Airstream 1000 series User manual

1 9 9 6

DRYER START UP

Q U I C K R E F E R E N C E G U I D E

AI R S T R E A M GR A I N CO N D I T I O N I N G SY S T E M S

PNEG-523

1000, 2000 & 3000 SERIES

DRYER MODELS

DRYER START UP REFERENCE GUIDE

TABLE OF CONTENTS

Warranty and Roof Damage Warning...........................................................................4

SafetyFirst...................................................................................................................5

StartUpProcedure...................................................................................................6

FullStartUpCheck..........................................................................................6

FillingTheDryer..............................................................................................6

StartingTheDryer......................................................................................7

AdjustingTheTemperature.............................................................................7

Full Heat-Continuous Flow Operation..........................................................8

1200 Series Continuous Flow Metering Roll Settings...................................9

Dry And Cool-Continuous Flow Operation For Dryers With Two or More Fans..10

1200 Series Continuous Flow Metering Roll Settings.........................................11

Adjusting The Moisture Control..................................................................12

Notes.....................................................................................................................14

QuickStartUpProcedure.......................................................................................15

Electronic Monitoring Control System-Quick Reference................................15

Starting The Drying Process For Full Heat Operation......................................16

This manual describes the

start up of Airstream Dryers. Many

different models are available, in-

cluding the 1000, 2000 and 3000

Thank you for choosing an Air-

stream product. It is designed to

give excellent performance and

service for many years.

series models. If the unit is in-

stalled and operated properly, ac-

cording to specification, you can

be assured many years of service.

DRYER START UP REFERENCE GUIDE

consequential damages, nor shall

Airstream's liability ever exceed the

selling price of the product.

This warranty does not cover

products or parts that have been

damaged by negligent use, misuse,

alteration or accident. All products

supplied by outside manufacturers

are warranted separately by the re-

spective manufacturer. This war-

ranty is exclusive and in lieu of all

other warranties, expressed or im-

plied. Airstream reserves the right

to make design or specification

changes at any time, without any

contingent obligation to purchasers

of products already sold.

All instructions shall be con-

strued as recommendations only,

because the actual installation may

vary according to local conditions.

Airstream assumes no liability for

results arising from the use of such

recommendations.

Grain Systems, Inc. assumes

no responsibility for field modifica-

tions or erection defects that create

structural or storage quality prob-

lems. If any field modifications are

necessary that are not specifically

covered by the contents of this

manual, contact Grain Systems, Inc.

for recommendations and approval.

Any unauthorized modification or

erection defect that effects the struc-

tural integrity of the GSI product will

be cause for immediate nullification

of the GSI warranty.

Airstream warrants all products

manufactured by Airstream to be

free of defects in materials and

workmanship under usual and cus-

tomary service. Airstream's only ob-

ligation is to repair or replace prod-

ucts returned on a prepaid basis

within 24 months after retail sale,

and in our opinion, found to be de-

fective by Airstream. If defective,

the product will be repaired or re-

placed without charge, F. O. B. fac-

tory, this constituting and fulfilling

our warranty obligation. Expenses

incurred without written authoriza-

tion from Airstream shall be the sole

responsibility of the bearer. Under

no circumstances will Airstream be

liable for any kind of special or

WARRANTY

Airstream cannot warrant any roof damages due to excessive

vacuum or internal pressure caused by fans or other air mov-

ing systems. Adequate ventilation and/or "make-up air" de-

vices should be provided for all powered air handling systems.

Airstream does not recommend the use of downward flow

systems (suction). Severe roof structural damage can result

from any blockage of air passages. Running of fans during

certain high humidity/cold weather conditions can cause freez-

ing over of air exhaust or intake ports.

ROOF DAMAGE WARNING

SAFETY FIRST

SAFETY ALERT DECALS

Grain Systems, Inc.'s principal con-

cern is your safety and the safety of

others associated with grain han-

dling equipment. This manual is writ-

ten to help you understand safe op-

erating procedures, and some of the

problems that may be encountered

by the operator or other personnel.

As owner and/or operator, it is

your responsibility to know what re-

quirements, hazards and precau-

tions exist, and to inform all person-

nel associated with the equipment,

or who are in the dryer area. Avoid

any alterations to the equipment.

Such alterations may produce a very

dangerous situation, where serious

injury or death may occur.

Safety decals should be read and

understood by all people in the grain

handling area. The right decal

should be present on the inside door

cover of the two ring door, 24" port-

hole door cover and the roof

manway cover. If a decal has been

damaged or is missing contact:

Grain Systems, Inc.

1004 E. Illinois St.

Assumption, IL 62510

217-226-4421

A free replacement will be sent to you.

WARNING! BE ALERT!

Personnel operating or working around

electric fans should read this manual.

This manual must be delivered with the

equipment to its owner. Failure to read

this manual and its safety instructions is

a misuse of the equipment.

The symbol shown is used to call

your attention to instructions con-

cerning your personal safety. Watch

for this symbol; it points out impor-

tant safety precautions. It means

"ATTENTION", "WARNING", "CAU-

TION", and "DANGER". Read the

message and be cautious to the

possibility of personal injury or

death.

SAFETY ALERT SYMBOL

Grain Systems, Inc. recom-

mends that you contact your local

power company, and have a repre-

sentative survey your installation so

your wiring will be compatible with

their system and you will have ad-

equate power supplied to your unit.

START UP PROCEDURE

Standard electrical safety practices

and codes should be used when

working with a dryer. Refer to the

National Electric Code Standard

Handbook by the National Fire Pro-

tection Association.

A qualified elec-

trician should make all wiring instal-

lations.

FULL START UP CHECK

ALWAYS DISCONNECT

AND LOCK OUT POWER

BEFORE WORKING ON OR

AROUND DRYER

This start up procedure assumes the following:

1. That you have read and understand the DRYER OPERATION AND

SERVICE MANUAL.

2. That you have taken special note of all SAFETY PRECAUTIONS.

3. That all safety shields are in place.

4. That all meter roll access doors have been opened and all foreign ob-

jects have been removed.

5. That you have done a pre-start up check out.

6. That all motors have been checked for proper rotation.

7. That all heaters have been test fired.

8. That the fuel has been turned on at the tank.

9. That the electric power has been turned on.

10. That the main disconnect switch on the dryer is on.

11. That you have wet grain in the wet holding bin.

12. That you know the incoming grain moisture.

13. That you have the dry grain take away equipment in place.

14. That you have the grain going to the proper bin.

15. That all switches have been set to the off position.

16. That the load mercury switch box is installed with the side stamped up,

in the up position.

FILLING THE DRYER

1. Turn the green CONTROL POWER knob to ON. It should light up, go

through 4 screens and end with the time and date.

2. Turn the DRYING MODE switch to CONTINUOUS FLOW.

3. Push the RESET on the computer key pad to activate the computer.

4. Make sure the UNLOAD switch is in the OFF position.

5. Push the DRYER POWER start switch, it should light up.

6. Turn the LOAD AUGER switch to the MANUAL position to fill the dryer.

The load auger should start and run until the dryer is full, then shut off

automatically. (If the switch is set to the AUTO position the dryer will

shut down each time the out of grain timer times out, and will have to be

restarted.)

7. When the dryer has filled, turn the LOAD AUGER switch to the AUTO

position.

START UP PROCEDURE

STARTING THE DRYER

This start up procedure is for a cold start on wet grain for continuous flow

operation.

1. Set the MAXON or FAST ACTION HAND VALVE on the incoming fuel

line to the ON position.

2. Make sure the MOISTURE CONTROL switch is in the OFF position.

3. Turn the FAN switch (or switches if a multi-fan dryer) to the ON posi-

tion. The light in the switch should light when the fan comes up to

about half speed.

4. Adjust the AIR PRESSURE SWITCH if necessary.

5. Turn the HEATER switch (or switches if a multi-fan dryer) to the ON

position. The heater will purge for about 10 seconds then ignite. The

light in the heater switch will come on during ignition and will stay on if

the heater ignites. If the heater does not ignite, the light will go out after

trial for ignition and the dryer will shut down, indicating that it did not

light. If this happens check gas supply, and all valves in the fuel line to

make sure they are ON.

ADJUSTING THE TEMPERATURE

1. Set the HI-LOW FIRE PLENUM THERMOSTAT on the left side of the

dryer to the drying temperature that you want to run (180 deg. to 200

deg.). On multiple fan dryers set the heat chambers 30 to 60 degrees

apart. Hottest at the top, most cool at the bottom.

2. On LP gas models adjust the PRESSURE REGULATOR (high fire) on

the burner fuel line, so that burner will reach the thermostat setting and

switch to (low fire) (pressures may be required up to 25 lbs.). Natural

gas does not have a regulator, but uses a LARGE BALL VALVE close

to the vertical supply line for adjustment (pressures may be required up

to 18 lbs.).

On LP gas models adjust the small RED HANDLED BALL VALVE

(low fire) so that the burner maintains flame then switches back to (high

fire). Natural gas has a BALL VALVE close to the burner control box,

for low fire adjustment.

3. Adjust the burner pressure so that the burners CYCLES 4 times per

minute (approx. 10 sec. on HIGH--approx. 5 sec. on LOW). When on

HIGH FIRE increasing the pressure with the pressure regulator DE-

CREASES the time spent on high fire. When on LOW FIRE increasing

the low fire pressure with the RED BALL VALVE INCREASES the time

spent on low fire.

4. On LP gas models adjust the VAPORIZER so the fuel pipes going to

the burner from the regulator are warm to the touch (not hot and cold).

How much gas pressure do I

use? See step number two in

the

Adjusting The Temperature

section.

How often should my burner

cycle? See step number three

in the

Adjusting The Temperature

section.

START UP PROCEDURE

1. Look in your operators manual in the DRYER START UP section (CON-

TINUOUS FLOW METER ROLL SETTINGS-FULL HEAT). You will

see the settings for (Initial Moisture) (Moisture Removed) (Approx. Dry

Time) (1 Speed) (2 Speed Low) (2 Speed High) pick the line that has

your initial starting moisture. These are the settings we will be referring

to during this start up procedure.

2. Make sure the UNLOAD switch is OFF.

3. Make sure the MOISTURE CONTROL switch is OFF.

4. Run the fan(s) and heater(s) for about 10% longer than the (APPROX.

DRYING TIME) required for the moisture you are trying to dry.

5. Example: 10% removal would be about 54 minutes, 15% removal would

be about 76 minutes and 20% removal would be about 100 minutes.

Add 10 minutes to insure that the grain is dry.

6. After the time in step 4 turn the UNLOAD to 1 SPEED and set the

METER ROLL SPEED, (HIGH SPEED) pot. to the setting for 1 SPEED

operation. Grain should begin to run at this time. Run time for this is

about 10% longer than the (APPROX. DRYING TIME) required for the

moisture you are trying to dry, as shown in the example #5 above. This

allows the moisture in the dryer to reach an even gradient top to bottom

without having any highs or lows in it. It will however, over dry some of

the corn a little.

7. Increase the drying temperature to 190 deg. for single fans or for mul-

tiple fan dryers set the heat chambers 30 to 60 degrees apart. Hottest

at the top, most cool at the bottom.

8. DO NOT TRY TO ADJUST THE DRYER FOR MOISTURE DURING

THIS PROCESS OR YOU WILL ESTABLISH HIGH AND LOW

SWINGS IN THE MOISTURE CONTROL. IT WILL TAKE SEVERAL

HOURS TO WORK ITSELF OUT.

9. After the run time in step 6 you are ready to set up the moisture control.

Now turn the MOISTURE CONTROL to the ON position. Set the tem-

perature to about 100 deg.

10. Turn the UNLOAD to 2 SPEED. Set the METER ROLL SPEED, LOW

SPEED and HIGH SPEED pots. to the settings listed for them. Let the

dryer run on these settings as shown in the example #5 before trying to

How often do I make speed

adjustment? See step number

ten in the

Full Heat-Continuous

Flow Operation

section.

The vaporizer can be adjusted two ways. First, by loosening the bolt in

the hinging mechanism and swinging it to a hotter or cooler position.

Second, by loosening the two bolts in the hinge pipe and sliding the

vaporizer in or out to a cooler or hotter position. Either one or both

methods may have to be used to get the vaporizer to the proper tem-

perature. Natural gas does not use a vaporizer.

FULL HEAT-CONTINUOUS FLOW OPERATION

START UP PROCEDURE

adjust moisture or meter roll settings. These settings will not have your

grain moisture adjusted exactly where you want it, but will be a good

place to start initially. A little different moisture at the bottom of the

storage bin is not usually a problem as long as you have full floor aera-

tion.

11. After the run time in step 10 you are ready to adjust the moisture con-

trol, and the meter roll speeds if required. Each time you make an

adjustment to the moisture control it will take about the time shown in

example #5 to see the results of this adjustment.

1100 & 1200 SERIES CONTINUOUS FLOW METERING ROLL SETTINGS

Initial

Moisture

17%

18%

19%

20%

21%

22%

23%

24%

25%

26%

27%

28%

29%

30%

31%

32%

33%

34%

35%

2 Speed

High

875

775

675

575

476

385

317

270

241

213

196

185

172

161

150

140

132

123

116

2 Speed

Low

317

270

241

213

196

185

172

161

150

140

132

123

116

110

104

100

096

087

082

1 Speed

625

476

385

317

270

241

213

196

185

172

161

150

140

132

123

116

110

104

100

Approx.

Dry Time

16 min.

21 min.

26 min

31.5 min.

37 min.

41.5 min.

47 min.

51 min.

54 min.

58 min.

62 min.

66.5 min.

71.5 min.

76 min.

81 min.

86 min.

91 min.

96 min.

100 min.

Moisture

Removed

2 pts.

3 pts.

4 pts.

5 pts.

6 pts.

7 pts.

8 pts.

9 pts.

10 pts.

11 pts.

12 pts.

13 pts.

14 pts.

15 pts.

16 pts.

17 pts.

18 pts.

19 pts.

20 pts.

Full Heat

These are approximate starting points.

START UP PROCEDURE

1. Look in your operators manual in the DRYER START UP section (CON-

TINUOUS FLOW METER ROLL SETTINGS-DRY & COOL). You will

see the settings for (Initial Moisture) (Moisture Removed) (Approx. Dry

Time) (1 Speed) (2 Speed Low) (2 Speed High) pick the line that has

your initial starting moisture. These are the settings we will be referring

to during this start up procedure.

2. Make sure the UNLOAD switch is OFF.

3. Make sure the MOISTURE CONTROL switch is OFF.

4. Run the bottom fan(s) and heater(s) (to be used for cooling later) for

about 20 minutes. This will start the bottom drying so we can cool it

before we begin to discharge grain.

5. Take the remaining number of burners to be started, divide that into the

total drying time required, working up, start each burner that many min-

utes apart. Run them about 10% longer than the (APPROX. DRYING

TIME) total required for the moisture you are trying to dry.

6. Example: 10% removal would be about 60 minutes, 15% removal would

be about 85 minutes, and 20% removal would be about 110 minutes.

Add 10 minutes to insure that the grain is dry.

7. After the required drying time turn the bottom heater (OFF) cool this

section for about 20 minutes. Set the upper plenum thermostats to the

decreed temperature (190°-230°F)

8. Turn the UNLOAD to 1 SPEED and set the METER ROLL SPEED

(HIGH SPEED) pot. to the setting for 1 SPEED operation. Run time for

this is about 10% longer than the (APPROX. DRYING TIME) required

for the moisture you are trying to dry, as shown in the example #6.

above. This allows the moisture in the dryer to reach an even gradient

top to bottom without having any highs or lows in it. It will however,

over dry some of the corn a little.

9. DO NOT TRY TO ADJUST THE DRYER FOR MOISTURE DURING

THIS PROCESS OR YOU WILL ESTABLISH HIGH AND LOW

SWINGS IN THE MOISTURE CONTROL. IT WILL TAKE SEVERAL

HOURS TO WORK ITSELF OUT.

10. After the run time in step 8 you are ready to set up the moisture control.

Now turn the MOISTURE CONTROL to the ON position. Set the tem-

perature to about 130 deg.

11. Turn the UNLOAD to 2 SPEED. Set the METERING ROLL SPEED,

LOW SPEED and HIGH SPEED pots. to the settings listed for them.

Let the dryer run on these settings as shown in the example #6 before

trying to adjust moisture or meter roll settings. These settings will not

DRY AND COOL-

CONTINUOUS FLOW OPERATION

FOR DRYERS WITH TWO OR MORE FANS

What temperature should I

dry at? See step number seven

in the

Dry and Cool-Continuous

Flow Operation for dryers with

Two or More Fans

section.

have your grain moisture adjusted to exactly where you want it, but it

will be a good starting place to adjust from. A little different moisture at

the bottom of the storage bin is not usually a problem as long as you

have full floor aeration.

12. After the run time in step 11, you are ready to adjust the moisture con-

trol and the meter roll speeds if required. Each time you make an

adjustment to the moisture control it will take about the time shown in

example #6 to see the results of this adjustment.

START UP PROCEDURE

1100 & 1200 SERIES CONTINUOUS FLOW METERING ROLL SETTINGS

Initial

Moisture

17%

18%

19%

20%

21%

22%

23%

24%

25%

26%

27%

28%

29%

30%

31%

32%

33%

34%

35%

2 Speed

High

650

550

450

363

272

218

187

163

145

131

119

109

101

093

087

082

077

073

069

2 Speed

Low

187

163

145

131

119

109

101

093

087

082

077

073

069

065

061

057

053

049

045

1 Speed

363

272

218

187

163

145

131

119

109

101

093

087

082

077

073

069

065

062

059

Approx.

Dry Time

18 min.

24 min.

30 min

35 min.

40 min.

45 min.

50 min.

55 min.

60 min.

65 min.

70 min.

75 min.

80 min.

85 min.

90 min.

95 min.

100 min.

105 min.

110 min.

Moisture

Removed

2 pts.

3 pts.

4 pts.

5 pts.

6 pts.

7 pts.

8 pts.

9 pts.

10 pts.

11 pts.

12 pts.

13 pts.

14 pts.

15 pts.

16 pts.

17 pts.

18 pts.

19 pts.

20 pts.

Dry & Cool

These are approximate starting points.

START UP PROCEDURE

How do I set my moisture

control? See step number one

in the

Adjusting The Moisture

Control

section.

ADJUSTING THE MOISTURE CONTROL

1. Each 5 deg. on the MOISTURE CONTROL will change the output mois-

ture by about 1%. Example: you have 100 deg. set, you are getting

16% corn out, you want 17% corn out, so you would reduce the MOIS-

TURE CONTROL temperature by 5 deg. to 95 deg. and this should

change the moisture out to about 17%. If you wanted the corn to come

out dryer, you would raise the temperature on the MOISTURE CONTROL.

2. There are 4 sensors that are averaged together for sensing MOIS-

TURE CONTROL temperature, 1 on each side of the dryer in the front,

and 1 on each side of the dryer in the back. They are located about

1/3 of the way up the grain column from the bottom, and in from the

side about 4 inches.

3. The small lights behind the temperatures on the MOISTURE CON-

TROL indicate the temperature of the grain at this sample point.

4. The 2 lights in the center are green, the lights to the right or to the left of

these are red.

5. When the grain temperature has the dryer cycling HIGH and LOW speed

on the green lights the moisture setting is being maintained correctly.

6. Set the METER ROLL SPEED in relation to the small red lights behind

the temperatures on the MOISTURE CONTROL.

7. RED lights to the left indicate that the grain at the sample point is too

cool or wetter than desired. With this condition turn the (LOW SPEED)

left pot. to a lower number. This will slow down the meter rolls and dry

the grain longer, warming it up.

8. RED lights to the right indicate that the grain at the sample point is too

hot or dryer than desired. With this condition turn the (HIGH SPEED)

right pot. to a higher number. This will speed up the meter rolls and

remove the grain quicker, cooling it down.

9. If the MOISTURE CONTROL switches to LOW and only stays on low

for a minute or two and switches back to HIGH, speed up the (LOW

SPEED) left pot. It is set too slow.

10. If the MOISTURE CONTROL switches to HIGH and only stays on low

for a minute or two and switches back to LOW, slow down the (HIGH

SPEED) right pot. It is set too fast.

11. The MOISTURE CONTROL should stay on HIGH about 50% of the

time and on LOW about 50%, give or take 25%. There is a broad range

that will work. It should be switching low to high and back to maintain

the desired moisture. A control that does not switch, will not maintain

an evenly dried grain moisture, when the incoming wet grain moisture

is varying.

12. When adjusting the meter roll speeds it is better not to change the

speed more than 20 points at a time.

START UP PROCEDURE

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