10' tower series installation manual -...

10' TOWER SERIESINSTALLATION MANUAL

Models: 10530 10740 10950 101160 101375

Warranty StatementMATHEWS COMPANY

LIMITED WARRANTY FOR WHOLE GOODS

Except as otherwise set forth herein, Mathews Company (Seller) warrants that the equipment supplied by Seller to Buyer shall be free from defects in materials and workmanship when properly installed and operated under normal conditions and in accordance with all applicable instruction manuals. This limited warranty shall expire two (2) years from the date of shipment from Seller's Crystal Lake, Illinois, U.S.A. facility. In addition, for a period of five (5) years from the date of shipment from Seller's Crystal Lake, Illinois, U.S.A. facility, Seller will re-balance M-C Shredder rotors for Buyer at Seller’s Crystal Lake, Illinois, U.S.A. facility, provided that the rotors did not become unbalanced through abnormal use by Buyer or were not damaged by Buyer in any way.

To obtain consideration under this limited warranty, Buyer must first notify Seller in Crystal Lake, Illinois, U.S.A., stating in what respects the equipment is believed by Buyer to be defective and providing a list of the parts at issue. Additionally, Buyer must complete a warranty request form stating the machine serial number. Upon receipt by Seller of such notice from Buyer, Buyer may receive authorization from Seller to return the parts. If parts are to be scrapped locally, Buyer will be so advised. If Seller provides Buyer with authorization to return the parts, Buyer shall return such parts to Seller’s facility in Crystal Lake, Illinois, U.S.A., transportation prepaid, for examination by Seller. No parts shall be returned to Seller unless Buyer first obtains a return authorization number from Seller. If, in Seller’s sole judgment, the parts returned by Buyer are defective and covered under this limited warranty, Seller shall have the option of repairing, rebuilding or replacing such parts. This limited warranty shall not apply to parts which, in Seller’s sole judgment, have been the subject of negligence, abuse, accident, misapplication, tampering, alteration, improper adjustment, or electrical problems caused by low voltage conditions; nor shall it apply to consumables, such as belts; nor shall it apply to parts damaged by acts of God, war or civil insurrection, acts of terrorism, improper installation, operation, maintenance or storage, or other than normal application, use or service, including, without limitation, operational failures caused by corrosion, erosion, wear and tear, rust or other foreign materials in the system in which they are utilized.

Failure to give notice within the warranty period shall be a waiver of this limited warranty and no assistance or other action thereafter taken by Seller shall be deemed to extend or revive the warranty period. This limited warranty covers only whole goods and shall not apply to replacement parts or upgrade kits. A separate warranty statement published by Seller covers the warranty on parts and upgrade kits. This limited warranty shall not apply to any products, parts, accessories or other equipment not manufactured by Seller, provided that Seller, upon request by Buyer, shall advise Buyer of any warranties known to Seller that may be offered by the manufacturer of such equipment. This limited warranty shall not cover, and Seller shall not under any circumstances be liable for, damages for injuries to persons or property; loss of crops or other products; losses caused by harvest delays; loss of profits; loss of use; cost of rental equipment; expenses of labor, travel or other items relating to the removal or replacement of defective parts; damages resulting from the removal of defective parts or the installation of repaired, rebuilt or replaced parts; expenses relating to the transportation of parts to and from Seller’s facility; any consequential, incidental, contingent or special damages, whether arising in contract, in tort or under statute; or any other damages or expenses not agreed upon in writing by Seller, even if Seller has been advised of the potential for any such damages or expenses.

THIS LIMITED WARRANTY IS IN LIEU OF ALL WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, ALL WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE OR USE.

No person is authorized to give any other warranty or to assume any other liability on Seller’s behalf.

Table of ContentsUnloading ............................................................................................................ 1.1Installing Base Section ......................................................................................... 2.1Stacking ............................................................................................................... 3.1

Section 3-4: Fan Section ................................................................................................ 3.2Burner .......................................................................................................................... 3.3Middle Sections ............................................................................................................ 3.4Optional Grain Exchanger.............................................................................................. 3.4Roof Section ................................................................................................................. 3.5

Walkway and Roof Assembly ............................................................................... 4.1Walkway Assembly ....................................................................................................... 4.1Roof Ladder Cage and Walkway Assembly.....................................................................4.6

Electrical Installation ........................................................................................... 5.1Drop Down Wire Bundles ..............................................................................................5.1Wire Motor ................................................................................................................... 5.3Plenum and Sloped Floor .............................................................................................. 5.4Discharge Sampling Box ................................................................................................ 5.5

Notes .................................................................................................................. 6.1

DOC-10T04-0614 Unloading 1.1

10' Tower Series Installation Manual

1Section

UnloadingThe first step of installing your 10' Tower is to unload the pre-built tower sections from the delivery truck(s). The sections will have been loaded onto the truck in no specific order, but unloading the sections in an intelligent way can reduce the overall assembly time.

It is recommended that when the sections are removed from the truck, they are placed either on a flat surface or on pallets. This will make it easier to assemble walkways and other components on sections that require them.

Any sections that will require a walkway should be placed near each other, along with the pallet containing the walkway components. Figure 1.1 shows the various 10' Tower models, and can be used to determine which sections will need walkways on your specific model. All sections are clearly labeled on one of the ladder brackets indicating both the section number and the serial number as shown in Figure 1.2. Note that a section with a walkway assembled will have an overall diameter of 19', so it is important to ensure room is left between sections.

Figure 1.1: 10' Tower model breakdown

DOC-10T04-06141.2 Unloading


Serial NumberSecti on Numbers

Figure 1.2: Serial number and secti on numbers

Figure 1.3: Shipping legs replaced by permanent legs

If possible, the base secti on should be the last secti on removed from the truck, as it will be the fi rst secti on that must be lift ed into place by the crane. While the base is held up by the crane, the shipping legs should be removed and replaced with the permanent legs as seen in Figure 1.3.

DOC-10T04-0614 Unloading 1.3


If the dryer is equipped with the optional grain exchanger, this section can remain connected to the roof section while being removed from the truck. If there is sufficient room around the build area, it is recommended to remove the grain exchanger from the roof section so that the walkway railings can be assembled on the roof.

**Note: If there are sufficient members on the build crew, it is highly recommended to allocate some members of the crew to begin assembling the walkways onto the appropriate sections and the railings and cages to the roof section. These tasks must be completed before the sections are lifted, so doing them now will greatly reduce the downtime of the crane. The guides found in Chapter 4 of this manual can be used to aid in assembling these components.

Installing Base Section 2.1


DOC-10T04-0614

2Section

Installing Base SectionOnce all of the secti ons and pallets have been unloaded from the truck, the base can be lift ed into its fi nal locati on. If the base secti on was unloaded last, it can be moved directly from the crane to its fi nal locati on. Remember that the permanent legs should already have been put on by this point. It is important to consider the following things while deciding how to orient the base:

• Where are the inlet lines for gas and electric?• Are the dryer legs interfering with takeaway equipment?• Are the locati ons of the various cabinets ideal?

Figure 2.1: Base installati on considerati ons

Cabinet Locati on

Takeaway Equipment

2.2 Installing Base Section


DOC-10T04-0614

Aft er these considerati ons have been accounted for, it is important to ensure that the base secti on is level and all of the legs are plumb. This should be done before drilling holes for the anchors. Once the base is level and all of the legs have been checked, the base should be fully anchored (4 anchors per leg) before stacking any secti ons. Use the equipment provided to anchor the legs, and follow the manufacturer’s instructi ons regarding the process and required drying ti me for the epoxy. Only aft er the base has been completely anchored should the build crew conti nue on to the next secti on.

**Note: A Hilti Gun will be provided with your fi rst 10' Tower, and should be kept for use in subsequent installati ons.

All of the secti ons (excluding the Roof Secti on) have 2-1/2” diameter holes on the parti ti ons. When lift ing any secti on, the crane should be att ached to a minimum of four (4) of these lift ing holes. It is also suggested that spreader bars are used across the top diameter when lift ing to ensure that the circular shape of the secti on remains in tact. In the case that no spreader bar is available, be sure that the straps connected to the crane are suffi ciently long to minimize the radial forces induced by the load.

Figure 2.3: Hilti gun and accessories

Lift From Here

Figure 2.4: Lift ing hole found on all parti ti ons

Figure 2.2: Shims used to level dryer base

Leveling Shim

Stacking 3.1


DOC-10T04-0614

Figure 3.1a: Motor and mounti ng components Figure 3.1b: Motor with motor brackets assembled

Figure 3.1c: Motor mount connected to fan housing

3Section

StackingThis secti on explains the process of stacking the remaining secti ons onto the base. Each 10' Tower model will require a slightly unique stacking process, but the following documentati on explains how the various types of secti ons should be installed. It is important to refer to Figure 1.1 to see the order in which these secti ons should be stacked for your specifi c model.

3.2 Stacking


DOC-10T04-0614

Secti on 3-4: Fan Secti onBefore lift ing Secti on 3-4, the motor mount assembly must be built; the required components can be seen in Figure 3.1a. Either the crane or a fork lift should be used to att ach the motor to the motor mount, and then the motor mount brackets can be connected. Once complete, the assembly should look like the one shown in Figure 3.1b.

With the motor remaining on the ground, Secti on 3-4 should be lift ed by the crane and moved over the motor mount assembly (Figure 3.1c). Use the provided hardware to att ach the motor mount frame to the fan housing.

Once the motor mount assembly has been securely fastened to Secti on 3-4, the secti on can be stacked onto the base. For this secti on, parti ti on alignment plates have been pre-installed, but note that for all future secti ons they will need to be added. Rotate the secti on unti l the motor is aligned with the free air door (the ladders should also be aligned). Once the secti on is oriented correctly, use the provided hardware to secure Secti on 3-4 to the base.

**Note: 10530 model dryers are shipped with the motor pre-installed, so this mounti ng process is not required.

Figure 3.2: Fan secti on being stacked onto base

Stacking 3.3


DOC-10T04-0614

BurnerBefore any additi onal secti ons are stacked above the Fan Secti on, the burner must be installed. The crane should be used to lift the burner above the fan housing. The plumbing inlets should be aligned with the square cutouts on the inside walkway and the sloped fl oor (Figure 3.3). Use the hardware provided with the burner to connect the burner to the fan housing.

Figure 3.3: Cutout for gas lines to the burner

Figure 3.4: Burner being installed into fan secti on

3.4 Stacking


DOC-10T04-0614

Middle Secti onsIf you have not already done so, see Figure 1.1 to determine which secti ons require a walkway and to fi nd the locati on of the opti onal grain exchanger (if your dryer is equipped with one).

**Note: Walkways should be installed onto secti ons before the secti on is stacked! A guide is provided in Chapter 4 to aid in assembling the walkways.

Unlike the previous secti on, parti ti on alignment plates have not been pre-installed to any remaining secti ons, so they must be att ached in the fi eld. In order to do this, the secti on should be lift ed high enough for crew members to work underneath. The required components of the alignment plates are shown in Figure 3.5. The assembled alignment plates should create a downward facing ‘V’ shape that will aid in stacking the secti on. The tapered geometry will allow the secti on to more easily be placed on top of the secti on below it. It is crucial to install the guide plates on each parti ti on in order to ensure that the tower is aligned correctly, and that the weight of the dryer is being properly distributed.

Once alignment plates have been added to each of the parti ti ons, the secti on can be stacked onto the dryer and att ached with the provided hardware. The outside ladders should be used to correctly orient each secti on as it is added.

Opti onal Grain Exchanger If your dryer is to be equipped with the opti onal grain exchanger, it will be shipped att ached on top of the roof secti on. If the grain exchanger has not yet been removed from the roof, this should be done now. The grain exchanger will then require the previously explained procedure (found in “Middle Secti ons”) to att ach alignment plates and stack the secti on.

**Note: Once the grain exchanger has been removed from the roof, the hand rails and ladder cages for the roof secti on can be assembled. Guides are provided in Chapter 4 of this manual to aid in the assembly of these components.

Figure 3.5: Components used to assemble parti ti on alignment plates

Figure 3.6: Grain exchanger shipped on roof secti on

Stacking 3.5


DOC-10T04-0614

Roof Secti onThis secti on requires some work to be done on the ground before it is lift ed. Stairs and the walkway come preinstalled on the roof, but handrails must be assembled and att ached. It is also recommended to build the ladder cage and install this onto the secti on prior to stacking.

When the roof secti on is ready to stack, the crane should pick up the secti on using the lift ing eye that can be found inside the infeed (Figure 3.7). Lift the secti on enough to enable the crew to install parti ti on guides, and then stack the roof secti on as described earlier. Again, the outside ladder should be used to orient the secti on before it is att ached to the rest of the tower.

Figure 3.7: Lift ing eye found on roof secti on

Figure 3.8: Roof secti on being lift ed onto tower

Walkway and Roof Assembly 4.1


DOC-10T04-0614

4Section

Walkway and Roof AssemblyThe following procedures are for building a standard walkway, followed by instructi ons for assembling the ladder cages and walkway supports required to fi nish the roof secti on. These next procedures must be completed while the secti ons are on the ground, before they can be stacked onto the tower. All required pieces will be listed in the following format: Part Name (MC Part Number x Quanti ty).

Walkway Assembly1. Connect Floor Plank Main Supports (4902635x7, 5602642x1, 5602643x1) to preinstalled brackets using 3/8” – 16 x 3/4” bolts (0018210)

2. Add Walkway Support Legs (475708x7, 5602649x2) with 3/8” – 16 x 3/4” bolts (0018210)

Figure 4.1: Various views of main support att ached to preinstalled bracket

Figure 4.2: Walkway support leg connecti ng main support to preinstalled bracket

Main Walkway Support

4.2 Walkway and Roof Assembly


DOC-10T04-0614

3. Add Guard Rail Support Posts (4903248x9) with 3/8” – 16 x 3/4” bolts (0018210)

4. Att ach Floor Plank Supports (475711x7) to all Main Supports (excluding those next to a ladder) with 3/8” – 16 x 3/4” bolts (0018210)

Figure 4.3: Guard rail support post att ached to the end of each main support

Figure 4.4: Rendered image of fl oor plank support to be att ached to all main supports

Guard Rail Support Post



DOC-10T04-0614

5. Att ach Walkway End Plates (475714x2) and Flip Door Stops (5602635x2) to remaining Main Supports(two next to ladder) with 3/8” – 16 x 1” bolts (0018209)

6. Add Inside Toe Kicks (5602638x6, 5602639x1, 5602640x1, 5602641x1) and Outside Toe Kicks (475712x6, 5602636x1, 5602637x1) with 3/8” – 16 x 3/4” bolts (0018210)

Figure 4.5: Flip door stop and end plate to be att ached on either side of ladder

Figure 4.6: Inside toe kicks att ached across two main supports

Figure 4.7: Inside toe kick with curved cutout for use by heat door

Flip Door Stop

Inside Toe Kick Curved Cutout for Heat Door

End Plate



DOC-10T04-0614

7. Add Flip Door Support Bracket (5602644x1) with 3/8” – 16 x 1” bolts (0018209)

8. Att ach Flip Door Hinges (4904939x2) to Walkway Flip Door (5602634x1) and Flip Door Support Bracket with 5/16” – 18 x 3/4” bolts (837524)

Figure 4.8: Flip door support bracket is att ached at either end to main supports by the ladder

Figure 4.9: Fully assembled fl ip door

Walkway Flip DoorDoor Hinges



DOC-10T04-0614

9. Install Grated Floor (475717x6, 475718x6, 5608701x1, 5608702x1, 5608703x1, 5608704x1) using 5/16” – 18 x 3” bolts (0018276) and Grati ng Anchor Clips (1208994)

10. Add Guard Rails (475715x12, 5602645x2, 5602646x2, 5602647x2, 5602648) with 3/8” – 16 x 3/4” (0018210) bolts

Figure 4.10: Fully assembled outside walkway

Guard Rails

Grated Floors



DOC-10T04-0614

Roof Ladder Cage and Walkway Assembly1. Att ach Guard Rail Support Posts (4903248x6, 476827x2) to pre-installed roof walkway with 3/8” – 16 x 3/4” (0018210) bolts

2. Att ach Walkway Guard Rails (476820x6, 476822x2, 476823x2) to Guard Rail Support Posts with 3/8” – 16 x 3/4” (0018210) bolts

3. Att ach Stair Guard Rails (476819x4) with 3/8” – 16 x 3/4” (0018210) bolts

4. Install Ladder Hoops (1282058x3) with 5/16” – 18 x 1” (0018213) bolts and 5/16” Fender Washers (095965)

5. Connect Ladder Straps (varies) between ladder hoops with 5/16” – 18 x 1” (0018213) bolts

Figure 4.11: Fully assembled roof ladder cage and walkway

Guard Rail Support Posts

Ladder Straps

Stair Guard Rails

Walkway Guard Rails

Ladder Hoop

Electrical Installation 5.1


DOC-10T04-0614

This secti on provides a walkthrough of the electrical installati on process. These tasks should not be completed unti l the tower has been fully stacked, and the High Voltage Cabinet has been dropped down onto its permanent legs.

Drop-Down Wire BundlesRigid EMT has been preinstalled up the length of the dryer, and wire bundles have been provided at several locati ons. These bundles must be fed through the preinstalled EMT and landed in the High Voltage Cabinet. Each wire is numbered, and should land in the terminal block with the corresponding number.

Feed the Rotary Bin Switch and LLC Bundle to HV Cabinet through the ½” Rigid EMT provided. An extra piece of conduit is temporarily att ached above the LLC box, shown in Figure 5.1. This piece must be permanently installed to the bott om of the LLC box, and run through the bracket on the bott om channel ring. The following wires from the Rotary Bin Switch and LLC Bundle should be landed in the HV cabinet:

• Wire #5 to HV Terminal #5• Wire #10 to HV Terminal #10• Wire #21 to HV Terminal #21• Wire #23 to HV Terminal #23• Wire #24 to HV Terminal #24• Wire #45 to HV Terminal #45

Next, the Infeed Sensor Bundle should be wired to the HV Cabinet (If tower is equipped with Infeed Sensor). Feed the grey, 4C/22AWG Shielded Cable through the provided liquati te whip, and down the length of ½” Rigid EMT preinstalled on the tower. On the HV Cabinet end of the run, the grey cable should be stripped back in order to access the wires inside, and these wires should be landed to the following:

• Green Wire to PLC – See Schemati cs• White Wire to PLC – See Schemati cs• Black Wire to HV Terminal #112• Red Wire to HV Terminal #113• Shield (Land ONLY at HV)

5Section

Electrical Installation

Figure 5.1: Roof Secti on with Bundled Wires

LLC and Rotary Bin Switch Bundle

Infeed Sensor Bundle

Extra EMT Run

5.2 Electrical Installation


DOC-10T04-0614

One of the middle secti ons will contain the mid grain RTDs, and has been shipped with an RTD Wire Bundle that must be fed to the HV Cabinet. A run of 1” Rigid EMT has been preinstalled to a T-Juncti on. All four of the 2C/18AWG Shielded Cables in the RTD Bundle should be fed through this 1” conduit. Once at the HV Cabinet, the cables should be stripped back to access the wires inside, and these wires should be landed as follows (see Figure 5.3):

• White Wire to TS1• White Wire to TS2• White Wire to TS3• White Wire to TS4• 4x Black Wires to Terminals #113 (2 Wires can go

into each terminal slot)• 4x Shields (Land ONLY at HV)

Figure 5.2: Middle Secti on with RTD Bundle

Figure 5.3: Middle Secti on with RTD Bundle

RTD Bundle



DOC-10T04-0614

Wire MotorA run of 2” Rigid EMT has been preinstalled onto the base secti on that leads into a free air door. Liquati te should be used to connect the HV Cabinet to this conduit at the bott om, and again at the top to connect to the motor. This run should ONLY contain the Motor Lines and the Motor Ground, as follows:

• L1 – Motor Control in HV to Motor Lead• L2 – Motor Control in HV to Motor Lead• L3 – Motor Control in HV to Motor Lead• GND Wire to HV Cabinet Ground

Figure 5.4: Liquati te whip inside Free Air Door



DOC-10T04-0614

Plenum and Sloped Floor Several components have been parti ally installed and bundled inside the base secti on, but must be installed through the sloped fl oor once the tower is stacked. These components will be fed through pre-punched holes in the sloped fl oor, and will be landed in the plenum.

The fi rst of these components is the Flame Sense Probe. This will be run through a ¼” Black Corrugated Tube from the Juncti on Box to the Burner, and will pass through a Cord Grip on the Sloped fl oor. New 10' Tower Dryers are equipped with two fl ame sense probes. These probes should be wired in parallel, allowing for a positi ve fl ame reading if either of them have a signal.

An orange insulated Igniti on Wire should be run along with a ground wire from the Juncti on Box, through the sloped fl oor via Cord Grip, and up to the burner. The igniti on and ground wires should be connected to the appropriate sides of the igniti on.

The High Limit Capillary Tube should be run through a ¼” Black Corrugated Tube up through the sloped fl oor via Cord Grip. Once into the plenum, this tube should be mounted around the burner housing.

The Plenum RTD Line will be run similarly to previous components, inside a ¼” Black Corrugated Tube up through the sloped fl oor. It should then be run through the pre-installed brackets on the inside screens. The locati on of these brackets should be near the top of the burner cone.

Lastly, the Air Pressure Line is run from the VFD Cabinet up to the Plenum chamber through the free air door and up through the sloped fl oor. The line should be att ached to one of the EMT runs for support, and can be connected to the C-Channels once inside the dryer. The end of the tube should be carefully bent to face downwards inside the plenum to avoid debris from entering the tube.

Figure 5.5: Air Pressure Line from VFD Cabinet

Air Pressure Line



DOC-10T04-0614

Discharge Sampling Box The tower is shipped with the center dump and bin switch preinstalled, however the discharge sampling box will need to be installed. Once the sampling box is connected, the 25W Sampling Motor should be wired to the HV Cabinet. The following wires should be fed through the ½” EMT provided near the Sampling Motor:

• Wire #5 to HV Terminal #5• Wire #81 to HV Terminal #81• GND Wire to HV Cabinet Ground

Once the Sampling Motor has been wired, the Discharge Sensor should be wired to the HV Cabinet. This will be done through a ½” Flexible Liquatite run that should be fastened to the bottom of the dryer. This run will consist only of a grey 4C/22AWG Shielded Cable. On the HV Cabinet end, the cable should be stripped back and landed as follows:

• Green Wire to PLC – See Schematics• White Wire to PLC – See Schematics• Black Wire to HV Terminal #112• Red Wire to HV Terminal #113• Shield (Land ONLY at HV)



DOC-10T04-0514

Notes 6.1


DOC-10T04-0614

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Notes6Section

6.2 Notes


DOC-10T04-0614

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Notes 6.3


DOC-10T04-0614

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

6.4 Notes


DOC-10T04-0614

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Notes 6.5


DOC-10T04-0614

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Mathews Companywww.MathewsCompany.com

Crystal Lake, ILphone: 815-459-2210fax: 815-459-5889email: [email protected]

DOC-10T04-0614

GRAIN DRYER SPECIALISTS

10' tower series installation manual -...

Documents