE 1 anma ammm Im 05 anma mi Ri BEN E lis a pwr nur 24 vo user B y p PwR OUT COMMON W H T REN PERIPHERAL mu _ m E 85 138 VAC IO D S H D D Ls JUMPER O 1 UJ M DE E cou 170 265 VAC O EI GND 4 ES L1 85 132 170 265 x G N D d L2 NEUTRAL CHASSIS GND E E s m MUDEM CABI WIRING DIAGRAM Bor DBe5F ape 8 3 3 2 LIMITS UNLESS OTHERWISE SPECIFIED 0 0625 00 0312 000 0156 ANGLES 1 4 2 0 MITI 5 7 HE GSI GROUP 6 SaaS Se 6 1004 E ILLINOIS ST ASSUMPTION IL 62510 qn 4 TLE TOWER DRYER CONTROL PANE M EM WIRING DIAGRAM B excute 9 25 P N ea 22 26 94 10 04 DC EXER D Piss Cre A WDC pu
14. CUNTROL PANE SUL ee CONTROL PEWER C DEAD I et 7 C DEAD TIN PILOT LIGHT El oy DEAD I PRT tsa BU 3 EAD XN I PILUI UNI PILOT LIGHT Der LING Ce TIN I PILOT LIGHT Y LEG DEAD IN ll AUX DRY CEN C DEAD FRUN PROAT AET TP BIS o CEN C DEAD 726 9 09 a 110 EL CRAIN H HIGH GRAIN UH War La IE 11 AUX WET CONV 5 Y 4 KEN N in
15. 101 _ 27 100 15 0 00 IRE LT SW 112 150 12 x 2AVDC LOCA 28 23 PY X o IRING VALVE W IS ON CANIDIAN GAS TRAIN H U 101 15 0701 Li GAS TRAIN pp o UTSIDE OVER HEAT 30 PPER LEF 1 MV AUX 113 150 13 g H UR 102 1 5 0 02 E ee i pe 1 OUTSIDE OVER HEAT _ i JPPER RIGH H ML 103 15 0 03 PROTECTOFIER wm on E 34 REF PAGE 8 09 IDDI 35 9 gt ACK FLAME N H MR 104 1 5 0 04 POWER PANEL 110 O co X e UN IDE HE AT 36 IDDLE RIGHT 0 1 lt Ha 355 0705 ISIDE z ACK AIR PRESS SWITCH y E we BLW COMB COMB BLOWER H LR 106 15 0 06 APS COMB SIDE OVER HEAT d WER RIGH H I 107 1 5 0 07 E INSIDE BIVER HEAT f INNER LEF H IR 108 1 5 0 08 d 5 INSID HEAT d INNER RIGH PLEN HI 109 1 5 0 09 e o i ENUM HI LIMIT SWITCH 46 ADJUSTABLE ET RIK 110 150 10 Pg ID 22 o O X W E PRE JR WI CH 48 o P C GAS TRAIN RED 150 11 ne 24 Ger HIGH GAS PRESSURE SWITCH C TRAIN GROUP lt RMINALS IN P W R PANEL DRYER PANE 26 e FIELD WIRING om
16. DATE DWG NO 04 10 04 TIS or 18 WET CONVEYOR s A amp These wet grain transports can be either conveyors or slide gates Either A or B can be selected from the WET PATH selector switch TH E WET PATH Wet coveyor starter wiring is like this STARTER STARTER 404 115VAC coil 405 115VAC A C C WET CONVEYOR 408 Wet slide gate wiring is like this WET LEG 407 Interlocked with the TOP WET CONVEYOR ACK 213 404 for GATE A or 405 for GATE B 115VAC CR SLIDE RE1 OPEN CR SLIDE RE2 CLOSE AUX WET CONVEYOR WET LEG AND TOP WET CONVEYOR 1 You may purchase the optional starters push buttons amp pilot lights installed in the dryer panel which are connected as shown by the draws in left and center columns 2 If you have an existing starter system connect the aux contact of your device as shown in the draws to the right column 3 Do not forget to select the device option from the DRYER SETUP screen of the operator WET CONVEYOR A 404 after the device is installed Interlocked with the AUX WET CONVEYOR 215 AUX WET CONVEYOR STARTER DCC 24VDC stop IN20 406 115VAC L 2 JEN C tart oe IN21 PLC 24VDC PLC 24VDC aux 215 UNLOA
17. sas ing Prat wage PONH omes EI 4 Ju 10180 4017 Psi Rar ot of es 2 w s 1051570 45 150 4017 Plated Hex Bott 22 4 0505 outside Comer Back Up Bar 2 1 119597 Inside Corner Back Up Bar NOTE These items included with fastener kits See pages 5567 amp 5568 for fastener kit details 9 03 Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice A INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES CORPORATION Page 5550 S 10 Series NP LE AIRFLO Burners Maintenance and Component Identification Spare Parts Fastener Kits End Plate Fastener Kit Body to Body Fastener Kit End Plate Gasket Es Shim Gasket Tai 5 v Shim Y M5 x 10 Hex Head Screw h NS M5 x 20 P te i Hex Head Screw p M5 Lock Washer 4 M5 Lock Washer SS only gt SS only M5 K Nut M10 x 1 5 y 4 Hex Nut M10 x 1 5 1 Hex Nut N M10 Lock Washer gt Body Gasket M10 x 40 RUN Body Gasket Hex Head Screw M10 Lock Washer Body Gasket Assembly Numbers Replacement Items NP1LE NP1LEAL NP1LEALSS NP2LE Flange to Flange Fa
18. ji o 8B i OF Sg 65 a ES 2 O CU q EC si zo eo 3 1 3 HBEB i a gt El Id o E E 5 BABE BHRR 0 7 5 BABE Z a 2 Y EI d 5 BABE Ben 2 lt lt lt S Y e gt SS ee tom LI OY Seu OL gt Me QJ gt 2 5 a 7 yo Is lt lt IH EH D AH EB 3 z 0 CUR 8 E 111 P GUO e 3 000 O es m m 2 O 84 Qui gt 25 a D OL Tolol Ier Jor JE 2 3 gl 8 ar ds U m 55 L e zi is QU 9 9 Z T CY presi n 7 Tg x O po Vbi 9 amp X 1 7 CO X Hu gt wp CU o aoe 4 gt a 4a lt L by E n er A gt y I TE Y Q e lt x a AA b I per em EL XU 9 QJ E A az Iu I Ca DE E os or i
19. LELT 120 VAC L 2 401 X x pi 80 00 DRY CONV 8 0710 BURNER CONTROL UNIT y O DRY CONV STARTER u BCU TOR ARTER D MOTOR a 5 FECTUFIER WIRING 403 80 01 SS ANEL e X0 P abl D FLAM 2 PANE 401 AUX DRY CONV 4 2 4 9 x NN AA DRY lb SAR TER E 9 MVS cor OR STARTER i LOC POWER PANEL s D 8 114 DRY LEG aum Es Da e DRY LEG STA Rn 7 DVS l pr CBE _ 80 03 paese E 2 A He gt DRY CONV STARTER 77 20V NI TOR STARTER 4 E x 6 lt 410 LUC DRYER PANEL i rst IGNITION XFORMER PR ARK PLUG 6000V LOC POWER PANEL iu en CUNV awi A WET CONV A STARTER 8 413 T ae COIL MOTOR STARTER LPI LIQUID BEEN LOC POWER PANEL v SOLENOID VALVE E 3 2 0 1 u 9 DIL PUMP 1 A R A N 80 05 pq 05 WET CONV B 1 66 86 I Qe WET CONV B STARTER COIL MOTOR STARTER S A i S S dU LUC POWER PANEL iE Pe i 1 5 L1 COMB AIR BLOW 80 06 ume EET OO ee er RB 406 NV STARTER I eS COIL MOTOR TARTER Bee Wiser 2 Berne LOC POWER P B 2452 ALARM 9 8 0 07 p 5 E p 8j RED ALARM LIGHT 07 407
20. Remove side cover plate Switches mount on bracket See B below Fig 3 4 6 7000 Remove 2 piece top cover Switches mount on support stand Fig 4 375 75 8700 Remove top cover Switches mount on actuator frame Wand Position Mounting Brackets For 1 1 25 034 6 2 0 w 2 3 4 6 2 amp 2 3 non CP Seay 2 1 2 1 VCS Switch on back B VOS switch wand should be actuated from above VCS switch mounts on back of bracket D Oil SOV 8 O 6 Gas o 1 1 2 1 14 o o 3 4 1 O o Pins Mounting Slots VOS switch VCS switch wand should be actuated from below Bracket Mounting Holes CORPORATION MUNCIE INDIANA USA Page 6100 S 8 Normally Closed Valves Manual Reset Series 375 3 Series 808 818 S 1 1 25 Series 730 760 790 S 1 1 25 Series 33790 S 2 5 4 Series 808 CP S 818 CP S 6 Series 808 818 S Automatic Reset Series 375 3 Series 5000 5100 S 1 1 25 Series 4730 4760 4790 S 1 1 25 Series 33479 2 5 4 Series 5000 CP S 5100 CP S 4 zu 6 Series 7000 7100 S 375 5 Series 8730 8760 and 8790 S Electro Mechanical Valves
21. 1051570 us t8 0 4017 Petea Hex Bolt 4 105069 outside Comer BackUp Ber i w T ff 57 inside Corner Back up Bar NOTE These items included with fastener kits See pages 5567 amp 5568 for fastener kit details 1 01 Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice A hy INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES en Page 5550 S 8 Series NP LE AIRFLO Burners Maintenance and Component Identification Spare Parts NP 1 LE AL SS To order replacement parts 1 See burner nameplate and indicate burner type 2 Sketch burner arrangement as viewed from casting side 3 Specify replacement items required from diagrams above 4 Specify quantity of each and assembly numbers from table below Quantity Required for Indicated Section Part Description 12 X 6 6 X 6 oo no Tee Elbow 1050388 1050389 1050386 1050391 Asby Tape fate eng Pia 2 T T 1082004 wing Piae ise Comer rap ers icing Petes Wedge Ss a LL T T Back Up Bar Amina e Pa 3 2 fases ro
22. For initial system start up 1 Close all burner fuel valves and or cocks Make preliminary adjustments to fuel regulators 2 Check all electric circuitry Verify that all safety devices and interlocks are operable and func tioning within their respective settings ranges Be sure all manifolds are tight and that test ports are plugged if not being used 3 Check that all duct and chamber dampers are properly positioned and locked into operating positions 4 Start main volume air fan Check for proper motor rotation and impeller direction Verify all safety interlocks are working Allow air handling equipment to run adequate purge of manifold and combustion chamber plenums Verify air volume and velocity across burner element to be within burner operating specifications CAUTION Do not by pass control panel timers typically controlling sequential operations 5 Disconnect the automatic control motor linkage from your Maxon Control Valve by loosening the control motor s connecting rod from the valve s toggle linkage Initial start up adjustment should only be accomplished during a manual control mode Manually set and secure control valve in its minimum position 6 03 Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Toggle Clamp Screw 1 Toggle Clamp 2 Toggle Clamp Bolt 3
23. 3 121 as shown 4 121 uses a spacer and 4 Model 121 FR Standard 9 Il EX S 24 2 1 NPT Vent gibus Ep lt 10 212 connection NS A a II gt VA c ai ie SC NA 13 28 gt 9 EZ 2500 13 A 1 2 NPT Control 26 d 14 a 14 NPT Control 5 Ra 2 B line connection co cia Ami 2 Ss N 9 121 12 T gt am RI PIPE SIZES inlet x outlet N UL 14 b Flanged ANSI 125 Ib 3 121 as shown 35 32 gt 19 18 17 3 15 159 4 121 uses a spacer 286 0 0 8 2 8 Ea x X thick 121 16 3 and 4 Model 121 1 2a mS es e 1 o 1 NPT Vent 4 B 9 connection 5 Em 40 613 b E 7 DE R 9 45 In 1 NPT Vent 13 Elle Pes ERE RII E les 23 connection FT gt Y line connection 25 C b 26 22 a 27 23 d b 6 28 24 XJ Do g 1 14 82 4 NPT Control 83 28 line connection 9 121 12 Back Pressure a 153 15 69 460 17 18 49 499 38 37 82 35 x34e thick 121 16 3
24. 8D321Y5X 8142125 Y5X 6142125YSX GIBIT 25YSX E HR 8102628 B122529Y5x 6142125 5 142125 5 61617 25 5 SIORSSIYAIK 225297 5X 6142935 75 6142835 55 amp 182935Y5X 61035YRX Si235YRX _ G142005YSX 8182935 5 3YSX 81243Y5X 61443 9 S0951YRX BIPSISBYSX 14 1442 50 5 S 050YRK Bearkig No Stamped on Eccentric Bearing Single Type Eccentric Bearing Double Type Eccentric And Bearings For Eccentric Frame Sizes Frame Sizes Frame Sizes A 12 Table A 23 IntermediateShaft Bearing Bass em EA sisi erasoa ens em erora 3 619008 819508 2 mans sme eme azma 2 EC CINMN a 8170DA 6175DA erae Peer fer7oc 17500 sex 3 Table A 24 Oil Seals 618508 Lm exce 610508 eme E E E eres 1 31 oe 13 ies 5 6145 aee D 37 2 l Rm NF ICE I Eee INN NN 180x225 16 Note 1 D indic
25. DWG NO 0004 05 212 213 214 215 216 217 218 219 1 415 200 6 0 00 AUX BLW 01 201 16 0 01 4 69 1 z INTERLOCK BLW 02 1 6 0 02 202 OH INTERLOCK BLW 03 203 1 6 0 03 He O INTERLOCK Te 204 1 6 0 04 INTERLOCK APS 01 205 1 6 0 05 e O 2 BLW 04 APS 02 206 1 6 0 06 e O A BLW 02 APS 03 207 6 0 07 BLW 03 ACK TRI START TRI START CONTACT AUX LOC POWER PANEL ACK BLOWER 01 BLW 01 STARTER AUX LOC POWER PANEL ACK BLOWER 02 BLW 02 STARTER AUX LOC POWER PANEL ACK BLOWER 03 BLW 03 STARTER AUX LOC POWER PANEL ACK BLOWER 04 BLW 04 STARTER AUX LOC POWER PANEL ACK AIR PRESS SWITCH 01 LOC APS 1 ACK AIR PRESS SWITCH 02 LOC APS 2 ACK AIR PRESS SWITCH 03 LOC APS 3 ACK DRIVE READY OK POWER FLEX 4 40 208 1 6 0 08 e DRY CONV 209 1 6 0 09 O AUX DRY CONV 210 160 10 DRY LEG CONV 211 1 6 0 11 CH DRY CONV 212 1 6 0 12 69 1 i 2 TOP WET CONV 213 1 6 0 13 WET LEG 214 1 6 0 14 64 AUX WET CONV 215 1 6 0 15 H
26. ce 6M oM 4M 3M E 1 UR BLWS TIMER Tale ja 1212121 1212121 la d Tela al eneel ow Dou Hn m gos eue c Zune 502 1 A i Hi N 4 if OR BLW2 3Sec TIMER m y TOME a ne m CR BLW1 TIMER gt lt 2 lt Ee TE A NEL on ts NE E SE EU Ee FUR 230V Et p pas GND we a NEM vs sonis 2 0198 2 THE GSI GROUP 6 7 ec 1004 E ILLINOIS ST ASSUMPTION IL 62510 DM E AA E ARA A E TITLE TOWER DRYER CONTROL PANEL WIRING DIAGRAM WET CONS A SLUWER BLOWER BLUW war DESC P N DWG BY DATE DWG NO MIR 03 idem TRUI PADAYY OIPY NO REVISIONS CHG BY DATE
27. UNLOAD UNLOAD UPPER LIMIT LOWER LIMIT CONTROL MODE RETURN 10 Tower Dryer Ops amp Service 18 Shutdown dryer The dryer will likely have to be shutdown from time to time The steps used to shut it down will depend upon the duration of the shutdown If the dryer will be shutdown for 4 hours or less follow the Short Shutdown proce dure For longer shutdowns such as overnight follow the Extended Shutdown procedure Short Shutdowns Less than 4 hours For short shutdown periods the dryer can be shutdown by pushing the DRYER POWER STOP button 7o restart the dryer push the DRYER POWER START button The PLC will restart the dryer automatically based on selec tor switch settings Extended Shutdowns 4 hours or more 1 Shut off the burner Turn the BURNER se lector switch to the OFF position All gas valves will immediately close and the burner will extinguish 2 Cool down grain PLC will continue to oper ate blowers to cool grain To avoid overdried grain upon restarting the dryer continue to move grain through the dryer during the cool ing off period 3 Shut off unload equipment Turn METER ING DEVICE and UNLOAD CONVEYOR selector switches to OFF position 4 Shut off blowers Turn BLOWER selector switch to OFF position 5 Shut off control panel Turn the CONTROL POWER selector switch to the OFF posi tion 6 Turn off main circuit breaker located on the power panel 7 Close mai
28. W Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice CORPORATION MUNCIE INDIANA USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Electro Mechanical Valves Page 6100 S 3 Installation Instructions cont d Top Assembly Rotation Series 25300 with socket welded Series 5000 CP Series 808 nipples amp flanges Maxon valves can and should be ordered in a con Auxiliary Switch Arrangement figuration compatible with planned piping but if open shut indicator window is not visible and or valve orienta tion is not proper the top assembly can be rotated in 90 increments around the valve body centerline axis by the following procedure 1 Shut off all electrical power and close off up stream manual cock 2 Remove wiring access cover plate 2 and disconnect power lead wires Tag carefully for later re assembly 3 Remove conduit and electrical leads 4 Note physical position of any signal switch actuator wands on auxiliary signal switches see switch arrangement sketch Wiring Diagram 5 Unscrew the two body bolts 4 screwed up from A Number Coded Wires H Mounting Screws the bottom to 1 4 inch DO NOT completely re Somme 2 d Extension Mounting Screws Switc an move These bolts secure the valve body 3 to the D Normal de energized Actual energized valves top assembly housing 5 Position Switch
29. acu oM a THE GSI GROUP M LA com N P Ad E NS E Bo i pi a 1004 E ILLINOIS ST ASSUMPTION IL 62510 p TITLE TOWER DRYER CONTROL PANE WET e BIOWER MTR NV B WIRI G DIAGRAM MAT L DESC P N DWG BY DATE DWG NO QL 04 10 04 OF 18 CHG BY DATE px 2 U ART WINDING ek ER ER MA 200 UT REVISIONS CHG BY DATE N Ja RCUIT
30. DRY LEG LNO DRY LEG CONTROL PANEL 602 EN NO PR DRYER 629 _ 3 pp START DRY LEG STAR a INI DRY LEG LOC CONTROL PANEL 604 o o SIAR 631 _ YER pr E R PANEL 29 1 PNIA N14 PB AUX DRY CONV e IN IN AUX DRY LOC CONTROL PANEL mE Sif START STOP BLOWER 633 CUL CONTROL PANEL u INIS IH START AUX DRY CONV N Ss 2 TN3 INS AUX DRY LOC CONTROL PANEL f 1 SW START STOP BURNER 639 LOC CONTROL PANEL np IN16 IN16 Dp TOP DRY CONV FOR TN4 b C LOC CONTROL PANEL 3 Lo L SW METER ROLL FORWARD LUC CONTROL PANEL START 611 638 e ace N17 D LFE START DRY CUNY INS DRY CONV LOC CONTROL PANEL X LOC CONTROL PANEL H INI8 1 8 p STOP WET LEG 613 640 FI LE ING W LOC CONTROL PANEL 614 1 X SAT WET PAT CA 641 STARI 19 INIS LOC CONTR PANEL PR ZU PB START WET LEG 615 642 ENS LUC PANEL RS ss we MANUAL ae OE PB STOP AUX WET CONV X LOC CONTROL PANEL AUX WET CUNV CONTROL PANEL INS START a 5 Bn SS WET AUT y 55 21 pp START AUX WET CONV LOC CONTROL PANEL UX WET CONV LOC CONTROL PANEL MAN 3 ENS 2 OUTSIDE LIGHT MANUAL u IN22 22 gt TOP WET CONV x CONTROL PANEL WET CONV LOC CONTROL PANEL c INTO Bun 255 OUTSIDE LIGHT AUI
31. 04 SCALE SHEET 07 OF 18 2 7
32. Inspect metering systems Clean accumulated stalks and old grain Start up dryer and check operating controls __ Other Itemize END OF SEASON SHUT DOWN PROCEDURE _ Start unload and and empty all grain from dryers Clean out grain cushion on plenum roof under fill spout Clean plenum roof Clean off grain exchangers Clean out divider hopper between heating and cooling section Clean inside cooling sheets and cooling floor Remove all grain and trash from unload section of dryer Open emergency grain discharge doors and drain doors in Zimmerman dryers Open drain valve in gas train Cover burner with a tarp or plastic sheeting 29 TROUBLE SHOOTING Tower Dryer Ops amp Service TROUBLESHOOTING The GSI amp Zimmerman Tower dryers are designed to be self diagnosing Most electrical or operating problems are displayed on the screen of the operator interface and the problem area is graphically high lighted Always insure that either 240 or 480 volt 3 phase power is being provided to the dryer All motor starters coils and the burner circuitry operate at 120v AC All of the safety circuit on the dryer operates at 24v DC Listed below are potential trouble shooting issues associated with the dryer and possible solutions to the problems TROUBLESHOOTING DRYING ISSUES Problem What to do Low dryer capacity Check to make sure the dryer is always full of grain Check all grain columns to make sure they are
33. TROUBLESHOOTING OIU SCREEN MESSAGES Message What to do LOST COMM TO MICRO Cycle the power OVERHEAT AT TOP LEFT POSSIBLE FIRE Check overheat condition and Term 101 OVERHEAT AT TOP RIGHT POSSIBLE FIRE Check overheat condition and Term 102 OVERHEAT AT MID LEFT POSSIBLE FIRE Check overheat condition and Term 103 OVERHEAT AT MID RIGHT POSSIBLE FIRE Check overheat condition and Term 104 OVERHEAT AT LOWER LEFT POSSIBLE FIRE Check overheat condition and Term 105 OVERHEAT AT LOWER RIGHT POSSIBLE FIRE Check overheat condition and Term 106 OVERHEAT AT INSIDE LEFT POSSIBLE FIRE Check overheat condition and Term 107 OVERHEAT AT INSIDE RIGHT POSSIBLE FIRE Check overheat condition and Term 108 OVERHEAT AT PLENUM POSSIBLE FIRE Check overheat condition and Term 109 OVERLOAD TRIPPED TRI STARTER Check Term 300 OVERLOAD TRIPPED BLOWER 1 STARTER Check Term 301 OVERLOAD TRIPPED BLOWER 2 STARTER Check Term 302 OVERLOAD TRIPPED BLOWER 3 STARTER Check Term 303 OVERLOAD TRIPPED BLOWER 4 STARTER Check Term 304 AUXILIARY STUCK CLOSED TRI STARTER Check Term 200 AUXILIARY STUCK CLOSED BLOWER 1 STARTER Check Term 201 AUXILIARY STUCK CLOSED BLOWER 2 STARTER Check Term 202 35 TROUBLESHOOTING Message AUXILIARY STUCK CLOSED BLOWER 3 STARTER AUXILIARY STUCK CLOSED BLOWER 4 STARTER AUX CONTACT FAILED TO CLOSE TRI STARTER AUX CONTACT FAILED TO CLOSE BLOWER 1 STARTER AUX CONTACT FAILED TO CLOSE BLOWER 2 STARTER AUX
34. bonnet washer cutaway view to 1 core small end up show positioning of retainer in solenoid base gasket gasket recess plugnut assembly CD retainer gasket adapter retainer gasket adapter disc holder 4 disc assembly 44 Air Only Construction Hia 5 disc spring disc holder d e dd Adapter T spring Adapter Figure 2 Series 8202G solenoids Figure 3 3 Way Construction Form No V6584R8 Page 3 of 4 ASTA 50 Hanover Road Florham Park New Jersey 07932 www ascovalve com Torque Chart Open Frame Solenoid Open Frame Solenoid Open Frame Solenoid with Screw Terminals with DIN Terminals Indicates parts supplied with 1 4 Spade Terminals Socket head screw is in Termination Module used for grounding Kit No K256104 See torque chart screw terminal FA gasket 9 adapter DIN terminal adapter terminal 9 block tapped hole for socket head 710 92 grounding screw grounding screw socket head screw not included 5 32 hex key wrench 5 32 hex key wrench Figure 4 Open Junction screw terminal block 4 cover screw with 1 4 Spade Terminals see note or Screw Terminals See torque chart above cover gasket grounding screw junction box gasket and cup washer Note Junction box with screw terminals shown With screw terminal block removed remaining parts junction box with comprise the junction box for 1 2 conduit connec
35. 1085 Jus f os og 569 us 10 0 4017 Hex Head Screw Stainless Stee of e 19959 Jus Hex Head Screw Class A Stainless Stee 4 1755 outside Corner Back Up Bar uminom T 1799 inside Corner Back Up Bar Aluminum 20 1051059 Jus Stantess Steel Lockwasher NOTE These items included with fastener kits See pages 5567 amp 5568 for fastener kit details Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice CORPORATION MUNCIE INDIANA USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Series NP LE AIRFLO Burners Page 5550 S 9 Maintenance and Component Identification Spare Parts NIS NP 2 LE To order replacement parts See burner nameplate and indicate burner type Sketch burner arrangement as viewed from casting side Specify replacement items required from diagrams above Specify quantity of each and assembly numbers from table below Quantity Required for Indicated Section Part Description 18 Str w w w w 6 Str 12 Str 1051634 24 Str 12 6 6x6 1051634 1051636 Elbow l d Burner Body 1051636 qty 2 1051640 1051644 1051638 1051642 Asby No o CT xing Pite msde Comer
36. 55 503 504 Speed Reducer Single Disc Multiple Reduction Reducers SM CYCLO single reduction Models No 6060 6095 Multiple reduction SM CYCLO Reducers are combi employ the use of a single planetary gear Cycloid nation of standard reduction mechanism assemblies Disc and a balance weight connected using an intermediate shaft Part No 5 01 and intermediate cover Part No 55 between them Table A 2 Frame Sizes and Ratio Combination of Double Reduction Models Frame Size Combination Reduction Ratio Combination 17508 6175 81750 5175 2008 4120 DA ras sus 6125 du 6186 a Note 1 For frame sizes 6205DA or DC 8285D4 DB or DC second stage ratio is 59 and first stage ratio is 87 LUBRICATION Standard Type Mounted Reducer Slow Speed Shaft Horizontal Table A 3 Horizontal Mounted Single Reduction Reducers a amp s 15 17 28 muxo 61106115 61206125 612H 61306135 6140 6145 46160 6165 GISH 61706175 6190 6185 61906195 87 Table A 4 Horizontal Mounted Double Reduction Reducers zur 43 4 14 ar i da y E HS EM nick secs o e i ned o 16008 016508
37. 6 Outside Light Switch turns the dryer service light on or off On AUTO the light turns on when the dryer is running and off when a shutdown occurs 7 Load Switch controls the filling of the dryer The ON position initially fills the dryer The OFF position turns the conveyor off shuts the slide gate The AUTO position enables automatic fill control and the OUT OF GRAIN TIMER On dryers filled on demand with a conveyor or slide gate In the ON or AUTO position the fill conveyor turns on slide gate opens when the dryer is low on grain and off closes when the dryer is full In the AUTO position only the dryer will auto matically shut down when the dryer is low on grain and the OUT OF GRAIN TIMER expires On choke filled dryers In the AUTO position only the dryer will auto matically shut down when the dryer is low on grain and the OUT OF GRAIN TIMER expires Tower Dryer Ops amp Service In the ON or OFF position the OUT OF GRAIN TIMER IS DISABLED The LOAD switch is illuminated whenever the load conveyor is running 8 Low Grain Light flashes when the grain level is low and the OUT OF GRAIN TIMER is running The LOW GRAIN light is on steady when the timer expires 9 Blowers Switch turns the blower s on or off On multifan dryers the blowers start sequentially The lighted switch flashes during blower start up The switch is illuminated when all of the blower airflow switches close indicati
38. FULLY CLOSED VERTICAL REFERENCE FULLY CLOSED 160 FULLY OPEN 160 DEGREE STROKE SPRING RETURN MOTORS 90 DEGREE STROKE M7261 M7274 M7281 M7284 M7294 VERTICAL REFERENCE FULLY CLOSED VERTICAL REFERENCE 45 FULLY VET FULLY OPEN 90 DEGREE STROKE 160 DEGREE STROKE NON SPRING RETURN MOTORS M5509 Fig 2 Motor shaft position at limit of rotation viewed from motor power end 63 2202 4 SERIES 72 MODUTROL IV MOTORS Adapter Bracket The 220738A Adapter Bracket positioned between the motor and the equipment raises motor shaft height by 0 75 in 19 mm to match that of previous Modutrol Motor models The following applications require this bracket e 0607 External Auxiliary Switch Damper linkage applications requiring added clearance to allow Crank arm rotation through the downward position Sufficient damper linkage to reach the motor shaft All valve linkages except the Q5001 NOTE When the bracket is not used in a replacement application the damper linkage requires adjustment for the new shaft position To mount the motor with the bracket 1 Mount the bracket to the equipment with existing or standard bolts 2 Using the provided bolts mount the motor to the bracket threaded holes See Fig 3 For valve linkage applications other than the Q5001 1 Mount the bracket to the linkage 2 Position the motor on the bracket to align the motor shaft
39. 480 or 575 volt 60 Hz power or 380 volt 50 cycle power The dryer is furnished with a power panel equipped with a main circuit breaker disconnect and motor starters and branch breakers for the individual blower motors Standard blower motor starting is across the line starting When necessary the dryer can be equipped with optional soft start motor starting equipment No dry grain conveyor is furnished with the dryer however a 10 hp motor starter for a dry grain conveyor is furnished in the control panel If the dryer is ordered with a demand fill a 10 hp motor starter 1s also provided in the control panel to operate a wet conveyor GSI personnel will perform all necessary dryer wiring from the power panel to the dryer The customer is responsible for bringing electrical power into the main circuit breaker and also for wiring the unload and load conveyor m Tower Dryer Ops amp Service A wiring diagram is furnished with each dryer Extensive safety controls are used on the dryer for equipment and personnel protection and should not be bypassed Fuel The burner is designed to burn either natural gas or propane vapor fuel The volume of fuel supplied must be sufficient to maintain a minimum of 7 to 10 psi pressure when the burner 15 operating at rated capac ity When propane is used as the fuel source external propane vaporizers must be used in order to supply vapor gas to the dryer Vaporizers must be s
40. Motor OL Current 0 0 Drive Rated Ampsx2 0 1 Amps Based on Drive Rating Set to the maximum allowable motor current P034 Minimum Freq 0 0 240 0 Hz 0 1 Hz 0 0 Hz Sets the lowest frequency the drive will output continuously P035 Maximum Freq 0 240 Hz 1Hz 60 Hz Sets the highest frequency the drive will output P036 Start Source 0 5 NU oe 0 3 Wire 2 W Hi i Sets the control scheme used to start the drive qe 5 Comm P ig t When active the Reverse key is also active unless disabled by A095 Reverse Disable P037 Stop Mode 07 0 CPX 4 0 Active stop mode for all stop sources e g keypad Coast 5 Coast run forward I O Terminal 02 run reverse 1 0 2 DC Brake 6 DC Brake Terminal 03 RS485 port except as noted below DCBrkAuto CF 7 DC BrakeAuto Important I O Terminal 01 is always a coast to stop input except when P036 Start Source is set for 3 Wire control When in three wire control I O Terminal 01 is controlled by P037 Stop Mode 1 Stop input also clears active fault P038 Speed Reference 10 5 ds an 0 InternalFreq Preset Freq rh me source of the speed reference to the IAN Input CCo Pore Important When A051 or A052 Digital Inx Sel is set to option 2 4 5 6 13 or 14 and the digital input is active A051 or A052 will override the speed reference commanded by this parameter
41. Note Consult the factory before operating units stored for periods greater than 1 year TROUBLESHOOTING AND REPAIR This troubleshooting guide is to help you identify and overcome common problems of reducers If you have a problem not listed below please consult factory REMEDY Check rated capacity of reducer replace with unit of sufficient capacity of reduce load Check lubricant level and adjust up to Dene ere d eaten recommended levels Improper Check lubricant level and adjust down to Lubrication cessive lubrication recommended level i Flush put and refill with correct lubricant as Wrong lubricant recommended Loose Weak mounting Inspect mounting of reducer Tighten loose bolts Fauncdatioan Structure andor reinforce mounting and structure Bolts Loose hold down batts Tighten bolts Crverinading unit may Disassambie and replace disc Recheck rated capacity of reducer May due to lack of Replace bearing Clean and flush reducer and fil Failure of lubricant with recommended lubricant Bearings i Overload Check rated capacity of reducer replace with unit af sufficient capacity or reduce load of lubricant in the reducer not property maintained Insufficient Check lubricant level and adjust to Lubricant factory recommended level Disassemble and replace ring gear pins and Overloading of reducer rollers Gheck load on reducer Input Shaf
42. Stroke Fixed 90 or 160 models available Other models available with field adjustable strokes from 90 to 160 Stroke adjusted by means of cams located in the wiring compartment Timing Nominal 30 seconds for 90 stroke and 60 seconds for 160 stroke Dead Weight Load On Shaft 200 Ib 91 kg on motor power or auxiliary end maximum combined load of 300 136 kg Motor Rotation Closed Counterclockwise rotation limit as viewed from motor power end Open Clockwise rotation limit as viewed from motor power end Mechanically Normally Closed Spring return Normally closed motors rotate to closed position on power loss Mechanically Normally Open Spring return Normally open motors rotate to open position on power loss Electrically Normally Closed Both spring return and non spring motors return to closed position on minimum signal Electrically Normally Open Both spring return and non spring return motors return to open position on minimum signal Ambient Temperature Ratings 40 to 150 F 40 to 66 C Shaft 3 8 in 9 5 mm square Approvals Underwriters Laboratories Inc Listed File No E4436 Guide No XAPX Canadian Standards Association Certified General listed File No LR1620 Guide No 400 E 63 2202 4 4 Accessories 198162AA Internal Transformer 120 208 240 Vac 50 60 Hz primary 24 Vac secondary 198162EA Internal Transformer 120 Vac 50 60 Hz primary 24 Vac secondary 198162G
43. Terminals 01 and 11 Remove this Dir Run REV o o jumper when using I O Terminal 01 Digital Common as a Stop Input Digital Input U 2 Two wire control shown For three Digital Input 2 wire control use a momentary input 4 on Terminal 02 to an command a start Use a maintained 10V DC input for Terminal 03 to 0 10V In change direction Relay N O Analog Common Relay Common 4 20mA In Potentiometer must be Relay N C RS485 Shield 1 10k ohm j 2 Watt Min 01 02 03 04 05 06 2 0 RS485 __ 30V DO 125V AC F240V SNK 1 12 13 14 15 16 bs Y Resistive 3 3 0A D D D D D m Inductive 0 5A j BHO 1 V 8 1 No Signal Default Description Param Ri Relay Fault Normally open contact for output relay A055 R2 Relay Common Common for output relay R3 Relay Fault Normally closed contact for output relay A055 Sink Source DIP Switch Source SRC be wired as Sink SNK or Source SRC DIP Switch 1 The factory installed jumper or a normally closed input 1 01 Stop Coast must be present for the drive to start i 02 Start Run FWD Not Active P036 P037 Command comes from the integral keypad by default 03 REV Active disable reverse operation see A095 Reverse Disable 2 P037 _ For digital inputs Electronically isolated with digital inputs 04 Digital Common from analog 05 Digital
44. Valves and Series Q adjustable gradient Flow Control Valves the minimum flow position is set by their minimum stop screw This adjustable stop is located on the side of the screw carrier of Series Q Valves and at the base of crank arm of Series CV Valves Screwing in on the minimum stop screw produces a physical stop on the quadrant s travel that prohibits valve from being completely closed off Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice CORPORATION MUNCIE INDIANA USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Tower Dryer Ops amp Service COMPONENTS IV COMPONENT MANUALS GAS SHUT OFF VALVE Page 6102 Normally open or normally closed valves 4 Series 5000 SCP 1 5 Series STO M position L position L Sanctioned service valve approvals 4 Series 7000 position L FM Factory Mutual sanctioned UL Underwriters Laboratories sanctioned CGA Canadian Gas Association sanctioned IRI Industrial Risk Insurers approvable for block bleed vent systems Contact your Maxon sales representative for international sanctions information Handles flowing fluid temperatures Rising stem bodies from 20 F 28 C to 140 F 60 C Swinging gate bodies from 20 F 28 C to 550 F 288 C Any ambient temperature from 20 F 28 C to 140 F 60 C Valve body
45. 121 62 150 50 121 62 150 52 121 10 178 50 121 16 058 52 121 16 550 51 903955 121 10 022 50 121 16 017 50 121 16 150 53 121 16 150 55 121 10 178 50 121 16 058 52 934007 902418 905481 904448 1190647 121 22 130 51 902922 902698 904085 904079 121 60 598 50 121 20 598 50 121 62 598 50 121 22 598 50 FOR BACK PRESSURE MODELS 121 22 102 52 121 22 103 50 ILL DESCRIPTION PART NUMBER 12a Piston 12b Seal Diaphragm Buna N 12b Seal Diaphragm Viton 12c Plate 12d Stem stainless steel Molded Valve Buna N 45 50 Duro Molded Valve Viton A 65 75 Duro Valve Wing Valve Wing stainless steel Tetraseal or O Ring 32 4 x 4 Orifice 31 4 dia steel Orifice 31 4 dia stainless steel Retaining Ring stainless Tetraseal or O Ring 5 x 51 4 Seal Diaphragm Ring Gasket 3 Model 121 only Travel Indicator specify scale 091 00 008 02 Pliers for retaining ring 19a Truarc 0600 121 20 053 50 121 20 364 50 121 20 364 51 121 20 010 50 121 20 016 51 121 20 311 50 121 20 311 51 121 20 018 50 121 20 018 51 904200 121 20 023 50 121 20 023 51 904658 1190648 934328 121 20 008 50 121 20 104 50 091 00 365 00 FOR BACK PRESSURE MODELS Stem Back Pressure Add Item 47 Valve Seal Diaphragm and Stem Assembly Item 12d above Stem substitute 12a Piston 12b Seal Diaphragm Buna N 12b Seal Diaphragm Viton 12c Plate 12d Stem steel 12d Stem stainless steel Molded Valve
46. 121 86 598 51 FOR BACK PRESSURE MODELS Item 12d above Stem Stainless Steel substitute 121 16 016 55 121 16 102 52 121 16 103 50 121 16 598 52 121 86 598 54 121 86 598 55 121 16 511 51 invensys Energy Metering Servicing General Instructions T 2 Make sure the regulator is entirely depressured before servicing Carefully note location and position of all disassembled parts to be certain reassembly is correct Inspect each one carefully and re place those that are worn or damaged or otherwise unsatisfactory A moderate application of lubricant to O ring 13 will help assure free stem movement and a tight seal Similar application of lubricant to the other O rings or Tetraseals will help assure their tightness Do not use petroleum base lubricants Bolted connections should be tightened evenly and firmly Carefully tighten diaphragms into place Bolts must be tight enough to prevent leakage but not so tight that the diaphragm material is crushed or damaged Upon completion of servicing make certain that regulator installa tion is entirely free of leaks Service Valve 15 2 3 4 Remove bolts 38 and remove bottom cap 37 and Tetraseal 32 Remove retaining ring 16a Use Truarc 0200 pliers Invensys Part No 1190646 Remove both halves of valve holder 16b Remove valve 15 wave washer 14 will probably also come off do not lose it To reassemble replace pa
47. 205 Check Term 206 Check Term 207 Check Term 306 Check Term 115 Check BCU and Term 114 Check Term 113 Check if pilot or Maxon valves stuck open and check flame rod BCU and Term 114 Check Term 111 Check gas pressure and Term 110 Check Term 111 Check Term 110 Reset and try again Check the RTD wiring Check the RTD wiring Check Term 307 Check Term 308 Check Term 307 Check Term 308 Clear dry path and check Term 309 Clear hopper and check Term 310 Check the drive and Term 208 Check Term 305 Clear wet path and check Term 311 Check Term 209 Check Term 210 Check Term 211 Check Term 212 Check the unload device and Term 313 Check Term 215 Check Term 214 Tower Dryer Ops amp Service TROUBLESHOOTING Message AUXILIARY STUCK CLOSED TOP WET CONVEYOR CONTACT FAILED TO CLOSE DRY CONVEYOR CONTACT FAILED TO CLOSE AUX DRY CONVEYOR CONTACT FAILED TO CLOSE DRY LEG CONTACT FAILED TO CLOSE TOP DRY CONVEYOR CONTACT FAILED TO CLOSE AUX WET CONVEYOR CONTACT FAILED TO CLOSE WET LEG CONTACT FAILED TO CLOSE TOP WET CONVEYOR BINDICATOR ERROR UBS closed while LBS still open SHUT DOWN OUT OF GRAIN Occurred at DRY SENSOR ERROR MOISTURE SIGNAL OUT OF RANGE DRY SENSOR ERROR GRAIN TEMP SIGNAL OUT OF RANGE WET SENSOR ERROR MOISTURE SIGNAL OUT OF RANGE WET SENSOR ERROR GRAIN TEMP SIGNAL OUT OF RANGE COLUMN GRAIN RTD SENSOR ERROR RTD OUT OF RANGE SHUT DOWN BY MOISTURE CONTROLLER FAILED TO MAINTAIN TO
48. Buna N 45 50 Duro Molded Valve Viton A 65 75 Duro Valve Spacer Tetraseal or O Ring 45 4 x 5 Orifice 47 32 dia steel Retaining Ring Orifice 47 37 dia Stainless steel Retaining Ring stainless O Ring 61 4 x 61 2 Seal Diaphragm Ring Gasket 4 Model 121 only Travel Indicator specify scale 091 00 008 02 FOR BACK PRESSURE MODELS Item 12d above Stem substitute Stem Back Pressure Add 47 Valve Seal Diaphragm and Stem Assembly Pliers for retaining ring 19a Truarc 0600 121 20 016 53 121 20 511 50 121 22 053 50 121 22 364 50 121 22 364 51 121 22 010 50 121 22 016 50 121 22 016 51 121 22 311 50 121 22 311 51 121 22 038 50 950625 121 22 023 50 904429 121 22 023 52 121 22 130 52 1190648 934337 121 22 008 50 121 22 104 50 091 00 365 00 121 20 016 53 121 20 511 50 13 invensys Energy Metering Servicing General Instructions Same general instructions as listed on Page 6 bag Service Valve 15 2 e De Remove bolts 38 and remove bottom cap 37 Remove retaining ring 16a Use Truarc 0400 pliers Invensys Part No 1190647 Remove both halves of valve holder 16b Remove valve 15 and wing 15a or spacer wave washer 14 will probably also come off do not lose it To reassemble replace parts in reverse sequence To Service Main Diaphragm 11d 1 2 Remove top cap 1 Release adjustment 3 count the turns of ad
49. Maximum Allowable Viscosity Allow Easy Starting Forced Lubrication For Vertical Units Table A 15 Pump Type 6160 6165 8170 6175 See A205 8215 5 6180 8185 4150 6196 Table 4 5 1245 6256 6266 6275 eL 10 24 Hours Day ee atmosphere ot Active Gas Plunger Pump Lubrication The plunger pump Fig A 2 Part 42 is automatically operated by a cam Fig A 2 Part 40 fitted on the slow speed shaft Fig 2 Part 1 01 The number of pumping cam teeth required is in direct relation to the reduction ratio and frame size Please consult the factory for input speeds other than standard arici ri 87 Shati 8275 HAVES HP 0 4 kW 4 heus aL annie wl Positive Displacement Trochoid Pump Lubrication Forced oil lubrication is accomplished by using a positive displacement pump and motor that reauires an additional electric power source It is recommended that the main motor be interlocked with the pump motor to avoid operation without lubrication The pump must be started 30 seconds or longer before the main motor is operated Notes 1 Please consut the factory for quantities when the reducer gearmotor mounted tn any other position or angle 2 Consult the factory when using an Inverter 3 A relief valve pressure set at 42 7 psi 3 kgf cm a standara attacnment on the trochoid pump OIL LEVEL DIMENSIONS Foot Mount Horizontal Type
50. The following is an example of basic integral keypad and display functions This example provides basic navigation instructions and illustrates how to program the first Program Group parameter Step 1 When power is applied the last user selected Display Group parameter number is briefly displayed with flashing characters The display then defaults to that parameter s current value Example shows the value of d001 Output Freq with the drive stopped Press Esc once to display the Display Group parameter number shown on power up The parameter number will flash Press Esc again to enter the group menu The group menu letter will flash Press the Up Arrow or Down Arrow to scroll through the group menu d P and A Press Enter or Sel to enter a group The right digit of the last viewed parameter in that group will flash Press the Up Arrow or Down Arrow to scroll through the parameters that are in the group Press Enter or Sel to view the value of a parameter If you do not want to edit the value press Esc to return to the parameter number Press Enter or Sel to enter program mode to edit the parameter value The right digit will flash and the Program LED will illuminate if the parameter can be edited Press the Up Arrow or Down Arrow to change the parameter value If desired press Sel to move from digit to digit or bit to bit The digit or bit that you can change will flash 10 Press Esc to cancel a change T
51. and 4 Model 121 invensys Energy Metering Condensed Parts List 3 and 4 ILL DESCRIPTION PART NUMBER Seal Cap for 121 16 Seal Cap for 121 12 Seal Cap Gasket for 121 16 Tetraseal for 121 12 21 4 x 23 Adjustment Spring Button for 121 12 Thrust Washer Spring see table Spring Ranges 121 16 Diaphragm Assembly 11a Elastic Stop Nut 52 NTE 066 11b Bottom Spring Button 11c Diaphragm Pan 11d Diaphragm Buna N 11d Diaphragm Viton 11f Seal Washer 11h Diaphragm Stud stainless steel 121 12 Diaphragm Assembly 31 2 w c to 2 psi outlet pressure 11a Elastic Stop Nut 29 NE 066 11b Bottom Spring Button 11c Diaphragm Pan 11d Molded Diaphragm Buna N 11d Diaphragm Viton 11f Seal Washer 11h Diaphragm Stud stainless steel O Ring Buna N 3 8 x 1 2 O Ring Viton s x 1 2 Wave Washer Retaining Ring Pliers for retaining ring 16a Truarc 0400 Valve Holder split pair required stainless steel O Ring 5 x 5 4 O Ring Viton s x 3 4 Tetraseal or O Ring 4 s x 4 s Tetraseal or O Ring 23 4 x 3 Repair Kits consisting of Buna N Main and Seal Diaphragm Buna N Molded Valve plus Wave Washer and Retaining Ring Buna N O Rings Tetraseals and Gaskets For 3 121 16 3 121 12 4 121 16 4 121 12 Item 14 above Wave Washer substitute Poly U Disk Retainer 138 02 005 01 143 16 005 00 120 08 066 00 905241 143 16 009 00 141 10 160 01 908561 121 62 022 50 121 62 017 50
52. gt WET CONV m ay Y UTSIDE LIGHT e O 1 V UE WE LIN DEA AUN I PALME E 2 Me DEAD T HIGH GRAIN LEVEL LUC DEAD EIN A ur UN EX WET CUNV C DEAD TIN I Fu er eiaa TOR WET I PILOT LIGHT TUTSIDE LHC DEAD UN TH EG A A ol GROUP 1004 E ILLINOIS ST ASSUMPTION IL 62510 TITLE TOWER DRYER CONTROL WIRING DIAGRAM MAT L DESC P N M e NO a
53. restarted by turning the BURNER switch OFF then back ON Cock and open the Maxon valves After the pilot is ignited the main burner can be lit by cocking and opening the two Maxon gas shutoff valves These valves will automatically open on dryers equipped with motorized Maxon Valves The main burner will light and the dryer s plenum temperature will be automatically controlled by the modulating motor and maintained at the selected temperature 12 1 Open firing valve Canadian dryers only 13 14 Let plenum come up to temperature and begin drying Depending upon ambient condi tions the dryer may take 10 minutes or more to reach the drying temperature Start unload system Before discharging grain from the dryer first make sure all dry legs and con veyors are operating ahead of the dryer Turn the UNLOAD CONVEY OR selector switch to the The metering device will not run unless the un oad conveyor is also running ON position to operate the dry grain conveyor leading from the dryer Turn the METERING DE VICE selector switch to the FORWARD position to start discharging grain from the dryer 15 DRYER START UP Set Unload Rate Moisture Control Tem perature manually While operating the dryer in manual mode set the unload rate by touching the U L Rate box on the LCD display On the pop up keypad enter the new unload rate and press return 16 Check discharge moisture content after 10 17 m
54. speed setting 1s most responsible for the first pass of drying Therefore set the manual unloading speed as close as it should be for the grain currently in the dryer before switching to AUTO control mode The manual speed setting does not have to be adjusted after the controller 1s switched into AUTO mode Tower Dryer Ops amp Service TRI POINT MOISTURE CONTROLLER V Alarms The controller checks the sensors and control status regularly If abnormal conditions are detected a corresponding alarm will go off an alarm message will come up on the main screen and the dryer will be shut down ALARM CAUSES SOLUTION Moisture out of range the moisture coming out of the dryer was 2 5 above or below the set point for more than one hour under AUTO control mode Dry sensor error sensor reading is less than 6 or higher than 40 Dry grain temperature out of range 0 300F Wet sensor error sensor readng 15 less than 6 or higher than 40 Wet grain temp out of range 0 300F Column grain temperature RTD out of range 0 300F Sensor box plugged and sensor was not covered by grain Dry sensor out of calibration Too big swing of moisture coming into the dryer Bad wiring Bad sensor Bad circuit board Bad wiring Bad sensor Bad circuit board Bad wiring Bad sensor Bad circuit board Bad wiring Bad sensor Bad circuit board Bad wiring Bad sensor Bad circuit board Clear the sampler and sensor box
55. to 28 w c Orange 3 O D 121 62 021 53 1 2 psi to 11 4 psi Yellow 121 62 021 56 3 and 4 1 psi to 2 psi Black 143 16 021 07 40 and 15 Model 121 12 11 2 psi to 3 psi Cadmium 143 16 021 08 Requires High Pressure Spring Adjustment T9 121 is 40 psi and 4 121 is 15 psi x not available Atmospheric Regulator or Zero Governor 2 4 1 and 1 4 121 8 11 2 w c vacuum 1 2 w c to 11 2 w c ata 121 10 021 50 Main Spring Red Black 143 82 021 00 Counterspring 120 10 021 10 3 and 4 Model 121 16 11 2 2 and 21 2 121 12 1 w c vacuum 1 w c to 11 2 w c and 4 121 16 11 4 w c vacuum 11 4 w c to 11 4 w c Main Spring only 121 62 021 54 invensys Energy Metering Differential Regulator 3 4 1 and 11 4 121 8 11 2 2 and 21 2 121 12 3 and 4 121 12 9 4 thru 21 2 121 8 9 4 thru 21 2 121 8 11 2 2 and 21 2 121 12 11 2 thru 4 121 12 DIFFERENTIAL PRESSURE RANGE 31 2 to 61 2 w c 5 to 81 2 w c 6 to 14 w c 12 to 28 w c 1 psi to 2 psi 31 2 to 6 w c 5 to 81 2 w c 6 to 14 w c 12 to 28 w c 1 psi to 2 psi 31 2 to 61 2 w c 5 to 81 2 w c 6 to 14 w c 12 to 28 w c 1 psi to 2 psi 11 2 psi to 3 psi 9 121 16 is 40 psi and 4 121 16 is 15 psi Back Pressure Regulator or Relief Valve SPRING COLOR Red Black Blue Black Green Black Green Orange 2 O
56. to your distributor Be sure to includethe SERIAL NUMBER and MODEL NUMBER This information along with our production records will enable us to provide you with the correct replacement unit or parts Name Plate on SM CYCLO a all PA ETTTES CHESAPEAKE CLO 20 MODEL cone of Storage And Operation After Storage Storage 6 Months 1 Year Oil Lubricated 1 Completely fill unit s with a rust preventive oil 20 or equivalent or a circulating oil Shell VSI No 100 or equivalent 2 At approximately 3 month intervals rotate the input shaft a sufficient number of times to insure all internal components remain coated The higher the ratio the greater the amount of rotations needed for proper lubrication Grease Lubricated Grease lubricated models do not require any special attention during storage Inspect unit before operation Note For both the Oil Lubricatedand Grease Lubricated models if units are to be stored for a period exceeding 1 year consult factory Operation After Storage 6 Months 1 Year Oil Lubricated 1 Completely drain the rust preventive or circulating oil from unit 2 Flush unit with the recommended operating oil as shown in Table A 11 3 After flushing fill the unit to the proper oil level with the recommended lubricating oil Grease Lubricated Add gt of the recommended quantity of new grease as shown in Table A 10
57. you must provide either a N O aux contact from your starter or a leg monitor contact that closes when the leg is running OK Connect the contact as shown in the draw to the right 3 Do not forget to select the DRY LEG option from the DRYER SETUP screen of the operator interface after the DRY LEG is installed STARTER DCC 24VDC stop IN12 402 115VAC L 2 54 Xx Start IN13 PLC 24VDC PLC 24VDC 211 Y on OUT6 24VDC er D 211 x x DRY CONVEYOR 400 Y N note located in control panel note located in power panel note located in power panel Interlocked with the TOP DRY CONVEYOR AUX DRY CONVEYOR ACK 21 0 If there is another conveyor after the Dry Leg we call this device TOP DRY CONVEYOR 1 You may purchase the optional starter push buttons amp pilot light installed in the Y dryer panel which are connected as shown in the left and center draws 2 If you have an existing starter system for the Top Dry Conveyor function connect aux contact of your device as shown in the draw to the right AUX DRY CONVEYOR 401 3 Do not forget to select the TOP DRY CONVEYOR from the DRYER SETUP screen of the operator interface after the TOP DRY CONVEYOR is installed Interlocked with the STARTER TOP DRY CONVEYOR ACK 211 DCC 24VDC stop IN16 403 115VAC coil 1 2 x gt x 0625 00 20812 000 0158 ANGLES 1
58. 02 143 16 021 04 143 16 021 05 143 16 021 06 143 16 021 07 143 16 021 08 143 16 021 08 143 16 021 13 143 16 021 03 143 16 021 04 143 16 021 05 143 16 021 06 143 16 021 07 143 16 021 08 121 62 021 50 121 62 021 51 121 62 021 52 121 62 021 53 121 62 021 56 gt Op m 11 2 2 and 2 Model 121 ZU Standard Differential Atmospheric or Zero Governors 22 D NEN 1 NPT Vent N SON connection 1 p uc _ a ter lt lt A 3 5 gt 1 NPT Vent 21 MINSA L i N b connection CUN IR ND MC ITN eis een 4 21 2 c 2a Op 25 E gt 14 Vent S a 3 connection 28 y 1 4 NPT Control 25 gt line connection E lt SAE ae AGES 2 Ea 5 121 8 Standard 7 AU VAR ee o DIETE SS eU E E PIPE SIZES inlet x outlet E NE 11 x 112 gt E 25 5 9 SEL 2 SR SSS pues High Pressure NEN 2 2 2 Screwed NPT 87 Spring Adjustment Ga c 21 5 x 215 Gea 19 18 ENS y 2 x 2 Flanged ANSI 125 Ib FF o 9 1
59. 10 months continuous operation Every 2 years Normal op eration ever 8 10 months continuous operation Beginning of season annually Change grease in box every 3 5 years Beginning of season Change every 2 years Beginning of season Change every 10 000 hours or 2 years Lubrication of motors Operate motor for 20 minutes Clean grease fitting Remove grease relief plug anc using a low pressure grease gun pump in the required grease After relubricating allow motor to run for 10 minutes before replacing relief hardware Do NOT overgrease 27 MAINTENANCE Tower Dryer Ops amp Service 28 Tower Dryer Ops amp Service MAINTENANCE PRE SEASON SERVICE CHECKLIST Lubricate blower bearings _____ Lubricate blower motor bearings if needed _____ Check blower belts and adjust 1f necessary gt Clean burner ports ____ Inspect flame rod and spark ignitor _____ Check oil levels in gearboxes ____ Inspect divider hopper between heat and cooling section Clean if necessary ____ Inspect Bindicator grain level switches Inspect metering system access door cover seals ______ metering system access door cover hold down latches ______Lube Modutrol motor linkage _____ Check butterfly operation in modulating valve _____ Check gas pressure gauges ____ Check interior of Maxon shutoff valves for corrosion Clean if necessary _ Clean control and power panels tighten loose connections and check for leaks
60. 1190648 Remove orifice 19 through top opening To reassemble replace parts in reverse sequence On reassembly be sure that 19a is fully seated in its groove Also beveled edge of 19a faces downward toward bottom cap 37 To Service Seal Diaphragm 12b 1 2 3 4 Remove valve 15 per section To Service Valve 15 Remove main diaphragm assembly 11 per steps 1 through 4 To Service Main Diaphragm 11d Remove bolts 25 and lower diaphragm case 24 Remove bolts 29 and centerpiece 27 and then remove seal diaphragm assembly 12 To disassemble 12 unscrew piston 12a from stem 12d Use a spanner wrench in notch in skirt of piston this can also be done by inserting a standard 32 Allen wrench the notch To reassemble replace parts in reverse sequence Make certain that fabric side of seal diaphragm 12b faces upward and rubber side faces downward toward body Do not pinch loop in seal diaphragm 12b between ring 33 and centerpiece 27 Also rounded edge of 33 faces upward toward seal diaphragm 12b Periodic Inspection Regulators are pressure control devices with numerous moving parts subject to wear that is dependent upon particular operation conditions To assure continuous satisfactory operation a periodic inspection schedule must be adhered to with the frequency of inspections determined by the severity of service and applicable laws and regulations Invensys Energy Metering
61. 265 11 05 5 3 10 140M C2E B63 1100 009 30 22A A3P6N103 0 75 1 0 3 6 180 265 18 92 15 140M C2E C16 100 12 50 22A A6P8N103 1 5 0 0 6 8 180 265 34 1142 25 140 2 16 100 16 75 22A A9P6N103 12 2 3 0 96 180 265 48 119 6 130 140M D8E C25 100 23 1 100 200 240V AC 10 1 Phase 7 Input 0 230V 3 Phase Output 22A MP5N104 0 2 0 25 15 180 265 0 75 15 0 10 140M C2E B63 100 09 25 22A A2P3N104 0 4 0 5 23 180 265 115 6 0 10 140M C2E B63 100 09 30 22A A4P5N104 0 75 1 0 45 180 265 2 25 10 0 15 140M C2E C16 100 12 50 22A A8PON104 1 5 2 0 8 0 180 265 40 180 130 140M D8E C20 100 C23 80 200 240V AC 10 3 Phase Input 0 230V 3 Phase Output 22A B1P5N104 0 2 0 25 15 180 265 0 75 1 8 3 140M C2E B25 100 09 25 22A B2P3N104 0 4 05 23 180 265 1 15 25 6 140 2 40 100 C09 30 22A B4P5N104 0 75 1 0 45 180 265 2 25 5 2 10 140 2 10 100 09 50 22A B8PON104 1 5 2 0 8 0 180 265 40 95 15 140M C2E C16 100 12 80 22A B012N104 2 2 3 0 112 0 180 265 55 1155 25 140 2 16 100 C16 115 22 017 104 3 7 5 0 17 5 180 265 86 21 0 35 140M F8E C25 100 C23 165 380 480V AC 10 3 Phase Input 0 460V 3 Phase Output 22A D1P4N104 0 4 0 5 1 4 340 528 14 11 8 3 140M C2E B25 100 09 30 22A D2P3N104 0 75 1 0 2 3 340 528 23 3 2 6 140 2 40 100 09 40 22A D4P0N104 1 5 20 40 340 528 40 57 10 140M C2E B63 100 C09 60 22A D6PON104 2 2 3 0 6 0
62. 4 45 0 VT 8 50 13 155 9 7 5 14 20 0 088 Maximum Voltage 20 Rated Volts 1 VAC Rated Volts A089 Current Limit 0 1 Drive Amps x 1 8 0 1 Amps Amps x 1 5 A090 Motor OL Select 0 2 0 No Derate 1 Min Derate 0 2 Max Derate A091 PWM Frequency 2 0 16 0 kHz 0 1 kHz 4 0 kHz A092 Rstrt Tries 0 9 1 0 A093 Rstrt Delay 0 0 300 0 Secs 0 1 Secs 1 0 Secs A094 Start At PowerUp 0 1 0 Disabled 1 Enabled 0 A095 Reverse Disable 0 1 0 Rev Enabled 1 Rev Disabled 0 A096 Flying Start En 0 1 0 Disabled 1 Enabled 0 A097 Compensation 0 3 0 Disabled 2 Mechanical 1 1 Electrical 3 Both A098 SW Current Trip 0 0 Drive Amps x 2 0 1 Amps 0 0 Disabled A099 Process Factor 0 1 999 9 0 1 30 0 A100 Fault Clear 0 2 0 Ready Idle 1 Reset Fault 0 2 Clear Buffer A101 Program Lock 0 1 0 Unlocked 1 Locked 0 See the PowerFlex 4 User Manual on CD for more information on parameters English 11 No Parameter Min Max Display Options Default A102 Testpoint Sel 1 400 A103 Comm Data Rate 0 5 0 1200 3 9600 3 1 2400 4 19 2K 2 4800 5 38 4K A104 Comm Node 11 247 1 100 A105 Loss Action 0 8 0 Fault 2 Stop 0 1 Coast to Stop 3
63. 746 DX8 PLC AB DUX8 ISOLATED 120 ut e GT3 XXX X 761 NET AIC ADVANCED INTERFACE CONVERTER 2 3 762 L40BWA PLC MICRO 1200 24DIX16D0 Talen elelelelelele lelelelelel POWER SUPPLY 4 XXX XXXX X 2711P RDBIOCIPV 1000 DISPLAY KEY amp TOUCH PANDE 5 XXX XXXX X 711 LOGIC MODULE HOO Ge ma 6 Our XXX XXXX X P711P RGK10 1000 ANTIGLARE OVERLAY UY EQ UU O 7 1 NOTE DC IRCE SW CABLE ION 9 s GND 20 DOXCXXXX X 1761 CBL AMO TABLE ASSM AIC TO MICRO 1844111 CONTRO 21 XXX XXXX X BELDEN 9842 DH485 NETWORK CABLE 85 23 24 056 2897 7 1747 C10 GABLE SECO 1 1 25 ODEM CABLE SA ARAS RARA 26 D03 0358 US ROBOTICS MODEM 33 6K DATA FAX 1 NOTE CONNECT CHASIS GND U 2 2 5
64. 817008 617508 Ser amp 1B0DA GTHSDA 2150 021500 6235DA 623500 _ _ 8245DA 624508 62550 625508 Notes 1 Tables A 3 and 4 show the standard lubrication method when tne drive is driven at the standard input speed 2 Rat os shown in white in Taoles A 3 and 4 are unavailable for the g ven unit sues LUBRICATION Standard Vertical Mounted Reducer Slow Speed Shaft Vertical Table A 5 Vertical Mounted Single Reduction Reducer 3 11 15 f eMe 8100 8105 81188115 6120 6125 8160 6165 6170 6175 61560 6185 Forced Lubmenti n Pj 160 4195 TF Postive Displacement Pump Lubrication seo Tania 1 1 Table A 6 Vertical Mounted Double Reduction Reducer 820504 620508 av Dc ENT TUE 821504 621500 amp D 625508 K Displscement Pump Lubricaton son Table Notes 1 Please consult the factory for applications where the siow speed shaftis up 2 Tables A 5 and A 6 show the standard lubrication method when the Cyclo drive is driven at the standard input speed 3 Ratios shown in white in Tables A 5 and A 6 are unavailablefor the given unit sizes A 6 Lubricants Table A 7 Standard Greases Grease Lubricated Models Those models listed in Tables A 3 A 6 as grease lubricated are filled with grease before shipmentto the i 4 Shell Anane customer and are ready for use
65. 8215C amp 8215G do not have a diaphragm disc Supplied in Rebuild Figure 1 Series 8215 Valve Without Solenoid Page 2 of 2 Form No V5495R4 amp ASUS 50 Hanover Road Florham Park New Jersey 07932 www ascovalve com Installation amp Maintenance Instructions JRed Hat P OPEN FRAME GENERAL PURPOSE WATERTIGHT EXPLOSIONPROOF SOLENOIDS SERVICE NOTICE ASCO solenoid valves with design change letter or H in the catalog number ex 8210G 1 have an epoxy encapsulated ASCO Red Hat II9 solenoid This solenoid replaces some of the solenoids with metal enclosures and open frame constructions Follow these installation and maintenance instructions if your valve or operator uses this solenoid See separate instructions for basic valve DESCRIPTION Catalog numbers 8003G and 8202G are epoxy encapsulated pull type solenoids The green solenoid with lead wires and 1 2 conduit connection is designed to meet Enclosure Type 1 General Purpose Type 2 Dripproof Types 3 and 3S Raintight and Types 4 and 4X Watertight The black solenoid on catalog numbers prefixed EF or EV is designed to meet Enclosure Types and 3S Raintight Types 4 and 4X Watertight Types 6 and 6P Submersible Type 7 A B C amp D Explosionproof Class I Division 1 Groups A B C amp D and Type 9 E amp G Dust Ignitionproof Class Division 1 Groups E F amp G The Cl
66. CIRCUIT IN L2 SWITCHING SWITCHING D N POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQURED A CONNECTING F TO WILL DRIVE MOTOR TO FULLY OPEN FEEDBACK M5778 POTENTIOMETER Fig 7 Typical system wiring OPEN 1 LIMIT L1 12 LIMIT HOT 20 mA A ONTROLLER CCW CW WINDING WINDING CLOSE VAN IX OPEN Zi POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED DIRECTION OF MOTOR TRAVEL AS VIEWED FROM POWER END INTERNALLY MOUNTED TRANSFORMER DO NOT CONNECT POWER SUPPLY TO T1 AND T2 ZN BRAKE CIRCUITRY ONLY ON SPRING RETURN MODELS M5511 Fig 6 Series 72 motor internal wiring schematic POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQURED A CONNECTING F TO WILL DRIVE MOTOR TO FULLY OPEN M5774 Fig 8 Driving up to six motors from one 4 to 20 mA controller 9 63 2202 4 SERIES 72 MODUTROL IV MOTORS SETTINGS AND ADJUSTMENTS Zero and Span Adjustment for M7284Q and haem Motors Fig 5 Adjust the start potentiometer fully clockwise maximum zero and the span potentiometer fully counterclockwise minimum span 2 Set the controller current to the value required to drive the motor to the closed position 3 Turn the start potentiometer slowly counterclockwise until the motor begins to open This is defined as the start or zero setting 4 the controller current to the value require
67. Calibrate the sensor Run the dryer manually for one pass Check connection Change the sensor Change the circuit board Check connection Change the sensor Change the circuit board Check connection Change the sensor Change the circuit board Check connection Change the sensor Change the circuit board Check connection Change the sensor Change the circuit board TRI POINT MOISTURE CONTROLLER Tower Dryer Ops amp Service VI Access Drying History 1 Press the DATA LOG button from the main screen to open the moisture 2 Press the browse buttons to browse the history screen The controller logs record quarterly data up to 120 records i e 30 hours into the archive DRYER CONTROL CENTER IET DRYER RUNNING j O x MI This run Ohr 19 man Total Ohr 18 mn Capacity 500 EPH To 4 LI E iuri B per PATH BATH AUTO CTA OUT OO FO na 0 007 0 0 ERASE RETURN Tower Dryer Ops amp Service NOTES NOTES 20 Tower Dryer Ops amp Service Tower Dryer Ops amp Service NOTES 21 NOTES 22 Tower Dryer Ops amp Service MAINTENANCE Tower Dryer Ops amp Service MAINTENANCE PRE SEASONAL INSPECTION AND SERVICE The dryer is made of weather resistant material and 1s 8 On Zimmerman Dryers
68. Continu Last A106 Comm Loss Time 0 1 60 0 0 1 5 0 A107 Comm Format 0 5 0 RTU 8 N 1 RTU 8 N 2 1 8 E 1 4 RTU 8 E 2 2 8 0 1 5 RTU 8 2 A110 Anlg In 0 10V Lo 0 0 100 096 0 196 0 0 O A111 Anlg In 0 10V Hi 0 0 100 096 0 196 100 0 112 In4 20mA Lo 0 0 100 0 0 196 0 0 O A113 In4 20mA Hi 0 0 100 0 0 1 100 0 A114 Slip Hertz O FLA 0 0 10 0 Hz 0 1 Hz 2 0 Hz A115 Process Time Lo 0 00 99 99 0 01 0 00 A116 Process Time Hi 0 00 99 99 0 01 0 00 5 Power to drive must be cycled before any changes will affect drive operation Fault Codes To clear a fault press the Stop key cycle power or set A100 Fault Clear to 1 or 2 No Fault Description F2 Auxiliary Input Check remote wiring F3 Power Loss Monitor the incoming AC line for low voltage or line power interruption F4 UnderVoltage 7 Monitor the incoming AC line for low voltage or line power interruption F5 Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install dynamic brake option F6 Motor Stalled Increase Accel Time x or reduce load so drive output current does not exceed the current set by parameter A089 Current Limit F7 Motor Overload An excessive mo
69. D Red 2 O D Blue 2 O D Green 2 O D Orange 2 O D Black Red 3 O D Blue 3 O D Green 3 O D Orange 3 O D SPRING PART NUMBER 143 82 021 00 143 82 021 01 143 82 021 02 143 16 021 05 143 16 021 06 143 16 021 03 143 16 021 04 143 16 021 05 143 16 021 06 143 16 021 07 121 62 021 50 121 62 021 51 121 62 021 52 121 62 021 53 Black 143 16 021 07 Cadmium 143 16 021 08 3 4 x 9 4 not available MAXIMUM BODY PRESSURE MAXIMUM DIAPHRAGM PRESSURE DIFFERENTIAL MAXIMUM DIAPHRAGM CASE PRESSURE n 40 and 15 RELIEF OR BACK PART MAX DIAPHRAGM PRESSURE RANGE SPRING COLOR NUMBER CASE PRESSURE to 51 2 w c 5 to 71 2 w c 6 to 13 w c 10 to 15 w c 12 to 25 w c 18 w c to 2 psi 1 psi to 4 psi 3 psi to 6 psi 6 psi to 10 psi 3 to 51 2 We 5 to 7 w c 6 to 12 w c 12 to 25 w c 20 w c to 134 psi 11 2 to 25 4 psi 3 to 4 1 2 W C 3 to 6 w c 5 to 11 w c 10 to 24 w c 14 w c to 11 4 psi Require High Pressure Spring Adjustment 121 8HP Red Black Blue Black Green Black Blue 2 O D Green 2 O D Orange 2 O D Black Cadmium White inner Red 2 O D Blue 2 O D Green 2 O D Orange 2 O D Black Cadmium Red 3 O D Blue 3 O D Green 3 O D Orange 3 O D Yellow 9 4 x 9 4 not available Cadmium outer 143 82 021 00 143 82 021 01 143 82 021
70. DRYER CONTROL PAN E WIRING DIAGRAM WET MTR WET CONV MTR BLUWER BLUWER BLUWER m DWG wo MTR 01 MTR 02 03 0004 01 K IR PANEL 2 1 DWG NO Uc
71. FEMOIST_CIR Display UPPER LIMIT CONTROL MODE AUTO MOIST CTR DIAGN 1 Unload upper limit the maximum unloading rate in which dryer can be run without plugging any unloading con veyors 2 Current column grain tempera ture measured from the RTD sensor at the end of the drying section it is not the temperatureof the grain coming out of the dryer 3 Unload lower limit the minimum unloading speed that can maintain the sam pling box of the dry sensor full of grain It is essential to have the sensor fully covered 14 MOISTURE CONTROL SETUP COLUMN GRAIN TEMP F B x UNLOAD LOWER LIMIT SENSOR CALIBRATION RETURN by grain to get an accurate reading of the grain moisture 4 Calibration button to access sensor calibration screen see Section III Step 3 B Control Mode button toggle the control mode between MANUAL and AUTO by pressing the button 6 Moisture Control Diagnosis button to access the diagnostic screen for factory trouble shooting Tower Dryer Ops amp Service TRI POINT MOISTURE CONTROLLER III Operation Procedure l Start the dryer set the dryer unload at a desired speed from the dryer control panel 2 Letthe dryer run under manual mode for warming up until the column grain temperature has stabilized and the moisture coming out of the dryer is within 2 of the target moisture 3 During the start up period calibrate bo
72. Grease 2 ALGI Grade i2 Table A 8 Grease Replenishment and Change Interval NOT REQUIRED Single and Double Reduction Maintenance Free Type Every 4 5 od i Less Than 30 Hours Per Day m 10 24 Hours Per Day Operation Every 500 1000 Speed Raducer Mechanism High Double Reduction Speed Shalt Bearings Somed Every 2 4 Years Change Puirkicgs Slow Spend Bearings Replenishment and Change Guidelines Replenish grease to the reduction mechanism 1 3 to 1 2 of Apply grease liberally to the central pan i e around the the quantity listed Table A 9 or 10 for the first reduction eccentric bearings of the mechanism Apply grease to both stage at the interval recommended in Table A 8 the slow T ed and speed shaft bearin you would N 2 g ordina ings at th time of re assembly When the unit is disassembled for overhauling refill with the grease quantities indicatedin Table A 9 or A 10 Or If excessive grease is added agitation heating of the grease alternatively 80 of the space around the reduction will raise theoperating temperature of the unit Avoid mechanism and slow speed shaft bearings of single excessive areasina but do not supply an insufficient amount reduction units and 50 around the reduction mechanism of grease When grease is insufficient it will raise the of both the first and second stage of doub
73. JURISDICTION ANY MODIFICATION VOIDS APPROVALS PRINTED INUSA 192 115 gt L3 FUSED POWER SUPPLY La a Es ur 14 1 j Lu USED FLAME RELAY IF COIL 1 EMEAGITED WHEN FLAME if CSTAGBLISHEO AND i PROTECTOFIER SEE SSE INTERAC OMWE CTI MANUAL OPERATION DIAGRAM BELOW i DETECTED TEST LAE FLAME PAR e START RELAY UR M CHECK F FLAME RELAY 4x 6 oe aL E 12 3 i OMT AMS a e 3 mu LT 4 jJ m JUMPER S Pad Se tel PILOT VALVE 454 SINGLE BURNER PROTECTOFIER FORM VA GROUP M2101 CE Fu Wah qup ipis ZZ E 3 5 M LI f NO CONNECTION MAIN Pumpen LIMES EET Li c 2 FLAME s LIGHT ALARM WORM SAFETY INTLK SERIES CIRCUIT FUEL ANDAIRPRESS SWS VENT FANS ETC ASREQ D INTERNAL WIRING WIRING n mmm WIRING DIAGRAM SINGLE BURNER 118 8 a HT PROTECTOFIER POWER FRR wa 1 VA SUPPLY GR UPMTIDI NOTES FLAME HIRE T 14 TT PE T
74. Motor U T1 _ Switch any two motor leads to 7 change forward direction W T3 To Motor W T3 BR BR Dynamic Brake Resistor Connection 0 75 TT 1 HP ratings and higher Safety Ground PE Power Terminal Block Specifications Frame Maximum Wire Size Minimum Wire Size 1 Torque A 3 3 mm 12 AWG 0 8 mm 18 AWG 5 1 7 2 2 N m 16 19 Ib in B 5 3 mm 10 AWG 1 3 mm 16 AWG 1 Maximum minimum sizes that the terminal block will accept these are not recommendations Input Power Conditions Input Power Condition Corrective Action Low Line Impedance less than 1 line reactance e Install Line Reactor Greater than 120 kVA supply transformer e or Isolation Transformer Line has power factor correction capacitors Line has frequent power interruptions Line has intermittent noise spikes in excess of 6000V lightning Phase to ground voltage exceeds 125 of normal line to line voltage e Remove MOV jumper to ground e or Install Isolation Transformer with grounded secondary if necessary Ungrounded Distribution System 2 Refer to Appendix B of the PowerFlex 4 User Manual on CD for accessory ordering information I O Wiring Recommendations Wire Type s Description Minimum Insulation Rating Belden 8760 9460 0 8 mm 18 twisted pair 100 shield with or equiv drain 300V 5 60 degrees Belden 8770 0 8 18AWG conductor shielded for 140 degrees F or equiv r
75. Position Switch 6 Gently lift the top assembly 5 not more than E Insulating Barrier L Switch Wand 1 4 in height just enough to break the seal F Bracket Mounting Pad M Switch Mounting Bracket between the valve body assembly and the rubber G Drive Pin Locating N Gasket gasket adhering to the bottom of the top housing WARNING LIFTING TOO FAR MAY DISLODGE SOME SMALL PARTS INSIDE THE TOP HOUSING REQUIRING COMPLEX RE ASSEMBLY AND RETESTING BY TRAINED FACTORY PERSONNEL 1 99 Maxon practices policy of continuous product improvement It reserves the right to alter specifications without prior notice CORPORATION INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES MUNCIE INDIANA USA Page 6100 S 4 Electro Mechanical Valves Installation Instructions conta Top Assembly Rotation cont d 7 Remove the two body bolts 4 screwed up from the bottom were partially unscrewed in step 5 8 Carefully rotate top assembly to the desired position in a plane parallel to the top of the valve body casting Rotate the top housing about 30 beyond this position and then rotate it back Reposition the top housing back down onto the valve body casting This should align the open shut indicator with its window and provide proper alignment of the internal mechanism 9 Realign holes in valve body casting with the corresponding tapped holes in the bottom of the top assembly housing Be sure the g
76. Refer to Chapter 1 of the PowerFlex 4 User Manual on CD for details P039 Accel Time 1 0 0 600 0 Secs 0 1 Secs 10 0 Secs Sets the rate of accel for all speed increases P040 Decel Time 1 0 1 600 0 Secs 0 1 Secs 10 0 Secs Sets the rate of decel for all speed decreases P041 Reset To Defalts 0 1 0 Idle State 0 Resets all parameter values to factory defaults 1 Reset Defaults English 10 See the PowerFlex 4 User Manual on CD for more information on parameters Advanced Group Parameters Parameter Min Max Display Options Default A051 Digital Int Sel 0 26 0 Not Used 8 RampStop CF 4 Terminal 05 1 Acc 2 amp Dec 2 9 CoastStop CF A052 Digital In2 Sel 2 Jog 10 DClnjStop CF Terminal 06 3 Aux Fault 11 Forward 4 Preset Freq 12 Jog Reverse 5 Local 13 10V In Ctrl 6 Comm Port 14 20mA In Ctrl 7 Clear Fault 26 Anlg Invert A055 Relay Out Sel 0 21 0 Ready Fault 6 Above Freq 0 1 At Frequency 7 Above Cur 2 MotorRunning 8 Above DCVolt 3 Reverse 9 Retries Exst 4 Motor Overld 10 Above Anlg V 5 Ramp Reg 20 ParamControl 21 NonRec Fault 056 Relay Out Level 0 0 9999 0 1 0 0 A067 Accel Time 2 0 0 600 0 Secs 0 1
77. Secs 20 0 Secs A068 Decel Time 2 0 1 600 0 Secs 0 1 Secs 20 0 Secs A069 Internal Freq 0 0 240 0 Hz 0 1 Hz 60 0 Hz A070 Preset Freq of 0 0 240 0 Hz 0 1 Hz 0 0 Hz 071 Preset Freq 1 5 0 Hz A072 Preset Freq 2 10 0 Hz A073 Preset Freq 3 20 0 Hz 1 To activate Preset Freq 0 set P038 Speed Reference to option 4 mpu Ti 1 npu Ti Frequency Source Accel Decel Parameter Used 2 0 0 Preset Freq 0 Accel Time 1 Decel Time 1 1 0 Preset Freq 1 Accel Time 1 Decel Time 1 0 1 Preset Freq 2 Accel Time 2 Decel Time 2 1 1 Preset Freq 3 Accel Time 2 Decel Time 2 2 When a Digital Input is set to Accel 2 amp Decel 2 and the input is active that input overrides the settings in this table A078 Jog Frequency 0 0 Maximum Freq 0 1 Hz 10 0 Hz A079 Jog Accel Decel 0 1 600 0 Secs 0 1 Secs 10 0 Secs A080 DC Brake Time 0 0 90 0 Secs 0 1 Secs 0 0 Secs A081 0 Brake Level 0 0 Drive Amps x 1 8 0 1 Amps Amps x 0 05 A082 Resistor Sel 0 99 0 Disabled 2 NoProtection 0 1 Normal RA Res 3 99 of Duty Cycle A083 S Curve 0 100 1 0 Disabled A084 Start Boost 1 14 Settings in of base voltage 8 Only active when A125 Torque Perf Mode is 0 Custom V Hz 7 5 HP Drives set to 0 V Hz Variable Torque Constant Torque 1 30 0 VT 5z 0 0 noIR 10 10 0 CT 2 35 0 6 0 0 11 125 3 40 0 25 1227150
78. THE TARGET READY TO START READY TO START BLOWER READY TO START BURNER OUT OF GRAIN START UNLOAD NOW DRYER COOLING OFF Current grain temp _ WET PATH NOT ON FILLING THE DRYER DRYER IS FULL EMPTYING THE DRYER NO POWER TO SLC START CHECKING Please wait seconds left TRI START ON ___ seconds left STARTING BLOWER 1 STARTING BLOWER 2 STARTING BLOWER 3 STARTING BLOWER 4 PURGING seconds left OPEN MAIN FUEL VALVES or will shut down in____ seconds IGNITION TRIAL seconds left FIRING VALVE LIMIT SWITCH OPEN OPEN THE FIRING VALVE INTERLOCKED START DRY CONVEYOR FIRST INTERLOCKED START AUX DRY CONVEYOR FIRST INTERLOCKED START DRY LEG FIRST What to do Check Term 213 Check Term 209 Check Term 210 Check Term 211 Check Term 212 Check Term 215 Check Term 214 Check Term 213 Check Term 314 amp 315 Check the sensor wiring Check the sensor wiring Check the sensor wiring Check the sensor wiring Check the sensor wiring Try again w close supervision Press the dryer control START Turn blower switch to ON to start Turn burner switch to ON to start Will shut down in seconds Or will shut down seconds Blower will shut down in secs N 5 or turn the blower switch off to shut down now Turn load switch to MAN or AUTO to start Please wait Press control STOP button to reset alarm Then press control START button to restart Please wait Pull E STOP button out and check Term 100 for
79. Valve Requires the 220738A Adapter Bracket Q181 Auxiliary Potentiometer for sequence or unison control of 1 to 4 additional modulating Series 90 motors Q5001 Bracket and Linkage Assembly connects Modutrol IV Motor to water or steam valve Q605 Damper Linkage connects motor to damper Includes motor crank arm Q607 External Auxiliary Switch controls auxiliary equipment as a function of motor position INSTALLATION Installing this Product Read these instructions carefully Failure to follow them could damage the product or cause a hazardous condition 2 Check the ratings given in the instructions and on the product to make sure the product is suitable for your application 3 Installer must be a trained experienced service technician 4 After installation is complete check out product operation as provided in these instructions N CAUTION Electrical Shock or Equipment Damage Hazard Can shock individuals or short equipment circuitry Disconnect all power supplies before installation Motors with auxiliary switches can have more than one disconnect N CAUTION Equipment Damage Hazard Can damage the motor beyond repair Never turn the motor shaft by hand or with a wrench Forcibly turning the motor shaft damages the gear train and stroke limit contacts IMPORTANT Always conduct a thorough checkout when installation is complete Location Allow enough clearance for accessory installation and m
80. WET LEG C PANEL EXTERIOR 20 69 N 69 C e W HEU PARTE INSTAL i COIL MOTOR TER 2 LUC POWER PANEL ALARM HOR 80 08 5 VET CONV gt VET CONV STARTER 4 80 15 ENE O gt COIL MOTOR STARTER A ALARM HURN 23 Po C POWER PANEL 22 apes eel 8 0 09 IELD INSTALLED MS OSS OTR SCID V V PART 40 Sa DUTSIDE LIGHT THE GSI GROUP 7 4 1004 ILLINOIS ST ASSUMPTION IL 62510 N C XTE a PIX IN P ANEL TITLE TOWER DRYER CONTROL PANEI 426 WIRING DIAGRAM HFIELD WIRING MAT L DESC P N mr 2004 08
81. a malfunctioning gas train component that could be causing excessive plenum temperatures Tower Dryer Ops amp Service TROUBLESHOOTING Problem What to do Dryer shuts down red light lights Check for possible fire in dryer at location indicated in message and horn sounds display shows Check for a plugged or slow moving grain column OVERHEAT AT Check for a plugged grain turner POSSIBLE Check to insure that the dryer is full of grain and 15 continually being kept full Check for a defective high limit sensor OIU displays message Indicates that the metering system inverter drive has tripped UNLOAD DRIVE FAULT Check for plugged metering drum or Accutrol metering system Reset drive by turning off the main circuit breaker for 15 seconds or by pressing the STOP button on the inverter OIU displays message Indicates that any overload has occurred in the item indicated CONTACT FAILED TO CLOSE Reset the overload of the starter indicated in the power panel and fix the DRY CONVEYOR overloaded conditions or WETCONVEYOR Of any auxiliary starter OIU displays message Indicates that overload has occurred in the blower indicated OVERLOAD TRIPPED Reset the overload of the starter of the blower indicated and fix the BLOWER STARTER overload conditions Blower overload can be caused by overly tightened blower belts or inadequately greased blower bearings
82. accessibility for lubrication maintenance purposes 7 Ventilation When the SM CYCLO Speed Reducer is mounted in a separate enclosure be sure that adeauate ventilation is provided Correct Method Incorrect Method GENERAL CONSTRUCTION Fig A 1 Speed Reducer Horizontal Foot Mount Single Reduction Table A 1 Speed Reducer Main Parts 102 90 2 gah 4 06 202 Ping Gear Pins Ring Gear Rollers Eccentric Assembly Ecoeniic Rietairing Ring Colas 2402 203 204 2 0 Fig A 2 Speed Reducer Vertical Base Mount Single Reduction Em 5 04 Eccentric Bearing 210 Fan Cover 4 Eum Ke 2 Bots For 55 Seal Housing 3 Spacers For Fan Cover Vertical Dil Seal Housing Vertical Jinleyral Y Plunger Purp d P pta Displacemert Pump i iur 7 imermedale Cover Eve Ball 4 4 5 Note For details of oil seals bearings or gaskets refer to A 11 13 Chl Singer TRefer to Table 16 on Pg 9 for units which require a positive displacement pump Pt No 58 frame sizes 6195 6275 only Pt No 59 frame sizes 6205 6275 only Fig A 3 Page 4 See Fig A 4 4 GENERAL CONSTRUCTION Fig A 3 Speed Reducer Single Disc Type Frame Size 6060 6095 Fig A 4 Speed Reducer Double Reduction 0 5 01 6 04
83. achieved with less than full control valve open ing Mark with a pencil or scribe the point on valve crank arm where the desired maximum is obtained then return crank arm to low position and shut system off 10 If using Maxon Series CV Valve reconnect control motor linkage with control motor in low or minimum position by loosening toggle clamp screw 1 and moving toggle clamp 2 along the connecting linkage to a point where toggle clamp bolt 3 can be placed at the outermost position of control motor crank slot Then tighten toggle clamp screw 1 thus fixing clamp to linkage Allowing toggle clamp bolt 3 to slide in the crank arm slot cycle control motor towards its maxi mum position and move fuel control valve crank 4 to the previously determined maximum firing rate position Tighten toggle clamp bolt 3 thus fixing clamp to motor crank Cycle control motor back to minimum watching carefully that it does not bind before reaching minimum If it is stopped or if minimum is not reached loosen toggle clamp screw 1 and move toggle clamp along the connecting linkage so both motor and valve can assume their minimum positions Then retighten toggle clamp screw 1 Refine adjustment by cycling several times between low and high control motor position while readjusting toggle clamp bolt 3 as neces sary until control motor travels through its full cycle while moving control valve crank arm from its minimum only up to the desired maximu
84. adapter was not intentionally disconnected check wiring to the port Replace wiring port expander adapters or complete drive as required Check connection An adapter was intentionally disconnected Turn off using A105 Comm Loss Action F100 Parameter Checksum Restore factory defaults F122 1 0 Board Fail Cycle power Replace drive if fault cannot be cleared 1 Auto Reset Run type fault Configure with parameters A092 and A093 Tower Dryer Ops amp Service COMPONENTS COMPONENT MANUALS MAXON BURNER Bulletin 5550 Series NP LE AIRFLO Burners Designed for direct fired make up air and process applications e Improved emissions performance over Maxon s standard NP AIRFLO Burner with significantly lower levels of CO and NO e Higher capacity up to 1 000 000 Btu hr ft Shorter flame length e Easily meets ANSI CSA standards e Available in low pressure version and corrosion resistant materials MAXON CORPORATION 201 East 18th Street P O Box 2068 Muncie Indiana 47307 0068 Phone 765 284 3304 Fax 765 286 8394 Page 5552 Design and Application Details Specifications Input Rating Up to 1 000 000 Btu hr ft Airstream Profile Differential Pressure 0 3 to 1 0 wc Pilot Capacity 25 000 Btu hr 4 6 wc Burner Turndown 30 1 Maximum Upstream Temperature 600 F cast iron 450 F aluminum Maximum Downstream Temperature 1000 F cast iron 850 F aluminum Maximum Temperature Rise
85. all moving Check outside dryer screen for dirt build up Clean if necessary Grain moisture discharges Reduce unload rate too wet Or increase drying temperature Grain moisture discharges Increase unload rate too dry Or decrease drying temperature Grain moisture discharges Check that plenum temperature is being held consistent inconsistently Check for widely varying incoming moistures Check for plugged grain columns Verify that an adequate supply of grain is being provided to the dryer to maintain a grain seal within the dryer Burnt or scorched kernels Some varieties of grain or frost damaged grain are sensitive to higher appear during drying drying temperatures Lower drying temperatures If dryer is equipped with an external LP vaporizer insure that liquid propane is not passing through the vaporizer and going to the dryer Grain not moving through Check the dryer for fines build up within the column Empty if necessary grain columns Do not leave the dryer full for extended periods of time or during rainy weather without occasionally moving grain through it TROUBLESHOOTING BURNER Problem What to do Pilot will not light Check to see that the gas shutoff valve is open Verify that gas is being provided to the dryer by checking the presure gauge located in the pilot line Verify that the pilot solenoid is opening by listening for a clicking sound Remove the pilot line
86. are spring return motors Oil immersed motor and gear train for reliable performance and long life e Wiring box provides NEMA 3 weather protection e Actuator motor and circuitry operate from 24 Vac Models available with factory installed transformer or an internal transformer can be field added Quick connect terminals standard screw terminal adapter available Adapter bracket for matching shaft height of older motors is standard with replacement motors e Nominal timing of 30 seconds for 90 stroke and 60 seconds for 160 stroke e Valve and damper linkages explosion proof housing and auxiliary switches available as accessories e Spring return motors are rated for 25 Ib in and 60 Ib in torque e Non spring return motors are rated for 35 Ib in 75 Ib in 150 Ib in and 300 Ib in torque e Models available with adjustable start zero and span e Models available with 4 to 20 mA input signal e Models available with 2 to 10 Vdc input signal e Die cast aluminum housing Contents ABC 1 EU 1 SODeclllcallghms cesta 2 Ordering Information 2 2 hti ME E 5 Settings and Adjustments 10 Operation and Checkout 12 e M Copyright 2000 Honeywell All Rights Reserved 63 2202 4 SERIES 72 MODUTROL IV MOTORS SPECIFICATIONS IMPORTANT The s
87. gt i PART NO sta IN17 PLC 24VDC aux PLC 24VDC 212 THE GSI GROUP O 94 1004 ILLINOIS ST ASSUMPTION IL 62510 TITLE OUT8 24VDC on Ha bus TOWER DRYER CONTROL PANEL 5 WIRING DIAGRAM 4 N MAT L DESC PIN note located in control panel note located in power panel note located in power panel E fures 2004XX 17 COMPONEN I MANUALS Tower Dryer Ops amp Service COMPONENTS COMPONENT MANUALS II IV VI IX AC FREQUENCY DRIVE MAXON BURNER GAS CONTROL VALVE GAS SHUT OFF VALVE GEARBOXES MODUTROL MOTOR GAS REGULATORS ASCO PILOT VALVE PROTECTOFIER Tower Dryer Ops amp Service COMPONENTS COMPONENT MANUALS AC FREQUENCY DRIVE gt b Quick Start PowerFlex 4 Adjustable Frequency AC Drive FRN 3 xx This Quick Start guide summarizes the basic steps needed to install start up and program the PowerFlex 4 Adjustable Frequency AC Drive The information provided Does Not replace the User Manual and is intended for qualified drive service personnel only For detailed PowerFlex 4 information including EMC instructions application considerations and related precautions refer to the PowerFlex 4 User Manual Publication 22A UMOO1 on the CD supplied with the drive or at www ab com manuals dr General Precautions ATTENTION The drive contains high voltage capacitors which take time to discharge after removal of mains supply Be
88. gt 2 4 724 lt 2 7 087 0 006 0 0004 gt 7 087 x 9 055 0 006 0 0005 gt 2 9 055 lt Y 12 402 0 000 0 0013 gt 12 402 lt 2 15 748 0 000 0 0014 gt 2 15 748 lt 2 19 685 0 000 0 0016 BOLT STRENGTH Bolt size strength and quantity should be verified to insure proper torque reaction capacity whatever the mounting arrangement LUBRICATE SHAFTS Both the hollow shaft and the driven shaft should be liberally lubricated before assembly The unit must slide freely onto the driven shaft Do not hammer or force the unit into place For shrink disc follow instructions below www nord com AXIAL RETENTION Each drive shaft must be retained in place relative to the gear reducer Or each gear reducer must be retained in place relative to the drive shaft Either way NORD recommends the use of shaft shoulders locking collars or FIXING ELEMENTS to axially retain the shaft or gear reducer in position SET SCREWS If set screws are used for axial retention they should be tightened evenly Flats may be filed on the driven shaft and a thread locking adhesive used for more position retention SNAP RING RETENTION Placing external snap rings on drive shafts must be performed with caution The groove which the snap ring fits into may weaken the drive shaft causing premature failure NORD does not recommend this type of shaft retention THRUST PLATE In applications which are subject to high vibratory loads a th
89. is recommended Thoroughly clean all parts Replace any worn or damaged parts Causes of Improper Operation e Faulty Control Circuit Check the electrical system by energizing the solenoid A metallic click signifies that the solenoid is operating Absence of the click indicates loss of power supply Check for loose or blown fuses open circuited or grounded solenoid broken lead wires or splice connections Burned Out Solenoid Check for open circuited solenoid Replace if necessary Check supply voltage it must be the same as specified on nameplate retainer and marked on the solenoid Check ambient temperature and check that the core is not jammed e Low Voltage Check voltage across the solenoid leads Voltage must be at least 85 of rated voltage Solenoid Replacement 1 Disconnect conduit coil leads and grounding wire NOTE Any optional parts attached to the old solenoid must be reinstalled on the new solenoid For 3 way construction piping or tubing must be removed from pipe adapter 2 Disassemble solenoids with optional features as follows Spade or Screw Terminals Remove terminal connections grounding screw grounding wire and terminal block screw terminal type only NOTE For screw terminals the socket head screw holding the terminal block serves as a grounding screw e Junction Box Remove conduit and socket head screw use 5 32 hex key wrench from center of junction box Disconnect junction box f
90. junction box See Figure 5 DIN Plug Connector Kit No K236034 Use this kit only for solenoids with DIN terminals The DIN plug connector kit provides a two pole with grounding contact DIN Type 43650 construction See Figure 6 OPERATION Series 8003G When the solenoid is energized the core is drawn into the solenoid base sub assembly IMPORTANT When the solenoid is de energized the initial return force for the core whether developed by spring pressure or weight must exert a minimum force to overcome residual magnetism created by the solenoid Minimum return force for AC construction is 11 ounces and 5 ounces for DC construction Series 8202G When the solenoid is energized the disc holder assembly seats against the orifice When the solenoid is de energized the disc holder assembly returns IMPORTANT Initial return force for the disc or disc holder assembly whether developed by spring pressure or weight must exert a minimum force to overcome residual magnetism created by the solenoid Minimum return force is 1 pound 5 ounces ASCO All Rights Reserved SERIES 8003G 8202G Form No V6584R8 INSTALLATION Check nameplate for correct catalog number service and wattage Check front of solenoid for voltage and frequency WARNING Electrical hazard from the accessibility of live parts To prevent the possibility of death serious injury or property damage install the open frame sole
91. mounted as close to the driven equipment bearing support as possible to minimize bearing loads due to overhung load Design of the joint connection between the torque reaction arm and the foundation is the user s responsibility Hollow Shaft Diameter tolerance Metric mm lt 18 0 018 0 000 gt 18 lt 2 30 0 021 0 000 gt 2 30 lt 50 0 025 0 000 gt 50 lt 80 0 030 0 000 gt 2 80 lt 2 120 0 035 0 000 gt 2 120 x 2 180 0 040 0 000 Inch lt 4 375 0 0010 0 0000 gt 4 375 0 0015 0 0000 Customer shaft diameter tolerances with keyed hollow shafts Metric mm lt 18 0 000 0 011 gt 2 18 lt 30 0 000 0 013 gt 2 30 lt 2 50 0 000 0 016 gt 50 lt 80 0 000 0 019 gt 2 80 lt 120 0 000 0 022 gt 120 lt 180 0 000 0 025 Inch lt 1 500 0 000 0 002 gt 1 500 lt 2 500 0 000 0 003 gt 2 500 lt Y 7 000 0 000 0 004 Shaft finish to be 125 micro inches or smoother Customer shaft diameter tolerance with Shrink Disc fit h6 Metric mm lt 18 0 000 0 011 gt 18 lt 30 0 000 0 013 gt 30 lt 2 50 0 000 0 016 BIM 1020 2005 03 gt 50 lt 2 80 0 000 0 019 gt amp 80 lt 2 120 0 000 0 022 gt 120 lt Y 180 0 000 0 025 Inch lt 0 750 0 0000 0 0004 0 750 lt Y 1 125 0 0000 0 0005 1 125 lt Y 2 000 0 0000 0 0006 2 000 x 2 3 000 0 0000 0 00
92. plugging the inside screens of the dryer no holes in the stainless steel air mixing plates are also creating a fire hazzard plugged If burner ports are plugged clear them with a piece of wire or a drill bit After a period of SEE PRE SEASON CHECKLIST AT several years it may become necessary to drill THE END OF THIS SECTION out the burner ports to clear away accumulated rust Use a 43 drill bit to return burner ports to their original diameter See burner drilling proce dure in the Maxon Burner area of the COMPO NENT MANUALS section of this book NOTE Pre 2002 model dryers require a 47 drill bit 5 Check electrical connections at both the flame rod and spark plug Clean spark ignitor and flame rod Replace if necessary 6 Check drain valve on gas train to insure that there is no water in the gas train Valve should always be open when the dryer is not being used Insure that drain valve is closed prior to dryer operation 7 Lubricate linkage on gas modulating valve 25 MAINTENANCE SEASONAL INSPECTION AND SERVICE Important The covers to the metering system access door s must be in place at all times when the dryer is in operation Before turning blowers always make sure this door is clamped into position Follow lubrication guides as outlined in the Lubrication Table Do not let grain fines and dust accumulate inside the cooling section of the dryer Bi weekly if drying most prod ucts or daily if dr
93. policy of continuous product improvement It reserves the right to alter specifications without prior notice W CORPORATION INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES MUNCIE INDIANA USA Tower Dryer Ops amp Service COMPONENTS COMPONENT MANUALS GEARBOXES All GSI Hopper Bottom Dryers Nord SK5382 All Zimmerman 12 Diameter Dryers Sumitomo 6145DB All Zimmerman 18 Diameter Dryers Sumitomo 6185DB All Zimmerman 24 Diameter Dryers Sumitomo 6195DB Installation and Maintenance Instructions Retain These Safety Instructions For Future Use zur UNICASE Shaft Mount Gearboxes BIM 1020 INSPECTION OF UNIT Thoroughly inspect the equipment for any shipping and handling damage before accepting shipment from the freight company If any of the goods called for in the bill of lading or express receipt are damaged or the quantity is short do not accept until the freight or express agent makes an appropriate notation on your freight bill or express receipt If any concealed loss or damage is discovered later notify your freight carrier or express agent at once and request him to make an inspection We will be very happy to assist you in collecting claims for loss or damage during shipment however this willingness on our part does not remove the transportation company s responsibility in reimbursing you for collection of claims or replacement of material Claims for loss or damage in shipment must not be deducted f
94. relay is energized thru N C contact of ACF FLAME relay F b Ignition transformer is energized thru contact of START button from PROTECTOFIER terminal 4 to provide spark ignition to the pilot c Pilot solenoid valve is energized to open from PROTECTOFIER terminal 4 2 With pilot flame established ACF FLAME relay F is energized a FLAME relay F contacts transfer 1 N C F contact in safe start checking circuit opens 2 F contact between terminal 12 and terminal 13 closes providing holding circuit around START pilot push button contact 3 N O F contact in main valve circuit closes to energize main valve thru N O CHECK relay contact Neon indicator light on PROTECTOFIER chassis will glow to 1n dicate flame is established 3 Release START button Ignition transformer is de energized Flame failure during operation de energizes fuel valves Power interruption to PROTECTOFIER terminal 12 de energizes relays and fuel valves Failure of Check Relay C prove safe start check prevent energizing fuel valves and ignition system Power Equipment Company Manufacturers Representative 2011 Williamsburg Rd Richmond VA 23231 804 226 3800 Fax 804 236 3882 PROTECTION CONTROLS INC INSTALLATION OPERATION AND MAINTE NANCE SHALL CONFORM WITH NATIONAL FIRE PROTECTION ASSOCIATION STAND ARDS NATIONAL AND LOCAL CODES AND AUTHORITIES HAVING
95. replace at GSI s option and expense products that in GSPs judgment contain a material defect in materials or workmanship Expenses incurred by or on behalf of the end user without prior written authorization from the GSI Warranty Group shall be the sole responsibility of the end user Warranty Extensions The Limited Warranty period is extended for the following products Product Warranty Period Performer Series Direct Drive Fan Motor AP Fans and ea ceno A a Portable Dryers 2 Years Portable Dryer Frames Screens 5 Years and Internal Infrastructure y Grain Systems Conditions and Limitations Warranty prorated from list price 0 to 3 years no cost to end user 3 to 5 years end user pays 25 5 to 7 years end user pays 50 7 to 10 years end user pays 75 Warranty prorated from list price 0 to 3 years no cost to end user 3 to 5 years end user pays 50 T Motors burner components and moving parts not included THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE LIMITED WARRANTY DESCRIPTION SET FORTH ABOVE SPECIFICALLY GSI MAKES NO FURTHER WARRANTY OF ANY KIND EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN CONNECTION WITH 1 PRODUCT MANUFACTURED OR SOLD BY GSI OR 11 ANY ADVICE INSTRUCTION RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT REPRESENTATIVE OR EM
96. sure the regulator is correctly connected and Buried Service adequately supported and pipe joints are tight The Model 121 Regulator is not recommended for buried service Invensys Energy Metering Set Point Adjustment A The 121 is factory adjusted as specified on the order To change the set point readjust as follows 1 Remove the top cap 1 2 Adjust set point with adjustment button 3 3a or 6 Turn clock wise to increase and counterclockwise to decrease the outlet pressure NOTE a Only make this adjustment when gas is actually flowing through the regulator The flow should be small approximately 1000 SCFH Do not adjust when the regulator is closed and there is no flow b Do not increase the set point beyond the upper limit of the outlet pressure range for the spring 9 refer to spring tables Page 3 c Always check the outlet pressure with a pressure gauge while adjusting the set point 3 When adjustment is complete replace top cap 1 Screw it securely into place Leaving it off could cause unstable regu lator operation CAUTION It is the user s responsibility to assure that all regulator vents and or vent lines exhaust to a non hazardous location away from any po tential sources of ignition Where vent lines are used it is the user s responsibility to as sure that each regulator is individually vented and that common vent lines are not used To Change Spring A The outlet pressure ra
97. tension spring may be located either above or below the wheel center line Draw free end of chain and tension spring to gether so that as much slack as possible is eliminated then insert the open eye of the spring S hook through the link in the chain that will most nearly maintain this position Crimp the S hook shut around the chain link then cut and discard excess chain Remove spring preload wood block insert from the tension spring and verify that the chain is drawn tight MA x ON CORPORATION MUNCIE INDIANA USA 8 10 11 Rotate the operating handle of the main valve fully to latching position for your particular valve then hold handle firmly in this position while performing the next few steps Rotate blocking valve wheel fully counter clock wise until it strikes a stop it will slide within the loop of chain Still holding main valve wheel in place move blocking valve wheel approximately 1 4 to 1 2 inch back in the clockwise direction Insert the 10 24 X 1 2 screw furnished through the chain link that lines up with the tapped hole on bottom of blocking valve wheel then fasten securely Verify that the valves are wired in parallel as shown in wiring schematic on page 6121 To add wheel amp chain assembly to existing tandem valves 1 Verify that both valves are in the same top assembly position TO or AW Rotate if neces sary See top assembly rotation instructions on pa
98. the requirements of ANSI B16 104 Class VI seat leakage when it leaves our plant Example of a gas piping diagram for leak test Shut off Manual Gas Pressure Valve Valve Regulator LGP Switch al Strainer TT TE ME TEE po Suggested leak test procedure for double blocking shut off valves without vent line a Shut down combustion system per manufacturer s recommended procedure Close manual valves A and B Visually inspect to verify that shut off valves 1 and 2 are closed Remove the 1 4 pipe plug from downstream side of shut off valve 1 Install leak test apparatus Safely vent any trapped gas pressure Open manual shut off valve A then close leak test apparatus Insert tube into a container of water just below the surface f Open test apparatus and test valve for leakage As a guideline valve should be tested for 2 minutes per inch of pipe diameter Large diameter pipes or long piping runs between shut off valves may need additional testing time If valve testing indicates leakage exceeding 15 bubbles per minute perform pre operational exercising as outlined on Page 6100 S 2 and retest the valve If valve continues to exceed allowable leakage limit remove from service and contact Maxon Shut off 54 Combustion es es Drip Syste Leg Example of a wiring diagram for leak test
99. the same construction as the larger sizes Follow the instructions given under Disassembly and Assembly Disassembly Of Output Side 6060 612H 1 With casing supported tap output shaft until it is disengaged from casing 2 Remove bearing A by using pulling tool 3 Replace all bearings gaskets and seals when reassembling Pages 11 7 A 13 on tire disc Hola Sel disc with number lacing spes sie Fig A 15 Assembly Of Output Side 6060 612H 1 Assemble the bearing Part No 1 03 on the slow speed shaft Part No 1 01 Heating of B bearing is recommended for easter assembly Note Do not exceed temperature of 200 F 2 Assemble Me casing PartNo 26 over the slow speed shaft Part No 1 01 being sure to maintain X Fig A 18 3 Carefully tap bearing A Part No 1 02 onto the slow speed shaft Part No 1 01 until the bearing is flush with the shoulder of the casing 4 Placethe collar Part No 1 04H onto the slow speed shaft Part No 1 01 Heating Me collar is recommended for easier assembly 5 Insert the oil seal Part No 18 lip in into the casing Part No 26 Note Measure for dimension X preferablyin 3 places to insure proper spacing Fig A 18 0 048 0 007 00432 0 007 A 15 DAILY INSPECTION 1 Visually check the oil level gauge on the vertical unit forced lubricated type Check lubrication flow by viewing piping set and
100. with the linkage 3 Attach the motor to the bracket with the four bolts provided See Fig 4 63 2202 4 6 Damper Linkages The motor does not include a crank arm Order the crank arm separately see Accessories in the Specifications section For detailed instructions on the assembly of specific linkages refer to the Installation Instructions packed with the linkage N CAUTION Equipment Damage Hazard Stalling a motor can damage the drive shaft Ensure installation of motors and linkages allows the motor to drive through full stroke without obstruction Valve Linkages The Q100 Linkage requires a 220738A Adapter Bracket for all valve applications Applications with the Q5001 Valve Linkage do not require the 220738A Adapter Bracket see Fig 4 For detailed instructions on specific linkage assemblies refer to the instruction sheet packed with the linkage In general check the following points when installing a motor and linkage Adjust valve and louver type damper linkages so the damper or valve moves through only the maximum required distance while the motor moves through its full stroke e With modulating control maximum damper opening should be no more than 60 degrees Little additional airflow is provided beyond this point Do not exceed load and torque ratings in any application Junction Box When used with liquid tight conduit connectors the junction box provides NEMA 3 weather protection for the motor
101. 07 3 000 lt 2 4 750 0 0000 0 0008 4 750 lt 7 000 0 0000 0 0010 Shaft finish to be 125 micro inches or smoother VV V Customer shaft diameter tolerance with Shrink Disc fit f6 looser fit Metric mm lt 18 0 016 0 024 gt 18 lt 2 30 0 020 0 029 gt 30 lt 50 0 025 0 036 gt 50 lt 80 0 030 0 043 gt 80x 2 120 0 036 0 051 gt 2 120 lt 2 180 0 043 0 061 Inch lt 2 0 750 0 0006 0 001 1 gt 0 750 lt 1 125 0 0008 0 0013 gt 1 125 lt 2 000 0 0010 0 0016 gt 2 000 lt 3 000 0 0012 0 0019 gt 3 000 lt Y 4 750 0 0014 0 0023 gt 4 750 lt 7 000 0 0017 0 0027 Shaft finish to be 125 micro inches or smoother FLANGE MOUNTED UNITS If a structural steel foundation is used i e wide flange beams or channels a base plate or sole plate of suitable thickness should be used and should extend under the entire unit If a bulk head plate is used it should be of proper strength to minimize buckling distortions Flange Pilot AK or AK1 tolerance Metric mm gt 2 50 lt 80 0 012 0 007 gt 2 80 lt 120 0 013 0 009 gt 2 120 lt 5 180 0 014 0 011 gt 2 180 lt Y 230 0 016 0 013 gt 230 lt Y 315 0 000 0 032 gt 315 lt Y 400 0 000 0 036 gt 2 400 lt Y 500 0 000 0 040 Inch gt 2 1 969 x Y 3 150 0 005 0 0003 gt 3 150 x Y 4 724 0 005 0 0004
102. 1 10 150 52 121 10 022 52 121 10 178 50 121 10 079 52 091 16 058 02 121 16 564 51 121 16 053 51 121 16 364 50 121 16 364 51 121 16 010 53 121 16 016 53 O Ring Buna N s x 1 2 O Ring Viton 9 8 x 1 2 Wave Washer Molded Valve Buna N 45 50 Duro Molded Valve Viton A 65 75 Duro Retaining Ring Pliers for retaining ring 16a Truarc 0200 Valve Holder split pair required stainless steel Tetraseal or O Ring 21 2 x 211 16 Orifice 25 32 dia steel Orifice 25 32 dia stainless steel Retaining Ring stainless Pliers for retaining ring 19a Truarc 0600 Gasket Copper Washer O Ring 31 s x 31 2 Tetraseal or O Ring 31 4 x 31 2 Seal Diaphragm Ring Gasket Travel Indicator Repair Kits consisting of Buna N Main and Seal Diaphragms Buna N Molded Valve plus Wave Washer and Retaining Ring Buna N O Rings Tetraseals and Gaskets For 121 12 For 121 8 For 121 8 HP Stem Back Pressure Item 14 above Wave Washer substitute Poly U Disk Retainer Item 46 above Repair Kits substitute For 121 12 Back Pressure For 121 8 Back Pressure For 121 8 HP Back Pressure Add 47 Valve Seal Diaphragm and Stem Assembly DESCRIPTION PART NUMBER 934007 902418 905479 121 16 311 50 121 16 311 51 904447 1190646 121 16 130 51 904207 121 16 023 51 121 16 023 52 904657 1190648 121 16 063 51 121 16 178 51 934041 904078 121 16 008 50 121 16 104 50 091 00 365 00 121 16 598 50 121 86 598 50
103. 2009 OWER DRYER OPERATION AND SERVICE MANUAL team Se A T T il oe Lil B INS d d 1 gt IL s T pa TN 1 E PNEG 526 12 16 24 amp 30 Diameter Dryer Models SR rJ pu 247 In x Br A JN 1 i i Je 1 i m E 1 1 y 2 f Ih mE 1 HI ee 9 pu n ri ert aE AY TERI a jt n DEI 5 gt 2 un ET ag GSI GROUP gt THIS PRODUCT IS PROTECTED UNDER ONE OR MORE OF THE FOLLOWING U S PATENTS 6233843 6189235 6141886 6101742 6098305 6088929 6076276 6073367 6073364 5570521 6457256 6035544 5860221 5653043 5651193 5604996 5566470 5400525 Tower Dryer Ops amp Service TABLE OF CONTENTS DRYER OPERATION A E 1 3 Installation T 4 Diver Control Panel ii 5 Diyer Start UD 7 Diver NICO Was ase ana 11 Viewing Temperature Moisture HIStOTry 11 Viewing BurnerFuel Train 9 0015 en ea 11 Viewing Grain Flow STIS aueh Ins 11 Setting
104. 21 12 251 74 i os a NPT Vent SH 7 en AR 1 f 5 connection Fig 1 A 7 Y Se gt ADJUSTMENT 2 3 5 and VENT CONNECTION 1 Go 5 21b for Differential Regulators 71 T Atmospheric Regulators t ES 9 and Zero Governors 3 24 YO N 25 2 Control t e a S line connection A rte En 121 8 HP High Pressure PU N NUN TENE SB 1 NPT Vent 1 u 1 connection 1 2 2 and 2 Model 121 Back Pressure gt 1 EN tet 1 4 NPT Control d ES 3 line connection 24 9 45 1 es 1 NPT Vent connection 21 LSR S b NEN 2 O 23 ts FEDO 24 X ji 25 es 9 7a 26 14 NPT Control AA 27 429 line connection at S a 1 Vent 116 m connection EI T E CINE 33 ON S cadi oe 34 E He ES 35 1 4 NPT Control T ee line connection NP LL A 2 14 140 15 16a 160 13 19a 19 18 38 37 32 121 8 HP High Pressure 121 12 Back Pressure Back Pressure nvensys Energy Metering Condensed Parts List 1 2 and 21 ILL DESCRIPTION Seal Cap Seal Cap Tetraseal or O Ring 21 4 x 23 Tetraseal or O Ring 11 2 x 1 s Adjustment Spring Button Spring Adjusting S
105. 24VDC Check Term 112 37 38 TROUBLESHOOTING Tower Dryer Ops amp Service Message What to do INTERLOCKED START TOP DRY CONVEYOR FIRST Check Term 112 INTERLOCKED START AUX WET CONVEYOR FIRST INTERLOCKED START WET LEG FIRST INTERLOCKED START TOP WET CONVEYOR FIRST ELEC I RICAL DIAGRAMIS WER PANEL Ge CK NO REVISIONS MAIN I 22928 RCUIT OOO 2820 e Le e e 990 113 E CE 1000 230V 6 8 84 1 10000460v 6 3 34 B 8 FU2 3 1000605757 6 37 34 150062307 8 6 18 1845 15000380 6 8 8 15008460vV 6 6 6A 15000575V 82676 000 000 OOO P000 230V 6 15 15 E j zi c0008460V 578 8 eu eu _ Ead BLW O1 ES oe 1 x P GND i GND GND ii GND GND GND WE f Eam 2s DE mam doce ESQ EST EN DES 955723 XL I m 15 za E 15 dj HU Sq L e HI H3 H2 H4 FOR 230V 5 1 d 2 GND GND Sie END s END A E EN SEL ox us a gif 8 M
106. 340 528 59 175 15 140 2 10 100 09 90 22A D8P7N104 3 7 5 0 87 340 528 8 6 9 0 15 140M C2E C16 100 16 145 Input Output Ratings Frequency to Hz Programmable UL508C EMC Directive 89 898 EEC LV Di 7323EEC Efficiency 97 5 Typical Us No 14 EMC EN 61800 3 Digital Control Inputs Input Current 6mA SRC Source Mode SNK Sink Mode 4 20mA Analog 250 ohm input impedance 18 24V ON 0 6V ON 0 10V DC Analog 100k ohm input impedance 0 6V OFF 18 24V OFF External Pot 1 10k ohms 2 Watt minimum Control Output Programmable Output form C relay Resistive Rating 3 0A at 30V DC 125V AC and 240V AC Recommended Fuses and Circuit Breakers Fuse UL Class J CC T or Type BS88 600V 550V or equivalent Circuit Breakers HMCP or Bulletin 140U or equivalent Protective Features Motor Protection 1 overload protection 150 for 60 Secs 200 for Secs Provides Class 10 protection Overcurrent 200 hardware limit 300 instantaneous fault Over Voltage 100 120V AC Input Trip occurs at 405V DC bus voltage equivalent to 150V AC incoming line 200 240V AC Input Trip occurs at 405V DC bus voltage equivalent to 290V AC incoming line 380 460V AC Input Trip occurs at 810V DC bus voltage equivalent to 575V AC incoming line Inductive Rating 0 5A at 30V DC 125V AC and 240V AC Under Voltage 100 120V AC Input Trip occurs at 210V DC bus voltage equivalent to 75V
107. 4x 2 30 M10 gt 30x 38 M12 gt 38 lt 50 M16 gt 50x 85 M20 gt 85 lt 130 M24 Inch lt 0 438 10 24 x 0 4 deep gt 0 438 lt 0 813 1 4 20 x 0 6 deep gt 0 813 lt 0 938 5 16 18 x 0 7 deep gt 0 938 lt 1 125 3 8 16 x 0 9 deep gt 1 125 lt 1 375 1 2 13 x 1 1 deep gt 1 375 lt 1 875 5 8 11 x 1 4 deep gt 1 875 lt 2 3 250 3 4 10 x 1 7 deep gt 3 250 1 8 x 2 2 deep Outboard pinion and sprocket fits should be as recommended by the pin sprockets with interference fits should be heated according to the manufacturers recommendations generally 250 F to 300 F 120 C to 150 C before assembling to the shaft LOCATION Coupling hubs should be mounted flush with the shaft ends unless specifically ordered for overhung mounting Pinions NN 9 M LAN IAS AS P N TN N R R E T 2 YV Ly sprockets and sheaves should be mounted as close as possible to the unit housing to minimize bearing loads and shaft deflections www nord com COUPLING ALIGNMENT Shaft couplings should be installed according to the coupling manufacturer s recommendations for gap angular and parallel alignment In many installations it is necessary to allow for thermal and mechanical shaft movement when determining shaft alignment The coupl
108. 68 Muncie IN 47307 Phone 765 284 3304 FAX 765 286 8394 www maxoncorp com Always include valve serial number and nameplate information to insure positive identification Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice CORPORATION MUNCIE INDIANA USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Electro Mechanical Valves Page 6100 S 7 Auxiliary Signal Switches Field Installation Instructions NOTE Instructions below are written for normally closed valves For normally open versions STO M STO A Fig 1 amp 2 reverse switch nomencla ture VOS becomes VCS and vice versa General Shut off fuel supply upstream of valve then de energize valve electrically Remove top or side cover to provide access being careful not to damage gasket Compare with illustrations at right to identify YOUR valve type To replace existing switches Note wand position and mounting hole location carefully then remove 2 screws and lift existing switch Install replacement switch in same mounting holes on bracket and verify correct wand position Replace existing wiring one connection at a time following original route and placement To add switches to existing valve Check illustrations at right If your valve uses a switch mounting bracket as in Fig 1 amp 2 mount switches to bracket using the mo
109. 760 F Minimum Upstream Oxygen 18 O NP1 LE Cast iron and aluminum NP2 LE Cast iron 6 Straight 12 Straight 12 Straight with Back Inlet 6 x 12 Tee 6 x 6 Elbow cast iron only 36 Back Inlet 12 x 12 H configuration Burner Bodies Burner Section Configurations Mixing Plates 430 Stainless Steel NP1 LE Standard Cast Iron Body Cast Iron End Plates AL Aluminum Body Cast Iron End Plates Assembly Material Availability ALSS Aluminum Body amp Back up Bars Nickle Plated End Plates Stainless Steel Fasteners NP2 LE Standard Cast Iron Body Cast Iron End Plates Spark Ignitor UV Flame Scanner Connection Flame Rod Adjustable Pilot Orifice Division Plate External Mounting Assemblies Accessories CO Emissions Profile NO Emissions Profile Nominal Conditions NP1 LE Nominal Conditions CO vs Temperature Rise NP1 LE vs Temperature Rise e Natural Gas Propane Natural Gas Propane ppm as measured CO ppm as measured BEER ma 0 20 40 60 80 100 120 140 160 180 200 Temperature Rise F Temperature Rise F Page 5553 Typical Applications for Maxon Series NP LE AIRFLO Burners Packaged Make up Air Systems with 100 Outside Air NP LE AIRFLO Burner Single stage Burner Heated Paint Spray Booths with Re heat Option Reheat N
110. 82 021 02 main spring TL Black Red 121 10 021 50 counterspring Model 31 2 to 61 2 w c Red Black 143 82 021 00 60 psi 121 8 5 to 81 2 w c Blue Black 143 82 021 01 AR 6 to 14 w c Green Black 143 82 021 02 12 to 28 w c Green 2 O D 143 16 021 05 1 psi to 2 psi Orange 2 O D 143 16 021 06 2 psi to 41 4 psi Black 143 16 021 07 3 psi to 6 2 psi 143 16 021 08 Cadmium 143 16 021 08 outer 60 psi 143 16 021 13 inner 143 16 021 03 main spring Nc 120 10 021 10 counterspring 11 5 to 12 wc 121 42 021 00 main spring 11 2 2 and 2 7 120 10 021 10 counterspring Model 3 7 061 WC Red 2 O D 143 16 021 03 60 psi 12 121 12 5 to 81 2 w c Blue 2 O D 143 16 021 04 6 to 14 w c Green 2 O gt 143 16 021 05 143 16 021 06 143 16 021 07 143 16 021 08 3 4 1 and 1 4 Model 121 8HP A 12 to 28 w c Orange 2 O D 1 psi to 2 psi Black 11 2 psi to 3 psi Cadmium 11 2 2 and 2 2 1psito2psi Orange 2 OD 16 021 06 Model 121 8 2 psi to 4 4 psi Black 16 021 07 P 112 2 and 21 5 3 psi to 67 2 psi Cadmium 143 16 024 08 16 021 08 Bb si Model 121 8HP 6 psi to 10 psi Cadmium 143 16 021 08 outer j White 143 16 021 13 inner 31 2 to 61 2 w c Red 3 O D 121 62 021 50 5 to 81 2 w c Blue O D 121 62 021 51 6 to 14 w c Green 3 O D 121 62 021 52 40 and 151 16 14
111. A Internal Transformer 220 Vac 50 60 Hz primary 24 Vac secondary 198162JA Internal Transformer 24 Vac 50 60 Hz primary 24 Vac secondary for electrical isolation 220736A Internal Auxiliary Switch Kit one switch can be field installed on TRADELINE models 220736B Internal Auxiliary Switch Kit two switches can be field installed on TRADELINE models 220738A Adapter Bracket raises motor shaft height by 19 mm to match that of previous Modutrol Motor models 220741A Screw Terminal Adapter converts the standard quick connect terminals to screw terminals 221455A Infinitely Adjustable Crank Arm can rotate through downward position and clear motor base without requiring an adapter bracket 4074ERU Weatherproofing Kit provides NEMA 3 rating for Modutrol IV Motors mounted in position other than upright 4074EZE Bag Assembly with parts that can provide CE compliance 7617ADW Crank Arm can rotate through downward position and clear motor base without requiring an adapter bracket ES650 117 Explosion Proof Housing encloses motor for use in explosive atmospheres Not for use with Q5001 or any other valve linkages Order separately from O Z Gedney Inc To order contact O Z Gedney Nelson Enclosures and Controls 918 641 7381 or 918 641 7374 or write to O Z Gedney Nelson Enclosures and Controls P O Box 471650 Tulsa OK 74147 1650 Requires Honeywell 7617DM Coupling Q100 Linkage connects Modutrol Motor to V51 Butterfly
112. AC incoming line 200 240V AC Input Trip occurs at 210V DC bus voltage equivalent to 150V AC incoming line 380 480V AC Input Trip occurs at 390V DC bus voltage equivalent to 275V AC incoming line Control Ride Through Minimum ride through is 0 5 Secs typical value 2 Secs Faultless Power Ride Through 100 milliseconds Dynamic Braking Internal brake IGBT included with all ratings except No Brake versions Refer to Appendix B of the PowerFlex 4 User Manual on CD for ordering information 200 240V AC 1 Phase drives are also available with an integral EMC filter Catalog suffix changes from N103 to N113 and N104 to N114 Refer to the Bulletin 140M Motor Protectors Selection Guide publication 140M SG001 to determine the frame and breaking capacity required for your application English 4 Power Wiring Power Wire Rating Unshielded 600V 75 C 167 F THHN THWN Recommended Copper Wire 15 Mils insulated dry location Shielded 600V 75 C or 90 C 167 F or 194 F RHH RHW 2 Belden 29501 29507 or equivalent Shielded Tray rated 600V 75 C or 90 C 167 F or 194 F RHH RHW 2 Shawflex 2ACD 3ACD or equivalent 5 12 T L3 UMI W T3 Power Terminal Block A Frame Shown Terminal Description eS ES eS eS ES R L1 S L2 1 Phase Input R L1 S L2 T L3 3 Phase Input BR BR U T1 To
113. C 0 15 AMP ruuv OPEN ee Je tel VALVE WIRING DIAGRAM VOS 2 er 27683 F SWITCH CONTACT POSITIONS CLUTCH SHOWN WITH VALVE CLOSED WARNING VALVE MUST 1 WIRED AS SWITCH RATINGS SHOWN Total connected load not to exceed 1800 VA SPDT DPOT 125 VAC 15 AMP 125 VAC 10 AMP 250 VAC 15 AMP 250 VAC 10 AMP 125 VOC 0 5 AMP 125 VDC 0 3 AMP L1 H 250 VDC 0 25 AMP 250 VDC 0 15 AMP AC POWER INPUT 7 9 7 8 79 10 11 10 12 NE 4 E 14 ne Ne jd PN SEE NAMEPLATE FOR VOLTS Hz VA RATINGS W Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice CORPORATION MUNCIE INDIANA USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Electro Mechanical Valves Page 6100 S 9 Electrical Data Normally Open Valves 75 2 Series STO M and STO A 5 2 5 4 Series STO MCP and STO ACP S SWITCH CONTACT POSITIONS VALVE WIRING DIAGRAM 26303 H1 SHOWN WITH VALVE CLOSED VOS 2 lt gt po VOS 1 MOTORIZED VALVE ONLY l SOLENOID WARNING INTERNAL VALVE WIRING MUST BE WIRED AS SHOWN INDEPENDENT T SOLENOID WIRING POWER SUPPLY 1 L2 N ACorDC SEE NAME PLATE FOR VOLTAGE AND Hz SWITCH RATINGS Total connected load not to exceed 1700 VA SPDT DPDT Herm S
114. C dry contacts in series between PLC amp 309 Do not forget to select the DRY CONVEYOR and DRY PATH PLUG options from the DRYER SETUP screen of the operator interface if those device are installed ES If the Dry Conveyor dumps into another conveyor in addition to the DRY LEG that must be running before starting Dry Conveyor we call this device AUX DRY CONVEYOR AUX DRY CONVEYOR TOP DRY CONVEYOR 403 1 You may purchase the optional starter push buttons amp pilot light installed in the O dryer panel which are connected as shown in the left and center draws 2 If you have an existing starter system for the AUX Dry Conveyor function connect the aux contact of your device as shown in the draw to the right 3 Do not forget to select the AUX DRY CONVEYOR option from the DRYER SETUP screen of the TOWER operator interface after the AUX DRY CONVEYOR is installed DRYER STARTER DCC 24VDC stop IN14 401 115VAC coil L 2 start 1 15 PLC 24VDC i PLC 24VDC 210 FAN 1 SES en cS 210 FAN 2 note located in control panel note located in power panel note located in power panel FAN 3 DRY LEG 402 UNLOAD Interlocked with the 1 If an optional DRY LEG STARTER was not provided with your panel connect your TOP DRY CONVEYOR ACK 21 2 starter as shown in the lest and center draws 2 If you have an existing DRY LEG STARTER with a separate control
115. CE SPECIFICATIONS Owner has the responsibility to consult with NORD GEAR if such items such as applied loads operating speeds or other operating conditions have changed Y WARNING LOCK OUT POWER before any maintenance is performed Make absolutely sure that no voltage is applied while work is being done on the gearbox START UP 1 Ensure that switches alarms heaters coolers and other safety and protection devices are installed and operational for their intended purpose 2 Verify that the installed mounting position is the same as the nametag mounting position If not adjust the oil level accordingly and relocate the vent plug fill plug and drain plug according to the mounting position See following AUTOVENT PLUG The Autovent plug is brass in color and will be located at the highest point on the gearbox It operates like a check valve to allow the reducer to relieve internal pressure while preventing lubricant contamination during cooling A spring presses a ball or plunger against a machined orifice until pressure exceeds 2 psi Above 2 psi the air is allowed to escape depressurizing the gearcase When internal pressure drops below 2 psi the autovent re seals closing the unit to the outside environment After shutdown the reducer cools along with the air inside the reducer The unit will temporarily maintain a slight vacuum until normalization occurs NORD Gear supplies an Autovent as a standard feature The Autovent
116. CONTACT FAILED TO CLOSE BLOWER 3 STARTER AUX CONTACT FAILED TO CLOSE BLOWER 4 STARTER SWITCH OPEN AIR PRESSURE SWITCH 1 SWITCH OPEN AIR PRESSURE SWITCH 2 SWITCH OPEN AIR PRESSURE SWITCH 3 SWITCH OPEN AIR PRESSURE SWITCH 4 SWITCH OPEN AIR PRESSURE SWITCH OF COMBUSTION BLOWER LOST FLAME SWITCH STUCK CLOSED MAXON VALVE FLAME DETECTED WHILE BURNER IS OFF HI GAS PRESSURE SWITCH OPEN LOW GAS PRESSURE SWITCH OPEN MAKE SURE MAIN GAS VALVE IS ON HI GAS PRESSURE SWITCH OPEN GAS PRESSURE TOO HIGH LOW GAS PRESSURE SWITCH OPEN GAS PRESSURE TOO LOW MAXON VALVES NOT TURN ON PL TEMPERATUR RTD CIRCUIT OPEN OR SHORTED GRAIN TEMPERATUR RTD CIRCUIT OPEN OR SHORTED AUXILIARY STUCK CLOSED OIL PUMP STARTER AUXILIARY STUCK CLOSED COMBUSTION BLOWER STARTER AUX CONTACT FAILED TO CLOSE OIL PUMP STARTER AUX CONTACT FAILED TO CLOSE COMBUSTION BLOWER STARTER PLUG SWITCH OPEN DRY PATH PLUGGED PLUG SWITCH OPEN HOPPER PLUGGED UNLOAD DRIVE FAULT OVERLOAD TRIPPED DRY CONVEYOR PLUG SWITCH OPEN WET PATH PLUGGED AUXILIARY STUCK CLOSED DRY CONVEYOR AUXILIARY STUCK CLOSED AUX DRY CONVEYOR AUXILIARY STUCK CLOSED DRY LEG AUXILIARY STUCK CLOSED TOP DRY CONVEYOR UNLOAD MONITOR PROXIMITY SWITCH OPEN AUXILIARY STUCK CLOSED AUX WET CONVEYOR AUXILIARY STUCK CLOSED WET LEG 36 Tower Dryer Ops amp Service What to do Check Term 203 Check Term 204 Check Term 200 Check Term 201 Check Term 202 Check Term 203 Check Term 204 Check Term
117. Controller These motors can be used with any electronic controller that provides a stable noise free proportional current output as specified in Electrical Ratings Input Range below Electrical Ratings Power Consumption See Table 2 Input Range Current Nonadjustable 4 to 20 mA nominal 25 mA maximum Current Adjustable 4 to 20 mA adjustable 50 mA maximum Zero Null Motor Closed 0 08 to 18 mA Span 1 8 to 18 mA Voltage Nonadjustable 2 to 10 Vdc Input Impedance 4 to 20 mA Input 100 ohms 2 to 10 Vdc Input 400K ohms SERIES 72 MODUTROL IV MOTORS TOP VIEW OF BRACKET 4 7 8 124 5 9 16 141 gt SPRING RETURN MODEL SHOWN N SOME MODELS DO NOT HAVE AN AUXILIARY SHAFT ALL OTHER DIMENSIONS ARE THE SAME A FOR HIGH TORQUE 60 LB IN SPRING RETURN MODELS 8 3 4 222 FOR LOW TORQUE 25 LB IN SPRING RETURN MODELS 8 1 4 210 NON SPRING RETURN MODELS 7 5 16 185 FOR HIGH TORQUE 60 LB IN SPRING RETURN MODELS SHOWN JA FOR LOW TORQUE 25 LB IN SPRING RETURN MODELS FOR NON SPRING RETURN MODELS M17089BB Table 2 Series 72 Modutrol IV Motor Power Consumption Ratings at 120 Vac 50 60 Hz 63 2202 4 SERIES 72 MODUTROL IV MOTORS Auxiliary Switch Ratings in Amps See Table 3 Table 3 Auxiliary Switch Ratings in Amps One Contact Fe 120V 240V 40 VA pilot duty 120 240 Vac on opposite contact
118. D x xi OUT13 24VDC pn DCC 215 54 54 NA note located in control panel note located in power panel note located in power panel WET CO NVEYOR B 405 Interlocked with the AUX WET CONVEYOR 215 DSertetvDe stop IN18 407 115VAC L 2 start IN19 PLC 24VDC aux PLC 24VDC aux 214 oa E z AUX WET CONVEYOR 406 Pe ij Y Interlocked with the g a a WET LEG 214 note located in control panel note located in power panel note located in power panel TOP WET CONVEYOR DCC 24VDC stop we Be coil ze start LIMITS UNLESS OTHERWISE SPECIFIED IN23 PLC 24VDC PLC 24VDC 213 0312 000 0156 ANGLES 1 THE GSI GROUP OUT 14 24VDC DCC 213 1004 E ILLINOIS ST ASSUMPTION IL 62510 2 TITLE TOWER DRYER CONTROL PANEL note located in control panel note located in power panel note located in power panel WIRING DIAGRAM DRY CONVEYOR THE DRY PATH This is the dry grain transport located directly under the dryer discharge hopper All tower dryer control panels include a starter to control this function Simply hook up the motor T leads to the starter amp check rotation The included dry Conveyor starter aux is the run permissive for the dryer unload Please use this starter If you wish to add plug switches to the Dry Conveyor remove the yellow jumper wire between PLC and 309 and install a N
119. EASES 40 to 230 F 40 to 110 C Synthetic Shell Aeroshell 6 40 to 230 F 40 to 110 C Food Grade Synthetic Lubriplate SFL1 BIM 1020 2005 03 6 WWW nord com LUBRICANT CAPACITY Each reducer has the oil level and oil quantity adjusted according to the mounting position shown in the tables When replacing the oil consult the tables below to determine the proper amount of oil to be installed according to the reducer size and mounting position Note that this is approximate and the final level will be adjusted when the reducer is installed Acceptable oil fill level is within Y inch of the bottom of the fill plug threads LUBRICATION CAPACITY SHAFT MOUNT CLINCHER GEARBOXES MOUNTING POSITION EN SK 0182NB quarts 0 58 ts sar a oar ao os SK0282NB quarts 1 06 ET Lites S77 18 53 Pie ras as liters quarts quarts 7 93 liters ZIEH SK 7282 quarts liters SK 8282 quarts ML quarts ML quarts E liters p 7 quarts Spe KAEA 17 5 28 5 27 43 3 41 76 1 72 95 206 195 4 0 2 2 21 4 9 33 4 0 95 169 160 liters UE E SK 1382NB quarts P es 135 ar io pom E Dites sns ere aon s cas zs e liters me quarts liters
120. ER PANEL OL BLOWER 4 BLW 4 OVERLOAD LOC POWER PANEL OL DRY CONV DRY CONV OVERLOAD LOC POWER PANEL ACK AIR PRE SWITCH 04 LOC APS 4 ACK OIL PUMP OIL PUMP AUX LOC POWER PANEL ACK COMBUSTION AIR BLOWER COMB BLOWER AUX LOC POWER PANEL 327 328 329 330 332 333 334 335 337 338 339 340 342 343 344 345 346 347 348 349 YELLOW JUMPER or 7 0 09 YELLOW JUMPER a 7 0 10 YELLOW JUMPER 3711 1 7 0 11 5 312 7 012 01 HO g RELAY SWEEP DRUM 313 1 7 0 13 oF O MONITOR ES NO 314 1 7 0 14 WS xg d E L 1 1 L 2 SEE PAGE 14 NS L 1 1 L 2 SEE PAGE 14 V lt TERMINALS IN POWER PANEL lt FIELD WIRING PLUG SWITCH DRY PATH LOC FIELD DEVICE PLUG SWITCH HOPPER LOC DISCHARGE AREA PLUG SWITCH WET PATH LOC DISCHARGE AREA ACK STANDALONE M CTR LOC POWER PANEL MONITOR UNLOAD ROTATION LOC UNLOAD UPPER BINDICATOR SWITCH LOC ROOF NOTE 120VAC FOR UB MOTOR LOWER BINDICATOR SWITCH LOC UPPER GARNER NOTE 120VAC FOR LB MOTOR LIMITS UNLESS OTHERWISE SPECIFIED 0 1 0625 00 0312 000 0156 ANGLES 1 PART NO THE GSI GROUP 1004 E ILLINOIS ST ASSUMPTION IL 62510 TITLE TOWER DRYER CONTROL PANEL WIRING DIAGRAM MAT L DESC P N DWG BY DATE DWG NO
121. Electrical Data SWITCH CONTACT POSITIONS VALVE WIRING DIAGRAM 26303 H1 SHOWN WITH VALVE CLOSED Voss ves vos 1 a MOTORIZED VALVE ONLY SOLENOID WARNING VALVE MUST BE WIRED AS SHOWN INTERNAL WIRING INDEPENDENT T SOLENOID WIRING POWER SUPPLY 4 4 L2 N ACorDC NAME PLATE FOR VOLTAGE AND Hz SWITCH RATINGS Total connected load not to exceed 1700 VA VALVE SPDT DPDT Herm Sealed 4 125 15 125 10 48 1 AMP 250 15 250 10 125 VAC 1AMP 5 1 125 0 5 125 VDC 0 3 48 VDC 3 AMP INTERMEDIAT 250 VDC 0 25 AMP 250 VDC 0 15 125 VDC 1 AMP FULLY OPEN SWITCH CONTACT POSITIONS VALVE WIRING DIAGRAM PRINTED eA SHOWN WITH VALVE CLOSED Pa NIE WARNING CIRCUIT BOARD ENERGIZED DO NOT TOUCH ELEC TRICAL COMPON ENTS EXPOSED INE LEADS TERMINALS OR CONTACTS VALVE MUST BE WIRED AS SHOWN 1 1 120 VOC OPTIONAL CLUTCH POWER SEE NAME PLATE NOTE DC POLARITY FOR VOLTAGE AND HZ MUST BE AS SHOWN SWITCH RATINGS TOTAL CONNECTED LOAD NOT TO EXCEED 1600 VA VALVE SPDT DPDT MODE er a AME T um T a J es 46 73 250 VAC 20 AMP 250 10 AMP Fuuv e ee Ab 125 VOC 0 5 AMP 125 VDC 0 3 AMP INTERMEDIATE pare far far e ab 250 VDC 0 25 AMP 250 VD
122. Fig A 6 817 5 011830 485 276 6 30 370 630 4 70 81900A 6185DA 212 310 050 126 1 93 984 4248 Base Mount Vertical Type Frame Size 6130 614H Fig 7 Base Mount Vertical Type Table A 18 Oll Level Dimensions Inches Frame Size 6130 614H Base Mount Vertical Type Frame Size 6160 6275 Fig A B Base Mount Vertical Type Table A 19 Oil Level Dimensions Inches Frame Size 6160 6275 18 76 B r 21 58 7 17 38 551 Note V6 amp 255 6265 Oi Gauge ls on me Ping Gear Housing instead of V Casing BEARINGS OIL SEALS GASKETS Fig A 9 18 1 02 1 03 3 02 3 04 3 03 19 Slow Speed Shaft High Speed Shaft Table A 20 Slow Speed Shaft Bearing i Reaction 02 Bear 03 BDF OCIA Go SOA on 6100 8105 19004 6110 8115 8120 8125 612H 612004 612504 812008 FE 6130 8135 1 0 613504 613008 613508 613006 4140 6145 614H ATADA 614508 614008 614508 6140040 _ 22211 E 6160 6185 BODA IB a DOC B 8178 Dc s In BIBDDA ETESDA 818008 618508 STANAN E 62203 819004 618504 819008 618508 Lah LL 11 _ 6222 821504 621508 622504823508 1226 623504 621508 6245DA B245DB Tn Tis Fan 6060 5085 BODA o 0 C
123. From Flame Hot Safeguard Neutral NOTES Push button must be tamper resistant Momentary Leak is fully open Shut off The From Flame Safeguard line is AID WE A energized only when all conditions for LS SV 1 Shut off Safe operation have been satisfied NJ Valve 2 N Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice CORPORATION MUNCIE INDIANA USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Electro Mechanical Valves Page 6100 S 13 Maintenance Instructions Suggested leak test procedure for double blocking shut off valves without vent line continued h Secure test apparatus on valve 1 1 Remove the 1 4 pipe plug from downstream side of shut off valve 2 Install leak test apparatus With an auxiliary power supply connected to valve 1 open test apparatus and test valve for leak age As a guideline valve should be tested for 2 minutes per inch of pipe diameter Large diameter pipes or long piping runs between shut off valves may need additional testing time k If valve testing indicates leakage exceeding 15 bubbles per minute perform pre operational exercising as outlined on Page 6100 S 2 and retest the valve If valve continues to exceed allowable leakage limit remove from service and contact Maxon Secure test apparatus on valve 2 m Upon completion of valve leak
124. IL 62510 WER DRY ANE ER CONTROL P WIRING DIAGRAM P N 04 10 04 DATE DWG NO E e sal Ic a UN SE R UN THE SIDE WALI F IHE LOWER BINDICATOR RE V dn UN MOISTUR TH YING SECTI WHT pcg WHI a ci er cece WHT Poona Nay BLK BLK MC7 BLK acota telnet MC AAA ECT EE RUNI IN GRAIN CULUMN A _ D D 604 amp S _ IM
125. IN M AM O N CORPORATION MUNCIE INDIANA USA Page 5550 S 4 Series NP LE AIRFLO Burners Start Up Instructions cont d A good minimum fire should provide uniform flame across the entire burner face contained within the zipper flame channel at the base of burner mixing plates Any thin spots or gaps indicate uneven air velocity over the burner which must be corrected or a higher minimum fire established by continuing to turn in on the minimum stop screw See drawing on page 5550 S 2 NOTE If your Maxon NP LE AIRFLO Burner was furnished with an adjustable gradient type Series or SYNCHRO Control Valve instead of a Series CV Valve refer to step 8A through 8l for specific instructions and differences in adjustment procedures For Series CV Valves skip to step 9 Adj Screws under cover 2 Handle for Manual Operation Position Indicator Pointer Locking Screw for manual operation A From step 5 the automatic control motor linkage has already been disconnected from your adjustable gradient type control valve and the valve is at its minimum position B Open fuel supply and begin adjustment of appropriate adjustable gradient valve by turning in minimum or lowest numbered screw until desired flame is achieved Main fuel regulator may need adjusted at this point C Once your flame is established and refined at this position and without advancing the screw carrier quadrant hi
126. Input 1 Preset Freq Program with A051 Digital In1 Sel A051 06 Digital Input 2 Preset Freq Program with A052 Digital In2 Sel A052 Drive supplied power for digital inputs DE Maximum output current is 100mA a Drive supplied power for 0 10V external potentiometer Maximum output current is 15mA 3 For external 0 10V input supply E input impedance 100k ohm or potentiometer wiper ii For 0 10V In or 4 20mA In Electronically isolated with Commen u analog inputs from digital I O 3 For external 4 20mA input supply 15 4 20 Not Active input impedance 250 ohm P038 8 Terminal should be connected to safety ground PE when 16 5485 DSI Shield using the RS485 DSI communications port Only one analog frequency source may be connected at a time If more than one reference is connected at the same time an undetermined frequency reference will result English 6 A Prepare For Drive Start Up ATTENTION Power must be applied to the drive to perform the following start up procedures Some of the voltages present are at incoming line potential To avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read and understand the procedure before beginning If an event does not occur while performing this procedure Do Not Proceed Remove All Power including user supplied control voltage
127. Motor Crank n By MEN 19 Control ie Motor lt ele a Connecting Linkage Motor Valve Mountin 4 4 Minimum Stop Screw Typical Control Motor To light and adjust gas pilot Pilot gas regulator should initially be set at 2 5 wc With pilot gas solenoid valves closed open main fuel gas and pilot gas cock Energize spark ignitor and open pilot gas solenoid Turn adjustable orifice screw out counter clockwise several turns from its fully seated position or adjust regulator pressure when fixed orifice is used Observe pilot ignition through a sight port and or by viewing micro amp signal metered from flame safeguard relay circuit Refine pilot setting for a hard blue flame and or strongest micro amp signal by adjusting gas flow through pilot orifice and or pilot regulator Prepare to ignite main burner by adjusting main gas regulator to approximately midpoint of its adjustment range Linkage arrangement for the use of Series CV Gas Control Valve is illus trated above for a typical control motor Arrange accordingly With control valve at minimum ignite main burner by opening main fuel shut off valves Adjust main gas regulator to give the desired outlet pressure Refine pilot adjustment if it has been affected Adjust burner minimum by turning in on the minimum stop screw of the gas control valve until stable flame appears in the narrow zipper channel at the base of burner mixing plates
128. NCIE INDIANA USA Page 5550 S 2 Series NP LE AIRFLO Burners Installation Instructions cont d Gas Train See piping layout below to identify various typical system components Pipe size of gas line must be large enough to assure ample fuel pressure at maximum system capacity Burner capacity is totally dependent on fuel differential being maintained See capacity specifica tion data for the actual fuel pressure required at the burner to achieve its rated capacity Clean fuel lines are essential to prevent blockage of pipe train components or burner gas ports All dirt scale and pipe dope should be blown out of any gas line before actually connecting to the burner system Main shut off cock should be upstream of both system regulator and pilot line take off Use it to shut off fuel to both pilot and main burner during extended shutdown periods Maxon Control Valves are not intended for tight shutoff Main system shut off should always be accomplished with a manual fuel cock Main gas regulator is essential to maintain a uniform system supply pressure A separate regulator should be provided in the branch leading to each burner system if more than one is served by a com mon main Size regulator for full system capacity at required pressure including pipe train losses The gas train piping illustrated should be installed as close to the burner as possible Pilot take off should be upsteam of main gas regulator but downstr
129. Note Filling quantities are approximate figures Oil level must be checked according to oil level plug after final installtion Acceptable oil fill level is within 1 2 inch of the bottom of the fill plug threads For mounting angles not shown consult factory BIM 1020 2005 03 www nord com PARTS LIST 5 1382 K5382 52 53 54 uu SS OO ved oU el 57 61 204 203 A 234 27 2 80 45 1b5 29 M8 28 62 63 SK 6382 SK 11382 20 20 245 2 3 M 4 4 2 BIM 1020 2005 03 9 Driving gear Hexagon screw Seal Supporting disc Third reduction gearcase Ball bearing Key Ball bearing Grclip Key Grclip Intermediate shaft plain Intermediate shaft gearcut im Arclip Drain plug Seal Driving gea Pinion shaft SK 6382 SK 9382 Driving pinion Output shaft Key Locking cap Supporting disc Drain plug Seal Grclip Ball bearing Key Shim Ball bearing Supporting disc Locking cap Spacer www nord com TROUBLE SHOOTING PROBLEM WITH THE REDUCER POSSIBLE CAUSES SUGGESTED REMEDY Check rated capacity of reducer replace Load exceeds the capacity of the Overloading with unit of sufficient capacity or reduce reducer e Check lubricant level and adjust up to Insufficient lubrication Runs Hot recommended levels m Check lubricant level a
130. O Burner during uncrating and installation These burners are used for the heating of fresh air in motion Mount the burners so they fire parallel to and in the same direc tion as the movement of the air see sketch 1 at right Velocity and flow of air at operating temperature 1 must be uniform Minimum silhouette profile plates of 6 should be installed in duct to completely surround burner assembly Adjustabie Profile Supports Series NP LE AIRFLO Burner assemblies must be adequately supported and positioned Avoid rigid mounting Burner assembly expands and contracts with temperature variations Maintain smooth even air flow over the burner by designing supports to provide minimum interference deflection and turbulence The sketches below show typical installation and support methods Allow Space for Burner Expansion Air Air Movement Strap Iron Frame Maxon Support Brackets Movement Bolt or Rod Long enough to permit brackets to move with burner expansion Angle Iron Strap Iron Support Frame 6 03 INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Stra To Maxon practices a policy of continuous product improvement lt reserves the right to alter specifications without prior notice Sketch 2 shows the burner suspended from a strap iron frame using Maxon USB support brackets Note that rigid mounting is avoided by the bracket hole which sl
131. OGN ME ER RH 6078 513004 613504 61400 B145DA en TE POTERE 6060 5085 830153 63022 BOO4PSHEZZC3 1 612008 612508 613006 BE 614008 614408 oe 616004 BIESDA 617004 61750A En A 613000 613500 614000 614550 616006 516508 517008 617508 8180DA 6185018 6110 6118 6120 6125 612H RENTEN 618008 014508 610008 619508 620508 xm 82150 622504 6160 6165 621508 629504 624504 BITO GITS 625508 CIN 823508 624508 _ 610 6198 E255DH B82550A amp 273DA 6205 6215 6225 ote 1 For grease lubricated modals a sealed bearing should used which changes the fofewirg batters in me pan number to those shown in bold NR 1584 ZNA NXR ZNXR Nooo add 2 BEARINGS OIL SEALS GASKETS Fig A 10 a 3 04 03 19 Retaining Ring Slow Speed Shaft Intermediate Shaft High Speed Shaft For Double Reduction Units Table A 22 Eccentric sean ng 512004 6512504 613004 613504 61400DA amp 145DA 616004 616504 612008 612508 amp 130DB 813508 414008 014508 6168008 616508 B130DC B135DC 6140DC ISDC B15DDC 5165DC EOL RS aoaos isvsx 6100 TREE SHOTIYSX etage TIYSX 60908 15YSX BiDiT 35YRX 6121317 B1413 17Y8X 61611 18YSX SOS 81011 18 121115 5 61413 178 amp 1413 17Y8X B1611 15Y5X
132. OINT MOISTURE CONTROLLER Tower Dryer Ops amp Service Optional Tri Point Moisture Controller Operation Manual Tower Dryer Ops amp Service TRI POINT MOISTURE CONTROLLER I Main Screen 7 04 21 04 DRYER CONTROL CENTER 11 49 02 DRYER RUNNING This run Ohr 18 min Total O hr 18 min Capacity 600 BPH PL TEMP F 182 1 Two hour moisture history chart green line for incoming moisture yellow line for outgoing moisture and the red line is the target moisture 2 Moisture Control button to access the Moisture Control Set up screen 3 Data Log button to access the mois ture history data up to last 30 hours 4 Back browse button to scroll the chart back in time 5 Forward browse button to scroll the chart in forward time B BLOWER PILOT BURNER MAIN FUEL UNLOAD DRY PATH WET PATE UL RATE MOST CONTROL 6 Moisture target To change the mois ture target press within the rectangular area and key the new target from the pop up keypad 7 Current moisture coming out of the dryer 8 Current moisture coming into the dryer 9 Moisture control status the LED turns on 1f the moisture controller is In auto mode 13 TRI POINT MOISTURE CONTROLLER Tower Dryer Ops amp Service II Set Up of the Controller Press the MOIST CONTROL button from the main screen to access the moisture set up screen
133. P LE AIRFLO Burner If Required Bag ee ree Filters Humidifier Drying Baking amp Curing Operations NP LE AIRFLO Burner Filter Packaged Make up Air Systems with Partially Recirculated Air NP LE AIRFLO Burner Supply Return Air Air Humidity Controlled 2 stage Burner Heated Paint Spray Booths Staged NP LE AIRFLO Burner Humidifier Supply 9 Air Bag Filters Grain Dryers Grain Bin Hot Air Chamber NP LE AIRFLO Burner Cooling Chamber Page 5554 Design and Application Details System components normally used in conjunction with a Maxon NP LE AIRFLO Burner application E lis Intake Louvers m Plate alt AIRFLO Burner ee Walls 9 y Main Volume Fan Legend NUS Description 1 Outside thermostat 2 Intake high temperature limit switch 3 Control valve 4 Vent valve 5 Strainer 6 Drip leg 7 Differential air switch 8 High temperature switch 9 Discharge air thermostat Sequencing Control Panel CORPORATION 201 East 18th Street P O Box 2068 Muncie Indiana 47307 0068 Phone 765 284 3304 Fax 765 286 8394 Series NP LE AIRFLO Burners Page 5550 S 1 Installation Instructions General Important Do not discard packing material until all loose items are accounted for Avoid bending or damaging the steel mixing plates of your Series NP LE AIRFL
134. PLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION INSTALLATION LAYOUT SUITABILITY FOR A PARTICULAR PURPOSE OR DESIGN OF SUCH PRODUCTS GSI shall not be liable for any direct indirect incidental or consequential damages including without limitation loss of anticipated profits or benefits The sole and exclusive remedy is set forth in the Limited Warranty which shall not exceed the amount paid for the product purchased This warranty is not transferable and applies only to the original end user GSI shall have no obligation or responsibility for any representations or warranties made by or on behalf of any dealer agent or distributor GSI assumes no responsibility for claims resulting from construction defects or unauthorized modifications to products which it manufactured Modifications to products not specifically delineated in the manual accompanying the equipment at initial sale will void the Limited Warranty This Limited Warranty shall not extend to products or parts which have been damaged by negligent use misuse alteration accident or which have been improperly inadequately maintained This Limited Warranty extends solely to products manufactured by GSI Prior to installation the end user has the responsibility to comply with federal state and local codes which apply to the location and installation of products manufactured or sold by GSI 9101239 CR rev5 DOC revised April 2009 This equipment shall be i
135. STRUCTIONS bulletin for pressure ratings The regulator outlet has a lower pressure rating than the inlet Do not expose the regulator outlet or control line to inlet pressure 2 Regulators manufactured for use with a control line and having a diaphragm chamber sealed from the body outlet chamber may be used as the upstream regulator in a monitor set The sealed body outlet chamber can be exposed to pressure higher than the normal outlet pressures Do not use a regulator manufactured for internal control nor a regulator having a control line with an open throat as the upstream regulator in a monitor set Doing so could result in a system failure where damage could occur along with personal injury 3 Overpressure protection such as relief valves automatic shutoff valves monitors etc are recommended to protect both the inlet and outlet side of the regulator if the inlet pressure is or could be greater than the emergency pressure rating for the regulator outlet or diaphragm chamber install suitable over REMOTE VENT LINE if required m TYPICAL INSTALLATION INSTALLATION AND START UP 1 Follow the appropriate REGULATOR INSTALLATION AND MAINTENANCE INSTRUCTIONS bulletin for the regulator when installing operating maintaining and servicing it KEEP THE BULLETIN FOR FUTURE REFERENCE If any of these instruc tions are not understood or there are any questions phone your Equimeter sales representative 2 Installation o
136. SWITCH CAM RED PRI E LEFT OUTER Ti AUXILIARY SWITCH NOTE FEATURES AVAILABLE ON SOME MODELS ONLY 2 TO 10 VDC INPUT MOTORS T2 3 Fig 5 shows that motor terminals are quick connects located on top of the printed circuit board 4 To access the wiring compartment a Remove the four screws from the junction box top b Lift off the cover 5 Fig 6 shows the internal wiring schematic 6 Refer to Fig 7 and 8 for typical wiring Wire the motor as follows 1 Remove the wiring box cover by removing the four screws holding the cover to the motor 2 Wire motor to system using quick connect terminals in wiring box 3 Replace wiring box cover AUXILIARY SWITCH 6 INNER AUXILIARY SWITCH CAM BLUE POWER END ig oe OUTER AUXILIARY SWITCH CAM RED Que Q LEFT OUTER AUXILIARY SWITCH NOTE FEATURES AVAILABLE ON SOME MODELS ONLY 4 20 mA NONADJUSTABLE INPUT MOTORS SPAN ADJUST E n SPAN ADJUST MINE MAX START ADJUST MINEN MAX E RIGHT INNER LO Ne 120b 24 B INNER AUXILIARY HAT SWITCH CAM BLUE POWER END OUTER AUXILIARY SWITCH CAM RED SI LEFT OUTER AUXILIARY SWITCH START ADJUST POTENTIOMETER NOTE FEATURES AVAILABLE ON SOME MODELS ONLY M5777 4 TO 20 mA ADJUSTABLE INPUT MOTORS Fig 5 Terminals and adjustments 63 2202 4 8 SERIES 72 MODUTROL IV MOTORS CONTROLLER ELECTRONIC BRAKE CIRCUITRY V ix L1 UN
137. The junction box standard with replacement motors encloses the terminals and provides knockouts for wiring conduits Housing an internal transformer or internal auxiliary switches requires using a junction box STANDARD g BOLTS 4 A ADAPTER BRACKET EQUIPMENT BASE er N No 12 OR 1 4 in ZINC PLATED MACHINE SCREWS OR BOLTS M452E NON SPRING RETURN SERIES 72 MODUTROL IV MOTORS SPRING RETURN Fig 3 Mounting the motor with an adapter bracket PE WIRING BOX y MOTOR m 05001 VALVE LINKAGE 0 1 4 20 UNC 1 in LONG MOUNTING Tj BOLTS VALVE M17092 Fig 4 Mounting the motor on a Q5001 Valve Linkage 63 2202 4 SERIES 72 MODUTROL IV MOTORS Wiring N CAUTION Electrical Shock or Equipment Damage Hazard Can shock individuals or short equipment circuitry Disconnect all power supplies before installation Motors with auxiliary switches can have more than one disconnect IMPORTANT All wiring must agree with applicable codes ordinances and regulations 1 Ensure that the voltage and frequency stamped on the motor correspond with the power supply characteristics 2 When connecting several motors in parallel ensure that the power supply V rating is large enough to provide power to all motors used without overloading RIGHT INNER AUXILIARY SWITCH INNER AUXILIARY SWITCH CAM BLUE POWER END IT OUTER AUXILIARY
138. Toggle Clamp Bolt A Toggle Clamp Bolt A Toggle Clamp A Mount with three short bolts Codina Les and nuts at indicated holes a Connectin By E Linkage Other VA i Linkage g Control 7 Control I WA o Str VOV Toggle y ers y Others Penn Johnson SSL nn Valve M80 M81 ti oe Base r aera ge MD3 600 Crank T Minimum Minimum Mount with two short bolts Stop Screw Stop Screw and nuts and long bolt 90 Control Motor 160 180 Control Motor screwed into operator base through slotted hole Crank amp Linkage Side 11 90 Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice W CORPORATION INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES MUNCIE INDIANA USA Page 7000 S 2 Flow Control Valves Adjusting Instructions Notice Only generalized instructions can be provided here Detailed adjusting instructions are provided with each individual Maxon burner and or mixer system General Instructions Important Do not discard packing materials until all loose items are accounted for To prevent damage in transit some connecting base and linkage components may be packed separately and shipped loose with your new Maxon Flow Control Valve The Flow Control Valve is normally only a part of your complete combustion system Ad
139. W YOO INSULATED WIRE GA EQUAL FLAME SITE MUST NOT BL iN GAME CONDUITS WITH POWER IGWITION CABLE MUST RUN IM SEPARATE CONDUIT TO SPARK ELECTRODE MIX WITH AA WIRING MOST DI i WIRING AND INSTALLATIGM TO lt OPERATING SIGNAL CONFORM WITH NATIONAL AND LIM FAD P C Hr LOCAL ELECTRICAL CODES FLAMLADO ALL WIRING EQUIPMENT FELLOW i PROTECTOFIER VIDLET SE AMMER E UNLESS OTHERWISE SPECIFIED Lu ID INS TALLETION OPERATION AND Mare T SHALL CONFORM WITH HAT FIRE PRaOTCCTION ASSOCIAT BTAMDAROS SATION AL ANO LOCAL AND AUTHOEITICG WAVING JuRISDICTIDM UTE DIAG RAM F DR PROTECTOFIER FORM 642 VAGRDUP M2101 DATE unm 530 5 X 735 ion DES RENISED AMODREDRAWN REV 9 30 81 SPARK 5 VALVE INTERCONNECTION DIAGRAM gt GROUP GSD Limited Warranty The GSI Group LLC GSI warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end user or if a foreign sale 14 months from arrival at port of discharge whichever is earlier The end user s sole remedy and GSI s only obligation is to repair or
140. Y lt TERMINALS IN POWER PANEL FIELD WIRING LOC POWER PANEL ACK DRY CONV DRY CONV AUX LOC POWER PANEL gt ACK AUX DRY CONV DRY CONV AUX LOC POWER PANEL ACK DRY LEG DRY CONV AUX LOC POWER PANEL ACK TOP DRY CONV TOP DRY CONV AUX LOC POWER PANEL WET CONV TOP WET CONV AUX LOC POWER PANEL ACK WET LEG TOP DRY CONV AUX LOC POWER PANEL ACK AUX WET CONV AUX WET CONV AUX LOC POWER PANEL LIMITS UNLESS OTHERWISE SPECIFIED 0 0625 00 0312 000 0156 ANGLES 1 PART NO THE GSI GROUP 1004 E ILLINOIS ST ASSUMPTION IL 62510 TITLE TOWER DRYER CONTROL PANEL WIRING DIAGRAM MAT L DESC P N DWG BY DATE DWG NO QL 04 10 04 SCALE SHEET 06 OF 18 415 300 17 000 O 310 311 312 313 314 315 316 317 318 319 321 322 323 BLW 01 301 1 7 0 01 ONG BLW 02 302 1 7 0 02 66 86 x 303 1 7 0 03 304 1 7 0 04 O 305 1 7 0 05 O 2 306 1 7 0 06 5 Dr e BLW 04 OIL PUMP 307 1 7 0 07 COMB BLW 308 1 7 0 08 O OL TRI START TRI START OVERLOAD LOC POWER PANEL OL BLOWER 1 BLW 1 OVERLOAD LOC POWER PANEL OL BLOWER 2 BLW 2 OVERLOAD LOC POWER PANEL OL BLOWER 3 BLW 3 OVERLOAD LOC POW
141. ading limits and change them if needed 6 Press the CONTROL MODE button from the moisture control set up screen and set the mode to AUTO The moisture controller will start adjusting the unload rate between the upper and lower limits of the unload speed to maintain the moisture coming out of the dryer IV How the Controller Works The controller continuously monitors the moisture coming in and out of the dryer and the column grain temperature at the end of the drying section The control action is mainly based on the dry sensor at the outlet of the dryer If the moisture coming out of the dryer is not right at the target the con troller will speed up or slow down the unload device accordingly The wet sensor and the column grain temperature sensor ar intended to detect moisture spikes coming into the dryer so that the moisture controller can react ahead of time For example if the wet sensor detects a jump of moisture coming into the dryer the controller will start slowing down the unload speed right away However the controller does not act to the full scale immediately Instead it 16 slows down the dryer gradually so that the grain currently in the dryer will not be overdried too much In the first pass after the dryer started the controller does not have enough informa tion of the grain in the dryer It controls the dryer by using the manual speed setting as a starting point In other words the manual
142. aged install a complete ASCO Rebuild Kit Valve Reassembly 1 Lubricate solenoid base gasket and body gasket with DOW CORNING 200 Fluid lubricant or an equivalent high grade silicone fluid 2 Install body gasket and core diaphragm sub assembly in valve body Locate the bleed hole in the diaphragm assembly approximately 45 from valve outlet The core diaphragm sub assembly is comprised of a rider ring core spring core guide hanger spring core assembly and diaphragm assembly CAUTION Do not distort hanger spring between core assembly and diaphragm assembly DuPont Co Registered Trademark Printed in U S A Page 1 of 2 50 Hanover Road Florham Park New Jersey 07932 www ascovalve com 3 Replace valve bonnet and bonnet screw on valve body Hand thread screws a few turns into valve body then torque bonnet screws in a crisscross manner to 70 8 in lbs 8 0 0 9 Nm 4 Install solenoid base gasket and solenoid base sub assembly Compress rider ring slightly to prevent damage when installing solenoid base sub assembly Torque solenoid base sub assembly to 175 25 in Ibs 19 8 2 8 Nm 5 Install solenoid see separate instructions and make electrical hookup 44 WARNING To prevent the possibility of death serious injury or property damage check valve for proper operation before returning to service Also perform internal seat and external leakage tests with a nonhazardous noncombustible fluid Part
143. ally attached on the right side when viewed from the vent plug Pg A 3 Fig A 2 Part 14 After filling apply slow speed shaft end sealing tape to threads of the vent piug before installing When draining oil remove drain plug Fig A 5 Part 46 or lower side plug of the oil level gauge Table A 11 Standard Oils Mobil Oil Shell Oil BP Qil monou senon mo Fig 5 141541 1 30 05 5 EP Lubricant Spartan Mobilgear 626 Oil Energol HD 68 EP 68 ISO VG 68 68 GR XP 68 cubricant Spartan sopiigear 627 629 90 32 086 01035 HD100 100 ies 100 HD 150 episg 89 9100 150 100 150 ACRE 15 EP Lubricant Spartan Mobilaear Eneraol AG to HD 220 EP 220 630 632 220 122 pis HD 320 EP 320 633 634 20 320 GA XP 3 HD 460 EP 460 ISO VG 220 460 460 460 Notes 1 Use the lower viscosity oil specified each ambient temperature range for use in winter or relatively low ambient temperatures 2 Please consult the factory for consistentuse in ambient temperatures other than 32 F 104 F 0 C 40 C A 8 Table A 12 Oil Fill Quantities _ Hanas 6140 6148 B14H 5180 a 185 0 66 zs es 20 7 to ELE 2450 624508 4 is with trochoid pump Table A 13 Alowab Viscosity
144. als or short equipment circuitry Disconnect all power supplies before installation Motors with auxiliary switches can have more than one disconnect N CAUTION Equipment Damage Hazard Can damage the motor beyond repair Never turn the motor shaft by hand or with a wrench Forcibly turning the motor shaft damages the gear train and stroke limit contacts Adjustable cams actuate the auxiliary switches These cams can be set to actuate the switches at any angle within the motor stroke Select switch differential of 1 or 10 Motors with factory added auxiliary switches are shipped in the closed position fully counterclockwise as viewed from the motor power end with auxiliary cams set to actuate switches 30 from the closed position and to provide 1 degree differential With the motor in the closed fully counterclockwise position the auxiliary switch breaks contacts R B See Fig 10 for auxiliary switch wiring TRADELINE Motors are shipped with auxiliary switch cams that permit acceptance of 220736A B Internal Auxiliary Switch Kits Refer to form 63 2228 for 220736A B Installation Instructions Auxiliary Switch Adjustment IMPORTANT When adjusting the auxiliary switch cams use the following procedure 1 Insert 1 8 in screwdriver blade into a slot on cam and move the screwdriver top as far as possible in the required direction See Fig 10 2 Repeat step 1 in successive cam slots until the cam is in the required pos
145. and maintenance instructions for maximum fluid temperature NOTE For steam service refer to Wiring section Junction Box for temperature rating of supply wires Temperature Limitations For Series 8003G or 8202G Solenoids for use on Valves Rated at 10 1 11 6 17 1 or 22 6 Watts Watt Catalog Class of Maximum Rating Number Coil Prefix Insulation Ambient Temp None FB KF KP 2 2 None FB KF KP o HT KB KH E t Minimum ambient temperature 40 40 Positioning This solenoid is designed to perform properly when mounted in any position However for optimum life and performance the solenoid should be mounted vertically and upright to reduce the possibility of foreign matter accumulating in the solenoid base sub assembly area Wiring Wiring must comply with local codes and the National Electrical Code All solenoids supplied with lead wires are provided with a grounding wire which is green or green with yellow stripes and a 1 2 conduit connection To Printed in U S A Page 1 of 4 50 Hanover Road Florham Park New Jersey 07932 www ascovalve com facilitate wiring the solenoid may be rotated 360 For the watertight and explosionproof solenoid electrical fittings must be approved for use in the approved hazardous locations CAUTION Cryogenic Applications Solenoid lead wire insulation should not be subjected to cryogenic temperatures Adequate lea
146. asket is still in place between the body and top housing 10 Reinsert the body bolts up from the bottom through the body and carefully engage threads of the top assembly Tighten securely 11 Reconnect conduit and electrical leads then check that signal switch wands are properly positioned and that open shut indicator moves freely Failure to correct any such misalign ment can result in extensive damage to the internal mechanism of your valve 12 Energize valve and cycle several times from closed to full open position Also electrically trip the valve in a partially opened position to prove valve operates properly 13 Replace and secure side cover access plate and place valve in service 10 24 Operator Cover 25 in lbs 25 20 All other access covers 50 in lbs 25 20 Extended Access Cover Plate 96 in lbs 31 Body Bolts 15 ft lbs 38 Body Bolts 40 tl lbs Alternate Top Assembly Positions Four top assembly positions are available for most Maxon valves When looking at the open shut window indicator of an electro mechanical valve assembly the motor for motorized version or the operating handle for manual version will be on the right side of the top assembly The valve body is on the bottom From this view the unidirectional valve AW body and the arrow on the valve body casting points in direction of fluid flow to the right position R to the left position L towards you position TO or aw
147. ass II Groups F amp G Dust Locations designation is not applicable for solenoids or solenoid valves used for steam service or when a class H solenoid is used See Temperature Limitations section for solenoid identification and nameplate retainer for service When installed just as a solenoid and not attached to an ASCO valve the core has a 0 250 28 UNF 2B tapped hole 0 38 or 0 63 minimum full thread NOTE Catalog number prefix EV denotes stainless steel construction Catalog numbers 820261 820263 820265 and 8202G7 are epoxy encapsulated push type reverse acting solenoids having the same enclosure types as previously stated for Catalog numbers 8003G1 and 8003G2 Series 8003G and 8202G solenoids are available in Open Frame Construction The green solenoid may be supplied with 1 4 spade screw or DIN terminals Refer to Figure 4 Panel Mounted Construction These solenoids are specifically designed to be panel mounted by the customer through a panel having a 062 to 093 maximum wall thickness Refer to Figure 1 and section on Installation of Panel Mounted Solenoid Optional Features For Type 1 General Purpose Construction Only e Junction Box This junction box construction meets Enclosure Types 2 3 35 4 and 4X Only solenoids with 1 4 de spade or screw terminals may have a junction box The junction box provides a 1 2 conduit connection grounding and spade or screw terminal connections within the
148. ates lip dust proof and seal lip type A 13 DISASSEMBLY ASSEMBLY Disassembly SM CYCLO Reducers are designed to provide maximum ease when disassembing and reassembling they require no special maintenance skills 1 Remove the complete SM CYCLO Reducer with adaptor motorized type from the driven machine 2 Remove the plug at the bottom of the oil gauge to drain all oil from the unit 3 Remove the cooling fan cover and fan from those opeed Reducers not motorized equipped with a cooling fan and stand the unit on a solid base with its high speed shaft side down Remove the through bolts for the high speed end shield ring gear housing and lift the slow speed side thus separating the unit into two parts so that the inner mechanism can be removed Figs A 12 7 A17 Note If the reducer is motorized C adaptor and coupling remove the motor and coupling before following the procedure outlined above As a final step remove the adaptor and cooling fan 4 If the unit will not separate easily gently drive a wedge at the line X shown in Fig 1 on page 3 if this produces a burr be sure to remove it before reassembly 5 To lift the slow speed side attach an eyebolt to the tapped hole on the end of the slow speed shaft and use a hoist or chain block Fig A 12 6 Take out the slow speed shaft rollers item 1 06 page A 3 Fig A 13 Check the slow speed shaft pins 1 01 to see whether any rollers h
149. ave adhered to them T Using both hands lift out the top cycioid disc 2 04 on the slow speed side Fig A 14 8 Remove the spacer ring 2 05 9 The eccentric 3 04 can be removed from the input shaft 3 01 after taking out the retaining ring M S and the inner bearing raceway Figs A 15 16 Note In certain sizes the eccentric bearings are roller bearings without a retainer Remove bearings of the top disc before proceeding with the next step 10 Take out the second disc located on the motor side Also remove second disc bearings and eccentric with inner bearing raceway if required 11 Removethe ring gear housing 2 01 12 Follow these steps to remove the slow speed shaft 1 01 with its bearings from the casing 26 a Remove the horizontal oil seal housing 25 b With a wooden or hard rubber mallet rap the inner end of the slow speed shaft to expose the retaining ring from the outer raceway of the bearing c Remove the retaining rina d Rap the outer end of the slow speed shaft with a wooden or hard rubber mallet and remove it from the casing 13 The high speed shaft 3 01 with bearings is removed from the high speed shaft end shield 8 by tapping the shaft end after first taking off the retaining ring 3 11 14 The cvcloid disc is made from heat treated bearing steel and the spacer ring is cast iron Take care not to strike them together while handling The above instructions cover comp
150. ay from you position AW With smaller size swinging gate valve bodies only position R and position TO may be used Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice CORPORATION MUNCIE INDIANA USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Electro Mechanical Valves Page 6100 S 5 Operating Instructions Refer to appropriate catalog bulletin and specifi cation page for operating sequence applying to your specific valve Never operate valve until all essen tial allied equipment is operative and any neces sary purges completed Failure of electro mechani cally operated valve to operate normally indicates that it is not powered Check this first Then check internal holding solenoid and or motor operator Main system shut off should always be accom plished with an upstream leak tight manual fuel cock All Maxon valves react within a fraction of a second when de energized can drop out if electrical power is interrupted for less than 1 2 cycle 8 ms All electro mechanical manual reset valves may be operated manually when solenoid is electrically energized but electrical tripping is recommended for normal shut downs Electro mechanical manual reset valves require two positive actions to open a half rotation of handle to latch internal mechanism and a reversed half rotation of handle to open valve This re
151. base sub assembly through customer panel 3 Position spring washer on opposite side of panel over solenoid base sub assembly 4 Replace solenoid nameplate retainer and red cap 5 Make electrical hookup see Wiring section Solenoid Temperature Standard solenoids are designed for continuous duty service When the solenoid is energized for a long period the solenoid becomes hot and can be touched by hand only for an instant This is a safe operating temperature MAINTENANCE WARNING To prevent the possibility of death serious injury or property damage turn off electrical power depressurize solenoid operator and or valve and vent fluid to a safe area before servicing Page 2 of 4 Cleaning All solenoid operators and valves should be cleaned periodically The time between cleaning will vary depending on medium and service conditions In general if the voltage to the solenoid is correct sluggish valve operation excessive noise or leakage will indicate that cleaning is required Clean strainer or filter when cleaning the valve Preventive Maintenance Keep the medium flowing through the solenoid operator or valve as free from dirt and foreign material as possible e While in service the solenoid operator or valve should be operated at least once a month to insure proper opening and closing Depending on the medium and service conditions periodic inspection of internal valve parts for damage or excessive wear
152. body face Any accumulation of scale or foreign material on either side of the mixing plates should be removed with a wire brush Check visually that no holes in the mixing plates are blocked See next page 5550 S 12 for inspec tion and maintenance instructions for gas ports WARNING Do not enlarge burner ports or performance may be drastically affected If any mixing plates are loose or missing fasteners tighten replace as necessary Always use zinc plated or stainless metric fasteners 3 Put system back into operation and if possible view from downstream side while cycling burner through full firing range This will give a visual check for blocked burner ports 4 Observe flame pattern and if necessary take steps to correct velocity and or air distribution problems Repair Replacement Procedures If adverse operating conditions or accidental damage make it necessary to replace either individual mixing plates or complete burner sections follow this procedure 1 ldentify necessary replacement parts from component identification drawings on preceding pages then order required quantities of each Consider carefully the economics of installing a complete replacement burner instead of replacing individual parts Once exposed to actual flame temperatures burner castings harden and the removal and replacing of fasteners can be time consuming and difficult Accessibility may also be severely limited requiring removal of co
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154. chanical top assemblies the motor access side plate 2 should always be vertical to the ground Valves are usually installed in horizontal piping however other 1 00 Maxon practices policy of continuous product improvement It reserves the right to alter specifications without prior notice CORPORATION INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES MUNCIE INDIANA USA Page 6100 S 2 Electro Mechanical Valves Installation Instructions conta orientations are acceptable subject to the above limitations The top assemblies of all Maxon valves are field rotatable to allow installations involving conflicts with these mounting restrictions F Main system shut off should always use a manual leak tight upstream fuel cock G Time lag between valve action and fluid flow or flame response is reduced if valve is located near the burner or outlet 4 Wire the valve in accordance with all applicable codes and standards Supply voltages must agree with valve s nameplate voltage within 15 10 AC or DC for proper operation For electrical B Maintain integrity of Maxon top assembly enclosure by using dust and water tight electrical connectors Use cable sealing grips and strain relief loops for any cord or cable Use internal sealing materials on all conduit connections Moisture can have a harmful effect on valve internals if permitted to enter through wiring connectors Make sure that all access co
155. close b If the contacts are closed rotate the cam clockwise until the R B contacts open c Make final adjustment in the proper direction to obtain contact make or break at the desired position 9 Check for the proper differential and switching of the auxiliary equipment by driving the motor though the full stroke in both directions 10 Disconnect power remove current source reconnect the controller and replace the top cover on the motor NOTE Changing the differential from 1 to 10 reverses the switching action For example with a 10 differential switch contacts R B make and R W break on a counterclockwise closed rotation With a 1 differential switch contacts R W make and R B break on a counterclockwise closed rotation NOTE CAMS ARE OFFSET VERTICALLY TO PROVIDE BETTER VIEW OF BACK CAM RIGHT INNER INNER AUXILIARY __ LEFT OUTER OUTER AUXILIARY AUXILIARY SOWER END CAM RED SWITCH OF MOTOR Fig 10 Auxiliary switch adjustment 63 2202 4 SERIES 72 MODUTROL IV MOTORS OPERATION AND CHECKOUT Operation The motor feedback potentiometer and control current input circuit form a bridge circuit As long as the final control element remains at the position proportional to the input current from the controller the circuit is balanced and the motor does not run When the value of the controlled medium changes the current from the controller changes and unbalance is amplified to energize th
156. connections designed to ANSI American National Standards Institute standards ISO International Standards Organization standards also available Various application requirements met with manual reset or automatic reset motorized operators Minimize line pressure drops with straight through flow swinging gate or rising stem guillotine action valve bodies Electro Mechanical Valves Page 6100 S 1 Installation Instructions 1 Read complete instructions before proceeding B Teflon tape acts as a lubricant and greatly and do not discard packing materials until any all reduces the pipe wrench turning force re loose items are located Also make sure that the quired to seal the threads installation of the Maxon valves will be in compli ance with all applicable governmental insurance this can damage the valve and or agency requirements or codes such as NFPA 70 National Electric Code CSA C22 1 C Good piping practice dictates that piping be Canadian Electric Code etc independently supported so that valve bodies 2 General considerations are not placed in a bind In addition large A Prior to shipment each valve is operated valves may require support electrically and cycled at rated and 1 1 2 D Clean pipe lines of foreign materials before rated pressure while being leak tested Every installing valve into line Maxon valve is operationally tested and meets the requirements of ANSI B16 104 Class VI Seat Leakage when it leav
157. control valve s operating crank arm by loosening the control motor s connecting rod from the burner s toggle linkage Initial adjustment should only be accomplished during a manual control mode 5 Start all system related fans and blowers Check for proper motor rotation and impeller direction Verify that all control interlocks are working Allow air handling equipment to run for adequate purge of your manifolds CAUTION Do not by pass control panel timers typically controlling sequential operations 6 With MICRO RATIO Valve combinations of air and fuel valves the minimum differential pressure setting is initially established with the air valve only A By disconnecting the linkage between the air butterfly valve and interconnected fuel valve s the minimum and maximum limits of travel on the air valve may be determined For example a combustion system may need the air valve to be 15 open for the minimum setting and the maximum requirements are satisfied with the air valve open to 60 By marking these points on the air valve s indicating strip you are ready to reconnect the SYNCHRO Fuel Valve s linkage to the air valve B The next step involves adjusting the connecting linkage between the air valve and the fuel valve s so that each fuel valve travels its full quadrant range i e from minimum to maximum while the air valve swings from its pre determined minimum and maximum positions C With Series CV
158. crew Hex Steel Nut Housing Cover Top Spring Button Thrust Bearing stainless ball 3 s diameter Spring see table Spring Ranges 121 12 Diaphragm Assembly 31 2 w c to 2 psi outlet pressure 11a Elastic Stop Nut 52 NTE 066 11b Bottom Spring Button 11c Diaphragm Pan 11d Molded Diaphragm Buna N 11d Diaphragm Viton 11f Seal Washer 11h Diaphragm Stud stainless steel 121 8 Standard Diaphragm Assembly 1 psi to 41 4 psi outlet pressure 11a Elastic Stop Nut 29 NE 066 11b Bottom Spring Button 11c Diaphragm Pan 11d Diaphragm Buna N 11d Diaphragm Viton 11f Seal Washer 11h Diaphragm Stud stainless steel 121 8 HP High Pressure Diaphragm Assembly 3 psi to 10 psi outlet pressure 11a Elastic Stop Nut 29 NE 066 11b Bottom Spring Button 11c Diaphragm Pan 11d Diaphragm Buna N 11d Diaphragm Viton 11e Upper Plate 11f Seal Washer 11g Lower Plate 11h Diaphragm Stud stainless steel 121 Seal Diaphragm Assembly 12a Piston 12b Seal Diaphragm Buna N 12b Seal Diaphragm Viton 12c Plate 12d Stem stainless steel PART NUMBER 143 16 005 00 121 10 005 52 905241 906534 143 16 009 00 906537 921005 121 10 005 51 121 10 009 51 930510 121 16 550 51 908561 121 10 022 50 121 16 017 50 121 16 150 53 121 16 150 55 121 10 178 50 121 16 058 52 121 10 551 52 903955 121 10 022 50 121 10 017 50 121 10 150 50 121 10 150 52 121 10 178 50 091 16 058 02 121 10 550 55 903955 121 10 022 53 121 10 017 50 121 10 150 50 12
159. cul N ENG NES PART The NEP DEN X LUC CONTROL PANEL WET CONV LOC CONTROL PANEL 1 1 IMITS UNLESS OTHERWISE SPECIFIED p e RUN INI p SW gt AR D RY NV zi 002 0312 000 0156 ANGLES 1 IE GSI GROUP 625 692 ILLINOIS ST ASSUMPTION IL 62510 ER PANE 626627 1m ne 10 DGGE 24VDC IGG LUTO CONTROL POWER om RYER STAR N jc BLOWER e cy ee N d 5 RURNER e cy 9 DIR N 04 4 UN A e 2 DRY CONV p N RYER LEG o 1 AUX DRY CUNV e N gt DRY CONV V V
160. d Important To disable reverse operation see A095 Reverse Disable If a fault appears on power up refer to page 11 for an explanation of the fault code For complete troubleshooting information refer to the PowerFlex 4 User Manual on the CD supplied with the drive English 7 Integral Keypad f N di EMEN e Description mo LI Display Group View Only II I Consists of commonly viewed drive operating PROGRAM FAULT conditions Basic Program Group Consists of most commonly used Ese Sel CA CV programmable functions Q Q Q O Advanced Program Group Consists of remaining programmable functions sl Fault Designator lo Consists of list of codes for specific fault conditions Displayed only when fault is present y LED LED State Description Run Direction Steady Red Indicates drive is running and commanded motor direction Status Flashing Red Drive has been commanded to change direction Indicates actual motor direction while decelerating to zero o Alphanumeric Steady Red Indicates parameter number parameter value or fault code Display Flashing Red Single digit flashing indicates that digit can be edited All digits flashing indicates a fault condition Displayed Units Steady Red Indicates the units of the parame
161. d assembly numbers from table below Quantity Required for Indicated Section Part Description 18 Str 6 Str 12 Str 1050373 24 Str Burner Body 1050373 1050376 1050376 Asby No 2 NOTE These items included with fastener kits See pages 5567 amp 5568 for fastener kit details 2 EN 5 8 9 10 Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice Wu CORPORATION MUNCIE INDIANA USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Series NP LE AIRFLO Burners Page 5550 S 7 Maintenance and Component Identification Spare Parts NP 1 LE AL j 4 N he see i d note iu below 11 see 1 note below To order replacement parts 1 See burner nameplate and indicate burner type 2 Sketch burner arrangement as viewed from casting side 3 Specify replacement items required from diagrams above 4 Specify quantity of each and assembly numbers from table below Quantity Required for Indicated Section Part Description 12 X 6 6 X 6 12 36 EOD Tee Elbow BL 1050388 e 1050386 1050391 Asby fixing Pater inside Gomer sors ining Pate wege se EN Ls pose msx 10 180 4017 Plated Hex Bot rep s
162. d to drive the motor to the fully open position The motor will open 5 Turn the span potentiometer clockwise until the motor starts to close The difference between the fully open span position current and the zero position current is defined as the operating span 6 Recheck the start and readjust the span potentiometer P1 if necessary Turn the start potentiometer clockwise to increase the zero position 7 Recheck the span and readjust the span potentiometer if necessary Turn it clockwise to increase the full span position 8 For sequential operation as shown in Fig 9 repeat the above steps for each motor SEQUENTIAL OPERATION FOR ADJUSTABLE ZERO AND SPAN MODELS 20 CONTROL OUTPUT mA CURRENT OR VOLTS N 7 CLOSED OPEN MOTOR 1 CLOSED OPEN MOTOR 3 MOTOR 1 PROPORTIONS BETWEEN 4 AND 12 mA FULLY CLOSED AT 4 mA FULLY OPENED AT 12 mA CLOSED OPEN MOTOR 2 MOTOR 2 PROPORTIONS BETWEEN 8 AND 16 mA FULLY CLOSED AT 8 mA FULLY OPENED AT 16 mA MOTOR 3 PROPORTIONS BETWEEN 12 AND 20 mA SIGNAL FULLY CLOSED AT 12 mA FULLY OPENED AT 20 mA UP TO 6 MOTORS CAN BE DRIVEN SEQUENTIALY OR IN UNISON FROM ONE CONTROLLER ADJUST ZERO ADJUST AND SPAN ADJUST POTENTIOMETERS TO ACHIEVE DESIRED SEQUENCE M2893A Fig 9 Sequential operation of motors 63 2202 4 10 Auxiliary Switches N CAUTION Electrical Shock or Equipment Damage Hazard Can shock individu
163. d wire protection and routing must be provided Additional Wiring Instructions For Optional Features Open Frame solenoid with 1 4 spade terminals For solenoids supplied with screw terminal connections use 12 18 AWG stranded copper wire rated at 90 C or greater Torque terminal block screws to 10 2 in Ibs 1 0 1 2 Nm A tapped hole is provided in the solenoid for grounding use 10 32 machine screw Torque grounding screw to 15 20 in lbs 1 7 2 3 Nm On solenoids with screw terminals the socket head screw holding the terminal block to the solenoid is the grounding screw Torque the screw to 15 20 in Ibs 1 7 2 3 Nm with a 5 32 hex key wrench Junction Box The junction box is used with spade or screw terminal solenoids only and is provided with a grounding screw and a 1 2 conduit connection Connect 12 18 AWG standard copper wire only to the screw terminals Within the junction box use field wire that is rated 90 C or greater for connections For steam service use 105 C rated wire up to 50 psi or use 125 C rated wire above 50 psi After electrical hookup replace cover gasket cover and screws Tighten screws evenly in a crisscross manner DIN Plug Connector Kit No K236034 1 The open frame solenoid is provided with DIN terminals to accommodate the plug connector kit 2 Remove center screw from plug connector Using a small screwdriver pry terminal block from connector cover 3 U
164. di v To IGN Xformer OVERHEAT OVERHEAT OUTSIDE INSIDE IGNITER PLC UPPER RIGHT PLC4 RIGHT 12 WIRES L PC8 PC7 PC6 SHLD OVERHEAT PLENUM PLENUM RTD OUTSIDE HI LIMIT PLC MIDDLE LEFT PLC SWITCH 109 FLP MC8 MC7 MC6 SHLD OVERHEAT GRAIN RTD OUTSIDE MIDDLE RIGHT 919 FIELD INSTALLED RTD 314 To L 2 RTD OVERHEAT WHT x WHT MC OUTSIDE BT E WHT WHT PLC LOWER LEFT re BLK BLK 414 RED RED RED RED FIELD INSTALLED OVERHEAT ALARM LIGHT OUTSIDE PLC LOWER RIGHT Black FIELD INSTALLED To PLC White z To PLC T A Blue lt 5 p m Red 5 g WORK LIGHT E To L 2 PLUG SW INSULATE amp STORE RED WIRE ALARM HORN HOPPER D N N N N 1 j N N 505 1 2 PLC 110 MVS 1 2 MVS 1 2 PLC 113 L 1 1 L 2 CM CM 111 NE REN T Lono o 2 i THE GSI GROUP MAXON VALVE 1 MAXON VALVE 2 TITLE TONER CONTROL PANEL PILOT GAS LPS MAIN GAS AUX 7 9 CLOSES MAIN GAS AUX 7 9 CLOSES HONEYWELL HPS WIRING DIAGRAM SOL VALVE ENABLE WITH VALVE ENABLE WITH VALVE M7284A 1012 m SOLENOID PARTIALLY OPEN SOLENOID PARTIALLY OPEN MODUTROL MOTOR 2009XX 14 14 OF 18 CANADIAN FUEL TRAIN WIRING
165. ditional pipe train accessories and control components may be required for a complete system installation Read complete instructions before proceeding and familiarize yourself with all the system s equipment components Verify that your equipment has been installed in accordance with the original manufacturer s current instructions CAUTION Initial adjustment and light off of burner systems should be undertaken only by trained and experienced personnel familiar with combustion systems with control safety circuitry and with knowledge of the overall installation Instructions provided by the company and or individuals responsible for the manufacture and or overall installation of complete system incorporating Maxon burners take precedence over these provided by Maxon If Maxon instructions conflict with any codes or regulations contact Maxon Corporation before attempting start up For initial adjustment and or burner start up 1 Close all burner fuel valves and cocks Make preliminary adjustments to fuel gas regulators 2 Check all electric circuitry Verify that all control devices and interlocks are operable and functioning within their respective settings ranges Be sure all air and fuel manifolds are tight and that test ports are plugged if not being used 3 Check that any air handling dampers are properly positioned and locked into operating positions 4 Disconnect the automatic control motor s linkage from your
166. djacent to the fill plug to determine the type of lubricant installed at the factory Standard lubricant is ISO VG220 mineral based oil However some units have special lubricants designed to operate in certain environments or to extend the service life of the lubricant If in doubt about which lubricant is needed contact NORD Gear STANDARD OIL ISO VG220 20 to 104 F to 40 C TYPICAL OILS Viscosity SEICE TE ISO NLGI Formulation m Mobil VG 460 Mineral 68F to 122 F 634 460 GEM 1 460 GR XP 460 1100 460 PAO 22 F to 176 F SHC 634 460 HD EP 460 EG 4 460 1510 460 VG 320 Mineral 32 F to 86 F 632 320 GEM 1 320 GR XP 320 1100 320 Synthetic 35 C to 80 C Mobil Tribol PAO 31 F to 176 F SHC 632 320 HD EP 460 EG 4 320 1510 320 VG 220 Mineral 20 F to 104 F 630 220 GEM 1 220 GR XP 220 1100 220 PAO 30 F to 176 F SHC 630 220 HD EP 220 EG 4 220 1510 220 amp en T E 180 GR XP 100 1100 100 nthetic 37 C to i obi mala solube ubersyn en PAO 35 F to 50 F SHC 629 EG nob Conventional 15 C 25 Mobilgear Kl beroil Tribol VG 68 en 20 68 1 68 GR XP 68 1100 68 nthetic 40 C to 10 obi solube Synthetic 40 C to 10 C Mobil Kl ber Summit PAO 40 F to 50 F SHC 624 HySyn FG 32 iid PAO Poly Alpha Olefin SPECIAL PURPOSE LUBRICANTS STANDARD BEARING GREASE NLGI 2EP Lithium 20 to 140 F 30 to 60 C OPTIONAL BEARING GR
167. ducar with mounting chart in manual NORD Gear Corporation NORD Gear Limited National Customer Service Toll Free 888 314 6673 www nord com Toll Free in Canada 800 668 4378 WEST MIDWEST SOUTH CANADA 1121 Railroad Street PO Box 367 100 Forsyth Hall Dr 41 West Drive Building 101 800 Nord Drive Building 100B Brampton Ontario L6T 4A1 Corona CA 92882 Waunakee WI 53597 Charlotte NC 28273 Phone 905 796 3606 Phone 951 279 2600 Phone 608 849 7300 Phone 704 529 1255 Fax 905 796 8130 Fax 888 408 6673 Fax 800 373 6673 Fax 888 259 6673 BIM 1020 2005 03 12 M CYCLO SPEED REDUCERS SECTION A CONTENTS ee e A 2 General Construction A 3 4 5 10 Grease 7 8 Designated Greases A 7 Grease Replenishment amp Change A 7 Quantities of Grease A 7 8 Pv A 8 7 10 Oil Fill Procedure Gauge A 8 Standard OIlS ue eee ee A 8 Oil Quantities 9 Mounting 1 Mounting on Exact Planes The Horizontal Type oil lubricated units must be mounted on horizontal surfaces Where they are mounted on inclined surfaces some modifications may be necessary Specify mounting plane inclination at time of ordering 2 Accurate Alignment Where the reducer is connected to the motor and the driven machine through couplings align the shafts accuratelv Where the reducer is con
168. e Triac switching to run the motor in the proper direction to correct the change in the temperature or the pressure The motor turns the feedback potentiometer to rebalance the circuit and stop the motor Checkout After installation and linkage adjustment operate the motor through the controller Make sure that The motor properly operates the damper or valve e The motor responds properly as the input is varied The auxiliary switch if used operates at the desired point of motor rotation Home and Building Control Home and Building Control Honeywell Asia Pacific Inc Honeywell Europe S A Inspect the motor linkage and valve or damper to see that all mechanical connections are correct and secure In damper installations the pushrod should not extend more than a few inches past the ball joints Check to see that there is adequate clearance for the linkage to move through its stroke without binding or striking other objects See controller or system instructions for additional checkout procedures Motor Operation Checkout Check motor operation as follows 1 Toclose the motor open terminals and F 2 To open the motor connect terminal F to the negative motor terminal Honeywell Honeywell Latin American Honeywell Honeywell Limited Honeywell Limit e Room 3213 3225 3 Avenue du Bourget Region 1985 Douglas Drive North 35 Dynamic Drive Sun Hung Kai Centre 1140 Brussels 480 Sawgrass Corporate Parkway Go
169. e operational difficulty Avoid pipe strain by properly supporting and aligning piping When tightening the pipe do not use valve or solenoid as a lever Locate wrenches applied to valve body or piping as close as possible to connection point CAUTION To avoid damage to the valve body DO NOT OVERTIGHTEN PIPE CONNECTIONS If Teflon tape paste spray or similar lubricant is used use extra care when tightening due to reduced friction All Rights Reserved ASCO Form No V5495R4 IMPORTANT To protect the solenoid valve install a strainer or filter suitable for the service involved in the inlet side as close to the valve as possible Clean periodically depending on service conditions See ASCO Series 8600 8601 and 8602 for strainers MAINTENANCE WARNING To prevent the possibility of death serious injury or property damage turn off electrical power depressurize valve extinguish all open flames and avoid any type of sparking or ignition Vent hazardous or combustible fluid to a safe area before servicing the valve NOTE It is not necessary to remove the valve from the pipeline for repairs Service Notice CAUTION Series 8215C and 8215G valve parts are not interchangeable with Series 8215B valves Series 8215B valves have a different valve body and a core diaphragm sub assembly with a diaphragm disc Interchanging parts will cause valve malfunction See Figure 1 for identification of parts Cleaning All so
170. e positioned to protect against flooding drain water ice formation traffic tampering etc The vent must be protected against nest building animals bees insects etc to prevent vent blockage and minimize the chances for foreign material from collecting in the vent side of the regulator diaphragm A It is the user s responsibility to assure that all regulator vents and or vent lines exhaust to a non hazardous location away from any potential sources of ignition Where vent lines are used it is the user s responsibility to assure that each regulator is individually vented and that common vent lines are not used NUPP8 98250M COPYRIGHT 1998 EQUIMETER INC MONITOR REGULATORS AND EXTERNAL CONTROL LINES When bypassing a regulator with an external control line the control line valve must be closed before the bypass valve is opened Failure to do so could result in the diaphragm being exposed to the inlet pressure USE WITH OTHER GASES 1 Donotuse Equimeter regulators on corrosive gases unless authorized by Equimeter for a specific corrosive condition 2 Where the gas is propane or butane LPG and the regulator has an internal relief valve IRV special care is required with the regulator vent Because propane and butane are heavier than air they do not disperse readily in the atmo sphere Instead they tend to collect in low places Since large volumes can discharge from the regulator vent at times of emergency care mus
171. e power end with increase in control signal Motor drives to normally closed position when powered with control wiring not connected Electrically normally open Shaft rotates counterclockwise viewed from the power end with increase in control signal Motor drives to normally open position when powered with control wiring not connected ORDERING INFORMAT ION When purchasing replacement and modernization products from your TRADELINE wholesaler or distributor refer to the TRADELINE Catalog or price sheets for complete ordering number If you have additional questions need further information or would like to comment on our products or services please write or phone 1 Your local Home and Building Control Sales Office check white pages of your phone directory 2 Home and Building Control Customer Relations Honeywell 1885 Douglas Drive North Minneapolis Minnesota 55422 4386 In Canada Honeywell Limited Honeywell Limit e 35 Dynamic Drive Scarborough Ontario M1V 429 International Sales and Service Offices in all principal cities of the world Manufacturing in Australia Canada Finland France Germany Japan Mexico Netherlands Spain Taiwan United Kingdom U S A 63 2202 4 TOP VIEW 4 1 16 103 5 4 1 16 103 BOX gt 9 16 15 3 4 ADAPTER BRACKET 19 EE Fig 1 Series 72 Modutrol IV Motor dimensions in in mm
172. e s control linkage the control operators Internal drive mechanisms within a control motor Use of pipe heavier than schedule 40 can may be damaged if linkage is restricted as to cause cause interference with butterfly type Flow Control binding in high or low flow position Valves and restrict the valve from full opening Flow Control Valves provide the means to adjust fluid and or gas flows They should be installed with at least four pipe diameter lengths of straight pipe before and after the valve This Main system shut off should always use a manual leak tight upstream fuel cock CAUTION All Flow Control Valves are designed for throttling service only and are not intended for tight shut off Mounting Instructions for motor operator on Series CV Flow Control Valves For those Series CV Valve assemblies furnished with connecting base and linkage the accompanying diagrams Honeywell illustrate mounting procedures relative to each specific type M644 M744 operator M941 or M944 First mount your control motor to connecting base in 7616BR Crank accordance with diagrams at right Secondly determine if your electric operator travels through 90 or 180 rotations Then arrange connecting linkage and motor crank arm as shown below for your specific operator Mount with four short bolts and nuts at indicated holes Barber Colman Toggle Clamp To gle Clamp 50 Serew A Toggle Se A Clamp A
173. e to discharge the excess pressure and close the inlet valve Only adjust set point when gas is flowing through the regulator DO NOT adjust if regulator is locked up tight shutoff IMPORTANT Small flow during set point adjustment is particu larly important where set point is in the top third of the spring range Large flow could result in over stressing the spring or loss of lock up from the spring compressing solid If the set point adjustment must be made at large flow 6096 to 10096 of maxi mum regulator capacity and set point is in upper third of spring range use the next higher range spring After set point has been determined to be correct check for lock up by slowly closing the outlet valve Again closely monitor the regulator outlet pressure gauge Regulator must be fully capable of tight lock up If outlet pressure continues to rise above the lock up pressure open the downstream valve to discharge excess pressure and close the inlet shutoff valve If the pressure goes above lock up the regulator is not closing properly Make the necessary corrections before resuming start up 9 Prompt attention is essential if there is regulator trouble if gas leaks from the vent or elsewhere from the regulator or if leaks develop in the piping Failure to shut down the regulator may cause serious hazards 10 The outlet of the vent piping must allow for the free and unobstructed passage of air and gas The diaphragm case vent must b
174. ealed 125 15 125 VAC 10 AMP 48 VAC 1 AMP 250 15 250 VAC 10 AMP 125 VAC 1 AMP 125 VDC 0 5 125 0 3 48VDC 3AMP INTERMEDIATE 250 VDC 0 25 AMP 250 VDC 0 15 AMP 125 VDC 1 AMP FULLY OPEN 1 99 Maxon practices policy of continuous product improvement It reserves the right to alter specifications without prior notice W CORPORATI INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES UNE IMD DEA Page 6100 S 10 Electro Mechanical Valves Tandem Arrangements for simultaneous opening of main and blocking valves Installation Instructions Review and comply with all general valve installa tion instructions provided separately See sketch below 1 Mount both valves in fuel line with center to center spacing as originally specified and blocking valve without handle downstream of main valve with handle Check valve alignment to be certain that operat ing wheels lie in the same plane Remove tape from the wheel of the main valve and unwind the attached chain Do not remove the screw holding chain to wheel it has been factory positioned to assure correct alignment Do not remove tension spring attached to one end of chain or the wooden block insert which preloads the spring Take free end of chain and loop it around the wheels of both main and blocking valve as shown in sketch below Depending on the specific valve series and arrangement
175. eam of main gas cock It normally includes pilot shut off cock pilot gas regula Bolt Rod Long Enough to Permit Strap Iron Brackets to Move Frame E cr S amp ale 1 Support hne i NM Movement J A Jj A i Movement LU T cos di Wer WI CORPORATION MUNCIE INDIANA USA Typical Piloted System tor and pilot solenoid valves For pilot adjustment a fixed orifice or adjustable orifice is recommended at or near the pilot gas inlet Fuel shut off valves when properly wired to a safety control system shuts the fuel supply off when a hazardous operating condition is sensed by your control circuit Manual reset valves require operator attendence each time the system is started up or restarted after a trip out Motorized shut off valves permit automatic start restart when used with appro priate control system Fuel control valve controls burner heat release by throttling gas flow to it It should include provision for an adjustable minimum and throttling over a turndown range that matches burner capabilities The illustra tion shows a Series CV Flow Control Valve but adjustable gradient SYNCHRO and or Q Flow Control Valves may be used Gas pressure test connections are provided in most Series NP LE Burner end plate sets but it is also helpful to provide a
176. ectric drill motor is not suggested after commissioning Visually check the gas ports unless both Pin Vise and Drill as shown below of new burner assemblies for any piping scale or can be chucked up in a vari speed drill unit Use debris Use Pin Vise with drill bit to remove caution because it is easy to snap the bits off ina Annual inspections are normally adequate once port when using a drill motor Removal of broken the initial piping debris is removed The operating bits from the gas ports is difficult conditions of the burner will determine how Contact your Maxon representative to answer frequently maintenance is actually required questions or address any problems Pin Vise NP LE AIRFLO Burner Body 1 inch Mixing Plates Not Shown Gas Ports All are 43 Drill Size Exception is several 47 holes at the intersection of 12x6 tee s and 36 BI s 36 BI Sections 12 x 6 All Straight Sections Tee Sections 6 12 18 amp 24 Mi A Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice wi CORPORATION MUNCIE INDIANA USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Tower Dryer Ops amp Service COMPONENTS COMPONENT MANUALS GAS CONTROL VALVE Page 7002 Flow Control Valves 3 Series Q Valve Series CV Control Valves incorporate a full flow fixed gradient butterfly valve design for high Capacit
177. ed after bushings have been tightened Check horizontal shaft alignment by placing a level vertically against the face of the sheave or sprocket Adjust belt or chain tension per the manufacturer s specified procedure OUTBOARD PINION ALIGNMENT Align the pinion by adjusting the gear tooth clearance according to the manufacturer s recommendations and checking for acceptable outboard pinion tooth contact The foundation bolts may have to be loosened and the unit moved slightly to obtain this contact When the unit is moved to correct tooth contact the prime mover should be realigned RECHECK ALIGNMENT After a period of operation recheck alignment and adjust as required 1 Properly install unit on a rigid foundation e adequately supported e securely bolted into place leveled so as not to distort the gear case 2 Properly install couplings suitable for the application and connected equipment 3 Ensure accurate alignment with other equipment 4 Furnish and install adequate machinery guards as needed to protect operating personnel and as required by the applicable standards of the Occupational Safety and Health Administration OSHA and by other applicable safety regulations 5 Ensure that driving equipment is running in the correct direction before coupling to reducers with backstops designed to operate only in a specific direction or machinery designed to operate only in one direction BIM 1020 2005 03 CHANGES IN PERFORMAN
178. ed on each side of the integral torque tab to dampen torque shocks and allow for mis alignment received from the machinery during operation Torque arm connection fabrications should always be mounted perpendicular to a line through the output shaft center and the point at attachment of the torque arm to the unit housing In this position the minimum load on the attachment structure arm will be experienced The attachment structure must be rigid and may not deflect under any load Doing so will place extra loads on the output bearings of the reducer PRIME MOVER MOUNTING Align the prime mover to the reducer input shaft using shims under the feet Make sure that the feet are supported Dowel the prime mover to its foundation SHAFT CONNECTIONS When connecting shafts to either the input or output of the reducer consider the following instructions FITS Clearance or interference fits for coupling hubs should be in accordance with ANSI AGMA 9002 A86 or as follows BIM 1020 2005 03 Output and Input shaft Diameter tolerance Metric mm lt 18 0 012 0 001 gt 2 18 lt 30 0 015 0 002 gt 2 30 lt 50 0 018 0 002 gt 2 50 lt 2 80 0 030 0 011 gt 2 80 lt 2 120 0 035 0 013 gt 120 lt 180 0 040 0 015 Inch lt 1 750 0 0000 0 0005 gt 1 750 0 0000 0 0010 Output and Input shaft Drill and tap shaft end Metric mm lt 16 5 gt 16 lt 21 6 gt 221 lt 0 24 M8 gt 2
179. ely 1000 SCFH Make sure the flow of gas does Apply pipe joint compound to male threads only not create a hazard The Model 121 Regulator is usually right side up as shown NOTE If piping downstream of outlet shutoff valve is pres on the Typical Installation drawing See Page 2 It may sured see CAUTION under B 2 be installed ee d inverted F With gas flowing check for correct inlet and outlet pressures me Se feste e PO SE DOS It may be necessary to further open the inlet shutoff valve to Caution Do not install sideways The diaphragm should maintain full inlet pressure be horizontal G Make sure the regulator closes tight tight lock up To do this On indoor installations requiring venting outdoors run the reduce flow to zero by slowly closing the outlet shutoff valve vent piping as short and direct as possible with minimum Outlet pressure should not exceed set point by more than bends and elbows Use the same size or larger pipe as 6 w c the vent connections on the regulator With natural gas or Fully open inlet and outlet shutoff valves Do this slowly and any other hazardous gas vent to a safe place outdoors in case gas should accidentally be discharged Screen and protect the opening outdoors to guard against water ice dirt debris or insects Install the control line Connect it into the outlet piping at least 5 pipe diameters downstream from the regulator CAUTIONS a On backpressure regulator
180. emote pot only 3 If the wires are short and contained within a cabinet which has no sensitive circuits the use of shielded wire may not be necessary but is always recommended Terminal Block Specifications Maximum Wire Size 0 13 mm 26 AWG 1 3 mm 16 AWG 0 5 0 8 N m 4 4 7 Ib in 4 Maximum minimum that the terminal block will accept these are not recommendations Refer to the PowerFlex 4 User Manual on CD for maximum power and control cable length recommendations Control Terminal Block 1 Important Terminal 01 is always a coast to stop input except when P036 Start Source is set to 3 Wire control In three wire control I O Terminal 01 is controlled by P037 Stop Mode All other stop sources are controlled by P037 Stop Mode English 5 Refer to the PowerFlex 4 User Manual on CD for detailed I O wiring examples P036 Terminal 01 Start Source Stop Stop Keypad Per P037 Coast 3 Wire Per P037 Per P037 2 Wire Per P037 Coast RS485 Port Per P037 Coast Typical Typical Stop 1 SRC Wiring SNK Wiring Important The drive is shipped with 2 10 1 a jumper installed between I O Start Run FWD 2 5
181. equipped with the designed to require minimum service However each Accutrol sweep unload metering system check season we recommend the following items be checked the discharge area to insure that the area is cleaned before the unit is used and any damaged or question of stalks and old grain Inspect the sweeps for able parts replaced These checks will help eliminate excessive wear possible failures and assure dependable operation of the equipment 9 GSI Dryers equipped with hoppered metering system check the hopper area and the 1 Shut off electrical power Open power box and area around the metering drum to insure that they control box and inspect for moisture rodent dam are cleaned of stalks and old grain Check the age or accumulated foreign material present In edges of the metering drum for excessive wear spect and tighten any loose terminal connections Replace any damaged or deteriorated wiring 10 Important The covers to the discharge sections on both the Zimmerman and GSI Tower 2 Lubricate the blowers motors and metering sys dryers must be in place and clamped down at all tem as outlined in the Lubrication Table below times when the dryer is in operation If the cover is off during operation the vacuum created by the 3 Check blower belts for proper tension blowers will suck foreign matter from the discharge area and deposit it in the heat section of 4 Inspect and clean the burner Visually check that the dryer
182. es of auxiliary conveyors are matched to dryer metering capacities Clean grain is easier to dry Fine material increases resistance to airflow and requires removal of extra moisture Do not adjust any moving part on the dryer while it is running SAFETY PRECAUTIONS Use Caution In The Operation Of This Equipment The design and manufacture of this dryer is directed toward operator safety However the very nature of a grain dryer having a gas burner high voltage electrical equipment and high speed rotating parts does present a hazard to personnel which can not be completely safeguarded against without interfering with ef ficient operation and reasonable ac cess to components Use extreme caution in working around high speed fans gas fired heaters augers and auxiliary convey ors KEEP THE DRYER CLEAN DO NOT ALLOW FINE MATERIAL TO ACCUMULATE IN THE PLENUM CHAMBER OR SURROUNDING THE OUTSIDE OF THE DRYER 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 recommen dations within this manual and make it a practice to regularly inspect the operation of the unit for any devel oping problems or unsafe conditions Take special note of the safety precautions listed above before at tempting to operate the dryer INSTALLATION REQUIREMENTS Electrical The dryer can be furnished to operate off of 240
183. es our plant u per NFPA 86 4 2 4 3 1999 B Inspect your valve for any shipping damage NFPA 86C 4 2 4 3 1999 Contact Maxon Corporation with the valve s NFPA 86D 4 2 4 3 1999 serial number printed on the valve s name plate for replacement and or repair parts C Read the nameplate on your valve This gives the maximum pressure temperature For new installations a gas filter or strainer shall be installed in the fuel gas piping to protect the downstream safety shut off valves If normal inlet pressure to the fuel pressure regula tor immediately upstream from the valve exceeds the valve s pressure rating a relief valve shall be limitation voltage requirements and service conditions of your specific valve DO NOT provided and it shall be vented to a safe location per NFPA 86 5 7 1 7 1999 exceed nameplate ratings 86C 5 7 1 7 1999 D Select mounting location carefully Your NFPA 86D 5 7 1 7 1999 Maxon valve is designed to operate for many years if installed in a location that is cool clean and dry 3 Pipe the valve in the direction of the flow arrow 3 on the valve body The Maxon valve body can shut off flow in one direction only A Remove all thread and flange protectors before installing valve in your service line E Mount valve so that open shut window indicator 1 will be visible to your operating personnel The open shut window indicator should never face downward With Maxon electro me
184. excess of the most stringent requirements of the various ap Insurance authorities agree proval agencies They are designed for long life even _ that the safety of any industrial fuel burning if frequently cycled and to be as maintenance free installation is dependent upon well trained and trouble free as possible operators who are able to follow instructions and Every Maxon valve is operationally tested and to react properly in cases of emergency Their meets the requirements of ANSI B16 104 Class VI knowledge of and training on the specific Seat Leakage when it leaves our plant installation are both vital to safe operation Top assembly components require no field Safety controls may get out of order without the lubrication and should never be oiled operator becoming aware of it unless shutdowns Auxiliary switches motors and solenoids may be result Production minded operators have been replaced in the field known to bypass faulty controls without reporting the trouble Continued safe operation of any installation is WARNING Do not attempt field repair of valve body top assembly or motor drive unit Any alterations void all warranties then assured only if the plant management carefully develops an exact schedule for regular Valve leak test performed with valve in line as periodic inspection of all safety controls insisting prescribed by jurisdictional authorities is strongly that it then be rigidly adhered to encou
185. f the sheet build up while it is still wet will usually plug the sheet more IN CASE OF FIRE When you first detect a fire the entire drying operation should be shut down including grain flow into and out of the dryer The emergency controls may have already done this Also shut off the electrical and fuel supply to the dryer Do not try to cool a fire by running fan s Never run grain from the dryer into the elevator or storage if a fire is known or suspected Tower Dryer Ops amp Service Locate the area of the fire If the fire can be extinguished with a fire extinguisher water hose or by removing the burning material this should be done right away Watch the dryer closely for another fire after one has occurred Emergency discharge slide gates at the bottom of each column as well as easy access gates located near the hopper discharge area permit fast dumping of each individual grain column A fire extinguisher should be located at or near the dryer if a fire seems to be getting out of control call the fire department END OF SEASON SERVICE Empty the dryer at the end of the drying season The dryer should not be used for grain storage Grain left in there for an extended period of time can become wet swell and spoil Chunks of spoiled grain can plug the metering system and swelled grain places undue stress on the interior and exterior sheeting of the dryer Clean out the plenum roof grain cushion and remove any gra
186. fers to normally closed valves With normally open valves the procedure is the same but the valve body position 1 open or closed is opposite to the normally closed version Remotely located manual reset valves may be equipped with wheel and chain assembly Instructions to operate the valve are on hand grip Locate counter weight overhead at pipe level and hand grip can be brought down to convenient operating personnel height Normally closed motorized valves begin open ing cycle immediately upon being powered motor runs only until full open position is reached Normally open valves begin to close immediately and motor runs until fully closed position is reached Operator should be aware of and observe characteristic opening closing action of the valve Should operation ever become sluggish remove valve from service and contact Maxon for recommendations Address inquiries to Maxon Corporation P O Box 2068 Muncie IN 47307 Phone 765 284 3304 FAX 765 286 8394 www maxoncorp com Always include valve serial number and nameplate information to insure positive identification 1 99 Maxon practices policy of continuous product improvement It reserves the right to alter specifications without prior notice INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES CORPORATION MUNCIE INDIANA USA Page 6100 S 6 Electro Mechanical Valves Maintenance Instructions Maxon valves are endurance tested far in
187. fore working on drive ensure isolation of mains supply from line inputs R S T L2 L3 Wait three minutes for capacitors to discharge to safe voltage levels Failure to do so may result in personal injury or death Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels ATTENTION Equipment damage and or personal injury may result if parameter A092 Auto Rstrt Tries or A094 Start At PowerUp is used in an inappropriate application Do not use this function without considering applicable local national and international codes standards regulations or industry guidelines ATTENTION Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION An incorrectly applied or installed drive can result in component damage or a reduction i
188. from the pilot solenoid with the dryer turned off to verify that no water is in the pilot line Blow the pilot line out with compressed air Before reattaching the pilot line attempt to light the pilot with the line removed Gas should be flowing from the pilot solenoid If gas 15 flowing reattach the pilot line and adjust of flow of gas by adjusting the pilot regulator 33 TROUBLESHOOTING Problem Pilot will not light Continued Pilot lights but main burner will not light Dryer will not reach operating temperature Plenum temperature fluctuates Dryer loses flame at regular intervals while running Modulating Valve does not open Problem Control power switch will not light OIU fails to light Dryer shuts down red light lights and horn sounds display shows OVERHEAT AT PLENUM POSSIBLE 34 Tower Dryer Ops amp Service What to do If pilot still doesn t light check pilot area on burner Clean if necessary If pilot area is hot indicating that the pilot was lighting replace flame rod If pilot area is cold replace spark plug If pilot still doesn t light check the Protectofier components in the control box Check for water in gas train by opening drain valve Maxon valve should offer some resistance when opening If it doesn t check latching solenoid inside Maxon valve Check for broken or bent butterfly valve Check to make sure burner ports aro
189. fuels without re adjustment Series Valves are UL Underwriters Laboratories listed for use with air natural gas and liquefied petroleum gases dm 2 Series CV Valve with optional connecting base and linkage assembly 2 1 2 Series BV Valve M 6 Manual Air Control Valve with optional Low Fire Start Switch 11 90 CORPORATION 201 East 18th Street P O Box 2068 Muncie Indiana 47307 0068 Phone 765 284 3304 FAX 765 286 8394 Flow Control Valves Page 7000 S 1 Installation Instructions Support weight of piping independently Do not lessens the chance of internal flow turbulence being place any Maxon Flow Control Valve in a piping set up in the piping manifolds and control valve bind Provide pipe hangers and or special support Check fluid flow direction through P and O for related manifolds poppet type valves It must flow only in direction Maxon connecting base and linkage assemblies matching the arrow cast into valve body If neces are designed to locate and or position the sary valve body may be rotated per instructions control operator for its interaction with the Flow given on page 7016 Control Valve assembly They are not intended to Install flow control valves carefully and maintain support the weight of the control motor Special adequate dimensional clearance to allow full provisions will be required to support the weight of stroke and travel of the valv
190. functions and automatic equipment in a controlled shutdown sequence Important In case of an automatic dryer shut down the DRYER POWER STOP button must be dense before the diver can herestarted_ a Tower Dryer Ops amp Service 1 Prepare dryer for start up DRYER START UP dryer ie wet legs conveyors etc Perform preseason inspection and service as 8 Fill the dryer by turning the LOAD selector outlined 1n the Maintenance Section before attempting to operate the dryer VN The dryer must have all Pre Season and Post Season maintenance to ensure reliable operation Make sure all discharge doors grain exchanger cleanout doors heat section door louvered switch to the ON position On a demand fill dryer the wet conveyor will turn on slide gate will open and the dryer will start filling with grain Once the dryer 1s full a horn will sound and the wet conveyor will stop slide gate will shut Turn the LOAD selector switch to the AUTO position to silence the alarm and begin normal cooling section doors etc are closed Make sure PN The burner should be covered before filling that all personnel are clear of the dryer and any the dryer to prevent accumulation of foreign grain handling machinery material on the Ignitor Flame Sensor and Burner Ports Foreign material may interfere with burner operation 2 Open main gas valve to dryer 3 Switch on main breaker to provide electrical power to t
191. g Option B 1 Rating requires installation of the PowerFlex 4 IP 30 NEMA 1 UL Type 1 option kit General Grounding Requirements Important Remove the MOV to ground jumper if the drive is installed on an ungrounded distribution system Tighten screw after jumper removal Jumper Location CE Conformity Refer to the PowerFlex 4 User Manual on the CD supplied with the drive for details on how to comply with the Low Voltage LV and Electromagnetic Compatibility EMC Directives English 3 Specifications Fuses and Circuit Breakers Catalog Output Ratings Input Ratings Branch Circuit Protection Dissipet B Number Voltage 140M Motor IP20 Open kW HP Amps Range kVA Amps Fuses Protectors Contactors Watts 100 120V 10 1 Phase Input 0 230V 3 Phase Output 22A V1P5N104 0 2 0 25 15 90 126 0 75 16 0 10 140 2 10 100 09 25 22A V2P3N104 0 4 0 5 23 90 126 1 15 9 0 15 140M C2E C16 100 12 30 22A V4P5N104 0 75 1 0 45 90 126 2 25 18 0 30 140M D8E C20 100 23 50 22A V6PON104 11 1 1 5 6 0 90 126 30 240 140 140M D8E C25 100 37 70 200 240V AC 10 1 Phase 7 Input 0 230V 3 Phase Output NO BRAKE 22A A1P4N103 0 2 0 25 1 4 180 265 07 3 2 6 140 2 40 100 09 25 22A A2P1N103 0 4 0 5 241 180
192. g equipment This operator or other personnel ations to the equipment Such manual was written with that As owner and or operator it is alterations may produce a very thought in mind We want to your responsibility to know dangerous situation where keep you as a customer by what requirements hazards and serious injury or death may helping you understand precautions exist and to inform occur A DANGER Airborne particles during gh speed belt drive operation May impair operating overhead vision and breathing Can cause serious injury Do not enter when Keep head and hands dryer is running AT clear Do not enter when dryer is running Disconnect electricity before inspecting or servicing Keep guards and screens on exposed areas DC 1064 A DANGER 1992 GRAIN SYSTEMS INC The GSI Group Inc recommends you contact your local power company and have a representative Flame and pressure Rotating drum below beyond door May cause Will cause serious injury survey your dryer installation so your wiring will be serious injury Do not or death Lockout power enter when dryer before entering is running or servicing ae equate power supplied to your unit DC 1061 MAY CAUSE SERIOUS INJURY OR DEATH compatible with their system and you will have ad Safety decals should be read and understood by all people in and around the dryer area If the follow 4 D A 1 ing safety deca
193. ge and check that operator does not bind and that all interlocks are performing properly Adjust burner high fire by slowly rotating fuel control valve crank arm towards its maximum Observe flame characteristics carefully Flame should remain a bright blue color with a length beyond the mixing plates as indicated in capac ity specification data If flame becomes long and yellow gas pressure is too high and or air velocity is too low NOTE Dust and or chemicals entrained into passing air stream may effect physical color of flame In this case adjust burner for stable flame shape and geometry To measure gas pressure connect water column manometer to the test connection in burner s end plate To determine air velocity use a velometer at the profile opening Correct velocities by increasing or decreasing profile opening size If flame is too short gas pressure may be too low and should be increased or velocities are too high and may need to be decreased Note that air velocities should be measured only when the fan is handling air at the desired control temperature l Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice CORPORATION MUNCIE INDIANA USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Series NP LE AIRFLO Burners Page 5550 S 5 Start Up Instructions cont d The desired maximum capacity may be
194. ges 6100 S 3 and 6100 S 4 Bend handle of main valve outward about 25 Cut off handle of blocking valve at outer wheel face Remove hardware holding main valve wheel in place and mount new wheel and spacer to the existing wheel with new hardware provided Cut chain loop to the desired length and secure to both wheels Blocking Valve Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Electro Mechanical Valves Page 6100 S 11 Overhead Wheel amp Chain Assembly Overhead wheel and chain assembly allows operation of a manual reset valve in an otherwise inaccessible overhead location A wheel is mounted onto the handle of the valve The attached chain is weighted on one end and has a paddle handgrip on the other Once the valve is electrically energized pulling down on the paddle will open normally closed ver sions or close normally open versions Maxon valve s free handle design permits valve to trip to its rest position on any power interruption Wheel and chain assembly includes a length of chain to position the paddle handgrip slightly below pipe centerline A standard length of 7 feet of chain is included with CP and larger valve sizes and 5 feet is included with all other valves Extra chain in one foot increments may be specified to fit your specific location Approximate envelope dimensions
195. gher screw all remaining screws down to at least the same level as your first adjusted screw NOTE A preliminary setting can be estab lished with all the remaining adjusting screws Generally each succeeding screw needs to be screwed in approximately one full turn deeper than its preceeding screw A smooth stair step gradient pre set at this point from low to high will simplify the remaining adjustment steps D Without advancing the SYNCHRO Valve quadrant screw down on 2 screw one or two turns Then slowly advance the SYNCHRO Valve quadrant to the 2 position Refine flame appearance at this new position 2 E Turn all higher numbered screws in at least as far as the one just adjusted then turn next one in as necessary to achieve desired flame while rotating valve mechanism to that position on indicator strip F Repeat for each remaining screw NOTE To avoid possible damage to cam strips always turn all higher numbered screws in as far as the last one adjusted G Refine adjustment as needed always turning valve so that position indicator matches screw being adjusted For more fuel turn screw in clockwise for less fuel turn screw out counter clockwise If screws must be turned in flush with carrier casting increase fuel pressure and readjust by starting at minimum over again H Cycle system off and on and through all firing rates until satisfied with performance I Reconnect control motor linka
196. he digit will stop flashing the previous value is restored and the Program LED will turn off Or Press Enter to save a change The digit will stop flashing and the Program LED will turn off Press Esc to return to the parameter list Continue to press Esc to back out of the programming menu If pressing Esc does not change the display then d001 Output Frequency is displayed Press Enter or Sel to enter the group menu Key s DoD Da Ea CAJA Example Displays o VOLTS o AMPS e HERTZ LI a PROGRAM O FAULT O 4 1 _ LI LI VOLTS AMPS o HERTZ PROGRAM O 7 1 FAULT O mn I N o VOLTS o AMPS o HERTZ 1 VOLTS 1 Jhen CAJA e e VOLTS o AMPS o HERTZ e VOLTS o AMPS HERTZ Afi PROGRAM FAULT y o Hertz PROGRAM d VOLTS O AMPS 7 FAULT O See the PowerFlex 4 User Manual on CD for more information on parameters Display Group Parameters English 9 No Parameter Min Max Display Options d001 Output Freq 0 0 Maximum Freq 0 1 Hz 9002 Commanded Freq 0 0 Freq 0 1 Hz 0003 Output Current 0 00 Drive Amps x2 10 01 A
197. he dryer by placing the main circuit breaker handle located on the dryer power panel to the ON position 4 Pull out both Emergency Stop Buttons located dryer operation In the AUTO position the dryer automatically controls the conveyor slide eate and the OUT OF GRAIN TIMER is en abled allowing automatic shutdown if the dryer remains low on grain after a preset period of time on the side of the control and power box to 9 Set drying plenum temperature by touching enable the main PLC circuit 5 1 Switch on the control panel by turning the CONTROL POWER selector switch to the ON position The switch will illuminate indicat ing that the control panel has power and is operating correctly After a short series of self diagnostic tests the LCD display screen will display a copyright message and a start button 5 2 Press the on screen Start button to enter the dryer status screen 10 6 Press the DRYER POWER START button to activate the LOAD BLOWERS BURNER UNLOAD and METERING DEVICE selector switches on the control panel 7 Start auxiliary equipment needed for filling the P L Temp box on the LCD display On the pop up keypad that is displayed enter the new drying temperature Recommended Drying Temperatures Ooa 180 to 210 F 140 to 160 F WY CAs ee 140 to 160 F 160 to 180 F 140 to 160 F Qr ens 140
198. he minimum precautions required to accomplish this end FOUNDATION The responsibility for the design and construction of the foundation lies with the user The foundation must be adequate to withstand normal operating loads and possible overloads while maintaining alignment to attached system components under such loads MOUNTING POSITION Unless a unit is specifically ordered for inclined mounting the foundation must be level and flat The lubrication system may not operate properly if the unit is not mounted in the position for which it is designed It may be desirable to elevate the foundation to facilitate oil drainage CONCRETE FOUNDATION If a concrete foundation is used steel mounting pads and bolts of sufficient size to distribute the stress into the concrete should be grouted into the foundation STEEL FOUNDATION If a structural steel foundation is used i e wide flange beams or channels a base plate or sole plate of suitable thickness should be used and should extend under the entire unit FOOT MOUNTED UNITS Use shims under the feet of the unit to align the output shaft to the driven equipment Make sure that all feet are supported so that the housing will not distort when it is bolted down Improper shimming will reduce the life of the unit and may cause failure Dowel pins may be installed to prevent misalignment and ensure proper realignment if removed for service SHAFT MOUNTED UNITS Shaft mounted drives should be
199. he outlet pressure during start up to prevent an outlet pressure overload General Servicing Instructions A Before any disassembly of the regulator make sure it is com pletely depressured Pressure must be fully released from the inlet the outlet and the control line connection Failure to ad equately depressure could result in serious personal injury B Carefully note the location and position of all disassembled parts to be certain reassembly is correct Inspect each part carefully and replace any that are worn or damaged or other wise unsatisfactory C Upon completion of servicing make certain that the regulator installation is entirely free of leaks CAUTION Regulators are pressure control devices with numerous moving parts subject to wear that are dependent upon particular operating conditions To assure continuous satisfactory operation a periodic inspection schedule must be adhered to with the frequency of inspection determined by the severity of service and applicable laws and regulations if required L TYPICAL INSTALLATION VENT CAP 74 NPT 121 8 and 121 12 114 NPT 121 16 CONTROL LINE CONTROL CONNECTION OUTLET A p Invensys Energy Metering Outlet Pressure Ranges and Springs PRESSURE SPRING SPRING INLET DIAPHRAGM RANGE COLOR PART NUMBER PRESSURE SIZE retest we 4172 to 12 w c Green Black 143
200. ial view of mounting bracket 42 1 1 656 Torque solenoid base sub assembly to 175 x25 in Ibs 19 8 2 8 Nm 7 1 281 diameter two positions 2 mounting holes optional feature m m I INCHES A solenoid base sub assembly solenoid base gasket mounting bracket 6 Restore line pressure and electrical power supply to valve 7 After maintenance is completed operate the valve a few times to be sure of proper operation A metallic click signifies the solenoid is operating ORDERING INFORMATION FOR ASCO REBUILD KITS Parts marked with an asterisk in the exploded view are supplied in Rebuild Kits e When Ordering Rebuild Kits for ASCO Valves order the Rebuild Kit number stamped on the valve nameplate If the number of the kit is not visible order by indicating the number of kits required and the Catalog Number and Serial Number of the valve s for which they are intended Partial views of core diaphragm sub assemblies showing the difference between 8215B 8215C amp 8215G parts Series 8215B has a diaphragm disc CAUTION 8215C amp 8215G parts are not interchangable with 8215B valve bonnet Torque bonnet screws in a crisscross manner LG core diaphragm sub assembly bleed hole from valve outlet body gasket CAUTION valve body Locate bleed hole 45 Do not damage valve seat to 70 8 in Ibs 8 0 0 9 Nm Series
201. ies at low pressure drops using minimum operating torque This economical assembly includes a minimum stop screw and can be supplied with connecting base and linkage assembly to mount your electric control operator Versions available with UL Underwriters Laboratories listing for air natural gas and liquefied petroleum gas service Series BV Balancing Valves are used to balance gas or air flows in multiple burner systems fed by acommon manifold They feature a full flow butterfly design with provision for locking in any position Air Control Valves permit throttling control of air to burners They feature a fixed gradient butterfly valve design with an adjustable minimum stop friction brake screw and provision for manual or automatic operation Air control valves are offered in 1 1 2 through 18 pipe sizes A complete system using Maxon Flow Control Valves will typically include burner gas and or oil pipe trains mixing equipment pressure blower and a control panel Your Maxon representative can help you choose from the broad range available MAXON Series Q Gas Control Valves provide the high capacity and low pressure drop benefits of a butterfly valve construction plus an adjustable gradient feature for accurate fuel flow control They are used independently for throttling of fuel gases and with PREMIX Blower Mixers and AIRFLO Mixers for stand by fuel systems where they allow change over to alternate
202. in that may be hanging up on the plenum roof Make sure the grain exchangers are clean Clean out the hopper that divides the heat section from the cooling section Clean the cooling chamber floor Remove all grain and trash from the metering drum floor This grain can be raked out by hand by opening the slide gates located in the hopper bottom of the dryer Make sure gas supply is shut off to the dryer Open the gas train drain valve located on the bottom of the gas train It is a good practice to cover the burner with a tarpaulin or plastic to insure a clean burner Tower Dryer Ops amp Service LUBRICATION TABLE LOCATION INSTRUCTIONS Metering drum drive shaft bearing On GSI hopper bottom dryers only Accutrol sweep unload top and bottom drive bearings On Zimmerman flat bottom dryers only Accutrol sweep unload coupling hub On Zim merman Dryers Blower shaft bearings Both GSI and Zimmerman Dryers Blower motor bearings Both GSI and Zimmerman Dryers Metering variable speed drive motor Both GSI and Zimmerman Dry ers 12 Diameter Accutrol gearbox 12 diameter sweep unload gearbox Zimmerman Dryers only 18 amp 24 Diameter Accutrol gearbox 18 and 24 diameter sweep unload gearbox Zimmer man Dryers only Metering drum gearbox On GSI hopper botto dryers only Lubricate slowly until lube shows through seal Wipe clean Lubricate slowly until l
203. ing manufacturer s recommendations should be followed AXIAL DISPLACEMENT The gap between shaft ends should be the same as the specified coupling gap unless overhung mounting of the coupling hub is specified The coupling gap and shaft gap must be sufficient to accommodate any anticipated thermal or mechanical axial movement ANGULAR ALIGNMENT Insert a spacer or shim stock equal to the required coupling gap between the coupling hub faces and measure the clearance using feeler gauges Repeat this at the same depth at 90 degree intervals to determine the amount of angular misalignment PARALLEL ALIGNMENT Mount a dial indicator to one coupling hub and rotate this hub sweeping the outside diameter of the other hub The parallel misalignment is equal to one half of the total indicator reading Another method is to rest a straight edge squarely on the outside diameter of the hubs at 90 degree intervals and measure any gaps with feeler gauges The maximum gap measurement is the parallel misalignment CHECKING ALIGNMENT After both angular and parallel alignments are within specified limits tighten all foundation bolts securely and repeat the above procedure to check alignment If any of the specified limits for alignment are exceeded realign the coupling SPROCKET OR SHEAVE ALIGNMENT Align the sheaves or sprockets square and parallel by placing a straight edge across their faces Alignment of bushed sheaves and sprockets should be check
204. ins into the rollers Fig A 12 The above instructions are for eccentric bearings with retainer Following are the instructions suggested for roller bearings without retainer a First insert the eccentric with inner raceways of bearings by rapping with a wooden or hard rubber mallet Fig A 12 b Apply grease to the raceway of the eccentric on the disc Fix the rollers and set disc in place c Insert the spacer ring and set second disc in such a way that mark is 180 opposed to mark on the bottom disc Eccentric Bearing Replacement Precautions The eccentric bearings are specially designed for in stallation on SM CYCLO Reducers They are special roller bearings without outer raceways refer to the list of bearings on pages 12 A 13 It is necessary to insert replacement bearings with numbered surfaces of the inner raceways facing outward Note that incorrect insertion of the bearings i e insertion of bearings with numbered surfaces inside causes trouble Disassembly and Assembly of Sizes 6060 6095 SM CYCLO Reducers Small sizes 6060 6095 have a single disc system so they differ in construction from larger sizes in the following ways 1 Abalance weight is providedin lieu of the two disc system Refer to figure A 18 2 The balance weight must be positioned exactly 180 as opposed to that of the eccentric 3 There are no end plates on either side of the eccentric In all other respects 6060 6095 have exactly
205. inutes Take five small samples from the dis charge and mix before taking a moisture reading Switch over to Automatic Moisture Control When the discharge moisture content has stabi lized at the desired amount for 20 to 30 minutes the dryer may be switched over to Automatic Moisture Control 17 1 Press the MOISTURE CONTROL button at the bottom of the LCD screen 17 2 On Moisture Control Setup screen set the upper and lower limits by touching the corre sponding box and using the pop up keypad These values prevent the unload from moving too fast or too slow should the incoming moisture be significantly greater or less than anticipated 17 3 Press the CONTROL MODE box to toggle between Manual and Automatic moisture control Note that the current and target grain tempertures are displayed next to the Temperature History Chart the discharge moisture content is consis tently too high or too low adjust the target grain temperature as follows 5 F increase moisture point decrease 5 F decrease moisture point increase Allow 30 minutes between adjustments DRYER START UP Tower Dryer Ops amp Service 04721 704 DRYER CONTROL CENTER 11 49 02 DRYER RUNNING This run O hr 18 min Total O hr 18 min Capacity 600 BPH NUI BLOWER UNLOAD UL RATE PILOT DRY PATH 182 E BURNER WETPATH 60 0 FUEL AUTO CTR DRYER MOIST SETUP CONTROL
206. ips loosely over a bolt or steel rod attached to the support Gas piping would need independent support Sketch 3 shows the burner assembly resting upon angle iron brackets and not attached to them in any way Be sure the angle iron supports allow the burner flanges to expand and contract Gas manifolding would be independently supported and prevent forward movement of the burner Ends Free Strap Iron To p Of Duct To in 12 um Balt M 12 Minim i Drawn Up Loosely Strap Iron To Air Bottom Of Duct Movement Soon Gas Manifold Independently pu d 2 Oversize U B Iron Brace Air ide Of Duct Movement Sketch 4 shows simple strap iron used to support the burner Note that narrow edge of strap faces air flow to avoid undue turbulence Sketch 5 shows gas manifolding used to support the burner If there are multiple inlets you must avoid rigid connection by Angle using the oversize U bolt Singer loosely drawn up illustrated Support for down fired Rod burners can be accomplished upport as shown in the illustration at right Always avoid rigid mounting Sketch 6 shows Maxon USB support brackets Suspending the burner from an overhead angle iron Sketch 7 shows an alter nate arrangement which offers the advantage of more controlled positioning Brackets Air la IN M AM o N CORPORATION MU
207. ition Use the following procedure to obtain the desired auxiliary switch settings 1 Remove the top cover from the motor to gain access to the motor terminals and auxiliary cams 2 Disconnect the controller from the motor 3 Connect a current source to the positive and negative terminals 4 Drive the motor to the position where the auxiliary equipment is to be switched by increasing or decreasing the current 5 Foraswitch differential of 1 check continuity of auxiliary switch contacts R B and rotate the cam as follows a Ifthe contacts are open rotate the cam clockwise until the R B contacts close b Ifthe contacts are closed rotate the cam counterclockwise until the R B contacts open MOVE SCREWDRIVER AT TOP ONLY TO ADJUST CAM TAL 1 8 INCH STRAIGHT BLADE SCREWDRIVER RIGHT INNER AUXILIARY SWITCH SLOW RISE PORTION APPROX 10 DIFF 2 FAST RISE PORTION APPROX 1 DIFF N SLOW RISE PORTION APPROX 10 DIFF LEFT OUTER AUXILIARY SWITCH FAST RISE PORTION APPROX 1 DIFF MOTOR gt END SERIES 72 MODUTROL IV MOTORS 6 Fora switch differential of 10 rotate the cam approximately 180 so the slow rise portion of the cam actuates the switch 7 Check continuity of the auxiliary switch contacts R B 8 Rotate the cam as follows a Ifthe contacts are open rotate the cam counterclockwise until the R B contacts
208. ized to the burner capacity of the dryer Fuel pressure to the dryer must be regulated to approxi mately 10 psi GSI personnel will plumb all necessary gas piping from the dryer s gas shutoff valve to the burner The customer must provide fuel to the gas shutoff valve Tower Dryer Ops amp Service DRYER CONTROL PANEL Figure 1 The grain dryer control panel with full color touch screen control DRYER CONTROL PANEL Dryer Control Panel Featuring The Allen Bradley PLC Control System 1 Full Color Graphical Display provides continu ous visual feedback on the current dryer status as well as a convenient means of setting operating parameters and options Most set points and status screens are accessed by simply touching an on screen object 2 Message Center displays current dryer condi tions and alarm messages with toubleshooting tips in easy to read language 3 Dryer View provides a quick visual indication of primary dryer functions as well as easy access to current burner and grain flow status screens 4 Temperature Moisture History Chart records up to 32 hours of dryer temperature and or moisture data with optional moisture control The chart can be easily rewound to view earlier drying conditions 5 Control Power Switch energizes the control panel and the PLC Control System NOTE It takes approximately 60 seconds to power up the Full Color Graphical Display once the Control Power Switch is turned on
209. justment 3 and use for returning the adjustment to this setting during reassembly Remove bolts 10 and housing 5 3 and 4 121 16 only Remove spring 9 Remove bolts 22 and upper case 21 Rotate diaphragm assembly 11 counterclockwise this unscrews 11h from 12d and remove To disassemble diaphragm assembly remove nut 11a Carefully note location and position of all parts to be certain of correct reas sembly Abrasive side of emery cloth washers face against diaphragm To reassemble replace parts in reverse sequence Make the screwed connection between 11h and 12d loose by approximately 1 2 turn To do this carefully rotate diaphragm assembly 11 clockwise until this screwed connection bottoms do not jam it together Then back off diaphragm assembly 11 counter clockwise approximately 1 2 turn this is very important the 11h to 12d screwed connection must not be tight Service Orifice 19 2 Remove valve 15 per section To Service Valve 15 Remove seal diaphragm assembly 12 per step 2 under To Service Seal Diaphragm 12 Remove retaining ring 19a Use Truarc 0600 pliers Invensys Part No 1190648 Remove ring 33 and orifice 19 through top opening To reassemble replace parts in reverse sequence On reassembly be sure that 19a is fully seated in its groove Also beveled edge of 19a faces downward toward bottom cap 37 To Service Seal Diaphragm 12b 1 2 3 Remove valve 15 per
210. lden Valley MN 55422 Scarborough Ontario No 30 Harbour Road Belgium Suite 200 MIV 4Z9 Wanchai Sunrise FL 33325 Hong Kong 63 2202 4 Rev 11 00 6 22 2 www honeywell com post consumer paper fibers Tower Dryer Ops amp Service COMPONENTS Vil COMPONENT MANUALS GAS REGULATORS nvensys Energy Metering RM 1328 Rev 9 Regulator Installation and Maintenance Instructions Model 121 Regulators Introduction The Model 121 Regulator represents a combination of capacity performance and value Start Up A The inlet and outlet shutoff valves should both be closed If a by pass is used the by pass valve should also be closed Streamlined body passages provide large capacity An external B Note the set point set point is the outlet pressure the regula control line is required from lower case to control piping The 121 tor is adjusted to deliver Regulator is factory adjusted to the has a fast speed of response yet is stable in operation Soft seats set point specified on the order 4 tight shutoff Orifices are replaceable Springs CAUTION This caution applies where the piping downstream of the outlet shutoff valve is pressured That pres And itis also available as a zero governor or atmospheric regula sure must not exceed the regulator set point by tor a differential regulator a relief valve or backpressure regula more than the pressure noted see Maximum tor vacuum regulator or vacuu
211. le reduction units unit s operating temperature due to breakdown of the reduction lubrication films on the eccentric bearing In this case if the Py rur be upped We h operating temperature rises supply grease immediately reduction ratio units Table A 9 Single Reduction Grease Quantities oz g i LA 8 3200 49 140 71200 118 1330 Slow Speed Shaft Bearing 2 35 3 5 100 Notes 1 Avoidthe use of grease otli r than shown in Table A7 2 Consult the factory when the drives are used under widely fluctuatingtemperatures ambient temperatures other than those listed in Table A 7 or any other special conditions 3 reduction frame sizes 6060 612H ana double reduction framesizes 6060DA 612508 are maintenance free units Grease reprenishment is not necessary Where longer life of the ar ve is expected or if re ubncating is preferrea before the recommendea interval referto Tables 7 A 8 A 9 and 10 4 Overhauling consists of disassembling the unit replacing the seals and gaskets cleaning the internal parts and then repacking the unit with designated grease d LUBRICATION Table A 10 Double Reduction Grease Quantities oz 9 Speed Reduction Mechanism 1st Stage E Speed Aeduction 09 3 2 4 4 Mecharesm 2nd 125 ao 140 Siow Speed Shaf i 3 5 Bearing 2rd Sagai Machanigm 15 S
212. lenoid valves should be cleaned periodically The time between cleanings will vary depending on the medium and service conditions In general if the voltage to the coil is correct sluggish valve operation excessive noise or leakage will indicate that cleaning is required In the extreme case faulty valve operation will occur and the valve may fail to open or close Clean valve strainer or filter when cleaning the valve Preventive Maintenance 1 Keep the medium flowing through the valve as free from dirt and foreign material as possible 2 While in service the valve should be operated at least once a month to insure proper opening and closing 3 Depending on the medium and service conditions periodic inspection of internal valve parts for damage or excessive wear is recommended Thoroughly clean all parts If parts are worn or damaged install a complete ASCO Rebuild Kit Causes of Improper Operation 1 Incorrect Pressure Check valve pressure Pressure to valve must be within range specified on nameplate 2 Excessive Leakage Disassemble valve and clean all parts If parts are worn or damaged install a complete ASCO Rebuild Kit Valve Disassembly 1 Remove solenoid see separate instructions 2 Unscrew solenoid base sub assembly and body gasket 3 Remove bonnet screws valve bonnet solenoid base gasket core diaphragm sub assembly and body gasket 4 All parts are now accessible to clean or replace If parts are worn or dam
213. lete disassembly In ordinary cases however only the removal of the cycloid discs and the eccentric and removal of the slow speed shaft from the slow speed end cap is necessary Note Retaining ring is part of bearing A Part No 1 02 Assembly SM CYCLO Reducers are reassembled by reversing the disassembly procedure Care must be taken to exclude dust or foreign matter from the moving parts and to see tnat aaskets are properly placed to make the assembly oil tight Following are some helpful points to remember when assembling SM CYCLO Reducers 1 Set the ring gear housing and insert the ring gear pins and rollers then test rotate the pins and rollers by hand Apply grease liberally to the ring gear pins and rollers before they are inserted in grease lubricated SM CYCLO Reducers 2 Cycloid discs are a matched pair Each carries the same number stamped on one side of the disc 3 Set the cycloid disc with the stamped number face up as shown in Fig A 17 4 Insert the spacer 3 07 and then insert the eccentric with bearings by rapping with a wooden or hard rubber mallet Fig A 16 5 Insert the other spacer and the inner bearing raceway Secure them with the retaining ring Fig A 15 6 Set the spacer ring in place T Insert top disc in such a way that the mark is 180 opposed to the mark on the bottom disc Fig A 13 8 Insert slow speed shaft rollers Fig A 13 9 Put the slow speed shaft p
214. ls are not displayed on your dryer or if they are damaged contact The GSI Group Inc for replacement The GSI Group Inc 1004 E Illinois St Assumption Illinois 62510 phone 217 226 4421 fax 800 800 5329 DO NOT STAND ON DRUM Rotating drum will cause serious injury or death Disconnect power before servicing DC 1062 Tower Dryer Ops amp Service 10 11 12 13 READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE SAVE FOR FUTURE REFERENCE Read and understand the operating manual before trying to operate the dryer Never operate the dryer while any guards are removed Power supply should be OFF for service of electrical compo nents Use CAUTION in checking voltage or other procedures requir ing power to be ON 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 Never attempt to operate the dryer by jumping or otherwise bypassing any safety devices on the unit Do not exceed maximum recommended drying temperatures Keep the dryer clean Do not allow fine material to accumulate in the plenum chamber Keep blower drive belts tight enough to prevent slippage Use CAUTION in working around high speed fans gas burners augers and auxiliary conveyors which START AUTOMATICALLY Do not operate in any area where combustible material will be drawn into the fan Be certain that capaciti
215. m previously determined 1 01 Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Toggle Clamp Toggle Clamp Screw 1 Toggle Bolt 3 Clamp Motor Crank Connecting By 2168 Linkage Control M Motor By ud Motor Valve Mountin 4 4 8 Minimum Stop Screw Typical Control Motor 11 Relight burner and cycle control system from low to high fire several times to observe per formance Refine adjustments of pilot and main burner minimum if necessary Warning Test every UV Flame Sensor System for dangerous spark excitation from ignitors and other burners as well as other possible sources of direct or reflected UV radiation 12 Check carefully that all interlocks and limits are in full operating condition Before system is placed into full service instruct operator person nel on proper start up operation and shut down of system Establish written instructions for reference IN M AM o N CORPORATION MUNCIE INDIANA USA Page 5550 S 6 Series NP LE AIRFLO Burners Maintenance and Component Identification Spare Parts NP 1 LE To order replacement parts 1 See burner nameplate and indicate burner type 2 Sketch burner arrangement as viewed from casting side 3 Specify replacement items required from diagrams above 4 Specify quantity of each an
216. m breaker Emergency Pressures Page 18 Installation C Slowly and carefully open the inlet shutoff valve just enough to allow inlet pressure to build up slowly in the regulator until Examine the regulator for shipping damage it is fully pressured Check nameplate data Be sure regulator conforms with CAUTION During start up a pressure gauge must be used what was ordered on the regulator outlet pressure and carefully madeo Bret df f watched While inlet pressure builds up outlet En SUM m Ta e S an a 2 pressure must not exceed set point by more than E al E SONS d Or s a aa M s OF 1 psi If outlet pressure begins to exceed set point al artes eee by more than 1 psi close the inlet shutoff valve AJS oT POUDIE This indicates the regulator is not closing properly Remove all shipping screens and covers from the regula Check and make necessary corrections before pro tor Do not let dirt get inside the regulator ceeding with start up If regulator outlet pressure exceeds set point by Install the regulator Make sure the inlet and outlet are correctly connected unas nn 1 High pressure connects to the inlet The flow arrow must gency point downstream D Check installation for leaks Screwed connections must conform with good piping prac E Slowly open the outlet shutoff valve to allow a small flow ap tice free of excess thread engagement per ANSI B2 1 proximat
217. mplete assembly in any case 2 When necessary parts have been received remove damaged mixing plates or burner sec tions taking care not to damage remaining portion of burner If new burner bodies are being installed place body gasket on the mating flanges of loose cast iron bodies This is neces sary to provide a gas tight seal after assembly Insert new section into place making sure that both flanges are square and flush then bolt sections together 1 01 Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES 3 Install new mixing plates back up bars and plate support brackets to the new body castings 4 plate sets must be installed put in position between mixing plates and insert fasteners loosely Do not tighten at this time 5 Tighten burner body bolts making sure that mating cast iron flanges remain square and flush 6 Align mixing plates and check that body gaskets are in position and properly aligned Tighten all mixing plate mounting screws and bolts T Double check that all fasteners are secure 8 Return burner to operation observing flame carefully at all firing rates IN M AM O N CORPORATION MUNCIE INDIANA USA Page 5550 S 12 Series NP LE AIRFLO Burners Inspection and Maintenance of Gas Ports Conduct initial inspection within the first month Use of an el
218. mps d004 Output Voltage 0 Drive Rated Volts 1 VAC d005 DC Bus Voltage Based on Drive Rating 1 VDC d006 Drive Status 0 1 1 Condition True Bit 3 Bit 2 Bit 1 Bit 0 Decelerating Accelerating Forward Running d007 Fault x Code F2 F122 F1 d009 d010 Process Display 0 00 9999 0 01 1 d012 Control Source 0 9 Digit 1 Speed Command Digit 0 Start Command See P038 9 Jog Freq See P036 9 Jog 9013 Contrl In Status 0 1 1 Input Present Bit 2 Bit 1 Bit 0 Reserved Stop Input Dir Run REV Start Run FWD 0014 Dig In Status 0 1 1 Input Present Bit 3 Bit 2 Bit 1 Bit 0 Reserved Reserved Digital In2 Sel Digital In1 Sel d015 Comm Status 0 1 1 Condition True Bit 3 Bit 2 Bit 1 Bit 0 Fault Occurred RS485 Option Transmitting Receiving d016 Control SW Ver 1 00 99 99 0 01 0017 Drive Type 1001 9999 1 d018 Elapsed Run Time 0 9999 Hrs 1 10 Hrs d019 Testpoint Data 0 FFFF 1 Hex d020 Analog In 0 10V 0 0 100 0 0 1 0021 Analog In 4 20mA 1 0 0 100 0 0 1 d024 Drive Temp 0 120 degC 1 degC Smart Start Up with Basic Program Group Parameters The Program Group contains the most commonly used parameters Stop drive before changing this parameter No Parameter Min Max Display Options Default P031 Motor NP Volts 20 Drive Rated Volts 1 VAC Based on Drive Rating Set to the motor nameplate rated volts P032 Motor NP Hertz 10 240 Hz 1Hz 60 Hz Set to the motor nameplate rated frequency P033
219. n additional test connection in the piping between main gas regulator and fuel control valve All connections must be plugged unless an actual pressure measuring device gauge or manometer is being used Maxon assumes no responsibility for the use or misuse of the piping layouts shown Specific piping and wiring diagrams should always be submitted to the appropriate agencies for approval on each application cR Maxon practices a policy of continuous product improvement It reserves the right to alter specifications without prior notice INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Series NP LE AIRFLO Burners Page 5550 S 3 Start Up Instructions Read complete instructions before proceeding and familiarize yourself with all the system s equipment components Verify that your equipment has been installed in accordance with the original manu facturer s Current instructions CAUTION Initial adjustment and light off should be undertaken only by trained and experienced personnel familiar with combustion systems with control safety circuitry and with knowledge of the overall installation Instructions provided by the company and or individuals responsible for the manufacture and or overall installation of complete system incorporating Maxon burners take precedence over these provided by Maxon If Maxon instructions conflict with any codes or regulations contact Maxon Corporation before attempting start up
220. n gas valve to the dryer DRYER SHUTDOWN 8 Inspect the inside of the dryer after opera tion to insure against the possibility of hot spots or fires Viewing Temperature Moisture History Press the left and right arrows above the Tempera ture Moisture History Chart to move backward and forward through the graph Viewing Burner Fuel Train Status Press the Burner region in the Dryer View portion of the LCD display to switch to the Fuel Train Status screen This screen displays the open closed state of all valves as well as the modulating valve control value Viewing Grain Flow Status Press the Unload region in the Dryer View portion of the LCD display to switch to the Grain Flow Status screen This screen displays therunning status of all controlled interlocked equipment in the grain flow path Modifying the Bushel Per Hour Factor The bushel per hour reading given by the PLC isa calculated value based on metering device speed Due to variations in grain test weight and unload system settings the correction factor may need to be calibrated so that the calculated and actual grain flow rates agree The bushel per hour factor is normally set at 1 0 If for example the actual grain flow rate 1s 5 percent higher than displayed change the bushel per hour factor to 1 05 To adjust the correction factor press the DRYER SETUP button then the BUSHEL COUNTER button Press the CORRECTION FACTOR box to adjust the value 11 TRI P
221. n on the gearbox nametag For mounting orientations other than shown consult NORD Gear Horizontal position SK 6282 SK 11282 SK 6282 SK 11282 1282 SK 5282 SK 6382 SK 12382 SK 6382 SK 12382 O SK 6382 SK 12382 E f SK 1282 SK 5282 SK 2382 SK 5382 SK 1282 SK 5282 SK 2382 SK 5382 H 1 H 2 H 3 H4 Vertical position L T 4 T Y H5 H6 Symbol Vent plug on Drain plug mbols ent plu il leve rain plu Mounting position H5 with lubricant expansion unit recommended SK0182NB amp SK1382NB have no vent or drain plugs They are filled with synthetic oil so the units are Lubed for Life BIM 1020 2005 03 5 www nord com MAINTENANCE Mineral lubricant should be changed every 10 000 service hours or after two years For synthetic oils the lube should be changed every 20 000 service hours or after four years In case of extreme operating e g high humidity aggressive environment or large temperature variations shorter intervals between changes are recommended OIL SPECIFICATIONS NORD supplies all reducers filled with oil from the factory Consult the sticker a
222. n product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system English 2 Mounting Considerations e Mount the drive upright on a flat vertical and level surface Install on 35 mm DIN Rail Or Install with screws Minimum Panel Thickness Mounting Torque 1 9 mm 0 0747 in M4 48 32 1 56 1 96 N m 14 17 Ib in Protect the cooling fan by avoiding dust or metallic particles Do not expose to a corrosive atmosphere Protect from moisture and direct sunlight Minimum Mounting Clearances See page 12 for mounting dimensions b 4 25 mm 1 0 in o SJ o y o l o 120mm 120 mm 4 7 in 3 Y 4 7 in 2888 Mounting Option Noclearance required OOODO amp ooll amp oo between drives 00 Powerflex Mounting Option B gt Powerflex Powerrlex y 120mm e 120mm 4 7 in 3 4 3 4 7 in Ambient Operating Temperatures Ambient Temperature Enclosure Rating Minimum Mounting Minimum Maximum Clearances 40 C 104 F IP 20 Open Type Use Mounting Option A 10 C 14 F IP 30 NEMA 1 UL Type 1 Use Mounting Option B 50 122 F 20 Open Use Mountin
223. nd adjust down to Improper lubrication Excessive lubrication recommended levels a Flush out and refill with correct lubricant as Wrong lubrication recommended Inspect mounting of reducer Tighten loose Weak mounting structure bolts and or reinforce mounting and structure Loose hold down bolts Tighten bolts Worn RV Disc Overloading unit may result in Disassemble and replace disc Recheck Runs Noisy damage to disc rated capacity of reducer Replace bearing Clean and flush reducer Failure of Bearings fill with recommended lubricant Loose foundation bolts Check rated capacity of reducer y Level of lubricant in the reducer not Check lubricant level and adjust to factory Insufficient Lubricant properly maintained recommended level Overloading of reducer can cause Replace broken parts Check rated capacity Internal parts are broken damage Output Shaft Key missing or sheared off on input Raniace ke Does Not Turn shaft p y Coupling loose or disconnected per align reducer and coupling Tighten coupling Worn Seals Caused by dirt or grit entering seal Replace or clean i Check lubricant level and adjust to Overfilled reducer recommended level Oil Leakage Clean or replace being sure to prevent any AUIOVEREEIOIgEN dirt from falling into the reducer Improper mounung positon ATAS Check mounting position Name tag amp verify wall or ceiling mount of horizontal ith harti e
224. nected through V pulleys or sprockets insure that the belts or chains are neither too tight nor too slack 3 Overhung Load Positions Overhung loads should be located as close to the bearing as possible See the SM CYCLO 6000 Series Catalog page E 8 4 Foundations Foundations must be rugged enough to withstand shock and stress applied from the load side through the reducer Incorrect Square And Parallel Allowable Oil Viscosity 9 Oi change E 9 Forced lubrication 35 2 A 9 Oil Level Dimensions A 10 Bearings Oil Seals amp Gaskets A 11 13 Dissassembly Assembly A 14 15 Daily Inspeclion 22222227222 A 16 Ordering Correct Replacement Units amp Parts A 16 Storage amp Operation After Storage A 16 Trouble SODIO nee ee A 17 Moles esc ee er A 18 5 Secure Housing Where the reduction units are operated under conditions of vibration and or frequent starts and stops it is recommended to secure them on their mounting surfaces by inserting dowel pins into the knock holes provided on the foot of the casing This will insure that bending or shearing forces are reduced on the mounting bolts Pins must be securely inserted particularly when the units are to be operated under conditions of severe recurrent peak loads 6 Mounting Accessibility The reduction units must be mounted in locations with easy
225. ng that the blowers are operat ing correctly After the closure of all of the airflow the dryer automatically goes through a 30 second purge cycle 10 Burner Switch turns the burner on or off When the switch is turned on the burner pilot will automati cally light after the purging cycle is completed The lighted burner switch will flash during the 15 second pilot ignition time The switch illuminates when the pilot flame is sensed at the pilot After the pilot flame is established the Maxon shut off valves in the fuel train are energized Motorized valves will automati cally open to provide gas to the main burner Manual valves must be opened manually to supply gas to the main burner 11 Unload Conveyor Switch turns the dry grain unload conveyor on or off The switch illuminates when the conveyor is operating 12 Metering Device Switch turns the metering device on or off in forward or reverse The device will not run unless the unload conveyor is on The switch illuminates when the metering device is discharging grain 13 Dryer Power Start Button initiates automatic operation of the dryer When depressed the dryer begins the startup cycle and operates based on the positions of the selector switches on the control panel To control the operation of individual components first depress the DRYER POWER START button then turn on the individual dryer components as desired 14 Dryer Power Stop Button manually stops all dryer
226. nges of spring 9 are given in the tables on Pages 3 and 4 To change the spring 1 Remove top cap 1 2 Unscrew and remove adjustment button 3 3a or 6 by turn ing counterclockwise and remove spring 9 3 Insert new spring Make sure it is positioned correctly at the bottom before replacing adjustment button 3 3a or 6 4 Adjust for the desired outlet pressure per previous section Set Point Adjustment 5 When adjustment is complete replace top cap 1 Screw it securely into place Leaving it off could result in unstable regulator operation 6 New spring range should be marked on regulator If old spring range appears on regulator it should be removed REMOTE VENT LINE CAUTION The diaphragm case vent must be positioned to protect against flooding drain water ice formation traffic tampering etc The vent must be protected against nest building animals bees insects etc to minimize the chances for foreign material from collecting in the vent side of the regulator diaphragm Shutdown A To take the regulator out of service close the inlet stop valve first Close it carefully Then close the outlet stop valve Before working on regulator read the next section General Servicing Instructions and the applicable servicing instructions CAUTION Turn gas on very slowly If an outlet stop valve is used it should be opened first Do not overload diaphragm with a sudden surge of inlet pressure Monitor t
227. noid in an enclosure BLACK ENCLOSURE TYPES 7 AND 9 ONLY CAUTION To prevent fire or explosion do not install solenoid and or valve where ignition temperature of hazardous atmosphere is less than 165 C On valves used for steam service or when a class H solenoid is used do not install in hazardous atmosphere where ignition temperature is less than 180 C See nameplate retainer for service NOTE These solenoids have an internal non resetable thermal fuse to limit solenoid temperature in the event that extraordinary conditions occur which could cause excessive temperatures These conditions include high input voltage a jammed core excessive ambient temperature or a shorted solenoid etc This unique feature is a standard feature only in solenoids with black explosionproof dust ignitionproof enclosures Types 7 amp 9 CAUTION To protect the solenoid valve or operator install a strainer or filter suitable for the service involved in the inlet side as close to the valve or operator as possible Clean periodically depending on service conditions See ASCO Series 8600 8601 and 8602 for strainers Temperature Limitations For maximum valve ambient temperatures refer to chart The temperature limitations listed only indicate maximum application temperatures for field wiring rated at 90 C Check catalog number prefix and watt rating on nameplate to determine maximum ambient temperature See valve installation
228. nominai in inches Swinging gate valves Rising stem valves 12 19 2 4 2 31 dia Maximum NOTE Overhead wheel amp chain can only be mounted on swinging gate valves with the top assembly position TO 2 00 Maxon practices policy of continuous product improvement It reserves the right to alter specifications without prior notice CORPORATION INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES MUNCIE INDIANA USA Page 6100 S 12 Electro Mechanical Valves Maintenance Instructions CAUTION Valve leak testing should be under taken only by trained and experienced personnel Instructions provided by the company and or individuals responsible for the manufacture and or overall installation of complete system incorporat ing Maxon valves take precedence over these provided by Maxon If Maxon instructions conflict with any codes or regulations contact Maxon Corporation before attempting this procedure Valve leak test should be performed ona quarterly basis to assure continued safe and reliable operation Each valve should be checked with available line pressure Absolute zero leakage may not be obtained in the field Any valve that exceeds the allowable leakage as set forth by your local codes or insurance requirements 15 bubbles per minute should be removed from service and your Maxon representative should be contacted Every Maxon valve is operationally tested and meets
229. nstalled accordance with the current installation codes and applicable regulations which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made GSI GROUP GSI Group 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4421 Fax 1 217 226 4420 www gsiag com Copyright 2009 by GSI Group Printed in the USA
230. oid base sub assembly and adapter to 175 25 in bs 19 8 2 8 Nm ORDERING INFORMATION FOR ASCO SOLENOIDS When Ordering Solenoids for ASCO Solenoid Operators or Valves order the number stamped on the solenoid Also specify voltage and frequency Form No V6584R8 amp ASUS 50 Hanover Road Florham Park New Jersey 07932 www ascovalve com Torque Chart Torque Value Inch Pounds Torque Value Newton Meters solenoid base sub assembly amp adapter 175 25 19 8 2 8 pipe adapter Remove red cap and push solenoid down Then pry here to lift red cap Remove red cap and nameplate retainer push solenoid down and push to remove nameplate Then pry here to lift retainer nameplate retainer and push to remove grounding wire green or green with yellow stripes solenoid with 1 2 NPT 062 to 093 maximum finger washer thickness of panel for mounting 0 69 diameter mounting hole solenoid base sub assembly collar to face Tapped hole in core 0 9375 26 UNS 2A valve body 0 250 28 2 thread 0 63 minimum full thread AC Alternate 0 38 minimum full thread DC Construction red cap Remove red cap and push solenoid down Then pry here to lift nameplate nameplate retainer retainer a and push to remove CE spacer St 2 grounding wire solenoid green or green with yellow stripes with 1 2 NPT 1 GP spring washer solenoid base sub assembly
231. oil signal Part No 41 Faulty operation is caused by a lack of lubrication oil damage to the plunger pump Part No 42 or the positive displacement pump Part No 43 or the clogging of pipes etc In case of faulty operation stop and inspect the unit immediately 2 Atemperature rise of approximately 105 F 40 6 C above ambient on the surface of the ring gear housing Part No 2 01 is allowable if the temperature fluctuation is small If temperature rises rapidly from a stable condition add the recommended oil or grease Tables A 7 and A 11 A rapid temperature rise may be caused from a lack of lubrication If after lubricating unit the problem persists stop operation and consult factory 3 When an abnormal sound is heard from inside the unit stop operation and inspectthe unit 4 f the lubrication oil leaks replace the damaged or worn part with a new one Refer to Part No 1 04H Page A 3 Ordering Correct Replacement Units Or Parts The SM CYCLO is fully standardized to offer maximum part interchangeability among models of the same frame size However there are many frame sizes models and types in the production range of SM CYCLO Therefore to get correct replacement units or parts proper information to identifv the speed reducer in auestion is essential The plate which is secured to the body of the drive provides this identifying data Please give the full description shown on the name plate
232. otor servicing when selecting a location see Fig 1 If located outdoors use liquid tight conduit connectors with the junction box to provide NEMA 3 weather protection If mounted outdoors in a position other than upright install a 4074ERU Weatherproofing Kit and liquid tight connectors to provide NEMA 3 protection N CAUTION Motor Damage Hazard Deteriorating vapors and acid fumes can damage metal parts Install motor in areas free of acid fumes and other deteriorating vapors In excessive salt environments mounting base and screws should be zinc or cadmium plated not stainless steel or brass Use the 220738A Adapter Bracket for mounting on these surfaces SERIES 72 MODUTROL IV MOTORS Mounting Use the following guidelines for proper motor mounting e Always install motors with the crankshaft horizontal Mounting flanges extending from motor housing base are drilled for 1 4 inch 6 4 mm machine screws or bolts e Non Spring Return Motors are shipped from the factory in the closed position at the counterclockwise rotation limit as viewed from the motor power e Spring Return Motors are shipped from the factory in their normal position Normally closed models are shipped at the counterclockwise rotation limit as viewed from the motor power end Normally open models are shipped at the clockwise rotation limit as viewed from the motor power end M7272 M7282 M7285 M7286 VERTICAL REFERENCE
233. pecifications given in this publication do not include normal manufacturing tolerances Therefore Models TRADELINE models are selected and packaged to an individual unit may not exactly match the listed provide ease of stocking ease of handling and maximum specifications Also this product is tested and replacement value TRADELINE model specifications are the calibrated under closely controlled conditions and same as those of standard models unless specified otherwise some minor differences in performance can be TRADELINE models have auxiliary switch cams expected if those conditions are changed NOTE Auxiliary switches can only be added to motors that Modutrol IV Order Number Guide See Table 1 include auxiliary switch cams These cams cannot be field added Dimensions See Fig 1 Table 1 Modutrol IV Order Number Guide m Motor 4 20 mA or 2 10 Vdc Control 7 1 7 Single ended shaft Non Spring Return 4 Normally Closed Spring Return Dual ended shaft Non Spring Return L Bibi NorSpingReun oooO OSOS Normally Closed Spring Return Normally Open Spring Return A 7 0Auxiliary Switches Fixed Stroke Normally Closed 1 Auxiliary Switch Adjustable Stroke eN 0 Auxiliary Switch Normally Open L 8 SeeCatalogforComplete O S Number Adjustable zero and span b Electrically normally closed Shaft rotates clockwise viewed from th
234. peration maintenance and service must be done only by qualified persons 3 Comply with all pertinent rules regulations and codes federal state local and insurance pressure protection to prevent regulator damage and possible personal injury see Maximum Emergency Pressures in the REGULATOR INSTALLATION AND MAINTENANCE INSTRUC TIONS bulletin The use of an internal or external relief valve is recommended for installations subjected to no flow for extended periods of time such as pilotless ignition systems PRIOR TO INSTALLATION 1 Examine the regulator for shipping damage 2 Check the name plate data Make sure the regulator con forms with what was ordered 3 Provide suitable shut off valves conveniently located 4 Protect the regulator from damage by vehicles or other out side sources 5 The inside of the regulator and piping must be clean Re move all dirt and debris before installing the regulator Failure to do this could result in regulator damage and improper operation Where there are dirt problems in the gas it may be necessary to install a suitable filter or strainer upstream from the regulator 6 Remove all shipping plugs and covers from the regulator before installing Do not let dirt get inside VENT CAP CONTROL LINE if required CONTROL CONNECTION 4 Make sure the inlet and outlet connections are correct High pressure connects to the regulator inlet The flow arrow on the bod
235. pment of these safety guidlines To help you recognize this information we use the symbols that are defined below Please read the manual and pay attention to these sections Failure to read this manual and it s safety instructions is a misuse of the equipment and may lead to serious injury or death This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently hazardous situation R which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation A WARN which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which A CAU TI O N if not avoided may result in minor or moderate injury CAUTION used without the safety alert symbol indicates a CAU TI O N potentially hazardous situation which if not avoided may result in property damage NOTE indicates information about the equipment that you N OTE should pay special attention to Ml SAFETY FIRST Tower Dryer Ops amp Service The GSI Group Inc s principle safe operating procedures and all personnel associated with concern is your safety and the some of the problems that may the equipment or who are in the safety of others associated with be encountered by the dryer dryer area Avoid any alter grain handlin
236. raged and should be done on a regularly A main gas shut off cock should be located scheduled basis In rare instances where valve shows upstream from all other fuel train piping compo leakage perform Pre Operational Exercising see nents and used to shut off all flow of fuel for below and retest If leakage does not stop remove servicing and other shutdowns valve from service All safety devices should be tested at least Pre operational exercising Prior to initial fluid monthly and more often if deemed advisable flow start up and with upstream manual cock stil Periodic testing for tightness of manual or motor closed operate the valve electrically for 10 15 cycles ized shut off valve closure is equally essential per NFPA 86 Appendix B 4 1995 This not only provides an electrical check but also wipes valve body disc and seat free of accumulated foreign matter Maxon valves are designed to be used with clean fluids If foreign material is present in the fuel line it will be necessary to inspect the valve to make certain it is operating properly If abnormal opening or closing is observed the valve should be removed from service Contact your Maxon representative for instructions Operator should be aware of and observe characteristic opening closing action of the valve Should operation ever become sluggish remove valve from service and contact Maxon for recommendations Address inquiries to Maxon Corporation P O Box 20
237. re approved for fuel gas service Check nameplate for correct catalog number pressure voltage frequency and service Never apply incompatible fluids or exceed pressure rating of the valve Installation and valve maintenance to be performed by qualified personnel Future Service Considerations Provision should be made for performing seat leakage external leakage and operational tests on the valve with a nonhazardous noncombustible fluid after disassembly and reassembly Temperature Limitations For maximum valve ambient and fluid temperatures refer to chart below Check catalog number prefix on nameplate to determine maximum temperatures Coil Catalog Max Max Construction Insulation Number Ambient Fluid AC or DC Class Prefix Temp F Temp F AC H H 140 140 DC None or DC None or Positioning AC Construction Valve is designed to perform properly when mounted in any position However for optimum life and performance the solenoid should be mounted vertical and upright so as to reduce the possibility of foreign matter accumulating in the solenoid base sub assembly area DC Construction Valve must be mounted with solenoid vertical and upright Mounting For mounting bracket optional feature dimensions refer to Figure 1 Piping Connect piping to valve according to markings on valve body Apply pipe compound sparingly to male pipe threads only If applied to valve threads the compound may enter the valve and caus
238. releases built up air pressure from inside the gearbox Max pressure 2 psi www nord com FILL LEVEL amp DRAIN PLUGS LUBRICANT The drain plugs are metric socket head cap screws They will be All NORD reducers are shipped from the factory properly filled located at the lowest part of the gearbox for ease of draining The with lubricant and all plugs are installed according to the mounting fill level plug is a hex head cap screw It will be located between position given on the reducer nametag Acceptable oil fill level is the Autovent and drain plug Both types of plugs will have gaskets within 72 inch of the bottom of the fill plug threads included to prevent oil from leaking OPERATION AND MAINTENANCE CHECKLIST Operate the equipment as it was intended to be operated Do not overload Run at correct speed Maintain lubricant in good condition and at proper level Dispose of used lubricant in accordance with applicable laws and regulations Apply proper maintenance to attached equipment at prescribed intervals recommended by the manufacturer 7 Perform periodic maintenance of the gear drive as recommended by NORD My ee D Ro Two types of plugs for maintenance MOUNTING POSITIONS These charts detail the mounting positions for horizontal and vertical mounting The Autovent oil fill plug and drain plug are indicated on each mounting position picture The factory set mounting position and plug locations match that show
239. rious personal injury Even at 10psig outlet pressure the force exerted on the adjustment screw by spring compression can be great Therefore adjustment screw lubrication and thread condition must be given careful attention 5 Upon completion of servicing make certain that the regu lator installationis entirely free of leaks Equimeter Incorporated 805 Liberty Boulevard DuBois Pennsylvania 15801 814 371 8000 d BTR Mielering Systems Company pa Tower Dryer Ops amp Service COMPONENTS COMPONENT MANUALS ASCO PILOT VALVE Installation amp Maintenance Instructions 2 WAY INTERNAL PILOT OPERATED SOLENOID VALVES SERIES 8215 NORMALLY CLOSED OPERATION 3 8 1 2 OR 3 4 NPT IMPORTANT See separate solenoid installation and maintenance instructions for information on Wiring Solenoid Temperature Causes of Improper Operation Coil or Solenoid Replacement DESCRIPTION Series 8215 valves are 2 way normally closed internal pilot operated solenoid valves Valve bodies are made of rugged aluminum with trim and internal parts made of steel and stainless steel Series 8215 valves may be provided with a general purpose explosionproof watertight explosionproof solenoid enclosure OPERATION Normally Closed Valve is closed when solenoid is de energized open when energized NOTE No minimum operating pressure differential required INSTALLATION CAUTION Not all valves a
240. rom solenoid DIN Plug Connector Remove center screw from DIN plug connector Disconnect DIN plug connector from adapter Remove socket head screw use 5 32 hex key wrench DIN terminal adapter and gasket from solenoid 3 Snap off red cap from top of solenoid base sub assembly For 3 way construction with pipe adapter Figure 3 remove pipe adapter nameplate and solenoid Omit steps 4 and 5 4 Push down on solenoid Then using a suitable screwdriver insert blade between solenoid and nameplate retainer Pry up slightly and push to remove NOTE Series 8202G solenoids have a spacer between the nameplate retainer and solenoid 5 Remove solenoid from solenoid base sub assembly 6 Reassemble in reverse order of disassembly Use exploded views for identification and placement of parts 7 Torque pipe adapter to 90 inch pounds maximum 10 2 Nm maximum Then make up piping or tubing to pipe adapter on solenoid Disassembly and Reassembly of Solenoids 1 Remove solenoid see Solenoid Replacement 2 Remove spring washer from solenoid base sub assembly For 3 way construction remove plugnut gasket 3 Unscrew solenoid base sub assembly from valve body 4 Remove internal solenoid parts for cleaning or replacement Use exploded views for identification and placement of parts 5 If the solenoid is part of a valve refer to basic valve installation and maintenance instructions for further disassembly Torque solen
241. rom the NORD Gear invoice nor should payment of the NORD Gear invoice be withheld awaiting adjustment of such claims as the carrier guarantees safe delivery If considerable damage has been incurred and the situation is urgent contact the nearest NORD Gear Sales Office for assistance Please keep a written record of all communications RECORD NAMEPLATE DATA Locate the gear reducer nameplate and record all nameplate data for future reference S N MAX TORQUE MTG POS STORAGE PROPER STORAGE UNTIL INSTALLED PROPER HANDLING OF THE UNIT Keep unit in a dry temperature controlled area If stored other Exercise care to prevent damage to the unit when moving Lift than said long term storage methods must be applied to the unit only at designed lifting points Do not attach other machinery and including complete fill with lubricant Protect machined surfaces lift by the unit lifting points The lifting points are to be used to lift and rotate shafts periodically Prior to putting unit into service the unit only Insure that adequate safety measures are taken to drain lubricant and refill to proper level as determined by the protect personnel during transportation Protect the mounting mounting position surface from damage BIM 1020 2005 03 1 www nord com INSTALLATION OF UNIT To ensure long service and dependable performance an enclosed gear drive must be rigidly supported and the shafts accurately aligned The following describes t
242. rts in reverse sequence To Service Main Diaphragm 11d 1 10 Remove top cap 1 and release and remove adjustment 3 On high pressure Model remove cap 1a release adjustment 3a and remove cover 5 and button 7a Mark or measure position of adjustment 3 or 3a Use this to return adjustment to this setting during reassembly Remove spring 9 Remove bolts 22 and upper case 21 Rotate diaphragm assembly 11 counterclockwise this unscrews 11h from 12d and remove To disassemble diaphragm assembly remove nut 11a Carefully note location and position of all parts to be certain of correct reas sembly Abrasive side of emery cloth washers face against diaphragm To reassemble replace parts in reverse sequence Make the screwed connection between 11h and 12d loose by approximately 7 2 turn To do this carefully rotate diaphragm assembly 11 clockwise until this screwed connection bottoms do not jam it together Then back off diaphragm assembly 11 counter clockwise approximately 7 2 turn this is very important the 11h to 12d screwed connection must not be tight To Service Orifice 19 1 2 Remove valve 15 per section To Service Valve 15 Remove main diaphragm assembly 11 per steps 1 through 4 To Service Main Diaphragm 11d Remove seal diaphragm assembly 12 per steps 3 and 4 under To Service Seal Diaphragm 12b Remove retaining ring 19a Use Truarc 0600 pliers Invensys Part No
243. rust plate will provide greater resistance to axial movement Follow the manufacturer s recommendations for assembly SHRINK DISC If a shrink disc is used to secure a reducer hollow shaft to the driven shaft follow this assembly procedure Start with the shrink disc mounted onto the extension of the hollow shaft disc locking bolts loosened 1 Clean reducer bore and mating solid shaft to be free of any lubricants or dirt 2 Slide reducer onto the solid shaft until it is about half way through 3 Lubricate the remaining portion of the solid shaft with a 2 grease or similar lubricant This part will be located under the bronze bushing Do not install grease under the shrink disc gripping area Finish installing the solid shaft into the reducer hollow bore 4 Finger tighten all shrink disc bolts Now moving a circular pattern tighten each shrink disc locking bolt 1 4 to 1 2 turn Do not use criss cross pattern Continue tightening in the same circular direction with 1 4 or 1 2 turn increments until all bolts reach the specified bolt tightening torque Bolt tightening torque is shown on the shrink disc label for the particular unit 5 Run unit for 24 hours then retighten shrink disc locking bolts to the proper bolt torque as indicated above TORQUE REACTION ARM On the shaft mount Clincher torque is reacted through the integral torque tab which is part of the casting Commonly NORD s optional RUBBER BUFFER bushings are install
244. s User supplied voltages may exist even when main AC power is not applied to the drive Correct the malfunction before continuing Before Applying Power to the Drive 1 Confirm that all inputs are connected to the correct terminals and are secure 2 Verify that AC line power at the disconnect device is within the rated value of the drive 3 Verify that any digital control power is 24 volts 4 Verify that the Sink SNK Source SRC Setup DIP Switch is set to match your control wiring scheme See page 5 for location Important The default control scheme is Source SRC The Stop terminal is jumpered I O Terminals 01 and 11 to allow starting from the keypad If the control scheme is changed to Sink SNK the jumper must be removed from I O Terminals 01 and 11 and installed between I O Terminals 01 and 04 5 Verify that the Stop input is present or the drive will not start Important If I O Terminal 01 is used as a stop input the jumper between I O Terminals 01 and 11 must be removed Applying Power to the Drive 6 Apply AC power and control voltages to the drive 7 Familiarize yourself with the integral keypad features see next page before setting any Program Group parameters Start Stop Direction and Speed Control Factory default parameter values allow the drive to be controlled from the integral keypad No programming is required to start stop change direction and control speed directly from the integral keypa
245. s and relief valves the external control line connects into the inlet piping 5 pipe diameters upstream from the regulator b Do not install any automatic shutoff device that closes completely between the regulator and the control line connection into the piping To avoid excessive turbulence the connection should be clean and smooth on the inside and be located in straight pipe clear of valves and fittings Keep the inside of the control line clean and protect it from corrosion Pitch it away from the regulator and avoid moisture pockets It must be strong for 121 8 and 121 12 for 121 carefully Watch pressure gauges Complete start up by making sure there are no leaks Do not exceed the regulator s pressure ratings The regulator outlet has a lower pressure rating than the inlet Do not expose the regulator outlet or control line to inlet pressure Regulator with external control may be used as an upstream monitor or upstream regulator in a monitor set The control line must connect into the outlet pip ing downstream of the downstream regulator If the regulator is to be moved to another location make sure its construction is compatible with the pres sure and flow conditions Temperature Limits 16 or larger steel tubing or pipe is preferred It must be well 2 against 2 The Model 121 Regulator be used for flowing temperatures open wide if the control line breaks from 20 F to 150 F Make
246. se 12 18 AWG stranded copper wire rated at 90 C or greater for connections Strip wire leads back approximately 1 4 for installation in socket terminals The use of wire end sleeves is also recommended for these socket terminals Maximum length of wire end sleeves to be approximately 1 4 Tinning of the ends of the lead wires is not recommended 4 Thread wire through gland nut gland gasket washer and connector cover NOTE Connector housing may be rotated in 90 increments from position shown for alternate positioning of cable entry 5 Check DIN connector terminal block for electrical markings Then make electrical hookup to terminal block according to markings on it Snap terminal block into connector cover and install center screw 6 Position connector gasket on solenoid and install plug connector Torque center screw to 5 1 in lbs 0 6 1 1 Nm NOTE Alternating current AC and direct current DC solenoids are built differently To convert from one to the other it may be necessary to change the complete solenoid including the core and solenoid base sub assembly not just the solenoid Consult ASCO Installation of Solenoid Solenoids may be assembled as a complete unit Tightening is accomplished by means of a hex flange at the base of the solenoid Installation of Panel Mounted Solenoid See Figure 1 1 Disassemble solenoid following instruction under Solenoid Replacement then proceed 2 Install solenoid
247. section To Service Valve 15 Remove bolts 29 and upper case assembly Then remove seal diaphragm assembly 12 To disassemble 12 unscrew piston 12a from stem 12d Use a spanner wrench in notch in skirt of piston this can also be done by inserting a standard 7 3 Allen wrench in the notch To reassemble replace parts in reverse sequence Make certain that fabric side of seal diaphragm 12b faces upward and rubber side faces downward toward body Do not pinch loop in seal diaphragm 12b between ring 33 and cen terpiece 27 Also rounded edge of 33 faces upward toward seal diaphragm 12b Make the screwed connection between 11h and 12d loose by approximately 7 2 turn To do this carefully rotate seal diaphragm assembly 12 clockwise until this screwed connection bottoms do not jam it together Then back off seal diaphragm assembly 12 counterclockwise approximately 1 2 turn this is very important the 11h to 12d screwed connection must not be tight uimeter INCORPORATED A BTR Metering Systems Company RM 1399 Rev 6 General Safety Instructions for Gas Regulators Keep this sheet for future reference AVOID OVERPRESSURIZATION wine Do not exceed the regulators pressure ratings Over pressuring the regulator could damage it internally cause leaks or even result in personal injury by bursting a pressure containing part 1 Refer to the appropriate REGULATOR INSTALLATION AND MAINTENANCE IN
248. stener Kit includes gaskets 1051879 1051879 1051880 1051879 End Plate to Flange Fastener Kit includes gaskets 1051881 1051881 1051882 1051881 1050424 1050424 1050424 1050424 Metal Shim Gasket 1049071 1049071 1049071 1049071 Metal End Plate Gasket 1050423 1050423 1050423 LT Plain End Plate to Flange Gasket Kit 1057896 N A 1057896 LT Pilot End Plate to Flange Gasket Kit 1057893 N A 1057893 LT Metal End Plate Gasket Pilot 1056603 N A 1056603 LT Metal End Plate Gasket Plain 1056604 N A 1056604 A Maxon practices policy of continuous product improvement It reserves the right to alter specifications without prior notice wi CORPORATION MUNCIE INDIANA USA INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Series NP LE AIRFLO Burners Page 5550 S 11 Maintenance Instructions Periodic maintenance will insure continued trouble free operation of your Series NP LE AIRFLO Burner system At least a yearly inspection is recommended for make up air heating installations and more frequently for process applications in year round operation Your own experience is the best guide in determining frequency of inspection As a minimum the following procedure should be followed 1 Shut the system down totally Disconnect or lock out power supply so there can be no accidental start up during inspection 2 Inspect the burners carefully including upstream and downstream sides of mixing plates as well as burner
249. t Overloading of raducer Replace broken shaft Check rated capacity of Broken can cause damage reducer Key missing or sheared Output Shaft off on input shaft Does Not Tum ET Eccentric Lack of lubricant Replace eccentric bearing Flush and refill with Bearing Broken _ recommended lubricant 7 un rer Coupling loose of Property align reducer and coupling Tighten disconnected coupling Caused by dirt or grit Replace seais Breather filler may be clogged entering seal Replace or claan filter Check lubricant level and adjust to recommended laval Clean or replace element being sure to prevent any dirt from falling into the reducer Improper mounting position such as wall or ceiling mount of horizontal reducer Maunt horizontally or rework reducer to wall or calling mount Tower Dryer Ops amp Service COMPONENTS VI COMPONENT MANUALS MODUTROL MOTOR APPLICATION The Series 72 Modutrol IV Motors are used to control dampers and valves The motors accept a current or voltage signal from an electronic controller to position a damper or valve at any point between open and closed Honeywell Series 72 Modutrol Motors PRODUCT DATA FEATURES Replaces M744S T Y and M745S T Y Motors e M7261 M7274 M7281 M7284 and M7294 are non spring return motors M7272 M7282 M7285 and M7286
250. t be taken to pipe any such discharge to atmosphere at a safe place to prevent any gathering or migration of explosive mixtures in low areas GENERAL INSPECTION AND SERVICE INSTRUCTIONS 1 Inspect the regulator periodically to make sure it is in satis factory working condition Establish the frequency of inspection on the basis of severity of service and applicable laws and regulations As a minimum recommendation pressure regulating and limiting equipment should be inspected at intervals not exceeding 15 months but at least once each calendar year 2 f the regulator is to be moved to another location make sure its construction is compatible with the new pressure and flow conditions WARNING Before any disassembly of the regulator make sure it is completely depressurized Pressure must be fully released from the inlet the outlet and any control line connections Failure to adequately depressurize could result in serious injury 3 Carefully note the location and position of all disassembled parts to be certain reassembly is correct Inspect each part carefully and replace any that are worn damaged or otherwise unsatisfactory 4 Adjustment screw lubrication should be checked whenever the regulator is serviced Make sure the threads are fully coated with lubricant Where there is evidence of thread wear such as loose fit or excessive sideplay the worn parts must be replaced WARNING Failure from worn threads can result in se
251. tapel i830 450 330 480 Speed Asduci n 3 amp B Mechanism 2nd Stage 750 d 1000 1100 Slow Speed Shaft L 17 6 21 2 Bearing 2nd Stage 500 600 Speed Reduction Machanigm let Stage Speed Reduction Mechanism er sage Speed Shan Bearing 2nd Stapa 1100 Oil Lubricated Models Oil Fill Procedure Oil Level Gauge Oil lubricated models are not filled with oil AM to shipping gauge must be replaced when it becomes difficult to Before start up remove the oil fill plug See Pg A 3 check the oil level due to S OU of the vinyl hose A 2 28 and fill the reducer with recommended Use the standard e for a reducer operatin Refer to Tables A 11 A 14 for standard oil allowable ambient temperature o OOF 20 to 40 here 52 1 quantity and change interval oil level must the reducer is used at ambient temperatures greater than be to the upper red line on the oil level gauge while the unit 100 F 40 or less than 4 F 20 C a glass gauge set is not operating and above the lower red line during ora dipstick 15 recommended operation If too much oil is supplied the unit s operating temperature will rise due to the churning heat e oil or The ail level gauge can be attached on either side of the oil will leak across the high speed shaft oil seal Ran VANE Hasidi As Before filling a vertical base unit with oil remove the usu
252. ter value being displayed Program Status Steady Red Indicates parameter value can be changed Fault Status Flashing Red Indicates drive is faulted Pot Status Steady Green Indicates potentiometer on Integral Keypad is active Start Key Status Steady Green Indicates Start key on Integral Keypad is active The Reverse key is also active unless disabled by A095 Reverse Disable No Key Name Description Escape Back one step in programming menu Cancel a change to a parameter value and exit Program Mode Select Advance one step in programming menu Select a digit when viewing parameter value Up Arrow Down Arrow Scroll through groups and parameters Increase decrease the value of a flashing digit Enter Advance one step in programming menu Save a change to a parameter value Potentiometer NN Wak O KI Q 9 Used to control speed of drive Default is active Controlled by parameter P038 Start Used to start the drive Default is active Controlled by parameter P036 Reverse Used to reverse direction of the drive Default is active A Controlled by parameters P036 and A095 Stop Used to stop the drive or clear a fault This key is always active Controlled by parameter P037 English 8 Viewing and Editing Parameters The last user selected Display Group parameter is saved when power is removed and is displayed by default when power is reapplied
253. testing test all other safety interlocks per manufacturer s instruc tions and verify they are operational n Restore combustion system to operational condition Be sure to remove all auxiliary power supplies and jumpers that may have been used during testing Suggested leak test procedure for double blocking shut off valves with vent line Example of a gas piping diagram for leak test with vent line Vent Valve If vent valve is present use auxil Shut off V Manual Gas Pressure Valve lary power supply to uve Regulator Shut off Valve 2 power vent valve to Manual closed position Switch HI Es stn Valve during this test Strainer AAA co r re Follow ES AA Ro Soe a Tm above Once test is S3 To Combustion complete be sure Drip il il system vent valve is re Leg stored to normal operation Example of a wiring diagram for leak test with vent line From Flame NOTES Hot Safeguard Push button must be tamper resistant LS VV Closes when Vent Valve is fully closed LS SV Closes when Shut off Valve 1 is fully open The From Flame Safe guard line is energized only when sall conditions for safe operation have been Neutral Shut off Valve 1 Momentary Leak Test Push Button Shut off Valve 2 Momentary Leak Test Push Button Vent Valve Shut off Valve 1 satisfied Shut off Valve 2 N MAXON 2 00 Maxon practices a
254. th the wet and dry sensors against a bench meter as follows a Press SENSOR CALIBRATION button from the moisture control set up screen to open the sensor calibration screen FS MOIST_CALIB Display NNN CURRENT TEMP CURRENT MOIST 4 CURRENT TEMP CURRENT MOIST Press the SENSOR OFFSET button ta change the offset if necessary b Take grain samples from the dryer measure the moisture with a bench meter and then compare to the sensor reading during the sampling period Change the sensor offset 1f the sensor reading does not match the bench measure ment For example if the offset was 1 096 and the sensor reading is 0 5 lower than the bench meter then change the offset to 1 596 to match the sensor to the bench meter Likewise if the sensor reading is higher than the bench meter the offset should be decreased accordingly WET SENSOR OFFSET 15 MIN MOIST AVERAGE H DRY SENSOR OFFSET RETURN 15 MIN MOIST AVERAGE 31 15 TRI POINT MOISTURE CONTROLLER VN The sensor should be calibrated 2 3 times a day At the same time check and clean the sensor and sensor sampling box to make sure that there is no debris blocking the grain flow around the sensor 4 Check or change the target moisture from the main screen 5 Press MOIST CONTROL to ac cess the moisture control set up screen Tower Dryer Ops amp Service Check upper lower unlo
255. the BPH Correction Patria 11 TRI POINT MOISTURE CONTROLLER Malm Scree 13 DEEL Ol TETTE PS 14 Operation Procedure rea dro 15 How the Controller ons 16 te MT ica 17 Access Drying SO aia 18 22 MAINTENANCE Pre Seasonal Inspection And Service nase 25 Seasonal Inspeetion And Servieren NE 26 Season Servicestelle 26 I btricattor De 27 Pre Season End of Season Checklist IR ati busca doct 29 TROUBLE SHOOTING Dryine A see obtenido O nidos 33 RM T E 33 34 N 35 ELECTRICAL DIAGRAMS Tower Dryer Control Panel Wiring Dilagranmngs 41 COMPONENT MANUALS Allen Bradley Variable Frequency Drive Maxon NP LE Burner Maxon CV Gas Control Valve Maxon 808 Gas Shut Off Valve Nord Gear Reduction Gear Unit Sumitomo Cyclo Drive Gear Unit Honeywell Modutrol Motor Actuator Invensys 121 Gas Regulator ASCO Solenoid Valves Protection Controls Protectofier Service Manual DRYER OPERATIONS Tower Dryer Ops amp Service SAFETY FIRST SAFETY GUIDELINES This manual contains information that is important for you the owner operator to know and understand This information relates to protecting personal safety and preventing equipment problems It is the responsibility of the owner operator to inform anyone operating or working in the area of this equi
256. tion ar crai spade terminal construction and grounding terminal 6 5 32 hex key wrench Open Frame Solenoid with DIN Terminal Indicates that these parts are included Plug Conector in DIN plug connector Kit K236034 DIN terminal adapter See gland nut 3X torque chart above 2 gasket connector gland gasket socket head screw washer X 5 32 hex key wrench Notes 5 1 Connector cover may be rotated in 90 increments from DIN connector position shown for alternate terminal block center screw position of cable entry see note 2 connector cover 7 Refer to markings on DIN see note 1 ol E connector for proper electrical connections Figure 6 DIN plug connector kit No K236034 optional feature Page 4 of 4 Form No V6584R8 ASUS 50 Hanover Road Florham Park New Jersey 07932 www ascovalve com Tower Dryer Ops amp Service COMPONENTS COMPONENT MANUALS PROTECTOFIER alt rotectofier Form 6642 VA OPERATING SEQUENCE 42 VA Single Burner Supervision Manual Pushbutton Ignition Plug in SS100A F LAME PAK Plug in Control Relays Power on PROTECTOFIER terminals L and L2 provides power to electronic network Terminal LI must be powered before terminal 12 Power on PROTECTOFIER terminal 12 thru permissive safety limits circuit permits manual pushbutton ignition Press and hold START pilot pushbutton CHECK
257. to 160 F Start the blower s by turning the BLOWERS selector switch to the ON position The blower s will automatically start On multiblower units the PLC will automatically start the blowers sequentially Once blower s are up to speed the airswitches will close and the blower switch light will illuminate DRYER START UP Tower Dryer Ops amp Service CONTROL POW A LOAD pert NLOAD conver a over CONTROL START OUTSIDE METERING vevice OFF cc OFF AUTO REV 0 rwn m 7 THE GSI GROUP TOWER DRYER CONTROL PROGRAM gt 1 0 DRTER CONTROL CENTER DRYER RUNNING This run Ohr 18 rn Total 0 hr 18 mm Capacity 600 BPH AI SER E oan UL lt B pO pev PATH B cicHrE Wil PATH PRESS TO ENTER NEW TEMP NOTE OR UNLOAD RATE Tower Dryer Ops amp Service 11 12 Start the burner by turning the BURNER selector switch to the ON position The dryer automatically goes through a 30 second purge period once the blowers are started The amount of time remaining on the purge cycle will be displayed on the LCD display screen After the purge period the burner pilot will automatically light Once the flame control circuit on the dryer senses flame the light in the BURNER selector switch will illuminate If the pilot fails to light in 15 seconds the burner will lock out and must be
258. tor load exists Reduce load so drive output current does not exceed the current set by parameter P033 Motor OL Current F8 OvrTmp Check for blocked or dirty heat sink fins Verify that ambient temperature has not exceeded 40 C 104 F for IP 30 NEMA 1 UL Type 1 installations or 50 C 122 F for Open type installations Check fan F12 HW OverCurrent programming Check for excess load improper DC boost setting DC brake volts set too high or other causes of excess current F13 Ground Fault Check the motor and external wiring to the drive output terminals for a grounded condition F33 Rstrt Tries Correct the cause of the fault and manually clear F38 U to Gnd Check the wiring between the drive and motor Check motor for grounded phase F39 Phase V to Gnd Replace drive if fault cannot be cleared F40 Phase W to Gnd F41 Phase UV Short Check the motor and drive output terminal wiring for a shorted condition F42 Phase UW Short Replace drive if fault cannot be cleared F43 Phase VW Short F48 Defaulted The drive was commanded to write default values to EEPROM Clear the fault or cycle power to the drive Program the drive parameters as needed F63 SW OverCurrent Check load requirements and A098 SW Current Trip setting F64 Drive Overload Reduce load or extend Accel Time F70 Power Unit Cycle power Replace drive if fault cannot be cleared F81 Comm Loss If
259. ube shows through seal Wipe clean Remove the two lube plugs from the cover Lubricate slowly until grease begins through relief plug Lubricate bottom bearing plug slowly counting the grease gun pump until lube shows through the seal Wipe clean Use same o grease gun pumps for top bearing See motor lubrication procedure below See motor lubrication procedure below Grease filled gearbox Re plenish grease to the first Ist stage upper reduction mechanism through grease fitting provided typically quantity 0 3 oz of grease Oil filled gearbox w oil pump Maintain oil level to upper red line on oil level gauge Fill to check plug TYPE OF LUBRICATION High quality grade 2 lithium based grease High quality grade 2 lithium based grease High quality grade 2 lithium based grease High quality grade 2 lithium based grease High quality grade 2 lithium based grease High quality grade 2 lithium based grease High quality grade 2 lithium based grease ISO VG 100 to 150 min eral based oil AGMA 1 scosity Grade 3EP to 4EP Mobilgear 627 629 or equivalent ISO VG 220 mineral based oil AGMA Viscos ity Grade 5EP Mobilgear 630 or equivalent MAINTENANCE LUBRICATION INTERVAL Beginning of season annually Beginning of season annually Beginning of season annually Every 4 weeks of dryer operation Every 2 years Normal op eration ever 8
260. und the pilot are clean Increase gas pressure on main gas regulator Make sure dryer is completely full of grain Gas ports on burner need to be drilled Clean by using a 43 drill bit Check to make sure butterfly valve is fully opening Check for water in gas train by opening drain valve Gas pressure is to high Lower gas pressure on main gas regulator Loose or dirty flame rod Clean and or tighten Defective Protectofier SS3CP transformer in control box Replace Check to see that Maxon shutoff valves are open Check to see that the plenum setpoint temperature is higher than the ambient temperature Check to see that 120V AC is being provided to the black and white wires in the modutrol motor Check the operation of the modutrol motor be momentary jumping the and terminals in the motor to see if the motor will open TROUBLESHOOTING GENERAL What to do Check to see that main circuit breaker in power box is on Check fuses F1 F2 in power box Check circuit breaker CB 04 in power box Check MicroLogix PLC in control box Check to see that main circuit breaker in power box is on Check fuses F1 F2 in power box Check circuit breaker CB 04 in power box Check for possible fire in heat section of dryer Make sure the plenum high limit control is set at least 30 above the desired drying temperature Check for
261. unting holes appropriate for valve type and size Position bracket so VCS wand just touches top of actuator then move downward slightly depressing wand until switch clicks then tighten mounting screws to hold this position Pin bracket by drilling 1 8 dia holes 1 4 deep into bracket mounting pad through drive pin holes then tap drive pin in until flush Route wires to wiring compartment as shown then complete wiring connections and clean out metal drilling chips from previous procedure Cycle valve checking switch actuation points carefully VCS actuates at top of stem stroke VOS at bottom Simultaneously the valve body must be tested for switch continuity and seat leakage Bend VOS switch wands slightly if necessary to insure valve is opening fully Replace gasket and cover then return valve to service Torque ft Is 10 24 Operator Cover 25 20 All other access covers 25 20 Extended Access Cover Plate 96 1 00 Maxon practices policy of continuous product improvement It reserves the right to alter specifications without prior notice INDUSTRIAL COMBUSTION EQUIPMENT AND VALVES Fig 1 75 3 non CP Remove side cover plate Switches mount on bracket See A below Fig 2 2 5 4 CP 6 808
262. ver plates are in place and securely fastened All cover screws should be tight ened using an alternate cross corner tighten ing pattern to the values shown below Cover Torque in Ibs wiring schematics refer to appropriate Maxon 10 24 Operator Cover catalog literature and or the wiring schematic 25 20 All other access covers diagram affixed inside your valve s access cover 251 20 Extended Access Cover Plate plate or in the terminal block cover housing A The Maxon valve must be electrically interlocked with your safety limit devices in accordance with all applicable codes stan dards and the authority having jurisdiction over the safety requirements for your overall system installation Normally Maxon valves are electrically wired in series with all of your safety limit devices Therefore any one device can cause the valve to react Each valve was production tested when manufac tured If it now appears inoperative make sure it is being powered properly from and through your control circuit While all covers are torqued at time of produc tion testing torque should be rechecked periodically to ensure adequate sealing protection Pre operational exercising Prior to initial fluid flow start up and with upstream manual cock still closed operate the valve electrically for 10 15 cycles This not only pro vides an electrical check but also wipes valve body disc and seat free of accumulated foreign matter
263. y must point downstream 5 Screwed connections must conform with good piping practice and be free of excess thread engagement per ANSI B1 20 1 Apply pipe joint sealant to male threads only 6 Tighten flanged joints evenly 7 Before start up make sure the regulator is correctly connected adequately supported and pipe joints are tight 8 Check the regulator set point and lock up pressure Set point is the outlet pressure the regulator is adjusted to deliver Lock up is the pressure where tight shutoff is achieved IMPORTANT During start up a pressure gauge must be connected to the outlet piping between the regulator outlet and the downstream shutoff valve to closely monitor the outlet pressure When checking the regulator for set point and lock up provision must be made to PERMIT FREE FLOW of gas beyond the outlet valve The regulator set point is factory adjusted as specified on the order Set point should be checked with small gas flow 10 of maximum regulator capacity or less Open the valve down stream of the regulator before turning on gas Slowly open the inlet valve while monitoring the outlet pressure gauge Small flow should be set by adjusting the outlet valve Warne Always closely monitor the outlet pressure gauge during start up while opening or closing valves and making adjustments If the outlet pressure continues to increase above the specified lock up pressure open the downstream valv
264. ying milo clean the cooling chamber floor of fines and dust Sweep down the cooling section sheets if necessary Fines can be swept into the unload systems on both the Zimmerman and GSI dryers Do not let grain fines and dust accumulate inside the heat section of the dryer Daily check the hopper divider that separates the heat section from the cooling section to insure that it remains clean and open When cleaning dryer check the grain discharge area on the dryer On GSI hopper bottom dryers check around the meter ing drum to insure that grain is flowing freely from each col umn and that there is no trash build up On Zimmerman Accutrol sweep dryers check the sweeps for trash or stalk buildups that could be obstructing grain flow If undried grain is left in the dryer for more than a week during the drying season inspect the plenum roof to make sure that there is no wet grain sticking to the roof that could restrict grain flow When the dryer is restarted make sure that all grain columns are evenly unloading When drying dirty corn in high humidity conditions sludge may build up in the upper outside sheets of the dryer This build up can be removed by either washing the sheets down with a high pressure water hose or by shutting incoming grain dropping the grain level to below the plugged area and then running the fans and burner to dry the affected area Tapping or sweeping the sheets will dislodge debris Attempting to sweep of

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