Be sure to support the lower section using a crane or setting it on temporary blocks, etc..

Transcription

1 9. INSTALLATION Position Lower Dryer at Location Position the lower dryer section at the final location. Be sure to support the lower section using a crane or setting it on temporary blocks, etc.. Anchor Lower To Pad / Foundation Most dryer system utilize a NECO support leg option. Some dryer systems utilize both concrete piers and either the NECO legs or customer supplied legs. No matter the method, double-check and verify proper assembly - make sure system is secure. Check & Verify ALL anchor attachment systems before installing optional leg kit or the addition of any upper dryer sections. DETERMINE NEXT STEP -- If the dryer is configured for a NECO support leg system, proceed to the following section. If other means are being used, after the lower section achor system is completed and verified continue with Stack and Secure s. 89

2 Install NECO Leg Kit (OPTIONAL) NOTE: Skip this section if the dryer system does not utilize the optional NECO lifting legs. OVERVIEW The optional lifting leg system is based on requirements that vary with the size and capacity of the dryer. Leg kits are available in 24, 48, or 60 lengths. Most dryer systems with legs are set atop a concrete slab. Some do not have a slab, but have individual foundation piers for support and anchoring. The dryer should also be secured in a secondary manner (guy wires, for example). This is especially true for taller dryers, which have greater surface area exposed to the wind. Refer to Figure 9B and the descriptions on the following page to identify the leg styles and locations: WARNING Be sure to support the dryer s lower section assembly by hanging from a crane or sitting on blocks prior to installing ANY lifting legs. WARNING Torque all attachment hardware to the proper values -- 1/2 grade 5 bolts -- to 65 ft-lbs torque value 5/8 grade 5 bolts -- to 135 ft-lbs torque value A LEGS OUTER & INNER B LEG(S) CENTER C LEGS COLUMN Figure 9B - Working dryer setup - with optional NECO leg kit. 90

3 Leg styles and location: A Side legs are located around the outside & inside perimeter of the dryer. B Center leg(s) are located in the area where the tongue meets the dryer frame and can be a single or double leg setup - based on the dryer height and load requirements. Table 9T1 - A Side Leg (Outter & Inner) ATTENTION - Use 5/8 x 1 1/2 bolts, flat washer, and flange nut Part Elevation Length Number inches mm inches mm / / / C Column legs (if needed) are located to provide column support for the platforms. Note: Single blower dryers DO NOT require these supports because there are no upper platforms. 5/8" WHIZLOCK NUT 5/8" X 1 1/2" BOLT 5/8" FLATWASHER WARNING Be sure to torque all legs properly as they are being installed - then, double-check torque values upon completion. Use shims, if needed -- Figure 9C - Frame to Side Leg Hardware Arrangement The extra hole is used for extra high capacity frames. A A Outer Legs & Inner Legs Refer to Figures 9C & 9D, with Table 9T1: NOTE: Extra-high capacity dryers(ehc) use the 2nd set of holes for added strength. Figure 9D - A attachment hole locations While the dryer lower section is hanging from a crane or setting on blocks: bolt the A outer side legs only around the outside perimeter of the dryer frame. Once the A side legs are mounted around the outside, go ahead and mount the inner A side legs to the inside frame positions. 91 B Center Leg(s) - Single or Double Dryers with seven tiers or less will use the B Single Leg style as shown in Figure 9E, with part numbers for available heights shown in Table 9T2.

4 C Column Support Legs B NOTE: Dryers with only one section (one blower) do not use column support legs. Part numbers for C Column Support Legs are shown in Table 9T4. Bolt the required column support leg to the I-beam on top of the dryer tongue using ½ x 1½ bolts and hardware as shown in Figure 9G. Figure 9E - Center Single Leg Attachment Table 9T2. B Center Single Leg ATTENTION - Use 1/2 x 1 1/2 bolts, flat & lock washer, and nut Part Number Elevation Length inches mm inches mm / / Dryers with more then seven tiers will use the B Double Leg style, as shown in Figure 9F, with part numbers for available heights shown in Table 9T3. B Figure 9F - Center Double Leg Attachment Figure 9G - Column (Platform) Support Attachment Table 9T3. B Center Double Leg ATTENTION - Use 1/2 x 1 1/2 bolts, flat & lock washer, and nut Part Elevation Length Number inches mm inches mm / / Table 9T4. C Platform Support Legs ATTENTION - Use 1/2 x 1 1/2 bolts, flat & lock washer, and nut Part Elevation Length Number inches mm inches mm / / /8 1965

5 Special Assembly for 32 Dryers OVERVIEW 32 units sent in shipping containers require some additional assembly / installation work due to shipping length requirements: The control panel needs to have a mounting bracket system added in order to mount and secure it to the proper operator height. The blower system needs to be attached to the transition. Refer to Figure 9G3: Bolt the Control Panel to the angle mounts, making sure it is mounted for easy operator access.. Refer to Figure 9G1: Bolt the # control panel mounting brackets to the dryer tongue. Figure 9G3 - Attach control panel ATTACH BLOWER SYSTEM Figure 9G1 - Attach Control Panel Mount Brackets Refer to Figure 9G2: Make sure the # angle brackets are positioned as shown & attach to to the mounting brackets. Refer to Figure 9G4: Lift blower into place with the flat edge facing upward. Install bolts - four connections on each side. 3/8" Nut 3/8" x 1" Bolt 3/8" Flatwasher 3/8" Flatwasher 3/8" Lock Washer Figure 9G2 - Attach vertical angle mounts 93 Figure 9G4 - Bolt on Blower

6 Install Cross-Auger System NOTE: The cross auger system was assembled at NECO, but due to shipping restrictions is taken off as a sub-assembly, and placed within the lower dryer section to ship. Re-install the cross auger system onto the rear of the dryer. Refer to Figure 9G5: Using 1/2 hardware, attach the trough and auger sub-assembly to the spouts at the back of the dryer. Figure 9G5 - Assemble Trough to Spouts 94

7 Refer to Figure 9G6 & associated tables: Attach the rear chain guard back plate to the spout and attach the side guard back plate to the spout. A -- Side Chain Guard Back Plate Standard High Capacity Extra High Capacity B -- Rear Chain Guard Back Plate Standard & High Capacity Extra High Capacity Figure 9G6 - Assemble Guard Backing 95

8 Refer to Figure 9G7: Mount the # sprocket with 1 bore onto the shaft of the gearbox and the # sprocket with 1 1/4 bore onto the shaft of the discharge. Mount the idler shaft onto the guard backing. Line up the sprockets and wrap the # roller chain around the sprockets and connect the # roller chain connection link. Position the idler sprocket against the chain to take up slack - do NOT over tighten /8" Flatwasher /2" x 2 1/2" 1/2" Nut Carraige Bolt 1/2" Lock Washer 1/2" Flatwasher Figure 9G7 - Assemble Sprockets and Chain Refer to Figure 9G8: Using 5/16 x 1 HB, FW & WL, mount the cover guards onto the guard back plates. Using 1/4 x 3/4 CB, FW, & WL, bolt the cross auger cover to the trough Standard High Capacity Extra High Capacity Standard & High Capacity Extra High Capacity Standard High Capacity Extra High Capacity Figure 9G8 - Attach Covers 96

9 Stack & Secure s WARNING Do NOT stack any additional sections on top of the bottom section unless it is secured to the foundation. ATTENTION -- The following stacking information is applicable for: Upper dryer sections - made up of 3-6 tier levels Top-most filling dryer section - made up of 1-2 tier levels and the topside filling system. NOTE: All styles of fill systems, including catwalk and / or safety cage, should be completely assembled on the ground and then lifted into position and secured. OVERVIEW Refer to APPENDIX - Dryer Layout Configurations for specifics on sections and section stacking order. Depending on the dryer model configuration, certain parts are installed at the factory and certain parts require installation as the sections are stacked. STACKING ORDER - If your dryer has multiple sections, make sure you stack the sections in the proper order. The dryer section with the cord set labeled 1 is the longest cord and would be the upper-most section located the furthest away from the control panel. Position the rest likewise - #2 cord set would be the next dryer section toward the bottom and so on. LP FUELED DRYERS: Be carefull of the LP vaporizer coils when stacking sections - they stick up slightly and can be damaged!!! PLATFORM SUPPORT COLUMNS: These are shipped wired to the platforms and should be mounted at the bottom to the Platform Support Angles prior to adding the next dryer section. LADDER SECTIONS: If ladder section lengths are level with the top tier of a dryer section, they are factory mounted. If they are not level with the shipped top tier, the ladder section for that section is wired to the platform floor - see Ladder Installation section for details. NEXT SECTION PLATFORM SUPPORT COLUMNS BOTTOM SECTION 97

10 Remove Lifting Lug Top Plates Refer to Figure 9H: Prior to stacking any dryer sections, remove all # lifting lug top plates from corners. - if these are left in place, the next sections flange lips will NOT position correctly. ALL of the factory mounted Corner Support Gussets MUST STAY ATTACHED. NOTE: Lifting lugs can be left in place or removed. If removed, replace the hardware Lifting Lug Top Plate , L Corner Support Gussets Install Air Plenum End Panel Spacers Figure 9H - Remove lifting lug top plates Refer to Figure 9J: Position # plenum end panel spacer for installation where ANY two air plenum end panels meet together. Position as shown and secure when outside flange lips are bolted together. End Plenum Spacer Plenum End Panel 1/4" x 3/4" Bolt 1/4" Flatwasher End Plenum Spacer 1/4" Whizlock Nut Figure 9J - Install spacers between any two air plenum end panels 98

11 Install Transition / Plenum Fill Strips Refer to Figures 9K: When the transition lip is level with the dryer sections top tier AND the next section to stack has a plenum end panel, use a # transition / plenum fill strip to secure the top of the transition to the underside lip of that next stacks plenum end panel. Use 1/4 x 3/4 HB, FW, & WL to secure the strip at both edges. Top of Transition Transition/Plenum Fill Strip Install Platform Support Columns Refer to Figure 9L1 & 9L2 with Table 9T5: SKIP to next step if the dryer does NOT have multiple platforms. The LOWER support column weldment mounts directly to the beam. ALL upper sections use UPPER support columns & mount using # support angles. The support column angles are factory mounted and the support columns for that section are wired to the platform for shipment. ATTENTION - The support columns must be in position PRIOR to the installation of the next dryer section. Figures 9K - Install transition / plenum fill strip TABLE 9T5 SUPPORT COLUMN SIZE REQUIREMENTS LOCATION & TIER SPAN COLUMN PART # COLUMN LENGTH ( REFERENCE) LOWER - 3 TIER /8 UPPER - 3 TIER /16 LOWER - 4 TIER /8 UPPER - 4 TIER /16 LOWER - 5 TIER /8 UPPER - 5 TIER /16 LOWER - 6 TIER /8 UPPER - 6 TIER /16 LOWER SUPPORT COLUMN FLANGE WELDMENT DRAWING NO SUPPORT ANGLE # USE 1/2 x 1-1/2 BOLTS & HARDWARE USED ON LOWEST SECTION ONLY USE 1/2 x 5-1/2 BOLTS & HARDWARE TOLERANCES TITLE UNLESS OTHERWISE SPECIFIED DECIMALS (.X) (.XX) Figure 9L1 - LOWER column with flange (.XXX) ` Figure 9L2 - UPPER column with support angles ` ` weldment.015 LOWER FRACTIONS ` 1/16 MATERIAL ANGLES ` 1~ DIMENSIONS IN INCHES UNLESS OTHERWISE SPECIFIED SIZE DRAWN BY A Division of 99 DATE IT IS ISSUED IN CONFIDENCE FOR A Dfort 7/8/2013 N E C O GLOBAL Industries Inc. WEIGHT DRAWING NO. REV NORTH 45TH STREET - OMAHA, NEBRASKA N/A NECO, a division of GLOBAL Industries Inc., CLAIMS PROPRIETARY RIGHTS IN THE INFORMATION DISCLOSED ON THIS DRAWING. ENGINEERING INFORMATION ONLY AND MAY NOT BE REPRODUCED OR USED TO MANUFACTURE ANYTHING SHOWN HEREON WITHOUT DIRECT WRITTEN PERMISSION FROM NECO TO THE USER. SUPPORT COLUMN WLD 5-T

12 Raise the next section & Lower into Position Either MINIMIZE strap angles or use a spreader system to raise the sections. Use the support columns as guides and lower the section into initial position. Ensure that the lowering flange lips overlap properly all around. USE SPREADER SYSTEM GUIDE LINES Refer to Figure 9M: NOTE: Do Not remove crane from supporting the load until all assembly / installation for that section is complete. Line up flange lips and secure the four corners first to ensure position is held - proceed with following steps 9N - 9R, then make sure all bolts are present and tight. 1/4" x 3/4" Bolt 1/4" Flatwasher ALIGNMENT PUNCH HELPS CENTER HOLES 1/4" Whizlock Nut Figure 9M - Basic Outer / Inner Lip Connection 100

13 Secure Platform Support Columns Refer to Figures 9N: Using 1/2 x 5-1/2 bolts and hardware, secure the support columns to the # support tabs fastened to the cross support tube. CROSS SUPPORT TUBE ATTENTION Note orientation of splice plates. Figure 9N - Secure top of Platform Support Legs Install Body Braces Refer to Figures 9O: Position and bolt a # Body Brace under the overlapped outside and inside flange lips, centered directly under ALL tier splices. Do ALL exterior braces first. NOTE: On model #D24108 shipped in sections (NOT assembled and towed) a divider floor will be installed in the plenum - the divider floor provides the needed support, so the INTERIOR body section braces are not needed for that level ONLY. 1/4" x 3/4" Bolt 1/4" Flatwasher Body Brace 1/4" Whizlock Nut Figure 9O - Body Brace Connection 101

14 Install (Model #24108 ONLY) NOTE: Skip this section if the dryer is NOT a model #D24108 AND the two sections were NOT assembled at the factory and towed to location as one unit. All other models # s have the divider floor(s) installed at the factory - see APPENDIX - Dryer Layout Configurations Refer to Figure 9P: Lay the divider floor sections in position - oriented so that divider door is closest to the rear access plenum door. Note the locations for the floor braces - these are at all floor panel joints and at mid-span for the longer floor panels. The mid-span floor braces can be installed prior to laying out panels Sheet 77" Sheets 68" Sheet 77" Slide Door Right Seal Door Sheet 39" Slide Door Left Seal Figure 9P - Position floor panels - Locate brace poitions Refer to Figure 9Q: Secure the floor panels to the overlapped interior tier lips using 1/4 hardware. Rivet # floor braces to the floor panels with the rivets facing down. Figure 9Q - Bolt on floor plates & rivet braces 102

15 Refer to Figure 9R: At the end of the divider floor, position the # right and # left door seals. Place the # slides to the # divider door and using both slides as templates, drill 9/32 holes through and using 1/4 hardware, bolt on the door slides & door seals. Slide the # divider door into place Attach Cross Braces Refer to Figure 6L: Figure 9R - Install divider door system NOTE: Cross brace installation is NOT done if THAT tier level has a divider floor or cooling floor. Either of these floor structures provide the necessary cross stability - skip to next step. Using 1/4 hardware, attach # cross braces at or near every inside splice plate location. CROSS BRACE INSIDE SPLICE PLATES Figure 6L - Attach body section cross braces 103

16 Optional Removal of Platform Braces / Lifting Lugs Refer to Figure 9S: NOTE: The following items can be removed AFTER the dryer section has been stacked and secured. The platform shipping braces can either be left in place or removed. The lifting lugs can either be left in place or removed. Be sure to replace all hardware removed if either of these are taken off. Lifting Lugs Platform Braces Figure 9S- Platform Braces & Lifting Lugs can be removed or left in place Attach Ladder s OVERVIEW See APPENDIX - Dryer Layout Configurations for information on ladder bracket attachment with the necessary ladder section lengths. Ladder location depends on model type - single blower units have the ladder system mounted at the rear of dryer, to the LEFT of the plenum door. Dryers with multiple platforms have the ladder system mounted at the front of dryer, going up through the platform floors, on the opposite side of transition fuel train. The 10 (#040370) & 8 (#040369) ladder sections include two ladder brackets with each section supplied. The 4 (#044117) section includes one ladder bracket and is used only as the top-most section in the ladder system when required. It will always have to be installed. The top-most section of ladder (10, 8, or 4 ) attaches to the # ladder connection plates of the safety cage system using # ladder clips and 3/8 hardware. It is suggested to either add each ladder section as the dryer sections are installed upward or to wait until all dryer sections and topside filling section have been installed. 104

17 Refer to Figure 9T: NOTE: For dryers with a roof and catwalk system, the 6 dimension from the edge of tier to the # ladder bracket edge should be held closely or the # ladder attachment brackets will not match up correctly. When ever possible, the ladder brackets should be positioned against the lip of a tier section to provide alignment and additional stability. NOTE: Ladder attachment brackets are positioned above or below any ladder section splice and can NOT be located at the same level or position as the ladder splices. Drill 3/8" (10mm) Holes 6" (152mm) Figure 9T - Transfer drill holes to mount Ladder Brackets 105

18 Refer to Figure 9U: NOTE: Ladder brackets can NOT be positioned at either end of any ladder section where the ladder splices are used to secure ladder sections together. Fasten the ladder sections to each bracket using two # ladder clips per bracket. 3/8" FLATWASHER 3/8" LOCK WASHER 3/8" NUT 6" (152mm) FROM OUTSIDE OF TIER TO LADDER # LADDER BRACKET 3/8" FLATWASHER 3/8" LOCK WASHER 3/8" NUT 3/8" x 1" BOLT (3X) 3/8" FLATWASHER 3/8" x 1 1/2" CARRIAGE BOLT # LADDER CLIP (2 PER LADDER BRACKET) Figure 9U - Bolt on Ladder Refer to Figure 9V: Between ladder sections, place a # ladder splice into each ladder leg as shown so that both sections are aligned and securely bolted together. # LADDER SPLICE 3/8" x 1" BOLT 3/8" FLATWASHER (2X) 3/8" LOCK WASHER 3/8" NUT LADDER SECTION Figure 9V - Bolt ladder sections together with ladder splice 106

19 Install Topside Filling WARNING Be sure to utilize spreader bars or similalr means to properly lift the unit. Main lift component should be vertical - do not use sharp angles on strapping!! Refer to Figure 9W: NOTE: Assembly of the topside filling section, attached to the topmost tier section, should have been done at ground level. Ensure the topside system is completed to this level before proceeding further. Make sure the # lifting lug top plates were removed for the section being stacked upon. Lift the completed topside filling section as one completed unit - use guide lines to assist in positioning. Figure 9W - Lift assembled topside filling section Refer to Figure 9X: NOTE: Be sure the safety cage # ladder attachment brackets or final lader section line up correctly with the lower existing ladder sections upon final positining. Install into final position and secure Reference Figures 6J thru 6V and complete all that are necessary to secure the section. NOTE: In most cases, the top-most ladder section is a 4 section and already attached to the safety cage attachment brackets - use ladder clips to secure the two ladder sections together. For some models, the final ladder section may be 8 or 10 and need to be installed to the safety cage ladder attachment brackets. Figure 9X - Install into final position and secure # ATTACHMENT BRACKET Refer to Figure 9Y: Using 3/8 hardware, finish connection of ladder system to the cage ladder connection brackets. # LADDER CLIP 107 Figure 9Y - Finish ladder connection

20 10. FINAL SYSTEM HOOKUP Adjust Control Box Height Refer to Figure 10A: NOTE: Support the weight of the control panel with a forklift as you adjust its height. Loosen the fasteners that hold the control panel in place. The vertical guide rails can also be adjusted upward or downward. Position the control panel at a comfortable operator height and secure in position. Figure 10A - Adjust the height of the control box Final Electrical Hookup WARNING NECO recommends hiring an expert for proper advise, accurate paperwork, and safe procedures to complete electrical work in conformance with local codes. The customer is responsible for providing materials & labor to the dryer system. A properly sized fused disconnect box must be in place PRIOR to finall connections are made to the dryer control box and all personnel should know the location and how to operate it. 108

21 Refer to Figure 10B: All cables that can be pre-routed and connected are completed at the factory. The upper Moisture Sensor cable will need to be routed and connected to the correct position labeled on the lower-right side of control box. Figure 10B - Identify cords & route cords - see panel cable connection callouts 109

22 Blower Motor Wire(s) Refer to Figure 7D, 7D1, & 7D2: Attach the cords through the holes in the left side of the control panel, using proper conduit connectors / clamps. Blower #1 starts at the top - See APPENDIX - DRYER CONFIGURATIONS for additional information and identification of section (blower) numbers Connect each blower system to the same numbered starter package within the main control following the three phase (3P) example shown below : Three Phase (3P) Wiring: Connect wires T1, T2, & T3 into the bottom of the respective starter(s). Connect the green ground wire to the ground terminal in the Control Box. T1 T2 T3 ID LABEL MOTOR STARTER T1 T2 T3 BLOWER # MOTOR STARTER 5M / 5MP Figure 10D - Three Phase CE Blower Motor Wiring 110

23 Thermocouple Wire(s) NOTE: Keep thermocouple wires away from the vaporizer coils on LP fueled systems. Refer to Figure 10E: The thermocouple wire and high temp bulb are wound up and located within the burner box for each dryer section. Route the items and locate as shown - located so that they are close to the center of the plenum overall length and at the edge of each upper-most triangular tube for that dryer section. The data from these is transmitted through the grey communications cable(s) to the PLC unit within the main control box. HIGH TEMP BULB THERMOCOUPLE WIRE Burner Box Cables(s) Figure 10E - Position Thermocouple Wire(s) Refer to Figure 10F: The grey cable entering left side of the burner box(s) is pre-wired at NECO from each modulating motor and controls the flow of fuel through the butterfly valve. The yellow burner cable(s) & the grey communication cable(s) are used between burner box(s) and also from the lowest burner box to the main control box. The cable plugs directly into the top burner box - multiple burner dryer s would use the T connector for all units below. YELLOW BURNER CABLE GREY COMMUNICATIONS CABLE 111 Figure 10F - Burner Box Connections

24 Fill Switch & Low Switch Location The installation location of the Fill & Low switches depends upon the style of fill and configuration of the intake grain supply. The various installation positions come from the factory covered with a # cover plate. Determine the correct switch position for the equipment configuration, install the switches, and connect the wiring as shown. ROOF WITH GRAVITY FILL SYSTEM Gravity fill systems intake grain at the center - the intake auger system must match to this location. THE FOLLOWING POSITIONS SHOULD STAY COVERED THE ROUND POSITIONS IN THE ANGLED END ROOF PANELS. 2. the ROUND AND SQUARE POSITIONS IN THE TOP TIER END PANELS. 3. TOTAL POSITIONS TO REMAIN COVERED ARE 4X ROUND & 2X SQUARE. FILL AUGER EXIT CHUTE NEEDS TO MATCH UP TO THIS FLANGE FILL DRYER SWITCH FLANGE IS 30 DEG. LOW DRYER SWITCH FLANGE IS 45 DEG. #059167R ROTARY SWITCH HOLE COVER PLATE # NOTE: FOR GRAVITY FEED SYSTEMS, THE FILL & LOW DRYER SWITCH ARE IDENTICAL, EXCEPT FOR THE ANGLE OF THE MOUNTING FLANGE. 112

25 Fill Dryer Switch - Gravity Fill System FILL DRYER SWITCH # Low Dryer Switch - Gravity Fill System LOW DRYER SWITCH #

26 LEVEL AUGER FILL SYSTEM OVERVIEW Grain intake position must be a minimum of 2 from either end of the dryer. Factory configuration, per motor cable length and catwalk access, has the level auger motor located at the front end of the dryer closest to the control box. The Fill Dryer Switch and the Low Dryer Switch must be located at the OPPOSITE end of intake grain entry for correct operation. Standard auger motor rotation brings the intake grain FORWARD from a grain entry position located at the rear end of the dryer. Reversed auger rotation results in the opposite. STANDARD AUGER MOTOR ROTATION PUSHES GRAIN TOWARD FRONT OF DRYER INTAKE GRAIN AT REAR (2 FT FROM END) REAR OF DRYER FILL & LOW SWITCHES AT OPPOSITE END OF FILLING FRONT OF DRYER INTAKE GRAIN AT FRONT (2 FT FROM END) REVERSE THE AUGER MOTOR ROTATION TO PUSH GRAIN TOWARD REAR OF DRYER 114

27 ROOF WITH LEVEL AUGER SYSTEM Fill Dryer Switch FILL DRYER SWITCH # COVER PLATE # FRONT OF DRYER Low Dryer Switch LOW DRYER SWITCH #

28 GARNER (OPEN TOP) WITH LEVEL AUGER SYSTEM NOTE: Be sure to install the Fill Dryer Switch & Low Dryer Switch at the end of dryer OPPOSITE the grain intake into the level auger system. The example below shows the Fill & Low switches mounted at the front of dryer for intake grain entry at the rear of dryer. Be sure to use # cover plates for these positions at other end. Fill Dryer Switch & Low Dryer Switch The Fill Dryer Switch mounts in the angled bracket / mount plate assembly - see circled detail area. The Low Dryer Switch mounts in the top tier end panel - install a # cover plate to close off the empty Low switch postion at opposite end.. FILL DRYER SWITCH LOCATION (SWITCH NOT SHOWN) # FRONT OF DRYER LOW DRYER SWITCH # (SEE MOUNTING NOTE) SWITCH BRACKET DETAIL NOTE: BE SURE TO MOUNT SO THAT SWITCH IS IN DOWNWARD POSITION TO HELP REDUCE ANY MOISTURE PROBLEMS. SPECIAL BRACKET POSTION THE ANGLE BRACKETS AND MOUNT PLATE WITH ATTACHED FILL DRYER SWITCH NEEDS TO BE POSITIONED SO THAT THE ROTARY VANES ARE FACING THE INCOMING FLOW OF GRAIN. A GOOD STARTING POINT IS TO SET THE UNIT AT A SLIGHT ANGLE BELOW HORIZONTAL. FINAL POSITIONING IS DONE DURING EQUIPMENT STARTUP. 116

29 Connect Fill Switch & Low Switch Refer to Figure 7G: The upper-most dryer section burner box will have the TWO cables (one YELLOW & one GREY) coiled and marked Fill and Low. Figure 7G - Fill & Low Switch Cables These standard lengths are sufficient for all styles of fill where the two switches are located at the front of the dryer. It may be necessary to use the extension cables provided when the two switches are located at the rear of the dryer. 117

30 Connect Moisture Sensors Overview The combination sensing unit shown has a moisture sensing fin with the temperature sensing probe directly below it. They provide CURRENT READING values to the DryerMaster system. One of these sensing units is located at the top of the dryer for gathering INLET values and another is located within the grain exit chute to gather OUTLET values. MOISTURE FIN TEMPERATURE PROBE CONNECTION IS WITH A GRAY 5-PIN x 20M LG CABLE FROM THE MAIN CONTROL CABINET. Open Top (Garner) Inlet Moisture Sensor NOTE: The inlet sensor needs to be mounted at the OPPOSITE end from the grain intake. Remove the rectangular cover from the end OPPOSITE the grain intake and mount the moisture sensor for inlet grain. Connect the cable marked Inlet Moisture - if the grain intake is at the front (control panel) end, a cable extension is needed to reach the top-rear level. INLET MOISTURE SENSOR 118

31 Roof style Inlet Moisture Sensor NOTE: For Roof with Gravity Feed or Roof with Level Auger fill systems. The Inlet sensor position is located on the catwalk side of the roof - see hatch style door at the end of catwalk for access. Mount the inlet sensor in the housing and connect the cable marked Inlet Moisture. CATWALK HATCH ACCESS DOOR MOISTURE SENSOR Outlet Moisture Sensor / Sample Button NOTE: Outlet moisture sensor / sample housing can be left-hand, center, or right-hand mounted onto the rear cross auger system. Mount the sensor in the housing and connect the cable marked Outlet Moisture. Mount the sample button and connect with the cable marked Sample Button. SAMPLE BUTTON 119

32 Discharge Plugged Sensor The discharge plugged sensor(#059118) will activate if the discharge becomes plugged - causing the hinged lid to open and trigger the proximity sensor. The sensor must be secured in position to maintain an approximate 1/8 gap between the sensor face and the hinged door face. Discharge Plugged Sensor # POSITION & SECURE SO THAT THERE IS AN APPROXIMATE 1/8 GAP BETWEEN THE SENSOR FACE AND THE DOOR FACE. COIL UP EXTRA WIRE AND SECURE UNDER DRYER PLENUM 120

33 HMI Wiring Connections NOTE: See APPENDIX - HMI Wiring Connections for detailed schematic. Electrical Wire from Main Control to HMI Labels are provided - pull the following wires from the Main Control terminals to the HMI terminals strip. ATTENTION: The 120V power source needs to be connected to a customer supplied VA battery backup unit. WIRE LABEL E1A E2 E2A 24V OV WIRE COLOR BLUE BLUE BLUE BLUE WHITE Terminal block - inside HMI enclosure Ethernet Cable from Main Control to HMI Pull Cat 6 shielded ethernet cable from the Main Control to the HMI - maximum distance should be less than 300 feet. One end will plug into the PLC within the Main Control Box and the other end will plug into the Ethernet Switch within the HMI enclosure. PLC UNIT LOCATED IN MAIN CONTROL : PLUG ETHERNET IN HERE ETHERNET SWITCH IN HMI CABINET : PLUG ETHERNET IN ANY SOCKET 121

34 Final Fuel Supply Hookup Liquid Propane (LP) WARNING NECO suggests hiring a professional to plan, setup, and connect your chosen fuel supply - Liquid Propane or Natural Gas. Either type MUST include an emergency shut-off valve. Plumbing assemblies for the liquid propane plumbing are preassembled in sections seperated by pipe unions as described below and shown in Figure 7K: 1. Regulator Leg - includes Regulator and Pressure Gauge 2. Vapor Line - includes 3/4 Schedule 80 elbow and pipes 3. Vaporizer 4. Liquid Line - includes 1/2 Schedule 80 elbow and pipes 5. Inlet - includes two 1/2 Solenoid Valves, Two Relief Valves, and Y Strainer # Support Bracket # Support Bar Vaporizer 3/4" Schedule 80 Pipe (Vapor Line) Regulator Leg Pressure Gauge Regulator Relief Valves 1/2" Sch 80 Pipe (Liquid Line) Inlet Solenoid Valves Y-Strainer Center sections have thru connection with union as shown. The top-most section will be an elbow. Table 7K - Installed Discharge Plugged Sensor in optional NECO housing 122

35 Refer to Figure 10M: The control loop, which includes the modulating valve / the primary & secondary solenoid valves / and the pilot solenoid valve, are already assembled on to the transition. Control Loop Figure 10M - Installed control loop on the transition Refer to Figure 10N: Attach the regulator at the union. The piping should be positioned between the transition and the platform. Regulator Leg Figure 10N - Attached Regulator Leg 123

36 Refer to Figure 10O: From inside the dryer run the 3/4 vapor line through the top pipe entry hole and connect the union to the regulator leg outside of the dryer. Top Pipe Entry Hole 3/4" Vapor Line Regulator Leg 3/4" Vapor Line OUTSIDE VIEW Connect at union INSIDE VIEW Figures 10O - Run 3/4 vapor leg through the top hole and connect at the union Refer to Figure 10Q: Position the # vaporizer tube support bracket so that the union lines up with the 3/4 vapor line. Using the bracket as a template, drill 5/16 [8mm] holes into the dryer section. Using 1/4 x 3/4 HB, FW, & WL, bolt the support bracket to the dryer section interior panel. Clamp the vaporizer to the bracket using the # support bar with 1/4 hardware. After the vaporizer is mounted, connect the 3/4 vapor line to the vaporizer with the union. Vaporizer /4" Vapor Line Figure 10Q - Mount vaporizer with bracket and connect 3/4 vapor line 124

37 Refer to Figure 10R: Push the 1/2 liquid line through the bottom hole and attach the vaporizer with the union. The liquid line should run through one of the platform supports. Bottom Pipe Entry Hole Vaporizer LIQUID LINE GOES THROUGH PLATFORM SUPPORT 1/2" Liquid Line VIEW - INSIDE DRYER Figure 10R - Connect 1/2 liquid line to vaporizer Refer to Figure 10S: Attach the Inlet to the 1/2 Liquid Line with the pipe union. Make sure the elbow or tee lines up with the pipe connection for the lower and upper pipe connections on the other dryer sections. 1/2" Liquid Line Inlet Figure 10S - Connect 1/2 liquid vapor line at union 125

38 Refer to Figure 10T: Connect between dryer sections using the 1/2 Schedule 80 pipe provided with the dryer section(s). NOTE: MIDDLE DRYER SECTIONS WOULD HAVE A T UPPER CONNECTION. THE TOP-MOST DRYER SECTION WOULD HAVE AN ELBOW. 1/2" Sch. 80 Pipe Figure 10T - LP connection between dryer sections Refer to Figure 10U: Connect the LP fuel source the the inlet elbow of the lowest dryer section. CONNECT LP FUEL SOURCE 126 Figure 10U - Connect LP Fuel Source

39 CE Natural Gas (NG) Refer to Figures 10V: Connect between dryer sections using the 2 Sch 40 pipe provided with the dryer section. Connect the NG fuel source to the inlet elbow of the lowest dryer section. s 2" Sch. 40 Pipe NOTE: MIDDLE DRYER SECTIONS WOULD HAVE A T UPPER CONNECTION. THE TOP-MOST DRYER SECTION WOULD HAVE AN ELBOW. Figures 10V - NG connection between dryer sections & fuel source connection Natural Gas Inlet CONNECT NG FUEL SOURCE WARNING After the plumbing is connected, check all connections and pipes for leaks. Because pipe connections can loosen up due to vibrations encountered during shipping, it may be necessary to reseal the pipes. 127

40 Wet Bin Empty & Dry Bin Full Switches NOTE: These OPTIONAL switches are provided and installed by the customer. Refer to Figure 7W: The wet bin empty switch should be placed near the bottom of the wet holding bin. NOTE: The switch, when activated, only shuts off that filling equipment - the dryer will continue to dry grain until the dryer goes into a Low Dryer alarm status. The dry bin full switch should be placed near the top of the dry holding bin. Once the switches have been positioned, route the wires to the main control box terminal strip and connect per the electrical schematic below: DRY BIN FULL WET BIN EMPTY Figure 7W - Connect wet bin empty & / or dry bin full sensor(s) 128

41 External Transport(s) Overview See APPENDIX - Wiring External Transports & Wiring NEMA Starters / IEC Starters / Air Systems for specific wiring information. Setup examples, as briefly shown here, are detailed with sample input data within the Commander Control Owner s & Operator s manual. NECO provides the ability to control two transport devices to FILL the dryer and two transport devices to EMPTY the dryer within the Commander Control system. All motor starters, starter coils, and overload contacts required are customer supplied. These external transport systems can control incoming (wet) grain and outgoing (dry) grain so that the overall system works in conjunction with the dryer. See Owner s & Operator s COMMANDER Manual for specifics to enter Fill / Empty Setup data. Examples of typical external transport systems that may be controlled within the automated Commander system -- EXAMPLE: Wet 1 Auger & Dry 1 Air System This example shows one wet system & one dry system to be controlled and operated by the Commander system. NOTE: Shown for example ONLY - individual configurations vary. 129

42 EXAMPLE: Wet 1 & Wet 2 Augers & Dry 1 Auger This example shows two wet systems & one dry system to be controlled and operated by the Commander system. NOTE: Shown for example ONLY - individual configurations vary. EXAMPLE: Wet 1 & Wet 2 Augers & Dry 1 & Dry 2 Augers This example shows two wet systems & one dry system to be controlled and operated by the Commander system. NOTE: Shown for example ONLY - individual configurations vary. 130

43 Commander Control Setup OVERVIEW NOTE: The setup of the Commander Control system is detailed within the Commander Control Owner s & Operator s manual. The dryer configuration information is input at the factory prior to system testing. This type of information includes: Language The dryer systems measurement units are either set to Imperial or Metric. Imperial units output temperature in Farenheight and volume in bushels. Metric units output temperature in Celcius and volume in cubic meters. The type of fuel supplied to the system. The dryer systems number of blowers & burners. Output gearmotor RPM The number of tiers each blower & burner supply. After installation, the Fill / Empty Setup and Timers Setup are completed by the customer. This type of information includes: If optional sensors are present, such as Wet Bin Empty or Dry Bin Full Presence of additional auxillary equipment, such as Unload Auger system, etc. Maximum grain output speed Various timers, such as amount of cooling time and metering roll stall time, etc. 131

44 11. APPENDIX Standard Model Specifications 132

45 Main Control Box Terminal Strip ATTENTION After installation is complete check the motor wires for the correct motor rotation & auger rotation direction. MODBUS COMMS 120 VAC 24 VDC WET BIN EMPTY SWITCH FILL SWITCH DRY BIN FULL SWITCH E-STOP WIRING AUX TRANSPORT OVERLOAD & RUN CONFIRMATION SIGNALS PLUGGED DISCHARGE SWITCH MOISTURE SENSORS LOW SWITCH SAMPLE SWITCH METERING ROLL STALL SWITCH AUXILLARY TRANSPORT RUN RELAY S 133

46 HMI Wiring Connections NOTE: The 120V power source needs to be connected to a customer supplied VA battery backup unit. The following schemetic indicates with dashed lines crossing INTO the HMI enclosure the connections to be made -- Electrical Wire from Main Control into thehmi Ethernet cable from Main Control into the HMI E-STOP 1PB XO OG JUMPER E-STOP 3PB XO XO OG JUMPER XO VDC V+ V- GND ETHERNET SWITCH N-TRON 105TX SPARE PORT FOR REMOTE ACCESS TO HMI ENCLOSURE PROGRAMMING PORT TO 309 TWIDO PLC FROM SEPERATE 120VAC, 1PH, 15A POWER SOURCE POWER OFF ON 1SS OX H N PC POWER SUPPLY MOXA MGATE MB3180 MODBUS ETHERNET SERIAL GATEWAY NULL MODEM COM2 RIBBON CABLE VDC OPTIONAL HEATER W/ THERMOSTAT PC BASED - MOISTURE CONTROLLER BAUD HMI ENCLOSURE (Indoors Installation Recommended) 134

47 Wiring External Transports The customer is responsible for wiring any external transport equipment. The following schematics are reference. 135

48 Wiring NEMA Starters / IEC Starters / Air Systems The customer is responsible for wiring any external transport equipment. The following schematics are reference. 136

49 Dryer Layout Configurations Each of the following graphic figures represent a standard dryer model: Each dryer model shows the sections as they are shipped - see towing section for additional information. Be sure to pay attention to the cord lengths of blower, etc. so that the longest cord will go to the secton FURTHEST from the control panel, and so on. For example only, a roof with level auger fill system (Safety Cage not shown) is shown above the top tier. See the OVERVIEW & ASSEMBLY section for details on the different fill systems. Dryer systems with only one blower use an angled transition and the ladder system is mounted at the rear of the dryer to the LEFT of plenum door. Dryer systems that have a roof (Level Auger or Gravity fill type) have a catwalk system. All ladder systems have a safety cage at the top. NOTE: This dryer model utilizes a rear mounted ladder system. Catwalk supports are shown for reference only & are located on the far side to line up with ladder system to the left of plenum door. TOP TIER 1 Dryer Model #D

50 NOTE: This dryer model utilizes a rear mounted ladder system. Catwalk supports are shown for reference only & are located on the far side to line up with ladder system to the left of plenum door. 4' TOP TIER 8' 1 14 GA. Dryer Model #D

51 NOTE: This dryer model utilizes a rear mounted ladder system. Catwalk supports are shown for reference only & are located on the far side to line up with ladder system to the left of plenum door. 4' TOP TIER 14 GA GA. Dryer Model #D

52 NOTE: This dryer model utilizes a rear mounted ladder system. Catwalk supports are shown for reference only & are located on the far side to line up with ladder system to the left of plenum door. 4' TOP TIER 8' 1 14 GA. Dryer Model #D

53 NOTE: This dryer model utilizes a rear mounted ladder system. Catwalk supports are shown for reference only & are located on the far side to line up with ladder system to the left of plenum door. 4' TOP TIER 14 GA GA. Dryer Model #D

54 NOTE: This dryer model utilizes a rear mounted ladder system. Catwalk supports are shown for reference only & are located on the far side to line up with ladder system to the left of plenum door. 8' TOP TIER 8' 14 GA. 14 GA. 1 Dryer Model #D

55 TOP TIER 8' 1 14 GA. 14 GA. 2 Dryer Model #D

56 TOP TIER 4' 14 GA. 14 GA. 1 8' 2 Dryer Model #D

57 Dryer Model #D16140 TOP TIER 8' 14 GA. 14 GA. 1 8' 2 145

58 TOP TIER 14 GA GA. 2 3 Dryer Model #D

59 TOP TIER 8' 14 GA. 14 GA. 8' 1 2 8' 3 Dryer Model #D

60 TOP TIER 4' 1 14 GA. 14 GA. 2 Dryer Model #D

61 TOP TIER 14 GA. 14 GA. 8' 1 2 Dryer Model #D

62 TOP TIER 4' 14 GA. 14 GA. 1 8' 2 Dryer Model #D

63 TOP TIER 8' 14 GA. 8' 1 14 GA. 2 3 Dryer Model #D

64 TOP TIER (18 GA) 14 GA GA. 2 3 Dryer Model #D

65 TOP TIER 4' 14 GA GA Dryer Model #D

66 TOP TIER 4' 8' Dryer Model #D

67 Top TOP TIER Dryer Model #D

68 TOP TIER 8' 14 GA. 8' 1 14 GA. 2 3 Dryer Model #D

69 TOP TIER 4' 14 GA GA Dryer Model #D

70 TOP TIER 4' 8' Dryer Model #D

71 Top TOP TIER Dryer Model #D

72 MANUFACTURED BY NECO A Division of GLOBAL Industries, Inc North 45th Street Omaha, Nebraska TEL: FAX: Toll-free (within Nebraska): Toll-free (outside Nebraska):