Farm Fans C-2125A User manual

,
-2125A, C-2130 ,& C-2140A
GRAIN DRYERS
fAR
fANS
Division of ffi CORPORATION
5900 ELMWOOD AVE .• INDIANAPOLIS, IN 46203
© 1992 ffi CORPORATION Printed in U.S.A.
C21A-01-2
Revised 8-92

READ THESE INSTRUCTIONS BEFORE INSTALLATION AND OPERATION.
SAVE FOR FUTURE REFERENCE.
Thank you for choosing a Farm Fans C-2100A Series grain dryer. These units are among the finest grain
dryers ever built; designed to give you excellent operating performance and reliable service for many
years.
This manual describes the installation and operation for all 1991 and later standard production type
C-2100A Series dryers. These dryers are available for liquid propane or natural
gas fuel supply, with
either 230V or 460V three phase (60Hz) electrical power (single phase 230V available for the C-2125A).
Operating information for the optional Heat Reclaimer equipment available for some models,
is contained
within a separate publication.
USE CAUTION IN THE OPERATION
OF THIS EQUIPMENT.
The design and manufacture of this dryer is directed toward operator safety. However, the very nature of
a grain dryer having a gas burner, high voltage electrical equipment and high speed rotating parts does
present a hazard to personnel which cannot be completely safeguarded against without interfering with
efficient operation and reasonable access to components.
Use extreme caution in working around high speed fans, gas-fired heaters, augers and auxiliary
conveyors which may start without warning when the dryer
is operating on automatic control.
Continued safe dependable operation of automatic eqUipment depends, to a great degree, upon the
owner and operator(s}. For a safe and dependable drying system, follow recommendations within the
manual and established safety practices. Also, make it a practice to regularly inspect the operation of the
unit for any developing problems or unsafe conditions.
MAKE CERTAIN
TO THOROUGHLY INSTRUCT ALL OPERATORS IN THE PROPER USE AND
SERVICE
OF THIS EQUIPMENT.
Take special note of the Operating Precautions listed on page
ii before attempting to operate the dryer.
Keep the dryer clean. Do not allow fine material to accumulate in the plenum chamber.
A
CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENT.
WARRANTY
ffi Corporation warrants its products to be free of defects in material and workmanship. The only obligation of the manufacturer is to
repair or replace products which have been submitted and found to be defective within 12 months after installation. If so found
defective, the products will be repaired or replaced without charge, this constituting and entirely fulfilling the warranty obligation. IIi
assumes no liability for expenses incurred without written authorization; in no event shall its liability include special or consequential
damages, or exceed the selling price of the product.
This warranty does not cover products or parts which have been damaged by negligent use, misuse, alteration or accident. Some
components supplied by manufacturers are warranted separately by those suppliers. This warranty is exclusive and in lieu of all
other warranties, expressed or implied. ffi reserves the right to make design or specification changes at any time, without any
contingent obligation to purchasers of products already sold.
All instructions, with the exception of those concerning safety, shall be construed as recommendations only; because of the many
variable conditions in actual installation, IIi assumes no liability for results arising from the use of such recommendations.
Copyright © 1992 by ffi Corporation. All rights reserved. No part of this publication may be used or reproduced in any form or by any
means without prior permission. Failure to comply with this notice is a violation of United States copyright laws.

CONTENTS
OPERATING PRECAUTIONS ................. ii Dryer Shutdown
............................... 5·2
Operating Instructions Chart
...................... 5·3
Drying Time
Table· C·2125A (Fig. 5·1) .............. 5·3
Drying Time
Table· C·2130A & C·2140A (Fig. 5·2) ..... 5·4
SECTIONONE SREGIHIGA'mI0NS"
Start·up Procedure (Fig. 5·3) ...................... 5·5
C·2125A Continuous Flow Operation (Fig. 5·4)
......... 5·6
General Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1·1
Spec Chart ................................. 1·2 C·2130A Continuous Flow Operation (Fig. 5·5)
......... 5·7
C·2140A Continuous Flow Operation (Fig. 5·6)
......... 5·8
Auger Specs
............................... 1·3
SCR Specs
................................ 1·6
SECTlON$lX DRYER 1l.[l.[USTRA'mI0NS
SECTIONlWO mRA'NSR0RmAmI0N & INSTAl.[l.[A'mI0N
TRANSPORTING DRYER ........................ 2·1
SECTIONSEVEN SERYIGE
INSTALLATION ............................... 2·1
FUEL CONNECTION ........................... 2·3 Seasonal Inspection and Service
................... 7·1
ELECTRICAL POWER SUPPLY ................... 2·5 Burner Control Sequence of Operation
............... 7·2
Propane Vaporizer Seasonal Inspection
.............. 7·3
Vaporizer Adjustment
........................... 7·3
Fan Propeller Removal and Installation
.............. 7·4
SECTIONllIREE 0RERAmiNG G0NTR0l.[S. Browning Taper·lock Bushing Bolt Tightening Torques . 7·6
Fan Motor Removal and Installation
................. 7·6
Control Stop/Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3·1
Fan Switches ................................. 3·1
Main/Safety Gas Shut·Off Valve ................... 3·1
Burner Switches ............................... 3·1
Plenum Temperature Controls
..................... 3·2
Load Auger Switch
......... . . . . . . . . . . . . . . . . . . . . 3·3
Load (Top Auger) Timer
......................... 3·3
Unload Auger Switch
........................... 3·3
Heater Parts Removal and Installation
............... 7·7
Grain and Plenum Temperature Sensor Locations
...... 7·8
SCR Drive and Meter Roll Information
............... 7·9
Meter Roll Blockage
............................ 7·9
How To Determine Metering Problem
............ 7·10
To Locate The Jam
......................... 7·10
To Clear Jam From Meter Roll
................. 7·10
SCR Motor Control
............................ 7·10
Meter Roll Controls
............................. 3·4
Meter Roll Selector Switch
...................... 3·4
Manual Unload Control Dial
.................... 3·4 SECTION EIGHT
WIRING DIAGRAMS
% Unload Rate (Meter Roll) Volt Meter ............. 3·4
Vari·Trol Moisture Control
........................ 3·4
Operating with Moisture Control
.................. 3·5
Dryer Operator Light
............................ 3·5
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
... 3·5
Meter Roll Monitor System
...................... 3·5
Shutdown Indicators
............................ 3·6
Power
Circuit· 230V 141 C·2125A models ............ 8·1
Power Circuit· all 3q, models ...................... 8·2
General Control Circuit (2 pages)
............. 8·3 to 8·4
Safety Shutdown Circuit
......................... 8·5
PL·021 Burner Control Circuit
..................... 8·6
Restarting Dryer after a Shutdown
................ 3·7
Hinged Fast·Trip Cleanout
....................... 3·6
SEC'nONNINE TROUBl.[ESH00TING
SECTION FOUR TEST HIRING
SECTION AVE DRYER ORERATI0N
Drying Temperatures ........................... 5·1
Full Heat Drying ............................... 5·1
Final Moisture Content .......................... 5·1

OPERATING PRECAUTIONS
1. Read and understand the operation manual 9. Do not operate the dryer if any gas leak is
before attempting to operate the unit. detected. Shut down and repair before
further operation.
2.
Keep ALL guards, safety decals, and safety
devices in place. Never operate dryer while 10. Clean grain is safer and easier to dry. Fine
guards are removed. material can be highly combustible, and it
also increases resistance
to air flow and
3. Keep visitors, children, and untrained personnel requires removal of extra moisture.
away from dryer at
all times. 11. Use CAUTION
in working around high speed
4. Never attempt to operate the dryer by jumping or fans, gas burners, augers, and auxiliary
otherwise bypassing any safety devices on the conveyors which start automatically.
unit. 12. Be certain that capacities of auxiliary
5. Always set the main power supply disconnect conveyors are matched to dryer auger
switch to OFF and lock
it in the OFF position capacities.
using a padlock before performing any service or
maintenance work on the dryer or the auxiliary 13.
Do not operate in an area where
conveyor equipment. combustible material will
be drawn into
the fan.
6. Before attempting to remove and reinstall the
propeller, make certain to read recommended 14. The operating and safety recommendations
procedure listed
in Section 7 -SERVICE. in this manual pertain to the common cereal
grains
as indicated. When drying any other
7.
Keep the dryer and wet holding equipment grain or products, consult the factory for
CLEAN.
Do not allow fine material to additional recommendations.
accumulate. 15. Routinely check for any developing gas
8. Set pressure regulator to avoid excessive gas plumbing leaks. Check to ensure that
pressure applied to a burner during ignition and vaporizer
on LP models does not come into
when burner
is in operation. See Fig. 2-3 for contact with burner vanes.
operating gas pressures.
Do not exceed
maximum recommended drying temperatures.
ii

TYPE:
Continuous flow, single module with two fan-heater
units and two temperature zones provided for
Dry &
Cool or Full Heat dryeration process. The upper
temperature zone and fan-heater
is sized larger
than the lower
to optimize Dry-Cool operation.
GRAIN COLUMNS:
Two 14" galvanized steel grain columns. Solid
column dividers every two feet. Grain movement
through columns
is controlled by the advanced
electronic variable speed Vari-Trol VMD metering
roll drive system designed to precisely control grain
moisture.
FANS:
Two heavy-duty direct driven, quiet, vane axial fans
with full motor overload protection. All fans run
at
1750 RPM, with the exception of the 3500 RPM
cooling fan of the C-2125A. Air Volume, HP and
static pressure are matched to grain volume.
e
0'-8'
15'-2'
HEATERS:
Two high capacity direct-fired, efficient "Star Fire"
burners with full electric ignition. Electronic temper-
ature control for precise drying heat. Stainless
steel burner
on upper fan of C-2140A models.
AUGERS:
Automatically controlled top leveling augers with
power circuit for simultaneous operation of auxiliary
loading conveyor. Bottom auger unloads grain
discharged from metering rolls. Power circuits for
loading and take away conveyors are standard.
Heavy-duty construction.
AUTOMATIC CONTROL:
Automatic 'control of all functions: loading, drying,
cooling, and discharge. Full safety control system;
automatic shutdown on wet grain outage, grain
Hi
Limit, and discharge safety shutoff. Safety circuit
shutdown indicators.
8'-0'
5;::' .. {;; 10
I
D I J U
--,---
-
2'-2'
STD
A
BODY
B
C
.n1~
1 1 J
L 0'-8' REINFORCED
----......,..-4'-10'- CONCRETE FOUNDATION
SUGGESTED FOUNDATION
.. ELECTRICAL SERVICE
III FUEL SERVICE
Fig, 1-1 Dryer dimensions.
MODEL
C-2125A
C-2130A
C-2140A
A B C D
18'-0'
25' 26'
16' MIN.
20'-0' 27' 28'
16' MIN.
26'-0' 33' 34'
16' MIN.
SPECIFICATIONS 1-1
NO. OF APPROX. \.IEIGHT
SUPPORTS
\.1/ TRANSPORT KIT
7
8200
7
9700
9 12600
I ~ 6'-4'j
L 8'-0'
21ADIMI, D~G

I FIG. 1-2 DRYER SPECIFICATIONS I
C·2125A C-213OA C·2140A
Basic Construction 1 Module with 2 Zones 1 Module with 2 Zones 1 Module with 2 Zones
Grain Column by Length
lS'
20' 26'
Grain Column Width 14" 14" 14"
Holding Capacity (total) 535 Bu. 595 Bu. 775 Bu.
Holding Capacity (dry and cool) 415 Bu. 460 Bu. 600 Bu.
Transport Length (hitch to dis. auger) 27-1-1/2" 29'-1-1/2" 35'-1-1/2"
Transport Width
S'-O" S'-O" S'-O"
Transport Height 12'-10" 12'-10" 12'-10"
Installed Length 25'-0"
27-0"
33'-0"
Installed Width
S'-O"
S'-O·
S'-O'
Installed Height (above foundation 15'-10· 15'-10" 15'-10"
supports')
Fans Dry
36' Dia, 1750 RPM, 15 HP
39" Dia, 1750 RPM, 20 HP 39" Dia, 1750 RPM. 25 HP
Cool 24"
Dia, 3500 RPM, 10 HP
2S" Dia, 1750 RPM, 13 HP 28" Dia, 1750 RPM, 13 HP
Heaters -Max. Capacity (Millions)
Top Heater 4.6
MM BtuIHour 6.0 MM BtuIHour 7.5 MM Btu/Hour
Btm. Heater (for full heat operation) 2.3
MM Btu/Hour 3.0 MM BtuIHour 3.0 MM Btu/Hour
Top Auger
S" Dia, 5 HP
S' Dia, 7.5 HP S" Dia, 10 HP
Capacity 2800 BU.lHour 2800 Bu.lHour 2800 Bu.!Hour
Bottom Auger
S" Dia, 3 HP
S" Dia, 5 HP S' Dia, 7.5 HP
Capacity -Maximum Rate2 1220 Bu.!Hour 1350 Bu.lHour 1760 BU.!Hour
Meter Roll Drive 3/4 HP, SCR 3/4 HP, SCR 3/4 HP, SCR
Electric Load (fans, top & btm. auger)3
Single Phase 230V 180 Amps NA NA
Three Phase 230V 100 Amps
12S Amps 146 Amps
Three Phase 460V 50 Amps 64 Amps 73 Amps
Drying Capacity -Shelled Corn·
Dry & Cool 25-15% 300
BPH
350 BPH 455 BPH
Dry & Cool 20-15% 505
BPH
595 BPH 774 BPH
Full Heat 25-15%5 515 BPH 600 BPH 780 BPH
Full Heat 20-15%5
S35 BPH
980 BPH
1274 BPH
1. 24" high supports required for heat redaimer installation.
2. Actual discharge rate is controlled by meter roll speed adjustment, at 5% to 100% of maximum rate.
3. Excludes auxiliary load and unload conveyor equipment.
4. Capacities listed are wet bushels at listed input moisture content and are estimates based on drying principles, field results,
and computer simulation. Variances may occur due to physiological grain factors (kernel size, chemical composition, variety,
maturity), excessive fines, adverse weather conditions, etc.
5. Grain discharged hot from the dryer at approximately 17% output moisture should result in a final moisture content of
approximately 15% after cooling (dryeration).
SPECIFICATIONS 1-2

I FIG. 1-3 AUGER DRIVE DATA I
AUGERS MOTOR SPROCKETS SHEAVES
Approx. Drive Driven
Capacity Drive Drive Driven PDlHub PDlHub
Size Bu.lhr.l
HP 3 RPM Belts Chain (Teeth) (Teeth) Bore Bore
Top Auger:
C·2125A 8" 2800 5 1750 BX·120 (2)
---- ----
-_ ....
3.6"/1·1/8" 18.4"/1·1/2"
C·2130A 8" 2800 7.5 1750 BX·120 (2)
----
-_ ....
----
3.6"/1·318" 18.4"/1·1/2"
C·2140A 8" 2800 10 1750 BX·120 (2) --
....
........
----
3.6"/1·318"
18.4"/1-112"
Bottom Auger:
C·2125A 8" 1220 2 3 1750 BX·93 (2) #50 15
48 2.8"/1-118"
10.4"/1·1/4"
C·2130A
8" 1350 2 5 1750 BX·93 (2) #50 15 48 3.6"/1·1/8"
12.4"/1·114"
C·2140A 8" 1760 2 7.5 1750 BX·93 (2) #50 25 48 3.2"/1·3/8" 13.4"/1·1/4"
1.
Dryer auger capacities and power requirements vary with grain moisture content and amount of fine material in
grain.
2.
This BuJHr. listing represents the maximum meter roll discharge rate. The bottom auger capacity exceeds the
maximum meter roll rate.
3.
Standard output auger motors listed.
SPECIFICATIONS 1-3

I FIG. 1-4
seR DRIVE INFORMATION and DATA I
APPROXIMATE DISCHARGE RATE -BU/HR at VARIOUS SETIINGS
Setting 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 80% 90% 100%
C-2125A 122 183 244 305 366 427 488 549 610
671
732 793 854 976 1098 1220
C-2130A 135 202 270 337 405 472 540 607 675 742 810 877 945 1080 1215 1350
C-2140A 176 264 352 440 528 616 704 792 880 968 1056 1144 1232 1408 1584 1760
SCR DRIVE DATA
C-2125A C-2130A C-214OA
SCR
Control· Part No. & Supply
Voltage 415-2302-8. 230V 415-2302-8. 230V 415-2302-8. 230V
DC MOTOR
PART NO. 002-1192-0 002-1192-0 002-1192-0
HORSEPOWER & SET RPM 3/4 hp, 1600 rpm 3/4 hp. 1600 rpm 3/4 hp, 1600 rpm
TYPE
SW SW SW
SET VOLTAGE (ARM) 155 155 155
FULL LOAD AMPS (ARM) 3.9 3.9 3.9
MOTOR SHEAVE
PITCH DIA. 3.0 3.0 3.0
NO. AND BORE AK32H. H·S/8" AK32H. H-5/8 AK32H. H·S/8
GEARBOX· PART NO. & RATIO 017-1393-2.50:1 017-1393-2.50:1 017-1403-9.50:1
GEARBOX DRIVE
INPUT SHEAVE
PITCH DIA. 5.7" 5.7" 5.7"
BORE H-5/8 H·S/8 H-7/8
BELT A26 A26 A26
OUTPUT SPROCKET NO. & BORE H4015-1.
H-1 1/8 H4015-1, H-1 1/8 H40H15, H-1 1/8
CHAIN #40 x 106" #40 x 106" #40 x 106"
METER ROLL
TYPE & MAX. RPM 6 Flute. 8.42 rpm 6 Rute. 8.42 rpm 6 Flute. 16.62 rpm
DRIVE SPROCKET NO. & BORE 40H30,
H-1
40H30, H-1
40H30. H-1
SPECIFICATIONS 1-4

% ~
SECmlON mwo mRI'~r5JllmfRm~mlmN IlINlm~Unl~mlmN
TRANSPORTATING DRYER
The dryer is available with an optional Transport Kit for transporting the unit by truck or tractor. Make
certain to observe the following safety precautions:
1. Recommended towing hitch height: 16 to 17
inches.
2. Hitch pin to be not less than 3/4 inch in dia. and
securely fastened so it will not come out in travel.
3. Use a safety chain.
4. Dryer must be towed empty and in accordance
with applicable state or provincial regulations.
5. Recommended tire pressure 55-60 psi (cold).
6. Maximum towing speed: 45 mph
7. After first 50 miles and every 200 miles
thereafter:
a. Check temperature of transport
wheels' hubs and spindles
immediately after stopping.
Temperature should not exceed
150°F. May
be hot to touch, but not
melting lubricant.
b. Check wheel lug bolts; they are factory
torqued at 115
to 120 ftllbs. Retighten,
if required, to approximately 90 ftllbs.
INSTALLA mlON
SYSTEM LAYOUT -Consider the grain handling system and location of storage bins and existing con-
veyors
in selecting the dryer site, to facilitate wet grain supply and dry grain discharge to conveyors.
SITE SELECTION -The dryer
is not to be operated inside a building or in any area not permitted by
electrical codes, fuel installation regulations, or insurance requirements.
Do not operate in an area
where combustible material can be drawn into the fans. Maintain the required minimum distance from
other structures. Refer
to Fig. 1-1 for dryer dimensions.
FILLING POINT -Wet grain must enter the dryer
at the hopper at the rear end of the top auger, since
the top auger moves grain forward, toward the paddle switch controlling the top auger (except for
special build front-loading units).
WET GRAIN SUPPLY - A wet holding bin may be utilized to supply grain
to the dryer, with gravity flow
into the dryer loading conveyor. Also, gravity flow from a wagon or truck into a loading conveyor may
be used to fill the dryer. The top leveling auger will accept grain at any rate up to its maximum
capacity as listed in Fig. 1-2.
In any case, the dryer must have a constant supply of wet grain. Auxilia-
ry loading conveyors should be sized to nearly match the capacity of the top auger, to avoid air loss
problems caused by underfilling during high drying rate operations.
WET GRAIN LOADING -The dryer will automatically start the top auger and any loading conveyor
electrically connected to the power terminal strip on the power panel (see Section 8 - Wiring Diagrams).
At the beginning, dryer will completely fill, requiring approximately its full holding capacity. During
drying, the top auger will start
and stop as required to maintain the dryer full of wet grain.
TRANSP. & INSTALL.
2-1

LOAD TIMER -The unit is equipped with a top auger Load Timer (inside ASC control box), to provide
automatic shutdown on wet grain outage,
if the top auger operates for a time exceeding the timer
setting (field adjustable).
DISCHARGE AUGER EXTENSIONS -Special discharge auger extension kits are available, with an
additional length of 1 to 10 feet (one foot increments) to provide
dry grain discharge points at various
distances from the rear of the dryer, for direct discharge into elevator legs or other conveyors.
Extensions are available with either a solid or perforated tube.
AUXILIARY CONVEYOR OVERLOAD RELAYS -Overload relays for the loading conveyor and take-
away conveyor are factory equipped with heater elements as listed in Figs. 2-4 to 2-6 for motors on
auxiliary conveyors.
If other HP ratings are used, it is necessary to change the heater elements to
provide proper running load protection for the motors.
DRYER FOUNDATION -The wheels are provided only for transportation of the empty dryers to the site
location. Before assembling and installing the dryer, prepare a level, secure foundation, with provisions
for dryer tie-down.
NOTE:
If the dryer is to be equipped with an optional Heat Reclaimer Package, also refer to
instructions included with the Heat Reclaimer. Heat Reclaimers for C-2100A dryers include special
dryer support structures which are intended for a conventional, flat type concrete foundation.
DRYER PREPARATION
1. Remove Parts -Remove hopper and other parts shipped inside dryer.
2. Wet Bin -Fold up the wet bin, assemble the top auger drive and connect fill hopper as described in
bulletin CIWB-01-2.
3. Install Fill Hopper as shown in CIWB-01-2.
4. Connect Electrical and Fuel.
5. Inspection & Testing -Thoroughly inspect dryer to make certain all parts have been properly
installed and tightened. See FUEL CONNECTION and ELECTRICAL POWER SUPPLY headings
in this section for important fuel and electrical requirements. Check that all gas fuel lines are free of
leaks. Also check vaporizer assembly on all liquid propane models to ensure that vaporizer coil
does not contact the burner vanes; see Section 7 - SERVICE, for vaporizer coil inspection details.
After dryer and all systems have been completed, start dryer and check it for proper operation as
outlined in Section 4 - TEST FIRING.
TRANSP. & INSTALL. 2-2