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1

Section 4: TEST FIRING

 . . . . . . . . . . . . . . . .17

Section 5: DRYER OPERATION

 . . . . . . . . . .21

Drying Temperatures . . . . . . . . . . . . . . . . . . . .21
Full Heat Drying  . . . . . . . . . . . . . . . . . . . . . . .21
Final Moisture Content  . . . . . . . . . . . . . . . . . .21
Dryer Shutdown  . . . . . . . . . . . . . . . . . . . . . . .21
Operating Instructions . . . . . . . . . . . . . . . . . . .22
Startup Procedure . . . . . . . . . . . . . . . . . . . . . .23
Drying Tables  . . . . . . . . . . . . . . . . . . . . . . . . .24

Section 6: DRYER ILLUSTRATIONS

 . . . . . . .33

Section 7: SERVICE

 . . . . . . . . . . . . . . . . . . .43

Seasonal Inspection and Service  . . . . . . . . . .43
Propane Vaporizer Seasonal Inspection  . . . . .44
Vaporizer Adjustment  . . . . . . . . . . . . . . . . . . .44
Burner Control Sequence of Operation  . . . . . .45
Fan Propeller Removal and Installation  . . . . . .45
Fan Motor Removal and Installation  . . . . . . . .47
Heater Removal and Installation  . . . . . . . . . . .48
Grain and Plenum Temperature Sensor 

Locations  . . . . . . . . . . . . . . . . . . . . . . . . .49

SCR Drive and Meter Roll Information  . . . . . .49

Meter Roll Blockage  . . . . . . . . . . . . . . . . .49
To Clear Jam from Meter Roll  . . . . . . . . . .50

SCR Motor Control  . . . . . . . . . . . . . . . . . . . . .50

Adjusting SCR Motor Speed  . . . . . . . . . . .50

Section 8: WIRING DIAGRAMS

 . . . . . . . . . .51

Section 9: TROUBLESHOOTING

 . . . . . . . . .59

General Troubleshooting . . . . . . . . . . . . . . . . .59
Improper Electronic Temperature Control 

Operation  . . . . . . . . . . . . . . . . . . . . . . . . .63

Improper Moisture Control Operation  . . . . . . .63

OPERATING PRECAUTIONS

 . . . . . . . . . . . .2

Section 1: SPECIFICATIONS

 . . . . . . . . . . . .3

Dimensions  . . . . . . . . . . . . . . . . . . . . . . . . . .3
General Specifications  . . . . . . . . . . . . . . . . . .4
Auger Drive Data  . . . . . . . . . . . . . . . . . . . . . .5
SCR Drive Information  . . . . . . . . . . . . . . . . . .5

Section 2: TRANSPORTATION & INSTALL

.   .7

Transporting Dryer  . . . . . . . . . . . . . . . . . . . . .7
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Fuel Connection  . . . . . . . . . . . . . . . . . . . . . . .8
Fuel Specs  . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Electrical Power Supply  . . . . . . . . . . . . . . . . .9
Electrical Load, Overload Relays, and Circuit

Breakers  . . . . . . . . . . . . . . . . . . . . . . . . . .10

Section 3: OPERATING CONTROLS

 . . . . . .11

Miscellaneous Components  . . . . . . . . . . . . . .11

Control Start/Stop  . . . . . . . . . . . . . . . . . . .11
Fan Switches  . . . . . . . . . . . . . . . . . . . . . .11
Main/Safety Gas Shutoff Valve  . . . . . . . . .11
Burner Switches  . . . . . . . . . . . . . . . . . . . .11
Plenum Temperature Control  . . . . . . . . . .11
Hi Lo Pressure Control  . . . . . . . . . . . . . . .11
Load Auger Switch  . . . . . . . . . . . . . . . . . .12
Load Timer   . . . . . . . . . . . . . . . . . . . . . . .12
Unload Auger Switch  . . . . . . . . . . . . . . . .12
Dryer Operator Light . . . . . . . . . . . . . . . . .12
Hour Meter   . . . . . . . . . . . . . . . . . . . . . . .12
Discharge Safety Shutoff Switch  . . . . . . . .12
Hinged Fast Trip Cleanout  . . . . . . . . . . . .13

Meter Roll Controls . . . . . . . . . . . . . . . . . . . . .13

Meter Roll Selector Switch  . . . . . . . . . . . .13
Manual Unload Control Dial  . . . . . . . . . . .13
% Unload Rate (Meter Roll) Voltmeter  . . .13
Vari-Trol Moisture Control  . . . . . . . . . . . . .13
Meter Roll Monitor System  . . . . . . . . . . . .14

Shutdown Features . . . . . . . . . . . . . . . . . . . . .15

Shutdown Indicators  . . . . . . . . . . . . . . . . .15
Restarting Dryer After a Shutdown  . . . . . .15

C O N T E N T S

Summary of Contents for C-2120A

Page 1: ...21A 02 2 OPERATOR S MANUAL C 2120A C 2125A C 2130A and C 2140A Model Grain Dryers 1997 LATER MODELS Division of ffi Corporation 5900 Elmwood Ave Indianapolis IN 46203 1998 ffi Corporation Printed in USA ...

Page 2: ...ng to operate the dryer Keep the dryer clean Do not allow fine material to accumulate in the plenum chamber A CAREFUL OPERATOR IS THE BEST INSUR ANCE AGAINST AN ACCIDENT Copyright 1998 by Farm Fans a division of ffi Corporation All rights reserved No part of this publication may be used or reproduced in any form or by any means without prior permission Failure to comply with this notice is a viola...

Page 3: ...ature Control Operation 63 Improper Moisture Control Operation 63 OPERATING PRECAUTIONS 2 Section 1 SPECIFICATIONS 3 Dimensions 3 General Specifications 4 Auger Drive Data 5 SCR Drive Information 5 Section 2 TRANSPORTATION INSTALL 7 Transporting Dryer 7 Installation 7 Fuel Connection 8 Fuel Specs 9 Electrical Power Supply 9 Electrical Load Overload Relays and Circuit Breakers 10 Section 3 OPERATIN...

Page 4: ...fine material to accu mulate 8 Set pressure regulator to avoid excessive gas pressure applied to a burner during igni tion and when burner is in operation See Table 2 1 for operating gas pressures Do not exceed maximum recommended drying temperatures 9 Do not operate the dryer if any gas leak is detected Shut down and repair before fur ther operation 10 Clean grain is safer and easier to dry Fine ...

Page 5: ...ial fans with full motor overload protection All fans run at 1750 RPM with the exception of the 3500 RPM cooling fan of the C 2120A and C 2125A Air Volume HP and static pressure are matched to grain volume HEATERS Two high capacity direct fired efficient burners with full electric ignition Electronic temperature control for precise drying heat Starfire burners used on all lower fans and the upper ...

Page 6: ... 86 Amps 43 Amps 226 BPH 390 BPH 395 BPH 640 BPH C 2125A 1 Module with Two Zones 18 14 535 Bu 415 Bu 27 1 1 2 8 0 12 10 25 0 8 0 15 2 8 Fill Hopper 36 Dia 1750 RPM 15 HP 24 Dia 3500 RPM 10 HP 4 6 2 3 8 Dia 5 HP 2800 BPH 8 Dia 3 HP 1220 BPH 3 4 HP SCR 186 Amps 96 Amps 51 Amps 300 BPH 505 BPH 515 BPH 835 BPH C 2130A 1 Module with Two Zones 20 14 595 Bu 460 Bu 29 1 1 2 8 0 12 10 27 0 8 0 15 2 8 Fill ...

Page 7: ... and set RPM Type Set voltage ARM Full load amps ARM Motor Sheave Pitch dia No and bore Gearbox Part no and ratio Gearbox Drive Input sheave Pitch dia Bore Belt Output Sprocket no bore Chain Meter Roll Type and max RPM Drive sprocket no bore Setting C 2120A C 2125A C 2130A C 2140A APPROXIMATE DISCHARGE RATES BU HR AT VARIOUS SETTINGS T A B L E 1 2 A U G E R D R I V E D A T A T A B L E 1 3 S C R D ...

Page 8: ...6 ...

Page 9: ...ryer will automatically start the top auger and any loading conveyor electri cally connected to the power terminal strip on the power panel see Section 8 Wiring Diagrams At the beginning dryer will completely fill requiring approxi mately its full holding capacity During drying the top auger will start and stop as required to maintain the dryer full of wet grain LOAD TIMER The unit is equipped wit...

Page 10: ...er To ensure that tanks are free of moisture the usual pre caution is to purge with methanol Avoid tanks which may contain an accumulation of oil or heavy hydrocar bons from long use on a vapor withdrawal system NATURAL GAS NG GAS VOLUME AND PRESSURE The dryer is designed to operate on natural gas having a heat value of about 1 000 BTU per cubic foot The dryer is equipped with a natural gas supply...

Page 11: ...or overload protection CONNECTING AUXILIARY CONVEYORS The maximum sizes of auxiliary conveyor motors which can be powered directly from the dryer s power termi nals are listed in Table 2 2 See appropriate power cir cuit wiring diagram for terminal connection numbers To connect auxiliary auger motors which are LARGER than the maximum refer to the following informa tion A Motors that must be powered...

Page 12: ... 77 Horsepower Full Load Amps Max Running Load dryer only amps Circuit Breaker Rating amps Overload Heater Element Voltage 1r 230V 3r 230V 3r 460V 1r 230V 3r 230V 3r 460V 1r 230V 3r 230V 3r 460V 1r 230V 3r 230V 3r 460V 1r 230V 3r 230V 3r 460V Top Auger 5 5 5 22 13 6 5 C22 8 C16 3 C8 67 80 60 30 Btm Auger 3 3 3 16 8 6 4 3 C15 1 C11 3 C5 92 80 60 30 C 2 1 2 5 A Top Fan 10 16 10 16 10 16 83 41 20 5 F...

Page 13: ... automatically reset itself before ignition may again be attempted PLENUM TEMPERATURE CONTROLS PLENUM CONTROLLER OPERATION Drying tem peratures are controlled by the Electronic Temperature ET plenum controllers located on the ASC control panel Each fan heater is controlled by a separate con troller see Fig 6 7 The controller senses air plenum temperature and cycles burner from Hi Fire to Lo Fire o...

Page 14: ...ill the wet grain holding bin If due to inadequate wet grain sup ply the load auger runs longer than a normal refill time the Load Timer causes a dryer shutdown The Load Timer located within the ASC control box is an automatic reset type timer The amber LOW GRAIN shutdown indicator will light whenever a shutdown is caused by the Load Timer TIMER SETTING To set the Load Timer observe the normal tim...

Page 15: ...ter as the Manual Control dial is adjusted See Dryer Tables in Section 5 for suggested start up settings UNLOAD RATE METER ROLL VOLT METER The UNLOAD RATE volt meter monitors the DC ARMATURE VOLTAGE on the SCR MOTOR driving the meter rolls This voltage represents the UNLOAD RATE of the dryer and should range from 7 to 100 as the unload speed is changed Be sure to use the Unload Rate volt meter as ...

Page 16: ...int temperature entered 6 If large changes in grain input moisture are encoun tered repeat the setup procedure to establish a new setpoint temperature 7 When restarting a loaded dryer following a shutdown period the dryer should be operated in the MANUAL mode until the newly dried grain has passed the RTD grain sensor 2 3 of the grain pass time and the grain temperature has stabilized before switc...

Page 17: ...y devices may act to interrupt the safety control circuit simultaneously If this occurs the LOWEST NUMBER INDICATOR LIGHT on the detector will always take pri ority as the unit is constructed to indicate only one cause at a time 2 Press the dryer START button When the start button is pressed the dryer control light should come ON indicating that all safety devices have been reset and the dryer is ...

Page 18: ...16 ...

Page 19: ...r terminals should also start and rotate in the proper direction C With the Unload Auger Switch ON set the Meter Roll Selector Switch to MANUAL position and check the direction of rotation The RH metering roll shaft should rotate clockwise as viewed from rear end of the dryer See Fig 6 14 7 Check meter roll operation With Unloading Auger still operating rotate the MANU AL UNLOADING control to incr...

Page 20: ...NUAL position and reset the unload rate to 60 Set the Moisture Control back to match the displayed mea sured temperature Again switch the Meter Roll Selector Switch to AUTO pausing in the OFF position Verify that the control starts at the manual unload rate Note that by decreasing the moisture control set point temperature 95 F the unload rate will not exceed 100 13 Check safety shutdown devices A...

Page 21: ...andle will trip closed The valve handle must be manually opened to allow gas flow for burner operation Shut off the circuit breakers and main power supply and close fuel supply valves if you are not ready to begin the drying operation 19 Yellow Red 90 27 41 42 Locator hole Assemble to dryer with hole in UP position Free hang Dryer calling for grain Switches A and B both closed Black Fig 4 1 Top au...

Page 22: ...20 ...

Page 23: ...g bin or storage bin then cool by an aeration fan at an air flow rate of 1 2 to 1 CFM per bushel of grain in the hot batch being cooled The process of tempering and slow cooling provides higher quality in shelled corn because of less stress cracking of kernels and less breakage during subsequent handling of the grain FINAL MOISTURE From 1 to 3 moisture is usu ally removed in the cooling process so...

Page 24: ...nt of the wet grain and determine method of drying to be performed 3 Refer to the DRYING TABLES ahead to determine the approximate drying time required to provide the required moisture reduction for the drying method and dryer model to be used 4 Refer to the START UP PROCEDURE within this section Perform all procedures listed 5 Using the recommended drying time refer to appropriate DRYING TABLES a...

Page 25: ...the drying time 8 Reduce the plenum temperature setting on the lower burner to its normal operating tempera ture 9 Turn the Unload Auger to ON the Meter Roll Selector Switch to MANUAL and adjust the Unload Rate as indicated in the Drying Tables to achieve the required drying time for FULL HEAT operation NOTE During initial start up of a continuous flow dryer the grain moistures discharged may not ...

Page 26: ...g capacities are estimates based on drying principles field results and computer simulations Variances may occur due to the grain s physiological factors kernel size chemical composition variety maturity escessive fines weather conditions etc ...

Page 27: ...g capacities are estimates based on drying principles field results and computer simulations Variances may occur due to the grain s physiological factors kernel size chemical composition variety maturity escessive fines weather conditions etc ...

Page 28: ...g capacities are estimates based on drying principles field results and computer simulations Variances may occur due to the grain s physiological factors kernel size chemical composition variety maturity escessive fines weather conditions etc ...

Page 29: ...g capacities are estimates based on drying principles field results and computer simulations Variances may occur due to the grain s physiological factors kernel size chemical composition variety maturity escessive fines weather conditions etc ...

Page 30: ...g capacities are estimates based on drying principles field results and computer simulations Variances may occur due to the grain s physiological factors kernel size chemical composition variety maturity escessive fines weather conditions etc ...

Page 31: ...g capacities are estimates based on drying principles field results and computer simulations Variances may occur due to the grain s physiological factors kernel size chemical composition variety maturity escessive fines weather conditions etc ...

Page 32: ...g capacities are estimates based on drying principles field results and computer simulations Variances may occur due to the grain s physiological factors kernel size chemical composition variety maturity escessive fines weather conditions etc ...

Page 33: ...g capacities are estimates based on drying principles field results and computer simulations Variances may occur due to the grain s physiological factors kernel size chemical composition variety maturity escessive fines weather conditions etc ...

Page 34: ...32 ...

Page 35: ...cal C 2100A Series dryer LP fuel Fan heater access door Main Safety gas shutoff valve Liquid fuel connection Main Safety gas shutoff valve Valve handle Do not use to close valve See Section 3 for details Relief valve Fuel strainer Indicator window ...

Page 36: ...d C 2140 models Liquid solenoid valve Fan heater control box Fuel strainer Gas pressure regulator Vaporizer adjust ment plate See Section 7 for adjust ment details Pressure gauge Pressure gauge Burner Hi Limit thermostat auto reset type Hi Fire solenoid valve Flow control valve Lo Fire adjustment Main solenoid valve ...

Page 37: ... fuel supply Pressure gauge Hi Fire solenoid valve Main solenoid valve Burner Hi Limit thermostat auto reset type Manual shutoff valve use to adjust Hi Fire gas pressure Fan heater access door 5 amp fuses partially hidden PL 021 burner control board Ignition transformer ...

Page 38: ...Fig 6 8 ASC control panel internal view 36 Fig 6 7 ASC control panel ...

Page 39: ...37 Fig 6 9 C 2100A power panel typical 3 phase model shown ...

Page 40: ...ral hours of operation during initial start up Check periodically thereafter Meter roll crossover chain Adjust to provide 1 4 inch total deflection Drive chain Adjust to provide 1 2 inch total deflection Meter roll crossover chain To avoid missalign ing speed jack bearings loosen drive belts before adjusting chain ten sion Note Auger and meter rolls have sealed bearings that do not require lubrica...

Page 41: ... 6 12 SCR meter roll drive SCR drive motor Gearbox drive cover Motor mount adjustment bolt Gearbox Motor mounting bolts Retighten securely after adjusting belt Drive belt Retension belt drive after first few hours of operation Check periodically thereafter ...

Page 42: ... chain Adjust to provide 1 4 to 1 2 inch total deflection Oil level plug hidden Maintain to bottom of plug opening near shaft level Meter roll access door Chain tension adjusting bolt C 2120A C 2125A C 2130A models Under normal conditions replace lubricant after first 250 hours of operation then change every drying season or 2500 hours thereafter using an AGMA 8 gear lubricant For cold ambient tem...

Page 43: ...owing installation Hinged plenum clo sures Lifts up to allow easier cleaning Important Keep inside of dryer clean Do not allow chaff and other cobustible material to accumulate within air plenum cham ber Make certain to turn off and lock out the main power before entering dryer ...

Page 44: ...42 ...

Page 45: ...ean the gas line strainers Make certain gas valves are closed and that gas is purged from sys tem before attempting disassembly 6 C 2130A and C 2140A upper octagonal burners Check burner for loose or missing hardware Also inspect the burner s combustion holes for excess buildup using a 086 dia 44 drill bit to clean if nec essary See Fig 7 1 All other Starfire burners Inspect the primary air screen...

Page 46: ...adjust the position of the vaporizer to provide clearance For Starfire burner models bend the edge of the burner vane if necessary to provide clearance If there has been significant abrasion of the steel vaporizer pipe it must be replaced 2 Inspect the fuel train components Liquid solenoid valve pressure relief valve pressure regulator vapor hi limit thermostat and the fuel lines and fittings The ...

Page 47: ...cuit opens its contacts and de energizes the Hi Fire gas solenoid valve No 1 Gas Valve When the Thermostat Control sensor is calling for more heat and closes its contacts the Hi Fire gas solenoid valve immediately opens then it cycles as required to maintain the desired heat 5 If the burner fails to start due to lack of fuel or malfunc tion and the Ignition Transformer and gas solenoid valves are ...

Page 48: ...ss of parts and also to main tain the original bushing propeller alignment Inspect propeller and bushing at this time looking for any cracks thread or bolt damage warpage etc Consult your dealer or the factory for any questions concerning damage NOTE During manufacture the propeller and bush ing are balanced together and the parts are marked with two small punch dots to identify their original ali...

Page 49: ...r places will be at owner s expense If service station determines motor failure to be caused by faulty material or workmanship repair will be under warranty when it is within the warranty period Motor failure because of external causes will result in a charge to the owner for repair 1 Make certain power is shut off and locked out then remove fan guard and propeller as outlined earlier 2 Remove cov...

Page 50: ...l box B Disconnect the pressure gauge line fitting from the pipe tee C Disconnect electrical connections to gas solenoid valve s located within control box D Lift pipe tee with orifice solenoid valve and other parts attached straight up and remove from control box Orifice and other parts can now be removed from pipe tee if desired Octagonal Burners Disconnect the gas supply line where it connects ...

Page 51: ...HC634 or equivalent lubricant C 2120A C 2125A C 2130A models only Although the gearbox requires no adjustment it is ini tially filled with an AGMA 8 mineral base oil which should be replaced after the first 250 hours of opera tion then changed every drying season or 2500 hrs thereafter AGMA 8 oil has an operating temperature range of 51 to 110 F For cold ambient temperatures 16 to 50 F use AGMA 7 ...

Page 52: ...etermined first seal off grain flow by inserting the Grain Column Cut Off Damper service tool from inside the plenum as described in Fig 6 16 Then from outside the dryer open the meter roll access door to remove any foreign object SCR MOTOR CONTROL When installing a new SCR motor control check torque switch setting control voltage jumper position and armature voltage jumper position Set as shown i...

Page 53: ...51 Fig 8 1 C 2100A power circuit 220V 1 phase ...

Page 54: ...52 Fig 8 2 C 2100A power circuit 220V 3 phase models ...

Page 55: ...53 Fig 8 3 C 2100A power circuit 440V 3 phase models ...

Page 56: ...54 Fig 8 4 C 2100A general control circuit p 1 of 3 ...

Page 57: ...55 Fig 8 4 C 2100A general control circuit p 2 of 3 ...

Page 58: ...56 Fig 8 4 C 2100A general control circuit p 3 of 3 ...

Page 59: ...57 Fig 8 5 C 2100A burner control circuit circuit ...

Page 60: ...58 ...

Page 61: ...STOP or START switch Also check switch wiring connections 5 1CR RELAY Check for a defective 1CR relay relay base or faulty wiring TROUBLE CHECKOUT PROCEDURE INFORMATION Control circuit not energized Shutdown indicator light ON SHUTDOWN INDICATOR LIGHTS on ASC Panel LOW GRAIN LIGHT Auto resets immediately May indicate a Insufficient grain to fill dryer b Load Timer is set incorrectly load time set ...

Page 62: ... grain from under grain discharge door for switch to reset Indicates that unload auger discharge switch has opened for the following possible reasons a Auxiliary unload equipment has failed or overloaded b Discharge door is not seated properly c Discharge proximity switch failed Various circuit breakers as shown in wiring schematics or Power Panel illustration Overload relays manual reset required...

Page 63: ...eck DC voltage between ARM A1 and A2 terminals on SCR board Voltage should increase from near 10V DC to 155V DC as speed control is moved to the MAXIMUM SCR speed setting If no voltage or erratic voltage is indicated check for possible bad wiring connections or a defective speed pot before replacing SCR board Check for voltage on load side of armature fuse Replace fuse as required 6 Inspect wiring...

Page 64: ...e if required 2 Check for improperly adjusted or problems within Hi Lo Fire thermostat control plenum controller circuit Temporarily increase the temperature setting If heater will still not cycle check for problem in control wires connections or sensor See Electronic Temperature Control Trouble in this Troubleshooting Section 3 Check for improperly connected or faulty Hi Fire gas vapor solenoid v...

Page 65: ...check dial thermometer for temperature compar ative reading See following problems and corrections Check with a 1260 ohm calibration resistor FF part no 38 322 as outlined in Bulletin ETS FC 03 5 When connected to terminals 10 and 11 of controller the resistor will cause the thermostat to switch at 180 F Readjust METER OFFSET trim pot as required Check with calibration resistor as mentioned above ...

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Page 68: ...Division of ffi Corporation 5900 Elmwood Ave Indianapolis IN 46203 1998 ffi Corporation Printed in USA 5 14 98 ...

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