DMC Calc-u-DRYER 25 User manual

OWNER’S MANUAL
Calc-u-DRYER
MODEL 25
DAVID MANUFACTURING COMPANY
1600 12th Street NE, Mason City, Iowa 50401 641-424-7010

TABLE OF CONTENTS
Warranty and Operating Precautions I
Safety Decal Display Information II - III
Fundamentals of DRYER Operation 1
Calc-u-DRYER Specifications 2
Concrete Specifications 3
Installation Checklist 4
Start Up Procedures 5 - 7
Operating Procedures 8 - 9
Maintenance 10
End of Season Operation 11
Automatic Startup Flow Diagram 12
Dryer Control Module & Definitions 13 - 14
Control Box Operation 15 - 16
Calc-u-DRYER Parts 17 - 27
Electrical Drawings 28 - 31
Honeywell Temperature Controller Programming 32
Control Box Diagrams & Parts Listings 33 - 38
Troubleshooting 39 - 40

DMC Calc-u-DRYER
You have chosen the newest technology in automated grain drying.
This unit will provide many years of efficient and dependable service.
Thank you for choosing a DMC Calc-u-DRYER.
READ THESE INSTRUCTIONS BEFORE INSTALLATION AND OPERATION.
SAVE FOR FUTURE REFERENCE
WARRANTY
DMC has a standard 12 month limited warranty on Calc-u-DRYERS. The warranty is
limited to defects in material and workmanship. The only obligation to DMC is to
repair or replace components which have been submitted and found to be defective.
DMC’s liability shall not include consequential damages or special costs or exceed
the selling price of the product.
This warranty does not cover damage caused by negligent use, misuse, alterations
to the dryer or accident. DMC reserves the right to make design or specification
changes at any time, without any contingent obligations to purchasers of products
already sold.
OPERATING PRECAUTIONS
Read and understand the operation manual before operating this unit.
Keep untrained people away from the dryer at all times.
All guards, safety decals, and shields must be kept in place for safe
operation.
Do not jump or bypass any safety devices on the dryer.
Always lock out the main power supply before performing any maintenance
work.
Never operate the dryer if any gas leak is detected.
Use caution in working around the dryer because automatic equipment may
start.
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I

THE DECALS ON THESE PAGES MUST BE DISPLAYED AS SHOWN
REPLACEMENTS ARE AVAILABLE UPON REQUEST
Write to: DMC
1600 12th Street NE
Mason City, IA 50401
Or call: 515/423-6182
Please note: 1. The decals on the page are not actual size.
2. Keep decals clean at all times.
3. All decals must be replaced if they are destroyed,
missing, painted over, or can no longer be read.
7217028 7217027
7217030
7217026
7217029
II

7217031
602L001
106L010
203L0303
III

EXTERNAL JACKET FOR
UNIFORM DRYING IN ANY
WEATHER
FAN & HEATER INSIDE FOR
QUIET & CLEAN OPERATION
HEAT RECYCLING JACKET
(HEAT RECOVERY)
STANDARD
SAFETY DECK
SIMPLE DESIGN -
FEW MOVING PARTS
USER-FRIENDLY
CONTROLS
PATENTED THIN TOP LAYER
9” COLUMN
HIGH AIR FLOW AT
LOW PRESSURE
SELF-CLEANING FLOOR
NO METERING ROLLS
DRY & COOL YOUR GRAIN
CALC-U-DRI MOISTURE
SENSING / CONTROLS
STANDARD
GALVANIZED BASE
FUNDAMENTALS OF CONTINUOUS FLOW DRYER OPERATION
In the DMC Calc-u-DRYER, grain enters at the top center peak of the perforated
cone and flows across the perforated roof cone. The grain depth on the roof is adjustable
and easily adaptable to the varying conditions from one year to another. The heated air
passes easily through this grain, taking away surface moisture quickly and easily because
of the thinner layer and the fact that there is no second screen to pass through. This
process also uses the initial heat to warm the grain entering the columns, thereby reducing
the chance of condensation forming on the outside of the dryer.
The drying procedure is also protected from the wind by an outer weather shield,
allowing a more uniform drying process to take place. The grain continues down the column,
drying as it goes. The transition from heat area to cooling allows steeping and then cooling.
The grain is then pulled across the floor and out of the dryer by the sweep augers. These
augers control the amount and the rate at which the grain is removed from the dryer.
The unloading system is controlled by the Calc-U-Dri Commander, which measures
the moisture level of the grain being discharged to control the unloading rate. The grain
column throughout the dryer column is only 9” thick, which enables the dryer to maintain
a low static pressure with a high air flow. Air in the dryer is drawn through the lower section,
cooling the grain as it passes through. This cooling effect is regulated by adjusting the
louvers on the doors. The air then passes through the burner, picking up the heat which is
then pushed through the upper section of the grain column. The air that passes through
the lower portion of the heating chamber is then directed back through the grain in the lower
section by the use of a recycling jacket. By doing this the cooling process is started with
warm air reducing the stress on the grain. The fan and burner are located inside the dryer
and thus the noise level outside the dryer is very low. The air leaks at the base of the
plenum cone control the build up of fines above the floor by allowing them to blow through
theleaks.
SINGLE FAN & MOTOR
1

100 125 150 175 200
Heat Heat Heat Heat Heat
Rise Rise Rise Rise Rise
5 pts. 340 425 510 595 680
7 pts. 250 313 375 438 500
10 pts. 218 272 326 381 435
13 pts. 155 193 232 271 309
Moisture
Removed
CAPACITY CHART
All above capacities are calculated in wet bushels
per hour for shelled corn at 65% ambient relative
humidity. Your actual capacities may vary with
humidity, corn variety, and other factors.
Holding Capacity Bushels
Heat 272
Cool 160
Total 432
Inside Diameter 10 ft.
Outside Diameter 12.5 ft.
Column Width 9 in.
Column Height 20 ft.
Dryer Height w/Roof 29 ft.
Diameter 38”
Horsepower 25
RPM 1750
CFM 38,000
Liquid Propane: 1/2 in.
Vaporizer Size: 3/4 in.
Orifice Size (Std.): LP 11/32 in.
BTU per Hour: 9 million
Natural Gas Line Size: 1-1/4”
@ 15 PSI
Heating 3
Cooling 2
Motor 1-1/2 HP DC
Augers 7 inch
Diameter 13 ‘ 6”
Pour in compliance with
DMC specifications
230 Volt, 3 Phase, 66 Amps
460 Volt, 3 Phase, 33 Amp
Dryer Dimensions
Fan
Fuel Line Size
Number of Rings
Sweep Auger
Fan Electrical Requirements
Concrete Pad
Discharge Auger: 6 inches Approximate Weight: 11,000 pounds
TYPE: Energy efficient, continuous flow, automatic grain dryer.
FAN: Heavy-duty axial, internally mounted, with adjustable pitch blades.
HEATER: Octagon style burner with transformer ignition and flame sensing.
TEMPERATURE: Controlled by a Honeywell Controller with a Maxon valve.
MOISTURE CONTROL: DMC Calc-U-Dri Commander with moisture sensing
and SCR drive for the sweep augers.
ROOF: Optional and requires a leg with over flow so dryer can be continuously
fed grain.
GARNER BIN: Standard without optional roof and holds 15 Bu. of grain and can
be fed with an auger.
DRY GRAIN: Make sure your unloading system has the capacity to handle 1000 bu./hr.
WET GRAIN: Your wet fill system should have at least 1000 bu./hr. capacity.
Calc-u-DRYER SPECIFICATIONS - MODEL 25
2

3

INSTALLATION CHECKLIST
After your dryer has been installed the operator should verify that everything has been
installed properly and quality workmanship has been maintained. This should be done
mainly to ensure that the dryer will operate properly.
1. Do a general walk-around check, observing general appearance of the dryer.
(look for damaged sheets, loose bolts, etc.)
2. Ensure that the filling and take-away components will be adequate to handle
the needs of the dryer.
3. Make sure the ladder and safety cage sections are properly and firmly attached.
4. Verify all safety shields and protective devices are present and properly installed.
5. Ensure that the proper electrical wiring has been installed to provide adequate
power to the dryer.
6. Verify that the dryer has been properly anchored down, according to the
specifications.
7. Check the fuel system supply lines to the dryer for proper sizing and check the
system for leaks.
8. Check the fluid levels in all gear boxes and lubrication points, verifying that
proper lubricants are present. Refer to the maintenance section if necessary.
4

START-UPPROCEDURES
General Practices
Before attempting to fill the dryer for the first time, it is recommended that the dryer be inspected for cleanliness
and/or damage. Before starting the dryer the second or subsequent day, the plenum chamber area should be
inspected for foreign material, and this material removed. Be sure to close the doors to the plenum before
starting fan.
When filling the dryer for the initial fill, it is recommended that dry grain be used whenever possible. Using this
process eliminates recycling grain back through the dryer, which would have to be done if wet grain were used.
Also, whenever wet grain is used to start the dryer, deposits of wet grain will always be present on the floor and
in the bottom outside of the grain column throughout the season. Over time these deposits will accelerate the
deterioration of the dryer components.
!WARNING! - BEFORE TURNING ON MAIN POWER TO THE
DRYER, MAKE SURE THAT ALL SWITCHES ARE IN THE “OFF”
POSITION OR UNWANTED START-UP OF EQUIPMENT MAY OCCUR.
BE SURE EVERYONE IS CLEAR OFTHE EQUIPMENT AND THAT ALL DOORS
ON THE DRYERARE CLOSED!.
1. Switch main breaker, in the dryer control box, to the “ON” position.
2. Place the control power switch down in the “MANUAL” position.
3. Place the fan switch down in the “MANUAL” position, at which time
the fan will start.
NOTE: The fan must be running in order for the grian to flow over the 18 degree perforated roof of the dryer.
4. If filling equipment is being run out of the dryer control box, place
the wet fill and wet bin switches down in the “MANUAL” position.
If not, start appropriate equipment at this time.
5. When the dryer is full, place ALL switches in the“OFF” position and
turn off any other equipment being used.
Before starting dryer, remove and reinstall all drain plugs in gas train to release moisture and other foreign
material from the line. Be sure there is adequate wet grain available to avoid unnecessary shut down occurring.
Turn on the main fuel supply valve at the tank and make sure the dryer gas hand valve is open, and turn on any
necessary breakers for auxiliary augers.
1. Verify dryer is completely full of grain and the wet fill auger has grain available to keep the perforated
roof covered with grain, and the take-away auger is ready.
2. Place all switches up in the “AUTO” position, except the Commander Box, which should be set in the
“MANUAL” position.
Set the temperature control to “MANUAL” and have the valve about 30% open (P30). Leave the
control in “MANUAL” position until the plenum is warmed up close to the desired plenum temperature,
then switch it to “AUTOMATIC”. Check the “AUTO” set point and have it at the desired temperature
(see definitions for operation instructions on Pg.16). If 30% open does not reach desired temper-
ature, adjust as needed.
!WARNING! BE SURE EVERYONE IS CLEAR OFTHE EQUIPMENT
AND THAT ALLDOORS ON THE DRYERARE CLOSED.
Check the operating temperature setting if you are drying with
low temperature or grain other than corn (see Pg. 16).
5

Initial Starting (cont’d)
NOTE: At this point nothing will start until the start switch is pushed.
!WARNING! WHENTHESTARTSWITCHISPUSHED,EQUIPMENTWILLSTART
AUTOMATICALLY. CARE SHOULD BE TAKEN TOAVOID CONTACT WITHANY
OF THIS EQUIPMENT.
3. At this time push the “START” button.
4. After approximately 10 seconds the gas solenoids will open and the spark plug will spark. Check the
pressure gauges to see if they are increasing.
5. When ignition occurs, check the fuel pressure gauge. The pressure should be no higher than 20 PSI.
If the reading is higher, the regulator should be turned down (counter-clockwise) to lower the pressure.
6. When the operating temperature has been reached in the plenum chamber, the unload system of the
dryer will start.
7. Continue to monitor the dryer until dryer temperature has been stabilized to the desired temperature.
8. Calibrate the wet and dry grain sensors while the dryer is stabilizing. Calibration is accomplished by:
a) Push down on the “DISPLAY SWITCH” and observe the calibration being displayed.
b) Turn the calibration adjustment knob until the value is zero.
c) Compare the moisture value displayed with the moisture content determined by averaging
several samples tested with a reliable tester (See Chart I).
d) Subtract the average of the displayed moisture readings from the average of the tested samples.
This value is the calibration needed for the Commander to make the displayed moisture match
the actual moisture content. (NOTE: The calibration can either be a positive or negative number.)
e) Push the “DISPLAY SWITCH” down and turn the calibration adjustment knob until the value
being displayed matches the calibration determined in step “d”.
f) This completes the calibration. Record the calibrations for the wet and dry grain sensors in the
back of this manual for future reference.
9. Grain samples should be taken on a daily basis to ensure that the electronic equipment is functioning
correctly. Use a quality moisture tester that will provide repeatable accuracy.
10. Use the following guidelines for safe and reliable sampling:
!CAUTION! USEA SAFE SAMPLING PROCEDURE. DO NOT
SAMPLE FROMAHOPPER WITH AN UNGUARDEDAUGER.
KEEPHANDS, FEETAND CLOTHINGAWAYFROM ROTATING
PARTS.
a) Take the samples when the displayed moisture is not changing rapidly.
b) Take several samples and record the moisture being displayed when each sample was taken
as well as the tested moisture content of each sample.
c) Take several samples as close to the moisture sensor as possible to ensure that the sensor is
displaying the moisture from the same batch of grain that you are sampling.
6

Example of Grain Moisture Sampling
This chart shows grain moisture readings of samples as they
should be taken to obtain reliable averages of moisture values.
9:33 a.m. 112 14.4% 109 14.7%
9:36 a.m. 112 14.4% 111 14.4%
9:38 a.m. 108 16.0% 107 17.5%
9:40 a.m. 110 14.6% 109 14.7%
9:43 a.m. 108 15.9% 104 17.3%
9:50 a.m. 111 14.5% 107 15.0%
TOTAL 89.8% 93.6%
AVERAGE 15.0% 15.6% 15.3
Temp. Moisture Temp. Moisture Moisture
Time Calc-U-Dri Dole Elevator
QUESTION: Where would you set the moisture offset, +0.3 or +0.6?
ANSWER: Most would want to set it to +0.3 which would make it
match the point of sale’s reading.
A. The Commander uses the comparison between the control moisture being displayed and the control
set point to vary the speed of the sweep augers. This displayed control moisture can be the average of:
1) wet, dry and column sensors; 2) wet and dry sensors; 3) dry and column sensors, or 4) just the dry
grain sensor. The toggle switches used to select the sensor combination are inside the box on the
left-hand side of the back panel.
Adjust the main speed until the discharged grain is at the desired moisture. The control mode should be
in “MANUAL”. This is best done while the incoming wet grain is at a consistent moisture level. Remem-
ber to allow enough time for the wet grain to flow through the dryer between any speed changes.
You have found the proper main speed when the dryer has stabilized and the discharge moisture is at
or very close to the desired moisture. At this time look at the control moisture displayed. This is the
average moisture of all three sensors. Adjust the control set point to this value.
B. Switch the control mode switch to “AUTO” and the Commander will start to control the speed of the
dryer metering rolls. The dryer will run in “HIGH SPEED” when the control moisture is .3% or more drier
than the set point. It will run in “MAIN SPEED” when it is within + (plus) or - (minus) .3%. It will run in
“LOW SPEED” when the control moisture is .3% or more wetter than the set point.
C. The amount of speed change from “MAIN SPEED” to either “HIGH SPEED” or “LOW SPEED” can be
varied by turning the high and low speed adjustment screws found on the front panel. A speed
change of approximately 15% should give good performance under most conditions. However, some
adjustments may be required for different drying situations. For example, a wider speed range may be
required to accomodate wet grain with inconsistent moisture content.
D. NOTE: if the main speed is changed, some readjustment of the low and high speeds may be
required to maintain the 15% speed change.
CHART I
7

STARTING AFTER ASHUT-DOWN PERIOD
When starting the dryer after it has been shut down, the same basic procedures are listed on
the preceeding pages. However, the reason for an automatic shut down should be investigated.
Getting Desired Plenum Temperature - (See page 16 for additional instructions)
Plenum temperature is controlled by the Honeywell Temperature Controller. The temperature controller signals
the Honeywell Modutrol Motor which drives the Maxon Control Valve. The temperature sensor is located at the
top of the dryer inside the plenum chamber.
The temperature controller works in either “MANUAL” or “AUTOMATIC” mode. Change to the “MANUAL” mode
by pushing the “MAN/AUTO” key. The top display reads temperature and the lower display reads percentage
open. For example: “P 60” means that the control valve is 60% open.
Change to “AUTOMATIC” mode by again pushing the “MAN/AUTO” key. The top display reads temperature and
the lower display reads set point. The controller will automatically change the control valve to maintain the temp-
erature at the set point. To change set point, press the “SETUP” key and then the up arrow or down arrow until
the desired set point is displayed. Press the “SETUP” key again. The controller will maintain this new set point.
The plenum temperature should be set to the grain type, quality and moisture. To get the maximum capacity out
of the dryer, a higher temperature can be used, but the susceptibility to cracks (quality) will also increase. The
orifice can be reduced if low temperature drying is desired. For more information contact DMC.
The supply pressure to the modulating valve should never exceed 30 PSI or damage to the valve may result.
The pressure regulator on the dryer has been preset to 20 PSI and should not be altered. It is recommended
that the orifice be changed instead, to change the operating temperature range, if necessary.
Other Dryer Ajustments
The grain depth on the perforated roof of the dryer is adjusted through the use of a chain and hook assembly
for garner bins. The depth is adjustable in order to fine-tune the dryer’s performance through a wide variety of
conditions. The depth to start with is 6 inches. If the roof option was installed, the skirt can be adjusted from the
ground with the adjusting lever. When the incoming grain is above 25% moisture, reduce the grain depth on the
perforated roof. The grain entering the column should be about 100 degrees F, but not above 140 degrees F.
This will minimize the amount of condensation on the outer perforated sheet.
SKIRT ADJUSTMENT is directly related to the amount of moisture needed to be removed. The following
tips will serve as a skirt adjustment guide to assist you in obtaining the maximum per-
formance from your DMC Calc-u-DRYER: Moisture Points To Be Removed-
(Refer to Drawing Point A. Measure at skirt).:
0-5 pts: Fully open or 8 to 10 inches.
5-8 pts: Skirt should be half open or 4 to 6 inches.
8-12pts: 3 to 5 inches open at skirt.
12 pts and up: 2 to 3 inches open without bubbling.
If grain dances or bubbles directly below skirt,
thicken grain by opening skirt one inch.
(Refer to Drawing Point B. Check temperature
of grain).: The grain entering the column should be
warm, just above 100 degrees F, but should never
exceed 140 degrees F. This will minimize the amount
of condensation on the outer perforated sheet.
The principle behind the perforated cone on the Calc-u-
DRYER is to preheat the grain and remove the surface
moisture before entering the columns. When grain is
25% or wetter, a thinner layer of grain will aid the drying
process. When grain is drier than 25%, a thicker
layer will help the drying process.
GRAIN DEPTH
B
A!CAUTION!
HOT SURFACE
8
OPERATING PROCEDURES

OPERATING PROCEDURES (cont’d.)
The louvers on the doors are used to regulate the amount of air pulled through the grain in the cooling section.
Increasing the amount of air through the column increases the cooling effect on the grain. When the louvers
are closed to increase cooling you will notice a reduction in performance, due to the fact that less air is
flowing through the dryer. When the louvers are fully opened maximum air flow through the dryer can be obtained,
but this will reduce the amount of cooling of the grain before being discharged. To adjust, loosen louver assembly,
adjust to desired setting, and tighten securely.
Louvers On Doors
The sweep augers can be moved closer or further away from the outside wall of the dryer. This is done to adjust to
the differences in incoming grain qualities, moisture and types. Adjustments are intended to enable the operator to
maximize the efficiency of the unloading system. After the dryer’s sweep system has been adjusted upon
installation future adjustments may not be necessary. To adjust, remove bolt holding flighting tube to the gear box,
adjust in or out, and replace bolt back in appropriate hole and tighten. Anominal distance from the support channel
is 1-1/2 inch. If the sweep augers are running in “HIGH” speed the majority of the time, and if speed adjustment on
Commander is not possible, move the auger closer to the column. If the sweep augers are running in “LOW” speed
the majority of the time, and if speed adjustment on Commander is not possible, move the auger away from the
wall.
Sweep Augers
Shut-Down Procedures
Temporary or Overnight Shut-Down
When shutting down temporarily, (service) push the “STOP” button and allow the dryer to shut down automatically.
After the flame goes out shut off the hand valve which supplies fuel to the dryer.
!CAUTION! IFYOUARE GOING TO ENTER THE DRYER, MAKE SURE THAT
THE PLENUM TEMPERATURE IS COOL ENOUGH TO ENTER THE DRYER
SAFELY, ANDALSO LOCK OUT THE MAIN POWER TO THE DRYER.
To shut down the dryer overnight, follow the instructions above. It is also recommended that main power
switches and breakers on the dryer be shut off. It is not necessary to cool the grain in the dryer down
completely unless it will be idle for several days.
9

SWEEP GEAR BOXES 80 - 90 GEAR OIL *CHECK EVERY 200 HOURSAND / OR EACH SEASON
SPEED REDUCER SYNTHETIC GEAR LUBE *CHECK EVERY 200 HOURS AND / OR EACH SEASON
*CHANGE EVERY 800 HOURS
FAN ELECTRIC MOTOR GREASE *1-2 PUMPS PER BEARING MAX AT BEGINNING OF
SEASON
PRE-SEASON MAINTENANCE
1. Be sure the main breaker is shut off in the dryer control box.
2. Visually inspect dryer for any noticeable damage which may have occurred in the off season.
3. Inspect and clean plenum chamber and cooling chamber, ensuring leak area around fan barrel
is free from debris.
4. Clear out gearbox sump and auger.
5. Inspect moisture sensors for cleanliness and / or damage.
6. Check fluid levels in gear boxes and speed reducer. The fluid should reach to the bottom of the
side hole in the boxes.
7. Grease motors and other devices, using the lubrication chart above as a reference.
8. Tighten all large lugs on the starters, distribution block, and circuit breaker. Make sure supply
power is turned off.
LUBRICATION
MAINTENANCE
ITEM LUBRICANT INTERVAL
10
SHUT DOWN DRYER AND LOCK OUT ELECTRICAL BOX BEFORE ENTERING THE DRYER!
The primary daily maintenance required is to check and clean out theplenum chamber. When cleaning the
plenum, pay special attention to the leak area, ensuring that there are no plugged openings. Also, during
operation, pay attention to any irregular sights or sounds around the dryer which could indicate a problem
occurring or about to occur.
DAILYMAINTENANCE
END OF SEASON MAINTENANCE
After the dryer has been cleaned out at the end of theyear the following procedures should be followed:
1. Lightly grease the sweep auger flight to prevent rusting in the off season.
2. Support ends of sweep auger to prevent bowing during off season.
3. Ensure fuel supply is shut off and the line is drained off.
4. Remove the filter plug from the fuel line strainer and clean, then re-install, using pipe sealant.
5. Remove cap from moisture trap, drain as necessary, then re-install, using pipe sealant.
6. Cover the burner.
7. Clean sensors and remove discharge sensor, if necessary.

End of Season Operation
Options for Final Grain Drying
To finish drying the final wet grain in the dryer, do either of the following:
1. Add dry corn to the dryer until the wet corn has passed through the heating section of the dryer.
2. The dryer may be shut off hot, allowed to steep for a short time and then turn on the fan to finish
the cooling.
Unloading Dryer and Final Cleanup
1. Ensure that all switches are in the “OFF” position and main power switch is in the “MANUAL” position.
2. Place the fan switch in the “MANUAL” position - this will start the fan. It is necessary to run the fan
to aid in the grain flowing off the roof and to avoid sweeping.
3. Start the take-away components at this time. If running out of the dryer control box, place the
appropriate switches in the “MANUAL” position.
4. Place the discharge switch and the sweep auger switch in the “MANUAL” position and set speed
to the system at a reasonable rate.
5. When the roof has cleared, the fan switch may be placed in the “OFF” position.
6. Continue running the sweep system until all the grain, that can be, is removed.
7. When sweeps have removed all possible grain, place the sweep auger in the “OFF” position and
run only the discharge.
NOTE: If the discharge system is not used, shut off the main breaker in the dryer control box.
8. Place the discharge switch in the “MANUAL” position.
!CAUTION! Make sure the sweep system is not operating before entering the dryer.
9. Before cleaning the floor of the dryer it is recommended that the perforated cone, plenum chamber,
and walls of the dryer be cleaned first. It is also suggested that the upper moisture sensors be
checked for foreign material. By doing the cleaning in this order, a second cleaning of the floor
can be prevented.
10. Run the discharge system until all material, that can be, is emptied from the auger.
11. When finished, place the discharge switch and main power switch in the “OFF” position.
12. Shut off the main breaker in the dryer control box.
13. Clean out discharge hopper by opening slide gate underneath.
14. Remove moisture sensor from discharge tube, clean off sensor and clean out tube. Mount sensor
back in the discharge tube.
15.
When the main breaker in the control box has been shut off, clean out foreign material both inside
and outside box.
Final Shut Down
When shutting down the dryer in the off season, it is recommended that the main disconnect for the
dryer be shut off. It is suggested that the control box be locked to prevent unauthorized entry. All fuel
supply lines should be shut off at the source, as well as on the dryer.
!CAUTION! SHUT OFF THE MAIN BREAKER IN THE CONTROL
BOX BEFORE CLEANING THE INSIDE OF THE BOX.
11

12

13

Calc-u-DRYER CONTROL DEFINITIONS
1. CONTROL POWER SWITCH: This switch controls the 115 volts AC power that is required for the Calc-u-
DRYER control. The switch must be in the “MANUAL” mode to enable any of the other functions
to run in the “MANUAL” mode. The “AUTOMATIC” mode provides power for normal drying
operations. NOTE: Turning this switch “OFF” will immediately shut down all functions.
2. CONTROLPOWER INDICATOR: This lamp will be “ON” whenever the power switch is in “AUTO” or
“MANUAL” and there is 115 volts AC present.
3. FIVE AMP FUSE: Use only AGC 5A fuses. DO NOT OVERSIZE!
4. OPERATING TEMPERATURE INDICATOR: This lamp will be “ON” when the plenum chamber has
reached operating temperature. The operating temperature is factory-set at 120
5. FLAME RESET:This button wil pop out when the dryer no longer is sensing a flame during operation,
and will shut down the system. (See page 16).
6. FAN SWITCH: This switch allows the fan to run in “AUTOMATIC” or “MANUAL” mode. Turning the
switch“OFF” will immediately stop the fan.
7. TAKE-AWAYSWITCH: This switch allows the take-away equipment to run in “AUTOMATIC” or
“MANUAL” mode. Turning the switch “OFF” will immediately stop the take-away equipment.
8. DISCHARGE AUGER SWITCH:This switch allows the discharge auger to run in “AUTOMATIC” or
“MANUAL” mode. Turning this switch “OFF” will immediately stop the discharge auger.
9. WET FILLSWITCH: This switch allows the equipment filling the dryer to run in “AUTOMATIC” or
“MANUAL” mode. Turning this switch “OFF” will immediately stop the wet fill equipment.
10. WET BIN SWITCH: This switch allows the equipment feeding the wet fill system to run in “AUTOMATIC”
or “MANUAL” mode. Turning this switch “OFF” will immediately stop the wet fill equipment.
11. SWEEPAUGERS SWITCH: This switch allows the sweep augers to run in “AUTOMATIC” or “MANUAL”
mode. Turning this switch “OFF” will immediately stop the sweep augers.
12. STOP SWITCH: This switch will stop the dryer and allow the fan, take-away, and wet fill equipment to
run for the “OFF DELAY” period before shutting down completely.
13. START SWITCH: This switch starts the dryer in the “AUTOMATIC” mode when the power switch is in
the “AUTO” position and will need to be reactivated to restart the dryer after any shutdown.
NOTE: This switch does not need to be activated for compenents to run in the “MANUAL” mode.
14. EMERGENCY STOP: This switch is located externally and will immediately stop the dryer and all
connected equipment when the “STOP” button is pushed in. NOTE: The dryer can not be
restarted until the button is unlocked with the switch key and pulled back out to its original position.
15. TEMPERATURE CONTROL: This module controls the plenum temperature by regulating the modulating
valve that provides gas to the burner. The controller will automatically regulate the modulating
valve to maintain a desired plenum temperature in the “AUTO” mode. The plenum temperature
is displayed in the top window of this module and the desired plenum temperature is set in the
lower window. The modulating valve can be manually regulated with this controller in the
“MANUAL” mode. The top window will display the plenum temperature and the lower window
will show the percent that the valve is open.
-To adjust the temperature in “AUTO” press the ‘setup’ key and then the ↑ or ↓ keys to
adjust the set point. Then push ‘setup’ again.
-To adjust the temperature in “MANUAL” mode, simply push the ↑ or ↓ keys.
16. OFF DELAY/ADJUSTMENT: This adjustment varies the off-delay period (the time that equipment will run
after an automatic shutdown) for 10 to 180 seconds.
17. HOURMETER: The hourmeter displays accumulated time that the discharge auger has discharged grain.
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CONTROL BOX OPERATION
CONTROL ON DELAYTIMER:
The purpose of the on delay timer is to give the dryer enough time during startup to reach operating temper-
ature. This is typically factory set at about two (2) minutes. The timer basically bypasses all of the sensors
that would normally shut the dryer down during operation. Once this time has elapsed, the dryer may auto-
matically shut down at any time. This can be lengthened if more time is required to reach operating temper-
ature by simply turning the knob clockwise.
ON-DELAYTIMERS,AUXILIARYEQUIPMENT
The Wet Bin, Wet Fill and Take-Away equipment have individual on-delay timers. This allows you to stagger
start all of the equipment to reduce the peak amperage draw. Each is adjustable from zero (0) to twenty (20)
seconds.
FLOW TEMP THERMOSTAT
The purpose of the flow thermostat and thermocouple is to detect when there is no longer grain being fed into
the dryer. The thermocouple is placed just above the grain on the perforated cone. When the thermocouple
is cool,the dryer will be allowed to run. If the grain entering the dryer has stopped, an opening will occur
through the perforated roof. This will allow more hot air to escape at the top and will heat the thermocouple.
Once the thermocouple temperature has risen above the thermostat setting, the dryer will shut down.
The flow temp setting needs to be above ambient temperature and the operating temperature and yet below
the plenum temperature. Plenum temperature is displayed on the temperature controller. Thermostat is
factory set at 170 .
It is recommended to test the setting by shutting off the incoming grain. The dryer should shut down
automatically and the FLOW TEMP light on the shutdown indicator should be on.
PURGE DELAYTIMER
The purge delay timer will allow the fan to run for ten (10) seconds during startup before the gas solenoids
open and ignition occurs.
OFF DELAY TIMER
The off delay timer will keep the fan, wet fill and take-away equipment on for the set time after the dryer has
been signaled to stop. This will occur after the stop button on the control panel has been pushed or during
an automatic shutdown. When the emergency stop button has been pushed, the off delay timer is not used,
and all equipment will shut down immediately.
DISCHARGE STARTER
The discharge starter consists of a circuit breaker, contactor and overload protection all housed in one unit.
The overload setting is made by way of the adjusting screw on the starter’s front panel. This setting should
equal the discharge motor’s full load rating. The control switch should be in the AUTO position. If the breaker
or overload should trip, then this switch will rotate to the OFF position. The dryer will shut down and the shut
down indicator’s discharge light will be on. To reset, first rotate the switch to RESET then toAUTO.
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TYPICAL DRYING SITUATIONS
GRAIN PLENUM OPERATING FLOW AMBIENT
TEMPERATURE TEMPERATURE TEMPERATURE TEMPERATURE
CORN 250 120 170 50
RICE 105 95 100 85
WHEAT 150 110 130 70°
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