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DeLUX Grain Dryer Operation Manual

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Operation Manual
Grain Dryer
2021 MODELS:
DP-DPSL-DPXSL-DPX4T-DPX8GT-DPX12GT-DPX16GT

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Summary of Contents for DeLUX Grain Dryer

  • Page 1 Operation Manual Grain Dryer 2021 MODELS: DP-DPSL-DPXSL-DPX4T-DPX8GT-DPX12GT-DPX16GT...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS  1    TABLE OF CONTENTS                        General  3    Introduction                    3    Use of Manual                    3 ...

  • Page 5: General

    Delux  Manufacturing  Company  of  Kearney,  Nebraska  has  many  years  of  experience  in  producing  energy  saving,  high  capacity  continuous  flow  grain  dryers  for  both  farm  and  commercial applications.    Delux  grain dryers are  designed  and  manufactured  to  produce  quality  grain  at  a  profit.  An  ideal balance of holding capacity, air flow, heat and exposure time are provided. All dryers  are designed for continuous flow operation. Grain enters the roof section of the dryer where  it is preheated as it flows down into the columns where the drying process is started. Twelve ...

  • Page 6: Dryer Labels

    GENERAL  2  Dryer Labels & Location      01/01/2020...
  • Page 7 GENERAL  3            01/01/2020...
  • Page 8 GENERAL  4     Grain Dryer Information Tags    The  Grain  Dryer  Information  Tags  are  located  on  the  right  side  of  the  Electrical  Service  Center and the Dryer Control Center. The information includes the model and serial number  of your grain dryer, as well as the schematic number that the dryer is wired to. Please have  this  information  ready  when  calling  your  dealer  or  the  factory  for  service  and/or  ordering  replacement parts.  The tags also contain important information regarding the electrical specifications for each  panel  box  and  fuel  specifications  of  the  grain  dryer.  This  information  is  helpful  when  determining power and fuel requirements from your local utility supplier. ...

  • Page 9: Service Information

      Delux Manufacturing Company has trained service technicians available to assist you in the  event  you  or  your  dealer  cannot  correct  a  problem.    A  phone  call  to  Delux  Manufacturing  Company will provide an answer to your service problems.    Delux Manufacturing Company keeps a complete record of each customer order.  However,  valuable  time  can  be  saved  if  the  information  below  is  provided  with  your  inquiry.    It  is ...
  • Page 10   6) If  the  part  returned  by  purchaser  is  found  by  Delux  Manufacturing  Company  to  be  functional and operational and in compliance with the manufactured specifications, it  will  be  returned  upon  request  to  purchaser  at  purchaser’s  cost.  If  no  request  is  received  by  purchaser,  the  part  shall  be  destroyed  after  a  period  of  ten  (10)  days. ...
  • Page 11 MAKE  ANY  MODIFICATIONS,  EXTENSION  OR  ADDITION  TO  THIS  WARRANTY.  DELUX  MANUFACTURING  COMPANY  SHALL  NOT  BE  RESPONSIBLE  FOR  ANY  CHARGES  INCURRED  IN  THE  REPAIRING  OR  SERVICING  OF  ANY  DELUX  MANUFACTURING  COMPANY  PRODUCT  OR  PART  EXCEPT  AS  SUCH  REPAIRS  ARE  MADE  BY  AUTHORIZED  DELUX ...
  • Page 12 Delux  Manufacturing  Company  standard  limited  warranty.    No electric motor warranty:    Delux  Manufacturing  Company’s  standard  limited  warranty  does  not  cover  any  and  all  electric motors used by Delux Manufacturing Company in its products. Purchaser’s sole claim  for  warranty  on  these  electric  motors  lies  with  the  motor’s  manufactures.  In  such  event,  purchaser’s dryer service manual contains a list of the motor manufacture’s service centers  where all further inquiries regarding the motor and its warranty should be placed. Under no ...
  • Page 13 GENERAL  9  Terms:    Delux dryers requiring service for customers who have an established line of credit will be  invoiced for services rendered. Customers not having an established line of credit will be on  cash in advance or cash on completion of service basis. All service or repair work rendered  by authorized Delux service personnel must be invoiced through an existing authorized  Delux Manufacturing Company dealer.  01/01/2020...

  • Page 15: Startup Procedure

      There are adjustable filler plates added to each side of the cooling floor cover. These allow you  to narrow the gap between the center walk plate and the screen to keep larger, lighter weight  foreign  material  from  being  drawn  back  up  into  the  cooling  section.  The  default  setting  for  these  plates  is  ¼”  gap.  Different  grain  conditions  may  influence  the  need  to  adjust  this  gap.  Delux does not recommend more than a ¼” gap.    The Stay‐Kleen system operates best with the fresh air intakes open as far as possible (See item  2 below). If it is necessary to close the intakes some to better cool the grain, be extra attentive  to the cleanliness of the inner chambers.   ...

  • Page 16: Main Power

    STARTUP  2  2.1. Fresh‐air intake ports are provided to allow fresh air to flow directly to the fan(s). The  fan(s)  cannot  receive  enough  air  directly  through  the  grain  being  cooled  so  fresh‐air  intake  ports  are  provided.  These  ports  allow  the  operator  to  have  more  control  over  the outgoing temperature of the product being dried.  2.2. Settings: Open the doors that are labeled ‘Full Open’, located directly on the fan(s), full  open.  Open  other  doors  labeled  ‘As  Needed’  as  far  as  possible  while  still  cooling  the  grain as needed. When the grain is not cool enough close the doors down that are not ...
  • Page 17 STARTUP  3  8. To start burner(s)    8.1. Turn on fuel supply to dryer.  8.1.1. Natural Gas ‐ Open manual valve.  8.1.2. LP Gas ‐ Open at supply tank. Open quick acting valve and ball valve on dryer.  8.1.3. LP GAS NOTE: Dryer must be started on vapor until internal vaporizer is warm,  then switched to liquid. Tank must have both vapor and liquid draw available to  dryer.  8.2. When burner ready light comes on, a 30 second purge cycle has been completed.  8.3. Move burner switch to "ON" position.  8.4. After a short delay, the ignition firing light(s) will come on and the gas safety valves are  energized. (If equipped with a manual Maxon valve, the handle should always be back  towards  the  dryer  to  start.  When  energized,  pull  the  handle  forward  until  ‘Open’  is  indicated.)  8.5. Within a few seconds the burner proven light(s) will come on showing burner(s) have  proven flame. As burner proven light(s) come on the ignition firing light(s) will go off.  8.6.
  • Page 18 STARTUP  4  9. To Start Unload  9.1. Turn discharge operation switch to “ON” to start the discharge auger and other  auxiliary handling equipment. Turn the switch to “METER” to active the DC metering  roll system. The Watlow Moisture Control becomes the source of metering the grain  from the dryer in either automatic or manual mode. (SEE BELOW)                                                                 ...
  • Page 19 5    Watlow EZ‐ZONE Automatic Temperature Controller  With Siemens Modulating Actuator / Butterfly Valve    Introduction  Your Delux grain dryer is equipped with an automatic temperature control system that is simple  and takes the hassle out of continually watching the dryer for temperature fluctuations. Simply  set  your  target  plenum  temperature  and  the  controller  will  maintain  that  temperature.  To  better  understand  the  controller  and  how  to  use  it,  please  spend  a  little  time  to  familiarize  yourself with common keys and the display.     ...
  • Page 20 STARTUP  6    Initial Start‐Up From Factory (Auto‐Tuning)  ***THIS PROCEDURE MUST BE DONE DURING INITIAL START‐UP FROM FACTORY***    The  temperature  controller  must  be  auto‐tuned  after  shipping  from  the  factory  to  the  customer.  Not  performing  the  auto‐tune  may  result  in  the  plenum  temperature  becoming  unstable during operation. To perform the auto‐tune, follow the steps below:    1) Must have power & fuel to the dryer.  2) The dryer must be full of grain.  3) Adjust the target plenum temperature on the controller to 180 °F (60 °C).  4) Turn main panel power “ON”.  5) Hold momentary fan switch “ON” until all fans have started. ...

  • Page 21: Micro-Tuning

    STARTUP  7  12) It may be necessary to repeat the process with changing variables outside the system,  but not needed every time starting the dryer.      Micro‐Tuning   From the factory, this mode is enabled. By enabling this, it allows the controller to constantly  change its parameters that control the stability of the temperature system.     For example: A change in gas pressure can reduce the stability of the system, but by having this  enabled it can change its calculations accordingly to compensate for the difference.     To change this parameter:   With main panel power “ON”, press the ADVANCE (green) key 5 times to reach the following  screen:                         Use the UP or DOWN key to change the upper display to “No”. Press the RESET key to return to  exit and return to the main screen.    “No”  ‐ feature disabled  “yes”  ‐ feature enabled    Minimum Flame Adjustment    The  minimum  flame  adjustment  is  programmed  from  the  factory,  and  under  normal  circumstances should not have to be adjusted. ...

  • Page 22: High Limit

    STARTUP  8      High Limit    The  controller  is  equipped  with  an  integrated  high  limit  control.  Should  the  operating  temperature rise above the high limit set point, the dryer will shut down automatically.  To change the high limit temperature set point:    1) From  the  Home  Page  press  the  ADVANCE  (green)  key  6  times.  “250”  (factory  default)  should appear in the upper display and “sp.5 ” in the lower display.  2) Use the UP or DOWN key to adjust the high limit set point.  3) Hold the RESET key until you return to the Home Page. ...
  • Page 23 STARTUP  9      Alarm, Limit, Indication & Error Messages           01/01/2020 ...
  • Page 24 STARTUP  10        01/01/2020 ...
  • Page 25 STARTUP  11          01/01/2020 ...
  • Page 26 STARTUP  12  Clearing Errors & Limit Messages    To clear error or limit messages press the RESET key. You may also turn main panel power  “OFF” and back “ON” again. Error or Limit messages will not clear until the cause or reason for    the error has been addressed.                                                                  ...

  • Page 27: Ez-Zone Automatic Moisture Controller

    STARTUP  13  Watlow EZ‐ZONE Automatic Moisture Controller    Introduction  Your  Delux  grain  dryer  is  equipped  with  an  automatic  moisture  control  system  that  is  simple  and takes the hassle out of continually monitoring incoming grain for changes in moisture. To  better  understand  the  controller  and  how  to  use  it,  please  spend  a  little  time  to  familiarize  yourself with common keys and the display.     ...
  • Page 28 STARTUP  14  Automatic Moisture Set‐Up Guide    1) On  initial  start‐up  with  wet  grain,  it  is  advisable  to  let  the  dryer  run  at  operating  temperature for 10‐20 minutes before starting the discharge process.  2) Move Unload Operation switch to “ON” position (grain unloading light will come on) to  start  discharge  auger  system.  Note:  Metering  rolls  will  not  operate  unless  all  auger  systems are on.  3) Move  Unload  Operation  switch  to  “METER”  position  and  with  the  Watlow  Moisture  Controller ...
  • Page 29 STARTUP  15  11) If final moisture content is within 1 or 2 points of target moisture, minor adjustments  can be made while in automatic mode. Be cautious not to make too much change too  often. Let the system have ample time to process and adjust. If the variance is too great  or not consistent, it may be necessary to return to manual mode and establish a new set  point.  12) Proportional Band (h.pb) – The proportional band is factory set for each model of dryer.  It  can  be  changed  by  pressing  the  ADVANCE  key  until  reaching  “h.pb”  in  the  lower  display.  It  can  be  adjusted  up  or  down  depending  on  what  the  moisture  of  the  discharged grain is doing. ...

  • Page 30: Grain Dryer Performance Chart

    STARTUP  16  GRAIN DRYER PERFORMANCE CHART CHART # 1 DRYING CAPACITY WET BPH PER 1000 BPH-RATED CAPACITY ON YELLOW CORN MOISTURE OF DRIED GRAIN % 1200 1900 1250 1000 1550 1200 1900 1400 1100 1600 1250 1800 1000 1350 1900...

  • Page 31: Grain Shrinkage Table

    STARTUP  17  GRAIN SHRINKAGE TABLE    SHRINKAGE WHEN GRAIN IS DRIED TO THESE LEVELS        01/01/2020 ...

  • Page 32: Dryer Operation Log

    STARTUP  18  DRYER OPERATING LOG                                                                            AIR TEMPERATURES, F  WET GRAIN  DRY GRAIN  MOISTURE  TIME OF DAY  AMBIENT DRYING VOLT  %MOISTURE  TEMP %MOISTURE  REMOVED                                                 ...
  • Page 33 STARTUP  19  DRY GRAIN UNLOADING RATE – DP AND DPSL SERIES DRYERS D.C. VOLTS = DRY UNLOAD RATE PER HOUR MODEL: 10FT. 15FT. 20FT. 25FT. 30FT. 40FT. D.C. VOLTS BU/HR BU/HR BU/HR BU/HR BU/HR BU/HR 10.0 1.22 64.15 96.23 128.30 160.38 192.46 256.61...
  • Page 34 STARTUP  20  DRY GRAIN UNLOADING RATE – DP AND DPSL SERIES DRYERS D.C. VOLTS = DRY UNLOAD RATE PER HOUR MODEL: 10FT. 15FT. 20FT. 25FT. 30FT. 40FT. D.C. VOLTS BU/HR BU/HR BU/HR BU/HR BU/HR BU/HR 41.0 4.98 263.02 394.53 526.05 657.56 789.07 1052.09...
  • Page 35 STARTUP  21  DRY GRAIN UNLOADING RATE – DP AND DPSL SERIES DRYERS D.C. VOLTS = DRY UNLOAD RATE PER HOUR MODEL: 10FT. 15FT. 20FT. 25FT. 30FT. 40FT. D.C. VOLTS BU/HR BU/HR BU/HR BU/HR BU/HR BU/HR 71.0 8.63 455.48 683.22 910.96 1138.70 1366.44 1821.92...
  • Page 36 STARTUP  22  DRY GRAIN UNLOADING RATE – DPXSL SERIES DRYERS D.C. VOLTS = DRY UNLOAD RATE PER HOUR MODEL: 10FT. 15FT. 20FT. 25FT. 30FT. 40FT D.C. VOLTS BU/HR BU/HR BU/HR BU/HR BU/HR BU/HR 10.0 1.62 85.50 128.30 171.60 223.20 256.80 357.00 11.0 1.78...
  • Page 37 STARTUP  23  DRY GRAIN UNLOADING RATE - DPXSL SERIES DRYERS D.C. VOLTS = DRY UNLOAD RATE PER HOUR MODEL: 10FT. 15FT. 20FT. 25FT. 30FT. 40FT. D.C. VOLTS BU/HR BU/HR BU/HR BU/HR BU/HR BU/HR 41.0 6.64 350.70 526.00 701.40 876.48 1052.10 1402.80 42.0 6.80...
  • Page 38 STARTUP  24  DRY GRAIN UNLOADING RATE - DPXSL SERIES DRYERS D.C. VOLTS = DRY UNLOAD RATE PER HOUR MODEL: 10FT. 15FT. 20FT. 25FT. 30FT. 40FT. D.C. VOLTS BU/HR BU/HR BU/HR BU/HR BU/HR BU/HR 71.0 11.50 607.30 911.00 1214.60 1518.00 1821.90 2429.20 72.0 11.66...
  • Page 39 STARTUP  25  DRY GRAIN UNLOADING RATE - DPX4T AND DPX8GT SERIES DRYERS D.C. VOLTS = DRY UNLOAD RATE PER HOUR MODEL: 10FT. 15FT. 20FT. 25FT. 30FT. 40FT. D.C. VOLTS BU/HR BU/HR BU/HR BU/HR BU/HR BU/HR 10.0 2.43 128.30 192.50 256.60 320.80 385.00 513.40...
  • Page 40 STARTUP  26  DRY GRAIN UNLOADING RATE - DPX4T AND DPX8GT SERIES DRYERS D.C. VOLTS = DRY UNLOAD RATE PER HOUR MODEL: 10FT. 15FT. 20FT. 25FT. 30FT. 40FT. D.C. VOLTS BU/HR BU/HR BU/HR BU/HR BU/HR BU/HR 41.0 9.97 526.03 789.25 1052.06 1315.28 1578.50 2104.94...
  • Page 41 STARTUP  27  DRY GRAIN UNLOADING RATE - DPX4T AND DPX8GT SERIES DRYERS D.C. VOLTS = DRY UNLOAD RATE PER HOUR MODEL: 10FT. 15FT. 20FT. 25FT. 30FT. 40FT. D.C. VOLTS BU/HR BU/HR BU/HR BU/HR BU/HR BU/HR 71.0 17.26 910.93 1366.75 1821.86 2277.68 2733.50 3645.14...
  • Page 42 STARTUP  28  DRY GRAIN UNLOADING RATE – DPX12GT & DPX16GT SERIES DRYERS D.C. VOLTS = DRY UNLOAD RATE PER HOUR MODEL: 10FT. 15FT. 20FT. 25FT. 30FT. 40FT. D.C. VOLTS BU/HR BU/HR BU/HR BU/HR BU/HR BU/HR 2.63 139.00 208.50 278.00 347.60 417.10 556.10 11.0...
  • Page 43 STARTUP  29  DRY GRAIN UNLOADING RATE – DPX12GT & DPX16GT SERIES DRYERS D.C. VOLTS = DRY UNLOAD RATE PER HOUR MODEL: 10FT. 15FT. 20FT. 25FT. 30FT. 40FT. D.C. VOLTS BU/HR BU/HR BU/HR BU/HR BU/HR BU/HR 41.0 10.80 569.90 854.85 1139.80 1425.16 1710.11 2280.01...
  • Page 44 STARTUP  30  DRY GRAIN UNLOADING RATE – DPX12GT & DPX16GT SERIES DRYERS D.C. VOLTS = DRY UNLOAD RATE PER HOUR MODEL: 10FT. 15FT. 20FT. 25FT. 30FT. 40FT. D.C. VOLTS BU/HR BU/HR BU/HR BU/HR BU/HR BU/HR 71.0 18.69 986.90 1480.35 1973.80 2467.96 2961.41 3948.31...
  • Page 45 STARTUP  31  Alarm, Limit, Indication & Error Messages 01/01/2020 ...
  • Page 46 STARTUP  32  01/01/2020 ...
  • Page 47 STARTUP  33  Clearing Errors & Limit Messages    To  clear  error  or  limit  messages  press  the  RESET  key.  You  may  also  turn  main  panel  power  “OFF” and back “ON” again. Error or Limit messages will not clear until the cause or reason for    the error has been addressed.   01/01/2020 ...

  • Page 48: Special-Sunflower Drying

    Harvest  when  seeds  are  below  20%  moisture  content.  Moisture  above  20%    adversely affects the flow characteristics of the sunflower seeds.    4.    Never leave dryer unattended while drying sunflowers.    5.  All  Delux  dryers  are  equipped  with  meter  roll  unloading  systems  and  should  be  checked  for  uniform  grain  movement  by  observing  downward  movement  of  sunflowers in the grain columns and by occasionally stopping the load operation to  observe the level of the top surface of the grain. If movement is not uniform, open  appropriate clean‐out doors  and inspect for possible obstructions or grain bridging.  All Delux dryers should also be completely unloaded daily for cleaning and inspection  inside the grain columns.   ...

  • Page 49: Sequence Analysis

    SEQUENCE ANALYSIS  1  System Sequence Analysis & Troubleshooting  DP/DPSL, DPXSL, DPX4T, DPX8GT, DPX12GT AND DPX16GT SERIES      Generic Schematic‐Standard PID:  900‐010959      Table of Contents    SEQUENCE                                                                                   PAGE #    Main circuit breaker “ON” * (230V‐1P, 240V‐3P systems only) *            2   1A.      3  1B.  Main circuit breaker “ON” * (380V, 480V, 575V‐3P systems only) *         3  2A.  Power switch (SW1) to “RUN”, energizing temperature                 and moisture controls    Power switch (SW1) to “START”, energizing safety circuit               4  2B.           ...
  • Page 50 SEQUENCE ANALYSIS  2      1A.  Sequence:  main circuit breaker "ON" *(230V‐1P, 240V‐3P systems) *    Action:  Main  power  light  "ON",  applies  power  to  high  voltage  circuits  and  120v control circuit breaker (CB1).          Symptoms:  A.    No main power light (LT1).  B.    Control circuit breaker (CB1) has tripped.          Possible  Causes:   A1.   Defective main power light (LT1).                     A2.   Defective control circuit breaker (CB1).                     A3.  Defective fuse in main panel disconnect. ...
  • Page 51 SEQUENCE ANALYSIS  3    Action:  Main  power  light  "ON",  applies  power  to  high  voltage  circuits,  step  down transformer (XMFR1) and 120V control circuit breaker (CB1).        Symptoms:    A .  No main power light (LT1).                     B.     Control circuit breaker (CB1) has tripped.        Possible      Causes:        A1.    Defective main power light (LT1).                     A2.    Defective control circuit breaker (CB1).                     A3.    Defective fuse in main panel disconnect.                    ...
  • Page 52 SEQUENCE ANALYSIS  4  Action:  Temperature control (Watlow EZ‐Zone) and moisture control (Watlow  EZ‐Zone) are energized. Approximate 3 second delay for temperature  control to lock in related safety functions before moving to “START”.    For information on operation and troubleshooting of the Watlow    Controls, see section 5.    2B.    Sequence:  Power switch (SW1) to "START", energizing safety circuit.    Action:  Safety circuit proven light on (LT12), all safety circuit monitor lights on  (LT2  –  LT8)  applies  power  to  entire  120  volt  circuit  and  energizes  power relay (K1).     How the safety circuit monitor lights work:    Safety circuit monitor lights (LT2 – LT8) indicate what part of the safety circuit is working. To  find the problem, press the power switch (SW1) to the "START" position and hold. Find the  first light that is not on. That will show the device that is not allowing the safety circuit to  lock in.       * Place all switches in "OFF" position before trouble shooting *    Symptoms:    A. ...
  • Page 53 SEQUENCE ANALYSIS  5  A7.  No  access  door  light  (LT7),  defective  door  safety  switch(s)  or  plenum and/or cooling door open.  A8.  No auxiliary safety light (LT8), (customer installed).  A9.  Defective burner switch (SW3).  A10.  Defective safety circuit proven light (LT12).  A11.  Defective power relay (K1).  A12.  Defective safety circuit relay (K2)      Corrective  Action:   A1.  If voltage is present on terminal #2 (120 volts) then  check for voltage on terminal #4 (120 volts) while holding the  power  switch  (SW1)  in  the  "START"  position.  If  no  voltage  is  present, the power switch (SW1) is defective, replace. ...
  • Page 54 SEQUENCE ANALYSIS  6  and  #21.  Voltage  should  be  present  on  each  terminal  about  every 2 to 4 seconds while the feedrolls are turning. If voltage  is not present on both terminals check feedroll monitor switch  (SW8)  for  correct  operation  and  cam  nut  adjustment  located  on  feedroll  sprocket.  Adjust  cam  nut  or  replace  feedroll  monitor  switch  (SW8).  If  voltage  is  present,  check  the  time  delay relays (TD2 & TD3) for proper operation and setting (60 ...
  • Page 55 SEQUENCE ANALYSIS  7  A8.  The auxiliary safety light would be installed as a special option  at the customer’s request. If voltage is present on terminal #12  (120 volts) the auxiliary safety light (LT8) is defective, replace.    A9.  If voltage is present on terminal #14 (120 volts) then check for  voltage  on  terminal  #18  (120  volts)  while  holding  the  power  switch  (SW1)  in  the  "START"  position  and  with  the  burner  switch (SW3) in the "OFF" position. If no voltage is present, the  burner switch contact (SW3) is defective, replace.    A10.  If voltage is present on terminal #22 (120 volts) while holding  the power switch (SW1) in the "START" position and the burner  switch (SW3) is in the "OFF" position, the safety circuit proven  light is defective, replace.    A11.  If voltage is present on terminal #18 (120 volts) then check for  voltage ...
  • Page 56 SEQUENCE ANALYSIS  8    Note: Delux provides three (3) types of loading systems.     A. Leveling system. (Standard)  [(Auger ‐ standard) (Drag conveyor ‐ optional)]   B. Gravity flow without high and low bin switches. (Optional)   C. Gravity flow with high and low bin switches. (Optional)    3.  Sequence:  Load switch (SW5) to "ON", energizing load circuit.                     Leveling system (standard)    Action:       Load  switch  (SW5)  "ON",  grain  load  light  "ON",  grain  loading  light  (LT26) “ON”.  Starts  leveling  auger  (conveyor)  on  dryer  and  wet  auxiliary  loading.  Loads  dryer  automatically  as  required.  Grain  loading  light  (LT26)  on ...
  • Page 57 SEQUENCE ANALYSIS  9  Turn  load  switch  (SW5)  to  "ON"  then  check  for  voltage  on  terminal #38. If voltage is not present the load switch (SW5) is  defective, replace.    A2.  If voltage is present on terminal #38 (120 volts), then check for  voltage  on  terminal  #39.  Note:  make  sure  high  /  low  grain  monitor  paddle  is  hanging  in  the  down  position.  If  voltage  is  not present, the switch (low) is defective, replace.    ...
  • Page 58 SEQUENCE ANALYSIS  10  D2a.  Front  low  grain  switch  (SW9).  If  voltage  (120  volts)  is  present  on  terminal  #15  check  voltage  on  terminal  #16  with  switch  paddle engaged. If voltage is not present the low grain switch  front (SW9) is defective, replace.    D2b.  Rear low grain switch (SW10). If voltage (120 volts) is present  on  terminal  #16  check  voltage  on  terminal  #17  with  switch  paddle engaged. If voltage is not present the low grain switch  rear (SW10) is defective, replace. ...
  • Page 59 SEQUENCE ANALYSIS  11                 B1.    Defective fan switch (SW2).  B2.    Defective starter coil (S1, S2, S3, S4).  B3.  Defective starter interlock (AC1, AC2, AC3, AC4).  B4.     Defective fan timer (TD6, TD7, TD8).    C1.  Incorrect fan rotation.  C2.     Defective fan air sensor (AS1).  Defective fan proven light (LT13).  C3.    Defective fan air sensor (AS2).  Defective fan proven light (LT14).  C4.  Defective fan air sensor (AS3).  Defective fan proven light (LT15).  C5.  Defective fan air sensor (AS4).  Defective fan proven light (LT16).    D1.  Defective fan sensor relay (TD5).                            Defective purging light (LT17).    E1.  Defective purge relay (TD4).                           ...
  • Page 60 SEQUENCE ANALYSIS  12  the fan switch contact (SW2) is defective, replace. The burner  switch (SW3) must be in "OFF" position.                                    B2.   If fan #1 does not pull in and voltage is present at terminal #24  (120  volts),  check  load  side  of  starter  coil  for  presence  of  voltage  when  fan  switch  (SW2)  is  depressed.  If  voltage  is  present  at  load  side  of  coil  on  starter  (S1),  the  holding  coil  is  defective ...
  • Page 61 SEQUENCE ANALYSIS  13  into operation. If no voltage is present the fan air sensor (AS2)  is defective, replace. If  voltage is present on terminal #26 the  fan proven light (LT14) is defective, replace.    C4.  If voltage is present on terminal #26 (120 volts) then check for  voltage on terminal #27 (120 volts) while the fan(s) are locked  into operation. If no voltage is present the fan air sensor (AS3)  is defective, replace. If  voltage is present on terminal #27 the  fan proven light (LT15) is defective, replace.    C5.  If voltage is present on terminal #27 (120 volts) then check for  voltage on terminal #28 (120 volts) while the fan(s) are locked  into operation. If no voltage is present the fan air sensor (AS4)  is defective, replace. If  voltage is present on terminal #28 the  fan proven light (LT16) is defective, replace.    D1.  With  fan(s)  running  check  to  see  if  voltage  is  present  on  terminal #28 (120 volts), then check for voltage (120 volts) on  terminal  #A1  (2)  on  the  purge  relay  (TD4),  if  voltage  is  not  present ...
  • Page 62 SEQUENCE ANALYSIS  14    5.  Sequence:  Burner operation switch (SW3) to "ON", energizing burner circuit.      Action:  Fuel supplied to burners. Ignition firing light(s) (LT18, LT19, LT20, LT21)  on for 3‐5 seconds, burner proven light(s) (LT22, LT23, LT24, LT25) on.     Symptoms:  A.  Dryer shuts down immediately upon engaging burner   Switch (SW3).  B.  Reset flame control light on.  C.  Some  or  none  of  the  ignition  firing  light(s)  (LT18,  LT19,  LT20,  LT21) light.  D.     Some or none of the burner proven light(s) (LT22, LT23, LT24,  LT25) stay lit.  E.  All  burner  proven  light(s)  (LT22,  LT23,  LT24,  LT25)  come  on  momentarily, then dryer shuts down. ...
  • Page 63 SEQUENCE ANALYSIS  15  D7.  Defective  ignition  transformer  (XMFR  2),  ignition  plug,  and/or  ignition wire  D8.  Defective  ignition  transformer  (XMFR  3),  ignition  plug,  and/or  ignition wire  D9.  Defective  ignition  transformer  (XMFR  4),  ignition  plug,  and/or  ignition wire  D10.  Defective  ignition  transformer  (XMFR  5),  ignition  plug,  and/or  ignition wire ...
  • Page 64 SEQUENCE ANALYSIS  16    B.  Manual reset is required, push reset button (SW4) located on  switch  panel  of  dryer  control  center.  Note:  when  resetting  Fireye model MicroM, fan(s) must be running.    C1.  If  voltage  is  not  present  on  terminal  #35  (120  volts),  with  burner  switch  (SW3)  "ON"  the  burner  switch contact  (SW3)  is  defective, replace.     C2.  If ...
  • Page 65 SEQUENCE ANALYSIS  17  volt source and listen for the valve to pull in, if not pulling in,  the coil is defective, replace.      D4.  Adjust regulator for 12 pounds of gas pressure on LP units and  10  pounds  on  natural  gas  units.  If  no  pressure  is  present  call  your local supplier.    D5a.   Inspect  burner(s)  for  plugged  holes  and  clean.  (Burner  holes  are  5/64"  diameter).  If  burner  holes  are  open  it  may  be  necessary to remove and vacuum inside of burner using a shop ...
  • Page 66 SEQUENCE ANALYSIS  18  flame sensor wire for tight connections and condition of wire.  Also  inspect  green  burner  ground  wire  for  tight  connections  and  condition  of  wire.  Replace  as  required.  If  flame  signal  is  present, flame control (FC2) is defective, replace.    D13.  If voltage is present on terminal #77 (120 volts), burner proven  light  (LT24)  is  defective,  replace.  If  voltage  is  not  present  on  terminal  #77,  refer  to  Fireye  bulletin  located  in  section  14,  component ...
  • Page 67 SEQUENCE ANALYSIS  19    6.    Sequence:   Unload operation switch (SW6) to "ON", energizing unload circuit.    Action:  Unload  switch  (SW6)  "ON",  switch  unload  light  “ON”,  starts  unload  auger and dry auxiliary unloading.       Symptoms:  A.  No switch unload light.  B.   Switch unload light “ON” but unloading system not running.  C.  Dryer shuts down immediately or during unloading operation.    Possible  Causes:       A.  Defective grain unloading switch contact (SW6).  Defective switch unloading light.                       B1.   Defective auxiliary unload starter coil (S8).  B2.       Defective auxiliary unload starter interlock (AC7).                  ...
  • Page 68 SEQUENCE ANALYSIS  20  what  corrective  steps  need  to  be  taken  to  resolve  this  condition.  Other  possible  causes  could  be:  (1)  Bad  motor,  replace;  (2)  Jammed  unload  system,  correct;  (3)  Loose  wiring  connections  on  terminals,  tighten;  (4)  Defective  overload,  replace.                      ...
  • Page 69 SEQUENCE ANALYSIS  21  volts  DC)  on  terminals  #47  (+)  &  #48  (‐).  If  voltage  is  not  present, the SCR control is defective, replace.    A5.    Disconnect  motor  wires  and  check  for  continuity.  If  no  continuity,  check  brushes  to  insure  both  brushes  are  making  contact with the rotor. If they are not, clean or replace. If both  brushes  are  making  contact  the  motor  is  defective,  repair  or  replace. ...
  • Page 70 SEQUENCE ANALYSIS  22      (b.)  Adjust  the  "MIN"  speed  pot  on  DC drive  (SCR1)  with  a  screwdriver  until  you  read  8  VDC  on  the  dc  voltmeter  (M1).                              Step 5: Maximum speed adjustment:                       (a.)  Adjust the Watlow moisture controller to 100% output.        (b.)  Adjust the "MAX" speed pot on the dc drive (SCR1) with  a  screwdriver  until  you  read  85  VDC  on  the  dc  voltmeter (M1). Note: do not exceed 90 VDC in manual ...
  • Page 71 SEQUENCE ANALYSIS  23         Corrective       Action:      A1.     Clean fan hub.  A2.  Tighten and align hub bolts.                     A3.    Reset blade pitch to proper setting and tighten.                     A4.    Replace fan or have fan repaired and rebalanced.  A5.    Repair and check fan for vibration cause and correct.                     A6.    Replace motor bearing(s) or replace motor.                       B1.    Inspect for problem, repair or replace.                                 (1) Bent auger tube                                 (2) Fighting not wearing even.                     B2.    Replace bearing(s).                  ...

  • Page 73: Shutdown Procedure

    SHUTDOWN PROCEDURE  1  SHUTDOWN PROCEDURE      1.  Move Unload Operation selector switch to "OFF" position.     2.  Move load switch to "OFF" position.    4.  Move  burner  switch  to  "OFF"  position.  Holding  the  power  switch  to  "START"  position  momentarily  while  moving  the  burner  switch  to  the  "OFF"  position  will  allow fans to continue to run. Otherwise moving burner switch to "OFF" position will  shutdown entire dryer and restart of fans will be necessary to cool grain.    Note:  To clear the lines of fuel ‐ turn "OFF" fuel supply at tank or dryer with burner switch  in ...

  • Page 75: General Maintenance

    GENERAL MAINTENANCE  1  GENERAL OPERATOR MAINTENANCE    The design and manufacture of this dryer is directed toward operator safety.    Use  extreme  caution  in  working  around  high  speed  fans,  gas  fired  burners,  discharge  augers, and auxiliary augers, which may start without warning when the dryer is operating  on automatic controls.    Continued  safe,  dependable  operation  of  automatic equipment  depends  to  a  great  degree  upon  the  owner/operator.    For  a  safe  dependable  drying  system,  follow  the  recommendations ...

  • Page 76: General Lubrication

    GENERAL MAINTENANCE  2         Clean fuel strainer‐drain fuel lines.                                                              During season    Inspect plenum and cooling chambers daily.  Clean out any accumulation of dirt, chaff,  fines, etc.         Check feedrolls for proper grain flow.         Check chain and belt alignment daily.         Inspect exterior screens for plugging‐‐clean for effective drying.    Post season service         Turn off all fuel and power to the dryer.         Clean out plenum and cooling chambers, grain columns and augers.         Clean exterior of dryer.         Leave auger slide gates open for drainage.         Clean fuel strainer‐drain fuel lines.         Lubricate per instructions ‐ section 14.         Apply protective coating to chain and sprockets.         Inspect for worn/damaged parts that should be replaced.         Keep all access doors closed.      General lubrication    1.   Gear drives   ...
  • Page 77 GENERAL MAINTENANCE  3       a. Bearings used are of the permanently lubricated type.    3.   Auger hanger bearings         a. Bearings used are of the permanently lubricated type.    4.   Roller chain         a. Spray with rust preventative lubricant at the end of each season.    5.   Fan motor         a. Follow manufacturer's instructions.     01/01/2016...
  • Page 79 VOLTAGE: [ ]230V-1P [ ]208V-3P [ ]230V-3P [ ]380V-3P(50HZ)[ ]460V-3P [ ]575V-3P CONTROL BOX DOOR LOCKS: Hoffman - 2233 ------------------------------------------------------------------------------- CONTROL CIRCUIT PART DESCRIPTION - INFORMATION DELUX PART NUMBER DISTRIBUTION BLOCK: 2 POLE 350 MCM 005-004765 DISTRIBUTION BLOCK: 3 POLE 350 MCM 005-003090...
  • Page 80 SPECS-2020-STD 2 OF 12 FAN SAIL SENSOR ASS'Y - SENSOR AND PERF PADDLE ASS'Y 400-008700 FAN SAIL SENSOR(S): HONEYWELL - S437A 1009 009-005213 FAN SAIL SENSOR WIDE ALUM. PADDLE W/ ARM ASS'Y: 400-009147 FAN SAIL SENSOR SOLID PADDLE W/ ARM ASS'Y: 400-007229 FAN SAIL SENSOR PERFORATED PADDLE W/ ASS'Y: 400-008699...
  • Page 81 FILL AUGER LEVEL CONTROL SWITCH: TILT SWITCH 010-003392 LOW GRAIN SHUTDOWN CONTROL: DELUX - ASS'Y –PADDLE MOTOR END 400-011014 LOW GRAIN SHUTDOWN CONTROL: DELUX - ASS'Y –PADDLE FILL END (40’) 400-011014 LOW GRAIN SHUTDOWN CONTROL SWITCH: SIDE PLUNGER SWITCH(BZE6-2RN) 010-003386...
  • Page 82 SPECS-2020-STD 4 OF 12 LEVELING 8" AUGER SECTION FOR 1 1/4" SHAFTS REAR 10FT: 200-006720 NON MOTOR END (SUPER EDGE FLIGHTING) LEVELING 10" AUGER SECTIONS FOR 1 1/4" SHAFTS (SUPER EDGE FLIGHTING) INCLUDES: AUGER ONLY - NO 1 1/4" SHAFTS OR BOLTS LEVELING 10"...
  • Page 83 SPECS-2020-STD 5 OF 12 LEVELING 8" AND 10" AUGER TROUGH SECTIONS (STANDARD FLIGHTING) INCLUDES: TROUGH ONLY, NO HARDWARE. LEVELING 8" AUGER TROUGH 5FT:10FT DRYER ONLY 200-007002 LEVELING 8" AUGER TROUGH INTERMEDIATE 10FT: 200-006992 LEVELING 8" AUGER TROUGH REAR 5FT: 200-007002 LEVELING 8"...
  • Page 84 RELAY SOCKET: (8) PIN 120V - FEEDROLL MONITOR TIME DELAY 007-008938 FEEDROLL MONITOR SENSOR SWITCH: SWITCH – ROLLER 010-005767 FEED ROLL MONITOR CAM: DELUX 200-006019 ------------------------------------------------------------------------------- DRY UNLOAD SYSTEM (DISCHARGE 8" AUGER OR DRAG CONVEYOR) UNLOAD SWITCH: 22MM - ACT SWITCH - 3-POS. ON/OFF/ON 010-010920 CONTACT: 22MM - ACT SWITCH –...
  • Page 85 SPECS-2020-STD 7 OF 12 DISCHARGE AUGER SET- 8" W/1 1/4" SHAFTS 25FT: 035-006872 DISCHARGE AUGER SET- 8" W/1 1/4" SHAFTS 30FT: 035-006873 DISCHARGE AUGER SET- 8" W/1 1/4" SHAFTS 40FT: 035-006874 DISCHARGE AUGER SECTIONS - 8" FOR 1 1/4" SHAFTS INCLUDES: AUGER ONLY NO SHAFTS OR BOLTS DISCHARGE 8"...
  • Page 86 SPECS-2020-STD 8 OF 12 ------------------------------------------------ DISCHARGE AUGER EXTENSIONS BY TYPE 8” AUGER, 1 1/4” SHAFTS ------------------------------------------------ ------------------------------- STANDARD DROP DISCHARGE AUGER EXTENSION (OPEN END TROUGH) ------------------------------- STANDARD DROP – ASSEMBLIES INCLUDES: AUGER, TROUGH, COVER, SHAFT, BOLTS/NUTS, BEARING DISCHARGE EXTENSION – ASSEMBLY: 1’ 400-009008 DISCHARGE EXTENSION –...
  • Page 87 SPECS-2020-STD 9 OF 12 DISCHARGE EXTENSION - TOP: 2’ 100-005409 DISCHARGE EXTENSION - TOP: 2’ 6” (30”) 100-008599 DISCHARGE EXTENSION - TOP: 3’ 100-005406 DISCHARGE EXTENSION - TOP: 4 100-005410 DISCHARGE EXTENSION - TOP: 5’ 100-005856 DISCHARGE EXTENSION - TOP: 6’ 100-005863 DISCHARGE EXTENSION - TOP: 7’...
  • Page 88 SPECS-2020-STD 10 OF 12 DISCHARGE EXTENSION - TOP: 5’ 100-007905 DISCHARGE EXTENSION - TOP: 6’ 100-007906 DISCHARGE EXTENSION - TOP: 7’ 100-007907 DISCHARGE EXTENSION - TOP: 8’ 100-007908 ------------------------------------------------------------------------------- DISCHARGE DRAG CONVEYOR DRAG CHAIN: SIZE 8” 2-5/8” PITCH (STRAIGHT W/UHMW PADDLES-PER FT) 054-006838 DRAG CHAIN: CONNECTING LINK FOR 8”...
  • Page 89 SPECS-2020-STD 11 OF 12 ------------------------------------------------------------------------------- AUTOMATIC TEMPERATURE CONTROL SYSTEM AUTOMATIC TEMP./H. LIMIT: WATLOW EZ-ZONE (PM6CFA-ALEJAAA)(STD.) 006-009149 TEMPERATURE CONTROL SENSOR: WATLOW 100Ω RTD STEM 009-007199 HIGH LIMIT SENSOR: WATLOW 100Ω RTD STEM 009-007199 TEMPERATURE/HIGH LIMIT SENSORS BOX ASSEMBLY 400-009304 TEMP. RELAY & HI LIMIT RELAY: INTERFACE RELAY-12A-120V 007-010929 QUICK ACTING VALVE: 1/2"...
  • Page 90 VIEWING WINDOW HOLDER – PLENUM 100-006168 ------------------------------------------------------------------------------- (OPTIONAL FEATURE) EXHAUST LIMITS SENSOR ONLY: 20FT 006-006925 ------------------------------------------------------------------------------- LABELS AND DECALS DECAL: "DELUX" - 6" HIGH - BLUE 018-006813 LABEL: "CAUTION DO NOT ENTER" 018-002407 LABEL: "DANGER HIGH VOLAGE" 018-001070 LABEL: "START-UP PROCEDURE"...
  • Page 91 COMBINATON STARTERS – SIEMENS (2019+) SIEMENS CATALOG NUMBER ------------------------------------------------------------------------------------------------------------------------ DELUX PART NUMBER 230V 3P MOTOR COMBINATION OVERLOAD * ADDITIONAL TERM. BLOCK or AMPS STARTER CONTACT AUX. CONTACT RANGE (MOUNT. RAIL) (SIEMENS) 3RA61201CP32 3RV2925-5EB 3RA6911-1A INCL. 1.0 – 4.0 001-010064 001-010074...
  • Page 92 460V 3P MOTOR COMBINATION OVERLOAD * ADDITIONAL TERM. BLOCK or AMPS STARTER CONTACT AUX. CONTACT RANGE (MOUNT. RAIL) (SIEMENS) 3RA61201CP32 3RV2925-5EB 3RA6911-1A INCL. 1.0 – 4.0 001-010064 001-010074 001-010076 3RA61201CP32 3RV2925-5EB 3RA6911-1A INCL. 1.0 – 4.0 001-010064 001-010074 001-010076 3RA61201DP32 3RV2925-5EB 3RA6911-1A INCL.
  • Page 93 575V 3P MOTOR COMBINATION OVERLOAD * ADDITIONAL TERM. BLOCK or AMPS STARTER CONTACT AUX. CONTACT RANGE (MOUNT. RAIL) (SIEMENS) 3RA61201CP32 3RV2925-5EB 3RA6911-1A INCL. 1.0 – 4.0 001-010064 001-010074 001-010076 3RA61201CP32 3RV2925-5EB 3RA6911-1A INCL. 1.0 – 4.0 001-010064 001-010074 001-010076 3RA61201CP32 3RV2925-5EB 3RA6911-1A INCL.
  • Page 94 400V 3P MOTOR COMBINATION OVERLOAD * ADDITIONAL TERM. BLOCK or AMPS STARTER CONTACT AUX. CONTACT RANGE (MOUNT. RAIL) (BALDOR) 3RA61201CP32 3RV2925-5EB 3RA6911-1A INCL. 1.0 – 4.0 001-010064 001-010074 001-010076 3RA61201CP32 3RV2925-5EB 3RA6911-1A INCL. 1.0 – 4.0 001-010064 001-010074 001-010076 3RA61201DP32 3RV2925-5EB 3RA6911-1A INCL.
  • Page 95 208V 3P MOTOR COMBINATION OVERLOAD * ADDITIONAL TERM. BLOCK or AMPS STARTER CONTACT AUX. CONTACT RANGE (MOUNT. RAIL) 3RA61201CP32 3RV2925-5EB 3RA6911-1A INCL. 1.0 – 4.0 001-010064 001-010074 001-010076 3RA61201DP32 3RV2925-5EB 3RA6911-1A INCL. 3.0 – 12.0 001-010065 001-010074 001-010076 3RA61201DP32 3RV2925-5EB 3RA6911-1A INCL.
  • Page 96 230V 1 Phase MOTOR COMBINATION OVERLOAD *ADDITIONAL TERM. BLOCK or AMPS STARTER CONTACT AUX. CONTACT RANGE (MOUNT. RAIL) (SIEMENS) 3RA2120-1HA24-0AK6 3RV2928-1H 3RV2901-1A 3RH2911-1HA11 5.5 - 8 001-010081 001-010079 001-010078 001-011883 3RA2120-1KA24-0AK6 3RV2928-1H 3RV2901-1A 3RH2911-1HA11 9 - 12.5 11.5 001-010082 001-010079 001-010078 001-011883 3RA2120-4AA26-0AK6...
  • Page 97 FAN PITCH SETTINGS - ALL MODELS GREENHECK FANS 60Hz 1750 RPM 230V-1P; 208V-3P; 240V-3P; 480V-3P; 575V-3P MODEL PITCH MODEL PITCH DIA. DIA. (DEG.) (DEG.) DP10 38” DPX4T20 43” DP15 38” 3 1/2 DPX4T25 43” DP20 38” 3 1/2 DPX4T30 43” DP30 38”...
  • Page 99 1 OF 1 FUEL TRAIN-MOD-RND FIN VPRZR-2020-2020 FUEL TRAIN W/MODULATING SYSTEM & ROUND FIN VAPORIZER PIPE SIZES L.P. L.P. L.P. MANIFOLD MANIFOLD LIQUID VAPORIZER VAPOR SOLENOID BUTTERFLY VALVES SIZES REGULATOR, VALVE VALVE & PIPE ROUND FIN VALVES & PIPE & PIPE MODEL DP10 1 1/4...

  • Page 101: Liquid Propane

    ORIFICE CHART – 2020+ ---NATURAL GAS--- -LIQUID PROPANE-- MODEL PART NUMBER PART NUMBER DP10 (15hp) 10FT 38" 100-003146 100-003145 9/32 DP15 15FT 38" 100-006955 11/32 100-006950 DP20 20FT 38" 100-006955 11/32 100-006950 DP30 30FT 38" 100-006955 11/32 100-006950 DP40 40FT 38" 100-006955 11/32 100-006950...
  • Page 103 1 OF 1 LEVSTDA-230V-240V-480V-2020 STANDARD L EVEL I NG ( AUGER) SYSTEM AL L MOTORS – 2 3 0 V- 1 P – 2 4 0 V- 3 P - 4 8 0 V- 3 P DEL UX MODEL TYPE MOTOR DESCRI PTI ON MOTOR P/ N.
  • Page 104 1 OF 1 LEVSTDA-380V-2020 STANDARD L EVEL I NG ( AUGER) SYSTEM AL L MOTORS – 3 8 0 V- 3 P DEL UX MODEL TYPE MOTOR DESCRI PTI ON MOTOR P/ N. DPSL 1 0 AUGER- 8 ” 1 HP- 1 4 5 0 RPM- 5 0 HZ- 3 8 0 V- 3 P- 1 4 3 T- 7 / 8 0 0 4 - 0 0 7 8 5 3...
  • Page 105 LEVSTDA-575V-2020 STANDARD L EVEL I NG ( AUGER) SYSTEM AL L MOTOR - 5 7 5 V- 3 P DEL UX MODEL TYPE MOTOR DESCRI PTI ON MOTOR P/ N. DPSL 1 0 AUGER- 8 " 1 HP- 1 7 5 0 RPM- 6 0 HZ- 5 7 5 V- 3 P- 1 4 3 T- 7 / 8 0 0 4 - 0 0 7 6 3 0...
  • Page 106 DATE: 0 1 - 0 1 - 2 0 DI S- L EV- DRAG- 2 3 0 V- 2 4 0 V- 4 8 0 V- L SN OPTI ONAL DRAG SYSTEM – DI SCHARGE AND/ OR L EVEL I NG L EESON/ OHI O GEAR ( FOR GEAR REDUCERS)
  • Page 107 DATE: 0 1 - 0 1 - 2 0 DI S- L EV- DRAG- 3 8 0 V- L SN- 2 0 2 0 OPTI ONAL DRAG SYSTEM – DI SCHARGE AND/ OR L EVEL I NG L EESON/ OHI O GEAR ( FOR GEAR REDUCERS) AL L MOTORS - 3 8 0 V- 3 P...
  • Page 108 DATE: 0 1 - 0 1 - 2 0 DI S- L EV- DRAG- 5 7 5 V- L SN- 2 0 2 0 OPTI ONAL DRAG SYSTEM – DI SCHARGE AND/ OR L EVEL I NG ( FOR L EESON/ OHI O GEAR GEAR REDUCERS) AL L MOTORS - 5 7 5 V- 3 P GEAR...
  • Page 109 1 OF 1 DIS-STD-230V-240V-480V-LSN-2020 STANDARD DI SCHARGE SYSTEM L EESON/ OHI O GEAR ( FOR GEAR REDUCERS) AL L MOTORS – 2 3 0 V- 1 P – 2 4 0 V- 3 P - 4 8 0 V- 3 P MOTOR GEAR MODEL...
  • Page 110 DIS-STD-380V-LSN-2020 STANDARD DI SCHARGE SYSTEM L EESON/ OHI O GEAR ( FOR GEAR REDUCERS) AL L MOTORS – 3 8 0 V- 3 P MOTOR GEAR PART GEAR REDUCER MODEL TYPE MOTOR NUMBER REDUCER PART NUMBER 1 HP- 1 4 5 0 RPM- 5 0 HZ- 3 8 0 V- 3 P DPSL 1 0 AUGER- 8 "...
  • Page 111 DIS-STD-575V-LSN-2020 STANDARD DI SCHARGE SYSTEM ( FOR L EESON/ OHI O GEAR GEAR REDUCERS) AL L MOTORS – 5 7 5 V- 3 P MOTOR GEAR PART GEAR REDUCER MODEL TYPE MOTOR NUMBER REDUCER PART NUMBER 1 HP- 1 7 5 0 RPM- 6 0 HZ- 5 7 5 V- 3 P DPSL 1 0 AUGER- 8 "...
  • Page 112 SHEAVES-230-240-480-575-380V-2020 SHEAVES & BUSHINGS STANDARD LEVELING SYSTEM (AUGER) 230V-1P & 240/480/575V-3P & 380V-3P 50HZ MOTOR AUGER MODEL SHEAVE BUSHING SHEAVE BUSHING 2B3.4 SH 7/8 2B15.4 SK 1-1/4 DP10 DP15 2B3.4 SH 1-1/8 2B15.4 SK 1-1/4 DP20 2B3.4 SH 1-1/8 2B15.4 SK 1-1/4 DP30 2B3.4...
  • Page 113 SPROCKET-230-240-480-575V-MAN-2020 SPROCKET CHART FOR 1 1 / 4 ” AUGER SHAFTS 2 3 0 V- 1 P – 2 4 0 V- 3 P – 4 8 0 V- 3 P - 5 7 5 V- 3 P METERING DC GEAR AUGER MODEL AUGER SHAFT...
  • Page 114 SPROCKET-380V-MAN-2020 SPROCKET CHART FOR 1 1 / 4 ” AUGER SHAFTS 3 8 0 V- 3 P METERI NG DC GEAR MODEL AUGER REDUCER AUGER SHAFT ROL L S REDUCER DPSL 1 0 4 0 3 2 - 1 4 0 1 2 - 1 4 0 1 6 - 7 / 8 4 0 2 0 - 1 1 / 4 DPSL 1 5...
  • Page 117 Quick-Acting Valves for Crop Driers and Charging Manifold Hoses 7554 Series Applic at ion 7554S Series valves provide instant shut-off and fast opening control on LP-Gas crop driers. They are also ideal for charging manifold hoses, stationary fuel transfer hoses and other applications requiring quick, positive shut-off.
  • Page 118 Sa fe t y Wa r ning — LP-Ga s Pre ssure Re lie f Va lve s Purpose In its continuing quest for safety, REGO® is publishing safety warning bulletins explaining the hazards associated with the WARN I N G use, misuse and aging of REGO®...
  • Page 119 I nspe c t Re gula rly A pressure relief valve discharges when some extraordinary 4. Physical damage. Ice accumulations and improper circumstance causes an over pressure condition in installation could cause mechanical damage. IF THERE ARE the container. If a pressure relief valve is known to have ANY INDICATIONS OF DAMAGE, REPLACE THE VALVE.
  • Page 120 Re gO® Pre ssure Re lie f Va lve s Requirements for Pressure Relief Valves The reasons for this are two-fold: Every container used for storing or hauling LP-Gas and anhydrous If the relief valve is called upon to open, the resulting ammonia must be protected by a pressure relief valve.
  • Page 121 Re gO® Pre ssure Re lie f Va lve s Ordering RegO® Pressure Relief Valves Part Number Explanation When ordering RegO® Pressure Relief Valves, be sure you are Products carrying an “A” or “AA” prefix contain no brass parts and certain that it will sufficiently protect the container as specified in are suitable for NH3.
  • Page 122 Sa fe t y I nform at ion - Re lie f Va lve s Don’t La st Foreve r Debris on valve seats which prevents reseating can occur Use of Protective Caps whenever the valve collects material in the relief valve opening which is not blown out when the relief valve opens.
  • Page 123 MEGR-1630 HIGH FLOW GAS REGULATOR Instruction Manual- Look Inside For: Description Installation Overpressure Protection Startup and Adjustment Shutdown Maintenance Parts Ordering Parts List Marshall Excelsior Company Marshall, MI 49068 269-789-6700 FAX 269-781-8340 www.marshallexcelsior.com...

  • Page 124: Installation

    DESCRIPTION: MEGR-1630 is a spring loaded, self operated pressure regulator for use with inlet pressures as high as 1500 PSIG and outlet pressures between 3 and 500 PSIG. INSTALLATION: Qualified personnel only should perform installation, operation and maintenance in accordance with NFPA 54 &...

  • Page 125: Maintenance

    NOTE: The sum of the outlet pressure and the maximum pressure differential must be greater than the inlet pressure. CAUTION: The maximum outlet emergency pressure (casing pressure) is 550 psig. This number takes precedence over the maximum outlet pressure above the pressure setting. VENTS: The MEGR-1630 pressure regulator is supplied with a screened vent assembly in the 1/4 NPT bonnet vent hole.
  • Page 126 following these procedures, refer to the diagram for item number locations unless otherwise directed. Assembly is the reverse of these procedures. Replacing the Orifice, Valve Disk Assembly and Lever 1. Disconnect the piping from the inlet housing (item 19) 2. Remove 4 screws (item 18) and the housing 3.

  • Page 127: Parts List

    PARTS LIST ITEM DESCRIPTION Nameplate Drive Screws (4 Req'd) Adjusting Screw (See Table 1) Hex Nut Upper Spring Guide (0-275 psig Pressure Range) Upper Spring Guide (over 275 psig Pressure Range) Bonnet - Iron Spring (See Table #1) Screw Lower Spring Guide (0-275 psig Pressure Range) Lower Spring Guide (over 275 psig Pressure Range) Diaphragm - Neoprene Hex Nut (4 Req'd)
  • Page 129 10 - 30.1 - 5 Gas Electro-mechanical Valves - 10/09 Valve model number description Every MAXON gas electro-mechanical valve can be accurately identified by the model number shown on the valve nameplate. The example below shows a typical gas electro-mechanical valve model number, along with the available choices for each item represented in the model number.
  • Page 130 10 - 30.1 - 6 Gas Electro-mechanical Valves - 10/09 Valve model cross reference MAXON valve model numbers have changed to intelligent coded model numbers for easy identification and specification. Valves manufactured prior to October 1, 2008 will contain an older model number system which can be easily cross referenced with the chart below.
  • Page 131 10 - 30.1 - 7 Gas Electro-mechanical Valves - 10/09 Valve body assembly options & specifications Normally-closed shut-off valves Trim MOPD Special service Nominal Flow Body connections Body material package Cv rating rating MOPD rating pipe size capacity available options (mbar) (mbar) [1] 3/4”...
  • Page 132 10 - 30.1 - 8 Gas Electro-mechanical Valves - 10/09 Normally-open vent valves Trim MOPD Special service Nominal Flow Body connections Body material package Cv rating rating MOPD rating pipe size capacity available options (mbar) (mbar) [1] 3/4” A, C 1, cast iron 1, 2, 4 8618...
  • Page 133 10 - 30.1 - 9 Gas Electro-mechanical Valves - 10/09 Valve actuator options Automatic reset valves Solenoid OR Nominal Flow Normal Area Motor Motor Switch circuit board pipe size capacity position classification voltage timing options voltage 3/4” A, B, C, D, E, F, G A, B C, D, E 1, 2 0, 1, 2, 3, 4...
  • Page 134 10 - 30.1 - 10 Gas Electro-mechanical Valves - 10/09 Manual reset valves Nominal Flow Normal Area Solenoid Handle side Switch pipe size capacity position classification voltage plate options options A, B, C, D, E, F, G A, B, C, D, E 0, 1, 2, 3 A, B, C, D, F, G A, B, C, D, E...
  • Page 135 10 - 30.1 - 11 Gas Electro-mechanical Valves - 10/09 Valve body assembly specifications 1) Body 2) Bonnet 3) Seat 4) Disc 5) Follower ring 6) Seat o-ring 7) Body o-ring 8) Wavy spring 9) Stem 10) Spring pin 11) Stem o-ring 12) Striker plate 13) Bumper 14) Flow direction...
  • Page 136 10 - 30.1 - 12 Gas Electro-mechanical Valves - 10/09 Valve body assembly - gas compatibility Agency approvals Suggested material options and certifications MOPD code rating CE [4] Body seals Body & Trim & bumper bonnet package A, B, C, E, F 1, 2, 5, 6 1, 2 Std.
  • Page 137 10 - 30.1 - 13 Gas Electro-mechanical Valves - 10/09 Electrical data General MAXON shut-off valves are electrically actuated from a power source. Standard assemblies include an internal holding solenoid or clutch and printed circuit board. Position switch wiring diagrams (reproduced below) are part of each valve assembly, summarizing electrical data and wiring for a valve equipped with terminal block and a full complement of optional switches.
  • Page 138 10 - 30.1 - 14 Gas Electro-mechanical Valves - 10/09 Figure 2: Normally-open valves 26379P NORMALLY OPEN VALVE VCS-1 VCS-2 VOS-1 VOS-2 Standard and CP valves L(+) N(-) SPDT SPDT SPDT SPDT DPDT DPDT VCS-2 VOS-1 GENERAL PURPOSE AREA DIVISION 2 AREA VCS-1 VOS-2 SPDT...
  • Page 139 10 - 30.1 - 18 Gas Electro-mechanical Valves - 10/09 Dimensions and weights Valve bodies: 3/4” (DN20) to 3” (DN80) Body connection A & C Body connection B, D & H 1) (2) 1/4” NPT test connection Body connection E Body connection F Approximate dimensions (in mm) Approximate weight (in kg)
  • Page 140 10 - 30.1 - 19 Gas Electro-mechanical Valves - 10/09 Valve actuators: 3/4” through 1-1/2” valves Automatic reset type (SMA11, SMA21, SMA12, SMA22) (formerly 5000, STO-A, 5000 NI, STO-A-NI) 1) (2) 3/4” NPT conduit connection 2) (2) 1/4” NPT test connection 3) Terminal block cover Manual reset type (SMM11, SMM21, SMM12, SMM22)
  • Page 141 10 - 30.1 - 20 Gas Electro-mechanical Valves - 10/09 Valve actuators: 2” through 3” valves Automatic reset type (SMA11, SMA21, SMA12, SMA22) (formerly 5000, STO-A, 5000 NI, STO-A-NI) 1) (2) 3/4” NPT conduit connection 2) (2) 1/4” NPT test con- nection 3) Terminal block cover Manual reset type SMM11, SMM21, SMM12, SMM22)
  • Page 142 10 - 30.1 - 24 Gas Electro-mechanical Valves - 10/09 Available top assembly positions The valve top assembly can be positioned on the body in four different orientations. See sketches below to determine the designation of the required orientation for your application. Position “R”...
  • Page 143 10 - 30.1 - 27 Gas Electro-mechanical Valves - 10/09 Valve actuator spare part identification 3/4” standard flow through Manual reset actuator Automatic reset actuator 4” CP actuators (side view) (side view) 1) Nameplate 2) Solenoid 3) VOS motor limit/signal switch for normally- closed valve;...
  • Page 144 10 - 30.1 - 28 Gas Electro-mechanical Valves - 10/09 Please read the operating and mounting instructions before using the equipment. Install the equipment in compliance with the prevailing regulations. Bedrijfs- en montagehandleiding voor gebruik goed lezen! Apparaat moet volgens de geldende voorschriften worden geïnstalleerd.
  • Page 145 10 - 30.1 - 29 Gas Electro-mechanical Valves - 10/09 The installation, operation and maintenance instructions contain important information that must be read and followed by anyone operating or servicing this product. Do not operate or service this equipment unless the instructions have been read. IMPROPER INSTALLATION OR USE OF THIS PRODUCT COULD RESULT IN BODILY INJURY OR DEATH.
  • Page 146 10 - 30.1 - 30 Gas Electro-mechanical Valves - 10/09 Component identification Automatic (motorized) valve Manual valve Current model designation Current model designation (former model designation) (former model designation) SMA11 (5000), CMA11 (5000 CP), SMM11 (808), CMM11 (808 CP), SMM21 (STO-M) SMA21 (STO-A), CMA21 (STO-A-CP) 1) Access cover screws 2) Access cover...
  • Page 147 10 - 30.1 - 31 Gas Electro-mechanical Valves - 10/09 Installation A gas filter or strainer of 40 mesh (0.6 mm) or smaller is recommended in the fuel gas piping to protect the downstream safety shut-off valves. Properly support and pipe the valve in the direction of the flow arrow on the valve body. Valve seats are directional. Sealing will be maintained at full rated pressures in one direction only.
  • Page 148 10 - 30.1 - 32 Gas Electro-mechanical Valves - 10/09 Actuator assembly rotation MAXON electro-mechanical valves should be ordered in a configuration compatible with planned piping. If valve orientation is not correct, the actuator assembly can be rotated in 90° increments around the valve body centerline axis using the procedure below.
  • Page 149 10 - 30.1 - 33 Gas Electro-mechanical Valves - 10/09 Field installation of valve position switch General Shut off fuel supply upstream of valve, then de-energize valve electrically. Remove terminal block and access cover to provide access, being careful not to damage gaskets. Compare with illustrations below to identify your valve type.
  • Page 150 10 - 30.1 - 34 Gas Electro-mechanical Valves - 10/09 Wand position (for normally-closed valves) VOS switch wand should be VCS switch wand should be actuated from above actuated from below Mounting brackets Mounting bracket A Mounting bracket B VCS switch mounts on back of bracket 3”, 4”, 6”...
  • Page 151 10 - 30.1 - 37 Gas Electro-mechanical Valves - 10/09 Maintenance instructions MAXON electro-mechanical valves are endurance tested far in excess of the most stringent requirements of the various approval agencies. They are designed for long life even if frequently cycled, and to be as maintenance-free and trouble-free as possible. A valve operational test should be performed on an annual basis.
  • Page 153 Technical Instructions VA Series Document No. VA-1000 Actuator Mounting Instructions In some cases, the actuator may need to be removed from the valve temporarily during piping. Additionally, the actuator and bracket can be rotated relative to the valve for wiring purposes. The instructions below and the exploded views in Figures 1 and 2 are a guide to proper disassembly and reassembly of a VA…...
  • Page 154 VA Series Technical Instructions Document No. VA-1000 Actuator Mounting Instructions (continued) Figure 1: Exploded View of VA45.2-NF-200 SCC Inc. Page 5...
  • Page 155 Technical Instructions VA Series Document No. VA-1000 Actuator Mounting Instructions (continued) SQM50 Actuators Disassembly 1. Start with the valve at the closed / 0° position. 2. Using a 10mm open end wrench (or crescent wrench), remove the (4) M6 hex head cap screws and lock washers that fasten the actuator to the bracket.
  • Page 157 Identify Board # and Terminal ID Row Board # Identification SQM4x.x1xxxx – Board #1 SQM4x.x2xxxx – Board #2 Etc… SQM4x.x8xxxx – Board #8 Since the same template plate below is used on all actuators, the appropriate Terminal Identification Row needs to be determined. Rows are identified below. Board #3, #6, #7, #8 Board #1, #2, #4, #5 Increasing for all...
  • Page 158 Wiring of SQM4x.x5xxxx Technical Instruction SQM4 page 23 for additional information Board 5 Green Indicates the minimum wiring for actuator to operate X2-7, Close/ Ignition (VI) X2-8 Neutral X2-6, Low-Fire / Ignition pos. reached (V,VI) X2-9, Controller Release X2-5, AUX switch (IV) / NC opener to Modulate X2-4, Aux Switch (IV) X1-1, 4-20 mA (+)
  • Page 159 Actuator SQM40.../SQM41... SQM40... Actuators for air and gas dampers SQM41... ∂ Electromotoric actuator up to 18 Nm torque ∂ Clockwise and counterclockwise variants ∂ Running times from 5 to 65 seconds ∂ Different shaft ends available Electronic version with analog control input ∂...
  • Page 160 Supplementary documentation Type of documentation Product type Documentation number Data Sheet SQM45... / SQM48... N7814 Data Sheet SQM10... / SQM20... N7812 Data Sheet ASZ... N7921 Mounting Instruction ASZ22.3x 74 319 0921 0 (M7921) Warning notes To avoid injury to persons, damage to property or the environment, the following warning notes must be observed! Only qualified personnel may open, interfere with or modify the actuators! ∂...
  • Page 161 Mounting notes ∂ Ensure that the relevant national safety regulations and notes on standards are complied with In geographical areas where DIN regulations apply, the mounting and installation ∂ requirements of VDE must be satisfied, especially DIN/VDE 0100, 0550 and DIN/VDE 0722 Make certain that the actuator is not exposed to direct solar radiation ∂...
  • Page 162 Electrical connection ∂ The actuators must always be powered via a prefuse of max. 6.3 AT (as per DIN EN 6012- 2/5) ∂ For the protective earth connection, the housing of all variants has a marked PE connecting terminal. A tightening torque of 1.2 Nm must be observed for fitting the screw ∂...
  • Page 163 Cam settings The mechanical setting facility for the cams is physically separated from the connection terminals. When the actuator is disconnected from power, the switches can be adjusted via a scale. The cams can be changed via adjusting screws. The scale indicates the angles of the switching points.
  • Page 164 Lifetime The actuator has a designed lifetime* of 250,000 start cycles (close  open  close) under load with the rated torque in the entire rotation angle range, which under normal operating conditions in heating mode corresponds to approx. 10 years of usage (starting from the date of manufacture on the device type plate). This lifetime is based on the endurance tests specified in standard EN 298.
  • Page 165 Mechanical design Housing ∂ Lower housing part made of die-cast aluminum ∂ Housing cover made of impact-proof and heat-resistant plastic Drive motor Synchronous motor ∂ Coupling ∂ Shaft can be manually disengaged from the motor by operating the coupling (coupling pin (K1)) ∂...
  • Page 166 Type summary (other types on request) Direction of Regional Operating Potentio- rotation version voltage meter Article no. Type ˜ 2.5 Nm / 5 s ˜ ˜ BPZ:SQM40.025A21 SQM40.025A21 ˜ 2.5 Nm / 5 s ˜ ˜ ˜ ˜ BPZ:SQM40.065A23 SQM40.065A23 ˜...
  • Page 167 Type summary (other types on request) (cont’d) Direction of Regional Operating Potentio- rotation version voltage meter Article no. Type 5 Nm / 15 s ˜ ˜ ˜ BPZ:SQM40.185R11 SQM40.185R11 ˜ ˜ 10 Nm / 30 s ˜ ˜ ˜ ˜ BPZ:SQM40.215R11 SQM40.215R11 10 Nm / 30 s...
  • Page 168 Type summary (other types on request) (cont’d) Direction of Regional Operating Potentio- rotation version voltage meter Article no. Type 10 Nm / 30 s ˜ BPZ:SQM40.265A11 SQM40.265A11 ˜ ˜ ˜ ˜ 10 Nm / 30 s BPZ:SQM40.265A20 SQM40.265A20 ˜ ˜ ˜...
  • Page 169 Type summary (other types on request) (cont’d) Direction of Regional Operating Potentio- rotation version voltage meter Article no. Type ˜ 18 Nm / 65 s ˜ ˜ ˜ ˜ BPZ:SQM40.387R11 SQM40.387R11 5 Nm / 15 s ˜ ˜ BPZ:SQM41.141A21 SQM41.141A21 ˜...
  • Page 170 Type summary (other types on request) (cont’d) Direction of Regional Operating Potentio- rotation version voltage meter Article no. Type ˜ 10 Nm / 30 s ˜ ˜ ˜ BPZ:SQM41.254R11 SQM41.254R11 10 Nm / 30 s ˜ ˜ ˜ ˜ S55452-D305-A100 SQM41.255R11 10 Nm / 30 s ˜...
  • Page 171 Type summary (cont´d) (other types on request) (cont’d) Note Β Not all types of actuators are available ex stock. Additional versions are available on request. Drive shafts: Shaft Type of drive shaft Torque ⊕ 10 mm, woodruff key as per DIN 6888 Max.
  • Page 172 Accessories Accessories must be ordered as separate items: Proportional controlling element with mounting plate VKP... Proportional controlling element for mounting between threaded flanges in gas trains. Refer to data sheet N7632. Mounting plate ASK33.1 Article no.: BPZ:ASK33.1 For mounting the SQM40... / SQM41... onto the VKP... proportional controlling element See Mounting Instruction 74 319 0843 0 (M7646) Mounting kit ASK33.4...
  • Page 173 Technical Data General unit data Operating voltage - SQM4x.xxxA1… AC 120 V -15%/+10% - SQM4x.xxxA2… AC 230 V -15%/+10% - SQM4x.xxxR1… AC 120 V -15%/+10% Operating frequency 50…60 Hz ±6% Drive motor Synchronous motor Power consumption 10 VA Operating angle Between 0°...
  • Page 174 Technical Data (cont´d) Lifetime 250,000 start cycles (close  open  close) under load with the rated torque in the entire rotation angle range. 2,000,000 control cycles under load with 75% of rated torque in rotation angle range of 10° Analog inputs General Linearity...
  • Page 175 Technical Data (cont´d) Conductive plastic Resistance 2*1000 ς double potentiometer with potentiometer separated resistance tracks Operating voltage DC 10 V Permissible hysteresis 0.3% of 90° or of 135°, depending on type Total resistance tolerance ±20% Effective angular rotation 90° or 135°, depending on type Terminal strip Triple-pole For cross-sectional areas of...
  • Page 176 Connection diagrams and connection terminals SQM4x.x1xxxx Electronic version with independent high-fire and low-fire feedback Note! Β For the sake of clarity, the plug-in contacts do not appear in sequential order in the circuit diagram. Consecutive numbers are printed on the unit, however, e.g. 1…7. Mains voltage terminals Dimensioning X1-1...
  • Page 177 Connection diagrams and connection terminals (cont’d) SQM4x.x2xxxx Electronic version, only for types with 5 seconds running time Note! Β For the sake of clarity, the plug-in contacts do not appear in sequential order in the circuit diagram. Consecutive numbers are printed on the unit, however, e.g. 1…7. Low-voltage terminals Dimensioning X1-1...
  • Page 178 Connection diagrams and connection terminals (cont’d) SQM4x.x3xxxx 2-position version with 2 end switches and 2 auxiliary switches, 3 relays Note! Β For the sake of clarity, the plug-in contacts do not appear in sequential order in the circuit diagram. Consecutive numbers are printed on the unit, however, e.g. 1…7. Mains voltage terminals Dimensioning X1-1...
  • Page 179 Connection diagrams and connection terminals (cont’d) SQM4x.x4xxxx Electronic version Note! Β For the sake of clarity, the plug-in contacts do not appear in sequential order in the circuit diagram. Consecutive numbers are printed on the unit, however, e.g. 1…7. Low-voltage terminals Dimensioning X1-1 2...10 V...
  • Page 180 Connection diagrams and connection terminals (cont’d) Max. potentiometer (high-fire) 90° / 135° Max. Min. 0° Min. potentiometer (low-fire) 7817z08e/0315 Β Note! When starting up, the direction of rotation of the potentiometer setting must be observed: 90° / 135° Max. Min. 0°...
  • Page 181 Connection diagrams and connection terminals (cont’d) SQM4x.x5xxxx Electronic version with independent auxiliary switch Note! Β For the sake of clarity, the plug-in contacts do not appear in sequential order in the circuit diagram. Consecutive numbers are printed on the unit, however, e.g. 1…7. Low-voltage terminals Dimensioning X1-1...
  • Page 182 Connection diagrams and connection terminals (cont’d) 3-position version with 2 end switches and 4 auxiliary switches SQM4x.x6xxxx Note! Β For the sake of clarity, the plug-in contacts do not appear in sequential order in the circuit diagram. Consecutive numbers are printed on the unit, however, e.g. 1…7. Mains voltage terminals Dimensioning X1-1...
  • Page 183 Connection diagrams and connection terminals (cont’d) 2-position version with 2 end switches and 3 auxiliary switches, 1 relay SQM4x.x7xxxx Note! Β For the sake of clarity, the plug-in contacts do not appear in sequential order in the circuit diagram. Consecutive numbers are printed on the unit, however, e.g. 1…7. Mains voltage terminals Dimensioning X1-1...
  • Page 184 Connection diagrams and connection terminals (cont’d) 3 position version with 2 end switches and 4 auxiliary switches SQM4x.x8xxxx Note! Β For the sake of clarity, the plug-in contacts do not appear in sequential order in the circuit diagram. Consecutive numbers are printed on the unit, however, e.g. 1…7. Mains voltage terminals Dimensioning X1-1...
  • Page 185 Position indication, preadjustment and coloring of the cams Position indication SQM40... Position indication SQM41... External angle scale Internal angle scale Marking in slot shape Arrow marking Pay attention to markings! Β Note! The setting of the switch positions must be checked before startup. Electronic version SQM4x.x1xxxx SQM4x.x4xxxx...
  • Page 186 Position indication, preadjustment and coloring of the cams (cont’d) 3 position version SQM4x.x6xxxx SQM4x.x8xxxx Color Position Preadjustment Cam I High-fire 90° Cam II Blue OFF / low-fire 0° Cam III Orange Ignition position 15° Cam IV Yellow 30° Auxiliary switch Cam V Black 30°...
  • Page 187 Dimensions Dimensions in mm SQM40.../SQM41… 93.5 3 blind holes (10 mm deep) for self-tapping screws M5 +0.1 4 through holes for screws M5 5 deep SQM4x.xxxAxxx connecting cover SQM4x.xxxRxxx connecting cover Shaft no. Slot for woodruff key SQM4x.xx1xxx 3x3.7 series A Din6888 10.6 SQM4x.xx4xxx...
  • Page 223  MC-5000 MAY 10, 2017 FIREYE MODULAR MicroM FLAME SAFEGUARD CONTROLS APPROVED WARNING: Selection of this control for a particular application should be made by a com- petent professional, licensed by a state or other government agency. Inappropriate application of this product could result in an unsafe condition hazardous to life and property. DESCRIPTION The Fireye MicroM Series Flame Safeguard Control is a compact, microprocessor based, modular burner management system designed to provide automatic ignition and continuous flame monitoring...

  • Page 224: Specifications

     MEC230 type chassis include the MEP100, MEP 200 and MEP500 series. Programmers for use with the MEC320 and MEC480 type chassis include the MEP300, MEP400 and MEP600 series. Some programmer modules are equipped with a series of dipswitches to select Purge Timing, Pilot Trial for Ignition (PTFI) timing, Proof of Air flow open at start, Post Purge, Recycle and Non-Recy- cle operation.
  • Page 225  LOAD RATINGS: All Ratings are 120V, 60 Hz Table 2: Fireye Terminal Typical Load Maximum Rating @120V 60 Hz 125 VA pilot duty (solenoid valve) plus 3 or 4 Pilot valve(s) 250 VA (Transformer) Individual or combined Solenoid valve Ignition Transformer 125 VA pilot duty (solenoid) or Main Fuel Valve(s)
  • Page 226  MOUNTING BASE 3/16” DIA. MOUNTING HOLES (4) KNOCKOUTS (12) FOR 1/2” CONDUIT 5 3/16” 4” µΜ 3/16” MOUNTING 1/2” HOLES 5 3/16” 5 5/16” 4” 1/2”’ 1.06” DIA. 13/16” HEX 2 3/8” 2.58” ”L” (27.0) (20.6) (60.3) (50.8) 1 3/16” (30) 15/16”...
  • Page 227  WARNING: This equipment is a Class B digital apparatus which complies with the Radio Interference Regulations, CRC c.1374. CAUTION: Published load ratings assume that no control be required to handle inrush current more often than once in 15 seconds. The use of control switches, solenoids, relays, etc.

  • Page 228: Ordering Information

     ORDERING INFORMATION MicroM Chassis Types (For use with MEP1XX, MEP2XX, and MEP5XX, includes dust cover) MEC120 120 VAC input with standard plug-in board. MEC120R 120 VAC input with remote reset capability. MEC120D 120 VAC input with alpha-numeric display interface to ED510. MEC120RD 120 VAC input with alpha-numeric display interface to ED510 and remote reset capability.
  • Page 229  MicroM Programmer Models (For use with MEC320 and MEC 480 Chassis) MEP300 Relight operation, 10 sec. fixed PTFI, 5 sec.pilot proving period, 5 second MTFI. lockout on flame fail during PTFI, pilot proving and MTFI. Recycle on air flow open. No post purge. Reset on line voltage. MEP304 Non-recycle on flame fail, 5 sec.
  • Page 230  Accessories ED510 Two line by 16 character, back lit LCD display with keypad. ED580-2, -4, -8 Remote display cable with RJ45 connection in 2, 4 or 8 foot long lengths. To be used with the appropriate daughter board. EC485 RS232 to RS485 converter with power supply and RJ12 jack.
  • Page 231  WARNING: Installer must be trained and qualified. Follow the burner manufacturer’s instructions, if supplied. Otherwise, proceed as follows: INSTALLATION OF CONTROL, SCANNERS AND FLAME DETECTORS Wiring Base Mount the wiring base on the burner or on a panel. The location should be free from excessive vibra- tion and within the specified ambient temperature rating.
  • Page 232  INSTALLING THE PROGRAMMER AND AMPLIFIER MODULES WARNING: Remove power from the control before proceeding. FIGURE 1. AMPLIFIER PROGRAMMER Select the appropriate programmer and amplifier modules for your application. Remove the dust cover from the chassis. Insert the amplifier module into the slot in the corner of the chassis and gen- tly push the module into position.
  • Page 233  FIGURE 2. Replaceable Fuse Location PROGRAMMER DIPSWITCH SETTINGS NOTE: The dipswitch settings become permanently stored within the programmer’s eeprom memory after 8 hours of continuous electrical operation. The first 8 hours of continuous operation is determined from the value of system hours being accu- mulated by the MicroM.

  • Page 234: Led Indicator Lights

     Once the switches are set, they become permanently stored after 8 hours of continuous operation or they can be manually set through the use of the optional ED510 display. Refer to the section using the optional ED510 display for detailed information. Where applicable, each MicroM programmer is shipped with dip-switch 6 set to non-recycle on flame fail, dipswitch 4 set to 5 second PTFI time, and dipswitches 1 &...

  • Page 235: Lockout Codes

     PTFI: This LED is illuminated only during the pilot trial for ignition period and the stabilization period when so equipped. Flame: This LED is on whenever a flame signal is detected, and the control is not in a locked out state.
  • Page 236  DIAGNOSTIC MESSAGES - TROUBLESHOOTING GUIDE POSSIBLE CAUSE SOLUTION Check Programmer Voltage on Terminal 5 at improper time. Inspect wiring to main fuel valve Welded watchdog relay Replace MEC chassis Internal diagnostic failure Replace MEP programmer Check Chassis Voltage on Terminal 3 or 4 at improper time. Inspect wiring to pilot valve and igniter.
  • Page 237  Safety Shutdown In the event pilot flame is not detected at the end of the 10 second PTFI period, the pilot gas valve and spark ignition are de-energized. A safety lockout occurs which de-energizes the burner motor and energizes the lockout alarm relay circuit, lighting the Alarm LED, 15 seconds after the safety lockout occurs.

  • Page 238: Timing Chart

     following a post purge of 30 seconds and a safe start check. Failure to ignition spark on the second attempt results in safety lockout. MEP100P The MEP100P programmers provides a fixed 15 second post purge period upon detection of the operating Control (1-7) or Air Flow switch (7-6) opening.

  • Page 239: Timing Charts

     If non-recycle operation is selected, in the event of a main flame failure, power is removed from Ter- minal 3 and Terminal 5. The control will enter a forced post purge period of 15 seconds, after which the Alarm LED is illuminated and the alarm relay is energized putting power on Terminal A. The MEP230H programmer operates the same as the MEP230 with the exception of an additional 8 second pilot stabilization.
  • Page 240  TYPE MEP236 PROGRAMMING SEQUENCE INTERLOCK FIRING PURGE L1/7 L1/7 AIR FLOW PERIOD COMPLETE PROVEN SELECTABLE POST PURGE SELECTABLE PILOT PURGE MFSP* SELECTABLE PTFI 6 SEC 5 OR10 SEC IGNITER MAIN VALVE *MAIN FLAME STABILIZATION PERIOD Terminal #5 is energized 3 seconds after the flame is detected. Selectable Recycle/Non-Recycle operation on loss of flame after flame is proven.
  • Page 241  A “run-check” switch is also provided to assist in testing size, position and stabilization of pilot in conjunction with the flame detector, For the MEP560 and MEP562, after pilot flame is detected, the control enters an 8 second pilot stabi- lization period with Terminal 3 and Terminal 4 energized.
  • Page 242  TYPE MEP562 PROGRAMMING SEQUENCE INTERLOCK FIRING PURGE L1/7 L1/7 AIR FLOW PERIOD COMPLETE PROVEN SELECTABLE POST PURGE SELECTABLE PURGE PTFI STABLIZATION 5 OR10 SEC PERIOD 8 SEC MTFI 10 SEC Pilot stabilization timing begins as soon as flame is proven. Lockout on loss of air flow (interlock circuit) after flame is proven.
  • Page 243  TYPE MEP304 PROGRAMMING SEQUENCE INTERLOCK FIRING PURGE L1/7 L1/7 AIR FLOW PERIOD COMPLETE PROVEN POST PURGE 5 SECOND PURGE 5 SEC 10 SEC 10 SEC INTERRUPTED PILOT PTFI MTFI PILOT PROVING 0 Second post purge on operating control open. 15 Second post purge on flame fail. Non-recycle operation on flame fail.
  • Page 244  TYPE MEP397 PROGRAMMING SEQUENCE INTERLOCK FIRING PURGE L1/7 L1/7 AIR FLOW PERIOD COMPLETE PROVEN POST PURGE 1 5 SECOND PURGE 5 SEC 7 SEC 5 SEC INTERRUPTED PILOT PTFI MTFI PILOT PROVING 0 Second post purge on operating control open. 15 Second post purge of flame fail during PTFI, Proving and MTFI.
  • Page 245  TYPE MEP697 PROGRAMMING SEQUENCE FIRING INTERLOCK PURGE L1/7 PERIOD L1/7 AIR FLOW COMPLETE (AUTO) PROVEN SELECTABLE POST PURGE SELECTABLE PURGE 5/10 SEC 5 SEC 10 SEC INTERRUPTED PILOT SELECTABLE MTFI PILOT PROVING PTFI MODULATE CONTACTS Lockout on flame fail. Lockout on air flow switch opening while main flame energized.
  • Page 246  Function Any MicroM chassis type with the appropriate plug-in board installed provides remote reset capabil- ities in the event of a lockout condition. A remote reset switch consists of a dry contact such as a remote momentary push-button wired to the two (2) terminals located on the plug-in board as shown in Figure 5.

  • Page 247: Remote Display

     MicroM will reset from the lockout state only. This is especially useful where, through the use of remote reset daughter boards, all reset inputs can be connected together to a common reset pushbut- ton or intelligent device (PLC). If the push button is depressed as described above it will only cause the unit that is in lockout to reset and not effect any other units.
  • Page 248  OPERATING STATUS TIMING (Standby, Purge, PTFI, (During Purge or PTFI) OR Auto, etc.) FLAME SIGNAL STRENGTH (During PTFI, MTFI, or Auto) PURGE 00:05 STARTING BURNER ADDITIONAL INFORMATION ON OPERATING STATUS (Flame Signal Strength, Cause of current Lockout, etc.) OR ARROW displayed when MODE key is required to BURNER HISTORY (SCRL key required)
  • Page 249  LOCKOUT HISTORY The sub-menu “LOCKOUT HISTORY” will display the last six (6) lockouts, along with the burner cycle and burner hour when the lockout occurred. When the MODE key is pressed, the screen will display the most recent lockout condition and the number of that lockout (e.g. LO #127 represents the 127th lockout of that control).
  • Page 250  UNIT ADDRESS 00 SCRL PRESS RESET TO Force storage of dipswitch settings before 8 hours time-out. ACCEPT SETTINGS MODE AUTO Mode key returns to normal run message. SYSTEM INFO The sub-menu “SYSTEM INFO” allows the user to review information pertaining to the operation of the control (e.g.
  • Page 251  The format of the data is 4800, N, 8, 1 meaning 4800 baud, no parity, and 1 stop bit. Below is a table of currently available messages provided by the MicroM programmers, followed by a description where necessary. MESSAGE WORDS RESPONSE VALUE...
  • Page 252  Message 26 returns the current operating status as well as stored burner hours and burner cycles as a snapshot of the entire MicroM system. When all 9 words are requested, the data returned consists of STATUS, MSGN, FLAME, INPUTS, OUTPUTS, BNRMINS, and BNRCYCS. The MSGN being transmitted is a numerical value and must be interpreted by the communicating device, which actually is an advantage since this can be made to be whatever message text the end user wants.
  • Page 253  It is suggested that repeated polling interval not be less than 200 mSec per request. Requesting data such as burner minutes, system minutes and burner cycles be kept at a minimum due to the amount of processing time required to gather that data. Table 1: Logic Dispatch LOGIC DISPATCHER VALUE...
  • Page 254  Table 2: Program Module Identification Programmer Module Identifier MEP100 0H, 01H MEP101 0H, 02H MEP102 0H, 03H MEP103 0H, 04H MEP100P 0H, 05H MEP109 0H, 06H MEP130 0H, 08H MEP104 0H, 09H MEP105 0H, 0AH MEP106 0H, 0BH MEP107 0H, 0CH MEP108 0H, 0DH...

  • Page 255: Ignition Timing

     Table 3: Message Description MicroM Message L1-7 OPEN FALSE FLAME STARTING BURNER INTRLCK OPEN LOCKOUT LINE FREQUENCY NOISE DETECTED LOCKOUT FLAME FAIL - PTFI UNIT ADDRESS MTFI IGNITION TIMING FLAME SIGNAL CYCLE COMPLETE LOCKOUT AMPLIFIER HIGH COUNT FAIL LOCKOUT FLAME FAIL – MTFI LOCKOUT FALSE FLAME –...
  • Page 256  line of the display. Pressing and releasing the RESET key will cause the address to increment. The address after 31 is 0. The second method is to use the local reset located on the plug-in board. It is first necessary to open the operating control (L1-7) to have the MicroM in the IDLE or STANDBY position.

  • Page 257: Installation Testing

     EXTERNAL METER CONNECTIONS The test jacks are located on the amplifier card. If external access is desired for a panel meter the shown below will assist you in locating the position to drill through on the front cover. The hole sizes should be large enough to accommodate the body of the meter probes.
  • Page 258  When using a flame rectification amplifier, a micro-ammeter may be connected in series with the wire to Terminal S2. Normal flame will produce a meter reading between 4 and 10 micro-amps. With the test meter on the AC scale, line and load voltages may be measured at the identified test points on the chassis.
  • Page 259  Manually shut off all fuel and observe the loss of flame signal on the test meter. If flame signal does not reduce to zero within the flame failure response time of the control (FFRT determined by the selection of the amplifier), verify the UV flame detector is not actu- ated by the ignition spark.
  • Page 260  NO HEAT MicroM SERVICE GUIDE O.C. ON TEST JACKS ALARM BLINKING SITUATION #1 ALL TYPES NORMAL LOCKOUT 4-10 VDC INSTALL DC VOLTMETER AMPLIFIER MODULE IN TEST JACKS MP100 4-7 SECONDS SHUT FUEL MP230 PREPURGE DELAY TIME SUPPLY COCK FLAME WAIT LED COME PROPER...
  • Page 261 ...
  • Page 262  Wiring Arrangements IMPORTANT: Use moisture resistant wire rated 90°C minimum. CAUTION: When powered, 560 VAC across S1, S2 with MEUV4, MEUV1, MEUVS4 and MEUVS1; 260 VAC across S1, S2 with MERT4 and MERT1. CAUTION: Control wiring procedures which deviate from those shown in the diagrams may bypass safety functions designed in the control.
  • Page 263  WIRING ARRANGEMENT FOR PILOT IGNITED BURNERS AND PROVISION FOR MAIN FLAME STABILIZATION FIGURE 7. USING MEP236 SERIES PROGRAMMERS AIR FLOW OPERATING INTERLOCK CONTROLS FLAME SCANNER FLAME ONLY (WATCHDOG) FLAME AMPLIFIER 120VAC 50/60Hz KF-1 INTERMITTENT SPARK MAIN VALVE ALARM BLOWER MOTOR IGNITION PILOT VALVE CONTACTOR...
  • Page 264  FIGURE 9. WIRING ARRANGEMENT FOR PILOT IGNITED BURNERS AND INTERRUPTED PILOT USING MEP500 SERIES PROGRAMMERS AIR FLOW OPERATING INTERLOCK CONTROL FLAME SCANNER FLAME ONLY (WATCHDOG) FLAME AMPLIFIER 120VAC 50/60Hz KF-1 INTERMITTENT INTERRUPTED MAIN FUEL ALARM BLOWER MOTER GAS PILOT VALVE PILOT GAS VALVE VALVE AND IGNITION...
  • Page 265  WIRING ARRANGEMENT FOR FLAME SWITCHES USING MEP100 PROGRAMMERS FIGURE 11. ENABLE/DISABLE INPUT FLAME SCANNER FLAME ONLY (WATCHDOG) FLAME AMPLIFIER 120VAC 50/60Hz KF-2 KF-1 ISOLATED SWITCHED OUTPUTS OUTPUTS REFER TO LOAD RATING VOLTAGE SOURCE * FUSE F1 CAN BE REMOVED NOTE: Air Flow LED will blink while flame is detected and KF relay is energized.
  • Page 266  ALTERNATE WIRING ARRANGEMENT FOR MEP CONTROLS FIGURE 13. A. FOR MANUAL A START-STOP STATION MAY BE ADDED TO REQUIRE OPERATOR START-UP EACH TIME THE BURNER FIRES. PILOT VALVE MAIN FUEL VALVE IGNITION START ON-OFF STOP LIMIT SW LR-2 BLOWER ALARM LR-1 CONTACTOR...
  • Page 267  BACKWARD COMPATIBLE WIRING USING MEP100 AND MEP200 SERIES PROGRAMMERS (PILOT IGNITED FIGURE 14. BURNERS). AIR FLOW OPERATING INTERLOCK CONTROL FLAME SCANNER FLAME ONLY (WATCHDOG) FLAME AMPLIFIER 120VAC 50/60Hz KF-2 KF-1 INTERMITTENT SPARK MAIN VALVE ALARM BLOWER MOTOR IGNITION PILOT VALVE CONTACTOR For intermittent ignition, connect to terminal 3 Combined current from Terminal 8 must not exceed 9.8 Amps...
  • Page 268  SUGGESTED GROUNDING RULES The MicroM system, being microprocessor based, requires a ground system that provides a zero- voltage reference. The voltage measured from L2 to all other terminals except L1 should be 0 volts. The most effective ground is to run the ground wire in the same raceway as the hot and neutral from the main distribution service panel (not intermediate sub-panels) to the burner control panel and insure that this ground wire is well bonded to the control panel.
  • Page 269  COMMUNICATIONS When interfacing Fireye controls to a communication system, be it an E500, PLC or other micropro- cessor based device, ferrite cores should also be utilized. Proper twisted shielded pair cable must be utilized. In a multi-drop system, the shields should be tied together within a cabinet and not to any ground point.
  • Page 270  than halfway through. Swivel flanges are available if desired (#60-302 for UV1A, UV2 Scan- ners, #60-1664-3 for 45UV5). The sight pipe must permit an unobstructed view of the pilot and/ or main flame, and both pilot and main flames must completely cover the scanner field of view. SCANNER MUST HAVE UNOBSTRUCTED FLAME MUST COMPLETELY COVER VIEW OF FLAME...
  • Page 271  OPERATION — 45UV5 SELF-CHECKING UV SCANNER Self-checking ultraviolet scanners should be used in applications where burner firing operation is continuous or where the burner is on for long periods of time without recycling. In addition, ultra- violet self-checking systems are mandatory in some locations. The operation of this type of system consists of maintaining the flame scanning capability at all times while also proving that the ultraviolet tube is firing properly.
  • Page 272  INSTALLATION—INFRARED SCANNER TYPE 48PT2 Where possible, obtain the burner manufacturer’s instructions for mounting the scanner, otherwise proceed as follows: A single scanner is used to detect both pilot and main flames. The sight pipe on which the scanner mounts must be aimed so that the scanner sights a point at the intersection of main and pilot flames. Proper scanner positioning must assure the following: Reliable pilot flame signal.
  • Page 273  INSTALLATION - 69NDl FLAME ROD The 69NDl flame rod proves a gas pilot flame and/or main gas flame. It is a spark plug type unit con- sisting of 1/2" NPT mount, a KANTHAL flame rod, a glazed porcelain insulating rod holder and a spark plug connector for making electrical connections.
  • Page 274  MAINTENANCE Type 48PT2 Infrared and Type UV1A, UV2 and 45UV5 Ultraviolet Scanners The viewing area of the scanner must be kept clean. Even a small amount of contamination will reduce the flame signal reaching the detector by a measurable amount. Wipe the viewing area rou- tinely using a soft cloth dampened with concentrated detergent.
  • Page 275  FIGURE 16. Mounting 45UV5 Scanner #60-1664 #60-1664 1” SWIVEL MOUNT AIR ENTRY 1” SWIVEL MOUNT APERTURE (PURGE AND #53-121 #35-127 COOLING) HEAT INSULATING NIPPLE 2.75” (70) RETAINER STANDARD MOUNTING #34-181 FOR TYPES OF SCANNERS #60-1664 AIR/ENTRY PURGE AIR ENTRY 1”...
  • Page 276  Mounting UV1A/UV1B Scanners FIGURE 18. BURNER FRONT PLATE 1/2” UV SCANNER 1/2” SWIVEL MOUNT 1/2” SWIVEL MOUNT TYPE UV-1A #60-302 #60-302 HEAT INSULATOR #35-69 1/2” NIPPLE 1/2” NIPPLE 2” 2” (51) (51) STANDARD MOUNTING MOUNTING WITH HEAT INSULATING NIPPLE 1/2”...
  • Page 277  M-SERIES TO M-SERIES II TO MICROM CROSS REFERENCE LISTING M-SERIES M-SERIES II REPLACEMENT MODULES MicroM REPLACEMENT MODULES Part Chassis Amplifier Programme Programmer Chassis Amplifier Programmer Programmer Number Dipswitch #8 Dipswitch #6 UVM1D MC120 MAUV1T MP100 MEC120 MEUV1 MEP100 UVM1F MC120 MAUV1 MP100...
  • Page 278  Red jumper wire FIGURE 19. Red wire...
  • Page 279 ...
  • Page 280  NOTICE When Fireye products are combined with equipment manufactured by others and/or integrated into systems designed or manufactured by others, the Fireye warranty, as stated in its General Terms and Conditions of Sale, pertains only to the Fireye products and not to any other equipment or to the com- bined system or its overall performance.
  • Page 285 LP Systems SERIES 8210 Gas Shutoff Valves 8214 1/4" to 3/4" NPT 8262 226787 Features • 2-Way Normally Closed operation. • For liquid petroleum gases (propane) in both liquified and gaseous states. • Applications such as grain dryers, incinerators, space heaters, etc.
  • Page 286 SERIES 8210 8214 8262 226787 Specifications Approx. Operating Pressure Pipe Orifice Shipping Capacity ➀ Differential (psi) Agency Size Size Max. Fluid Const. Weight (ins.) (ins.) Flow Btu/hr. Min. Max. Temp.˚F Catalog Number Ref. Wattage (lbs) COMBUSTION (Fuel Gas) - NORMALLY CLOSED 0.35 27,250 8262G232B...
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