DMC Calc-u-DRYER 25 Owner's Manual

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OWNER'S MANUAL

Calc-u-DRYER

MODEL 25

DAVID MANUFACTURING COMPANY

1600 12th Street NE, Mason City, Iowa 50401 641-424-7010

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Page 1 OWNER’S MANUAL Calc-u-DRYER MODEL 25 DAVID MANUFACTURING COMPANY 1600 12th Street NE, Mason City, Iowa 50401 641-424-7010...
Page 2: Table Of Contents
TABLE OF CONTENTS Warranty and Operating Precautions Safety Decal Display Information II - III Fundamentals of DRYER Operation Calc-u-DRYER Specifications Concrete Specifications Installation Checklist Start Up Procedures 5 - 7 Operating Procedures 8 - 9 Maintenance End of Season Operation Automatic Startup Flow Diagram Dryer Control Module &...
Page 3 DMC has a standard 12 month limited warranty on Calc-u-DRYERS. The warranty is limited to defects in material and workmanship. The only obligation to DMC is to repair or replace components which have been submitted and found to be defective.
Page 4 THE DECALS ON THESE PAGES MUST BE DISPLAYED AS SHOWN REPLACEMENTS ARE AVAILABLE UPON REQUEST Write to: 1600 12th Street NE Mason City, IA 50401 Or call: 515/423-6182 Please note: 1. The decals on the page are not actual size. Keep decals clean at all times.
Page 5 7217031 602L001 203L0303 106L010 I I I...
Page 6: Fundamentals Of Dryer Operation
STANDARD GALVANIZED BASE In the DMC Calc-u-DRYER, grain enters at the top center peak of the perforated cone and flows across the perforated roof cone. The grain depth on the roof is adjustable and easily adaptable to the varying conditions from one year to another. The heated air passes easily through this grain, taking away surface moisture quickly and easily because of the thinner layer and the fact that there is no second screen to pass through.
Page 7: Calc-U-Dryer Specifications
Octagon style burner with transformer ignition and flame sensing. TEMPERATURE: Controlled by a Honeywell Controller with a Maxon valve. MOISTURE CONTROL: DMC Calc-U-Dri Commander with moisture sensing and SCR drive for the sweep augers. ROOF: Optional and requires a leg with over flow so dryer can be continuously fed grain.
Page 9: Installation Checklist
INSTALLATION CHECKLIST After your dryer has been installed the operator should verify that everything has been installed properly and quality workmanship has been maintained. This should be done mainly to ensure that the dryer will operate properly. Do a general walk-around check, observing general appearance of the dryer. (look for damaged sheets, loose bolts, etc.) Ensure that the filling and take-away components will be adequate to handle the needs of the dryer.
Page 10: Start Up Procedures
START-UP PROCEDURES General Practices Before attempting to fill the dryer for the first time, it is recommended that the dryer be inspected for cleanliness and/or damage. Before starting the dryer the second or subsequent day, the plenum chamber area should be inspected for foreign material, and this material removed.
Page 11 Initial Starting (cont’d) NOTE: At this point nothing will start until the start switch is pushed. !WARNING! WHEN THE START SWITCH IS PUSHED, EQUIPMENT WILL START AUTOMATICALLY. CARE SHOULD BE TAKEN TO AVOID CONTACT WITH ANY OF THIS EQUIPMENT. At this time push the “START” button. After approximately 10 seconds the gas solenoids will open and the spark plug will spark.
Page 12 CHART I Example of Grain Moisture Sampling This chart shows grain moisture readings of samples as they should be taken to obtain reliable averages of moisture values. Time Calc-U-Dri Dole Elevator Temp. Moisture Temp. Moisture Moisture 9:33 a.m. 14.4% 14.7% 9:36 a.m.
Page 13: Operating Procedures
(quality) will also increase. The orifice can be reduced if low temperature drying is desired. For more information contact DMC. The supply pressure to the modulating valve should never exceed 30 PSI or damage to the valve may result.
Page 14 OPERATING PROCEDURES (cont’d.) Louvers On Doors The louvers on the doors are used to regulate the amount of air pulled through the grain in the cooling section. Increasing the amount of air through the column increases the cooling effect on the grain. When the louvers are closed to increase cooling you will notice a reduction in performance, due to the fact that less air is flowing through the dryer.
Page 15: Maintenance
MAINTENANCE LUBRICATION ITEM LUBRICANT INTERVAL SWEEP GEAR BOXES 80 - 90 GEAR OIL *CHECK EVERY 200 HOURS AND / OR EACH SEASON SPEED REDUCER SYNTHETIC GEAR LUBE *CHECK EVERY 200 HOURS AND / OR EACH SEASON *CHANGE EVERY 800 HOURS ELECTRIC MOTOR GREASE *1-2 PUMPS PER BEARING MAX AT BEGINNING OF SEASON...
Page 16: End Of Season Operation
End of Season Operation Options for Final Grain Drying To finish drying the final wet grain in the dryer, do either of the following: Add dry corn to the dryer until the wet corn has passed through the heating section of the dryer. The dryer may be shut off hot, allowed to steep for a short time and then turn on the fan to finish the cooling.
Page 19 Calc-u-DRYER CONTROL DEFINITIONS CONTROL POWER SWITCH: This switch controls the 115 volts AC power that is required for the Calc-u- DRYER control. The switch must be in the “MANUAL” mode to enable any of the other functions to run in the “MANUAL” mode. The “AUTOMATIC” mode provides power for normal drying operations.
Page 20: Control Box Operation
CONTROL BOX OPERATION CONTROL ON DELAY TIMER: The purpose of the on delay timer is to give the dryer enough time during startup to reach operating temper- ature. This is typically factory set at about two (2) minutes. The timer basically bypasses all of the sensors that would normally shut the dryer down during operation.
Page 21 CONTROL BOX OPERATION (cont’d) FAN STARTER The fan starter consists of a definite purpose contactor and an overload relay. If the overload should trip, allow the three thermal units a minute to cool down before pushing the red reset handle down. SCR DRIVE The SCR drive is an electronic device that controls the sweep auger DC motor.
Page 23 DMC Calc-u-DRYER MODEL 25 PARTS LIST 7110295 DISCHARGE HOPPER & FLIGHT ASSY 7110001 CHANNEL-RING SUPP. 7210121 SUPPORT RING-SLICE 7110028 TUBE-DISCHARGE 6” WLDMNT 7210280 HOPPER-DISCHARGE - ZINC PLT 7110026 AUGER-DISCHARGE, 5” WLDMNT 7110318 STUB SHFT - DISCHG, 1-1/4 DIAM 104B2056 SPRG-EXT. W/LOOPS .50 OD x 4.50L 1FH0738 NUT-LK, 1/2-13, 2-WAY, GRD.
Page 24 DMC Calc-u-DRYER MODEL 25 PARTS LIST (cont’d.) 2EL0221 RTD SENSOR 7210313 DOOR FRAME - ASSY 7210404 BRACKET - RTD MS5382 HINGE 7210101 LEG - INSIDE 32” 7210311 DOOR ASSY 7210351 PAD - LEG ADJUSTABLE 7210039 LOUVER W/O ADJUST BRACKET 7210129...
Page 25 DMC Calc-u-DRYER MODEL 25 PARTS LIST (cont’d.) 7220075 SKIRT FEED IN ASSY GAS TRAIN MODULATING - LP 7220007 SKIRT FEED IN 7210375 BRACKET - PLUMBING 3FH1240 CLEVIS PIN 5/16X1-3/8 PT1406 REGULATOR (0-30 PSI) W/ 3/16 ORF. 3FH0712 COTTER PIN 1/8 X 3/4...
Page 26 Calc-u-DRYER Model 25 ROOF OPTION Skirt Adjustment Bracket BRACKET - CABLE ADJ. 7210511 EYEBOLT - CABLE 7210517 BRACKET - CABLE ADJ MS5411 HANDLE 1FH0765 NUT-HEX 3/8 x 16 5FH0088 CLAMP - CABLE 5FH0092 CABLE - 3/16...
Page 27 DISCHARGE AUGER ASSEMBLY (7210396) 7110295 DISCHARGE HOPPER & FLIGHT ASSY 7110028 TUBE-DISCHARGE 6” WLDMNT 7210280 HOPPER-DISCHARGE - ZINC PLT 7110026 AUGER-DISCHARGE, 5” WLDMNT 7110318 STUB SHFT - DISCHG, 1-1/4 DIAM 104B2056 SPRG-EXT. W/LOOPS .50 OD x 4.50L 1FH0738 NUT-LK, 1/2-13, 2-WAY, GRD. 2 1FH0997 NUT-LK, FLG, 3/8-16 WHIZ LOCK 601B0003...
Page 28 SKIRT - GARNER BIN ASSEMBLY 7110067 CHAIN - SUPPORT 7110087 LEG - GARNER BIN ZINC PLT 7110139 CHANNEL - GRNR BIN 7110140 CHANNEL - SKIRT ZINC PLT 7110180 BRACE - SENSOR, FLAT 7110190 GUIDE - GARNER BIN ASSY 7110191 HOOK - CHAIN GRNR BIN 7110200 GARNER BIN-16GVx28”x96”...
Page 29 FEED-IN SKIRT ASSEMBLY (7220075) SAFETY SWITCH 7210415 MOUNT-MOTOR, DC DR WLDMNT 7210366 ROD-ARM LIMIT SWITCH 2EL0343 SWITCH-LIMIT TYPE C-PLUG IN UNIT 2EL0344 SWITCH-LIMIT TYPE C-PLUG IN RECP 2EL0345 SWITCH-LIMIT TYPE C-HEAD ONLY FEED-IN TUBE & LID 7220075 SKIRT FEED IN ASSY 7220007 SKIRT FEED IN 3FH1240...
Page 30 GAS TRAIN - MODULATING LP GAS TRAIN MODULATING - LP 7210375 BRACKET - PLUMBING PT1406 REGULATOR (0-30 PSI) W/ 3/16 ORF. 4FH0592 FIT - UNION 3/4 2EL0208 MODUTROL MOTOR- HONEYWELL 2EL0222 CRANK ARM - MOTOR 2EL0232 THERMOSTAT - VAPOR PT1309 GAUGE - PRESSURE (0-200 PSI) PT1521 VALVE COIL - 115 V...
Page 31 GAS TRAIN - INLET LP (7210374) 7210374 GAS TRAIN - INLET LP 4FH0591 FIT-UNION 1/2 FPT, (SCH 80) 4FH0685 FIT-STRAINER,(7P-1/2) PT1319 VALVE-(RELIEF) 1/2 NPT PT1504 VALVE-BALL,FULL PRT 1/2 MPT PT1513 VALVE-SOLENOID 2 WAY 7210375 BRKT-PLUMB.,LG 12GVx6.75”x48.25” GAS TRAIN - 1-1/4 NATURAL GAS 7210395 ORIFICE-GAS LINE, 2”...
Page 32 BARREL & BURNER ASSEMBLY (LP SHOWN) 556605 SPARK PLUG(IGNITION) 749812 FLAME PROBE-NORM CLOSE *7210124 BRKT-VAPORIZER SHORT *7210127 BRKT-VAPORIZER SUPP. *7110003 VAPORIZER-38” BARREL 7110209 BURNER-OCTAGON 38” ASSY 7210292 BRKT-BURNER 7210299 BRKT-FLAME PROBE 7110261 BARREL-BURN.EXT. WLDMT 1FH0751 NUT-JAM, 3/8-24 1FH0995 NUT-LK, FLG, 1/4-20 2FH0980 SCREW- WZ.LK.
Page 37: Honeywell Temperature Controller Programming
Loc value. Record for future use. Press the Raise and Set Up keys simultaneously to return to the original temperature display. The following controller parameters are programmed by DMC for use in your Calc-u-DRYER: CONFIGURATION MODE: InPt = 2298...
Page 38: Control Box Diagrams & Parts Listings
Calc-u-DRYER CONTROL BOX 230V, MODEL 25...
Page 39 Calc-u-DRYER CONTROL BOX 230 Volt, MODEL 25 851808 SWITCH-TIME DELAY, E.T.A. 5041218 SHUTDOWN INDICATOR ASSY 1EL0702 FUSE-ABC, CART. 12A, 250V 1EL0754 FUSE-AGC,CART.(CSA) 5A,32V 1EL0786 THERM.UNIT-TYPE CC 1EL0826 FUSEHOLDER-30A, 250V 1EL0831 FUSEHOLDER-2 POLE, 1/4 1EL0891 LUG-GRND(CSA)600V,#2-14WIRE 1EL0898 TERM.BLCK-DBL(CSA) 5 TERM. 1EL0900 TERM.BLCK-DBL(CSA) 12 TERM.
Page 40 Calc-u-DRYER CONTROL BOX 460V, MODEL 25...
Page 41 Calc-u-DRYER CONTROL BOX 460 Volt, MODEL 25 851808 SWITCH-TIME DELAY, E.T.A. 5041218 SHUTDOWN INDICATOR ASSY 1EL0701 FUSE-FLQ, CART. 15A, 500V 1EL0702 FUSE-ABC,CART. 12A, 250V 1EL0752 FUSE-CLS CC,TIME-DLY1.5A 1EL0754 FUSE-AGC,CART.5A,32V 1EL0785 THERM.UNIT-TYPE B, #B 40 1EL0826 FUSEHLDR-30A, 250V 1EL0831 FUSEHLDR-2 POLE, 1/4 1EL0839 FUSEHLDR-2 POLE,30A, 600V 1EL0891...
Page 43 Calc-u-DRYER CONTROL MODULE 851808 SWITCH-TIME DELAY, E.T.A. 1EL0754 FUSE-AGC, CART.(CSA) 5A, 32V 1EL0826 FUSEHOLDER-PAN MNT(CSA)30A,250V 1EL0852 KNOB-CNTRL,BLACK 1 DIAM. FOR 1/4 SHFT 1EL2042 GROMMET-RUBBER .62OD x .38ID x .15T 2EL0207 TEMPERATURE CONTROL 2EL0618 SWITCH-PUSHB, SPST(CSA) GRN 2EL0619 SWITCH-PUSHB, SPST(CSA) RED 2EL0627 SWITCH-TOGGLE, DPDT, 15A, QUICK 2EL0632...
Page 44: Troubleshooting
SHUTDOWN INDICATOR TROUBLESHOOTING GUIDE FOR CALC-U-DRYER The shutdown indicator will help determine what has shut the dryer down.During the dryer start up procedure, some of the lights will turn on. Once the dryer has exceeded operating temperature, the shut down indicator will automatically reset, turning off all lights.
Page 45 !CAUTION! DO NOT SERVICE OR ENTER DRYER WITH POWER “ON” PROBLEMS ITEMS TO CHECK FOR SOLUTION Main circuit breaker tripped Power light does not light Main power “OFF” Control fuse blown (5A 250V AGC fuse) Control switch turned “OFF” Emergency button pushed in (need key to unlock before pulling out) Fan does not start Tripped thermal overloads Dryer shuts down before the...
Page 46 Calc-u-DRYER MODEL 25 OWNER’S MANUAL DMC markets across the U.S. and around the world. For more information, contact the DMC Distribution Center nearest you. DMC’s Corporate Headquarters, Dakota Distribution Center Ft. Wayne Distribution Center Factory, and North Central Sales Center 3520 Ninth Avenue S.W.