pre-season maintenance procedures

Pre-Season Maintenance Procedures

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G A

Inlet

Garner Area

Plenum Area

Burner

Divider Hopper

Blower (s)

Motor (s)

Cooling Area

Unload Area

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GSI Tower Dryer Zimmerman Tower Dryer

Unload Area

Use high quality, grade #2 lithium based grease. Clean grease fittings (zerts). C i h b b i ilCount pumps put in the bottom bearing until grease begins to come out of seal and put the same in top bearingsame in top bearing.

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Bottom blower bearingg

Grease tube leading to upper bearing (side of blower usually

above motor)

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above motor)

Use high quality, grade #2 lithium based grease. If motor is equipped with relief plug then operate motor forIf motor is equipped with relief plug then operate motor for 20 minutes and shutdown. Clean grease fittings (zerts). Remove grease relief plug and pump in enough greaseRemove grease relief plug and pump in enough grease through fittings (zerts) to pass through bearing. Allow motor to run for 10 minutes before replacing relief plug. If motor is not equipped with relief plug clean grease fitting and put in one pump of grease per ten horsepower of motor.

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Top & bottom grease fittings

( ll(usually on back side of

motor)

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Squalling belts is indication that belts need tightened. Do not over tighten or motor could draw to many ampsmany amps. Each belt should be able to push in a belts width halfway between pulleys with thumbwidth halfway between pulleys, with thumb.

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Should be able toShould be able to push in a belts width

with thumb

Belt adjustment plate

GSI Company Confidential Technical Support 8

Locate blower motor starter(s) in power panelWith amp probe check amperage on each leg of starter for each blower motor. R d di i i kRecord amp readings to service ticket.

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Blower motor

starters (older

panels will look

different)different)


Look over entire dryer for any damage, excessive wear, or rust. Report any findings to customer and suggest they contact GSI for a repair quotethey contact GSI for a repair quote.

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Inspect internal and external sheets for rips, excessive wear or rust. Look for missing bolts. P h h d l b l if h blPatch sheets and replace bolts if reachable. Report any findings to customer and suggest they contact GSI for a repair quotethey contact GSI for a repair quote.

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Check sheets for rips or missing bolts insideor missing bolts inside

and outside


Standard sheet perforation has never been larger than .078 perforations. In a few special cases .094 has been installed at the outside top of the dryeroutside top of the dryer. Confirm that customer hasn’t put anything larger than .094 perforations on the dryer.larger than .094 perforations on the dryer.

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Measure and confirm perforations are under .094 everywhere on

dryer


Check fill cap, inlet tube, and plenum roof cap for d i t N t idamage, excessive wear, or rust. Note on service ticket if fill tube is less than 12”. Check discharge hopper and moisture sensor housing g g(if equipped) for damage, excessive wear, or rust. Report any findings to customer and suggest they contact GSI for a repair quotecontact GSI for a repair quote.

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Inlet tube (if equipped)

Plenum cap

Bottom side of fill cap.

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GSI Discharge Hopper

Zimmerman Discharge Hopper W/Moisture Sensor

Housingg

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Check integrity of seals on cooling floor doors, heat doors, and roof/ roof hatch.Replace if necessary. If l i k d iIf seal is not on truck, advise customer to order and explain how to replace.

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Zimmerman cooling floor doors w/seals

GSI cooling floor doors w/seals

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Roof hatch door (not

Heat doors

(shown)

w/seals (not all dryers have two

doors)

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GSI Tower DryersGearbox is located inside at the cooling section floor (some models have full floor and gearbox may be located between the two floors)gearbox may be located between the two floors). Top off with mobilegear 630 or equivalent gear lube and fill to the check plug.

Zimmerman Tower DryersNewer Zimmerman dryers (1997-Current) with the accutrol unload system has one y ( ) ygearbox located inside at the cooling section floor. Top off with mobilegear 629 or comparable gear lube and will fill between the marking bands on the sight level (Smaller models only have fill plug, fill to top).Older Zimmerman dryers (1996 & Prior) have a triple stacked gearbox inside between the two floors with unload augers. gThe bottom two gearboxes have reservoirs that should be completely full. The top (blue) gearbox has a dipstick that should be filled to the bottom line. There is a right angle gearbox on the outside of the dryer at the bottom floor. This gearbox has two Allen screw plugs on one side. Remove both plugs and fill from the top hole until oil begins to run out of bottom hole then reinstall both plugsthe top hole until oil begins to run out of bottom hole, then reinstall both plugs. All the fore mentioned gearboxes on the older Zimmerman dryers take 80/90W gear lube.

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Zimmerman new style gearbox – Located on cooling

floor (1997-Current)floor (1997 Current)

GSI Gearbox Located onGSI Gearbox – Located on cooling floor

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Older style Zimmerman gearbox – 1996 & Prior

(located inside between the floors)

Older style Zimmerman i ht l bright angle gearbox –

1996 & Prior (located outside below bottom

floor)


)

Zimmerman Dryers Only (1996 & Prior)Zi d ith th t hZimmerman dryers with the auger system have sprockets and chain on the inner gearbox that must be checked for damage or excessive wear. h k th ( ) f d icheck the augers (sweeps) for damage or excessive

wear. Check that augers are level. Replace if necessary or advise customer to order and explain how to replace or contact GSI for quote.

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Older style Zimmerman

unload system –1996 & Prior

(showing(showing sweeps, Idler, and sprockets

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GSI Tower DryerOn GSI dryer check metering drum for damage or excessive wear, paying

l l d dspecial attention to leading edge. Inspect bottom bearing (accessed from outside of dryer at bottom most slide gate on discharge hopper) for damage or excessive wear.Report any findings to customer and suggest they contact GSI for a repair quotequote.Lubricate bottom bearings slowly, with high quality grade #2 lithium based grease until lube shows through seal.

Zimmerman Dryer (1997-Current)Check the accutrol unload (Sweep arms & structure) for excessive wear orCheck the accutrol unload (Sweep arms & structure) for excessive wear or damage. Check that sweep arms are level. Report any findings to customer and suggest they contact GSI for a repair quote.

b b h b l l h h h l d l h b dLubricate both bearings slowly, with high quality grade #2 lithium based grease until lube shows through seal.

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Top Bearing

Zimmerman Accutrol unload system – Located below

cooling floor (1997-Current)

Zimmerman Accutrol unload system – Located below

cooling floor (1997-Current)

Bottom bearing

Sweep arms

Bottom bearing (not shown)

Bottom bearing below drum (Not

shown)

Bottom bearing below drum (Not

shown)

GSI unload system – Located

shown)shown)

GSI unload system Located below cooling floor (shown

without floor)

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Metering Drum

Newer GSI & Zimmerman dryers have grain temperature probe mounted in outside wall of dryer, next to ladder, in the area of the burner access door.Remove cover from grain probe and check for dirt clean if necessaryRemove cover from grain probe and check for dirt, clean if necessary. Check integrity of wiring.Newer GSI & Zimmerman dryers equipped with Tri-Point moisture system will also have two “shark fin” sensors. One located at top of dryer mounted in sidewall next to ladder and the other one located at bottom of dryer mounted in moisture sensor housing below discharge hopperdischarge hopper.If equipped, clean “shark fin” sensors and check integrity of wiring.Older GSI dryers have four 2” X 4” gang boxes with one “bolt” sensor mounted in each box. Located about same area as grain probe would be.Remove cover on bolt sensor boxes and check for dirt and clean if necessary.

h k fCheck integrity of wiring.Oder Zimmerman dryers with Partlow style moisture control has sensor mounted behind ladder with protective covers. Covers have flap at bottom that can be opened to let out any foreign material collected inside.

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Newer GSI & Zimmerman grain temperature probe

(1993 – Current)

Older Zimmerman Partlow sensor coversPartlow sensor covers

(1993 & Prior)

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Individual “bolt” Sensor (one per box)

Older GSI “bolt” sensor

boxes

(2003 & Prior)

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Lower Bindicator will be located on outside wall at top of dryer near ladderdryer near ladder.If equipped, upper Bindicator will be located on roof next to hatch door.Make sure Bindicator(s) are turning when should be. ( ) gStop Bindicator(s) by hand and ensure indication comes on at panel. Remove outside cover of Bindicator(s) and clean inside if necessary. Check switch and motor for corrosion or rust. Replace any parts necessary.

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Upper Bindicator –

Located on roof ( t h ) Close up of

Lower Bindicator

(not shown) Close-up of Bindicator

Lower Bindicator Located on

Sidewall


Zimmerman dryers only (1993 & prior)Zi d ith DC l d t d thZimmerman dryers with DC unload motor need the brushes pulled out and checked for wear. Excessive wear will require replacement or motor will burn up. Whil b h t l /bl b h d t t fWhile brushes are out clean/blow brush dust out of motor and off of brushes.If too much wear change brushes or advise customer

GSI f l b hto contact GSI for replacement brushes.

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Older Zimmerman dryer DC motor 1993 & PriorDC motor – 1993 & Prior

Inside of motor showing old brush and new brush

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Zimmerman dryers only (1996 & prior)Older Zimmerman dryers with auger unload systemOlder Zimmerman dryers with auger unload system has two u-joints joining outside gearbox with inside gearboxes.One u-joint is accessible from under the dryer nextOne u joint is accessible from under the dryer next to the divider hopper, while the other u-joint is located inside the dryer between the floors in the discharge hopper.L b i b h j i l l i h hi h liLubricate both u-joints slowly, with high quality grade #2 lithium based grease until lube begins to come out.

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Inside u-joint on older Zimmerman

dryer 1996 &dryer – 1996 & Prior

Outside u-joint on older Zimmermanolder Zimmerman

dryer – 1996 & Prior


Divider hopper is located about 1/3 up the dryer, inside the burner access door below the burnerinside the burner access door, below the burner catwalk.Check for excessive fines built up in hopper. If h i di t d i t t l dIf hopper is dirty advise customer to clean and explain the risk of fire. Check bottom gap (3/8” to 1/2”) in hopper to ensure i i l ll h d h ifit is open evenly all the way around hopper; if not, readjust gap with a piece of flat bar.

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Divider hopper below catwalk (Older Zimmerman dryers may have different style catwalk, buthave different style catwalk, but

divider hopper is still below)

Bottom side of divider hopper showing gap that allows fines to g g pdrop through and not build up.

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Brush or blow burner out. On older steel burners (pre-2002) drill pilot ports with a noOn older steel burners (pre 2002) drill pilot ports with a no. 47 or 5/64" diameter bit, no shorter than 5". On new aluminum burners (2002-present) drilling pilot ports should be cut dramatically; if needed drill with a no. 43 bit, no shorter than 5”no shorter than 5 . For either burner you should feel the bit go through the top of the burner pipe about an inch, then open up, and the bit will hit the bottom of the pipe. A h bi ill d ill d h b f h h k f hA short bit will not drill deep enough before the chuck of the drill hits the mixing plates of the burner.A properly drilled burner will come up to heat, with a full dryer, in three minutes or less.y ,

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Burner pilot ports

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Look for damaged (cracked porcelain) or excessive build up of soot on both igniter or flame rod. Check wiring and connections to both igniterCheck wiring and connections to both igniter and flame rod. Replace igniter or flame rod if necessaryReplace igniter or flame rod if necessary

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Flame rod & igniter both glocated in open end

corner of burner (igniter below flame rod)


Disconnect linkage between valve and motor. Move valve arm left to right while pulling out. If valve shaft is broken, shaft will come off in your handyour hand. Inspect valve body for cracks, replace if necessarynecessary.

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Modutrol Motor

CV Valve

Linkage

Valve arm

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CV ValveValve arm

With power on jump F to + and motor should open upup. Remove jumper and motor should close. Check motor operates correctly when starting up d ( k d i t t i t bdryer (make sure drying temperature is set above ambient temperature).Remove lid from motor and carefully clean inside of

i i l imotor paying special attention to contacts.Lube all moveable parts on linkage connected between modutrol motor and cv valve.

47

Modutrol Motor

Inside of modutrol motor showing terminal strip

48

Standard gas train will have two gauges, one b i d d th th b ibeing a pound gauge and the other being an ounce or inches of water column gauge.Make sure gauges are not sprung and areMake sure gauges are not sprung and are reading correctly. Check glass is not cracked and face is legible. R l ifReplace if necessary.

49

Pound gauge located before regulator, sometimes mounted

in pilot train

Pilot train

Ounce gauge located after modutrol motor & cv valve


Clean inside if necessary. Check that switch and solenoid are operational and look for corrosion or rust.R l i h l id ifReplace switch or solenoid if necessary.

51

Maxon 808 shut-off valve(s)

Interior of Maxon 808 valve


Solenoid Switches

Check for leaks and physical appearance of gas train is not rusty. Advise customer to paint if necessary.R i fil d lRemove strainer filters and clean.

53

Large strainer on main line before big regulator

Small strainer on pilot line


Check if customer removed gas train plug and/or d d i l t d f (Oldopened drain valve at end of season (Older

Zimmerman dryers will have ¼” drain plug directly below ounce gauge).If plug has not been removed or drain valve has not been opened, gas train may have damaged cv valve or gauges.or gauges.Advise customer to always remove plug or open drain valve at end of drying season.

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Gas train drain valve (open with plug removed)

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Clean inside of control panel. If using compressed air ensure compressor has filter so water doesn’t get to components.For the first three or four years tighten allFor the first three or four years tighten all connections in panel. Check for leaks or water damageCheck for leaks or water damage.

57

Control panel (older panels will be different)

Power panel (older panelsPower panel (older panels will be different)

Open view of power panelOpen view of power panel (older panels will be

different)


Start dryer and turn on burner and unload.Set plenum temperature above ambient temperature.Burner will not build up heat without grain; but modutrol motor should open wide and pressure should display on ounce gauge. Note: Some models of dryers will not allow the modutrol motor to open without low Bindicator being satisfied. If BIndicator will not open after a few minutes; refer to print, to see if low Bindicator is wired normally open or normally closed. If wired to see o d cato s ed o a y ope o o a y c osed ednormally closed, Bindicator switch wire will have to be disconnected from terminal strip. If wired normally open, power will have to be applied to Bindicator switch wire at terminal strip. If uncertain please call GSI technical support.Test modutrol motor by lowering temperature below ambient temperatureTest modutrol motor by lowering temperature below ambient temperature, motor should close.Ensure that all controls and dryer is operating properly.If problem with safety circuit, alarm will sound.Close manual gas valve and ensure that Maxons slam shut. C ose a ua gas a e a d e su e t at a o s s a s utIf unable to start blowers or burner because customer is on demand, please note on service ticket.

59

Dryer full of grain and running in cold outdoor

temperatures

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Remind customer at the end of each drying th d h ld b l d i idseason the dryer should be cleaned inside

and out; paying special attention to the inner roof, grain exchangers, burner, divider , g g , ,hopper, cooling floor, and unload area. The burner should be tarped and the gas train drain plug should be removed and/ortrain drain plug should be removed and/or the drain valve opened.Cooling floor doors should be opened for g pdrainage.On Zimmerman dryers bottom floor gates should be removed for drainage

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should be removed for drainage.

ACF Relay ACF Relay Flame Pak Adjustable Hi Li it

y yHi-Limit

(160D – 260D)

SS3CP TransformerFlame Rod 210 Degree

Fixed overheat

Igniter

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pre-season maintenance procedures

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