Zoltec BELTOMATIC User manual

OPERATORS MANUAL

To: Sales Order:
Number:
Date:
PO:
B.N.W. Industries Terms:
7930 N. 700 E. Amount
Tippecanoe, IN. 1
46570 USA
Office 574-353-7855
Fax [phone] Gas safety and modulating control valves
Email [email protected]
Web www.belt-o-matic.com Belt wiper product spreader, two 1-Hp drives
Mild steel construction, insulated, Zoltec Blue
Auto fines clean out in bottom plenum of dryer, 1-Hp drive
No pre--wired electric control panel
No variable speed drives for motors
Fireye "M" series flame monitor, dwyer vacuum airflow
switch, ignition transformer, electric jct box (NEMA 4),
Important Note
% Down 35%
Entered By
:
Aaron Norris Total
Down Pmt
Received By: Balance
Date:
-$
All Prices in US Dollars
5' wide x 24' long, single-pass air up dry and cool
Belt-o-matic model 5-303B carbon pellet dryer/cooler
FOB Tippecanoe, IN, 46570. Allow 10 weeks ARO. Dated Required 2/15/08
35% down, 50% when ready to ship, 15% 30 days.
Description Price
Zoltec Corporation
Clancy Duttlinger
3101 McKelvey Road
St. Louis, MO. 63044
Product feed and discharge conveyors and fines discharge conveyor
and typical wiring scehmatic.
Not included
Air intake air duct
Motor controls for spreader, auto fines, and combustion blower
122670
All quotes are good for 30 days
Transportation, installation, and foundation
Electric power and gas supply
Pre-wired electric control cabinet
Temperature controller and thermocoupler
Variable speed drives for fan and conveyor motors
X
07247R3
1/7/2008
High temperature limit switches & dial temperature thermometers
Perforated plate conveyor belt with 0.078 x 0.156 slots, 304SS
3-Hp NYB combustion blower series 20 GI fan, 2500 CFM
3/4-Hp conveyor drive
TEFC premium efficiency motors 240/480 volt, 3 phase
Maxon Ovenpak gas burner, 750,000 Btu maximum
60" width belt w/ 2" tall side plates & 6" pitch mild steel roller chain
BNW Industries is not responsible for
compliance of required local, state,
and national regulatory guidelines
concerning gas, burner, and electrical
features. "As built" electrical
schematic is included. UL approved
electric enclosure available at an
additional cost. All pricing is for
budget purposes. Final pricing will be
submitted after approved engineering
drawings. B.N.W. Industries is NOT
responsible for any and all sales, use,
import or value added taxes.
Cyclone and fan for cleaning exhaust air & exhaust air duct
-$ -$

Table of Contents
I. Introduction pg. 1
A.Warnings
B. Equipment ID
C. Warranty
D. Disclaimer
II. Safety pg. 2
A. Fire Safety
B. Fire Safety Equipment on all New Belt-o-matic Dryers
1. Burner control power interlock
2. Airflow switch
3. High limit safety switches
C. Emergency Fire Shut Down Procedure
D. General Safety
III. General Information pg. 3
A. Manufacturer Information
B. Servicing Statement
C. Using the Manual
IV. Receiving and Handling pg. 4
A. Inspection
B. Damages
C. Handling
D. Packaging
V. Installation pg. 4
A. Installation Site
B. Electric Hook Up
C. Gas Hook Up
D. Assembly of Parts
1. Top cover and inlet hopper
2. Shaft-mounted gearboxes with C-face motors
3. Removed drive plate
4. Air intake duct
E. Air Ducts
F. Rotations and Alignments
G. Motors
VI. Operations pg. 7
A. Start-up Procedure
B. Shut Down Procedure
C. Filling the Machine, Product Depth
D. Adjustments and Controls
1. Depth
a. Inlet hopper and level gate
b. Inlet spreaders
2. Conveyor belt speed
3. Flame adjustment
4. Temperature adjustment
5. Airflow

E Controlling Capacity
F. Controlling Efficiency
VII. Maintenance pg. 12
A. Housekeeping
B. Bearing Service
C. Gearboxes
D. Chain Adjustments
E. Maintaining Woven Wire Conveyor Belt
1. Belt maintenance
2. Belt traction
3. Belt adjustments
4. Belt removal and replacement
F. Maintaining Solid Tray Conveyor Belt
1. Belt maintenance
2. Belt tension
3. Belt adjustments
4. Belt removal and replacement
G. Conveyor Racks
H. Drive Roller Lagging
VIII. Optional Equipment pg. 16
A. Auto Fines Clean Out Systems
B. Stirring Equipment
C. Cyclones
D. Stainless Steel Contact Points and Construction
E. Steam Heat Exchangers
F. AC Inverters
G. Inlet Level Beater
H. Rotary Air Locks
I. Auger Discharge
IX. Troubleshooting pg. 18
Appendix
Roller Adjustment for Discharge Drive (fr#499 or lower) A-1
Roller Adjustment for Discharge Drive (fr#500 or higher) A-2
Fines Conveyor Adjustment B
Oscillating Inlet Spreader C
Web Disassembly D-1
Flat Wire Belt Assembly Instructions D-2
Roller Lagging E
Gas Train F-79
Electric Control Panel H-1
Power Hook Up H-2
Honeywell Controller Schematic and Lock Out Codes H-3-33
Definite Purpose Contact Assembly H-34-35
Drive Plate and Chain Tightener I
Setting the Fan Blade Pitch J-1
Fan Hub Assembly J-2
Level Gate Adjustment for Product Depth K
Air Duct to Cyclone Transition Diagram L

Gun Style Burner M
Foot per Minute Web Travel Chart N
Lesson Motors Technical Information O-1-6
Leeson VFD Quick Reference Guide O-8-9
Gear Speed Reducers P-1-8
Gas pressure gauge, and thermometers Q-1-2
High Limits R-1-4
Pressure Switch S-1-2
Parts List T-1-2
Parts Order Form T-3

I. INTRODUCTION
A. Warnings
When drying combustible material with heated air, there is a fire hazard.
Warning. Avoid pulling particles through the burner or heat exchanger. The heat source can ignite
the particles and send sparks into the drying chamber.
Warning. Product left in and around the machine can ignite and start a fire. Clean the air chamber
and the area around the machine daily or more often, if necessary
Warning. Check the high limit safety switches. These switches should be set about 20°F above the
air temperature of the zone it is located in. These switches will shut off the fan and the burner to
prevent overheating.
Warning. Immediately stop the burner and all fans in case of fire. Shutting off all airflow will
reduce the size and temperature of the fire. Interlock all exhaust fans with the high limit safety
switches.
Warning. Machines equipped with an auto fines clean out system need to run at all times to reduce
the threat of fire.
Warning. Lock out and tag out power before opening and entering any access panel or inspection
door.
Warning. Close and secure all access and inspection doors before operating the machine.
Warning. Maintain all safety guards and warning stickers.
B. Equipment ID
Each Belt-o-matic machine has a frame number for identification. The number is welded on the
bottom left-hand corner of the frame next to the product discharge. The left-hand corner is determined
by facing the product discharge. Each unit also has an ID tag on the electric control panel. This tag
gives the model, serial number, voltage, amps, cycles, phase, fuel type, fuel pressure, maximum CFM,
and fan horsepower. If the machine did not come equipped with an electric control panel, the tag is
located above the bottom conveyor drive motor and gearbox.
C. Warranty
The Belt-o-matic has a one-year warranty which covers B.N.W. Industries manufactured parts and
workmanship. Other component warranties are based on the manufacture warranty and may vary.
Check with B.N.W. Industries on all other component warranties. The warranty begins on the day of
delivery. Warranty parts must be returned to B. N. W. Industries for replacement.
D. Disclaimer
Improper installation, operation, handling, or unauthorized modifications of the Belt-o-matic
constitutes loss of warranty. B.N.W. Industries is not responsible for loss if not all warnings and
recommendations of this manual are observed.

II. SAFETY
A. Fire Safety
When drying combustible product with heated air there is a threat of fire. With certain products that
are flammable and have a high amount of fines, the fines material can be ignited as it passes through
the burner.
In a direct fire situation, the first source of fire comes from moving combustible product through the
burner. The flame can ignite the product sending sparks into the drying chamber. These sparks may
ignite product that is being dried or product that has not been cleaned out of the air plenum. Product
left in the air plenum becomes very dry and can easily ignite.
To reduce the risks of fire and avoid sparks, maintain clean air to the burner. A clean air duct can
supply fresh air supply to the fan and burner. This is necessary with certain products that have a high
fire risk.
When heating air with a steam coil or other various heat exchangers, the danger of fire occurs when
combustible product accumulates in and around the heat exchanger. The product will eventually ignite
and send sparks into the drying chamber. Heat exchangers need to be inspected and cleaned daily.
The frequency of cleaning and the extent of modification to avoid a fire depend on the flammability of
the product, the amount of fines in the product being dried, and the air quality of the installation.
In many Belt-o-matic dryers and coolers, the vacuum side of the burner fan pulls the air through the
cooling section. With certain products that are very flammable and have a high amount of fines, the
fine material can be ignited as it passes through the burner. Observe the air chamber, while in
operation, to see if there is a high amount of sparks. To reduce the amount of fines being pulled
through the fan and decrease the amount of sparks, open the sliding fresh air intake doors as far as
possible and yet achieve a cool product at the discharge. If you still observe sparks in the air chamber,
it may be necessary to use a separate fan to do the cooling.
Fire safety starts with these prevention steps:
1. Cleanliness. Daily, if not more, clean heat exchangers, air plenums, and air ducts.
2. Provide clean air to the heat source. If needed install a fresh air duct to the heat source. Find the
best and cleanest air to supply the heat source.
3. Observe the air chamber while in operation to see if there is a high amount of sparks.
B. Fire Safety Equipment on all New Belt-o-matic Dryers
1. Burner control power interlock. Power for the gas burner controls originates from the interlock
with the fan starter. Turning the burner switch on without the fan running and the hand gas valve
closed can check this interlock. If interlocked properly, the burner controller display will not
illuminate. Older models without the external display will have a small light for indicating power
to the burner controller.
2. Airflow switch. An airflow switch senses air movement at the fan. The fan must be running
before the burner will light. This switch must send a signal to the burner controller before the
burner will light. You can check this safety by disconnecting the copper or plastic tube at the
airflow switch. The burner controller should not advance to trial for ignition (TFI).
3. High limit safety switches. High limit safety switches are located in the air chamber and on the
top cover by the exhaust opening. The switches are normally closed. The two high limit switches
2

in the air chamber are wired in series with the burner controller. If these switches overheat, they
will automatically shut the burner off. The fan will remain running. Once the switches cool and
reset, the burner controller will once again light the burner. These switches are usually set at
250°F, but may vary. You can take a wire off one of the switches to test. The burner should not
light. You can also take a switch out and place it in an oven at the temperature of the setting on
the switch. The switch should open once it reaches the set temperature.
The other high limit by the exhaust opening is wired in series with the burner fan thermo overload.
It is usually set at 210°F, but may vary. If this switch overheats, it will shut the fan off. This will
interrupt the power to the burner controller shutting the burner off. The burner controller will go
into lock out and will need to be reset before the burner can be lit again. It can be tested in the
same manner as the other high limit switches. This switch is usually the first detection of a fire.
The high heat from a fire will be first detected in the exhaust opening by this switch. It is very
important to stop all airflow, if a fire occurs. Interlock all auxiliary fans to this high limit switch.
There are several safety features that are not standard Belt-o-matic components. Please contact
B.N.W. Industries for further information.
 Automatic Sprinklers placed in the top cover of the dryer are a very good safety measure.
These sprinklers can detect high temperatures and spray the dryer in case of a fire.
 Infrared spark detectors are also a good safety measure. These detectors can extinguish a
spark before it enters the drying chamber.
 CO2 fire suppression systems are available. This system will release CO2 on the product bed,
air plenums, and air ducts, if a fire is detected. This system is available for new and used
units.
C. Emergency Fire Shut Down Procedure
Inspection and good housekeeping are one of the best fire preventions. In case of fire, follow these
procedures:
1. Stop all airflow. All fans including exhaust fans should be shut down. Be sure to interlock
exhaust fans with the high limit by the exhaust opening. Cover all air intakes and outlets to
prevent any drafts. This is very important to contain a fire.
2. Unload the product into a noncombustible container or area so the product on fire can be
extinguished.
D. General Safety
All OSHA safety practices need to be observed. Employee safety training is recommended.
III. GENERAL INFORMATION
A. Manufacturer Information
B.N.W. Industries takes pride in personal support of all clients and potential clients. If any questions
occur, please feel free to contact Lee Norris (President), Dan Norris (Vice-President), or Aaron Norris
(Sales Manager) at the following address and telephone number:
Mail/Shipping address – B.N.W. Industries
7930 N 700 E
Tippecanoe, IN. 46570 USA
3