Owners Operation Manual (CE) Sukup Manufacturing Company

Transcription

AUTOMATIC GRAIN DRYER
Continuous Flow / Automatic Batch
Owners Operation Manual (CE)
Sukup Manufacturing Company
1555 - 255th Street P.O. Box 677
Sheffield, Iowa 50475
Phone 641 – 892 – 4222
Fax 641 – 892 – 4629
Manual # L14103DDC
2008/01
©Sukup Manufacturing Company
Table of Contents
Limited Warranty.............................................................................................................................. 2
Safety Section.................................................................................................................................. 3
Emergency Shutdown Locations ..................................................................................................... 9
Power Box Component Location ................................................................................................... 10
Control Box Components Location................................................................................................ 11
Dryer Installation............................................................................................................................ 12
Gas and Electric Hook-up.............................................................................................................. 12
Heater Operation ........................................................................................................................... 12
Air Proving Switch...................................................................................................................... 14
Low Temperature vs. High Temperature Kit ................................................................................. 14
Dry Fire Tests ................................................................................................................................ 15
Manual Control Operational Check ............................................................................................... 17
Maintenance and Service .............................................................................................................. 19
General Dryer Operation ............................................................................................................... 25
Continuous Flow ........................................................................................................................ 25
Automatic Batch ......................................................................................................................... 25
Grain Transfer ............................................................................................................................ 26
Manual ....................................................................................................................................... 26
Dryer Operation ............................................................................................................................. 29
Continuous Flow ............................................................................................................................ 30
Initial Dry .................................................................................................................................... 30
Restart With or Without Stabilization ......................................................................................... 34
Manual Control .............................................................................................................................. 40
Automatic Batch Control................................................................................................................ 45
Grain Transfer................................................................................................................................ 50
Functional Maintenance Requirements ......................................................................................... 51
Start of Drying Season requirements ............................................................................................ 51
Shutdown Faults ............................................................................................................................ 57
Appendix A – Auxiliary Motor Operation and Installation .............................................................. 63
Appendix B – Tonnes per Hour Information (Corn)....................................................................... 66
Appendix C – Dryer Startup Checklist........................................................................................... 67
Appendix D – Heater Operations (CE) .......................................................................................... 69
Appendix E – Dan-Corn Heater Troubleshooting Guide ............................................................... 72
Appendix F – Explanation of DanCorn Heater Box Components ................................................. 74
Appendix G – Ladder Diagrams…….……………...…………………………………………………...76
Single Fan…………...……….……………………………………………………………….... 76
Two Fan…………………………………………………………………………………………..97
NOTICE: The information contained herein is a confidential disclosure. All information contained
in this manual is property of Sukup Manufacturing Co., Sheffield, Iowa, USA and is provided on
the condition that it will not be used in any way detrimental to their interest. Reproduction of the
contents of this document is prohibited unless expressed written consent is given from Sukup
Manufacturing Co.
Limited Warranty
Congratulations on your purchase of a new Sukup Automatic Dryer! We’re pleased to add your
name to the growing list of Sukup Dryer customers. Your Sukup Automatic Dryer offers the most
advanced automatic operation of any dryer on today’s market. You can feel confident that you
have purchased your Dryer from a company committed to serving farmers for years to come.
Sukup Manufacturing is one of the few family-owned companies in an era of corporate mergers.
Our family has more than 40 years of grain drying and handling experience and an excellent
reputation for standing behind our products - we appreciate your purchase. You can look forward
to many years of superior performance from your Sukup Automatic Dryer!
Limited Warranty
SUKUP MANUFACTURING COMPANY (Sukup) warrants to original retail purchaser that within time limits set forth, new
equipment shall be free from defects in material and workmanship. A part will not be considered defective if it
substantially fulfills performance specifications. Should any part prove defective within the warranty period, the part will
be replaced without charge F.O.B. Sukup Mfg. Co., Sheffield, Iowa USA or Distribution Centers - Arcola, Illinois; Aurora,
Nebraska; Defiance, Ohio; Jonesboro, Arkansas; Cameron, Missouri; Watertown, South Dakota. To obtain warranty, a
copy of original invoice is required.
THE FOREGOING LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF
MERCHANTABILITY, FITNESS OR PURPOSE AND OF ANY OTHER TYPE, WHETHER EXPRESSED OR IMPLIED.
Sukup neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said part,
and will not be liable for incidental or consequential damages. THE REMEDIES STATED HEREIN SHALL BE THE
EXCLUSIVE REMEDIES AVAILABLE UNDER THIS LIMITED WARRANTY.
Sukup reserves the right to change specifications, add improvements or discontinue manufacture of any of its equipment
without notice or obligation to purchasers of its equipment. This warranty gives you specific legal rights. You may also
have other rights, which vary according to state or province.
WARRANTY EXCLUSIONS - Labor, transportation, or any cost related to a service call is not provided by Sukup. This
Limited Warranty does not apply to damage resulting from misuse, neglect, normal wear, accident or improper installation
or maintenance. ITEMS NOT MANUFACTURED BY SUKUP (i.e. Tires, Belts, Motors, etc.) ARE COVERED UNDER
WARRANTIES OF THEIR RESPECTIVE MANUFACTURERS AND ARE EXCLUDED FROM COVERAGE UNDER THE
SUKUP WARRANTY. Since the down augers are so critical to the successful operation of the stirring machine, Sukup
Mfg. will not warranty any machines unless they are equipped with Sukup down augers.
BASIC WARRANTY – All Sukup manufactured products are warranted for one year from date of purchase.
EXTENDED STIRRING MACHINE WARRANTY – Sukup warrants Stirring Machines for two years from date of purchase.
EXTENDED STIRRING AUGER WARRANTY – Stirring Augers are warranted for two years from date of purchase. Must
return top 18” of down auger to obtain credit.
EXTENDED FAN WARRANTY - Sukup warrants fans for two years from date of purchase.
EXTENDED GRAIN DRYER WARRANTY - Sukup warrants grain dryers for two years from date of purchase.
EXTENDED HEATER CIRCUIT BOARD WARRANTY - Sukup warrants heater circuit boards for three years from date of
purchase.
ELECTRIC MOTOR WARRANTY - The manufacturers of electric motors warranty their motors through authorized
service centers. Contact motor manufacturer for nearest location. If motor warranty is refused by a service center based
upon date of manufacture, use the following procedure: Have the motor repair shop fill out the warranty report form as if
they were providing warranty service. State on the report the reason for the refusal. Send the report, motor nameplate,
and proof of purchase date to Sukup. If electric motor warranty is not satisfactorily handled by motor service center,
contact Sukup for assistance. Warranty may also be obtained by returning motor to Sukup Mfg. Co. or Distribution
Centers with prior authorization.
NOTE: Sukup will not be responsible for unauthorized motor replacement or repair.
WARRANTY CERTIFICATION - Warranty registration card and the Start-up Checklist performed by your dealer upon
successful completion should be mailed to certify warranty coverage.
UNAPPROVED PARTS OR MODIFICATION - All obligations of Sukup under this warranty are terminated if: unapproved
parts such as stirring augers are used, or if equipment is modified or altered in any way not approved by Sukup.
1-2
Safety Section
GRAIN DRYER
Safety Section
TRANSPORT SAFETY WARNING:
TRUCKER/TRANSPORTER IS TO
PROVIDE APPROVED SAFETY CHAIN
WHEN TOWING DRYER.
WARNING: Transporting this
equipment on public roads may
result in serious injury or death. If road travel
is required it is essential that all the following
procedures be followed:
The above safety-alert means “ATTENTION!
Be Alert! Your personal safety is involved”
This symbol draws your attention to
important instructions concerning your
personal safety. Read the message carefully
to avoid personal injury or death.
1. Read and understand -- operator’s
manual.
2. Check and comply with state & local
regulations.
3. Use required emblems or lights.
4. Travel at a reasonable and safe speed.
Reduce speed and/or use lower gear on
rough ground or slopes.
5. Stop slowly.
6. Have extended rear angle mirrors on
vehicles.
7. Signal & check behind you when turning.
FOLLOW MACHINE SAFETY SIGN &
MESSAGES
Observe
safe
operating
practices.
Carefully read this
manual and all safety
signs
on
your
equipment. Safety sign
must be kept in good
condition.
Replace
missing or damaged safety decals; available
from Sukup Mfg. Co.; Box 677, Sheffield,
Iowa 50475 at no charge.
WARNING: Check for other
vehicles when turning. (2/3 of roadway
farm accidents occurs when turning.)
• Use mirrors
• Be sure to have clear visibility,
• Use signal lights
Learn how to use controls and operate
machine. Do not let anyone operate unit
(especially youth) without thorough training
of basic operating and safety procedures.
WARNING: do not transport unit
in areas of poor visibility -• Especially on hills,
• During poor weather conditions,
• Or at night
Failure to do so may cause serious injury or
death. Use good judgement when
transporting. Maintain complete control of
unit at all times. Comply with State and local
laws governing. Read safety regulations
when moving units. Always strive to prevent
accidents! Watch out for other vehicles.
Make no unauthorized modifications to
machine. Modifications may endanger
function and/or safety of unit. Keep unit in
good working condition.
EMERGENCIES - KNOW WHAT TO DO
Have emergency numbers near your
telephone:
For doctors:
Emergency medical squad:
Ambulance service:
Hospital:
Fire department:
Have written directions to your location.
1-3
Safety Section
Make sure location for decal is free from
grease, oil and dirt. Remove backing from
decal and place in proper position. To order
replacement decals (no charge) contact
Sukup Manufacturing Company, P.O. Box
677, Sheffield, Iowa 50475 Phone
641.892.4222 Please specify computer
number.
WARNING:
TO PREVENT EXPLOSION OR FIRE
•
•
•
•
•
•
Carefully review
operators
manual.
Clean
under
unit, as fines
may cause a bin fire.
Check for gas leaks, (spray soapy
solution on piping and joints.)
Run fan at least a half minute before
starting heater.
NEVER start heater if you smell gas or
hear a hissing sound.
NEVER run heater with inspection door
open.
1. WARNING-L0281-To Avoid serious injury
or death.
Failure to heed these warnings may cause
serious injury or death.
2. DANGER - L02741-98 - Keep away from
any electrical lines, especially when moving
unit.
WARNING:
KEEP CLEAR OF ALL MOVING
PARTS
Keep people (ESPECIALLY YOUTH) away
from
equipment,
particularly
during
operation. Keep away
from all moving parts. Entanglement can
cause serious injury or death. Keep inlet
guard in place and in good working
condition.
3. DANGER - L0237 - Door interlock switch.
Augers are dangerous.
Failure to follow the above precautions may
cause serious injury or death.
+++++++++++++++++++++++++++++++++
Mount safety decals when unit is
assembled. Please check that all decals are
in place according to the drawing/picture
and in good legible condition.
IMPORTANT!! If suggested locations are
not clearly visible, place safety decals in
more suitable area. Never cover up any
existing safety decals.
1-4
Safety Section
4. WARNING - L0166 - Guards & shields in
place.
Disconnect Electricity. Check fan blade.
7. CAUTION - L0285-98
Not intended for use on public roads.
If road travel is required:
8. WARNING - L02831
Lower & secure parking stands before
unhitching unit.
5. DANGER -L0271 - Shield missing, do not
operate.
6. WARNING - L0284-98
Keep away from all moving parts.
9. DANGER - L0301
Rotating augers are dangerous!
1-5
Safety Section
10. CAUTION - L0520
Failure to keep unit clean may cause fire
and serious injury or death.
12. WARNING - L0512
Use safety chain when towing unit to
eliminate detachment hazard.
11. WARNING - L0164
Metal is slippery when wet; Never carry
items when climbing; Have another person
present;
Use safety harness & safety line; etc
1-6
Safety Section
1-7
Safety Section
3. WARNING - L0166
Disconnect electricity; guards, shields in
place; Check fan blade tight.
SAFETY DECAL LOCATIONS FOR FAN &
HEATER
Safety decals and shields are mounted
whenever possible at factory. Please check
that all decals are in place according to
these drawings and in good legible
condition. To order replacement decals or
shields (NO CHARGE) contact your dealer
or Sukup Mfg. Co., 1555 - 255th Street P.O. Box 677 - Sheffield, Iowa 50475.
Please specify computer number.
IMPORTANT ! The following safety decals
should be mounted on your equipment as
shown below. If suggested locations are not
clearly visible, place safety decals in more
suitable area. Never cover up any existing
safety decals.
4. DANGER - L0204
Close service door.
Make sure location area for decal is free
from grease, oil and dirt. Remove backing
from decal and place in proper position.
1. WARNING - L0281
Safe operation decal.
The numbers on the drawings below refer to
the location of the safety decals listed
above.
2. WARNING - L0165
Disconnect Electricity; Bleed gas
1-8
Emergency Shutdown Locations
Emergency Shutdown Locations
The power distribution box is located at the front left of the dryer.
It contains all of the main power distribution components.
On the outside of the
power distribution box,
the front door has two
latches mounted to it.
The door lock handle
secures the door and
can be locked with a key.
The main disconnect
mechanism prevents the
opening of the power box while power is present in the system.
Caution:
Power is still present at the lower side of the main switch
when the power box is open.
The picture at right shows
the main disconnect in the
closed position, power is
present in the system.
Located on the side of the
power distribution box, is the
Emergency Stop switch.
During operation, the switch
is pulled out and is
illuminated red.
Pressing the Emergency
Stop Switch or turning off the
system control switch on the
control panel will shut down
control system. Main power
is still present to the system.
System Control Switch
1-9
Control Box Components Location
Power Box Component Location
The picture below displays the power box and identifies all of the
major components.
SCR
Control Transformer
Transformer
SCR
110V
Relays
Load
Unload
Fan
Power
Distribution
Block
Starter/Protectors
3A
Breakers
Contactors
Y/∆ Starter
Hour
Meter
Main
Switch
Terminal Strip
Important Note:
During initial setup or after relocation of the dryer, it is
highly recommended that ALL of the main power wiring
connections be inspected for security and tight
connections. The wires are tightened at the factory;
however the connections should be checked after transport.
Note
All power boxes are wired to prevent EMC conditions. Varistor
and Snubber networks are provided for extra protection against
electromagnetic charges. When installing and running the dryer,
do not remove any EMC protection.
1 - 10
Manual Control Operational Check
Control Box Components Location
LCD Display
Printer
System Switch
Keypad
Load Auger
Unload Auger
Control Switches
Work Light
Meter Roll Speed
Adjustment (for Manual
operation)
Heater Switches
Fan Switches
Power Supply
EMOD Board, I / O
Board, & Processor
(processor located
under I/O board, I/O
board located under
EMOD board)
EMI Filter
Control Relays
24VDC
Power Supply
Expansion Modules
PLC
(programmable
logic control)
Terminal Strip
Note
All power boxes are wired to prevent EMC conditions. Varistor
and Snubber networks are provided for extra protection against
electromagnetic charges. When installing and running the dryer,
do not remove any EMC protection.
1 - 11
Dryer Installation
Gas and Electric Hook-up
Initial gas hookups should only be performed by qualified gas
service technicians in accordance with all applicable code
requirements. In conditions of a threaded pipe train, a regulator
must be installed on the gas tank and limit the pressure to 72 psi
(5 bars).
Initial electric hookups should only be performed by qualified
electrical service technicians in accordance with all applicable
code requirements.
Heater Operation
The heater and fan switches on the control box front panel must
be in either the “ON” or “AUTO” position. Power must be applied
to the fan before the dryer control box will apply power to the
heater(s).
Purge
After the heater is switched on, an automatic 30-second purge
cycle commences. During this cycle, with the fan operating, any
residual gas is cleared. The ignition board controls heater
startup sequences. The ignition board is located in the heater
control box.
Air Pressure Check
If operating in manual or automatic control, the dryer must be
filled with grain since without grain, insufficient air pressure will
develop and the dryer will shutdown in 5 seconds due to the low
static air pressure. If operating in the dry fire mode, the air
pressure sensor is disabled. No gas is being supplied during the
30-second purge cycle due to the gas solenoids being closed.
The static air pressure switch must sense the air pressure for the
control system to send a heater on signal. The differential air
switch is located in the heater box and must detect airflow to
allow the ignition sequence to begin.
Ignition
After the 30-second purge delay, the liquid and the vapor
solenoid is opened and a 4-second ignition attempt occurs.
Operation
The red power light on the heater box’s right side should be on at
this time. If a flame is not sensed within 5 seconds, the burner
will shutdown indicating that no flame was sensed.
1 - 12
Plenum Temperature Adjustment
Liquid Propane systems
To adjust the plenum temperature, refer to the Dryer Operation
section of the Operators Manual
Heater Housing Over Temp
The heater housing
high
limit
switch
detects
excessive
temperatures
inside
the heater housing. It
is rated to open above
200°F (94°C). If this
trips, the dryer will
display a housing high
temp fault on the LCD.
Reset switch
The heater housing
high limit switch must
be manually reset.
Vaporizer Over-Temp
The heater’s vaporizer serves to
convert the liquid propane into
vapor propane by using the heat
from the burner. A vapor high limit
fault will shut the dryer down if
vapor fault exceeds 140°F (60°C).
The dryer will lock out the system
and
display
the
vapor
high temp alarm.
The limit
switch needs to be reset once the
vapor temperature drops, the
Control Box will latch the fault until
the operator acknowledges the
fault by pressing the control box
keypad “RESET”.
The vaporizer should be adjusted before operating. Normally,
the vaporizer outlet hose should be very warm to the touch but
not so hot that it can’t be held. To adjust the vaporizer, refer to
the next section, dry fire tests.
Caution
Vaporizer may be hot, use extreme caution when handling.
1 - 13
-
Air Proving Switch
Velocity and pressure of the
airflow is measured by two tubes,
90° from each other. The air
proving switch then analyzes the
airflow. If airflow is not present,
the switch will turn off the
heater(s). This switch is located
inside the heater box. To adjust
the air-proving switch, turn the
end of the inner screws with a
flat head screwdriver.
To
decrease the amount of airflow detected, turn the screw counterclockwise. To increase the amount of airflow detected, turn the
screw clockwise.
Heater Operation at Low Plenum Temperatures
Operating the dryer at low temperatures (approximately less than
27°C above ambient temperature) requires low temperature
heater kit. This kit is automatically installed on all CE dryers. A
symptom of operating at temperatures with high temperature
equipment is a rumbling sound. This symptom occurs when the
gas pressure is low and the flame is burning back into the port
cup. Contact your Sukup dealer to purchase additional
equipment to reach lower temperatures.
Caution
Operating the dryer with too low of gas pressure will
damage the port cup. Contact dealer if symptoms occur.
Low Temperature vs. High Temperature Kit
Plenum Temp
Canola
Wheat
Corn
60°C (140°F)
80°C (176°F)
99°C (210°F)
Low Temp
Low Temp
NR
Low Temp
Low Temp
High Temp
Low Temp
High Temp
High Temp
At 10°C (50°F) ambient temperature
Heaters for Dan-Corn (Recommendations only)
Dryer
Fan Size
TE283
TE163
TE163,TE121
TE283
28”
28”
38”
44”
Dryer
TE283
TE163
TE163,TE121
TE283
Dryer Orifice Size
LP High Temp
LP Low Temp
Size (IN) Part # Size (IN) Part #
15/64
D7111
13/64
D7110
13/64
D7110
11/64
D7125
19/64
D7112
13/64
D7110
23/64
D7113
19/64
D7112
NG High Temp
Size (IN)
Part #
25/64
D71125
25/64
D71125
1/2
D71124
9/16
D71127
Dryer Port Cup Size
LP High Temp
LP Low Temp
NG High Temp
Size (IN) Part # Size (IN)
Part #
Size (IN) Part #
28”
9/16
D4027
3/8
D4025
9/16
D4027
28”
9/16
D4027
3/8
D4025
9/16
D4027
38”
3/4
D4044
9/16
D40443
3/4
D4044
44”
3/4
D4044
9/16
D40443
3/4
D4044
38” and 44” High Temp LP units also use flame deflector T16204
Fan Size
1 - 14
NG Low Temp
Size (IN)
Part #
19/64
D7112
19/64
D7112
23/64
D71131
7/16
D71129
NG Low Temp
Size (IN)
Part #
3/8
D4025
3/8
D4025
9/16
D40443
9/16
D40443
Dry Fire Tests
Introduction
The “Dry Fire” mode of operation enables the operator a means
of running the dryer when there is no grain. Pre-season tests for
troubleshooting. Ensure that the power box main switch is ON.
Pull the red emergency stop button out. The emergency stop
button should illuminate red, indicating control power is available.
Dryer is NOT susceptible to EMI (electromagnetic interference)
due to being shielded by metal boxes.
Caution
While the dryer is running, excessive audible noise is present.
Hearing protection is strongly recommended.
At the control box, turn the system control switch to the
”COMPUTER” position. Place the fan and heater selector
switches to the “AUTO” position. The LCD display should show
“SYSTEM READY”, meaning the dryer is in the standby mode. If
any error messages are displayed, they must be corrected
before the dryer can be started. See faults section for isolation
of displayed system faults.
From the Control Panel, press “MODE” then “2” for the Dry Fire
Mode.
A screen will appear on the
LCD
prompting
the
operator as to which 1 of 4
Dry Fire Tests is to be
performed.
DRY FIRE OPTIONS
1 = FAN 2 = FAN + HEAT
3 = ROLLER RAMP TEST
9=ROLLER/SCR ADJUST
Fan Only
Selecting 1 at the prompt will energize the fan(s) only. The
static air pressure switch is disabled during this test. All other
monitored safeties are operational at this time.
If the LCD contrast is not to the operator’s liking, turn the R99
potentiometer on the I/O board (clockwise to darken, counterclockwise to lighten). Operator MUST be grounded with a
grounding strap while turning potentiometers on I/O board.
Fan and Heater
Selecting 2 for fan and heat will apply power to the fan and
heater. First the fan will come on, followed by the heater after a
30 second delay. As before, the static air pressure switch is
bypassed and the differential air switch is still used for burner
operation.
Selecting options 1 or 2 will commence a 10 minute timer
countdown followed by the fan and if selected, the heater
startup. At the end of the 10 minute period, the fan and heater
will turn off automatically and return the dryer to the standby
mode. The heater may not be started independent of the fan
being started.
Note
This screen (shown below) will appear if selecting the FAN or
FAN+HEAT option on dual fan systems. This allows the
operator to test each barrel independently if desired.
On Dual Fan systems, if selecting
fan and heater will start first,
followed by a short delay
before starting the lower fan
and heater.
1 - 15
“BOTH STAGES”, the upper
DRY FIRE OPTIONS
1 = UPPER STAGE
2 = LOWER STAGE
3 = BOTH STAGES
Vaporizer Coil Adjustment (LP Models Only, Not Applicable to Natural Gas)
Adjusting the Heater: Vaporizer Coil.
Caution
If vaporizer is not adjusted correctly, piping could be hot!
Selecting the Dry Fire Mode Option 2 (fan and heater) is
required to operate the dryer’s
fan and heater when there is no
grain in the dryer. After the dryer
has been allowed to run and the
plenum
temperature
has
stabilized, the vaporizer outlet
(top) should be warm but not hot
to the touch. If the vapor side of
the pipe train is hot, or if the
dryer has shut down due to a
“VAPOR HIGH TEMP ALARM”,
the vaporizer may need to be
adjusted out (away from the
flame). To adjust the vaporizer
loosen the 2 pivot bolts (1 top, 1 bottom) of the vaporizer
adjustment bracket and then pivot the vaporizer either in or out
of the flame as necessary to regulate the temperature at the
vaporizer outlet. The U-Bolts mounting the vaporizer to the
adjustment bracket can also be loosened and vaporizer can be
moved in and out to adjust. Viewing hole is present to watch
vaporizer adjustment.
Meter Roll Ramp Test
WARNING
The Unload auger(s) will come on during the following
operations, as well as at any time the Meter Rolls are rotating to
avoid stuffing the unload auger.
Before performing either option 3 or option 9 of the Dry Fire
operations involving the Meter Rolls, the Control Panel
UNLOAD AUGER Switch must be turned to “AUTO”.
Selecting Dry Fire (Mode 2) then Option 3 (Roller Ramp Test)
will perform an automated voltage increase of the SCR drive
signal, which will cause an incremental step up of the Meter Roll
speed.
The speed will increase from 0 to 99% in 5% increments. The
display will show the current roll order in percent speed. The
whole process takes about 45 seconds. Pressing “RESET” will
stop the test and return the dryer to the standby mode.
Option 9 is only to be used by service technicians for calibration.
1 - 16
As part of an installation / pre-season operation checkout, only a
limited test may be made of the Manual Control System. This is
due to the fact that with no grain in the dryer, static air pressure
will be too low, which would
cause a fan shutdown and
not allow heater operation.
The following items may be
checked in manual with no
grain in the dryer.
1. Load Auger(s)
2. Unload Auger(s)
3. Meter Rolls
4. Work light (if added)
Note
In manual operation ALL safety interlock circuits are still
monitored by the PLC and should a fault occur, there would be a
safety shutdown.
To perform any operational
check in manual mode,
ensure that power is
applied to the power
distribution box and the Estop switch is illuminated.
All manual operations must be performed with the system control
switch in the “Manual” position.
1. Load Auger Test.
a. Position the load auger switch to “ON” position.
b. At this time the load auger should come on, and the light in
the load auger switch should illuminate.
Note
The load auger would run for 45 minutes if you were loading the
dryer before a loading time out shutdown would occur.
c. Position the load auger switch to “OFF”
d. The load auger should turn off, and the light in the load
auger switch should extinguish.
1 - 17
2. Unload Auger Test
a. Position the unload auger switch to the “ON” position.
b. The unload auger should
come on and the light in the
unload auger switch should
illuminate.
c. Position the unload auger
switch to “OFF”. The unload
auger should turn off and
the light in the unload auger
switch should extinguish.
3. Meter Roller Test
Note
Unload Auger must be “ON” for the Meter rollers to operate.
a. Position the unload auger switch to “ON”
b. The unload auger should come on and the unload auger
light in the switch should illuminate.
c. Unlock Meter Roll Potentiometer by moving the lock lever
up.
d. Dial in any desired meter roll speed.
For example: If you desire 50% meter speed, set the dial to
indicate 50.0.
e. The meter rollers should be
rotating.
f. When complete, return Meter
Roll
Potentiometer to
000 and lock.
g. Turn the unload auger switch
to “OFF”.
Percent
Meter
Roll
Speed
Indicator
Adjust
Knob
Lock
4. Work Light Test (if added)
a. Position the work light to on, the work light on the dryer
should illuminate as well as the light in the switch. This light
will be on as long as power is applied to the dryer.
b. Position the work light
switch to “Auto”. The work
light on the dryer and in
the
switch
will
be
illuminated as long is there
is no fault condition. This
is true in either manual or
automatic control. Turn
work light switch off.
1 - 18
Maintenance and Service
Preventative
Performing preventative maintenance on your dryer is very
important and can help to ensure that the dryer will perform well
throughout the drying season. The following guidelines are the
minimum recommended procedures to be performed.
When performing maintenance and using the ladder attached to
the dryer, make sure the ladder is dry before climbing. Ladder
may be slippery when wet.
Caution
All bolts used to keep enclosures locked MUST be tightened
beyond hand removal after opening to prevent undesired access.
Prior to Drying season
*Plan well in advance in case repairs or parts are needed! !
Warning
Lock out power before removing any safety shields
Note:
When working with the top section of the dryer, a walkway must
be installed that meets any applicable standards / codes.
Physical Inspection
1. Remove fan inlet screen. Check for foreign material on fan
blade. Check that the fan rotates freely and that all blade tip
clearances are the same. Check belts for wear.
2. Reinstall fan inlet screen. Check ventilation openings in
motor for any blockage.
3. Check wiring of fan and heater. Look for loose connections,
bare wires or rodent damage. Be sure to check ignition wire
and flame sensor wire for damage or short to ground.
4. Examine the flame rod for cracked porcelain insulation.
5. Examine
spark
plug for proper gap
and
clean
the
electrodes
if
Retaining Bolt
required. The gap
should be 1/8”
(3.175 mm). Spark
plug and flame rod
should
be
examined
periodically
through out the
drying season.
Flame Sense
6. Inspect the port
Flame Deflector
Rod
cup
for
any
accumulation
of
foreign material. Clean if required. Foreign material in the
port cup will not burn out, and will impair burner operation,
(Port cup located behind the deflector)
Inspect Vaporizer, Diffuser, Flame Deflector, and heater venture
supply pipe for damage and physical integrity.
1 - 19
Caution
One drop of Liquid propane will expand 270 times as it
converts to Vapor. It is very dangerous to have the
Vaporizer coil develop a leak during heater operation. Be
sure to check the vaporizer coil yearly. The Vaporizer
should be replaced every 5 years.
7. Remove and clean the gas strainer.
8. Inspect all valve train components for physical integrity.
9. Inspect all valve train connections for tightness.
Liquid Propane
8
7
9
6
11
12
13
10
5
14
4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
3
2
1
NPT LP Inlet Fitting
Fuel Shutoff Valve
LP Gas Strainer
Vaporizer Inlet
Vapor Outlet and Pressure Relief Valve (not shown)
Pressure Regulator
Main (Upstream) Gas Valve and Actuator
Blocking (Downstream) Gas Valve and Actuator
Electronic Modulating Valve
High Pressure Gas Switch
Valve Proving Pressure Switch
Pressure Gauge
Valve Proving Pressure Gauge
Pressure Relief Valve (behind regulator)
Vapor Pressure Relief (not shown)
1 - 20
Natural Gas
5
6
7
2
1
3
1.
2.
3.
4.
5.
6.
7.
4
Gas Inlet Street Fitting
Fuel Shutoff Valve
Main (Upstream) Gas Valve and Actuator
Blocking (Downstream) Gas Valve and Actuator
Electronic Modulating Valve
Pressure Gauge
High Pressure Switch
11. Open inner and outer unload auger clean out/access doors,
and inner and outer column clean out /access doors.
1 - 21
12. Remove any accumulation of fines, dirt or foreign material
from the bottom auger trough area, meter rolls and lower
column.
13. Inspect unload auger, 1 ¼” (3.175 cm) auger end flange
bearings and wooden hanger bearing and flighting for
damage and security.
14. Inspect meter rolls for damage and security.
15. Inspect meter roll wood bearings for damage, hole
elongation (excessive play), and security.
Note
Auger end flange bearings are lifetime lubricated and do not
require service lubrication.
Auger wood hanger bearings are oil-impregnated and do not
Meter roll bearings are oil-impregnated wood and do not require
service lubrication.
1 - 22
16. Refer to the pictures below when checking the unload auger
/ meter roll drive train.
Upper Meter Roller
Right
Left
Left Idler
Right Idler
Lower Meter Roller
Right
Left
Reduction
Gear Box
(behind
shield)
Unload
Auger
Belt
Unload
Auger
Pulley
Reduction
Gear Box
17. Inspect unload auger pulleys and meter roll sprockets for
wear or damage.
18. Inspect unload auger belts for cracks or breaks. Check belt
tension for proper adjustment. For proper belt tension test,
press on the belt mid-way between pulleys. Belt should not
deflect more than the distance of one belt width.
19. Inspect the chain belt links, and idler rolls for wear or
damage.
20. Check that the idlers are adjusted properly to remove slack
in drive chains.
21. Check that the reduction gearbox/DC motor is adjusted
outward enough to remove slack on lower drive chain
1 - 23
22. Inspect reduction gearbox for damage / leakage. Check fluid
level.
23. Inspect unload auger motor, DC meter roll motor for damage
and security.
24. Reinstall unload auger/ meter roll drive train shield.
25. Remove cover from load auger motor drive and covers from
top of wet bin.
(see pictures below)
26. Inspect load auger drive pulleys for damage and security
27. Inspect load auger drive belts for cracks and breaks. Check
auger drive belts for proper tension. To test for proper
tension, press on each belt at the mid-way point between the
two pulleys. Belt should not deflect more than the distance of
one belt width. Adjust as necessary.
28. Inspect load auger end flange bearings and mid wood
hanger bearing for wear or damage.
29. Inspect flighting for wear or damage.
Note
The load auger bearings are lifetime lubricated and do not
30. Reinstall all covers and shield.
31. Perform overall inspection of the rest of the dryer looking for
loose, missing or damaged parts.
Operational Check
32. Perform pre-season operation test of dryer by performing the
Dry Fire Test. While the fan and heater are running, perform
a leak test of the heater gas train using a soapy water
solution.
1 - 24
General Dryer Operation
Continuous Flow
Continuous Flow dryer operation requires creating a gradient of
moisture from the top to the bottom of the dryer and is
accomplished by three main functions; initial dry, stabilization,
and continuous flow. Before the first drying operation is started,
the user must enter the incoming moisture and the desired
output moisture into the control panel. These moistures are
used to calculate the time necessary to perform the initial dry at
160°F (71°C) temperature, during which no grain is unloaded
from the dryer. After initial dry is complete, the user will set the
desired drying plenum temperatures and the controller calculates
a meter roll speed corresponding to the plenum temperatures
entered. The dryer then performs a stabilization routine. During
stabilization, a gradient of moisture is established in the dryer by
drying and unloading one full load of grain without adjusting the
meter roll speed. After stabilization has completed, the dryer
enters continuous flow operation. During this operation, the
dryer adjusts the meter roll speed for variances seen in the
actual output moisture compared to the desired output moisture.
When the final dry of the season is achieved, the user simply
enters the final dry function and follows the simple instructions
listed on the screen of the control panel.
When continuing a drying operation after the dryer has run out of
grain or has been shut down, it is often desirable to run with the
settings as before the shut down. Therefore, quick methods of
restarting the dryer have been developed to meet this demand.
Restarting the dryer with or without stabilization, depending upon
the particular situation, can be accomplished by following a short
series of steps, explained on the control panel screen during
normal startup operation.
Automatic Batch
Automatic batch is a standard feature of the Sukup Continuous
Flow Grain Dryer. Batch operations enable operators to dry their
grain in a manner they have become accustomed to, enables
them to dry extremely wet grain, allows single fan dryers to be
operated in a heat cool manner, and makes it possible to dry
grains which require a low plenum temperature.
Two controlling operations of automatic batch have been
developed. The first method dries batches according to time
entries. The operator enters set times into the control panel
during which the dryer will heat, cool, and unload the grain.
During unload the dryer calculates the average moisture of each
batch and prints it. The user can then adjust the time entries
according to the desired output moisture. The second method of
operation requires purchasing the temperature control option.
The operator enters a desired dry temperature value into the
control panel.
When the kernel temperature in the column
reaches the set temperature, the dryer proceeds to cool the
grain, if necessary, and then unload the grain. The set variables
may be changed to the operator’s choosing at anytime during the
batch operation (The new settings take effect the next batch).
1 - 25
Grain Transfer
Increasingly, operators require the dryer to transfer grain through
it to reach their storage facilities. A mode of grain transfer has
been developed to simplify this process. The control panel
display, steps the user through a simple process to begin and
end the procedure through normal startup operation.
Manual
Manual operation serves many purposes. When operators want
complete control of their dryer, manual operation fulfills this
need. Manual operation serves as a redundant control set,
allowing the user to operate their dryer while the dealer meets
any necessary service demands. Manual operation is a simple
procedure of manually turning on fans, heaters, loads, and
unloads. The dryer automatically loads the dryer during manual
operation while the user has control of the meter roll speeds.
1 - 26
Grain Dryer Control System Menus
Quick Reference Guide V4.3A
[SET] Menu: Continuous Flow
1=CALIBRATE SENSORS
2=PLENUM TEMPERATURE
3=MOIST OUT 4=MST IN
5=CONFIGURATION
1 – Calibrate Moisture/Temperature Sensors
2 – Set Plenum Temperatures(s) and Options
3 – Set Output Moisture Setpoint
4 – Set Input Moisture
5 – Set Configuration Parameters
[SET] Menu: Autobatch
1=CALIBRATE SENSORS
3=DRY TIMES 4=COOL
-or3=DRY TEMPS 4=COOL
5=UNLOAD
6=CONFIG
1 – Calibrate Moisture/Temperature Sensors
2 – Set Plenum Temperature(s) and Options
3 – Set Dry Cycle Time of Dry Kernel Temperature
4 – Set Cool Cycle Time
5 – Set Unload Cycle Time
6 – Set Configuration Parameters
[1] Calibrate Sensors Menu:
1=OUTPUT MST 2=TEMP
3=PLENUM RTD TEMP
4=COLUMN RTD TEMP
5=INPUT MST 6=TEMP
1 – Calibrate Output Moisture
2 – Calibrate Output Temperature
3 – Calibrate Plenum RTD Temp(s) (if applicable)
4 – Calibrate Grain Column RTD Temp (if applicable)
5 – Calibrate Input Moisture (if applicable)
6 – Calibrate Input Temperature (if applicable)
[2] Plenum Temperature Menu:
-or (two fan)1=UPPER PLENUM TEMP
2=LOWER PLENUM TEMP
3=MIN TMP 4=MAX TMP
5=TMP ADJ INC 6=TIME
1 – Set Single/Upper Plenum Temperature Setpoint (if equipped)
2 – Set Lower Plenum Temperature Setpoint (if equipped)
3 – Set Minimum Plenum Temperature
4 – Set Maximum Plenum Temperature
5 – Set Temperature Adjustment Increment (if applicable)*
6 – Set Temperature Adjustment Time (if applicable)*
* Adjusts plenum temperature when meter roll speed is at a
min/max limit (if equipped with Electronic Mod Valve)
[5] (CF) of [6] (AB)
Configuration Menu:
1=TIME/DATE 2=LANG
3=ROLL SPD MIN 4=MAX
5=VALVE MIN 6=MAX
7=CLEANOUT8=FAN DELAY
1 – Set Time and Date
2 – Set Language Selection (if applicable)
3 – Set Minimum Allowed Meter Roll Speed
4 – Set Maximum Allowed Meter Roll Speed
5 – Set Minimum Allowed Electronic Mod Valve Opening (if
equipped)
7 – Set Unload Auger Cleanout Delay Time
8 – Set Fan Shutdown Delay Time
[MODE] Menu:
MODE = ?
1=VALVE
2=DRY FIRE
4=CAL/SETUP 5=SENSOR
6=SET PROC 7=UNITS
1 – Perform Electronic Mod Valve Diagnostics (if applicable)
2 – Perform Dryer Dry Fire Diagnostics
4 – Monitor Sensors
5 – Select Moisture Sensor
6 – Select Processor PCB Version
7 – Select Temperature Units (F or C)
1 - 27
Before Loading or Starting the Dryer
Caution
Ensure that all safety shields are in place. Ensure that outside
access covers on both sides of Dryer are secured and latched.
Dryer Startup Preliminary Steps
1. Prior to starting the dryer, turn the Main Disconnect on the
front of the power box to “OFF”.
2. Open the front panel of the power box by turning the chrome
cabinet latch 1/4 turn. (See next page).
3. Ensure
that
all
starter/protectors in
the
power
box
(shown at right) are
turned ON for dryer
operation.
Starter/Protectors
4. Close the power box
front panel and latch
by
turning
the
chrome cabinet latch
1/4 turn.
5. Engage the main disconnect, by turning the lever 45°
clockwise indicating “ON”. The main disconnect lever must
appear as shown for dryer operation. On the left front side of
the power box, pull the red “Emergency Stop” button out.
The “Emergency Stop” button illuminates RED if pulled out
with the main disconnect “ON”.
1 - 28
Dryer Operation
Four operations have been designed to operate the Sukup Grain
Dryer.
1.
2.
3.
4.
Continuous Flow
Automatic Batch
Manual Operation
Grain Transfer
To operate continuous flow, automatic batch, or grain transfer,
select the computer position of the system control switch on the
front panel and auto position for all others. Operating the dryer
in manual requires turning the system control switch to manual
and all other switches to on. In manual, when turning the other
switches to the on position, this will start the corresponding
device immediately.
Instructions for operation of the dryer are in the following
locations:
• Continuous Flow, next page
• Automatic Batch p. 45
• Manual p. 40
• Grain Transfer p. 50
1 - 29
Continuous Flow
Three options exist to begin the operation of continuous flow:
Initial Dry, Restart with Stabilization, and Restart. The table
below details the starting scenarios to choose the correct method
to start the dryer.
Start/Restart scenario
Initial Dry w/
Stabilization
Restart w/
Stabilization
Restart
All wet grain, No gradient
established
Shutdown greater than 1 Hours,
gradient established, grain cool
Change of plenum temperature
more than 20°F.
Yes
No
No
No
Yes
No
No
Yes
No
Instructions for starting the dryer in continuous flow:
• Initial Dry, below
• Restart with Stabilization and Restart page 34
Initial Dry
During initial dry, two procedures are performed followed by
continuous flow operation. The first procedure is to perform an
initial dry. Initial dry dries the grain at a specific temperature, 71º
C, over a calculated period of time without unloading. The time
value is calculated based upon the input moisture entered into
the controller. The second procedure performed is stabilization.
Stabilization begins unloading the grain and does not adjust the
meter rolls until the dryer has completely turned over the grain in
the dryer. This meter roll speed is calculated off of the input
moisture given and the entered plenum temperatures. The time
for stabilization is calculated off of the determined meter roll
speed to completely turn the dryer over.
Press start to begin
automatic
operation,
ensuring all of the control
switches are turned to
the auto position.
From the display outlined
here, choose Continuous
Flow by pressing 1.
On the next screen,
select initial dry by
pressing 1.
1 - 30
** SYSTEM READY **
SET SWITCHES TO AUTO
THEN PRESS START
01/25/08
12:45PM
CONT. FLOW
AUTOBATCH
GRAIN TRANS.
FINAL DRY
1
2
3
4
OPERATION
PRESS
INITIAL DRY
1
STAB & RESTART
2
RESTART
3
A series of menus is then displayed to enter the appropriate
settings for the date/time, input moisture, desired output
moisture, minimum meter roll speed, and maximum meter roll
speed. The previous recorded values will be displayed on these
menus, to accept these values press (+), to change these values
press (-).
After
setting
these
values, the screen will be
displayed as below.
**DRYER NOT FULL**
START TO BEGIN
OR RESET TO ABORT
OR 1 FOR FINAL DRY
Press start and the dryer will perform an initial fill if necessary,
followed by starting the heaters and fans for initial dry. Pressing
reset would take the operator to the start screen. Pressing 1
would allow the operator to perform the end of season final dry
procedure.
After pressing start, if the dryer requires filling, the fill will begin.
If the fill time exceeds 45 minutes, the fill will shutdown. Ensure
that the dryer is filling correctly and that sufficient grain is present
to fill the dryer. Press start for another load attempt if necessary.
Once the dryer is full, determined by the dryer’s paddle switch
assembly, the load auger(s) will turn off automatically.
Automated starting of the
fans and firing of the
STARTING FAN
heaters is now performed.
The upper or single fan is
turned on followed by the
corresponding heater. The LCD will display ‘Starting Fan…’ until
proper plenum air pressure is detected. If insufficient air
pressure is present, the dryer will shutdown with a static air
pressure fault. Refer to Shutdown Faults in Troubleshooting
Section.
HEATER PURGE IN
The dryer will then start the
heater. The fan will purge
PROGRESS FOR LOWER
for 30 seconds after which
HEATER PLEASE WAIT
ignition will occur.
The
flame sensor will then
attempt to detect a flame. If flame is not sensed within 5
seconds, the dryer will shutdown and display a Flame Timeout
Fault. Refer to Shutdown Faults.
On two fan dryers, the
same
procedure
is
followed for the second
fan and heater.
PLENUM TEMPERATURE
STABILIZING
PLEASE STAND BY
90 SECONDS REMAINING
The dryer will then
stabilize the plenum
temperature for 100 seconds. During this time, the plenum
temperature will exceed the set temperature, and then fall back
to the proper setting. This is typical operation of the modulation
value. Often, 100 seconds is not sufficient to stabilize the
plenum. The plenum temperature is indicated on the control box
and the front of the dryer in sight of the mod valve.
1 - 31
If start is not pressed
within 10 minutes, the
dryer will shutdown due to
inactivity.
The
dryer
will
perform initial dry.
Dryer Stabilization
now
SYSTEM IDLE SHUTDOWN
OPERATOR INPUT REQ’D
PRESS ANY KEY
INITIAL DRY
TIME = 33:50 MINUTES
31:04 REMAINING
PLENUM TEMP = 71C
After initial dry is complete, the operator must enter the
stabilization period.
For two fan dryers,
SELECT OPERATION
select
whether
to
operate the dryer in full 1 = FULL HEAT,
heat mode or in heat 2 = TOP HEAT ONLY
cool mode. If operating 3 = BOTTOM HEAT ONLY
in heat/cool, the lower
heater will now be shut off.
Single fan units can only operate in heat/cool mode in automatic
batch operation.
1 - 32
Next, set the operating
plenum
temperatures
PLENUM TEMPERATURE
within the operating
IS SET TO 220F
range of 140ºF (60°C)
and 220ºF (104°C).
OK(+) OR CHG(-)
The controller records
the last setting the operator had input.
The table below outlines approximate point removals based on
given plenum temperatures. Use it to establish the proper
plenum temperatures to maximize output and remain within
system output capacity limitations.
Approximate meter roll speed given the plenum temperature and points removal for a
single fan.
(This chart is to be used for CORN only)
Pts
Removed
15
10
5
3
Plenum
71°C
6.9%*
9.7%*
19.4%
32.3%
Plenum
77°C
7.1%*
10.7%
21.4%
35.7%
Plenum
82°C
7.8%*
11.7%
23.4%
39.0%
Plenum
88°C
8.5%*
12.7%
25.4%
42.3%
Plenum
93°C
9.1%*
13.7%
27.4%
45.7%
Plenum
99°C
9.8%*
14.7%
29.4%
49.0%
Plenum
104°C
10.5%
15.7%
31.4%
52.3%
*If it is necessary to run the meter rolls lower than 10%, Automatic Batch must be used.
Upon entering the plenum temperature, the controller calculates
the proper meter roll speed. Allowed meter roll speeds are 10%
to 99%. If the calculated speed exceeds the maximum meter roll
user setting or cannot reach the minimum meter roll speed, the
user will be prompted to adjust the plenum temperatures settings
or accept the setting with a warning. If the dryer requires
operation below 10% meter roll speed and the plenum
temperatures have been set to their maximum setting or set to
the operator’s desired maximum, the dryer must be run in
automatic batch operation. Proceed as necessary, press reset
to cancel start and begin automatic batch operation.
After setting the temperatures and accepting the calculated
meter roll speed, the stabilization countdown will occur.
Changing the meter roll speed from the calculated speed for
stabilization is not recommended.
When stabilization completes, the dryer will automatically
proceed to continuous flow operation. Refer to continuous flow
operation section.
1 - 33
Restart With or Without Stabilization
Restart was created to simplify the process of restarting the
dryer with settings similar to those previously set.
When
restarting, the dryer will resume the same full heat or heat cool
operation as previously run. Changing between full heat and
heat cool requires running the initial dry operation.
When selecting restart without stabilization, it is necessary to
check whether the dryer must be re-stabilized. The control panel
display will show when the dryer was last shutdown. Use this
information, along with the chart on p. 33, to determine whether
or not it is necessary to restabilize the dryer. If it is necessary to
restablize the dryer, press (-), otherwise press (+).
Once it has been determined whether or not to run stabilization,
the display will prompt the operator to approve or change dryer
settings.
The display will show date/time, minimum and
maximum meter roll speeds, previous plenum temperature
settings, and last recorded meter roll speed. Upon changing any
of the plenum temperatures or the meter roll speed, the operator
will be prompted to reset all plenum temperatures and the meter
roll speed. This is necessary to prevent the dryer from running in
an undesirable manner. If resetting these values, the controller
will require the same parameters as those required when
entering plenum temperatures for initial dry.
After
accepting
or
**DRYER NOT FULL**
resetting the settings, the
PRESS START TO LOAD
operator is prompted to
OR RESET TO ABORT
press start to perform an
OR 1 FOR FINAL DRY
initial fill, if necessary,
followed
by
the
immediate starting of the fans and heaters. Pressing reset would
take the operator to the standby screen. Pressing 1 would allow
the operator to perform the end of season final dry procedure.
After pressing start, if the dryer required filling, the fill will begin.
assembly, the load auger(s) will turn off automatically.
STARTING FAN
corresponding heater. The
LCD will display ‘Starting Fan…’ until proper plenum air pressure
is detected. If insufficient air pressure is present, the dryer will
shutdown with a static air pressure fault. Refer to Shutdown
faults section.
1 - 34
HEATER PURGE IN
heater.
The heater will
PROGRESS FOR LOWER
purge for 30 seconds after
which ignition will occur.
HEATER PLEASE WAIT
The flame sensor will then
attempt to detect a flame.
If flame is not sensed in 5 seconds, the dryer will shutdown and
display a Flame Timeout Fault. Refer to Shutdown faults section
On two fan dryers, the same procedure is followed for the
second fan and heater.
If start is not pressed
within 10 minutes, the
dryer will shutdown due to
inactivity.
PRESS ANY KEY
Dryer Stabilization from restart
If stabilization is required, the dryer will immediately begin
stabilization, otherwise, refer below for continuous flow
operation.
When stabilization completes, the dryer will automatically
proceed to continuous flow operation.
Continuous Flow
During continuous flow, the dryer will begin sampling the grain
moisture and temperature. The plenum temp, current moisture,
grain temperature, and meter roll speed are displayed along with
three-minute temperature compensated average moisture.
The desired moisture will also be displayed alternately with the
current moisture value.
The meter rolls are adjusted, based upon a running three-minute
average, every 15 minutes. The meter rolls will not be adjusted
if the new moisture average is approaching the desired moisture
value or if the new meter roll speed is within 0.2% of the current
meter roll speed. The amount of adjustment made is based
upon the difference of the desired moisture value and the actual
three-minute average moisture value.
1 - 35
Print-out Information
Once the dryer is running, discharged grain temperature, current
moisture, 3-minute moisture average as well as the current roll
order will be printed once every 15 minutes.
If a shutdown occurs, the date & time that the shutdown occurred
will be printed along with a brief description of the particular
shutdown.
SUKUP AUTO DRYER
** VERSION 4.3A **
Starting operation. Initial
Dry, Restart, or Restart with
Stabilization
Moisture setting
Maximum meter roll setting
Temperature sensor
calibration adjustment
indicator
Time Initial load started
Time Initial load ended
Time Initial Dry started
Time Initial Dry ended
Dryer stabilization
completed
Computer goes into full
automatic moisture control
Data is printed every 10
minutes and can be adjusted
to not print or to print every
10 minutes.
SINGLE FAN DRYER
CONTINUOUS FLOW OPERATION
INITIAL DRY
DATE: 2/01/06 TIME: 2:15PM
INPUT MOISTURE = 22.5%
OUTPUT MOISTURE SETPOINT= 16.5%
MAXIMUM ROLL = 50%
MINIMUM ROLL = 10%
MOISTURE CAL ADJ = 0.0%
TEMP. CAL ADJUST = 0
----------------------------------------------------------------2:15PM INITIAL LOAD STARTED
2:15 INITIAL LOAD COMPLETED
2:17PM INITIAL DRY STARTED – 30.0 MIN.
2:47PM INITIAL DRY COMPLETED
PLENUM TEMPERATURE = 220F
CALCULATED INIT. ROLL = 26%
2:48PM STABILIZATION STARTED-54.7 MIN.
3:43PM STABILIZATION COMPLETED
SAMPLING 10 MIN PRINTOUT
TIME OUT OUT
ROLL COL PLEN
TEMP MOIST SPEED TEMP TEMP
-----------------------------------------------------------3:43 125F 16.4% 39% 190F 220F
3:53 125F 16.5% 39% 191F 220F
4:03 125F 16.6% 39% 190F 220F
4:05PM USER SHUTDOWN
1 - 36
Program version number
Operation selected
Continuous Flow, Automatic
Batch, or Grain Transfer
User entered incoming
moisture content
Minimum meter roll setting
Moisture sensor calibration
adjustment indicator
Computer calculated time for
stabilization
Prints time, output
temperature, output
moisture, roll speed, column
temperature, and plenum
temperature.
Whenever the dryer shuts
down, it will print the time
and reason for shutdown
Setting’s Adjustment During Continuous Flow
Pressing the set key
during continuous flow
operation allows the
user to change the
settings listed on the
display right.
1=CALIBRATE SENSORS
3=COL TEMP 4=MST IN
5=CONFIGURATION
Output Calibration Procedure During Continuous Flow
Once the dryer has begun sampling and the grain kernel
temperature has stabilized the output moisture sensor’s
accuracy should be verified.
1. At the display, note the current 3-minute moisture average
and the current temperature reading.
2. Immediately test the discharged grain from the sample spout
at the rear of the dryer.
3. Test the moisture and temperature of the sample. Using a
moisture tester that has been calibrated to the tester of the
location the grain will be sold at.
4. Compare the tested moisture value against the value noted
earlier by the dryer. Set the temperature before setting the
moisture.
5. Press set from the continuous flow operating screen, then
press 5 to set the temperature calibration
• Example:
The dryer read 120°F (49°C) kernel
temperature and the actual temperature was 110°F
(43°C). The difference between the recorded versus the
set temperature was -10 degrees. After pressing set,
the displayed temperature is 115°F (46°C). Update the
current temperature to read 105°F (41°C).
6. Allow 3 minutes for the temperature change to take effect.
7. Again, press set from
CURRENT MOISTURE
the continuous flow
VALUE IS 16.0%
operating screen, then
press 1 to set the
DESIRED INDICATED
moisture calibration.
VALUE ??.?%
• Example:
The
dryer read 16.5 % moisture and the actual moisture was
16.0 %. The difference between the recorded versus the
set moisture was –0.5 %. After pressing set, the
displayed moisture was 15.5 %. Update the current
moisture to read 15.0 %.
8. Sensor calibration is complete. Calibrate as necessary.
1 - 37
Stopping of Automatic Moisture Control
Continuous flow operation can be stopped by any of the three
following methods:
1. User shutdown by pressing
the ‘Reset’ button.
OUT OF WET GRAIN
2. Automatic shutdown due to
PLC 10 MIN. TIMEOUT
an Out-of-Grain timeout
FOR RESTART PRESS 1
3. Automatic shutdown due to
PRESS 2
a fault.
Refer to Fault FINAL DRY
Shutdown section
Final Dry
The final dry procedure was designed to dry the remaining grain
in the dryer and empty the dryer. Since the dryer will not be
completely full, the static air switch will be bypassed.
When Final Dry has been
selected, the screen will
display the following:
LAST RECORDED INPUT
MOISTURE WAS 21.0%
OK(+) OR CHG(--)
At this point, the last input moisture entry is displayed. The user
may either accept this indication or change it by pressing “OK” or
“CHG”.
The fan and heater will start
in sequence, this is followed
by a 100 second Plenum
temperature
stabilization
period.
The amount of dry time is
calculated by the computer
based on 3.0 minutes per
point of moisture removal
comparing the incoming
moisture
content
with
desired moisture out.
PLENUM TEMPERATURE
STABILIZING.
PLEASE STAND BY.
95 SEC. REMAINING
RECOMMEND 60C DRY
TIME FOR 13.5 MIN.
OK(+) OR CHG(--)
At this point you can accept the computers recommendation or
change it anywhere between 5 minutes and 60 minutes.
Whether you accept the time
recommendation or change
it, the next screen to appear
will be:
At this point the Final Dry is
in progress.
At the end of the timed
sequence, the next screen
is listed here.
1 - 38
FINAL DRY 60C
TIME = 13.5 MINUTES
13.49 REMAINING
PLENUM TEMP = 60C
HEATER IS NOW OFF
PRESS ANY KEY TO
START FINAL UNLOAD
OR ‘RESET’ TO ABORT
Press any key on the keypad to start Final Unload.
The meter rolls will be set
to the maximum speed.
* FINAL UNLOAD *
MOIST=16.5% TMP=33C
ROLL ORDER = 50%
REMAINING = 27:25
The third line displays time
remaining for Final Unload.
The fan is still on during Final Unload. It may be turned off by
turning the front panel fan selector switch to “OFF”.
After the calculated time is complete, the screen will display
“Final Dry Complete Press Any Key”. The Final Dry cycle should
now be complete and the last of the dried grain will have been
transferred. If there is still grain in the dryer, a manual unload
can be performed to empty it.
Press any key on the keypad to return to the main screen.
1 - 39
Manual Control
Introduction
This mode of operation is provided primarily as a back up for
operating the dryer should there be a problem with the automatic
controller. However, the dryer may be run in manual at any time.
When operating in the manual mode, safety circuits are
monitored by the PLC, and a fault condition will cause a system
shut down. In the event of a fault, the switches must be turned to
the “off” position to reset the control system. If the computer
system is non-operational, turn switches to OFF and cycle
power.
Starting Dryer from Empty
To start the dryer in
the manual mode, turn
the
system
power
switch to manual. If the
computer
is
nonoperational, the screen
will not appear:
** SYSTEM READY **
** MANUAL CONTROL **
The dryer is now ready
START TO MONITOR
for manual operation.
8/22/05
12:45PM
Step 1. Load Dryer
Load the dryer, by turning
the load auger switch to
“ON”. At this time the dryer
will load. When the dryer is
full, the load auger will shut
off automatically. It is not
necessary to turn the load
auger off with the switch.
During manual operation,
the PLC will monitor the
dryer and control the load device to automatically fill the dryer
during operation.
If the computer is operational, and the operator desires to
monitor the moisture and
** MANUAL CONTROL **
temperature
of
the
output
grain,
press
NO AUTO CONTROL OR
“START”
and
the
SENSE OF METER ROLLS
following screen will
START TO CONTINUE
appear:
Press any key on keypad to continue to the monitoring function.
1 - 40
Step 2. Starting Fans/Heaters
Next, start the fans and heaters by first turning the fan switch to
“ON” and then turning the heater switch to “ON”.
Note
The Heater will still have a 30-second purge before starting.
#1 Fan/Heater
Allow the plenum temperature to stabilize for approximately 100
seconds.
Step 3. Initial Dry Time
Manually adjust the heaters for a plenum temperature of 71°C
(160°F) as indicated on the digital temperature indicator by
pressing SET [2] for plenum temperature.
On dryers using the manually adjusting mod valve, turn the Thandle clockwise to increase the plenum temperature, and
counter-clockwise to decrease the plenum temperature.
On dryers using the electronic mod valve, open the inner door of
the control box and locate the electronic circuit board with the
digital temperature display. On this board, are there are small
slide switches labeled #1, #2, etc. Place the correct slide switch
into the manual position and adjust the corresponding
potentiometer (also marked #1, #2, etc.) to the correct
temperature.
The amount of time to keep the dryer in this condition is
determined by the incoming grain moisture and the desired
output moisture.
Use the formula below to determine the Initial Dry time.
(Incoming Moisture Content – Desired Moisture Content Out) x 5 Minutes = Initial Dry Time
Example
(21% Incoming – 16% Desired Out) x 5 Minutes = 5% x 5
Minutes = 25 Minute Initial Dry Time
After the Initial Dry time is complete, it is necessary to allow the
dryer to stabilize the moisture gradient. At this time, manually
increase the plenum temperature to 140-220°F (60°C-104°C) by
pressing SET [2] for plenum
temperature adjust.
Step 4. Dryer stabilization
After the initial dry time is
completed,
set
the
plenum
temperature to the operating
temperature.
Begin dryer stabilization by turning
the unload auger switch to “ON”.
1 - 41
Next adjust the
Meter Roll Speed
to the desired
speed. To adjust
the
meter
roll
setting, move the
locking lever up,
and rotate the
knob
to
the
desired setting.
Percent
Meter
Roll
Speed
Indicator
Adjust
Knob
Lock
The speed setting is indicated by a 3-digit indicator in the center
of the knob. This value indicates 000 to 999. Example: If desired
speed is 25%, dial indicator to 250.
To determine the correct meter roll speed setting, follow the
chart below. If the speed settings require the dryer to run at less
than 10% meter roll speed, or a manual setting of 100, it is
necessary to dry the grain in the Automatic Batch mode, or
increase the plenum temperature.
Approximate meter roll speed given the plenum temperature and points removal for a
single fan. This chart is a starting point, adjust as necessary for each dry.
(This chart is to be used for CORN only)
Pts
Plenum
Plenum
Plenum
Plenum
Plenum
Plenum
Plenum
Removed
71C
77C
82C
88C
93C
94C
104C
065 *
071 *
078 *
085 *
091 *
098 *
105
15
097 *
107
117
127
137
147
157
10
194
214
234
254
274
294
314
5
323
357
390
423
457
490
523
3
*If it is necessary to run the meter rolls lower than 100 and more than 999, Automatic
Batch must be used.
Important
At this point it is very important to let the dryer stabilize. DO
NOT make any further Meter Roll adjustments until the dryer
has turned the grain over completely one time. To determine
the amount of time to turn the dryer over one time, refer to
the chart below.
Time to Clear Dryer at Given Meter Roll Settings (Approximate)
Roll
Setting
Minutes to
Unload
Roll
Setting
Minutes to
Unload
Roll
Setting
Minutes to
Unload
100
150
200
250
300
350
400
161
114
90.5
76.4
67.0
60.3
55.3
450
500
550
600
650
700
750
51.3
48.2
45.6
43.5
41.7
40.1
38.8
800
850
900
950
999
37.6
36.6
35.7
34.8
34.1
At this point a proper moisture gradient will have been
established if the roll speed was left alone.
1 - 42
Step 5. Dryer Operating under Manual Meter Roll Control
At the end of the Dryer stabilization period as determined above,
monitor the discharge moisture content by either observing the
control box display (only if computer is operational) or by
performing a manual sample test using the sample spout.
Calibrate temperature and moisture readout as described on
page 37 if necessary.
SAMPLING…
OUTPUT TEMP = 35C
CURR. MOIST. = 16.0%
AVG. MOIST = 15.9%
This display, detailed here,
will show the output moisture
while running in manual.
If the discharge moisture content is not correct, adjust the meter
roll potentiometer according to Figure #1 if moisture content is
too high, or according to Figure #2 if moisture content is too low.
Deviation Above Set Point
Moisture 0.5% High
Moisture 1.0% High
Moisture 1.5% High
Moisture 2.0% High
Moisture 2.5% High
Moisture 3.0% High
Moisture 3.5% High
Moisture 4.0% High
Moisture 4.5% High
Decrease Meter Roll Setting
Decrease Dial setting 025
Figure 1
Deviation Below Set Point
Moisture 0.5% Low
Moisture 1.0% Low
Moisture 1.5% Low
Moisture 2.0% Low
Moisture 2.5% Low
Moisture 3.0% Low
Moisture 3.5% Low
Moisture 4.0% Low
Moisture 4.5% Low
Increase Meter Roll Setting
Increase Dial setting 025
Figure 2
Important
After adjusting the meter roll speed, allow at least 15 minutes of
operation before re-checking moisture and/or re-adjusting meter
speed again.
1 - 43
Step 6. Dryer Shut Down
To shut the dryer down when in manual operation, perform the
following steps in sequence.
a. Set meter roll potentiometer to “000” and lock.
b. Turn the heater switch to “OFF”.
c.
Turn the load auger switch to “OFF”.
d. Turn the unload auger switch to “OFF”.
e. Turn the fan switch to “OFF”.
f.
Turn the system power switch to “OFF”.
Starting the Dryer after a Shut down
The following table is a guideline for restarting the dryer after a
shutdown.
Initial Dry w/
Stabilization
All wet grain, No gradient
established
Shutdown greater than 1 Hours,
gradient established, grain cool
Shutdown less than 1 Hour,
gradient established
Change of plenum temperature
more than -7°C.
Restart w/
Stabilization
Restart
Yes
No
No
No
Yes
No
No
No
Yes
No
Yes
No
The method used for restarting the dryer depends on how long
the dryer has been shut down.
1 - 44
Automatic Batch Control
Note
Two-fan/heater operation is the same as a single fan/heater,
except for controlling and monitoring the second fan and
heater. Operator must set both plenums at the same
temperature.
To start the dryer, turn all
switches to ‘Auto’ and
press start.
Begin automatic batch by
pressing 2.
CONT. FLOW
AUTOBATCH
GRAIN TRANSFER
FINAL DRY
1
2
3
4
Set Date/Time
If the date and time are
correct, press OK (+). If
you wish to change the
date or time, press CHG (-)
and follow the screen
instructions.
01/14/08
02:37:47 PM
ARE THE DATE/TIME
OK(+) OR CHG(-)?
Set Input Moisture
Accept or change the
incoming grain moisture
content.
THE CURRENT INPUT
MOISTURE SET=20.5%
OK(+) OR CHG(-)?
Set Max Roll Speed
The Maximum Roll Speed
will now be displayed. If
MAXIMUM METER ROLL
the speed of the unload
IS SET TO = 50%
matches the capability of
the unload system, press
OK(+).
To change the
OK(+) OR CHG(-)?
maximum meter roll speed
setting press CHG(-) and
follow the screen instructions.
Full Heat or Heat Cool
Select full heat or heat/cool
operation.
The cool
FOR FULL HEAT –
operation
is
always
PRESS 1
controlled by a user
FOR HEAT/COOL –
settable
time
value.
PRESS 2
During full heat operation,
the heaters will remain on
continuously. When heat/cool is chosen, the heaters are turned
off during the cool cycle and the unload cycle.
Set Batch Number
Each batch is assigned
a batch number and
used on the printout.
Set the starting threedigit batch number.
1 - 45
PREVIOUSLY ASSIGNED
BATCH NUMBER = 1
RESUME FROM PREVIOUS?
OK(+)
CHG(-)
Dryer Fill
After
accepting
or
**DRYER NOT FULL**
resetting the settings, the
PRESS
START TO LOAD
operator is prompted to
OR
RESET
TO ABORT
press start to perform an
OR ‘1’ FOR FINAL DRY
initial fill, if necessary,
followed
by
the
immediate starting of the fans and heaters. Pressing reset would
take the operator to the main standby screen.
After pressing start, if the dryer requires filling, the fill will begin.
assembly, the load system will turn off automatically.
Fan and Heater Start-up
STARTING FAN
corresponding heater. The
LCD will display ‘Starting Fan…’ until proper plenum air pressure
is detected and if insufficient air pressure is present, the dryer
will shutdown with a static air pressure fault. Refer to Shutdown
faults section.
HEATER PURGE IN
heater.
The heater will
PROGRESS FOR LOWER
purge for 30 seconds after
which ignition will occur.
HEATER PLEASE WAIT
The flame sensor will then
attempt to detect a flame.
If flame is not sensed in 5 seconds, the dryer will shutdown and
display a Flame Timeout Fault. Refer to Shutdown faults section
On two-fan dryers, the same procedure is followed for the
second fan and heater.
If start is not pressed within
10 minutes, the dryer will
shutdown due to inactivity.
PRESS ANY KEY
1 - 46
The following table provides suggested guidelines for various start/restart scenarios.
Change Dry Time
Dry Cycle
RESTART
All wet grain
Shutdown greater than 6
Hours, grain cool
Shutdown 1 to 6 Hours, grain
warm
Change of plenum
temperature more than -7°C.
Shutdown less than 1 Hour
No
Yes. Possibly lower dry time (Check printer tape).
Yes
Yes
Yes
No. (Check moisture of next batch)
No
Yes
The plenum should now
be adjusted to the
desired
drying
temperature.
Time and/or Temperature Selection
Choose the method of
operation for automatic
batch. If the dryer does
not have the temperature
option installed, the only
option given on this
screen will be the timed
batch option.
PLENUM TEMPERATURE
IS ISET TO 104C
OK(+) OR CHG(-)
GRAIN DISCHARGE BY –
TIME ONLY = ENTER 1
TEMP ONLY = ENTER 2
If TIME ONLY is selected, all functions, dry, cool and unload are
controlled by a time setting.
If TEMP ONLY is selected, the dry function is controlled by a set
temperature with a maximum four-hour batch limit. Upon failure
to reach the set temperature in four hours, the dryer is shut
down. The cool function, if selected, and unload function remain
time controlled.
1 - 47
Set Batch Variables
For the time option,
the time to dry must
now be entered.
BATCH DRY TIME
IS SET TO __MIN.
OK(+) OR CHG(-)?
For the temp option
the
desired
dry
temperature
must
now be entered.
DESIRED GRAIN COLUMN
DRY DISCHARGE TEMP
IS SET TO 52C
OK(+) OR CHG(-)?
If heat cool has been
selected,
the
controller will prompt
the operator to enter
the desired cooling
time.
BATCH COOL TIME
IS SET TO __MIN.
The unload time
must now be set. A
recommended time
has been calculated
off of the maximum
meter roll speed.
BATCH UNLOAD TIME
IS SET TO = __ MIN
RECOMMENDED = __ MIN
OK(+) OR CHG(-)?
OK(+) OR CHG(-)?
After
beginning
operation, any of the
1=CALIBRATE SENSORS
settings listed below
can be altered by
3=DRY TIMES/TMP 4=COOL
pressing the set
5=UNLOAD 6=CONFIG
button.
Changing
time
values
will
affect the next time the operation is performed. Changing the
temperature value will immediately affect the output.
1.
2.
3.
4.
5.
6.
7.
Moisture Calibration Offset
Temperature Calibration Offset
Dry Time
Cool Time
Unload Time
Maximum Meter Roll Speed
Dry Temperature Setting
1 - 48
Drying in Automatic Batch
As automatic batch operation begins drying, the remaining time
or current kernel temp will be displayed.
When the dry cycle is completed, the cool cycle, if running in
heat/cool, will begin. The remaining time will be displayed.
During
unload,
the
average moisture and
current temperature will
be displayed, as shown
here.
UNLOAD TIME = 30 MIN.
MOIST=15.5% TMP=33C
COLUMN TEMP. = 33C
29:59 AVG. MST = 15.2%
Unload Cycle
After unloading the first batch, a display informs the user the
batch is finished and begins the drying operation for the next
batch. A printout is then given showing average temperature
and moisture of the entire batch.
A screen displaying the
next batch number will
come up when the dryer
is ready to begin the next
batch.
Note
READY TO DRY BATCH
NUMBER 2
Please remember to refer back to the parameters printed out by
the printer for each batch number to determine if a change is
required for the next batches or if one of the following has
occured.
1.
2.
3.
4.
The input moisture of the grain changes.
The plenum temperature has been increased or decreased.
A shut down occurred due to a fault.
A drastic change in climate (ambient temperature, winds,
etc).
1 - 49
Grain Transfer
Introduction
Increasingly, operators require the dryer to transfer grain through
it to reach their storage facilities. A mode of grain transfer has
been developed to simplify this process. During grain transfer
the dryer will not run the fans, heaters, or moisture sensing
equipment. All relevant safety circuits are monitored.
Starting Grain Transfer
Press “3” to continue
with the Grain Transfer
mode.
CONT. FLOW
AUTOBATCH
GRAIN TRANS.
FINAL DRY
1
2
3
4
Set the Maximum Meter
Roll Speed. This speed
will be used to transfer
grain as quickly as
possible.
MAXIMUM ROLL SPEED
IS SET TO 50%
The operator is then
prompted to press start
to perform an initial fill, if
necessary.
**DRYER NOT FULL**
PRESS START TO LOAD
OR RESET TO ABORT
OR '1' FOR FINAL DRY
OK(+) OR CHG(-)?
After pressing start, if the dryer requires filling, the fill will begin
(Completely filling the dryer is necessary in order to still monitor
safety functions by the PLC). If the fill time exceeds 45 minutes,
the fill will shut down. Ensure that the dryer is filling correctly
and that sufficient grain is present to fill the dryer. Press start for
another load attempt if necessary. Once the dryer is full,
determined by the dryer’s paddle switch assembly, the load
system will turn off automatically.
After the meter roll speed has been set, and the dryer filled, the
operator will be prompted to press start to begin transferring
grain.
The operator is asked whether the 30-minute “Out of Wet Grain”
timeout is to be used. If
selected, the load system
IS 30 MINUTE OUT
will automatically be shut
OF WET GRAIN
down after 30 minutes of
TIMEOUT DESIRED?
no grain being detected by
YES(+) OR NO(-) ?
the paddle switch. The
unload
system
will
continue to run for another 10 minutes to clean out.
The
grain
transfer
operating
screen
will
display the meter roll
speed, as shown here.
To end the Grain Transfer
mode, press “RESET”.
1 - 50
**GRAIN TRANSFER**
MOIST=16.5% TMP=19C
ROLL ORDER = 50%
TO EXIT PRESS RESET
Functional Maintenance Requirements
Start of Drying Season requirements
At the start of every drying season, the Trantorque screw on
each fan(s) must be checked for proper torque. See Appendix A
in the Installation-Service part of the manual for more
information.
Daily Maintenance requirements
This assumes 24-hour day operation during harvest.
1. Clean foreign material from fan air inlet screen.
2. Sweep off top of exhaust slope where fines may have
accumulated on the outer perforated skins.
3. Visually inspect for an even grain movement along all
perforated panels of the lower outer grain column slope. If
grain in one section is not moving, or it is moving slowly,
check for obstructions in the flow gate area or columns. Pay
particular attention to the area directly under the wet grain
bin, where excessive amounts of fines and foreign material
can accumulate.
4. Perform plenum clean out where fines and foreign material
may have accumulated. Shut the Dryer down. Open rear
access door. Sweep all fines and debris from front of plenum
area to the rear plenum area. Close rear access door and
insert interlock key.
1 - 51
5. Open rear clean out door
6. Operate the fan only by either running it in the Dry Fire mode
or in the manual mode. Continue running the fan until no
more fines / debris come out of the rear clean out.
7. Turn fan off.
8. Reinstall rear clean out door.
9. Sweep fines / debris of discharge chute screen.
1 - 52
10. Remove discharge moisture sensor and clean sensor flag
and copper tube.
Reinstall moisture sensor.
11. Inspect plenum RTD temperature sensor. Clean if necessary.
The RTD is located on the side of the plenum. It is an
aluminum tube that runs the length of the dryer.
RTD Temp
Sensor Wire
12. Restart dryer operation per automatic control or per manual
control
1 - 53
Semi-weekly Maintenance requirements
1. Perform all steps of daily maintenance requirements as
listed in previous section, except step 12, restarting dryer.
2. Open inner and outer unload auger clean out / access doors.
Inner Unload
Auger
Access/Cleanout
Door
3. Inspect unload auger area and meter roll area for
obstructions, fines, and debris. Clean as necessary. Close
inner and outer unload auger clean out / access doors
4. Restart dryer operation per automatic control or per manual
control.
1 - 54
Weekly Maintenance requirements
1. Unload grain from dryer by performing Final Dry in automatic
2. Perform all steps from the Daily and Semi-weekly
requirements except for restarting dryer.
3. Thoroughly inspect grain columns for accumulation of trash
and fines, at peak of inner perforated grain walls, and above
meter roll flow gates.
4. Check tension of load and unload auger drive belts.
5. Restart the dryer per automatic control (Initial Load, Initial
Dry).
End of Season Maintenance requirements
1. After dryer is unloaded for the last time, open all access
doors and panels. Thoroughly clean the entire dryer by
sweeping and using compressed air. Ensure cleaning of the
wet bin trash pan.
Caution
Do not blow compressed air directly into static air pressure
switch.
2. Perform all steps listed in prior to season maintenance
inspection.
3. Reinstall all access panels and doors with one exception.
Leave the Unload Auger clean out doors open for water
drainage.
4. Lock out electrical power.
5. Install a cover on fan inlet screen to keep debris from
entering the fan and to keep the fan from windmilling.
6. Remove discharge moisture
sensor from grain discharge
chute and put into sensor
holder (sensor could be
covered in standing water if
left inside tube).
1 - 55
Year-Round Maintenance requirements
1. Remove fan inlet cover and control box cover. Apply
electrical power.
2. Operate the fan, load auger, unload auger and meter rolls for
10 minutes using the Dry Fire mode (see page 15). This will
redistribute the grease in the motor bearings, auger
bearings, reduction gearbox and meter roll drive train.
3. Remove and lock out electrical power, reinstall covers.
4. Remove Wye strainer on the Liquid pipe train (see picture
below) and clean out all fines. Replace strainer.
1 - 56
Shutdown Faults
Shutdown Faults
Upon fault detection, whether in Automatic or Manual operation,
the LCD will display which fault and/or faults caused the
shutdown.
Warning
If necessary, when a fault occurs, power must be disconnected
from the dryer and gas must be turned off before correcting the
fault. If at all unsure, contact your Sukup dealer. Be cautious of
other people or objects around the dryer.
Upon shutdown, the dryer unload may be allowed to run an
additional period of time to clear the unload auger of grain. To
change this amount of time, see Out of Wet Grain Fault.
All fault messages are latched, meaning that they will remain on
screen until the operator acknowledges the message by pressing
the reset key. This is useful in the event of a nuisance trip that
may have otherwise reset by the time the operator realizes that
the dryer has shut down. A summary of all on-screen faults
follows:
Grain Discharge Chute / Unload Auger Warning
Possible Problems
Grain Discharge lid
opened
Grain overflow
discharge
DISCHARGE CHUTE OPEN
OR UNLOAD
AUGER STOPPED
PRESS ANY KEY
Possible Solutions
Return lid to a closed position
of
Slow maximum roll speed. (Grain may over dry)
Insure that take-away system is operating properly.
Lower plenum temperature, maximum roll speed was achieved.
Indicated by asterisk on screen.
Broken or jammed
unload auger
Check unload auger for broken flighting or foreign material.
Check motor and belts.
Rear Access Door Open
Possible Problems
Interlock key removed from rear door switch
REAR ACCESS DOOR IS
OPEN--CHECK DOOR AND
INTERLOCK SWITCH
PRESS ANY KEY
Possible Solutions
Replace Key
1 - 57
Shutdown Faults
Housing High Temperature Alarm
Possible Problems
Housing temperature has
exceeded 93°C
HOUSING HIGH TEMP
INSPECT HTR HOUSING
AND/OR TEMP SETTING
Possible Solutions
Manually reset switch in 5X5 box of proper heater after
temperature has gone down. Refer to heater operation
section.
Check for plugged fan grill.
Check for defective MOD valve.
Vaporizer High Temperature Alarm
Possible Problems
Vapor coil exceeded 60°C
VAPOR HIGH TEMP
ADJ. VAPORIZER COIL
AND CHK FUEL SUPPLY
Possible Solutions
Manually reset the O/T switch in the 2x4 box located on
the vaporizer pipe train.
Supply tank may be low. Fill tank
Vaporizer misadjusted, readjust, and refer to the heater
operation section.
Fan airflow obstructed. Check for obstructions.
Plenum High Temperature Alarm
Possible Problems
Plenum temperature
163°C
exceeded
PLENUM HIGH TEMP
INSPECT PLENUM AREA
AND/OR TEMP SETTING
Possible Solutions
Check plenum by placing back of hand near rear door,
checking for heat. If ok, remove interlock key and
assess problem.
Plenum temperature set too high (adjust setting)
COLUMN HIGH TEMP
POSSIBLE CLOG OR
TEMPERATURE SETTING
Grain Column High Temperature Alarms
Possible Problems
Column temperature
93°C (200°F)
exceeds
Possible Solutions
Check for stagnant column that has overheated.
Unplug if necessary.
Lower plenum temperature if no columns are plugged.
1 - 58
Shutdown Faults
Motor Thermal Overload Alarm
Possible Problems
Motor overload occurred for fan,
load or unload auger, or auxiliary
device.
MOTOR OVERLOAD ALARM
CHK THERM OVERLOADS
IN POWER DIST. BOX
Possible Solutions
Check overload devices in power and auxiliary box for
fault.
Check faulted device for possible
overheating conditions caused by an obstruction in
the auger or a bad bearing in the motor or auger.
Output Sensor Not Found
MOISTURE SENSOR
NOT FOUND SHUTDOWN
PRESS ANY KEY
Possible Problems
Current moisture or temperature
reading is outside the boundaries
of normal operation.
Possible Solutions
Check sensor calibration adjustments.
Check if motor is rotating.
Check if sensor is placed in operating position.
Meter Roller Failure
Possible Problems
Meter rolls have stopped turning
SYSTEM SHUTDOWN
METER ROLL FAILURE
CHECK PROX OR I/O
PRESS ANY KEY
Possible Solutions
Check for obstruction in meter rolls
Check chain linkage for broken chain
Low Static Air Pressure (located on dryer)
LOW STATIC PRESSURE.
CHECK FAN/AIR SWITCH
PRESS ANY KEY
Possible Problems
Internal plenum pressure could
not be reached upon start-up.
Possible Solutions
Dryer is not filling.
operation.
(Check load auger for proper
Internal plenum pressure was lost
during operation.
Wet bin has run out of grain and allowed inner plenum
to release air pressure before out of wet grain time
out occurs.
Air switch out of calibration
Contact your Sukup Dealer to adjust air switch.
1 - 59
Shutdown Faults
Out of Wet Grain
OUT OF WET GRAIN
PLC 10 MIN. TIMEOUT
FOR RESTART PRESS 1
FINAL DRY
PRESS 2
(Dryer is not full)
Possible Problems
Wet bin has been emptied
Possible Solutions
Run Final Dry if end of season
Fill device has failed
Check all fill devices
Dryer unloading faster than filling
Adjust load auger secondary fill time delay off. Refer to
instructions on below.
Unload Auger Time Delay Off and Secondary Auxiliary Time Delay Off Adjustment
If you desire to have your unload system have a timed delay off
function, (To clear augers so as not to heavily load them on
restart), this is provided. This feature is adjustable from 0 to 60
seconds of “Off Delay”.
If you desire to have your second fill auxiliary have a timed delay
off function, (To allow additional grain to unload from bin before
turning off secondary fill) this is also provided. This feature is
adjustable from 0 to 20 seconds of “Off Delay”.
Note
The unload and fill system will still shut off immediately under the
following fault conditions. 1.) Rear Door open. 2.) Grain
discharge chute open. 3.) Motor Overload.
1. Gain access to the inside of the control box by opening
the front door and the inner panel.
2. Locate the Programmable Logic Controller, (PLC), which
is on the middle of the back panel. Refer to component
location section.
3. Open the access door by lifting up on the right side
(hinged on left). (Refer to picture below)
4. There are two adjustable potentiometers located at the
top of opening (see picture below).
Timed Unload
Adjustment
0 to 60
seconds
Timed Load
Adjustment 0
to 20 seconds
1 - 60
Shutdown Faults
The potentiometer on the left side is the adjustment for
the timed unload, the right is for the adjustment of the
secondary fill auxiliary. Both are factory pre-set to 0.
To change the setting to a timed delay, rotate the potentiometer
clock-wise, (see the diagram above) to the desired amount of
“Delay Off” time.
5. Close the access door on the PLC.
6. Close control box inner door.
DRYER FILL SHUTDOWN
CORN NOT UNLOADING
15 Minute without Fill Timeout
(Dryer is full)
PRESS ANY KEY
Possible Problems
Dryer must fill at least every 15
minutes when unloading for
Continuous Flow or Automatic
Batch
Possible Solutions
Unload Auger is turned off
Broken unload or meter roll
SYSTEM SHUTDOWN
2 HR DRY LIMIT
2 Hour Maximum Batch Timeout
PRESS ANY KEY
Possible Problems
Batch temperature setting has not
been reached in 2 hour period
Possible Solutions
Heat set too low (Increase heat)
Temperature set too high (Decrease temperature)
Contact Dealer if problem continues
Defaults Set
Possible Problems
Battery backed data is corrupted
DEFAULTS SET
CURRENT VALUES
OUT OF RANGE.
PRESS ANY KEY
Possible Solutions
If displayed multiple times when starting the dryer,
contact your Dealer for battery backed data part
replacement.
1 - 61
Shutdown Faults
Air Timeout
This will occur when the
fan is started and static air
pressure is not detected
within 5 seconds.
Heater Fault
This will occur on upper
heater start if flame is not
sensed within 5 seconds
LOWER AIR TIMEOUT
(PLC) CHECK LOWER
FAN AND AIR SWITCH
PRESS ANY KEY
UPPER HEATER FAULT
PLC 45 SEC TIMEOUT
PRESS ANY KEY
Out of Grain timeout
This will occur on initial
dryer loading if dryer does
not fill within 45 minutes
1 - 62
LOADING TIMEOUT
EXCEEDED - DRYER IS
NOT FULL OF GRAIN
PRESS ANY KEY
Appendix A
Appendix A – Auxiliary Motor Operation and Installation
Auxiliary controls can be set up in a number of configurations.
Three control circuits exist, one for the auxiliary unload and two
for the auxiliary fill. For the unload, a single control circuit is
used to start an external unload device at the same time as the
unload of the dryer. The auxiliary fill operations have two control
circuits. When turning the fill of the dryer on, a delay of 5
seconds exists between the start of each motor, the dryer fill
motor, the first auxiliary load, and the second auxiliary load. The
fill paddle will send a signal to the controls that the dryer is nearly
full, a switch is triggered to turn the second auxiliary load off.
This operation can be delayed by up to 20 seconds with a simple
setting on the PLC, explained in detail on page 60. Upon
receiving the signal that the dryer is completely full, all auxiliary
motors are shut off. If the second auxiliary is within its delay
period, it will shut off when the dryer is full.
Caution
Auxiliary components should
not be installed in the power
box, only in auxiliary box
located above the power box.
Installing the components
When installing the components
into the box, the starter/protector
is mounted on the top DIN rail
and the contactor is mounted on
the middle DIN rail directly
below.
rter/Protectors
If the components kits are
purchased
from
Sukup
Manufacturing,
the
starter/protector and contactors will be pre-wired together.
Contactors
Wiring the components
trip
Three sets of wires must be installed for the auxiliaries:
1. Control wiring, including jumpers to terminal 3 across the
terminal strip
• Wire 5 – Auxiliary load one (nearest the dryer)
• Wire 9 – Auxiliary load two
• Wire 15 – Auxiliary unload
2. Fault protection wiring
• Wire 18 – Fed from terminal into first auxiliary N/O
contact
• All contacts are then wired in series
• Wire 49D – Taken from last contact to terminal strip
3. Power wiring
• Installed similar those located in power box
• Direct wire leaving space from transformer as the
transfer heats up slightly during operation.
Caution
If contacts installed are not purchased from Sukup
Manufacturing, fault protection must be installed. Contact
Sukup Manufacturing to purchase these components.
1 - 63
Appendix A
1 - 64
Appendix A
1 - 65
15
18
21
24
27
30
60% Meter
Roll
70% Meter
Roll
80% Meter
Roll
90% Meter
Roll
100% Meter
Roll
12
40% Meter
Roll
50% Meter
Roll
9
6
20% Meter
Roll
30% Meter
Roll
3
12 Foot
1 Module
10% Meter
Roll
Dryer
1 - 66
The above chart is an approximation only!
40.6
36.6
32.5
28
24
20
16
12
8
4
16 Foot
1 Module
51
45.7
40.6
35.6
30
25
20
15
10
5
20 Foot
1 Module
61
55
49
42.7
36.6
30
24
18
12
6
24 Foot
1 Module
71
64
57
50
42.7
35.6
28
21
14
7
28 Foot
1 Module
61
55
49
42.7
36.6
30
24
18
12
6
16 Foot
2 Module
76
68.6
61
53
45.7
38
30
23
15
7.6
20 Foot
2 Module
91
82
73
64
55
45.7
36.6
27
18
9
24 Foot
2 Module
76
68.6
61
53
45.7
38
30
23
15
7.6
20 Foot
3 Module
91
82
73
64
55
45.7
36.6
27
18
9
24 Foot
3 Module
Appendix B
Appendix B – Tonnes per Hour Information (Corn)
38
Approximate Tonnes per Hour Information for each Module
Appendix C
Appendix C – Dryer Startup Checklist
Following are the minimum operator actions required to successfully start the Dryer
Warning
Augers, fans, and heaters will start with out warning at the appropriate
times. Please use caution around dryer.
1. Open the power box and ensure that all internal breakers are turned
on. Close the door to the power box, close the latch and turn the
master disconnect “ON”.
2. On the power box, pull the Emergency Stop button out. It should
illuminate red.
3. On the control box front panel, turn system control switch to the
“COMPUTER” position. Turn all other front panel switches to
“AUTO”.
4. The Display should show “SYSTEM READY”. All faults must be
cleared before the dryer can start. Press “START” if there are no
faults.
5. The display will give the options of selecting Continuous Flow “1”,
Automatic Batch “2”, or Grain Transfer “3”. Press “RESET” to abort
dryer startup.
For Continuous Flow
Initial Dry
•
Operator must select Initial Dry, Restart & Stabilization, or Restart.
•
Date/Time, Input Moisture Set, Output Moisture Set, Maximum
Roller Speed, Minimum Roller Speed must be accepted or changed
A 71ºC plenum temperature is required for an Initial Dry
It is HIGHLY RECOMMENDED that the operator is at the dryer to
verify the grain moisture accuracy once sampling has started and
adjust if necessary.
If an output sensor moisture or temperature calibration adjustment
is necessary, while the dryer is sampling, press “SET” and select
OUTPUT MOIST to change the moisture or TEMP CAL ADJUST to
change the temperature. Once the required calibration adjust has
been entered, the dryer will recommence with the moisture
sampling. Allow 30 minutes for the dryer to stabilize before
repeating this procedure.
•
•
•
Restart & Stabilization
•
•
•
Restart
•
•
Date/Time, Input Moisture Set, Output Moisture Set, Maximum
Roller Speed, Minimum Roller Speed must be accepted or
changed.
Plenum temperatures and meter roll speed must be accepted or
changed.
Dryer will run through stabilization. This choice is recommended if
dryer has been off for longer than three (3) hours and the grain in
the dryer is partially dry.
If dryer has been off for less than three (3) hours, it is
recommended that this option be used.
If dryer is off for more than three (3) hours, the operator can choose
to use stabilization or can skip that option.
1 - 67
Appendix C
For Automatic Batch
•
•
•
•
For Grain Transfer
•
•
If user has the “Temperature Option”, the user must choose if the
dryer will run in Time Setting or Temperature Setting.
When the Time Option is chosen, user must decide the times for
heating and cooling of the grain.
If the Temperature Option is present and chosen, user must decide
the temperature for heating and time for cooling the grain.
When the dryer unloads the grain, the meter rolls will run at the
maximum meter roll setting given by the operator.
Dryer operator must decide the maximum meter roll speed for this
option.
Do not exceed unload system capability.
1 - 68
Appendix D
Appendix D – Heater Operations (CE)
3 Wire Air Switch without Low Pressure Switch
The following parts will be found on either the gas pipe train or in the
heater box.
•
•
•
•
•
•
•
•
•
•
•
Burner Operation
Automatic Valve Proving Control – LDU11 – heater box
Valve Proving Pressure Switch – low and high – between the
upstream and downstream valves on the pipe train
CE Gas Burner Control – LME21.350A1 – heater box
High Pressure Switch – pipe train – after downstream valve
Housing High Temperature Switch – 5 x 5 box on fan barrel
Differential Air Switch – heater box
Vapor Over-Temp Switch (on LP systems) – pipe train
Ignition Transformer – heater box
Main – Upstream Gas Valve – pipe train
Blocking – Downstream Gas Valve – pipe train
Electronic Modulating Gas Valve (EMOV) – pipe train
On heaters not requiring the LDU11 valve proving control (28” heater),
once the burner control relay is energized, 120VAC must flow through
the housing O/T, and the high-pressure switch, before being applied to
the CE heater control unit (LME21.350A1).
On heaters requiring the LDU11 (valve proving control), once the main
power is being supplied to the dryer, 120 VAC is supplied directly to the
LDU11.
The LDU11 valve proving control goes through two valve tests. During
TEST 1, the downstream valve is energized for 4 seconds, evacuating
all of the gas pressure between the upstream and the downstream
valves. This test is used to determine if an increase in pressure is
detected between the two valves by the valve proving pressure switch.
If an increase in pressure is detected, TEST 1 will FAIL, and lockout will
occur. The valve proving control can be reset by pressing the clear
plastic on top of the unit, or by pressing the reset button on the control
box keypad. During TEST 1, a voltage is output from terminal 15 of the
LDU11. If no leaks are present, pressure will remain low and the
voltage will pass through the N.C. contacts and be present on terminal
16 of the LDU11. If TEST 1 has not failed, TEST 2 will begin.
In TEST 2, the upstream valve is energized for 4 seconds, which
pressurizes the piping between the two valves. If a decrease in
pressure is detected by the valve-proving pressure switch, TEST 2 will
fail and lockout will occur. The valve proving control can be reset by
pressing the clear plastic on top of the unit, or by pressing the reset
button on the control box keypad. During TEST 2, a voltage is again
output from terminal 15 of the LDU11. If no leaks are present, pressure
will remain high and the voltage will be present on terminal 17 of the
LDU11. The valve-proving test will be initiated each time main power is
supplied to the dryer (not when turning the control system on and off, or
going between automatic and manual).
If both test 1 and 2 pass, 120 VAC is output from terminal # 6 of the
LDU11. If no faults have been detected by the dryer control system,
then, at the proper time, the control system will call for burner operation
1 - 69
Appendix D
by closing a set of N.O. contacts. This voltage must flow through the
housing high temperature switch, and the high-pressure gas switch.
This voltage is then supplied to terminal # 12 of the CE Burner Control
Unit (LME21.350A1).
Upon supplying voltage to the CEBC, the following ignition sequence
takes place.
Ignition Sequence
1. 120 VAC is supplied to terminal # 12 of the LME21.350A1 (CEBC).
2. A 2.5 second wait time begins.
3. The fan ON control signal is enabled. This voltage is output on
terminal # 3 of the LME21.350A1, which checks for this same
voltage on terminal # 6, which comes from a N.C. contact in the
differential air switch. This verifies that the fan is off and no airflow
is being detected.
4. Within 5 seconds of the fan ON signal being enabled, the differential
air switch must close a set of N.O. contacts, which applies this
same voltage to terminal # 11. This indicates that air movement
has been detected. If this signal is not detected, the unit will go into
a fault mode.
5. Upon receiving a voltage on terminal #11, the unit goes into a 30
second pre-purge time delay.
6. Following the purge time, the ignition transformer is energized.
After a 2 second pre-ignition time, the fuel valve is opened.
7. The ignition transformer remains energized for an additional 4
seconds. (total of 6 sec.)
8. Flame must be detected within 5 seconds, or the unit will go into a
fault mode.
9. The flame signal must be maintained for an additional 10 seconds
before opening other fuel valves.
Loss of flame will cause the CEBC to lockout. The unit may be reset by
pressing the small clear plastic button on the front of the unit for
approximately 2 seconds, or the reset button may be pressed on the
keypad located on the front of the control box. 3 attempts will be
allowed for burner ignition. On the 4th attempt, the unit will be locked
out and power must then be cycled to the unit before the ignition
sequence may be re-initiated.
The electronic modulating valve is in the low fire position for the ignition
sequence. After flame has been established, the main control system
on the dryer will send a control signal to the valve, which will open or
close the valve to maintain a desired temperature set point which is set
by the user.
Note
CEBC = CE Burner Control Unit
This is a general description of burner operation. For specific details of
the LME21.350A1, please refer to the Siemens bulletin # CC1N7101en.
A more detailed explanation of the above is as follows:
1. The Fan has been turned ON.
2. 120 VAC is sent to the heater board by energizing the respective control
relay.
• CR3 – Upper Heater
• CR6 – Lower Heater (Located in the Power Box)
1 - 70
Appendix D
3. A dry contact on each of the relays (CR3 & CR6), when closed, will
send a 24VDC signal to the PLC, indicating that 120VAC has been
applied to the heater board.
4. The 120VAC must pass through a 3 Amp circuit breaker located in the
Power Box.
• F9 – Upper Heater – Wire # 1D
• F10 – Lower Heater – Wire # 1I
NOTE: On dryers built in 2007 and after, the above wires were
switched. Wire # 1D – Lower Heater, Wire # 1I – Upper Heater
5. After 120 VAC is applied to the heater board, a 25 second purge time
begins. This purge time is designed into the heater board circuitry.
6. After the purge cycle is complete, 120 VAC is sent out by the heater
board on wire # 9, to energize the ignition transformer and on wire # 10
to energize the liquid solenoid valve, the vapor solenoid valve, and the
flame sense relay. The flame sense relay sends a signal to the PLC
indicating that the heater ignition sequence has started.
• 0CH10 – Upper Heater
• 1CH10 – Lower Heater
7. The RED light on the side of the Heater Box is ON during the ignition
process.
8. An external 60-second timer is also energized at this time (on pre –
2006 dryers).
9. The ignition transformer is energized for 6 seconds and then turned off.
If a flame has not been detected within 5 seconds, the gas valves are
shut OFF and the heater board goes into a lockout condition. The flame
sense relay is de-energized, losing the 24VDC signal to the PLC. The
dryer is then shut down with a flame failure fault.
10. On the electronically controlled modulation valve, the valve remains in
the low fire position for 20 seconds after the flame has been proven.
The valve then begins to slowly open until the programmed set point
has been reached.
11. At any time, if the flame sense signal is lost for 4 seconds, the heater
board will turn OFF the gas valves and go into a lockout condition. The
Flame Sense relay is also de-energized, interrupting the 24VDC signal
being sent to the PLC. This causes a flame failure fault to occur and
the dryer is shut down.
1 - 71
Appendix E
Appendix E – Dan-Corn Heater Troubleshooting Guide
38” / 44” – Fan / Heater
1. Turn on the main power. The LDU11 (valve proving) should begin
rotating.
2. Test 1 releases pressure between the upstream (main) valve and
the downstream (blocking) valve.
3. During test 1, the yellow light on the downstream (blocking) actuator
will turn on for 4 seconds.
If the test fails, the orange light on the front of the LDU11 will turn
on. The test failure is most likely due to a leak. If a leak is not
found, a pressure gauge may need to be installed to verify. After
being repaired, press the clear plastic window on the front of the
LDU11, or press reset on the keypad, and the next test will begin
after rotating to the test 1 starting position.
4. Test 2 pressurizes the piping between the upstream (main) and the
downstream (blocking) valve.
5. During test 2, the yellow light on the upstream (main) valve will turn
on for 4 seconds. The liquid valve will also be energized at this
time. If the test fails, the orange light on the front of the LDU11 will
turn on. The test failure is probably due to a leak. If a leak is not
found, a pressure gauge may need to be installed to verify. After
being repaired, press the clear plastic window on the front of the
LDU11, or press reset on the keypad, and the next test will begin
after rotating to the test 1 starting position.
6. If the valve proving test was successful, 120 VAC should now be
present on terminal # 6 of the valve proving unit. On the 38” / 44”
heaters, this wire number will be 1E. (28” heaters do not use the
valve proving unit)
All Burners
NOTE:
If this is a 38” / 44”, the LDU11 valve proving - test 1 & 2 - must have
been successfully completed before proceeding.
1. Wire numbers for both the 28” heater, and the 38” / 44” heater are
listed in the following paragraphs.
2. If the CE burner control unit (LME21) does not display an orange or
red light, measure for 120 VAC at the housing O/T switch on
terminal #1 (if 28”), or terminal # 1E (if 38” / 44”).
3. An orange light indicates the burner sequence has begun – red
indicates a fault condition. If 120 VAC is not present, measure both
sides of the housing O/T switch. Wires 1 and 1A (on 28”), 1E and
1F (on 38” / 44”). If voltage is present on one side of the housing
O/T switch, but not the other side, the housing O/T switch is tripped
out or defective. Try pushing the reset button and re-check for
voltage.
4. Once 120 VAC is present on both sides of the housing O/T switch,
measure wire # 1A (on 28”) or 1F (on 38” / 44”) at the high pressure
switch. If 120 VAC is not present, check the wiring between the
housing O/T switch and the high pressure switch. If 120 VAC is
1 - 72
Appendix E
present on wire # 1A (on 28”) or 1F (on 38” / 44”), measure wire 1B
(on 28”) or 1G (on 38” / 44”) for 120 VAC. If voltage is not present,
the high pressure switch is not adjusted properly or is defective.
(the contact remains closed, unless the gas pressure exceeds the
setting of the pressure switch)
5. If 120 VAC is measured on 1B (on 28”) or 1G (on 38” or 44”), but
not measured on wire # 1D (on 28”) or 1I (on 38” / 44”), go to the
power box and check the heater control relay (CR3 – Lower CR6 Upper) and the circuit breaker for 120 VAC through both
components. Be sure that the control system is calling for heat, and
the circuit breaker has not tripped.
6. If voltage is measured on terminal # 1D (on 28”), or 1I (on 38” / 44”),
the LED on the front of the CE burner control unit will turn on. If the
unit had not previously locked out, then the LED should be orange
in color. If the indicating light is red, press the clear plastic reset
button on the front of the unit (for 2 seconds) or press the reset
button on the keypad. The red light will go out for a few seconds
and come back on with an orange color.
7. The fan should be running at this time.
8. When the orange light comes ON, use a voltmeter to measure 120
VAC on terminal #3 (FO) of the LME21 burner control unit.
9. If 120 VAC is present on terminal # FO, both air switch solenoids
should energize. If the air switch solenoids do not energize, and the
light on the front of the LME21 burner control unit is orange, the
most likely cause would be the differential air switch contact not
being in the closed position when the air switch solenoids were first
energized.
10. Shortly after both air switch solenoids energize, the 120 VAC will
shift (on the air switch contacts) from terminal # 6 to terminal # 11.
After the air switch contact has closed, measure for 120 VAC on
terminal # 11. If no voltage is present and the fan is running, the
venturi is connected backwards, or the air switch needs to be
adjusted. (turn the adjustment screw all of the way out and turn
back in 1 full turn)
11. The yellow light will remain ON (steady) while waiting for the air
switch to activate. After approximately 20 seconds, the light will
change to red and will not attempt burner ignition. If the air switch
did close the contact, 120 VAC can be measured on terminal # 11.
12. After a short purge time (and after 120 VAC was measured on
terminal # 11), the yellow light will now begin to flash. At this time,
the ignition transformer will energize, followed by the gas valve.
Within 1 – 2 seconds, if flame is sensed, the LED will turn green
and remain ON.
13. If flame is not detected, check for ignition, and gas supply
to the burner. Also, a bad ground will prevent flame from
being detected.
1 - 73
Appendix F
Appendix F – Explanation of DanCorn Heater Box Components
Components:
1.
2.
3.
4.
5.
6.
7.
1 ea
1 ea
2 ea
3 ea
1 ea
1 ea
1 ea
LME.21 - CE BURNER CONTROL UNIT
LDU11 - CE VALVE PROVING UNIT
ASCO SOLENOIDS (2 ea - used with the differential air switch)
ICE CUBE RELAYS - RR, IR, FSR
CE DIFFERENTIAL AIR SWITCH - 3 – WIRE
IGNITION TRANSFORMER (controlled directly by the LME.21)
RED INDICATING LIGHT
Reset Relay – (RR) CONTACTS: RR1 & RR2
RR1 – Resets the LME.21 (heater control unit) - Terminal #8 (wire #57) is connected to
terminal #2).
RR2 - 28” (RR2A, RR2B) When the RESET button is pressed on the keypad, the liquid
valve opens to pressurize the pipe train in the event that a low pressure switch is included
on the pipe train.
RR2 - 38” / 44” - Resets the LDU11 (valve proving unit) by applying 120 VAC to terminal
#18 (wire #65).
Isolation Relay – (IR) CONTACTS: IR1, IR2, & IR3
IR1 – 28” IR1 is closed when the main and blocking gas valves are energized, allowing
the flame sense signal back to the dryer control system. The FSR interrupts the signal if
no flame is sensed.
IR1 - 38” / 44” Separates the LDU11 from the reset signal, if the valve proving unit test 1
and 2 were successful.
IR2 - Separates the LDU11 alarm output from the LME.21 alarm output.
IR3 – This contact is closed if the valve proving unit test 1 and 2 were successful. Closing
this contact allows a voltage to be sent back to the dryer control system indicating that no
burner faults exist. At this point, contact FSR will open if no flame is sensed.
Flame Sense Relay - (FSR) CONTACT: FSR1
FSR1 - If this N.C. contact opens (during burner operation), the flame sense signal is lost,
and a fault will be detected by the dryer control system and the dryer will be shut down
(the burner would already be shut down by the LME.21 Burner Control Unit).
Air Switch
The air switch has 3 colored wires attached to an internal set of contacts. BLUE, RED,
and BLACK.
The RED # 6 wire is connected to the N.C. contact.
The BLACK # 11 wire is connected to the N.O. contact.
The BLUE # FO wire is the common connection for the N.O. and N.C contacts.
Red Indicating Light
The RED indicating light will illuminate when the gas valves are energized.
ASCO Solenoid Valves (2 ea)
The solenoid valves are energized when the FAN ON signal is present on terminal #3,
(wire #FO) of the burner control unit (LME.21). The solenoid valves prevent the
differential air flow switch from sensing air flow, except, when the fan is turned on by the
LME.21 Burner Control Unit.
1 - 74
Notes
1 - 75
Appendix G
Single Fan Ladder Diagrams
MAIN DISCONNECT SWITCH
MAIN DISCONNECT
SW ITCH
1
2
3
POW ER DIST
BLOCK
FUSE F1
3 AMP
460 VOLTS
FUSE F1
3 AMP
FUSE F2
3 AMP
FUSE F2
3 AMP
H3 H2
H4
H1
H1
H3 H2
H4
4
CONTROL TRANSFORMER
PRI-230V / 1 PHASE
SEC-120V / 1 PHASE
CONTROL TRANSFORMER
PRI-460V / 1 PHASE
SEC-120V / 1 PHASE
X2
X1
2
2
X1
X2
FUSE F3
3 AMP
5
E-STOP
6
PLC COM
10CH02
1
PLC OUT
10CH02
10CH02
33
1
7
SYSTEM
CONTROL
MOC
1
8
SWITCHED
AC CR1
33
MOV
91.6(6)
22
22
OOX
F6 C.B.
.5 AMPS
23
POW ER
TO PLC
F7 C.B.
.5 AMPS EMI FILTER
25
9
+5 & +15VDC
POW ER SUPPLY
22
1
+24 VOLT DC
POW ER SUPPLY
XOO
25
26
1
10
SWITCHED
AC CR1
3
11
AUO/MAN CR2
26
XOO
NOTE #2
PLC COM
12CH00
12CH00
3
12
91.4(9)
91.10(8)(9)
91.10(10)(11)
MOV
24
XOO
91.1(7)
91.1(11)
91.9(7)(8)
LOAD SWITCH
MO A
PLC OUT
12CH00
32
LOAD M2
32
6
91.3(12)
91.4(3)
91.9(9)
91.11(1)(2)(3)
XOO
MOV
I/O K1 I/O F1
I/O J2
I/O J2
RELAY FUSE
PIN 1
PIN 2
86
13
OOX
NOTE 2
RC SNUBBER
1
3
2
24
Title:
PORTABLE DRYER: DAN-CORN SINGLE
FAN & HEAT: 120 VOLT CONTOL
Author: Sukup Mfg.
Date: 08/07
Revision: 1-10-08
Sheet: 91.1
1
3
UNLOAD
SWITCH
24
2
MO A
UNLOAD M3
10
1
91.3(12)
91.5(5)
91.9(10)
91.11(4)(5)
91.11(6)(7)
24 XOO
MOV
CR UNLOAD
91.2(12)
87
1
2
CR
UNLOAD
87
91.2(2)
10A
91.2(11)
91.9(17)(18)(19)
OOX
I/O J2
PIN 3
3
I/O K2 I/O FUSE
RELAY F2 .25A
3
NOTE 2
I/O J2
PIN 4
METER ROLL
CR5
91.9(4)(5)(6)
91.9(19)
91.10(3)(4)
FAN SWITCH
87
MO A
FAN M5
RC SNUBBER
11
24
4
91.2(4)
91.3(12)
91.11(8)
XOO
I/O J2
PIN 5
3
I/O K3 I/O FUSE
RELAY F3 3.15A
I/O J2
PIN 6
88
MOV
HOUR METER
88
5
OOX NOTE # 2
RC SNUBBER
HEATER
SWITCH
M OA
I/O J2
PIN 7
6
7
I/O K4 I/O FUSE
RELAY F4 3.15A
3
24
I/O J2
PIN 8
CR-M 5
OR M 5
12
91.2(8)
91.2(9)
91.9(1)
91.4(8)
NOTE #1
91.11(10)
XOO
89
HEATER CR3
13
89
RC SNUBBER
OOX
WIRE NUMBERS
B, C, D, FOR 28"
G, H, I, FOR 38"/44"
8
FROM THE HEATER
CONTROL BOX
HEATER
CR3
1C
1B
F9 C.B.
3 AMP
LOCATED IN POWER BOX
TO THE HEATER
CONTROL BOX
SEE DRAWING 91.12
WORK LIGHT
SWITCH
9
1D
WORK LIGHT
RELAY
CR11
MO A
1
19
XOO
10
3
3
PLC COM
10CH03
10CH03
11
1
12
OOX
NOTE 2
PLC OUT
10CH03
CR UNLOAD
31
31
91.6(7)
MAIN GAS SOLENOID
NOTE 3
1
91.2(2)
91.9(17)(18)(19)
3
3
(only on NG single fan)
Title:
2
PORTABLE DRYER: DAN-CORN SINGLE
FAN & HEAT: 120 VOLT CONTROL CONT.
Author: Sukup Mfg.
Date: 08/07
Revision: 1-10-08
Sheet: 91.2
+24 VDC
18
DC COMMON
95
INPUT 0CH
95
COM
REAR DOOR
0CH00
18
1
36
36
0CH01
2
SPARE
VAPOR HIGH LIMIT
18
3
0CH02
37
37
0CH03
CONNECT #18 TO INPUT IF NOT USING THE HOUSING HIGH LIMIT
4
18
18
PLENUM HIGH LIMIT
18
5
6
7
0CH04
39
39
RIGHT COLUMN HIGH LIMIT
18
40
40
LEFT COLUMN HIGH LIMIT
18
41
41
0CH05
0CH06
0CH07
GRAIN DISCHARGE CHUTE
18
42
8
42
STATIC AIR PRESSURE SWITCH
18
9
0CH08
43
43
LOWER PADDLE
18
10
0CH09
44
44
FLAME RELAY
18
11
0CH10
45
45
MOTOR OVERLOAD MOTOR OVERLOAD
LOAD M 2
UNLOAD M 3
49D
12
+
+
18
49
+
+
18
NOTE 4
49E
MOTOR OVERLOAD
FAN M 5
49F
0CH11
49
Title:
P O R T A B L E D R Y E R : D A N -C O R N
S IN G L E F A N & H E A T P L C IN P U T S
CHANNEL 0
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.3
+24 VDC
18
DC COMMON
95
INPUT 1CH
95
FAN ON
18
46
1
I/O J2
PIN 11
18
2
I/O K6 I/O FUSE
RELAY F6 .25A
1CH00
46
I/O J2
PIN 12
51
1CH01
DRYFIRE
LOAD ON M2
18
47
3
I/O J2
PIN 9
18
4
I/O K5 I/O FUSE
RELAY F5 3.15A
COM
51
1CH02
47
I/O J2
PIN 10
52
1CH03
RESET
52
1CH04
5
UPPER PADDLE
18
6
7
1CH05
53
53
HEAT ON
18
48
48
1CH06
AUTO/MAN
18
8
54
1CH07
54
1CH08
9
1CH09
10
1CH10
11
1CH11
12
18
Title:
CHANNEL 1
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.4
DC COMMON
95
+24 VDC
18
INPUT 2CH
18
1
COM
2CH00
2
2CH01
CONNECT #95 TO THE INPUT IF NOT USING THE AIR SWITCH
3
95
95
2CH02
4
UNLOAD ON M3
95
5
2CH03
94
94
92
92
93
93
96
96
LEFT METER ROLL
PROXIMITY SWITCH
2CH04
6
RIGHT METER ROLL
PROXIMITY SWITCH
2CH05
7
UNLOAD AUGER
PROXIMITY SWITCH
2CH06
8
2CH07
9
2CH08
10
2CH09
11
2CH10
12
LOAD SWITCH
UNLOAD SWITCH
95A
13
FAN SWITCH
95B
2CH11
95C
95
10
+
18
+
11
+
95
+
12
TO PLC
INPUT
BROWN
+24VDC
BLUE
DC COMMON
BLACK
SIGNAL
PROX SWITCH
Title:
CHANNEL 2
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.5
OUTPUT 10CH
1
2
3
4
5
6
7
3
COM
21
10CH00
COM
10CH01
MODEM (if used)
+ 55 +
56
MODEM (if used)
+ 56 +
33
10CH02
87
10CH03
HEATER TIMER SOLENOID
(older models only)
+
+
21
55
1
COM
(120 VAC)
SWITCHED AC
+ 3
+
+
120 VAC
1
+
SWITCHED AC
COIL CR1
2
TIMED UNLOAD
(OFF DELAY set by user)
+ 87 +
DC COMMON
8
95
COM
9
10CH04
10
10CH05
11
10CH06
12
10CH07
+
95
+
1A
1A
REAR DOOR
I/O J15 PIN 1
14A
14A
AUTO/MAN
I/O J15 PIN 14
3A
3A
VAPORIZER HIGH LIMIT
I/O J15 PIN 3
4A
4A
HEATER HOUSING HIGH
LIMIT I/O J15 PIN 4
Title:
S IN G L E F A N & H E A T P L C O U T P U T S
CHANNEL 10
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.6
OUTPUT 11CH
DC COMMON
1
95
COM
2
11CH00
3
11CH01
4
11CH02
11CH03
+
5A
PLENUM HIGH LIMIT
I/O J15 PIN 5
6A
6A
COLUMN HIGH LIMIT
I/O J15 PIN 6
7A
COLUMN HIGH LIMIT
I/O J15 PIN 7
2A
GRAIN DISCHARGE
CHUTE I/O J15 PIN 2
91
2A
95
COM
95
5A
Meter Roll Fault
5
6
+
I/O J1
PIN 5 & 7
91
DC COMMON
+ 95 +
7
11CH04
11A
11A
5 SECOND AIR FAULT
I/O J15 PIN 11
8
11CH05
13A
13A
10 MINUTE OUT OF WET
GRAIN I/O J15 PIN 13
9
11CH06
12A
12A
45 SECOND HEATER
FAULT I/O J15 PIN 12
10
11CH07
8A
8A
MOTOR OVERLOAD
I/O J15 PIN 8
Title:
S IN G L E F A N & H E A T P L C O U T P U T
CHANNEL 11
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.7
OUTPUT 12CH
1
2
3
4
5
7
COM
12CH01
COM
12CH02
7
12CH03
COM
9
12CH04
10
12CH05
11
12CH06
12
12CH07
+
32
12CH00
6
8
3
COM
3
+
32
+
SWITCHED AC
120 VOLTS
LOAD SWITCH
MANUAL
7
+
5
+
5
+
8
+
8
+
1ST AUX LOAD
(incline auger or leg)
NOTE: 6
2ND AUX LOAD
(wet bin)
NOTE: 6
9
+
95
DC COMMON
+ 95 +
9
+
15A
15A
AIR SENSE
I/O J15 PIN 15
16A
16A
FLAME SENSE
I/O J15 PIN16
9A
9A
LOWER PADDLE SWITCH
I/O J15 PIN 9
10A
10A
UPPER PADDLE SWITCH
I/O J15 PIN 10
Title:
S IN G L E F A N & H E A T P L C O U T P U T
CHANNEL 12
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.8
AUTO/MAN CR2
HEATER RELAY CR3
1
13
FROM CRM5
OR M5
A
B
2
AC COMMON
11
26
FROM COMP
MAN SWITCH
A
2
B
AC COMMON
91.1(10)
91.2(6)
17B
18
2
SCR REF.
12via THUMBWHEEL
4
7
48
1B
TO HEATER
BOX
9
6
C.B. F9
3 AMP
1C
1D
9
17
TO SCR
TERM SIG
95
TO SCR
TERM COM
91.10(9)
TO PLC 1CH06
91.4(7)
3
6
13 via PROCESSOR 17A
SCR REF
3
91.10(10)
TO HEATER
BOX
91.2(8)
14
DC COMMON
95
4
7
91.10(8)
15
DC COMMON
95
1
91.10(7)
METER ROLLS CR5
4
FROM CR
UNLOAD
10A
B
A
16 +24VDC
2
18
AC COMMON
54
8
5
91.4(8)
TO PLC
1CH07
91.2(2)
CR UNLOAD
L2
5
4
7
L2A
91.10(4)
L1
6
6
9
91.10(3)
TO SCR
TERM L2
C.B. F4
220VAC
3 AMP
L1B TO SCR
L1A
TERM L1
17
FROM PLC
31
OUTPUT
10CH03
18 110VAC
1
B
2
A
AC COMMON
91.2(11)
9
87
6
TO UNLOAD SW
MANUAL SIDE
91.2(2)
19
UNLOAD ON
SIGNAL
10
7
1
10A
TO CR5 COIL
METER ROLLS
91.2(2)
SWITCHED AC CR1
7
FROM
10CH02
33
A
B
2
AC COMMON
20
91.1(7)
8 120VAC
1
91.11(7)
TO TERMINAL
#15- POWER BOX
DRY CONTACTS THAT CAN BE USED TO TURN
ON AUX UNLOAD EQUIPMENT- SEE NOTE 9
91.1(11)
9
TO TERMINAL
#14-POWER BOX
AUX CONTACT
ON M3 (UNLOAD)
14
15
6
3
SWITCHED AC
TO TERM 3
FAN ON SIGNAL
AUX CONTACT
ON M5 (460V )
9
+24VDC
AUX CONTACT
ON M2 (LOAD ON)
47
18
+24VDC
18
21
46
TO PLC INPUT
1CH00
91.4(1)
TO PLC INPUT
1CH02
FAN - HEAT INTERLOCK
AUX CONTACT
ON M5 (460V)
10 -24VDC
AUX CONTACT
ON M3 (UNLOAD ON)
95
94
22
TO PLC INPUT
2CH03
FROM THE
HEAT ON SWITCH
Title:
13
12
TO HEAT ON
RELAY CR3
91.2(6)
S IN G L E F A N & H E A T R E L A Y
C O N T A C T W IR IN G
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.9
1
+
AC.B. F5 3AMP
A+
L1B
3
L1
4
L2
L2A
+
TO DC MOTOR
+
2
+
+
C.B. F4 3AMP METER ROLLS CR5
L1A
L1 POW ER FROM
DISTRIBUTION
BLOCK
230 VAC
L2
91.2(2)
5
F-
6
F+
AUTO/MAN CR2
7
91.1(10)
I1
95
8
95
91.1(10)
COM
17
9
10
DC COMMON
+ 95 +
95
95
METER ROLL
SPEED POT 10K
17B
SIG
91.9(15)
+15 VDC
85
+
+12
+
5K OHM RESISTOR
17
91.9(16)
17A
REF VOLTAGE
FROM PROCESSOR
CR2 IS ENERGIZED
WHEN IN MANUAL
Title:
S IN G L E F A N & H E A T S C R B O A R D
W IR IN G
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 91.10
L1
L2
L3
STARTER PROTECTOR
CB2
LOAD CONTACTOR
M2
1
LOAD
MOTOR
2
3
4
+24VDC
AUX CONTACT
18
47
TO PLC INPUT 1CH02
91.4(4)
STARTER PROTECTOR
CB3
UNLOAD CONTACTOR
M3
5
UNLOAD
MOTOR
6
7
AUX CONTACT
94
95
-24VDC
8
91.5(5)
AUX CONTACT
14
15
9
STARTER PROTECTOR
CB5
TO PLC
INPUT 2CH03
DRY CONTACTS FOR
AUXILIARY UNLOAD
FAN CONTACTOR
M5
10
FAN
MOTOR
11
12
See Drawing # 91.19 & 91.20
13
+24VDC
AUX CONTACT
18
46
TO PLC
INPUT 1CH00
91.4(2)
Title:
S IN G L E F A N & H E A T 3 P H P O W E R
W IR IN G
Author: Sukup Mfg.
Date: 01/04
Revision: 1-10-08
Sheet: 91.11_3ph
TO POWER BOX
GND 2
1 1I 18 37455216195
1G
2
TERMINAL STRIP
IN HEATER BOX
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
1G
1
2
1I
18
21
37
45
52
161
FO
95
GND
VAPOR OVER TEMP.
18
18
FSR1
IR3
RR2
1
13
67
15
62
62
17
63
IR1
66
64
19
FO
37
52
58
SPARK
TRANSFORMER
9
6
RED LIGHT
10
PRESSURE SWITCH FOR
VALVE PROVING CONTROL
(NO)
64
62
IR2
23
58
67
63
(NC)
LIQU ID SOLENOID
59
+
MAIN GAS VALVE
+
+
1E +
+
+
+
+
1 +
BLOCKING GAS VALVE
60
VALVE PROVING U N IT
1E
DC COMMON
18
61
AIR SWITCH
65
1
+
+
air
s w.
11
10 +
60 +
+24VDC
SPARK PLUG
FO - Blue
65
21
Black
Red
FSR
2
10 +
95
IR
1I
2
HOUSING
OVER TEMP
+
RR
E lectronic Mod Valve
+
+
+
+
+
+
+
+
+
+
+
+
12
11
10
9
8
7
6
5
4
3
2
1
AIR SW ITCH SOLENOID #2
45
BURNER CONTROL UNIT
12 1I +
11 11 +
10 58 +
RR1
+
9
+
57
8
9 +
7
6 +
6
+
5
10 +
4
FO +
3
+
2
+
1
FLAME ROD
1
AIR SW ITCH SOLENOID #1
TO HIGH PRESSURE SWITCH (see below)
+
+
+
BLACK 95
RED 18
WHITE 61
1F
1I (from the power box)
H IGH
PRESSURE
1G (to the pow er box)
1G
-1
- 23
-
NOTE: Pipe train components connect to a terminal strip
in the 5 x 5 junction box located on the front of the
dryer. From that terminal strip through a conduit to
the heater box terminal strip.
CONTROL SIGNAL
ELECTRONIC MOD VALVE
MOTOR-ON PIPE TRAIN
Title:
IR - ISOLATION RELAY
RR - RESET RELAY
FSR - FLAME SENSE RELAY
- INDICATES NO CONNECTION
PORTABLE DRYER: DAN-CORN SINGLE FAN & HEAT
HEATER CONTROL & FAULT WIRING - 38" OR 44"
HOUSING
Author: Sukup Mfg.
Date: 01/04
Revision: 1-10-08
Sheet: 91.12
95
85
SIG
1
2
3
PLENUM TEMP SIGNAL
+
71
TEMP DISPLAY
71
+
4
5
ELECTRONIC MOD VALVE CONTROL BOARD
7
DC COMMON
+ 95 +
8
+
9
10
11
+15VDC
85
95
85
61
61A
6
+
61A
REF VOLTAGE
FROM PROCESSOR
DC COMMON
+ 95 +
+
+24VDC
18
+
MOTOR- ON PIPE TRAIN
Black
Red
White
95
18
61
1
2
3
12
13
Title:
S IN G L E F A N & H E A T E L E C T R O N IC
M OD VALVE CONTRO L
Author: Sukup Mfg.
Date: 01/06
Revision: 1-10-08
Sheet: 91.13
82
61A
17A
+
82
TO ELECTRONIC MOD VALVE CONTROL BOARD
TO CR2 SCR REF VOLTAGE
01 23 4567
REMOTE
PRINTER
CONNECTOR
+
SMARTWATCH
GRAY
A to D CONNECTOR
DALLAS
LANGUAGE
CHIP
D to A CONNECTOR
EPROM
PINK
PLENUM TEMP
+ 71 +
71
70
+
70
+
COLUMN TEMP (if used)
.01uF
CAP
POWER PLUG
YELLOW HARNESS TO PLC
KEYPAD
HARNESS
+
+
95
85
+
+
+
84
+
0 +5 +15
POWER PLUG
LCD
HARNESS
OUTPUT SENSOR
PINK
RED
BROWN
BLUE
BLACK
WHITE
GREEN
SHIELD
51
DRYFIRE SIGNAL
89
18
52
TO HEATER SWITCH
+24VDC
RESET SIGNAL
88
TO FAN SWITCH
87
TO UNLOAD SWITCH
SWITCHED AC
TO LOAD SWITCH
3
86
INPUT SENSOR
GRAY
(if used)
CABLE TO
MOISTURE SENSOR
Title:
S IN G L E F A N & H E A T I/O &
P R O C E S S O R B O A R D W IR IN G
Author: Sukup Mfg.
Date: 01/07
Revision: 1-10-08
Sheet: 91.14
+5 VDC
+
841
+
841
+5 VDC
+
84
+
DC COM.
+
95
+
+
85
+
+
82
+
95
95
95
PRINTER POWER
HARNESS
SIGNAL FROM
PROCESSOR
PAPER ROLLER CONTROL BOARD
82
85
95
+15 VDC
84
82
FOR MANUAL
PUSH BUTTON
(if installed)
811
801
80
81
DC MOTOR AND PAPER ROLLER
Title:
S IN G L E F A N & H E A T P R IN T E R A N D
P A P E R R O L L E R W IR IN G
Author: Sukup Mfg.
Date: 01/07
Revision: 1-10-08
Sheet: 91.15
MINCO TRANSMITTER (DISCONTINUED IN 2007 - REPLACE WITH T17028)
POWER
1
2 3
RED
DC COMMON
95
1 2 3
SENSOR
+15VDC
85
BLACK
RED
SIGNAL BACK TO PROCESSOR
RED
YEL
WHITE
RTD'S & TRANSMITTERS ARE USED
TO SENSE PLENUM TEMPERATURE
AND ALSO WITH THE COLUMN TEMP OPTION.
TO RTD SENSOR
T17028 NEW AS OF 2007
SIGNAL BACK TO
PROCESSOR
FROM RTD SENSOR RED
1 2 3
FROM RTD SENSOR YEL
RED 85
+15VDC
DC COMMON BLACK 95
WHITE
1VDC - 5VDC
1 2 3
Title:
S IN G L E F A N & H E A T R T D
T R A N S M IT T E R W IR IN G
Author: Sukup Mfg.
Date: 01/07
Revision: 1-10-08
Sheet: 91.16
NT
1
EK
uC control
RESET
K1
FSV
K2/1
2
12
2
K2/2
10
3
K3
7
K4
4
5
9
11
6
8
1
ION
3
LP
AL
4
Pa
BV2
Z
EK
1D
5
3 AMP
C.B. F9
BV1
M
1C
6
CR3
1B
7
HIGH GAS
PRESSURE SW
1A
8
A
HEATER
HOUSI NG OT
B'
B
C
D
SB/R
12
W/GP
1
2
AL
10
M
3
Z
7
BV1
4
(LR)BV2
5
LP
6
FS
1
9
AL = Alarm
BV1 = Fuel Valve # 1
FS = Flame Signal
GP = Gas Pressure Switch
LP = Air Pressure Switch
LR = Load Controller
M = Fan Motor
R = Control Thermostat
SB = Safety Limit Thermostat
W = Limit Thermostat / Pressure S w.
tw t10
t1
t3
Title:
t3n
TSA
11
t4
PORTABLE DRYER:DAN-CORN SINGLE
FAN & HEAT: BURNER CONTROL
Author: Sukup Mfg.
Date: 08/07
Revision: 1-10-08
Sheet: 91.17
SINGLE FAN ELECTRICAL DRAWING NOTES
NOTE 1:
On 3 phase dryers the control voltage comes from an auxiliary contact on motor starter M5.
NOTE 2:
On all switches, XOO indicates that the switch is in the Manual or ON position. OOX
indicates that the switch is in the Computer or AUTO position.
NOTE 3:
CR Unload is an off delay timer, allowing the unload to clean out when a fault occurs.
NOTE 4:
Terminals found in the auxiliary box. If no auxiliary controls are installed, place a jumper
between terminal 18 and terminal 49.
NOTE 5:
For auxiliary wiring of 12CH01 and 12CH02, Refer to Appendix 1 in the Dryer Manual.
NOTE 6:
Drawing 91.12 covers both LP & NG heaters. If the heater is NG, then the vapor high limit
and the liquid solenoid valve are not used.
NOTE 7:
- indicates the screw terminal on the relay socket that the wire is attached to,
found in drawing 91.9.
NOTE 8:
The Differential Air Flow switch is only used on CE and CSA dryers. It is not used on the
domestic dryers.
NOTE 9:
Auxiliary contacts on M3 are a dry set of contacts that can be used for controlling extra
unload equipment when the dryer unload is running. If a Sukup Cyclone air system is used,
just connect between terminal #17 & #18 on the air system and terminals # 14 and # 15
on the dryer for automatic control.
NOTE:
There are different types of electrical noise protection installed throughout the dryer. These
components might not be shown.
L1
L2
1
L3
3
WIRE FOR Y-DELTA STARTER
J5225 AND J5226
5
KM2
1
3
5
1
3
5
KM3
2
4
6
KM1
2
4
6
2
4
6
14
U1
V1
W1
KM2
13
14
KM1
U2
V2
W2
13
TERM #11
55
67
KM2
TERM #12
14
56
68
22
22
KM3
KM3
KM1
21
21
13
A1
A1
TERM #12
KM1
KM3
A2
TERM #2
A1
KM2
A2
Term #12*
Term #11*
Term #2
Term #13*
Title:
Y-D E LT A W IR IN G
Author:
Date:
Sukup M fg.
1 1 /3 0 /0 5
Revision: 1-10-08
Sheet:
9 1 .1 9
A2
L1
L2
1
L3
3
5
1
KM2
3
1
5
3
5
KM3
2
4
U1
V1
6
KM1
2
4
6
2
6
4
14
W1
KM2
13
14
KM1
13
U2
V2
TERM #11*
W2
55
TERM #12*
67
KM2
KM2
68
56
14
22
21
KM3
13
KM3
A1
TERM #13*
KM1
21
KM1
A2
22
A1
KM2
A1
KM3
A2
A2
TERM #2
Term #1 2*
Term #1 1*
A1
A1
A2
A1
* WIRE NUMBERS MAY VARY DEPENDING IF IT IS ON
THE UPPER FAN OR THE LOWER FAN.
A2
A2
21
21
13
55
67
56
68
21
13
KM3
LOWER FAN
#11 FAN ON
#12 HEAT INTERLOCK
#13 HEAT INTERLOCK
13
UPPER FAN
#110 FAN ON
#109 HEAT INTERLOCK
#111 HEAT INTERLOCK
K M1
K M2
14
14
14
22
22
22
A2
A2
T erm # 2
T erm # 13 *
Title:
Y-D EL TA W IR IN G
Author: Sukup Mfg.
Date: 12/08/05
Revision: 1-10-08
Sheet:
9 1 .2 0
Appendix G
Two Fan Ladder Diagrams
1
MAIN DISCONNECT
SW ITCH
POW ER DIST
BLOCK
2
480 VOLTS
3
FUSE F1
3 AMP
FUSE F1
3 AMP
FUSE F2
3 AMP
H1
H3 H2
H4
4
FUSE F2
3 AMP
H3 H2
H1
H4
CONTROL TRANSFORMER
PRI-230V / 1 PHASE
SEC-120V / 1 PHASE
X1
CONTROL TRANSFORMER
PRI-480V / 1 PHASE
SEC-120V / 1 PHASE
X2
2
X1
X2
FUSE F3
3 AMP
5
E-STOP
6
PLC COM
10CH02
1
1
7
1
92.8(6)
MOC
22
1
22
OOX
1
9
SWITCHED
AC CR1
33
92.1(11)
92.12(7)
MOV
33
SYSTEM
CONTROL
8
PLC OUT
10CH02
10CH02
F6 C.B.
.5 AMPS
F7 C.B.
.5 AMPS
23
POWER
TO PLC
25
+5 & +15VDC
POWER SUPPLY
EMI FILTER
22
+24 VOLT DC
POWERSUPPLY
XOO
1
10
26
26
AUO/MAN CR2
92.5(9)
92.12(15)
XOO
11
24
12
I/O J2 I/O K2
RELAY
PIN 3
MOV
87
CR
UNLOAD
OOX
I/O FUSE
I/O J2
F2 3A
3
13
3
METER
ROLL CR5
PIN 4
10A
87
2
RC SNUBBER
1
UNLOAD
AUGER M2
XOO
NOTE #2
CR UNLOAD
1
87
1
10
10
24
XOO
92.1(7)
MOV
UNLOAD
SWITCH
MO A
SWITCHED
AC CR1
1
3
24
Title:
PORTABLE DRYER: DAN-CORN TW O FAN
& HEAT: 120 VOLT CONTOL
Author: Sukup Mfg.
Date: 01/08
Revision: 1-10-08
Sheet: 92.1
1
3
LOWER HEAT
SWITCH
24
2
CR-M 5
OR M 5
MO A
1
I/O J2
PIN 15
I/O J2
PIN 16
I/O K 8 I/O FUSE
RELAY F8 3 A
12
24
XO O
LOWER HEAT
CR3
13
NOTE #1
89
2
89
RC SNUBBER
FROM LOWER
HEATER
BOX
3
LOWER
HEAT CR3
1B
PLC COM
13CH00
OO X
F9 C.B.
3A
1C
1D
( FOR 28")
TO LOWER
HEATER
BOX
SEE DRAWING # 92.16
LOWER FAN
SWITCH
PLC OUT
13CH00
13CH00
120
4
LOWER
FAN M5
MO A
11
120
XO O
I/O J2 I/O K7 I/O FUSE
RELAY F7 3A
PIN 13
5
I/O J2
PIN 14
MOV
88
88
OO X
UPPER HEAT
SWITCH
RC SNUBBER
MO A
6
CR-M 6
OR M 6
109
24
UPPER
HEAT CR6
111
XO O
NOTE #1
I/O J2
PIN 7
7
I/O K4 I/O FUSE
RELAY F4 3A
I/O J2
PIN 8
113
OO X
RC SNUBBER
FROM UPPER
HEATER
BOX
8
UPPER
HEAT CR6
1G
10CH00
1H
1I
( FOR 38" / 44" )
TO UPPER
HEATER
BOX
SEE DRAWING 92.15
UPPER FAN
SWITCH
MO A
9
PLC COM
10CH00
F10 C.B.
3 AMP
PLC OUT
10CH00
121
UPPER
FAN M6
110
XO O
10
I/O K3 I/O FUSE
I/O J2
F3 3A
I/O J2 RELAY
PIN 5
11
PIN 6
MOV
114
OO X
HOUR METER
3
RC SNUBBER
2
Title:
PORTABLE DRYER: DAN-CORN TW O
FAN & HEAT 120 VAC CONTROL
Author: Sukup Mfg.
Date: 1/08
Revision: 1-10-08
Sheet: 92.2
1
3
2
PLC OUT
10CH03
PLC COM
10CH03
10CH03
CR UNLOAD
31
31
1
MOV
PLC COM
12CH00 12CH00
LOAD
SWITCH
PLC OUT
12CH00
2
LOAD AUGER M2
MO A
32
6
XOO
I/O J2
PIN 1
3
I/O K1 I/O FUSE
RELAY F1 3A
I/O J2
PIN2
MOV
86
OOX
RC SNUBBER
WORK LIGHT
SWITCH
MO A
19
1
4
WORK LIGHT
19
2
1 XOO
5
3
OOX
MAIN GAS
VALVE
3
6
7
8
9
10
11
1
2
3
Title:
PORTABLE DAN-CORN DRYER: TW O FAN
& HEAT 120 VOLT CONTROL
Author: Sukup Mfg.
Date: 01/08
Revision: 1-10-08
Sheet:
92.3
+24 VDC
18
DC COMMON
95
1
INPUT 0CH
95
COM
REAR DOOR
0CH00
2
18
3
LOWER VAPOR
HIGH LIMIT
18
37
37
UPPER VAPOR
HIGH LIMIT
18
102
102
4
5
36
36
0CH01
0CH02
0CH03
CONNECT #18 TO THE INPUT IF NOT USING HOUSING HIGH LIMIT
18
6
UPPER PLENUM HIGH LIMIT
18
104
104
7
RIGHT COLUMN HIGH LIMIT
18
40
40
8
LEFT COLUMN HIGH LIMIT
41
18
41
9
GRAIN DISCHARGE CHUTE
42
18
42
10
UPPER STATIC AIR
PRESURE SWITCH
18
105
105
LOWER PADDLE
18
44
44
11
0CH04
0CH05
0CH06
0CH07
0CH08
0CH09
UPPER FLAME RELAY
18
12
LOAD M 2
49D
13
0CH10
106
106
UNLOAD M 3
49E
LOWER FAN M 5
49F
UPPER FAN M 6
49G
0CH11
49
18
+
+
18
49
+
+
NOTE 4
MOTOR OVERLOAD CIRCUIT
Title:
P O R T A B L E D R Y E R : D A N -C O R N T W O
F A N & H E A T P L C IN P U T S C H A N N E L 0
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10-08
Sheet: 92.4
+24 VDC
18
DC COMMON
95
1
INPUT 1CH
95
UPPER FAN ON
18
107
2
COM
1CH00
107
92.3(1)
I/O J2
PIN 11
3
I/O K6 I/O FUSE
RELAY F6 .25A
I/O J2
PIN 12
18
1CH01
51
51
DRYFIRE
4
1CH02
LOAD ON M2
47
18
I/O J2
PIN 9
5
47
I/O K5 I/O FUSE
RELAY F5 .25A
I/O J2
PIN 10
18
1CH03
52
52
RESET
6
1CH04
CONNECT #18 TO INPUT IF NOT USING THE HOUSING HIGH LIMIT
18
18
7
UPPER PADDLE
18
53
53
8
UPPER HEAT ON
108
18
108
1CH05
1CH06
92.1(11)
9
10
11
12
13
AUTO/MAN
18
54
LOWER PLENUM HIGH LIMIT
39
18
LOWER STATIC AIR
PRESSURE SWITCH
18
1CH07
54
1CH08
39
1CH09
43
43
LOW ER FLAME RELAY
18
45
45
LOWER FAN ON
18
46
46
1CH10
1CH11
Title:
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10-08
Sheet: 92.5
DC COMMON
95
+24 VDC
18
1
95
COM
2CH00
2
3
INPUT 2CH
50
LOWER HEAT CR3
18
48
2CH01
48
4
2CH02
5
2CH03
6
2CH04
7
2CH05
2CH06
8
2CH07
9
2CH08
10
2CH09
11
2CH10
12
2CH11
13
Title:
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10-08
Sheet: 92.6
+24 VDC
18
DC COMMON
95
INPUT 3CH
COM
1
95
PRIOR TO 2007 DIFFERENTIAL AIR SWITCH INPUT
- CONNECT TO #95 SO INPUT IS ALWAYS ON
95
95
PRIOR TO 2007 DIFFERENTIAL AIR SWITCH INPUT
- CONNECT TO #95 SO INPUT IS ALWAYS ON
95
3CH00
2
3
3CH01
3CH02
4
3CH03
UNLOAD ON M 3
95
5
94
94
LEFT METER ROLL
PROXIMITY SWITCH
95
6
3CH04
92
92
RIGHT METER ROLL
PROXIMITY SWITCH
95
7
3CH05
93
93
UNLOAD AUGER
PROXIMITY SWITCH
95
8
3CH06
96
96
3CH07
9
3CH08
10
3CH09
11
3CH10
12
LOAD SWITCH
95
13
95A
10
+
18
+
11
+
95
+
12
UNLOAD SWITCH
TO PLC
INPUT
LOWER FAN
SWITCH
95B
UPPER FAN
SWITCH
95C
3CH11
95D
BROWN
+24VDC
BLUE
DC COMMON
BLACK
SIGNAL
PROX SWITCH
Title:
PO RTAB LE DRYER : D AN=C O RN TW O
Author: Sukup Mfg.
Date: 01/01
Revision: 1-10-08
Sheet: 92.7
OUTPUT 10CH
1
2
3
COM
10CH00
COM
(120 VAC)
SWITCHED AC
+ 3
+
3
121
UPPER FAN SWITCH
MODEM (if used)
+ 55 +
55
MUST CONNECT DIRECTLY TO THE PLC TERMINALS
4
5
10CH01
COM
56
1
MODEM (if used)
+ 56 +
+
120 VAC
1
+
SWITCHED AC
COIL CR1
6
7
8
9
10CH02
33
2
CR UNLOAD
10CH03
COM
10CH04
31
2
95
DC COMMON
+
95
+
1A
1A
REAR DOOR
I/O J15 PIN 1
14A
14A
AUTO/MAN
I/O J15 PIN 14
3A
3A
4A
4A
10
10CH05
11
10CH06
12
13
10CH07
Title:
UPPER VAPORIZER HIGH
LIMIT I/O J15 PIN 3
UPPER HEATER HOUSING
HIGH LIMIT I/O J15 PIN 4
PORTABLE DRYER: DAN-CORN TW O FAN
& HEAT PLC OUTPUTS CHANNEL 10
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10/08
Sheet: 92.8
OUTPUT 11CH
1
DC COMMON
+ 95 +
95
COM
2
5A
5A
6A
6A
11CH00
UPPER PLENUM HIGH
LIMIT I/O J15 PIN 5
3
11CH01
4
COLUMN HIGH LIMIT
I/O J15 PIN 6
I/O J1
PIN 5 & 7
11CH02
5
91
7A
COLUMN HIGH LIMIT
I/O J15 PIN 7
2A
GRAIN DISCHARGE
CHUTE I/O J15 PIN 2
METER ROLL FAULT
2A
11CH03
6
7
8
95
COM
9
11CH04
DC COMMON
+ 95 +
11A
11A
UPPER 5 SECOND AIR
13A
13A
10 MINUTE OUT OF WET
GRAIN I/O J15 PIN 13
12A
12A
UPPER 45 SECOND HEATER
8A
8A
10
11CH05
11
11CH06
12
13
11CH07
Title:
MOTOR OVERLOAD
I/O J15 PIN 8
FAN & HEAT PLC O UTPUT CHAN NEL
11
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10/08
Sheet: 92.9
OUTPUT 12
1
2
COM
12CH00
3
32
SWITCHED AC
120 VOLTS
+ 3
+
LOAD SWITCH
MANUAL
92.1 (8)
3
4
5
6
7
8
9
COM
12CH01
COM
12CH02
7
+
7
+
1ST AUX LOAD
(incline auger or leg)
NOTE: 6
5
+
5
+
8
+
8
+
2ND AUX LOAD
(wet bin)
NOTE: 6
9
+
95
DC COMMON
+ 95 +
9
+
12CH03
COM
12CH04
15A
15A
16A
16A
9A
9A
LOWER PADDLE SWITCH
I/O J15 PIN 9
10A
10A
UPPER PADDLE SWITCH
I/O J15 PIN 10
UPPER AIR SENSE
I/O J15 PIN 15
10
12CH05
UPPER FLAME SENSE
I/O J15 PIN16
11
12CH06
12
13
12CH07
Title:
12
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10/08
Sheet: 92.10
OUTPUT 13CH
1
2
3
4
5
6
7
8
9
COM
13CH00
COM
13CH01
COM
13CH02
13CH03
COM
13CH04
3
120
95
SWITCHED AC
120 VOLTS
+
+3
LOW ER FAN
SWITCH MANUAL
DC COMMON
+ 95 +
5B
5B
LOW ER FLAME SENSE
I/O J16 PIN 5
3B
3B
LOWER VAPOR HIGH
LIMIT I/O J16 PIN 3
2B
2B
LOWER HOUSING HIGH
LIMIT I/O J16 PIN 2
1B
1B
LOWER PLENUM HIGH
LIMIT I/O J16 PIN 1
6B
6B
LOWER 5 SEC AIR
FAULT I/O J16 PIN 6
7B
7B
LOW ER 45 SEC FLAME
FAULT I/O J16 PIN 7
4B
4B
LOW ER AIR SENSE
I/O J16 PIN 4
95
95
DC COMMON
+ 95 +
DC COMMON
+ 95 +
10
13CH05
11
13CH06
12
13
13CH07
Title:
13
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10/08
Sheet: 92.11
LOWER HEAT RELAY CR3
1
13
FROM CRM5
OR M5
B
AUTO/MAN CR2
2
A
15
FROM COMP
MAN SWITCH
26
A
92.2(1)
18
2
1B
3
7
48
TO PLC 2CH01
C.B. F10
3 AMP
1C
6
1D TO HEATER
BOX
16
SCR REF.
via THUMBWHEEL
SCR REF
17 via PROCESSOR
17B
6
METER ROLLS CR5
FROM UNLOAD
2
A
B
SWITCH
10A
92.1(12)
L2
5
L1
6
7
17A
7
92.13(4)
C.B. F4
220VAC
3 AMP
L1B TO SCR
L1A
6
9
TERM L1
92.13(5)
FROM
10CH02
1
92.1(11)
6
9
SWITCHED AC
TO TERM 3
UPPER HEAT RELAY CR6
92.2(6)
FROM CRM6
2
111 B
OR M6
A
18
10
1G
11
7
9
DC COMMON
19
DC COMMON
20
12
B
18
+24VDC
13
14
10
9
6
7
1
TO SCR
TERM COM
1
5
8
54
TO PLC
1CH07
AUX CONTACT ON M2
47 TO PLC INPUT
18
+24VDC
1CH02
LOAD ON SIGNAL
AUX CONTACT ON M3
22
95
-24VDC
TO TERMINAL
#14 - POWER BOX
94 TO PLC INPUT
3CH03
UNLOAD ON SIGNAL
AUX CONTACT ON M3
15
14
TO TERMINAL
#15 - POWER BOX
AUX CONTACT ON M5
1I
TO HEATER
BOX
24
2
+24VDC
18
46
TO PLC INPUT
1CH11
LOWER FAN
ON SIGNAL
25
AUX CONTACT ON M6
18
107 TO PLC INPUT
+24 VDC
1CH00
92.3(1)
1
95
TO PLC 1CH06
1H
A
95
4
7
92.13(9)
92.5(9)
CR UNLOAD
31
95
92.13(8)
23
C.B. F9
3 AMP
6
18
DRY CONTACT THAT CAN BE USED TO TURN
ON AUX UNLOAD EQUIPMENT
92.5(8)
108
4
92.15
TO SCR
TERM SIG
92.13(11)
21
3
17
3
TO SCR
TERM L2
SWITCHED AC CR1
92.1(7)
2
33
A
B
8 120VAC
9
4
L2A
9
92.13(10)
92.16
4
2
92.1(10)
4
92.6(3)
9
B
UPPER FAN
ON SIGNAL
87
10A
Title:
FAN & HEAT RELAY CO N TAC T
W IR IN G
Author: Sukup Mfg.
Date: 01/01
Revision: 1/10/08
Sheet: 92.12
1
2
+
AC.B. F5 3AMP
+
3
A+
4
5
6
7
L1B
L1
L2
L2A
DC COMMON
I1
+
95
+
92.12(19)
COM
SIG
95
95
95
92.12(18)
17
17B
92.12(17)
17
METER ROLL
SPEED POT 10K
+15 VDC
+ 85
5K OHM RESISTOR
17A
92.12(16)
12
POWER FROM POWER
DISTRIBUTION BLOCK
230 VAC
AUTO/MAN CR2
F+
+12
11
+
F-
17
10
+
L2
95
9
+
METER ROLLS CR5
C.B. F4 3AMP
L1
L1A
95
8
-
TO DC MOTOR ARMATURE
+
REF VOLTAGE
FROM PROCESSOR
CR2 IS ENERGIZED
WHEN IN MANUAL
13
Title:
PORTABLE DRYER: TW O FAN & HEAT
SCR BOARD W IRING
Author: KWC
Date: 01/01
Revision: 01/04 , 01/07
Sheet: 92.13
L1 L2 L3
1
CB2
M2
2
LOAD
MOTOR
3
4
AUX CONTACT ON M2
18
+24VDC
5
47
TO PLC INPUT 1CH02
M3
CB3
6
UNLOAD
MOTOR
7
8
AUX CONTACT ON M3
95
94
TO PLC INPUT 3CH03
-24VDC
9
AUX CONTACT ON M3
14
15
DRY CONTACT FOR
THE AUXILIARY UNLOAD
10
M5
CB5
LOWER FAN
MOTOR
11
12
NOTE: Please see Drawing 92.24 & 92.25
AUX CONTACT ON M5
18
46
TO PLC INPUT 1CH11
+24VDC
13
CB6
M6
14
UPPER FAN
MOTOR
15
16
17
+24VDC
AUX CONTACT ON M6
18
107
TO PLC INPUT 1CH00
Title:
F A N & H E A T 3 P H P O W E R W IR IN G
Author: Sukup Mfg.
Date: 08/07
Revision: 1-10-08
Sheet: 92.14
TO POWER BOX
GND 2
1 1I 18 37455216195
1G
2
TERMINAL STRIP
IN HEATER BOX
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
1G
1
2
1I
18
21
37
45
52
161
FO
95
GND
VAPOR OVER TEMP.
18
18
FSR1
IR3
RR2
1
13
67
15
62
62
17
63
IR1
66
64
19
FO
37
SPARK
TRANSFORMER
9
6
FO - Blue
RED LIGHT
10
PRESSURE SWITCH FOR
VALVE PROVING CONTROL
(NO)
64
62
IR2
23
58
67
63
(NC)
LIQUID SOLENOID
59
+
MAIN GAS VALVE
+
+
1E +
+
+
+
+
1 +
BLOCKING GAS VALVE
60
VALVE PROVING UN IT
1E
DC COMMON
18
61
AIR SWITCH
65
1
+
+
air
s w.
11
10 +
60 +
+24VDC
SPARK PLUG
2
Black
Red
65
21
FSR
58
10 +
95
IR
1I
2
HOUSING
OVER TEMP
+
RR
52
+
+
+
+
+
+
+
+
+
+
+
+
12
11
10
9
8
7
6
5
4
3
2
1
AIR SWITCH SOLENOID #2
45
BURNER CONTROL UNIT
12 1I +
11 11 +
10 58 +
RR1
+
9
+
57
8
9 +
7
6 +
6
+
5
10 +
4
FO +
3
+
2
+
1
FLAME ROD
1
+
+
+
BLACK 95
RED 18
WHITE 61
1F
1I (from the power box)
HIGH
PRESSURE
1G (to the power box)
1G
-1
- 23
-
NOTE: Pipe train components connect to a terminal
strip in a 5 x 5 box located on the front of the
dryer. From that terminal strip through a conduit
to the heater box terminal strip.
CONTROL SIGNAL
MOTOR-ON PIPE TRAIN
Title:
RR - RESET RELAY
PORTABLE DRYER: DAN-CORN TWO FAN & HEAT
UPPER HEATER CONTROL & FAULT - 38" OR 44"
HOUSING
Author: Sukup Mfg.
Date: 01/04
Revision: 1-10-08
Sheet: 92.15
TO POWER BOX
1
1D
37 52 95
18 45 61
2
1-10-08
2
1B
TERMINAL STRIP
IN HEATER BOX
+
+
+
+
+
+
+
+
+
+
+
+
+
1B
1
2
1D
18
21
37
45
52
61
FO
95
GND
+
+
+
+
+
+
+
+
+
+
+
+
+
18
18
FSR1
IR1
37
45
RR
52
IR
10
SPARK
TRANSFORMER
SPARK PLUG
9
Black
Red
6
11
FO - Blue
air
s w.
AIR SWITCH
RED LIGHT
10
RR2A
1
FSR
58
BURNER CONTROL UNIT
12 1D +
11 11 +
10 58 +
RR1
+
9
57 +
8
9 +
7
6 +
6
+
5
10 +
4
FO +
3
+
2
+
1
FLAME ROD
1
VAPOR OVER TEMP.
LIQUID SOLENOID
10A
10A
RR2B
MAIN GAS VALVE
BLOCKING GAS VALVE
10
2
HOUSING
OVER TEMP
1
1
DC COMMON
+
+
95
+24VDC
18
+
+
BLACK 95
RED 18
WHITE 61
1A
HIGH
PRESSURE
1B
-1
- 23
-
1B (to the power box)
NOTE: Pipe train components connect to a terminal
strip in a 5 x 5 box located on the front of the
dryer. From that terminal strip through a conduit
to the heater box terminal strip.
CONTROL SIGNAL
+
61
+
MOTOR-ON PIPE TRAIN
RR - RESET RELAY
Title:
PORTABLE DRYER: DAN-CORN TWO FAN & HEAT
LOWER HEATER CONTROL & FAULT - 28" HOUSING
Author: Sukup Mfg.
Date: 01/04
Revision: 1-10-08
Sheet: 92.16
95
85
SIG
1
2
UPPER PLENUM
TEMP SIGNAL
3
72
TEMP DISPLAY
+
+
71
4
71
72
+
+
LOWER PLENUM
TEMP SIGNAL
5
ELECTRONIC MOD VALVE CONTROL BOARD
DC COMMON
+
95
7
+
8
+
9
+15VDC
85
REF VOLTAGE
FROM PROCESSOR
95
85
61
61A
161
161A
6
+
DC COMMON
+ 95 +
MOTOR- ON UPPER PIPE TRAIN
61A
+
161A
+24VDC
18
+
BLACK 95
RED 18
WHITE 161
10
1
2
3
11
12
13
DC COMMON
+ 95 +
+
+24VDC
18
+
MOTOR- ON LOWER PIPE TRAIN
BLACK
RED
WHITE
Title:
95
18
61
1
2
3
F A N & H E A T E L E C T R O N IC M O D
VALVE CO NTRO L
Author: Sukup Mfg.
Date: 01/06
Revision: 1-10-08
Sheet: 92.17
+
82
+
82
161A TO UPPER EMOV CONTROL BOARD
61A TO LOWER EMOV CONTROL BOARD
17A TO CR2 SCR REF VOLTAGE
01 23 4567
REMOTE
PRINTER
CONNECTOR
SMARTWATCH
GRAY
PINK
A to D CONNECTOR
DALLAS
LANGUAGE
CHIP
D to A CONNECTOR
EPROM
PLENUM TEMP
+
+
+
71
70
70
+
+
+
COLUMN TEMP
(if used)
.01uF
CAP
+
+
+
POWER PLUG
72
71
95
85
84
+
+
+
POWER PLUG
YELLOW HARNESS TO PLC
KEYPAD
HARNESS
BLUE HARNESS TO PLC
LCD
HARNESS
OUTPUT SENSOR
PINK
RED
BROWN
BLUE
BLACK
WHITE
GREEN
SHIELD
89
TO LOWER HEATER SWITCH
88
TO LOWER FAN SWITCH
51
DRYFIRE SIGNAL
113
18
52
+24VDC
RESET SIGNAL
TO UPPER HEATER SWITCH
114
TO UPPER FAN SWITCH
87
TO UNLOAD SWITCH
SWITCHED AC
TO LOAD SWITCH
3
86
GRAY
INPUT SENSOR
(if used)
Title:
CABLE TO
MOISTURE SENSOR
PORTABLE DRYER : DAN-CORN TW O FAN &
HEAT I/O & PRO C ESSO R B OARD W IRIN G
Author: Sukup Mfg.
Date: 01/07
Revision: 1-10-08
Sheet: 92.18
+5 VDC
+
841
+
841
+5 VDC
+
84
+
DC COM.
+
95
+
+
85
+
+
82
+
95
95
95
PRINTER POWER
HARNESS
SIGNAL FROM
PROCESSOR
PAPER ROLLER CONTROL BOARD
82
85
95
+15 VDC
84
82
FOR MANUAL
PUSH BUTTON
(if installed)
811
801
80
81
DC MOTOR AND PAPER ROLLER
Title:
PORTABLE DRYER : DAN-CORN TWO FAN & HEAT
PRINTER AND PAPER ROLLER WIRING
Author: Sukup Mfg.
Date: 01/07
Revision: 1-10-08
Sheet: 92.19
MINCO TRANSMITTER (DISCONTINUED IN 2007 - REPLACE WITH T17028)
POWER
95 DC COMMON BLACK
+15VDC
85
RED
WHITE
YEL
RED
1
2 3
RED
1 2 3
SENSOR
RTD'S & TRANSMITTERS ARE USED
TO SENSE PLENUM TEMP AND ALSO
WITH THE COLUMN TEMP OPTION.
TO RTD SENSOR
T17028 NEW AS OF 2007
FROM RTD SENSOR RED
1 2 3
FROM RTD SENSOR YEL
BLACK 95
DC COMMON
RED 85
+15VDC
WHITE
1VDC - 5VDC
1 2 3
Title:
PORTABLE DRYER : DANCORN TW O
F A N & H E A T R T D T R A N S M IT T E R
W IR IN G
Author: Sukup Mfg.
Date: 01/07
Revision: 1-10-08
Sheet: 92.20
TWO FAN ELECTRICAL DRAWING NOTES
NOTE 1: On 3 phase dryers, the control voltage comes from an Auxiliary contact on M5 & M6 starter.
NOTE 2: On all switches XOO indicates that the switch is in the Manual or ON position. OOX
indicates that the switch is in the Computer of AUTO position.
NOTE 3: CR Unload is a timed off delay, so that the unload will clean out when a fault occurs.
NOTE 4: Terminals found in the Auxiliary box. If no auxiliary controls are installed, place a jumper
between terminal 18 and terminal 49.
NOTE 5: For Auxiliary wiring of 12CH01 and 12CH02, Refer to Appendix 1 in the Dryer Manual.
NOTE 6: Drawing 91.12 covers both LP & NG heaters. If the heater is NG, then the vapor high limit
and the liquid solenoid valve are not used.
NOTE 7: - indicates the screw terminal on the relay socket that the wire is attached to,
found in drawing 91.9.
NOTE 8: Differential Air Flow switch is only used on CE and CSA dryers. It is not used on the
domestic dryers.
NOTE: There are different types of electrical noise protection that are installed throughout the dryer,
that might not be shown in these drawings.
NT
1
EK
uC control
RESET
K1
FSV
K2/1
2
12
2
10
K3
K2/2
3
7
K4
4
5
9
11
6
1
8
ION
3
LP
4
1I
AL
Z
Pa
BV2
EK
CR6
6
BV1
M
5
1H
3 AMP
C.B. F9
1G
7
HIGH GAS
PRESSURE SW
1F
8
HEATER
HOUSING OT
B
A
B'
C
D
SB/R
1E
12
W/GP
AL
10
NOTE: 1A COMES FROM TERMINAL M
#6 OF THE VALVE PROVING UNIT
3
Z
7
BV1
4
9
1E 2
AL = Alarm
(LR)BV2
FS = Flame Signal
LP
M = Fan Motor
FS
W = Limit Thermostat / Pressure Sw.
5
6
11
1
tw t10
t1
t3
t3n
TSA
t4
Title: PORTABLE DRYER: DAN-CORN TW O FAN
& HEAT: UPPER BURNER CONTROLLER
Author: CSP
Date: 08/07
Revision: 1-10-08
Sheet: 92.22
NT
1
EK
uC control
RESET
K1
FSV
K2/1
2
12
2
10
3
K4
K3
K2/2
7
4
5
9
11
6
8
1
ION
3
LP
1D
4
AL
Z
Pa
BV2
EK
3 AMP
C.B. F9
5
6
BV1
M
1C
CR3
1B
7
HIGH GAS
PRESSURE SW
1A
8
B
A
HEATER
HOUSING OT
C
B'
D
SB/R
12
W/GP
9
1
AL
10
M
3
Z
7
BV1
4
2
AL = Alarm
(LR)BV2
FS = Flame Signal
LP
M = Fan Motor
FS
W = Limit Thermostat / Pressure Sw.
5
6
11
1
tw t10
t1
t3
Title:
t3n
TSA
t4
PORTABLE DRYER: DAN-CORN LOW ER
FAN & HEAT: BURNER CONTROL
Author: Sukup Mfg.
Date: 08/07
Revision: 1-10-08
Sheet: 92.23
L1
L2
1
L3
3
WIRE FOR Y-DELTA STARTER
J5225 AND J5226
5
KM2
1
3
5
1
3
5
KM3
2
4
6
KM1
2
4
6
2
4
6
14
U1
V1
W1
KM2
13
14
KM1
U2
V2
W2
13
TERM #11
55
67
KM2
TERM #12
14
56
68
22
22
KM3
KM3
KM1
21
21
13
A1
A1
TERM #12
KM1
KM3
A2
TERM #2
A1
KM2
A2
Term #12*
Term #11*
Term #2
Term #13*
Title:
Y-D E LT A W IR IN G
Author:
Date:
Sukup M fg.
1 1 /3 0 /0 5
Revision: 1-10-08
Sheet:
9 2 .2 4
A2
L1
L2
1
L3
3
5
1
KM2
3
1
5
3
5
KM3
2
4
U1
V1
6
KM1
2
4
6
2
6
4
14
W1
KM2
13
14
KM1
13
U2
V2
TERM #11*
W2
55
TERM #12*
67
KM2
KM2
68
56
14
22
21
KM3
13
KM3
A1
TERM #13*
KM1
21
KM1
A2
22
A1
KM2
A1
KM3
A2
A2
TERM #2
Term #1 2*
Term #1 1*
A1
A1
A2
A1
* WIRE NUMBERS MAY VARY DEPENDING IF IT IS ON
THE UPPER FAN OR THE LOWER FAN.
A2
A2
21
21
13
55
67
56
68
21
13
KM3
LOWER FAN
#11 FAN ON
#12 HEAT INTERLOCK
#13 HEAT INTERLOCK
13
UPPER FAN
#110 FAN ON
#109 HEAT INTERLOCK
#111 HEAT INTERLOCK
K M1
K M2
14
14
14
22
22
22
A2
A2
T erm # 2
T erm # 13 *
Title:
Y-D EL TA W IR IN G
Author: Sukup Mfg.
Date: 12/08/05
Revision: 1-10-08
Sheet:
9 2 .2 5

Owners Operation Manual (CE) Sukup Manufacturing Company

Transcription

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