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Continuous Flow Low Profile Sq Series Grain Dryers 2014

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® Continuous Flow Low Profile SQ Series Grain Dryers Mechanical Installations Manual 2014 TICE! LER NO L A located T S IN KEY is X O . B L ect Box NTRO Disconn THE CO r e ry D e inside th A Supplement to MFH1932, BROCK® Low-Profile Dryer Owner/Operator Manual MFH1977, Electrical Installation and Wiring Diagrams with SPECTRUM® Controllers MFH1978, Electrical Installation and Wiring Diagrams with QUANTUM® Controllers February 2014 MFH1956E General BROCK® SUPERB® Low Profile Grain Dryers SQ Installation General Be a quality-conscious Installer. Get it DONE, done RIGHT, the FIRST time. Remember! Think SAFETY First! This symbol is used throughout this Manual to identify particular stages where the bin Contractor and/or Operator need to take special note and precautions regarding the danger described in these Instructions. Please read all the SAFETY information and the instructions completely prior to beginning the construction. Tools and Equipment Needed at Delivery WARNING! Inventory all tools and pieces of hardware near the Dryer during installation or servicing. Tools left inside in the Dryer could cause damage or injury. 1/2'' impact and 1 1/4'' impact socket (to unbolt the Garner Bin at delivery) IMPORTANT! Deliver Manuals to the Customer Remember to leave THIS Manual (MFH1956) with the Customer. It contains useful Part Numbers in the event service is needed. Upon completion of the Dryer installation, deliver the Owner/Operator Manual MFH1932 to the customer. Figure 1. SQ Owner/Operator Manual, MFH1932 Leave Supplemental Installation Manuals with the Customer Leave the Electrical Supplemental Manual (SPECTRUM® MFH1977 or QUANTUM® MFH1978) with the Customer. It contains necessary Controller information and wiring schematics that will be needed should electrical service be necessary. 2 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation General Locate These Important Items Control Box Key To prevent loss during shipping, the Key to the Controller Box is shipped inside the Dryer/Equipment Disconnect Box. Uninstall the 5/16'' bolt to open the Box, then reinstall the bolt or some other locking device. Figure 2. Unlatch the Bolt on Dryer Disconnect Box Specifications Plate and Serial Number inside the Control Box Outer Door If you have a question about your Dryer, locate the Serial Number before calling Brock Grain Conditioning. The Serial Number contains the information needed to answer questions about your Dryer. Figure 3. Specifications Plate Distributor and Installer Information Dealers: Please provide the Customer with the information to complete the easy reference below. Dealer or Customer: Complete the following information about your BROCK® product. Store this Manual in a safe, dry place for future reference. Please fill in the following information about your Product. Keep this Manual in a clean, dry place for future reference. Distributor’s Name ___________________________________________________ Distributor’s Address ________________________________________________ Distributor’s Phone _______________________ Date of Purchase ___________ Installer’s Name _____________________________________________________ Installer’s Address ___________________________________________________ Installer’s Phone _______________________ Date of Installation ___________ Dryer System Specifications Model:_______________________________________________________________ Serial Number:________________________________________________________ MFH1956E 3 Contents BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Contents General.............................................................................................................................................................. 2 Remember! Think SAFETY First • Tools and Equipment Needed at Delivery .....................................2 Deliver Manuals to the Customer Leave Supplemental Installation Manuals with the Customer ..................................................................2 Locate These Important Items ......................................................................................................................3 Control Box Key .......................................................................................................................................3 Specifications Plate and Serial Number Inside the Control Box Outer Door ...........................................3 Distributor and Installer Information ...........................................................................................................3 About This Manual .......................................................................................................................................... 6 Definition of Terms and Pictures • Measurements • Identification of Parts and Hardware.....................6 SAFETY............................................................................................................................................................ 7 Recognize SAFETY information • Understand Signal Words ................................................................... Restrict Grain Dryer Areas and Designate a SAFETY Zone .......................................................................7 Dryer installations ........................................................................................................................................8 Electrical SAFETY..................................................................................................................................... 8-9 Train Dryer Operators Properly ...................................................................................................................9 Even the Safest Dryer Poses Multiple Hazards...........................................................................................10 Practice SAFE Dryer Operation and Maintenance • Always Keep Guards on Moving Parts .................10 Use CAUTION When Servicing Exposed Parts (Moving or Electrical ) ...................................................11 Always wear PPE .......................................................................................................................................11 FIRE SAFETY ................................................................................................................................................ 12 In the Event of a Fire, act immediately! EMERGENCY PROCEDURES .............................................. 12-14 Location of Shutoff Valves .........................................................................................................................14 SAFETY Decals.............................................................................................................................................15-25 Overview .................................................................................................................................................. 15-17 Electrical Control Area: DANGER! HIGH VOLTAGE! ...........................................................................18 Service Disconnect (sidebar) ..................................................................................................................18 Dryer Disconnect, AC Drive and Controller ....................................................................................... 18-20 Top Transition Service Door: Electrical Rotation Hazards.........................................................................21 Doors / Guards on Moving Belts, Drives and Augers.............................................................................. 21-23 Fan Motion Hazards • Danger of Heat ....................................................................................................24 CAUTION When Climbing: Ladder Safety............................................................................................. 25-26 Planning the Installation ............................................................................................................................... 27 System Analysis • Canadian Dryers........................................................................................................27 Concrete Pad Foundation for the Dryer ......................................................................................................28 SQ Series Dimensions • SQ Model Features ..........................................................................................29 Mechanical Installations ................................................................................................................................ 30 Anchoring the Dryer ................................................................................................................................30 Leg Kit Assembly..................................................................................................................................... 30-32 Garner Bin Assembly ............................................................................................................................... 33-37 Connect the Wet Grain Sampler Cable/Handle...........................................................................................38 Side Ladder............................................................................................................................................... 39-43 Parts Identification ...................................................................................................................................39 SQD and SQM Models.......................................................................................................................... 40-41 SQA and SQE Models........................................................................................................................... 42-43 Additional Items Shipped Loose ............................................................................................................. 44-46 SQA Models: Hot Air Return Ducts ..................................................................................................... 44-46 Internal Diagonal Straps and Braces (Hot Air Return Ducts) .............................................................46 Unload Trough Floor Extension Panel (Dryers with Air Systems)....................................................... 47-48 4 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Contents Dry Grain Sample Port • Free the Unload Trip Lever .......................................................................... 49 Plumbing Train Connections....................................................................................................................... 50-59 Proper Fuel Line Connection is Critical! • Combo Dryers • Before Initial Startup.............................. 50 Plumbing Train Components ...................................................................................................................... 51 Emergency Hand Shutoff Valves............................................................................................................. 51 Upper Plumbing Train ............................................................................................................................ 52-54 Modulating Motor and Butterfly Valve ................................................................................................... 52 Upper Plumbing Train, Top of Dryer ................................................................................................... 53-54 Liquid Propane (LP) Fuel Supply Requirements (U.S.) .......................................................................... 55-56 Natural Gas Supply Requirements (U.S.) ................................................................................................... 57 Canadian Plumbing Requirements........................................................................................................... 58-59 Electrical Installation ................................................................................................................................... 60-69 SAFETY Requirements • Lockout SAFETY Switches .......................................................................... 60 The AC Drive Box • Dryer Disconnect Box........................................................................................... 61 Control Box .............................................................................................................................................. 62 SPECTRUM® Electronic-Based Temperature Controller (Standard) .................................................... 62 QUANTUM® Controller (Optional) ....................................................................................................... 63 Auxiliary Conveyor Connection ............................................................................................................. 64-65 Auxiliary Starter Control Connection ...................................................................................................... 65 Field-Installed Auxiliary Conveyor Starters • Auxiliary Motor Starter Schematic ............................. 65 BASO Flame Sensor Switch and Thermocouple ........................................................................................ 66 Flame Relay ............................................................................................................................................... 67 Check Fan Rotation..................................................................................................................................... 68 Check Motor Rotation................................................................................................................................. 68 SAFETY System Checkout.......................................................................................................................... 70-71 Major Alarm • Stoppage at Unload......................................................................................................... 71 Pre-Startup Electrical Testing and Inspection .......................................................................................... 72-73 Electrical Connection/Disconnection Procedures for Dryer Testing .......................................................... 72 Checkout and Adjustments ....................................................................................................................... 73 SQ Series Specifications ............................................................................................................................... 74-76 Dryer Dimensions • Electrical Specifications • Fan Specifications ....................................................74 SQ Series Burner and Fuel Supply Specifications (U.S. and Canada).......................................................75 SQ Series Burner and Fuel Supply Specifications (metric) .......................................................................76 Manufacturer’s Recommended Minimum Lockout/Tagout Energy Control Procedures .................... 77-78 Electrical Symbols ........................................................................................................................................... 79 Electrical Schematics Schematic, ATV31/312 AS Auxiliary Unload for SQ and MEYER® ME-S Models ............. 3724-00052 Auxiliary Motor Starter, All SQ Models ....................................................................................3724-00016A MFH1956E 5 About This Manual BROCK® SUPERB® Low Profile Grain Dryers SQ Installation About This Manual IMPORTANT! CAUTION! The intent of this Manual is to help you follow step-by-step instructions for identification and installation of the BROCK® SUPERB® SQ Series Dryer. Pay particular attention to all SAFETY Information in this Manual. For operation and use of your Dryer, read and understand this Manual. Failure to follow proper operational procedures may cause damage to equipment or personal injury. Contact your Brock Dealer to replace this Manual should it become lost or damaged. Store it in a convenient place for easy reference. Electrical Schematic Diagram(s) are located in the back of the Controller Manual. Definition of Terms and Pictures REAR • The Planning Symbol at left is used in Item Description 1 areas where planning needs to take place Access before assembly and/or installation con1 Plenum Door tinue. CL • “Horizontal,” “vertical,” “bottom,” and 2 Control Panel “top” refer to the Dryer as it is standing. 3 3 Basket • The “front” (end) of the Dryer is the end 4 Plumbing with the Plumbing, Controls and Fan. 4 The “rear” has the Plenum Access Door. Figure 4. See Figure 4: Dryer Orientation • “Dryer/Equipment Disconnect”: (noun) (Top View) lever/handle located on the outside of the Electrical Power Cabinet, on the left-hand 2 FRONT door or between the doors on the center post. Turns power ON/OFF to the Dryer. • • “Service Disconnect”: (noun) sometimes located away from the Dryer in an electrical room on the facility. Turns power ON/OFF from the outside power service provider. Depending on local codes, it is the responsibility of the Service Provider and/or Owner to clearly mark the Service Disconnect and apply SAFETY Decals for dangers within. See also Pages 18 and 56. Measurements The symbols ('') equals inches and (') equals feet in English measurements. Metric measurements are shown in millimeters and square brackets following the English measurement. For example: 15' [4 572] 90' [27 432] ('') in inches (') ft feet A amps or amperes FLA full load amps V volts sqft square feet Ph phase Identification of Parts and Hardware IMPORTANT! Guards/Covers have been removed in some photos for illustrative purposes only. Diagrams are provided throughout this Manual to identify Parts used in that application. Parts and basic components are identified in Figures and their accompanying Tables as “Items” with a black number in white circle. See Figure 5. Names for some components which have BROCK® Part Numbers have been capitalized within headings and body copy throughout this Manual to call attention to them. Dimensions and lengths are noted with a white circle on an arrow or line, then identified with numeric values in a Figure Table. Item Description 1 Lower Burner Pressure Gauge 2 Upper Burner Pressure Gauge 3 Modulating Motor 4 Electric Conduit 1 2 3 4 Figure 5. Parts Identification 6 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY SAFETY Recognize SAFETY information This is the Safety-Alert Symbol. When you see this symbol on the equipment or in this Manual, be alert to the potential for personal injury. Signal words DANGER, WARNING, or CAUTION, are used with the Safety-Alert Symbol. Be sure to follow ALL National and Local Safety Standards governing each installation site. Understand signal words DANGER indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury. CAUTION indicates a hazardous situation which, if not avoided, MAY result in minor or moderate injury. Lockout/Tagout (LOTO) refers to the systematic procedures as outlined by OSHA (29 CFR 1910.147) for dealing with hazardous electrical energy. LOTO is the procedure by which qualified and licensed electrical personnel must abide to approach electrical testing and maintenance on these Dryers. The “Manufacturer’s Recommended Minimum Lockout/Tagout Energy Control Procedures” on Pages 77-78 incorporates LOTO steps, and is referred to several times in this Manual. IMPORTANT! When “Lockout/Tagout” is referred to in this Manual, it is always with the understanding that procedures are to be done only by qualified, licensed electrical personnel who are following the National Electrical Code plus all applicable state and local codes. ATTENTION! Dryer Contractor, Installer, Owners, Operators: Read and follow THIS MANUAL—especially this SAFETY Section! Reading and understanding this Manual is REQUIRED before Dryer usage. Keep this Manual in a safe, dry place where the Dryer Operator can easily obtain it for future reference. Contact your Brock Dealer to replace a Manual should it become lost or damaged. Restrict Grain Dryer Areas and Designate a SAFETY Zone Designate a SAFETY zone for unauthorized personnel or visitors. Provide adequate fencing and security of restricted areas. Unauthorized entrance to restricted areas around the Dryer exposes persons to hazards. This area should only be entered by authorized personnel with proper personal protective equipment (PPE). Be sure this designated area is clear before turning power on to the Dryer. Since Dryers are often installed on non-commercial farms, it is essential to keep unqualified/untrained personnel, especially children, out of the working area at all times. Accident reports stress that children must be given special precautionary attention because of their natural curiosity for exploring where the grain is going. BROCK can provide an optional “Hazardous Area” Decal which can be posted in areas where only trained Operators of the Dryer have authorized access. It is the responsibility of the Installer and/or Owner/Operator to post and comply with these guidelines and/or other governing standards that may apply. MFH1956E 7 SAFETY BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY Dryer installations Damage to a Dryer can occur due to improper installations. Dryer foundation pads and/or Legs must be level and installed correctly before a Dryer is installed. IMPORTANT! DANGER! CAUTION! Improper installation of electrical or fuel sources will void the Warranty and may cause death or serious injury. Installing any non-BROCK® (another manufacturer’s) components to this Dryer WILL VOID THE WARRANTY on the BROCK® Dryer. Do not modify or attach any other equipment to the Dryer. DO NOT use tanks for liquid propane (LP) that have been used for anhydrous ammonia! This includes previously purged tanks that have been used for anhydrous. Gas train components may be damaged, causing a Dryer malfunction which could lead to serious safety hazards and/or fire. Installing any tank (for an LP fuel supply to the Dryer) which has previously been used for anhydrous ammonia poses a safety threat. Brock Grain Systems will not be held liable for any purging and cleaning methods used for such tanks. If such a tank is used, this will void the Dryer Warranty. Bypass of factory SAFETY controls and switches is strictly prohibited, and will void the Dryer Warranty. IMPORTANT! With the exception of a CONVERSION to the BROCK® QUANTUM® Controller specifically designed for use with the BROCK® SUPERB® Dryer, installing a non-BROCK® (another manufacturer’s) Controller or any other type Controller on a BROCK® SUPERB® Dryer WILL VOID THE WARRANTY on the BROCK® SUPERB® Dryer. IMPORTANT! It is the responsibility of the Contractor, Installer, Owner and Operator to supplement the Dryer furnished by Brock Grain Systems with any necessary ELECTRICAL or STRUCTURAL items to make the Dryer installation comply with the National Electric Code, National Electric Safety Code, OSHA, and all other applicable federal, state and local laws and ordinances. Contact only qualified and licensed electrical and gas contractors to install your Dryer and connect its power and fuel sources. Follow recommended precautions and safe operating practices of national and local codes at each installation site. Dryer installations shall meet the National Fire Protection Association Standard 61B for the prevention of fires and explosions in grain elevators and facilities handling bulk raw agricultural commodities. All components must meet the National Fire Protection Association Standard NFPA No. 70 (National Electrical Code), American National Standard Inst. ANSI-C1, as well as state and local requirements and/or amendments. Failure to follow these standards could result in death or serious injury. WARNING! Electrical SAFETY DANGER! Electricity can KILL! Use extreme CAUTION around electrical components. Disconnect electrical power BEFORE inspecting or servicing the Dryer. Your Installer should have your electric company check the transformer and lead wires before any installation or service work is performed on the Dryer. Be sure the wires are an adequate gauge to carry the load of your Dryer Motors, including starting and full-load operating conditions. Failure to follow these instructions will result in death or serious injury. IMPORTANT! All electrical wiring must be done by a QUALIFIED ELECTRICIAN. Brock Grain Systems neither assumes responsibility for the electrical wiring used with this Dryer; interlocking equipment EXTERNAL to the Dryer; nor will be liable for damage to the Dryer, or persons, or other property, because of improper electrical installation or use. Improper installation or use will void the Warranty. The “Service Disconnect” is sometimes located away from the Dryer in a designated electrical room on the facility. Turns power ON/OFF from the outside power service provider. Depending on local codes, it is the responsibility of the Service Provider and/or Owner to clearly mark the Service Disconnect. 8 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY SAFETY CAUTION! DANGER! All SAFETY devices, including wiring of electrical devices, shall be arranged to operate in a “FAIL-SAFE” manner. That is, if a power failure or failure of the device occurs, a HAZARDOUS CONDITION will not result. To prevent a hazardous condition, the machine and all associated equipment MUST be PREVENTED FROM RESTARTING on its own after a power failure when power returns or a jam is cleared. A MANUAL re-start is required. A Lockout/Tagout device/lockable disconnect switch MUST be installed on Dryer Control enclosures containing hazardous voltage wiring to prevent the Dryer from restarting during a safety check, maintenance, etc. DANGER! To guard against electrical shock, all Dryers shall have a GROUND connection. Make sure electrical equipment and the Dryer are properly installed and GROUNDED by a QUALIFIED ELECTRICIAN according to the National Electrical Code and all applicable state and local codes. DANGER! DO NOT take shortcuts or bypasses in installation by using electrical tape instead of proper means. DO NOT remove any SAFETY devices installed on the Dryer. Do not install or use any method to start or restart the Dryer which bypasses factory-installed SAFETY features. Train Dryer Operators properly WARNING! MFH1956E The Manufacturer requires that all persons who will be operating or working around this equipment be trained in proper operational and SAFETY procedures. Only Operators completely familiar with both the SUPERB® Dryer and this Manual and its SAFETY/operational practices should be permitted to operate the Dryer. This Manual is supplementary to any law or code covering fire or health regulations. It is essential that Owners and Operators use, instruct, and insist on responsible and safe operation according to published grain handling standards applicable in your local area. It is the responsibility of the Contractors, Installers, Operators, Owners and Supervisors to: • Read and follow this Manual, SAFETY instructions, and SAFETY Decals and procedures herein; • Make the above known to all who work with the equipment or who may be in the working area; • Read and follow the SAFETY procedures and Decals in your Manuals to supplemental equipment and accessories; • Know and observe proper grain industry operating precautions, practices and requirements to comply with all federal, state and local laws and ordinances and applicable SAFETY codes. This Grain Dryer is operated by AUTOMATIC CONTROLS that drive highspeed fans and rotating parts, high voltages, burners, moving augers, and other hazards. The Dryer may start without warning. Work around Dryers with extreme CAUTION! DO NOT OPERATE the Dryer with any Guards missing or removed. Failure to follow these instructions could result in death or serious injury. Failure to follow proper operational procedures may cause damage to equipment or property and/or death or personal injury. 9 SAFETY BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY Even the SAFEST Dryer Poses Multiple Hazards BROCK® Dryers are designed with your SAFETY in mind. However, accidents can happen with improper installation or use of any system using a flammable fuel, high-speed moving fan wheels and high voltage. Grain Dryers by their function pose several types of significant, operational hazards that cannot be completely eliminated or safeguarded. BROCK strives to take every reasonable precaution to design equipment that is safe without compromising or restricting necessary movement of Dryer components. Installers, Owners and Operators are expected to take necessary precautions to reduce the risks associated with Dryers. Injuries or death can be caused by electrocution, gas explosions, auger flighting, fan blades, entanglement in a belt drive or power unit, or other hazards. Using this Dryer for any other purpose or in a way not within the operating recommendations specified in this Manual will void the Warranty and could cause injury or death. This Dryer is designed and built with SAFETY features. Under no circumstances shall the safety characteristics of this Dryer be altered. Practice SAFE Dryer Operation and Maintenance Make your farming business safer for all—by educating, training and emphasizing the need to avoid taking risks. Make certain a QUALIFIED OPERATOR is in attendance at all times while the Dryer is operating. If you should need to enter the Dryer (for an adjustment, inspection, etc.), enter only if you: 1. Shut off, Lockout and Tagout all power. See Pages 72 and 77-78. 2.Wear proper BREATHING equipment during cleanout. 3. Enforce a NO SMOKING policy on the premises. 4. Station trained people to help from OUTSIDE the Dryer. 5. Replace all Doors and Guards before resuming Dryer operation. Safe restarts—after emergency stops—require inspection. If a machine is stopped for unclogging, it may clog again upon the return from a RESTART. Before restarting a Dryer that has been manually or automatically shut down because of an emergency or stoppage, an inspection of the Dryer shall be made and the cause of the stoppage determined. Power to the starting device shall be shut off and LOCKED OUT before any attempt is made to remove the cause of the stoppage. Always Keep Guards on Moving Parts To avoid being struck, do not open Guards or Doors while the Dryer is running. Do not step on the Unload device. Do not attempt to poke or prod material in any moving Dryer parts with a bar, stick, or other instrument such as a common “hay hook” device. These can be hazardous. Moving parts such as fans pose a special danger of entanglement and traumatic amputation if approached or used improperly. Some parts and bearings must remain exposed to facilitate operation. DANGER! KEEP HANDS, LIMBS, ALL PARTS OF YOUR BODY AWAY from Dryer parts and openings when the Dryer is running. Severe personal injury will result if equipment is operated without Guards properly installed/latched. Do not operate the Dryer unless all SAFETY devices and Guards are in place. If the Dryer is to be opened for inspection, cleaning or observation, all Dryer power must first be shut off, LOCKED OUT and TAGGED OUT so the Dryer CANNOT be restarted by anyone remote from the area. Failure to follow this instruction will result in death or serious injury. Visually inspect the Dryer prior to operation. Correct any hazardous situation. Repair any faulty equipment. Ensure that electric motors are operating at the proper speed. 10 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY SAFETY Use CAUTION When Servicing EXPOSED Parts (Moving or Electrical) DANGER! Electricity can KILL! Moving parts, fires, and explosions can KILL! Use extreme CAUTION around electrical, mechanical and plumbing components of this Dryer. Always shut off, disconnect, LOCKOUT and TAGOUT all power before adjusting, inspecting servicing, cleaning, repairing, unclogging, performing any maintenance on the Dryer, or opening it in any way. If testing instructions specifically state otherwise or if power must be on to check voltage, use extreme CAUTION. Failure to follow these instructions will result in death or serious injury. IMPORTANT! Review and always follow the “Electrical Connection/Disconnection Procedures for Dryer Testing” (Page 72), and the 'Manufacturer’s Recommended Minimum Lockout/ Tagout Energy Control Procedures” (Pages 77-78) in this Manual. • • • • • • WARNING! Never enter a Dryer while in operation. Be sure all safety Doors are functioning properly to shut down power if they are open. Never enter a Dryer that has automatic unloading equipment without locking out and tagging out the control circuit. Always hire a licensed electrical contractor to repair electrical wiring, switches, fuses or electrical machinery and equipment. Shut down, Lockout and Tagout all power when replacing Fan wheels. Regularly inspect wiring, cords, plugs, tools and equipment for obvious external damage. Watch for shorts and sparks in fittings, or loose wiring. Check fuel line connections for leaks; minor leaks can go undetected a long time. Always Wear PPE (Personal Protective Equipment): Avoid noise / eye dangers, and other personal hazards. Failure to do these could result in death or serious injury. Require hearing protection around Grain Dryers (approximately 80% of all farmers have some hearing loss). Have an emergency hand-communication system in place in areas where Dryer, tractor or equipment noise is excessive. Because of the DANGER of flying debris to eyes, protective eyewear/safety glasses must be worn during assembly, installation, maintenance or servicing of this Dryer. It is important that all operators use good common sense and always be aware of and understand these additional SAFETY rules, which should be enforced: • Never wear loose-fitting clothing or flowing scarves around moving parts. Keep long hair secured. Wear suitable footwear for grain handling areas. Keep shoestrings secured. • Restrict or prohibit jewelry (some types of rings, earrings, and body jewelry) that poses an entanglement hazard. • Do not stand in the suction area of the Dryer Fan while it is operating. • Work alert after adequate rest. Never operate equipment if you are tired or distracted. (National occupational accident reports indicate that operators are typically getting tired and anxious to get work completed just before lunch, and between 3 pm and 5 pm when their energy reserves are depleted). Any worker who is tired and/or under pressure increases his/her chances of having an accident. Give extra breaks and/or varied jobs to all workers. • Never operate the Dryer if intoxicated or under the influence of alcohol or drugs. • Never work alone after all other personnel have left the site. You may find yourself injured and unable to reach help or a way out. MFH1956E 11 FIRE SAFETY BROCK® SUPERB® Low Profile Grain Dryers SQ Installation FIRE SAFETY In the event of a Dryer FIRE, act immediately! EMERGENCY PROCEDURES: ACT IMMEDIATELY if there are gas FUMES or unusual noises or vibrations. ACT IMMEDIATELY at the FIRST APPEARANCE of smoke or smolder. * In the event of a FIRE, CALL 9-1-1 IMMEDIATELY. Follow applicable procedures for such an emergency. Below: Take Step 1 or Step 2 FIRST, whichever Control you are closest to. Within a minimum 15 seconds between, shut off power at the other control: ONE. Press the RED EMERGENCY STOP Button on the red Control Panel to shut down the Dryer immediately. This stops the Fans to eliminate air supply to the fire. Remember: Doing this does NOT yet shut off the incoming power from the Electrical Power Cabinet to the Control Panel. TWO. Pull DOWN the Dryer DISCONNECT Handle on the inner door of the Dryer Disconnect Box. This shuts off electrical current to the Dryer Control Panel and trips the main breaker. Remember: Doing this does NOT yet shut off the Electrical Power Cabinet’s INCOMING power from the outside electrical Service Provider. THREE. Shut off power from the Provider’s incoming lines at the Service Disconnect so there is NO POWER AT ALL coming to the Dryer. It is important for all Operators to know the location of, and obey safety warnings regarding the power Service Provider’s Service Disconnect, sometimes in a building away from the Dryer. The Service Disconnect is provided by the Owner. Figure 6. Initial EMERGENCY Shutoffs FOUR. Shut off the fuel supply valve closest to the fire and at the Tank (if LP is used). Turn the Gas Hand Shutoff Valve at a 90degree angle to the Lower Plumbing Train to CLOSE. SQD Model shown; see Figure 8 for SQA. 12 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation FIRE SAFETY FIRE SAFETY IMPORTANT! Locate the fire and determine: Can it be quickly contained / extinguished? Failure to quickly recognize the need for professional fire fighters could result in the loss of life, and will result in increased property loss. DANGER! There is toxic gas and smoke in the event of a fire. DO NOT ENTER the fire area or any enclosed space within the Dryer. Failure to follow this warning could lead to death or serious injury. To avoid becoming trapped above the fire, DO NOT CLIMB up to any area of the Dryer to attempt to put out the fire yourself! Starve the fire of oxygen by injecting it into the hot spot. Or blanket the grain from the top down. However, do not RELY on fire extinguishers to put out grain fires on this Dryer. A fire extinguisher may only be useful for small, containable fires near the pad. Figure 7. Dryer Fire If it becomes necessary to dump burning grain on the ground, open the Quick-Draw Slide Doors in the lower basket area for gravity dumping of the Dryer columns. However, do not dump grain until the fire department and water are available to extinguish burning embers that may come out. Stop all nearby equipment. Protect and move nearby equipment and other combustibles. Monitor the temperature in adjacent bins and structures. Check grain storage for any signs of hot embers that may have conveyed before Dryer shutdown occurred. MFH1956E IMPORTANT! Use water wisely: Hose down / cool propane tanks and grass surrounding the area. DO NOT spray water in the Dryer or adjacent grain bins. This could cause a “water gas” explosion with a CO-hydrogen gas mix, and/or swell the grain, (damage bin sidewalls). IMPORTANT! Always consult your local fire / emergency department for their recommendations given any emergency, and HAVE AN EMERGENCY PLAN IN PRACTICE for your facility. 13 FIRE SAFETY BROCK® SUPERB® Low Profile Grain Dryers SQ Installation FIRE SAFETY In the event of a Dryer FIRE, act immediately! (continued) Location of Shutoff Valves 3 1 4 2 Detail Figure 8. Emergency Gas Hand Shutoff Valve, (SQA Model shown) VALVE OPEN Item Description 1 Incoming gas line 2 Gas Hand Shutoff Valve 3 Unload Drive 4 Fuel WARNING Plate 1 2 4 Detail 3 1 2 VALVE CLOSED 1 14 Figure 9. Gas Shutoff Hand Valve (SQD Model shown) MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation FIRE SAFETY SAFETY Decals Overview IMPORTANT! Along with the Dryer shipment will be DANGER, WARNING and CAUTION Decals which have been placed on the Dryer to insure safe and proper use of the product. Locate, read and follow all SAFETY DECAL information on your Dryer and in this Manual. Installers: Review Pages 15-26 and be sure ALL SAFETY Decals are properly in place before this equipment is released to the Customer. Figures 10 through 26 on Pages 16-26 show the proper location of the SAFETY Decals as shipped from the factory. Always observe SAFETY information on additional equipment from other Manufacturers. IMPORTANT! MFH1956E Check all equipment for WARNING, DANGER and CAUTION Decals and their proper placement, BEFORE equipment is operated. Keep them clean and grease-free. Take care not to damage factory-installed Decals during the installation. Never use or release equipment if Decals are missing, hidden improperly placed, damaged or altered. If the SAFETY Decals are not properly placed or if they are in any way damaged or altered, contact your BROCK Dealer for immediate replacements. Do not remove any SAFETY Decals unless they are being replaced with proper Decals as shown here. 15 FIRE SAFETY BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY Decals 3 4 FRONT VIEW-L Model SQ 12D 11 6 10 1 6 2 12 7 8 5 10 6 9 5 4 REAR VIEW 16 Figure 10. SQ SAFETY Decals FRONT VIEW-R See Item Table on the facing page. MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY Decals SAFETY Decals Refer to the Table below for Figure 10 (facing Page) Decal locations. Item 1 2 Decal Description DANGER, 13-23790 DANGER Ladder Shock, Explosion, 40271-847-04 DANGER: 3 Arc Flash 1315-00238 WARNING: Keep Guard On 4 3536-00055 WARNING: Emergency Doors 5 1315-00247 WARNING: Keep Doors Closed 6 7 3136-00038 CAUTION Decal, Ladder 1315-00240 WARNING Decal 8 1315-00236 WARNING High Temperatures 9 10 5537-00052 WARNING Arc Flash 11 3734-00028 WARNING Decal 12A 5537-00050 WARNING Plate Fuel Type 12B 5537-00049 MFH1956E Part No. Location AC Drive Box Side Ladder Dryer Disconnect Cover (larger boxes) Belts/Drives Guards Quick-Draw Slide Panels Guards/AC Drive/ Top Door Ladder Control Box Rear Plenum Door Dryer Disconnect Cover Control Box, back Plumbing Connection-LP Plumbing Connection-NatG 17 SAFETY Decals BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY Decals DANGER! HIGH VOLTAGE! The Service Disconnect (Box) MAY also be located near the Electrical Control area at the Dryer pad. The Service Disconnect turns power ON/OFF from the outside power service (utility) provider. The Electrical Power Cabinet (provided by BROCK) in Figures 1415 is not to be confused with the Service Disconnect example (provided by the Owner) shown below. Depending on local codes, it is the responsibility of the local electrician and/or Owner to clearly mark, apply and follow SAFETY Warnings for HIGH VOLTAGE DANGERS within the Service Disconnect. Electrical Control Area: DANGER! HIGH VOLTAGE! Dryer Disconnect, AC Drive and Control The Dryer/Equipment Disconnect is located in the Disconnect Box. For additional information on this area of the Dryer, see also Page 61. IMPORTANT! Review and always follow the “Electrical Connection/Disconnection Procedures for Dryer Testing” (Page 72), and the “Manufacturer’s Recommended Minimum Lockout/Tagout Energy Control Procedures” (Pages 77-78) in this Manual. Dryer/Equipment Disconnect Box: This Box is located at the front of the Dryer. See Figures 11-12. Larger Dryer models have a taller Dryer Disconnect Box which has trilingual DANGER Decal (40271-847-04). It addresses several hazards: “HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH. • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. • This equipment must only be installed and serviced by qualified electrical personnel. • Turn off all power supplying this equipment before working on or inside equipment. • Always use a properly rated voltage-sensing device to confirm power is off. • Replace all devices, doors and covers before turning on power to this equipment. Failure to follow these instructions will result in death or serious injury.” Bilingual WARNING Decal (5537-00052) is on the Dryer Disconnect cover. Figure 11. Dryer Disconnects Customer-Provided Service Disconnect (Example) Figure 12. Dryer Disconnect Box SAFETY Decals 18 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY Decals SAFETY Decals AC Drive Box IMPORTANT! DANGER! Locate and read your literature provided by the Vendor/Manufacturer of the AC Drive. An AC Drive must be grounded and can be extremely dangerous if all safety precautions are not observed. It is very important with an AC Drive to WAIT for capacitors to discharge stored electrical energy BEFORE any service is begun on the Drive. If a capacitor explodes, there will be a shotgun-like blast. The danger of a capacitor explosion is similar to that of an arc flash. WAIT at least fifteen (15) minutes for the energy to dissipate from the capacitors. VERIFY THAT NO VOLTAGE IS PRESENT before proceeding. Failure to observe this instruction will result in death or serious injury. WARNING Decal 1315-00247 is on the AC Drive Box Door. It reads, “WARNING! Keep door closed except for service.” See Figure 11. A bilingual DANGER Decal is visible inside the AC Drive glass door (some models). It reads, “DANGER! Hazardous voltage. Ground equipment. Before servicing, disconnect all power. Wait 15 minutes, then verify that no voltage is present. Close cover after servicing. Failure to follow these instructions will result in death or serious injury. Figure 13. AC Drive Box SAFETY Decals Control Box WARNING Decal (1315-00240) is located on the Control Box cover. See Figure 14. It contains general precautions for several areas of Dryer operation. Bilingual WARNING Decal 3734-00038 is inside the Control Box back. Figure 14. Control Box SAFETY Decals MFH1956E 19 SAFETY Decals BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY Decals 6 9 4 2 1 DANGER! Use extreme CAUTION around electrical components. SHUT OFF, LOCKOUT and TAGOUT electrical power BEFORE opening or servicing any electrical control boxes. Keep Control Box Doors CLOSED during Dryer operation. Failure to do so will result in death or serious injury. 5 7 8 Item 1 2 3 4 5 6 7 8 9 20 3 Description Control Box Dryer/Equipment Disconnect Box Bilingual DANGER Decal (AC Drive) Bilingual WARNING Decal 3734-00038 AC Drive Box Bilingual WARNING Decal PPE 5537-00052 WARNING Decal 1315-00240 WARNING Decal 1315-00247 Trilingual DANGER Decal 40271-847-04 (on larger Disconnects) Figure 15. Overview: DANGER and SAFETY Decals at the Control Box, Dryer Disconnect and AC Drive Area MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY Decals SAFETY Decals Top Transition Service Door: Electrical / Rotation Hazards The Top Transition Service Door is on the top of the Dryer near the Upper Plumbing Train. Be sure this door is closed and secure before operating the Dryer. The Burner Ignition Transformer Box is located next to the Burner Access Door on the top of the Dryer. Inside the Box are the BASO Switch and Ignition Transformer. On the Box cover is bilingual WARNING Decal 1315-00247. See Figure 16. 4 3 5 Item Description 1 Burner 2 Top Transition Service Access 3 WARNING Decal 1315-00247 4 Burner Ignition Transformer Box (BASO) 5 BASO Switch (not shown) 1 2 Figure 16. Top Transition Service Door Area Doors / Guards on moving Belts, Drives and Augers DANGER! Areas with these WARNING Decals are entanglement hazards. Keep all Guards on at all times during operation, except for service. Keep hands, feet and clothing away from belts and drives. Do not place fingers or hands under Guards at the Load and Unload areas.Failure to follow this instruction could result in death or serious injury. 2 1 2 1 2 Item Description 1 Fan Belt Guard WARNING Decal 2 1315-00238 FIgure 17. Fan and Load Drive Belt Guards WARNING Decal 1315-00238 is used on Guards and Doors which should be kept on Drives and Belts at all times during operation. See Figure 17. MFH1956E 21 SAFETY Decals BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY Decals Detail: Head Takeup 3 4 4 1 2 Detail: Larger Models 6 1 5 Item Description 1 Paddle Return Cover 2 Unload Drive 3 Sprocket DANGER 4 WARNING Decal 1315-00238 5 WARNING Decal 3536-00055 6 Fan Belt Guard ON 4 Figure 18. Guards and Covers Near Fan and Unload Drive (Front of Dryer) Emergency “Quick-Draw” Slide Panels (at the bottom of each Dryer column; see Page 13, Figure 7) must be closed before the Dryer is operated. If these Doors are open there is a moving hazard. Do not place hands or objects into this area. Failure to follow this instruction could result in personal injury and damage to the equipment. Each Slide Door has a WARNING Decal on its pull. See Item 5, Figure 18. DANGER! 22 Areas with these WARNING Decals are entanglement hazards. Keep all Guards on at all times during operation, except for service.TURN OFF, LOCKOUT AND TAGOUT ELECTRICAL POWER BEFORE servicing electrical or moving components. Failure to follow this instruction could result in death or serious injury. Keep hands, feet and clothing away from belts and drives. Do not place fingers or hands under Guards at the Load and Unload areas. Failure to follow this instruction could result in death or serious injury. MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY Decals SAFETY Decals Doors / Guards on moving Belts, Drives and Augers (continued) 3 1 2 Belts and Drives are pictured EXPOSED to show HAZARD. DANGER! DO NOT allow the Dryer to run while any adjustments are being made. Lockout and Tagout all electrical power BEFORE working on or near the Dryer. Keep hands, feet, hair, and clothing away from all augers and parts in motion. Failure to shut off and LOCK OUT power to the Dryer will lead to personal injury or death. 4 FIgure 19. Fan and Belt Hazards Item Description 1 Load Auger Belt Guard ON 2 Load Motor 3 WARNING Decal 1315-00238 4 Fan Shroud/Free Air Inlet 5 Discharge exposed 6 Discharge Cover ON 7 Bearing exposed Cover in Place 5 7 6 CAUTION! Avoid moving hazards at the Unload Discharge. Do not wear loose-fitting clothing that can become caught in the drag conveyor. MFH1956E Without Cover Figure 20. CAUTION at Unload Discharge 23 SAFETY Decals BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY Decals Fan Motion Hazards WARNING! The Fan continues to ROTATE after power is disconnected. Do NOT enter or service until ALL motion of the Fan stops. Make sure the power is LOCKED OUT and TAGGED OUT while servicing. Failure to follow this WARNING could result in death or serious personal injury. Do not stand in front of the Fan while it is in operation. SUCTION may draw clothing into the Fan. Failure to follow this instruction could result in death or serious personal injury. Note: Some Decals refer to the Fan as the Blower. Figure 21. Fan Hazards DANGER of Heat DANGER! There are high operating temperatures inside the Dryer. Parts become hot during operation. Keep all Doors closed except for service. Failure to heed these warnings could result in death or serious injury. Do not open the Rear Plenum Access Door (Figure 22) unless all power to the Dryer has been disconnected, LOCKED OUT and TAGGED OUT. This is a Door into the heat plenum through the Dryer bulkhead on the rear end opposite the Fan(s). To avoid dangers of excessive heat, allow twenty (20) minutes for the Dryer to cool before entering. Keep the Fan ON to aid in cooling the Dryer. A Door SAFETY Switch is standard on all lowprofile Dryers. If the Door is opened during operation, the Dryer will shut down. 4 1 3 Item 1 2 3 4 24 Description Rear Plenum Door Door SAFETY Switch WARNING Decal, Heat 1315-00236 WARNING Decal, Door 1315-00247 2 Figure 22. WARNING Decals, Rear Plenum Door MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY Decals SAFETY Decals CAUTION When Climbing: Ladder SAFETY Watch your Step. Use the Ladder, Upper Guardrails and the rear Handrail and rear Step(s) provided when servicing the Dryer. Never sit on the Guardrail. Do not climb on other areas of the Dryer. Follow the instructions on the Ladder CAUTION Decal located at the Ladder on applicable models. See Figure 23. IMPORTANT! The Unload Cover has been designed as a Step. It must be kept clean, or a buildup of chaff residue here can decompose and become slippery and hazardous. 3 1 2 3 UNLOAD COVER ON 3 Item Description 1 Unload Discharge Cover 2 Rear Handrail 3 Rear Step 4 Unload Discharge 4 1 UNLOAD COVER OFF Figure 23. Rear Handrail, Steps and Unload Cover Side Ladders are provided on all SQ models for access to the Transition Door area. There should always be a Ladder DANGER Decal (13-23790) near the bottom of the Ladder. It contains important SAFETY information necessary because the Dryer is near grain bins. Some statements on the Decal directly applicable to the Dryer include, but may not be limited to, the following statements: • Face the Ladder when ascending or descending. Maintain a firm grip. Center your body between Side Rails. • Do not use Ladders or climb up to service the Dryer if you tire easily, are in poor health, are subject to fainting spells, use medicine or alcohol, or are physically handicapped /tired. • Keep steps and rungs free from slippery material such as ice, snow, mud, grease, manure, etc. Wear slip-resistant shoes. • Never climb a damaged Ladder. Before use, inspect the Ladder carefully for deterioration from chemicals or weather. If it is damaged or exposed to fire or damaging chemicals, contact your BROCK Dealer for a replacement. • The maximum load of the Dryer Ladder is 300 pounds [136 kg]. MFH1956E 25 SAFETY Decals BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY Decals WARNING! The following actions are a misuse of the Ladder. NEVER exceed the maximum load, apply a side load, or use the Ladder as a scaffold. DO NOT drop or apply an impact load to the Ladder; push or pull anything while on the Ladder; or use the Ladder as a horizontal platform, plank or material hoist. To do so is a misuse of the equipment and could cause personal injury or equipment damage. 4 5 5 3 Figure 24, left. Upper Walkway (Top View) Item Description 1 Side Ladder DANGER Decal 2 Ladder 13-23790 3 Top Walkway 4 Ladder Extension 5 Support Tube 5 2 4 3 Figure 25. Ladder SAFETY Decal 1 1 Figure 26. Side Ladder and Top Walkway 2 26 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Planning the Installation Planning the Installation IMPORTANT! Qualified professionals and/or millwrights should be contacted prior to the installation to provide adequate electric power, gas and other components. Brock Grain Systems is not responsible for these installations. System Analysis Location of the Dryer from storage and driveways: a minimum of 4' [1.2 m] should be maintained between the Dryer and driveways or other structures. A minimum of 5' [1.52 m] should be maintained between the Dryer and nearest combustible structures. DANGER! Canadian Dryers The equipment shall be installed in accordance with the current installation codes for gasburning appliances and equipment, CAN1 B149.1 and B149.2, and/or applicable Provincial regulations, which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made. All electrical wiring shall be done in accordance with the current CSA C22.1 Canadian Electrical Code, Part 1, and/or applicable provincial regulations as required. IMPORTANT! MFH1956E KEEP THE DRYER AWAY from power lines and live electric wires. Failure to follow this instruction will result in death or serious personal injury. The grain load can enter at the rear (standard) or front (Fan end). The Unload Auger may be standard (rear) or front (Fan end). If two Dryers are installed side-by-side, a minimum of 3' [.9 m] clearance is required between (U.S.) Canada: 5' [1.52 m] between is required. Figure 27. SQ Dryer Do not “box in” the Dryer amid tall structures. Allow passageways for air movement, such as beside a driveway. Plan for future expansion. Canada: Locate the Dryer a minimum of 50' [15.24 m] from any inhabited building. Handling: minimize handling distances and number of handling operations. Locate the Dryer close to an elevator leg for gravity unload, and close to an overhead hopper tank for gravity fill where practical. Drainage and Supply: Locate the Dryer pad, dump pit, and storage bins in a welldrained area, or provide an adequate tile drainage system. Keep hoses and pipes away from areas where equipment may drive over them. Power and gas suppliers: contact licensed contractors early to determine the best method and size of service for present and future requirements, and the need for reduced voltage starter. Future expansion: keep open the potential for changing Dryer sizes or adding additional drying units as your grain volume increases, both space and power-wise. Place the Dryer to take full advantage of future changes in handling equipment. Continuous flow Dryers may be a good option over in-bin drying when the yield exceeds 100,000 bu [3 524 m3] per year and where the climate is high-moisture or a short growing season (turnaround time must be short). 27 Planning the Installation BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Concrete Pad Foundation for the Dryer IMPORTANT! WARNING! The Dryer should be mounted on a level 5'' [12.7 cm] thick-reinforced concrete slab. Do not mount the Dryer on concrete blocks, which can be unstable. Failure to follow this instruction could result in death, serious injury, and or damage to the Dryer and other equipment. The concrete pad design is based on 3000 pounds psf [143.7 kPa] soil bearing capacity. For soils with lower capacity, consult the Brock Grain Systems Engineering department at the Frankfort, Indiana, location. See the Concrete Pad drawing below. Use these Figures to position the Dryer before it is installed. The Dryer must be properly anchored so it will not blow over in excessive winds. IMPORTANT! It is the responsibility of the Contractor, Installer, Owner and Operator to supplement the Dryer furnished by Brock Grain Systems with any necessary ELECTRICAL or STRUCTURAL items to make the Dryer installation comply with the National Electric Code, National Electric Safety Code, OSHA, and all other applicable federal, state and local laws and ordinances. A B C 5 11 Figure 28. Concrete Pad 2 6 3 4 1 9 7 Detail A-A. Cross View 6 8 Item Description 1 Footing Outline 2 Dryer CenterLine 5' [30.5 cm] 3 Wire Overlap 1' Mesh 4 Wire (no. 6 or heavier) 5 10' [304.8 cm] 6 3'' [7.6 cm] 7 1' - 6'' [45.7 cm] 8 10'' [25.4 cm] 9 5'' ± 1'' [12.7 ± 2.5 cm] 10 2'' [5.1 cm] 11 Rear of Dryer Base Frame 28 10 Dryer Concrete Pad Dimensions Dryer Model SQ8 SQ12 SQ16 SQ20 SQ24 SQ28 SQ32 SQ36 SQ40 A: Concrete width ft/in cm B: Length of Base Frame ft/in meters 23' - 0'' [7 010] 8' - 2'' [2 489] 27' - 0'' [8 230] 12' - 3'' [3 734] 31' - 0'' [9 449] 16' - 4'' [4 978] 35' - 0'' [10 668] 20' - 5'' [6 223] 40' - 0'' [12 192] 24' - 6'' [7 468] 44' - 0'' [13 411] 28' - 7'' [8 712] 49' - 0'' [14 935] 32' - 8'' [9 957] 53' - 0'' [16 154] 36' - 9'' [11 2010] 57' - 0'' [17 373] 40' - 10'' [12 446] ft/in C cm 3' - 9'' [1 143] 3' - 9'' [1 143] 3' - 9'' [1 143] 3' - 9'' [1 143] 3' - 9'' [1 143] 3' - 9'' [1 143] 3' - 9'' [1 143] 3' - 9'' [1 143] 3' - 9'' [1 143] D Concrete req.* cubic yds/ cubic meters 7 [5.85] 8 [6.69] 9 [7.52] 10 [8.36] 11.5 [9.62] 12.5 [10.45] 14 [11.70] 15 [12.54] 16 [13.4] * Includes 10% overrun. Concrete is to have a 3000 psi , minimum 28-day strength. Concrete pad design based on 3000 pounds per sq ft [143.7 kPa] soil-bearing capacity. For soils with lower capacity, consult Brock Engineering. MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Planning the Installation SQ Series Dimensions Dryer Model Total Fan HP Auger Load HP Chain Unload HP Column Length Overall Length Overall Height Bushels Held SQ8 SQ12 SQ16 SQ20 SQ24 10 2 2 8' - 2'' [2 489] 19' - 0'' [5 791] 14' - 2'' [4 318] 163 10 3 2 12' - 3'' [3 734] 23' - 1'' [7 036] 14' - 2'' [4 318] 245 15 3 2 16' - 4'' [4 978] 27' - 2'' [8 280] 14' - 2'' [4 318] 326 20 25 5 5 2 2 20' - 5'' 24' - 6'' [6 223] [7 468] 31' - 3'' 36' - 4'' [9 525] [11 074] 14' - 2'' 14' - 2'' [4 318] [4 318] 408 490 SQ28 SQ32 SQ36 SQ40 30 7.5 2 28’ - 7'' [8 712] 40' - 5'' [12 319] 14' - 2'' [4 318] 572 40 7.5 2 32' - 8'' [9 957] 44' - 6'' [13 564] 14' - 2'' [4 318] 654 50 10 2 36' - 9'' [11 201] 48' - 7'' [14 808] 14' - 2'' [4 318] 734 50 10 2 40' - 10'' [12 446] 52' - 8'' [16 053] 14' - 2'' [4 318] 815 SQ-A/E DRYERS Overall Width (SQ-A Dryers) Overall Width (SQ-E Dryers) Burner Rating (SQ-A, E Dryers) 10' - 2'' [3 099] 7 - 9'' [2 362] 10' - 2'' [3 099] 7 - 9'' [2 362] 10' - 2'' [3 099] 7 - 9'' [2 362] 10' - 2'' [3 099] 7 - 9'' [2 362] 10' - 2'' [3 099] 7 - 9'' [2 362] 10' - 2'' [3 099] 7 - 9'' [2 362] 10' - 2'' [3 099] 7 - 9'' [2 362] 6.6m 7.5m 7.9m 9.5m 12.6m 13.4m NA NA NA NA NA NA 4.3m 7' - 4'' [2 235] 7' - 4'' [2 235] 7' - 4'' [2 235] 7' - 4'' [2 235] 7' - 4'' [2 235] 7' - 4'' [2 235] 7' - 4'' [2 235] 7' - 4'' [2 235] 7' - 4'' [2 235] 4.4m 4.8m 6.3m 8.5m 10.9m 11.9m 14.4m 15.9m 16.5m SQ-D/M DRYERS Overall Width (SQ-D, M Dryers) Burner Rating (SQ-D, M Dryers) SQ Model Features A E Plenum Floor for 2 Temperature Zones          Louvers Hot Air Return Duct Full Heat Drying Pressure Heat/Pressure Cool Drying Pressure Heat/Vacuum Cool Drying Two Temperature Zones D M          * *Pressure Heat/Pressure Cool Drying can be accomplished with a D Model Dryer by operating in Batch Mode. MFH1956E 29 Mechanical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Mechanical Installations Anchoring the Dryer IMPORTANT! To minimize damage from high winds, the Dryer must be firmly anchored to the foundation at or near each corner. Mount the Dryer on a 6'' [15.24 cm] thick reinforced concrete slab. Position and level the Dryer Basket Assembly to match load and unload conveyors, using two (2) 8 x 8 x 16'' [20.32 x 20.32 x 40.64 cm] concrete blocks at 16'' [406] elevation, spaced at approximately 48'' [1.22 m] center-to-center along the side frames. Place a reinforcing rod in each core and fill the cores with concrete. To provide crosswind stability, place blocks at the end of the base frame and place alternate sets of blocks at a 90-degree angle from the Dryer centerline. Anchor the Dryer Basket to steel anchors in the concrete pad by use of turnbuckles at or near each corner, or other suitable means. Leg Kit Assembly Brock offers optional Dryer Legs. Start at the rear end of the Dryer and locate a Leg set every 49'' [1 245 mm]. There must be a Leg also located in the four corners of the Fan Base where it attaches to the Basket. A Leg Kit Assembly (4128-2----; number changes with model and Leg height desired) is available for SQ8 through SQ40 Dryers. Installation shown here is the same for all sizes. Before installing the Leg Kit, remove the Bolt and Nut at both rear corners as shown in Figure 29. Leg attachment: Position each Leg Weldment (Item 1) with the flat side facing out, and the mounting tabs facing inward. The FRONT pair of Legs are set in the position shown (Item 9, Figure 30) under the Fan (all installations). The REAR pair of Legs is always in the position shown (Item 10) at 2.5'' [6.4 cm] from the back end of the Frame. Remaining Legs are set 49'' [124.5 cm] on centers from the rear. Use 1/2 x 1 1/4'' Carriage Bolts (Item 6) and existing 1/2'' Whizlock Nuts to secure the Legs to the Dryer support frame. Item Part No. Description 1 4128-00006G0_ Leg Weldment 2 4128-00005 Brace, Cross-Leg Packages 3 2330-00002 Screw, 3/8-16 x 1'' HWH Whizlock-zinc 4 Nut, 1/2'' Whizlock (existing) 5 2364-00002 Washer, 3/8'' Flat galvanized 6 2335-00011 Bolt, 1/2-13 x 1 1/4'' Carriage Gr. 5 z Remove this Bolt and Nut at both rear 7 corners before installing the Leg Kit. 8 49'' [124.5 cm] on center between Legs All FRONT Legs are installed in this 9 position under the Fan. All REAR Legs are located in this position 10 2.5'' [6.4 cm] from the end of the Frame 30 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Mechanical Installations . 1 VIEW FROM FRONT INSIDE VIEW 2 7 Figure 29. Remove Hardware, Rear Frame (See Item Table on facing Page.) 2 OUTSIDE VIEW 1 4 6 SIDE VIEW 9 10 Figure 30. Leg Attachment (See Item Table on facing Page.) MFH1956E 8 31 Mechanical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Leg Crossbrace attachment: Join a pair of Crossbraces (Item 2) between each pair of Leg Weldments as shown in Figure 31 below. 2 END VIEW 2 4 5 5 2 3 Figure 31. __. Crossbrace Connection 2 1 Item Part No. Description 1 4128-00006G0_ Leg Weldment 2 4128-00005 Brace, Cross-Leg Packages 3 2330-00002 Screw, 3/8-16 x 1'' HWH Whizlock-zinc 4 2363-00001 Nut, 3/8-16 HWH Whizlock-zinc 5 2364-00002 Washer, 3/8'' Flat galvanized 6 2335-00011 Bolt, 1/2-13 x 1 1/4'' Carriage Gr. 5 z Remove this Bolt and Nut at both rear 7 corners before installing the Leg Kit. 8 49'' [124.5 cm] on center between Legs All FRONT Legs are installed in this 9 position under the Fan. All REAR Legs are located in this position 10 2.5'' [6.4 cm] from the end of the Frame Figure 32. Crossbrace Connection from Rear 32 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Mechanical Installations Garner Bin Assembly For this operation, a 1/2'' impact with a 1 1/4'' impact socket works best. The Garner Bin is the wet grain holding bin at the top of the grain columns. It provides a surge, or working volume of wet grain so the Plenum air seal is not broken on Dryers with leveling augers that operate intermittently. The Garner Bin holds approximately 4.5 bushels per foot of Dryer length, providing 10 to 30 minutes’ drying volume (5 to 15 percent moisture removal). The Garner Bin can be folded down for shipping. REAR REAR CL CL LEFT RIGHT TOP VIEWS FRONT Figure 33. Standard Load/Unload: Garner Bin falls on LEFT IMPORTANT! FRONT Figure 34. Reverse Load: Garner Bin falls on RIGHT If more than one Lifting Rod (may also be called an Erection Screw) is used on the Dryer, two (2) impact wrenches are better. To avoid bending the Garner Bin, lift it as evenly as possible. Take your time and be safe. Lubricate the Garner Bin Lifting Rod (Detail B, Figure 35) prior to use. The Garner Bin can be lifted into assembly position with the provided Lifting Rod assembly. An impact or heavy-duty drill are best suited for driving the assembly. 1. Unbolt the Garner Bin from the top edge* (see Detail B) of all the shipping braces. This will require two (2) 1/2'' wrenches or sockets. There are times when the shipping brace will not release from the Garner Bin. Do not discard the hardware as it should be reinstalled when the lifting operation is completed. Apply a slight amount of upward pressure using the Lifting Rod. Locate the lifting mount which is attached to the Garner Bin. It should be on the same rib as the lift bolt. Remove the shipping brace, for access, (do not discard) and reinstall it when the lifting operation is complete. The bolt used to attach the Lifting Rod to the lift bracket is a 3/8'' Bolt with a self-locking Nut. 2. Rotate the Garner Bin Lifting Rod into position. Secure the lifting brackets together with the 3/8'' Lock Nut and 3/8'' Bolt. Finger-tighten snugly. 3. Lift the Garner Bin into position by turning the Lifting Rod clockwise. For Dryers with more than one Lifting Rod, make sure that the Garner Bin rises fairly level. For best results, alternate between Lifting Rod assemblies, raising 5'' or 6'' [12.7 or 15.2 cm] at a time at each location. Lift until the skin flanges are in alignment with the holes in the gussets on the Upper Basket on the opposite side of the Lifting Rod. As you install the Lifting Rod to the bracket, be sure the pivot bolt is not too tight. The Lifting Rod must be allowed to pivot freely. MFH1956E 33 Mechanical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Garner Bin Assembly (continued) 4 2 Left, Dryer rear end: Looking up toward the Garner Bin before it is raised upright. The Fill Hopper is installed over this open Auger opening. 3 Item Description 1 Shipping Brace 2 Top Leveling Auger 3 Top Grain Level Switch (TGL) 4 Garner Bin 5 Lifting Rod 4 Detail B: Shipping Brace * 5 1 The Top Grain Level Switch (or TGL, Item 3) is a mercury switch connected to a paddle that is hanging vertically beside the wet fill auger. When the paddle is rotated counterclockwise either by hand or by grain flow, the Switch contacts close, starting the WET FILL timer. Check the TGL Paddle for free rotation. Figure 35. Garner Bin Components Detail A: Lifting Rod IMPORTANT! IMPORTANT! 34 4. To install the galvanized End Panels (approx. 21'' x 27''): Remove the lower 5/16'' x 3/4'' Bolts on each end of the Garner Bin near the upper triangular bulkhead. These End Panels are to be installed on the outside of the upper triangular bulkhead and the upper galvanized bulkhead using 5/16 x 3/4'' Self-tapping Screws along the top, sides, and inner four (4) holes along the bottom edge. Leave all these fasteners loose until the 5/16'' x 3/4'' Bolts and Nuts can be installed in the outer four holes above the Garner Bin Pivot Bolts (at the galvanized upper bulkhead). Tighten completely. If the Dryer is set for REVERSE load, the Garner Bin will fall on the RIGHT side of the Dryer. 5. Install the 5/16 x 3/4'' Whiz Lock Bolts connecting the gussets to the Garner Bin (both sides) and into the open hole in the skin flanges. 6. The Top Grain Level Switch Assembly is located at the end OPPOSITE the fill end of the Garner Bin. Check the Paddle for free rotation. For Auxiliary Conveyor connections, see Pages 64-66 in Electrical Installation. MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Mechanical Installations 1 9 2 8 3 4 5 6 7 Figure 36. Garner Bin Being Lifted into Place (Front View) Item Description 1 Upper Triangular Bulkhead 2 End Bulkhead Bolts (on after fully raised) 3 Bolts required after raised 4 Gusset 5 Shipping Braces 6 Upper Bulkhead 7 Drive end of Lifting Rod (turn clockwise) 8 Lifting Rod Assembly 9 3/8'' Bolt and Lock Nut 8 Figure 37. Lifting Rod MFH1956E Figure 38. Garner Bin set for Reverse Load (Rear View) 35 Mechanical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation 7. On the opening over the load Auger, install the Fill Hopper Assembly with 1/4 x 1/2'' Sheet Metal Screws to the opposite end of the Garner Bin. It can be located at either end of the Dryer. The Fill Hopper Control Slide Plate is an inclined slide plate that is adjusted to provide a grain feed opening adequate for the volume being conveyed, while keeping the grain column weight from loading down the end of the auger. It maintains a seal in gravity systems and keeps the auger from throwing grain out of the Hopper on both conveyor and gravity-filled systems. Install the Slide Gate and Lid. See Figure 39. 5 8 4 9 Subassemble Items 2, 3, 4, 5, and 6 before installing the Hopper Extension on the Dryer. 3 2 10 1 8 Item Part No. 1 5516-00008G01 2 1162-0015G01 3 1162-0003P01 4 1162-00009 5 3516-00022 6 1315-00249 8 2331-00006 9 2363-00001 10 2331-00004 Description Req’d Base Subassembly Fill Hopper 1 Extension Weldment, Load Hopper 1 Slide Gate, Load Hopper 1 Adjustment Rod 1 Lid Plate, Fill Hopper Extension 1 Decal: “This Side Toward Dryer” 1 Screw, 1/4-20 x 1/2'' HWH type c 26 Nut, 3/8-16 HWH Whizlock zinc 4 Screw, 5/16-18 x 3/4'', HWH type c 8 TOP VIEW 4 3 9 END VIEW 2 6 9 Figure 39. Garner Bin and Extension Assembly 36 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Mechanical Installations 2 3 8. Check that the Auger turns freely by hand. Install the Load Auger Belts, making sure they are aligned. Tighten the Belts. Install the Belt Guard. See Figure 40. 9. The Lifting Rod Assembly can be removed, or can remain on the Dryer for future Garner Bin fold-down (for storage/ transport). 10. Once the Garner Bin has been erected, secure the Top Grain Level Switch “Can” to the Paddle Weldment as shown, using the Nuts and Bolts provided. See Figure 41. 11. Install the Drag Extension option (shipped loose). 5 4 Figure 40. Upper Belt Guard Installation Item Description 1 Top Grain Level Switch Can 2 Garner Bin 3 Upper Belt Guard Subassembly 5532-00001 4 Load Motor 5 Existing 5/16'' Screws 1 Figure 41. Top Grain Level Switch Assembly MFH1956E 37 Mechanical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Connect the Wet Grain Sampler Cable/Handle Item Description Grain 1 Wet Sample Tube 2 Cable 3 Handle 3 1 2 Detail Figure 42. Wet Grain Sample Tube, Cable and Handle (as shipped) 1 Figure 43. Upper Tube Installation 38 1 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Mechanical Installations Side Ladder 12 6 7 3 16 17 14 9 18 2 11 13 10 8 4 19 15 20 1 5 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 MFH1956E Figure 44. Ladder Parts Models: SQ8-20 A/E SQ24-40 A/E SQ8-20 DM SQ24-40 D/M 5621-00021 5621-00023 5621-00024 5621-00022 Part No. Description Qty. Qty. Qty. Qty. U-00008 Ladder Assembly, 8' [243.8 cm] 1 1 1 1 9-42654 Tube, 1 3/16'' Ø x 42 1/8'' [3 x 107 cm] 2 2 5621-00018 Top Ladder Bracket 1 5621-00019 Top Ladder Bracket 1 5621-00020 Bottom Ladder Bracket 2 2 5621-00036 Ladder Bracket LEFT 2 2 5621-00037 Ladder Bracket RIGHT 2 2 5644-00075 Safety Tread 16 x 18'' [40.6 x 45.7 cm] 1 1 U-23779 Locking Clip Assembly 6 6 6 6 U-24072 Tube, 1 3/16'' Ø x 49 1/4'' [3 x 125 cm] 2 2 U-24142 Extension Rail 2 2 2 2 U-24316 Extension Rail Brace Bracket 2 2 2 2 U-24016 Ladder Cap 2 2 2 2 U-24339 Spacer Tube 6 6 4 4 3136-00018 DANGER Decal, Ladder/Walkways 1 1 2331-00004 Screw, 5/16-18 x 3/4'' HWH “c” z 4 4 6 6 2318-00038 Screw, 5/16-18 x 1 1/4'' HHC Gr 5 2 2 2 2 2318-00047 Screw, 5/16-18 x 2 1/2'' LG HHC-z 6 6 4 4 2363-00006 Nut. 5/16'' HWH Serrated Flange 18 18 14 14 2364-00014 Washer, 5/16'' NOM x 1 1/2'' OD Flat 2 2 2 2 39 Mechanical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Side Ladder: SQD and SQM Models 13 13 13 20 19 17 Detail A 11 Detail A 11 Figure 45. SQD8 through SQD20 SQM8 through SQM20 See Item Table on facing Page. 19 2 2 6 16 9 16 12 2 14 15 16 11 7 2 7 1 19 18 14 19 16 19 Detail B 1 18 Detail B 6 7 7 SIDE VIEW 1 9 19 Detail C 40 16 19 Detail C MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Mechanical Installations Side Ladder: SQD and SQM Models 13 13 20 19 17 13 11 Detail A 2 12 11 19 11 2 9 Detail A 16 6 16 2 Item Part No. 1 2 6 7 9 11 12 13 14 15 16 17 18 19 20 Description Ladder Assembly, 8' [243.8 cm] U-00008 Be sure DANGER Decal 13-23790 is right-side-up. 9-42654 Tube, 1 3/16'' Ø x 42 1/8'' [3 x 107 cm] 5621-00036 Ladder Bracket LEFT 5621-00037 Ladder Bracket RIGHT U-23779 Locking Clip Assembly U-24142 Extension Rail U-24316 Extension Rail Brace Bracket U-24016 Ladder Cap U-24339 Spacer Tube 3136-00018 DANGER Decal, Ladder/Walkways 2331-00004 Screw, 5/16-18 x 3/4'' HWH “c” z 2318-00038 Screw, 5/16-18 x 1 1/4'' HHC Gr 5 2318-00047 Screw, 5/16-18 x 2 1/2'' LG HHC-z 2363-00006 Nut. 5/16'' HWH Serrated Flange 2364-00014 Washer, 5/16'' NOM x 1 1/2'' OD Flat Detail B Facing page 15 7 WARNING! Ladder installations MUST use all specified connecting Brackets to maintain SAFETY. Failure to follow specific Hardware instructions during assembly could result in serious operator injury and /or structural damage. 6 1 Detail C Facing page Figure 46. SQD24 through SQD40 SQM24 through SQM40 MFH1956E 7 41 Mechanical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Side Ladder: SQA and SQE Models 13 13 20 19 17 13 Detail A SIDE VIEW 11 11 19 9 10 11 10 3 8 12 Detail A Detail B 10 19 19 9 1 12 18 TOP VIEW 14 SIDE VIEW 9 11 1 9 19 1 Detail C 16 19 Figure 47. SQA8 through SQA20 SQAE through SQE20 See Item Table on facing Page. 5 5 Detail C 42 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Mechanical Installations Side Ladder: SQA and SQE Models WARNING! Item Part No. 1 Description Ladder Assembly, 8' [243.8 cm] U-00008 Be sure DANGER Decal 13-23790 is right-side-up. 3 4 5 8 9 10 11 12 13 14 16 17 18 19 20 5621-00018 Top Ladder Bracket 5621-00019 Top Ladder Bracket 5621-00020 Bottom Ladder Bracket 5644-00075 Safety Tread 16 x 18'' [40.6 x 45.7 cm] U-23779 Locking Clip Assembly U-24072 Tube, 1 3/16'' Ø x 49 1/4'' [3 x 125 cm] U-24142 Extension Rail U-24316 Extension Rail Brace Bracket U-24016 Ladder Cap U-24339 Spacer Tube 2331-00004 Screw, 5/16-18 x 3/4'' HWH “c” z 2318-00038 Screw, 5/16-18 x 1 1/4'' HHC Gr 5 2318-00047 Screw, 5/16-18 x 2 1/2'' LG HHC-z 2363-00006 Nut. 5/16'' HWH Serrated Flange 2364-00014 Washer, 5/16'' NOM x 1 1/2'' OD Flat 13 Ladder installations MUST use all specified connecting Brackets to maintain SAFETY. Failure to follow specific Hardware instructions during assembly could result in serious operator injury and /or structural damage. 14 19 18 1 11 14 19 18 13 Detail B Detail A 11 20 19 17 11 Detail A 19 9 10 4 8 10 12 Detail B 11 10 19 19 9 1 12 TOP VIEW 14 MFH1956E 9 19 18 11 1 Detail C Facing page Figure 48. SQA24 through SQA40 SQE24 through SQE40 5 16 19 43 Mechanical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Additional Items Shipped Loose: SQA Models: Hot Air Return Ducts Side Ducts are designed to simply “hang on” to galvanized Brackets located the length of the Dryer Basket. The end flanges on the Ducts are bent sightly outward to seal against each other without bolting. The Ducts may be bolted together if desired using the holes provided. TOP VIEW 1 3B 4 See additional details on Page 46. . 3A 7 2 8 Item Description 1 Upper Skin Duct Extension 2 5612-00048 RIGHT 5612-00047 LEFT size changes here, except on 36' 3A Duct [10 973] and 40' [12 192]. size changes here for SQ36 and 3B Duct SQ40 Removable Side Duct 4 5612-00077 (Small Duct) 5612-00078 (Large Duct) secured with 1/4''-20 5 3512-00570, Screws and Nuts 6 3512-00569 7 Bolt, 1/4''-20 x 3/4'' HWH Whiz 8 Handle 3512-0303 Nut, 1/4''-20 HWH Whiz Lock 10 2363-00002 11 Bolt, 1/4''-20 x 3/4'' HWH Whiz Nut, 6-32 HWH Whiz-Lock zinc 12 2363-00030 *SQ36 and SQ40 only; **all SQA models 44 END VIEW 6 5 Figure 49. Hot Air Return Ducts MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SIDE VIEW 1 5 3 2 Mechanical Installations Item Description 1 Upper Skin Duct Extension 2 5612-00048 (RIGHT side shown) 5612-00047 LEFT (not shown) Removable Side Duct 3 5612-0077 (Small Duct) 5612-00078 (Large Duct) 4 Panel Retainer 1/4''-20 x 1/2'' Self-Tappers 5 2331-00006 6 Side Seal 3512-00537 7 1/4''-20 HWH Nuts 2363-00002 8 Nut, 6-32 HWH Whiz-Lock zinc 2363-00030 9 Screw, 6-32 x 1/2'' LG HWH SelfTapping type F 2310-00033 10 Latch 2405-00024 4 Panel Retainers (Item 4) are to be removed and reinstalled, securing the bottom flange of the Duct Extensions (Item 2). TOP VIEW 1 2 3 3 5 7 Side Seals (Item 6) are installed with 1/4''-20 x 1/2'' Self-Tappers (Item 5) and 1/4'' HWH Nuts. 6 Figure 50. Panel Retainers and Side Seals MFH1956E 45 Mechanical Installations 20° 15° BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Internal Diagonal Straps and Braces, Hot Air Return Ducts OR 1 4 2 OR 5 13 7 1 OR 4 2 OR 5 7 9 10 8 8 11 12 2 5 1 OR 4 3 OR 6 8 10 9 30° SIDE VIEW 36° Note the Strap end with the larger angle is the HANDLE end toward the bottom/ Item Part No. 1 3512-00528 Smaller Duct 2 5612-00081 3 3512-00642 4 3512-00529 Larger Duct 5 5612-00082 6 3512-00643 7 3512-00303 8 2405-00024 9 2310-00033 10 2363-00030 11 2320-00001 12 2363-00002 13 Description Qty. Duct, Removable Side 1 SQ8AC-40ACG Strap 26 1/4 x 2'' 14 ga. 2 SQ8AC-40ACG Horizontal Brace 2 Duct, Removable Side 1 SQ36AC - 40ACG Strap 27 13/16 x 2'' 14 ga. 2 SQ36AC-40ACG Horizontal Brace 2 Handle, Access Panel 2 Latch Screw, 6-32 x 1/2'' Lg HWH 4 Self-Tapping type F Nut, 6-32 HWH Whiz Lock zinc 4 Bolt, 1/.4-20 x 3/4'' HWH Whiz 6 Nut, 1/4-20 HWH Whiz Lock 6 49'' [497 cm] 1 OR 4 2 OR 5 SIDE VIEW (SQ8AC-40ACG shown) 3 OR 6 Figure 51. Return Air Duct Internal Diagonal Strap and Horizontal Braces 46 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Mechanical Installations Unload Trough Floor Extension Panel (for Use on Dryers with Air Systems) When using an air system to move the grain away from a dryer equipped with a drag unloading system, some “pulsing” of the system can occur. To counter this on the SQ Dryer models and earlier SD dryers supplied with the drag unload option, a special panel has been developed. This panel, when placed in the discharge box, can split the grain flow being presented to the air system, evening out the fill process. IMPORTANT! The Unload Trough Floor Extension Panel (5644-00078) is included in items shipped loose in all SQ models. It is used ONLY on Dryers that are attached to an AIR SYSTEM. If your Dryer Discharge is readily accessible: 1.Remove one of the Discharge Side Panels completely. See Figure 52. 2.Loosen the eight (8) screws holding the opposite Side Panel. 3.Slide the Extension Panel through the side of the Discharge that is open, making sure the tab on the opposite end of the Extension goes between the third and fourth Screws down the side of the Side Panel still attached. The large corner notches must point away from the Dryer basket. 1 Item Part No. Description Drag 1 5644-00068 Discharge-SA Unload 2 Discharge Side Panel Extension3 5644-00078 Panel, Trough (Bottom) 1/4''-20 Self-Tapping 4 Screws (existing) 3 2 4 Figure 52. Extension Panel Position 4.Reinstall the Discharge Side Panel previously removed, leaving the bolts loose. Again, make sure the tab on the near end of the Extension goes between the third and fourth screws. 5.By moving the Extension Panel front to back, a variable gap is opened between 0'' to 1.5'' [0 - 3.8 cm]. Different grains may require different gap settings. Adjust the Extension position either through the Rear Access Cover, or use a screwdriver in the gap between the Discharge box flanges. 6.Once the Extension Panel is positioned, retighten all the screws. MFH1956E 47 Mechanical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation 1 2 3 4 Item 1 2 3 4 Part No. 5644-00068 5644-00078 Description Discharge-SA Drag Unload Discharge Side Panel Panel, Extension-Trough (Bottom) 1/4''-20 Self-Tapping Screws (existing) Figure 53. Extension Panel Position If your Dryer Discharge is NOT readily accessible: 1.Remove the screws down both sides of the Discharge box Side Panels. Loosen the eight screws used to secure the front and rear of the Side Panels. 2.Remove the Rear Access Cover. Rotate the Chain so that one Paddle assembly is at the nine o’clock position. Remove this Paddle assembly and the one just coming off the Trough Bottom Panel. You will need a minimum of 6'' [15.2 cm] clearance below the Side Panels to pivot the Extension into position. 3.Using flat-blade screwdrivers or similar tools, pry apart the Discharge box and the Side Panels so that there is a gap of at least 1/16'' [.6 mm]. 4.Place the Extension, tab end down, into the Discharge box. Pivot the Extension under the tail shaft and back into the trough area. 5.Rotate the Extension into position, making sure that the tabs on the ends of the Extension go between the third and fourth screws down the side of the Side Panels. The large corner notches must point away from the Dryer basket. 6.Reinstall the Discharge Side Panel screws previously removed, leaving the bolts loose. Again, make sure the tab on the near end of the Extension goes between the third and fourth screws. 7.By moving the Extension Panel front to back, a variable gap is opened between 0'' to 1.5'' [0 - 3.8 cm]. Different grains may require different gap settings. Adjust the Extension position either through the Rear Access cover, or use a screwdriver in the gap between the Discharge box flanges. 8.Once the Extension Panel is positioned, retighten all the screws. 48 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Mechanical Installations Dry Grain Sample Port This Port is shipped loose and is mounted under the opening below the Discharge. See Figure 54. VIEW FROM UNDER DISCHARGE Figure 54. Dry Grain Sample Port Location Free the Unload Trip Lever The Unload Trip Switch is shipped secured with a screw that must be removed before operation. IMPORTANT! Remove the Trip Lever Screw before operating the Dryer. 3 1 4 2 Item Description 1 Unload Discharge 2 Trip Lever 3 Sensor Paddle 4 Screw (remove) Figure 55. Unload Sensor and Trip Lever MFH1956E 49 Plumbing Train Connections BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Plumbing Train Connections Proper Fuel Line Connection is Critical DANGER! DEALERS and INSTALLERS DANGER! IMPORTANT! It is of utmost importance that care be taken by the Dealer and Installer to match the type of FUEL noted on the Fuel Warning Plate. Starting the Dryer one time on the wrong fuel can produce a firestream tens of feet in length, that can destroy many Dryer components and possibly the entire Dryer. Failure to follow specific instructions on Fuel WARNING Plates and tags could result in fire, explosion, equipment damage, death or personal injury. Installation and filling of liquefied propane (LP) gas storage and transfer systems must conform with National Fire Protection Association Standard: Storage and Handling of Liquefied Petroleum Gases, NFPA No. 58, (current edition in effect at the time of the installation). Installation and/or service must be done only by licensed gas contractors conforming to national and local applicable codes. Failure to follow these requirements will result in death, serious injury, or equipment damage. Connect the Plumbing lines only to fuel lines specified. A Fuel WARNING Plate (5537-00049 or 5537-00050) is located on or near the connection hose or pipe. See below. See also Figures 5 and 6. Review specific approved Fuels on Pages 55-59 and Pages 75-76. Figure 56. Fuel Warning Plate (LP Only) 5537-00050 Figure 57. Fuel Warning Plate (Nat Gas) 5537-00049 LP Dryers must have one SHUTOFF VALVE at each tank, and should have another valve within 5' - 25' [1 524 - 7 620] of the Dryer. All valves must be easily accessible. Natural-gas Dryers must have a MANUAL SHUTOFF VALVE installed in the supply line at least 25’ [7 620] from the Dryer and easily accessible. All Dryers must have a proper EXCESS FLOW valve —in the LP fuel line at the tank—sized according to fuel line size. Combo Dryers Combo Dryers are shipped with LP Orifices installed. Burner Orifices need to changed when switching fuel types. Natural Orifices are shipped loose with Combo Dryers. Before Initial Startup Check the complete plumbing system for leaks or tightness of fittings, especially at unions. Use a liquid soap solution with the plumbing train under normal operating pressure. Purge new plumbing lines before final assembly to blow oil, dirt, and thread chips out of the lines that could interfere with proper operation and damage plumbing components. 50 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Plumbing Train Connections Plumbing Train Components Emergency Hand Shutoff Valves IMPORTANT! All Hand Valves on liquid lines should be opened very slowly to allow the downstream line pressure to build up and equalize with the tank pressure. This eliminates “flashing” of the liquid to a vapor, which is accompanied by a large temperature drop in the partial-vapor, partial-liquid mixture. Emergency Hand Shutoff Valve / “Inlet Hand Valve”: located where the fuel line enters the Dryer on the lower bulkhead. See Figure 58. See also Figures 5 and 6. This quick-action, manual Shutoff Valve located near the Inlet connection on both LP and natural gas plumbing trains. This Valve is located upstream of the Strainer to facilitate Strainer cleaning without shutting off the tank and draining the line. The Inlet Valve(s) should be turned off any time the Dryer is not operating. The Hand Valve needs to be OFF and gas bled out of the Plumbing Train before removing the Strainer. Additional Hand Valves are located on the Upper Plumbing Train on top of the Dryer. See Figures 61 and 62. Pilot Hand Valve: The quick-action, manual Shutoff Valve in the pilot plumbing train, used for service on the pilot plumbing assembly. Burner Hand Valve: The quick-action, manual Shutoff Valve in the main Burner plumbing train, downstream of the Primary Regulator and other valves. It is used for test-firing and service work on the Burner assembly. Hydrostatic Relief Valves: Pressure safety-relief valves are pre-set to 300 psi [2 068.4 kPa]. These protect piping from “ram,” “liquid hammer,” or surge effects that occur when valves suddenly close, instantly stopping an incompressible liquid flow. Liquid propane “flashes” (from a complete liquid to a partial vapor state) after leaving the tank and passing through a restriction (such as Strainer and Inlet Hand Valve), so it is somewhat compressible. Item Description 1 Incoming gas line 2 Gas Hand Shutoff Valve 3 Fuel WARNING Plate 3 3 , 2 1 1 Figure 58. Gas Shutoff Hand Valve and Fuel Connection Plate MFH1956E 51 Plumbing Train Connections BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Upper Plumbing Train Gauges are located on the Upper Plumbing on top of the Dryer. See Figures 61-62. Inlet Pressure Gauge: This Gauge near the fuel inlet connection point (on either LP or natural gas) gives the supply line pressure at the inlet for service and operating reference. It is used to evaluate the fuel supply adequacy or possible line restrictions. Burner Pressure Gauge: The pressure on the Burner manifold pipe, downstream of all controls, which measures Burner gas pressure (LP or NAT). There is no “correct” setting for this. The pressure will vary until the proper air drying temperature is established. Figure 59. Plenum Static Air Pressure Line Modulating Motor and Butterfly Valve The Modulating Motor is a self-contained device with a transformer for stepping down 120V Control Voltage to 24V to power the motor. It is controlled by a set of contact closure signals from the I/O Panel (discussed in the Controller Installation Manual). The Modulating Motor develops 150 in-lb. of torque and rotates 160 degrees to open and close a butterfly Modulating Valve through a linkage system that prevents the Modulating Valve from rotating beyond the maximum of 90 degrees full open rotation. The Valve linkage has been factoryadjusted so that the valve is closed when the Motor is in its full counterclockwise position, which will be the case any time the burner is turned OFF. The Modulating Valve is a butterfly-type control valve, which is moved by linkage from the Modulating Motor. Should the Modulating Motor or Valve be replaced, the linkage should be set in accordance with Figure 60 at right. As a temporary measure, the Burner can be manually adjusted in the event of a defective Modulating Motor by removing the linkage arm and running the Modulating Valve by hand and manually setting fuel flow to the Burner. Figure 60. Modulating Motor and Butterfly Valve 52 MFH1956E 10 11 14 12 7 15 8 7 16 8 9 6 2 3 4 5 3 13 24 23 Part No. Item Description 2434-00004 11 Butterfly Valve, 1 1/4'' NPT Maxon 2790-00005 12 Heat Solenoid Valve, 1 1/4'' N 120v 0-48643 13 Pilot Shutoff Valve, 1/2'' Ball 2430-00061 14 Pilot Regulator, 1/2'' NPT-6''-14'' WC 15 Pilot Solenoid Valve, 3/8'' NPT-120V 2447-00001 16 Pilot Pressure Gauge, 0-30'' WC 1/4 NPT 2 1/2'' Regulator, 1'' 8-20 psi [55.12460-00030 17 First-Stage 137.9 kPa] .50 ori. 18 To Top Burner 2460-00027 19 Burner 20 To Bottom Burner 2434-00101 21 Pipe, orifice 1 x 4 x 3/4'' FPT Sch80 Blk 5630-00009 22 Gas from LP Tank 2541-00056 23 Top Transition Access Cover 2541-00161 24 Burner Ignition Transformer Box Part No. 2431-00037 2430-00007 2434-00004 2446-00029 2430-00062 2460-00025 2449-00032 5630-00009 Plumbing Train Connections 53 Item Description 1 Shutoff Valve, 1/2'' Ball 2 Strainer, 1/2 NPT Y 50 Mesh 3 Relief Valve, 1/4 NPT 300 psi [2 068.4 kPa] 4 Solenoid Valve, 3/4 120V LP Regulator, 1/2'' NPT-30-60 psi [206.85 Liquid 413.7 kPa] .25 ori. Pressure Gauge, 0-200 psi [0-1 378 kPa] 6 Inlet 1/4 NPT 2 1/2'' Line Pressure Gauge, 7 Burner 0-30 psi [0-206.8 kPa] 1/4 NPT 2 1/2'' Shutoff Valve, 1 1/4'' Ball 8 Burner (shuts off the entire Burner gas train) 9 Pipe, orifice 1 x 4 x 3/4'' FPT Sch80 Blk Motor 10 Modulating (Modulating Motor Transformer) BROCK® SUPERB® Low Profile Grain Dryers SQ Installation MFH1956E LEFT SIDE VIEW 7 Figure 61. Upper Plumbing Train, Top of Dryer (LP shown) Plumbing Train Connections BROCK® SUPERB® Low Profile Grain Dryers SQ Installation 25 14 16 7 12 13 24 FROM VAPORIZER 7 15 17 Figure 62. Upper Plumbing Train, Pilot Side, Top of Dryer (LP shown) Item Description Line Pressure Gauge, 0-30 psi [0-206.8 7 Burner kPa] 1/4 NPT 2 1/2'' 12 Heat Solenoid Valve, 1 1/4'' N 120v 13 Pilot Shutoff Valve, 1/2'' Ball 14 Pilot Regulator, 1/2'' NPT-6''-14'' WC 15 Pilot Solenoid Valve, 3/8'' NPT-120V Pressure Gauge, 0-30'' wc 1/4 16 Pilot NPT 2 1/2'' Regulator, 1'' 8-20 psi 17 First-Stage [55.1-137.9 kPa] .50 ori. 24 Burner Ignition Transformer Box 25 Vapor Relief Valve 54 Part No. 2460-00027 2430-00007 2434-00004 2446-00029 2430-00062 2460-00025 2449-00032 2433-00019 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Plumbing Train Connections Liquid Propane (LP) Fuel Supply Requirements (U.S.) LP gas fuel tanks of 2000 gallons (water volume) [7 571 L] capacity or less must be installed with the nearest point at least 25' [7.62 m] from the nearest point of the Dryer. LP tanks with a combined volume of 2001 - 30,000 gallons [7 575 - 11 362 L] capacity must be installed with the nearest point at least 50' [15.24 m] or more from the nearest point of the Dryer. This is mandatory per NFPA Bulletin No. 58, Storage and Handling Liquefied Petroleum Gases. IMPORTANT! LP piping must be Schedule 80 black iron pipe or stronger, connected to the supply line on LP-gas Dryers. Each LP gas supply tank must have an excess flow valve that has a rated flow less than the flow capacity of the piping from the tank to the Dryer. The piping and excess flow valve design must be installed inside each LP tank and must meet the requirements of NFPA No. 58, Paragraph 3135 (a) (3) current edition in effect at the time of installation. Suggested excess flow valve capacity ratings are 3 - 6 gallons [11.4 - 22.7 L] per minute. A manual gas shutoff valve must be installed as close to the LP tank as possible, must be at least 25' [7.62 m] away from the Dryer, and readily accessible. Each tank must have a separate shutoff valve. For manifolds connecting parallel tank installations, a main shutoff valve should be installed in the pipe just downstream of the manifold. MFH1956E IMPORTANT! DO NOT OPERATE the Dryer while the LP tank is being filled—wait for ten minutes after the truck filler hose has been removed. Refer to the Owner/Operator Manual MFH1932 for recommended tank capacity for desired hours of use. DANGER! DO NOT use tanks for liquid propane (LP) that have been used for ANHYDROUS ammonia! This includes previously purged tanks that have been used for anhydrous. Dryer gas train components may be damaged, causing a Dryer malfunction which could lead to serious safety hazards and/or fire. Installing any tank (for an LP fuel supply to the Dryer) which has previously been used for anhydrous ammonia poses a safety threat. Brock Grain Systems will not be held liable for any purging and cleaning methods used for such tanks. If such a tank is used, this will void the Dryer Warranty. 55 Plumbing Train Connections BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Upper Plumbing Train for LP (Top of Dryer) Hydrostatic Relief Valves (Item 3): Pressure safety-relief valves are pre-set to 300 psi [2 068.4 kPa]. These protect piping from “ram,” “liquid hammer,” or surge effects that occur when valves suddenly close, instantly stopping an incompressible liquid flow. Liquid propane “flashes” (from a complete liquid to a partialvapor state) after leaving the tank and passing through a restriction (such as the Strainer and Inlet Hand Valve), so it is somewhat compressible. Modulating Motor (Item 10) is located on the plumbing train and is an electric motor powered from a 120V - 24v transformer. The Motor receives an OPEN or CLOSE command from the Temperature Control. With this signal the Modulating Motor drives the Modulating Valve (more opened or closed) to maintain desired drying air temperature. The Butterfly Valve (Item 11) rotates approximately 90 degrees from full-closed to full-open, to vary the inches of water-column pressure to the Burner. The Modulating Motor and Valve are connected with adjustable linkage. 7 3 4 8 26 6 7 2 8 5 3 LP INLET VA TO Main Solenoid Valve (Item 4): opened and closed by an electrical-powered solenoid and capable of handling liquid propane. A larger valve is used near the inlet on U.S.model natural gas Dryers and on Canadian Dryers. ER R IZ PO 10 28* 9 12 Heat Solenoid Valve (Item 12): controls gas flow to the main Burner manifold on LP and natural gas Dryers. This valve is opened and closed by an electrically actuated solenoid as an automatically controlled safety device in the plumbing train. 7 FROM VAPORIZER 11 16 18 25 13 15 14 17 19 27 1 20 22 Item Description 1 2 3 4 Shutoff Valve, 1/2'' Ball Strainer, 1/2 NPT Y 50 Mesh Relief Valve, 1/4 NPT 300 psi [2 068.4 kPa] Solenoid Valve, 3/4 120V LP Regulator, 1/2'' NPT 30-60 psi [206.85 Liquid 413.7 kPa] .25 ori. Inlet Pressure Gauge, 0-200 psi [0-1379 kPa] 6 1/4 NPT 2 1/2'' Line Pressure Gauge, 7 Burner 0-30 psi [0-206.8 kPa] 1/4 NPT 2 1/2'' Shutoff Valve, 1 1/4'' Ball 8 Burner (shuts off the entire Burner gas train) 9 Pipe, orifice 1 x 4 x 3/4'' FPT Sch80 Blk Motor 10 Modulating (Modulating Motor Transformer) 11 Butterfly Valve, 1 1/4'' NPT Maxon 56 9 28* Figure 63. Typical LP Gas Upper and Lower Plumbing Train Part No. Item Description 2434-00004 12 Heat Solenoid Valve, 1 1/4'' N 120v 2790-00005 13 Pilot Shutoff Valve, 1/2'' Ball 0-48643 14 Pilot Regulator, 1/2'' NPT-6''-14'' WC 2430-00061 15 Pilot Solenoid Valve, 3/8'' NPT-120V 2447-00001 2460-00030 2460-00027 2434-00101 5630-00009 2541-00056 2541-00161 2431-00037 Part No. 2430-00007 2434-00004 2446-00029 2430-00062 Pressure Gauge, 0-30'' WC 1/4 NPT 2460-00025 16 Pilot 2 1/2'' 17 First-Stage Regulator, 1'' 8-20 psi [55.1- 2449-00032 137.9 kPa] .50 ori. 18 19 20 22 25 26 27 *28 To Top Burner Burner To Bottom Burner Gas from LP Tank Vapor Relief Valve Plumbing Assembly, UPPER Vapor Plumbing Assembly, LOWER Vapor Metering Orifice (see charts pp. 75-76) 2433-00019 0-48776-xxx MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Plumbing Train Connections Natural Gas Supply Requirements (U.S.) DANGER! IMPORTANT! Installation of natural gas transfer systems must conform with National Fire Protection Association Standard: Natural Fuel Gas Code, NFPA No. 54, (or current edition in effect at the time of the installation). Installation and/or service must be done only by licensed gas contractors conforming to national and local applicable codes. Failure to follow these requirements will result in death, serious injury, or equipment damage. Natural Gas piping must be Schedule 40 black iron pipe or stronger, connected to the fitting on natural gas Dryers. For proper operation, at least 8 psi [55.2 kPa] must be supplied. Use maximum line size when natural gas pressure is 8-10 psi [55.2 - 68.9 kPa]. Table values apply on natural gas downstream of the gas company meter and Regulator only. Contact the gas company for greater equivalent lengths than shown in the Chart. If available natural gas pressure is higher than 20 psi [137.9 kPa], a primary Regulator must be provided to reduce the Dryer inlet pressure to 10-20 psi [68.9 - 137.9 kPa]. Upper Plumbing Train for Natural Gas (Top of Dryer) 9 12 9 11 10 12 Main Solenoid Valve (Item 4): opened and closed by an electricalpowered solenoid, used near the inlet on natural gas Dryers. 4 13 17* 4 7 8 9 14 5 6 15 16 13 17* Figure 64. Typical Natural Gas Upper and Lower Plumbing Train Item Description Part No. 1 Incoming Natural Gas 2 Shutoff Valve, 1 1/2'' Ball 2434-00121 3 Strainer, 1 1/2 NPT Y 20 Mesh 2790-00002 4 Heat Solenoid Valve, 1 1/4'' NPT 120V 2430-00007 Pilot Regulator, 1/2'' NPT 5 6''-14'' WC-.188 ori. 2447-00029 6 Pilot Solenoid Valve, 3/8'' NPT 120V 2430-00062 Pressure Gauge, 0-30'' WC 7 Pilot 2460-00025 1/4 NPT 2 1/2'' 8 Pilot Shutoff Valve, 1/2'' Ball 2434-00004 Burner Line Pressure Gauge, 0-30 psi 9 [0 - 206.8 kPa] 1/4 NPT 2 1/2'' 2460-00027 Motor 2541-00056 10 Modulating 2541-00161 (Modulating Motor Transformer) 11 Butterfly Valve, 1 1/4'' NPT Maxon 2431-00037 12 Burner Shutoff Valve, 1 1/4'' Ball 2434-00101 Pipe, orifice 1 x 4 x 3/4'' FPT Sch80 13 Blk 5630-00009 14 To Top Burner 15 Burner 16 To Bottom Burner *17 Metering Orifice (see charts pp.75-76) 0-48776-xxx 3 2 1* MFH1956E 57 Plumbing Train Connections BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Canadian Plumbing Requirements Upper Plumbing Train for LP (Top of Dryer) 18 17 8 16 8 22 23 15 10* 11 8 20 21 9 9 19 3 7 25 24 12 3 3 6 5 Item Description Part No. 2 Valve, 3/4'' Quick-Release Hex-Body 2436-00004 2433-00017 3 Valve, Hyd. Relief 1/2'' NPT 2433-00018 300 psi [2 068.4 kPa] w/Adapter 4 Strainer, 1/2 NPT Y 50 Mesh 2790-00005 5 Solenoid Valve, 3/4 120V LP 2430-00061 Regulator, Liquid 1/2'' NPT 30-60 psi 6 [206.8-413.7 kPa] .25 orf. Factory- 2447-00001 set to 45 psi [310.3 kPa] Gauge, 0-200 psi [0-1 379 kPa] 7 1/4 NPT 2 1/2'' 2460-00030 Line Pressure Gauge, 8 Burner 0-30 psi [0-206.8 kPa] 1/4 NPT 2 1/2'' 2460-00027 Item Description Part No. 9 Burner Shutoff Valve, 1 1/4'' Ball 2434-00101 *10 Metering Orifice (see charts pp.75-76) 0-48776-xxx 11 Pipe, orifice 1 x 4 x 3/4'' FPT Sch80 Blk 5630-00009 12 To Upper Burner 13 Burner 14 To Lower Burner 15 Butterfly Valve 1 1/4'' NPT Maxon 2431-00037 Modulating Motor 2541-00056 16 (Modulating Motor Transformer) 2541-00161 17 Switch, 2-60 psi [13.8-413.7 kPa] Hi-Gas Pressure (manual reset) 2429-00016 18 Heat Solenoid Valve, 1 1/4'' NPT 120V 2430-00007 19 Low Gas Pressure Switch 2429-00021 20 Pilot Shutoff Valve 1/2'' Ball 2434-00004 21 Pilot Regulator, 1/2'' NPT 6-14'' WC .188 ori 2446-00029 22 Pilot Solenoid Valve, 3/8'' NPT 120v 2430-00062 23 Pilot, Pressure Gauge 0-30'' WC - 1/4'' NPT 2 1/2'' 2460-00025 Regulator, 1'' Vapor 8-20 psi [55.2-137.9 kPa] 50 orf. Factory- 2449-00032 24 set to 15 psi [103.4 kPa] 25 Valve, Safety Relief 1'' Factory-set to 25 psi [172.4 kPa] 2433-00019 *3/4'' internal orifice pipe thread this end MFH1956E 14 10* 11 2 4 Figure 65. Typical LP Gas (Canadian) 58 13 BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Plumbing Train Connections Description Part No. Incoming Natural Gas Valve, Inlet Shutoff, Ball 1 1/2'' 2434-00121 Strainer, 1 1/2'' NPT Y 20 Mesh 2790-00002 Low Gas Pressure Switch 2429-00021 Burner Solenoid Valve, 1 1/4'' NPT 120V 2430-00007 Pilot Shutoff Valve, 1/2'' Ball 2434-00004 Gauge, Burner 0-30 psi [0 - 206.8 kPa], 2460-00027 1/4 NPT 2 1/2'' Pilot Regulator 1/2'' 6-14'' WC .188 2446-00029 Pilot Solenoid Valve, 3/8'' NPT 120V 2430-00062 Gauge, Pilot Pressure 0-30'' WC 1/4'' NPT 2 1/2'' 2460-00025 Switch, 2-60 psi [13.8 - 413.7 kPa] 2429-00016 Hi-Gas Pressure (manual reset) Modulating Motor 2541-00056 (Modulating Motor Transformer) 2541-00161 Butterfly Valve 1 1/4'' NPT Maxon 2431-00037 Canadian Plumbing Requirements (continued) Upper Plumbing Train for Natural Gas (Top of Dryer) 4 7 5 11 5 12 8 9 7 14 6 MFH1956E 21 17 High-Fuel Pressure Switch (Item 11): A manual-reset Switch (located in the vapor section) which contains a normally-closed switch. Figure 66. Typical Natural Gas (Canadian) 20 16 15* 1 7 Low-Fuel Pressure Switch (Item 4): An automatic-reset fuel pressure Switch (located in the vapor section) which senses the presence of adequate fuel pressure and automatically closes a SPDT Switch for control action in the Burner circuit. If inadequate pressure exists, this Switch opens and prevents further operation of the Burner. 10 13 14 2 3 18 19 15* 16 Item 14 *15 16 17 18 19 Description Burner Shutoff Valve, 1 1/4'' Ball Metering Orifice (see charts pp.75-76) Pipe, orifice 1 x 4 x 3/4'' FPT Sch80 Blk To Top Burner Burner To Bottom Burner Regulator, 1'' Vapor 8-20 psi [55.1-137.9 kPa] .50 orf. to 15 psi [103.4 kPa] **20 Factory-set SQ08 - SQ16 Models SQ20 - SQ40 Models **21 Valve, Safety Relief 1'' Factory-set to 25 psi [172.4 kPa] *3/4'' internal orifice pipe thread this end **shipped loose for field installation Part No. 2434-00101 0-48776-xxx 5630-00009 2449-00032 2433-00019 59 Electrical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Electrical Installations IMPORTANT! IMPORTANT! DANGER! Electricity can KILL! Use extreme CAUTION around electrical components of this Dryer. Installations MUST be done by a certified/ licensed electrician, in accordance with all national, state and local electrical SAFETY codes listed at right. Failure to follow these instructions will result in death or serious injury. DANGER! Locate Your ELECTRICAL SCHEMATIC DIAGRAMS: They represent the control wiring circuit, also known as a ladder-type diagram. The Schematic clearly shows how the various controls are interlocked and allows a qualified electrician to quickly troubleshoot electrical problems or malfunctions. These are found at the end of this Manual, the Owner/Operator Manual MFH1932, and Controller Installation Manuals MFH1977 and MFH1978. Dryer installations and all components SHALL MEET the National Fire Protection Association Standard 61B (for the prevention of fires and explosions in grain elevators and facilities handling bulk raw agricultural commodities) and Standard 70, as well as the National Electric Safety Code, American National Standard Inst. ANSI-C1, and all other applicable state and local requirements. Brock Grain Systems neither assumes responsibility for the electrical wiring used with this Dryer, nor will be liable for damage to the Dryer because of improper electrical installation or use. Improper installation or use will void the Warranty. Your SUPERB® Dryer is completely factory pre-wired. Locate the Wiring Diagrams in your project packet. After proper installation, keep them in a handy place for future reference in case of the need for service. On both single-phase and three-phase models, power wires connect to the lugs at the top of the Dryer Disconnect Circuit Breaker. Dryers are normally wired for 230-volt single-phase or 230 / 460-volt three-phase power. However, 208V, 380V, 415V, or 575V three-phase models are also available. SAFETY requirements Contact your power provider before installation. They can determine if any adjustments in their lines will be necessary to accommodate the increase in load the Dryer will make on the current wiring. Adequate electrical service must be supplied. The main power transformer must be sized to handle maximum Dryerconnected horsepower (see Electrical Specifications Table, Page 74), plus all other auxiliary conveyor and grain center Motors that operate simultaneously. Low voltage may cause Motor and Control damage, voiding the Manufacturer’s Warranty. Do not jeopardize your SAFETY or your BROCK® Dryer Warranty with improper electrical installation. Your Installer should have your electric company check the transformer and lead wires. Be sure the wires are of an adequate gauge to carry the load of your Dryer Motors, including starting and full load operating conditions. Failure to follow these instructions will result in death or serious injury. IMPORTANT! It is the RESPONSIBILITY of the Contractor, Installer, Owner and Operator to supplement the Dryer furnished by Brock Grain Systems with any necessary ELECTRICAL or STRUCTURAL items to make the Dryer installation comply with the above codes. IMPORTANT! Review and always follow the “Electrical Connection/Disconnection Procedures for Dryer Testing” (Page 72), and the “Manufacturer’s Recommended Minimum Lockout/Tagout Energy Control Procedures” (Pages 77-78) in this Manual. Lockout SAFETY Switches IMPORTANT! A LOCKOUT device/lockable disconnect switch must be installed on Dryer Control enclosures containing hazardous voltage wiring. IMPORTANT! To prevent a hazardous condition, all SAFETY devices, including wiring of electrical devices shall be arranged to operate in a “FAIL-SAFE” manner. That is, if a power failure or failure of the device occurs, a HAZARDOUS CONDITION will not result. To prevent a hazardous condition, the machine and all associated equipment MUST be PREVENTED FROM RESTARTING on its own after a power failure when power returns or a jam is cleared. A MANUAL re-start is required. Do not install or use any method to start or restart the Dryer which bypasses factoryinstalled SAFETY features. IMPORTANT! 60 To guard against electrical shock, all Dryers shall have a GROUND connection. MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation IMPORTANT! Electrical Installations Review and always follow the “Electrical Connection/Disconnection Procedures for Dryer Testing” (Page 72), and the “Manufacturer’s Recommended Minimum Lockout/Tagout Energy Control Procedures” (Pages 77-78) in this Manual. The AC Drive Box IMPORTANT! DANGER! Electricity can KILL! Use extreme CAUTION around electrical components of this Dryer. Installations MUST be done by a certified/ licensed electrician, in accordance with all national, state and local electrical SAFETY codes listed at right. Failure to follow these instructions will result in death or serious injury. The AC Drive Box must be grounded. Locate and read your literature provided by the Vendor/Manufacturer of the AC Drive. An AC Drive must be grounded and can be extremely dangerous if all safety precautions are not observed. It is very important with an AC Drive to WAIT for capacitors to discharge stored electrical energy BEFORE any service is begun on the Drive. If a capacitor explodes, there will be a shotgun-like blast. The danger of a capacitor explosion is similar to that of an arc flash. WAIT at least fifteen (15) minutes for the energy to dissipate from the capacitors. VERIFY THAT NO VOLTAGE IS PRESENT before proceeding. Failure to observe this instruction will result in death or serious injury. A solid copper ground wire is shipped coiled from the bottom of the Control Panel Box. A copper Equipment Ground Rod 5/8'' dia. x 10' [3 048] is shipped loose. Weatherproof all outdoor outlets and fittings that are exposed to wind, rain and snow. Avoid using electrical equipment outdoors in wet conditions. Use a ground fault circuit interrupter (GFCI) wherever water and electricity may come into contact with each other. When a GFCI senses current leakage in an electrical circuit, it assumes a ground fault has occurred and interrupts the power, helping to prevent serious injury from electrical shock. Dryer/Equipment Disconnect Box The Dryer Disconnect is on the front of Dryers with centrifugal Fans. • The Dryer Disconnect and the Dryer unit should be grounded. See the Electrical Specifications Chart on Page 74 for Dryer amperage to properly size components. See additional SAFETY Decal information on Page 18. • After connecting power and turning on the Dryer Disconnect, the “POWER ON” light should be on, if that option is present. Figure 67. Circuit Breaker in Dryer Disconnect MFH1956E 61 Electrical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Control Box CAUTION! IMPORTANT! Service and program the computer component properly. Failure to properly service this computer component according to its specific Manual could damage the equipment and void the Warranty. The Dryer must be completely installed with auxiliary equipment ready to run BEFORE either Controller system can be tested or will work properly. With the exception of a CONVERSION to the BROCK® QUANTUM® Controller specifically designed for use with the BROCK® SUPERB® Dryer, installing a non-BROCK® (another manufacturer’s) Controller or any other type Controller on a BROCK® SUPERB® Dryer WILL VOID THE WARRANTY on the BROCK® SUPERB® Dryer. Locate the Controller Supplemental Manual—either MFH1977 (SPECTRUM®) or MFH1978 (QUANTUM®). 11'' x 17'' [279 x 432] wiring schematic drawings for the Controller are in the back of that Manual. You will need Part No. 3724-00058 as shown in Figure 69 below: Figure 68. Control Box Figure 69. 11'' x 17'' [279 x 432] Schematic 3724-00058 (SPECTRUM® and QUANTUM® Wiring) SPECTRUM® Electronic Based Temperature Controller (Standard) Figure 70. SPECTRUM® Controller and Owner/ Operator Manual MFH1977 62 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Electrical Installations QUANTUM® Controller (Optional) Figure 71. QUANTUM® Controller and Owner/ Operator Manual MFH1978 If you are wiring a Dryer with a QUANTUM® Controller you will need schematic 3724-00085, Control wiring for the Control Box Inner Door. This is an 11'' x 17'' [279 x 432] diagram located in the back of the QUANTUM® Manual, MFH1978. Figure 72. 11'' x 17'' [279 x 432] Schematic 3724-00085 (QUANTUM® Control Box Inner Door Wiring) MFH1956E 63 Electrical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Auxiliary Conveyor Connection Wet Conveyor capacity required for ''catch up'' capacity on powered Garner Bins; Dryeration capacity is approximately 30-40% higher than standard; Dry Conveyor capacity is based on emergency unload requirement plus conveyor manufacturer over-ratings. WARNING! IMPORTANT! This Grain Dryer can operate auxiliary load and unload conveying equipment automatically. Any auxiliary equipment wired into the Dryer’s control circuit can be started automatically by the Dryer at any time. Stand clear of all auxiliary equipment drives, moving parts and discharges any time the Dryer is in operation. Disconnect all power to the Dryer and auxiliary equipment before servicing. Failure to observe these safety precautions can result in death or serious injury. Read “Auxiliary Starter Control Connection.” Review and follow the “Electrical Connection/Disconnection Procedures for Dryer Testing” below, OSHA Lockout/Tagout regulation 1910.33(b)(2) through 1910.333(c)(2), and the “Manufacturer’s Recommended Minimum Lockout/Tagout Energy Control Procedures” (Pages 77-78) in this Manual. 1. Read “Auxiliary Starter Control Connection” in the following section before wiring auxiliary Load and Unload Conveyors (Augers). You will need wiring drawing Part No. 3724-00052 (as shown in Figure 73) for the AC Drive. It is located in the back of this Manual and the Controller Manual: Figure 73. 11'' x 17'' [279 x 432] Schematic 3724-00052 (AC Drive Wiring) 2. If the Dryer is equipped with a factory-installed auxiliary Starter Unit, check for proper Motor voltage and horsepower ratings. Connect the Auxiliary Motor wires directly to the connect overload relay block below the contactor. In all cases, a separate auxiliary Starter Disconnect will be factory-mounted beside the Main Dryer Disconnect, and will tap into the service feeder wires powering the main Disconnect. If magnetic starters for Auxiliary Conveyors are supplied by the customer, the power wiring to the starters must be supplied from outside the Dryer to an auxiliary disconnect circuit breaker. 3. Terminal sets 66-67 and 68-69 can provide only switching action, not power, for auxiliary load and Unload Motor starter coils, respectively. (U.S. only) 115-volt control power (Auxiliary Starter Control Connection, Method I, see Pages 6566) may be supplied from an external source or from the terminal strip to the terminal contacts; the voltage depends on the individual starter coil rating. If an external power source is used, install a tag or decal on the Control Panel stating that “This Panel has more than one source of power.” 5. Auxiliary conveyors must be installed so that they are not supported by the Dryer. 6. Install the Load Hopper so that the Slide Adjustment Bolt is on the side of the hopper away from the Dryer. 7. Auxiliary conveyor capacity for loading and unloading should be sized to meet maximum Dryer handling requirements if feasible. For pneumatic conveyors, the recommended rated capacity is closer to the Dryer rated capacity to keep system costs reduced. 64 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Electrical Installations 8.When gravity bins are used, adjust the grain hopper Slide to regulate flow and eliminate Motor overload. Grain flow should be set so that the Load Motor amperage goes no higher than full-load amperage. The highest Motor load occurs at the end of the cycle. Auxiliary Starter Control Connection DANGER! Since this Dryer can operate auxiliary Load and Unload conveying equipment automatically, it is IMPERATIVE that the Owner/Operator warn all operators, service personnel, employees and family members about the hazards involved when working near automatic equipment. Failure to do so could cause death or severe injury. Factory-Installed Auxiliary Starter Units: Dryers ordered with the optional auxiliary starter unit have been wired at the factory. Verify that Motor sizes to be used match the sizes labeled on the starters within the auxiliary starter enclosure. You will need wiring drawing Part No. 3724-00016A for Auxiliary Motor Starter wiring information. See Figure 74. IMPORTANT! Different circuit breakers, contractors, and/or overload relays may be needed if sizes do not match. Connect the auxiliary Motor power wires directly to the correct overload relay block below the Starter. Start the Motors and check for correct rotation. Single-phase Motors must be rewired at the Motor junction box to change rotation. Three-phase Motors can be reversed by exchanging any two (2) of the three (3) Motor power wires. Field-Installed Auxiliary Conveyor Starters Consult a SUPERB® serviceman or a qualified electrician in selecting the correct Motor Starter for auxiliary conveyors. For automatic sequencing with the Dryer, auxiliary conveyor starters supplied by the customer should be wired according to Schematic 3724-00016A in the back of this Manual and the SQ Dryer Owner/Operator Manual MFH1932. Figure 74. 115V Auxiliary Starter Coils, Single- and Three-Phase Schematic 3724-00016A 1. Typical example of 115V auxiliary starter control circuit with overload relay interlock for one auxiliary load motor (M3) and two auxiliary Unload Motors (M1 and M2). Load Auger Motor starter auxiliary contact wire terminals 66 and 67, and unload auger motor starter auxiliary contact wire terminals 68 and 69, provide switching action, not power, for the auxiliary motor starter coils. 115V coil power may be supplied from an external source or from the Dryer terminal strip to terminal contacts. IMPORTANT! MFH1956E A tag or decal should be placed on the Control Panel stating that “This Panel has more than one source of power.” 65 Electrical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation BASO Flame Sensor Switch and Thermocouple The BASO thermocouple sensor is mounted in an adjustable sleeve at the end of the Burner pilot baffle plate with its tip extending into the pilot flame. The other end of the thermocouple is connected to the BASO Switch inside the Burner Ignition Transformer Box. In operation, the thermocouple is heated and sends a millivolt (mv) signal to the BASO Switch which activates an internal relay. To see the thermocouple signal strength, a millivolt meter is supplied with one lead grounded to the BASO SW and the other lead connected to a terminal inside the BASO Switch just opposite the thermocouple attachment point (the thermocouple must be connected to the BASO Switch). An unheated thermocouple will have an output signal of 0mv. As the thermocouple is heated, the BASO Switch relay should activate at approximately 9mv and drop out at 2-3mv. (The meter needle should “jump” when the internal relay switches.) The desired output range is 18-21mv. A lower signal causes marginal operation; a higher signal reduces the life of the thermocouple. The thermocouple can be observed through the Plenum Access Door at the rear of the Dryer. In the desired range of 18-21mv, the tip of the thermocouple should have a dull red glow. If no color is visible, the mv signal is usually low (below 18mv). If a bright red color is observed, the mv signal is usually high (23-27mv). If the thermocouple signal needs to be adjusted, use the millivolt meter. If the meter signal is low (such as 1-13mv) or no color change is observed, follow these steps to increase the signal: (1) Check the BASO thermocouple for a loose connection at the BASO Switch junction, (2) Move the thermocouple tip in the burner pilot baffle sleeve farther into the flame and tighten the lock collar set screw, or (3) adjust the pilot regulator to heat the thermocouple more (if increasing the gas pressure doesn’t increase signal, try decreasing the pressure). For a high signal or a “bright or cherry red” tip: (1) Reduce the amount of thermocouple exposure or (2) Adjust the pilot flame length with the pilot regulator to change the color to a “dull red” and/or the signal to 18-21 millivolts. If the millivolt reading (and color) are close to the “ideal” range of 18-21 millivolts, turn on the main burner and observe the thermocouple conditions. The full burner flame compresses the pilot flame and sometimes changes the thermocouple signal to a desirable level. If no signal or a low signal is observed under all adjustment conditions, the thermocouple is probably weak and should be replaced. 66 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Electrical Installations Flame Relay Flame Sensor Switch is also called the BASO, located in the Burner Ignition Transformer Box next to the Burner Access Door on the top of the Dryer. A BASO flame switch with a BASO thermocouple serves as the pilot flame sensor. The BASO Switch normally closes within 10-20 seconds after the pilot flame is established, energizing the Flame Relay. If the pilot flame goes out or weakens (to the point the thermocouple signal is inadequate), the BASO will open, instantly de-energizing the Flame Relay. Control wiring for the SPECTRUM®/QUANTUM® Flame Relay is found on 11'' x 17'' [279 x 432] Schematic diagram 3724-00081, located in the back of the QUANTUM® Controller Manual Supplement, MFH1978; the SPECTRUM® Controller Manual Supplement, MFH1977; and the SQ Owner/Operator Manual MFH1932. Figure 75. 11'' x 17'' [297 x 432] Schematic 3724-00081 (SPECTRUM®/QUANTUM® Flame Relay) 3 2 Item Description 1 Burner Ignition Transformer Box 2 BASO Switch 3 Ignition Transformer 1 Figure 76. BASO Flame Sensor Switch MFH1956E 67 Electrical Installations BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Check Fan Rotation For details on reversing singlephase Motors, see the Wiring Diagram inside the Motor terminal box cover. To reverse a three-phase motor, switch any two of the three power leads. If all Motors have the wrong rotation, exchange the two (2) outer leads (L1 and L3) in the Dryer Disconnect Switch. Figure 77. Proper Fan Rotation (arrow direction) Check Motor Rotation IMPORTANT! Pay attention to ROTATION Decals (1315-00038) on the Dryer housing. Do not reverse Motor directions until all Motors are checked. Check rotation of Motors before loading the Dryer and starting the drying operation. • Turn the Main Disconnect ON. • Check the Load Auger for clockwise rotation (looking at the Auger sheave) and for correct rotation of auxiliary loading conveyors (load Auger sheave should turn counterclockwise if the Dryer loads on the Fan end). If two or three Motors have wrong rotations, switch two power leads in the Dryer Disconnect. If only the Fan Motor is reversed, switch two of the leads at the Fan Motor Starter in the Control Panel. Figure 78. Proper Fan Rotation, Unload Drive Motor, front of Dryer (note arrow Decal direction) 68 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Electrical Installations This page left blank for your convenience. MFH1956E 69 SAFETY System Checkout BROCK® SUPERB® Low Profile Grain Dryers SQ Installation \ SAFETY System Checkout Your SUPERB® Dryer has many SAFETY controls interlocked to stop the Dryer if a hazardous condition develops. The following controls stop all Dryer functions immediately and necessitate a manual restart of the Dryer. Your Dryer installation (including Plumbing Train Connections on Pages 50 - 59) should not be considered complete until a SAFETY Systems checkout is run to see that all SAFETY systems are in working order. This should be done before initial startup. It should also be done at the beginning of each season and any components replaced if necessary. Red Power Light (optional) Turn the Dryer Disconnect Circuit Breaker ON. Observe the red light on the front of the Control Cabinet. Fuel Line Shutoff Valves (optional) 1. Individually test for complete closure of each shutoff Valve between the Dryer and LP gas tank or natural gas meter. 2. Start the Fan and Burner. 3. Close each Valve separately and observe if the fuel supply is definitely cut off to the Dryer by each Valve. Vent Pipe Outlets 1. Inspect all Hydrostatic Relief Valves (LP gas Dryers). 2. Make sure outlets are unobstructed, covered with the rubber rain cap, and pointed in a direction away from the Dryer (or any other Dryer, Fan Motor, work platform, office, etc.). (continued) Interlocked SAFETY Controls (need MANUAL RESET before Restarting the Dryer) Control Auxiliary Conveyors Motor Overload Relays (Control Box) Functions And Features Protects against excessive Motor amperages due to Motor failures or overloading Protects the Dryer against temporary power loss; Master Relay (Control Box) Shuts down all Dryer functions Protects against excessive fuel pressures downstream of the priHigh Fuel Pressure Switch (Canadian only) mary Regulator *if the Motor starters and relays have been factory pre-wired per instructions in Auxiliary Starter Control Connection (p. 49) Additional SAFETY Controls Control Modulating Valve (on Plumbing) Hydrostatic Relief Valves (located in the liquid line, LP Dryers) Low Fuel Pressure Switch (Canadian only) Functions And Features Automatically maintains drying air temperature at a preselected level Allows fuel to be vented away from the Dryer if pressure in the highpressure liquid plumbing exceeds 300 psi [2 068.4 kPa] Shuts off the Burner if an insufficient fuel supply is detected 2 The single line on the opposite side is the (Upper Plenum) Static Pressure Tube. Item Description 1 Plenum RTD 2 Hi-Limit Sensor 1 Figure 79. Upper Plenum RTD and Hi-Limit Sensor 70 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SAFETY System Checkout SAFETY System Checkout (continued) Figure 80. Lower Plenum RTD and Hi-Limit Sensor Figure 81. Exhaust Air Temperature Thermostat (front Bulkhead, looking UP) Major Alarm A Major Alarm consists of any of the following situations which cause the Master Relay to open immediately and stop all Dryer functions: • Opening of the High-Limit Thermostat due to excessive drying air temperature; • Opening of an overload relay contact protecting any Motors, due to an overload or low voltage condition, causing a higher-than-allowable current or amperage flow through the relay contacts. • Opening of an overload (if the overload is wired into the system) protecting an auxiliary conveyor motor, due to an overload or low-voltage condition, causing a higher-than-allowable current or amperage flow through the relay contacts; • Opening the Rear Plenum Door while the Dryer is operating, causing the Door Safety Switch to shut down the Dryer immediately; • Exhaust air (being monitored for temperature) exceeds 210° F [98.89°C], thereby causing the Exhaust Air High Temperature Switch to shut down the Dryer so the cause of the excessive heat can be determined; • A momentary power failure. Stoppage at Unload IMPORTANT! Remove the Trip Lever Screw before operating the Dryer. If the Unload Discharge has a heavy enough grain load to clog and trip the Sensor Paddle (see Figure 78) the Trip Lever on the exterior of the Cover will activate and shut down the Dryer unload system. The Unload Trip Lever is shipped secured with a screw that must be removed before operation. Item Description 1 Unload Discharge 2 Trip Lever 3 Sensor Paddle 4 Screw (remove) 3 1 4 2 Figure 82. Unload Sensor and Trip Lever MFH1956E 71 Pre-Startup Electrical Testing and Inspection BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Pre-Startup Electrical Testing and Inspection Pre-Startup Electrical Testing Is Required! DANGER! Electricity can kill! Startup inspections MUST be done with the MAIN POWER LOCKED OUT and TAGGED OUT. Failure to follow these instructions will result in serious injury or death. IMPORTANT! With MAIN POWER LOCKED OUT and TAGGED OUT, and with NO VOLTAGE detected, inspect electrical controls and wire connections for tightness. Make sure your fuel supply is adequate. Be sure the initial SAFETY Systems Checkout has been done. Review and follow the “Electrical Connection/Disconnection Procedures for Dryer Testing” below, OSHA Lockout/Tagout regulation 1910.33(b)(2) through 1910.333(c)(2), and the “Manufacturer’s Recommended Minimum Lockout/Tagout Energy Control Procedures” (Pages 77-78) in this Manual. Electrical Connection/Disconnection Procedures for Dryer testing WARNING! IMPORTANT! Pre-Startup electrical testing is REQUIRED. The procedures outlined on this page provide minimum instructions to be followed by the Qualified Electrical personnel performing Startup on this Dryer. Any additional applicable laws, regulations, and codes that may apply to such procedures MUST be followed. Inclusion of these procedures in this Manual does NOT in any way imply that these procedures can be used BY unqualified personnel or in substitution FOR Qualified Electrical Personnel. 72 These procedures MUST be followed by Installers of BROCK® Dryers and related equipment. Failure to follow these procedures could result in death or serious injury, and an unsafe situation. Connecting Procedures: 1. BEFORE ANY TESTING, make certain all Service Disconnects are in the OFF position and LOCKOUTS/TAGOUTS are in place!!!! 2. Verify that the Disconnect to the Dryer being tested is in the OFF position. 3. Verify proper voltage to be used: 240V single-phase, 208V, 240V, 380V, 480V or 575V three-phase. 4. Verify that your voltage tester is operating properly: Test it on a known live voltage source to verify that the tester is working properly before testing the power source to the Dryer. 5. Check for voltage at the Dryer Disconnect. NO VOLTAGE should be present! 6. Before powering up, a 10' [3 048] area around the open panel to be “energized” will need to be blocked off with a non-conductive perimeter guard. Only properly protected and trained personnel can enter this area when the open panel is energized. 7. You may now TURN ON the Service Disconnect (wherever it is located for your facility, usually in a building away from the Dryer), and then turn on the Dryer Disconnect (the lever/handle on the inside door of the Dryer Disconnect) to perform all required tests. Disconnecting Procedures: 1. Turn OFF the Dryer Motor or Motors, and then turn off the Dryer Disconnect. Refer to the photos on Pages 18 and 61. 2. Turn OFF, LOCKOUT and TAGOUT the Service Disconnect (wherever it is located for your facility). 3. a. If the purpose of the disconnection is to POWER DOWN while not in use: After the power is locked/tagged OUT, check that all is clear. Then push the START switch to confirm that the unit will not start, as instructed in the Manufacturer’s Lockout/Tagout procedures (Pages 77-78). b. If the purpose of the disconnection is to WORK on the electrical controls, a qualified electrician with proper PPE should perform these tests, after following LOCKOUT/TAGOUT (LOTO) Procedures (Pages 77-78). The qualified electrician must: Verify that the voltage meter being used is working properly (i.e., with a fully charged battery source that will give an accurate reading). Test the voltage meter on a known voltage source, and then confirm after Locking/Tagging out the power source, so there is no voltage present. 4. All Disconnects MUST ALWAYS REMAIN IN THE "OFF" POSITION, LOCKED OUT and TAGGED OUT when not in use! MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation Pre-Startup Electrical Testing and Inspection Checkout and Adjustments 1. Make sure all removable Doors, Guards and Covers are in place. 2. Be sure the Unload area is clean and Covers are secured. CAUTION! Do not step on and/or bend the perforated inner grain panel sheets when the Dryer is empty. 3. Fill Hopper Control Gate: Initially set to 3'' - 5'' [7.6 - 12.7 cm] clearance at the intake side. Final Gate clearance should be set while filling, so grain covers the lower edges of the Plate to provide a seal to keep dust and fines from blowing out. 4. Wet and Dry Auxiliary Conveyors: Check that they are correctly oriented and operational. 5. Modulating Valve: Check that linkage is tight and in alignment. 6. The manual Shutoff Valve located near the Inlet connection on both LP and Natural Gas plumbing trains. The Inlet Gas Valve(s) should be turned OFF any time the Dryer is not operating. U.S. only: If the Dryer is equipped with the dual LP-NAT plumbing option, make sure proper orifices are installed per gas type. After verifying both Inlet Gas Valves are closed, open the manual Inlet Gas Valve for the desired fuel. 7. Service Light: To keep electrical control circuit components warm, turn on at least one hour prior to daily startup (or leave on overnight) if the outside temperature is below 32 degrees F. Do not use this light in the daytime if the temperature is above freezing (32 degrees F). CAUTION! Failure to follow the following directions may result in an unsafe situation. 8. If the Dryer is wired for three-phase power, check the control circuit voltage before starting the Dryer, to verify that it is within a 110V to 125V range. Follow instructions on the bilingual Circuit Breaker Card shown below (5542-00001, ships loose): • Install the card with the circuit breakers facing toward the I/O Panel. make sure that the fuse is installed and that it is rated at 6 amps. • Make sure that the connector on the circuit breaker is lined up with the male end on the I/O Panel. • Firmly press the card straight into the connector until it is secure and in place. Failure to press the card straight may cause the male connector to break on the board. Figure 83. Circuit Breaker Card 9. Check rotation of Motors. See Page 68. 10. With the fuel in the Plumbing Train under pressure, check all fittings for leaks with a liquid soap solution, especially at unions. MFH1956E 73 SQ Series Specifications BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SQ Series Specifications Dryer Dimensions Model Grain Column Length Total Fan HP Single Phase Three Phase RPM SQ8D SQ12D SQ16D SQ20D SQ24D SQ28D SQ32D SQ36D SQ40D 8' 2'' 12' 3'' 16' 4'' 20' 5'' 24' 6'' 28' 7'' 32' 8'' 36’ 9'' 40' 10'' [2 469] [3 734] [4 978] [6 223] [7 468] [8 712] [9 957] [11 201] [12 446] 10 10 15 20 25 30 40 50 50 1 1 1 2@10 2@15 2@15 1 1 1 1 1 1 1 1 1 946 1027 1186 830 874 906 See Chart below. SQ Series Electrical Specifications Model Phase Voltage SQ8 SQ12 SQ16 SQ20 SQ24 SQ28 1 3 3 1 3 3 1 3 3 1 3 3 1 3 3 1 3 230 230 460 230 230 460 230 230 460 230 230 460 230 230 460 230 230 Motor HP (Electric) 10 10 10 10 10 10 15 15 15 20 20 25 25 30 1M - Fan (1) 2M - Load Auger 2 2 2 3 3 3 3 3 3 5 5 5 5 5 5 7.5 7.5 3M - Unload System 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1M/4M -Fans (2) 10 15 15 Total Horsepower 14.0 14.0 14.0 15.0 15.0 15.0 20.0 20.0 20.0 27.0 27.0 27.0 37.0 32.0 32.0 39.5 39.5 Motor Amps (full load) (4) 40.0 26.0 13.0 40.0 26.0 13.0 60.0 39.2 19.6 52.0 26.0 64.0 32.0 76.0 1M - Fan (1) 2M - Load Conveyor 11.0 6.2 3.1 15.0 8.2 4.1 15.0 8.2 4.1 27.8 13.2 6.6 27.8 13.2 6.6 32.0 20.0 3M - Unload Conveyor 6.2 6.2 3.1 6.2 6.2 3.1 6.2 6.2 3.1 6.2 6.2 3.1 6.2 6.2 3.1 6.2 6.2 1M/4M Fans (2) 80 120 120 Total Amperage 57.2 38.4 19.2 61.2 40.4 20.2 81.2 53.6 26.8 114 71.4 35.7 154 83.4 41.7 158.2 102.2 Circuit Breaker (Amp Rating) 100 70 40 100 70 40 125 100 40 175 125 60 225 125 70 225 150 Service Disconnect 1M/4M (1CB/4CB) (3) 80 20 80 20 80 80 100 100 2M (2CB) 20 10 6 30 15 10 30 15 10 40 25 15 40 25 15 60 40 3M (3CB) 30 25 10 30 25 10 30 25 10 30 25 10 30 25 10 30 25 Control (CCB) 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 QUANTUM (QCB) 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 Notes: (1) Blanks indicate where two fan motors are used. (2) Blanks indicate where one fan motor is used. (3) Blanks indicate where the Service Disconnect is also protecting the fan motor. (4) Motor amps can vary slightly from one order to the next. SQ32 3 3 3 460 230 460 SQ36 3 3 230 460 SQ40 3 3 230 460 30 7.5 2 50 10 2 50 10 2 40 7.5 2 40 7.5 2 50 10 2 39.5 49.5 49.5 62.0 62.0 62.0 62.0 38.0 100.0 50.0 124.0 62.0 124.0 62.0 10.0 20.0 10.0 26.0 13.0 26.0 13.0 3.1 6.2 3.1 6.2 3.1 6.2 3.1 51.1 126.2 63.1 156.2 78.1 156.2 78.1 80 225 100 225 125 225 125 20 10 4 1.8 40 25 4 1.8 50 25 4 1.8 20 10 4 1.8 50 25 4 1.8 20 10 4 1.8 20 10 4 1.8 SQ Series Fan Specifications Basket (feet) 8 12 16 20 20 24 24 28 28 32 36 40 74 Phase 1P/3P 1P/3P 1P/3P 1P 3P 1P 3P 1P 3P 3P 3P 3P Fan Size (HP) 10 10 15 10 (2) 20 15 (2) 25 15 (2) 30 40 50 50 Fan Shaft Dia. (in) 2 7/16 2 7/16 2 7/16 2 7/16 2 7/16 2 15/16 2 15/16 2 15/16 2 15/16 3 7/16 3 7/16 3 7/16 Fan Speed (RPM) 946 1027 1186 1113 1096 866 857 909 893 830 874 906 50 10 2 Drive Pulley Driven Pulley 4.2X2B-SH 4.0X2B-SH 6.2X2B-SDS 4.2X2B-SH 5.2X3B-SD 5.2X2B-SDS 5V5.5X3-SDS 5.6X2B-SDS 5V7.1X2-SK 7.0X4B-SK 7.4X4B-SK 8.0X4B-SK 8.0X2B-SK 7.0XSB-SK 9.4X2B-SK 6.8X2LB-SF 8.6X3B-SK 11.0X2LB-SF 5V11.3X3-SF 11.0X2LB-SF 5V14.0X2-SF 15.4X4B-SF 15.4X4B-SF 16.0X4B-SF MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SQ Series Specifications SQ Series Burner and Fuel Supply Specifications (U.S) Model Fuel Type Min BTU/hr D/M Max BTU/hr D/M Max BTU/hr A/E Max Gals/hr (Prop.)D/M/A/E Max Therms/hr (Nat.)D/M/A/E Typical Usage BTU/hr D/M Typical Usage BTU/hr A/E Orifice Dia. Upper (In.) D/M Orifice Dia. Upper (In.) A/E Orifice Dia. Lower (In.) D/M Orifice Dia. Lower (In.) A/E Burner Min. PSI Burner Max. PSI Min line size 100 feet (In.) Min. Supply Pressure PSI Max Supply Pressure PSI SQ8 SQ12 SQ16 Prop Nat 694518 4414068 Prop Nat 975421 4826412 48.2 52.7 44.1 2778071 48.3 3901686 0.297 0.375 0.297 0.375 0.203 0.250 0.219 0.281 0.5 8 0.5 30 180 0.5 7 1.5 8 20 0.5 8 0.5 30 180 0.5 7 1.5 8 20 SQ20 Prop Nat 1205187 6321780 4285894 69.1 63.2 4820750 2072893 0.344 0.438 0.281 0.375 0.250 0.313 0.203 0.250 0.5 0.5 8 7 0.5 1.5 30 8 180 20 Prop Nat 1560674 8554896 6655381 93.5 85.5 6242697 2943867 0.406 0.500 0.359 0.438 0.281 0.359 0.250 0.313 0.5 0.5 8 7 0.5 1.5 30 8 180 20 Model Fuel Type Min BTU/hr D/M Max BTU/hr D/M Max BTU/hr A/E Max Gals/hr (Prop.)D/M/A/E Max Therms/hr (Nat.)D/M/A/E Typical Usage BTU/hr D/M Typical Usage BTU/hr A/E SQ28 Prop Nat 2158933 11893392 7894400 130.0 118.9 8635731 3845386 SQ32 Prop Nat 2592543 14357520 9487638 156.9 143.6 10369814 4885226 SQ36 Prop Nat 2791873 15897600 12602822 173.7 159.0 11167492 5368842 SQ40 Prop Nat 2937102 16493760 13376340 180.3 164.9 11748409 5664341 Diam. Orifice UPPER. (in./) D/M Diam. Orifice UPPER (in.) A/E Diam. Orifice LOWER (in.) D/M Diam. Orifice LOWER (in. A/E Burner Min. PSI Burner Max. PSI Min. Line Size 100 feet in/ Min. Supply pressure PSI Max. Supply pressure PSI 0.469 0.594 0.531 0.656 0.563 0.703 0.563 0.703 0.375 0.344 0.281 0.5 8 0.75 30 180 0.500 0.438 0.344 0.5 7 2 8 20 0.438 0.375 0.297 0.5 8 0.75 30 180 0.531 0.469 0.375 0.5 7 2 8 20 0.500 0.375 0.344 0.5 8 0.75 30 180 0.609 0.500 0.438 0.5 7 2 8 20 0.500 0.406 0.344 0.5 8 0.75 30 180 0.609 0.500 0.438 0.5 7 2 8 20 MFH1956E SQ24 Prop Nat 2033212 10867500 7575952 118.8 108.7 8132847 3571902 0.438 0.563 0.375 0.469 0.313 0.406 0.281 0.344 0.5 0.5 8 7 0.75 2 30 8 180 20 75 SQ Series Specifications BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SQ Series Burner and Fuel Supply Specifications [metric] Model Fuel Type Min kJ/hr D/M Max kJ/hr D/M Max kJ/hr A/E Max L/hr (Prop.)D/M/A/E Max m3/hr (Nat.)D/M/A/E Typical Usage D/M (kJ/hr) Typical Usage A/E (kJ/hr) Orifice Dia. Upper (cm) D/M Orifice Dia. Upper (cm) A/E Orifice Dia. Lower (cm) D/M Orifice Dia. Lower (cm) A/E Burner Min. (bars) Burner Max. (bars) Min line size 30.48m (cm) Min. Supply Pressure (bars) Max Supply Pressure (bars) SQ8 Propane Natural Gas 732098 4652911 Model Fuel Type Min kJ/hr D/M Max kJ/hr D/M Max kJ/hr A/E Max L/hr (Prop.)D/M/A/E Max m3/hr (Nat.)D/M/A/E Typical Usage D/M (kJ/hr) Typical Usage A/E (kJ/hr) Orifice Dia. Upper (cm) D/M Orifice Dia. Upper (cm) A/E Orifice Dia. Lower (cm) D/M Orifice Dia. Lower (cm) A/E Burner Min. (bars) Burner Max. (bars) Min line size 30.48m (cm) Min. Supply Pressure (bars) Max Supply Pressure (bars) SQ20 Propane Natural Gas 1645121 9017797 7015500 353.9 242.2 6580486 3103158 1.031 1.270 0.912 1.113 0.714 0.912 0.635 0.795 0.034 0.034 0.552 0.483 1.27 3.81 2.069 0.552 12.414 1.379 SQ24 Propane Natural Gas 2143228 11455535 7985883 449.5 307.7 8572911 3765176 1.113 1.430 0.953 1.191 0.795 1.031 0.714 0.874 0.034 0.034 0.552 0.483 1.905 5.08 2.069 0.552 12.414 1.379 SQ28 Propane Natural Gas 2275752 12536938 8321562 492.0 336.8 9103006 4053458 1.191 1.509 0.953 1.270 0.874 1.113 0.714 0.874 0.034 0.034 0.552 0.483 1.905 5.08 2.069 0.552 12.414 1.379 Model Fuel Type Min kJ/hr D/M Max kJ/hr D/M Max kJ/hr A/E Max L/hr (Prop.)D/M/A/E Max m3/hr (Nat.)D/M/A/E Typical Usage D/M (kJ/hr) Typical Usage A/E (kJ/hr) Orifice Dia. Upper (cm) D/M Orifice Dia. Upper (cm) A/E Orifice Dia. Lower (cm) D/M Orifice Dia. Lower (cm) A/E Burner Min. (bars) Burner Max. (bars) Min line size 30.48m (cm) Min. Supply Pressure (bars) Max Supply Pressure (bars) SQ32 Propane Natural Gas 2732824 15134399 10001010 593.9 406.5 10930920 5149563 1.349 1.666 1.113 1.349 0.953 1.191 0.754 0.953 0.034 0.034 0.552 0.483 1.905 5.08 2.069 0.552 12.414 1.379 SQ36 Propane Natural Gas 2942940 16757811 13284755 657.6 450.2 11771760 5659347 1.430 1.786 1.270 1.547 0.953 1.270 0.874 1.113 0.034 0.034 0.552 0.483 1.905 5.08 2.069 0.552 12.414 1.379 SQ40 Propane Natural Gas 3096027 17386229 14100127 682.3 467.0 12384110 5970836 1.430 1.786 1.270 1.547 1.031 1.270 0.874 1.113 0.034 0.034 0.552 0.483 1.905 5.08 2.069 0.552 12.414 1.379 76 182.6 SQ12 Propane Natural Gas 1028201 5087567 199.6 125.0 136.7 2928391 4112804 0.754 0.953 0.754 0.953 0.516 0.635 0.556 0.714 0.034 0.552 1.27 2.069 12.414 0.034 0.483 3.81 0.552 1.379 0.0345 0.552 1.27 2.069 12.414 0.034 0.483 3.81 0.552 1.379 SQ16 Propane Natural Gas 1270399 6663848 4517802 261.5 179.0 5081598 2185056 0.874 1.113 0.714 0.953 0.635 0.795 0.516 0.635 0.034 0.034 0.552 0.483 1.27 3.81 2.069 0.552 12.414 1.379 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SQ Series Specifications The following procedures amount to minimum instructions for Lockout/Tagout. Any more stringent, current, or up-to-date requirements pursuant to OSHA or other regulations must be followed to the extent applicable. Manufacturer's Recommended Minimum Lockout/Tagout Energy Control Procedures Purpose The procedures listed herein are intended to provide minimum instructions to operators and/or end users of products supplied by the Manufacturer. To the extent that applicable laws, regulations, and/or codes, (such as, without limitation, OSHA regulations and requirements), provide more stringent requirements, all erectors, installers, operators and/or end users of the products referenced in this manufacturer’s product manual, such applicable laws, regulations and/or codes MUST be followed. Whenever maintenance or servicing is completed to machines or equipment, all such maintenance and servicing shall be completed in accordance with the requirements of OSHA's 1910.147, et seq., including any amendments thereto. Such requirements are designed to ensure that the machine or equipment is stopped, isolated from all potentially hazardous energy sources and locked out before employees or operators perform any maintenance or servicing where the unexpected energization or start-up of the machine or equipment or release of stored energy could cause injury. Authorized and Affected Individuals Authorized operators and individuals who must be trained on these procedures include, without limitation, individuals who must lock out or tag out machines or equipment in order to perform servicing or maintenance on that machine or equipment. Affected individuals who must follow these procedures and be trained on the minimum requirements stated herein include individuals whose job responsibilities or operational responsibilities require him/ her to operate or use a machine or equipment on which servicing or maintenance may be performed, or whose job responsibilities or operational responsibilities require him/her to work in an area in which such servicing or maintenance is being performed. An individual should not be authorized to perform such job responsibilities and/or operational responsibilities until he/she is properly trained on these procedures and is properly trained to complete such servicing or maintenance tasks. Service and/or Maintenance Work place activities such as construction, installing, setting up, adjusting, inspecting, modifying and maintaining and/or servicing machines or equipment must be subject to the minimum procedures stated herein and any additional procedures required by applicable law, regulation or code. Additional activities, such as lubrication, cleaning or unjamming of machines or equipment, and making adjustments or tool changes, where the individual performing the activity may be exposed to the unexpected energization or start up of the equipment or release of hazardous energy must also be subject to the minimum procedures stated herein and any additional procedures required by applicable law, regulation or code. These minimum procedures must be followed by maintenance and setup personnel. Maintenance personnel must follow such minimum procedures in the event that any type of required repair, cleaning, maintenance, inspections, adjusting, or servicing (e.g., electrical, mechanical, or other such servicing that requires entrance into or close contact with the machinery). Setup personnel must follow these minimum procedures in the event that any type of setup is required (e.g., replacing dies, adjusting guards, adjusting die components / tooling, removal of jammed parts, or other such activities that require entrance into or close contact with the machinery). Machinery and Equipment Unlike small appliances or hand tools, industrial machinery requires more than turning off a switch and unplugging. The power for such equipment comes from multiple, interactive energy sources. If all energy sources are not isolated before service (setup and/or maintenance) is performed, an accidental release of energy could occur which could result in serious injury or even death. These forms of energy include: electrical, pneumatic, chemical, thermal, hydraulic, mechanical, or gravity. When machines or equipment need to be serviced, this energy must be isolated so authorized personnel can safely perform the work. Each individual fitting the above descriptions must be issued locks, with identifying tags, which must be used only by that person. Locks must not be transferable from person to person, and each individual must be held responsible for his/her own locks and keys. Each lock must be numbered and a master list showing the number, and the individual using it, must be under the supervision of the facilities or project site manager. Lockout/Tagout Procedures Lockout/Tagout is the preferred method of isolating machines, or equipment, from energy sources. Tagout is to be performed, instead of lockout, only when there is no way to lockout a machine. The authorized maintenance supervisor must be notified if there is no way to lockout a machine. The authorized maintenance supervisor must then evaluate equipment for future lockout capabilities. Affected individuals must be notified when their machine is to be locked out according to the following method. All types of machinery and equipment mentioned above must be subject to these minimum shutdown, isolation, blocking and securing procedures for Lockout/Tagout. Step One: Preparation for shutdown Before an authorized or affected individual turns off a machine or equipment, the authorized individual shall have a working knowledge of the specific equipment, the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy. Step Two: Machine or equipment shutdown The machine or equipment shall be turned off or shut down using the procedures established for that specific machine or piece of equipment. An orderly shutdown must be utilized to avoid any additional, or increased, hazard(s) to individuals as a result of equipment stoppage. Step Three: Machine or equipment isolation All energy isolating devices that are needed to control the energy to the machine or equipment shall be physically located and operated, in such a manner, as to isolate the machine or equipment from the energy source(s). Step Four: Lockout/Tagout device application All types of machinery and equipment listed above fall under these lockout placement, removal, transfer, and responsibility minimum procedures. Lockout/Tagout devices shall be affixed to each energy isolating device by authorized individuals. Lockout devices, where used, shall be affixed in a manner that will hold the energy isolating devices in a "safe" or "off" position. Tagout devices, where used, shall be affixed in such a manner as will clearly indicate that the operation or movement of energy isolating devices from the "safe" or "off" position is prohibited. Where a tag cannot be affixed directly to the energy isolating device, the tag shall be located as close as safely possible to the device, in a position that will be immediately obvious to anyone attempting to operate the device. Step Five: Stored energy Following the application of Lockout/Tagout devices to energy isolating devices, all potentially hazardous stored or residual energy must be relieved, disconnected, restrained, and otherwise rendered safe. If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of isolation shall be continued until the servicing or maintenance is completed, or until the possibility of such accumulation no longer exists. Step Six: Verification of isolation Prior to starting work on machines or equipment that have been locked out or tagged out, the authorized individual shall verify that isolation and deenergization of the machine or equipment have been accomplished, even though isolation is performed prior to shutdown and is checked at that point. Verify the isolation of the equipment by operating the push button or other normal operating or startup control(s) to make certain the equipment will (continued) MFH1956E 77 SQ Series Specifications BROCK® SUPERB® Low Profile Grain Dryers SQ Installation operate. Return the operating control(s) to neutral or ìoffî position after verifying that the equipment is isolated. The machine or equipment is now locked out and servicing or maintenance may safely begin. Step Seven: Release from Lockout/Tagout (continued) Before Lockout/Tagout devices are removed and energy is restored to the machine or equipment, procedures shall be followed and actions taken by the authorized individual(s) to ensure the following: The machine or equipment: The work area shall be inspected to ensure that nonessential items have been removed and to ensure that machine or equipment components are operationally intact. Individuals Present: The work area shall be checked to ensure that all individuals have been safely positioned or removed. After Lockout/Tagout devices have been removed and before a machine or equipment is started, affected individuals shall be notified that the Lockout/Tagout device(s) have been removed. Step Eight: Lockout/tagout devices removal Each Lockout/Tagout device shall be removed from each energy isolating device by the individual who applied the device. Exception: When the authorized individual who applied the Lockout/Tagout device is not available to remove it, that device may be removed under the direction of the authorized supervisor, provided that specific procedures and training for such removal have been developed, documented and incorporated into the owner’s control program. The owner shall demonstrate that the specific procedure provides equivalent safety to the removal of the device by the authorized individual who applied it. The specific procedure shall include at least the following elements: a. Verification by the owner (supervisor / manager) that the authorized individual who applied the device is not at the facility / project site. b. Making all the reasonable efforts to contact the authorized individual to inform him/her that his/her Lockout/Tagout device has been removed. c. Ensuring that the authorized individual has the knowledge before he/she resumes work at that facility / project site. Shift or Personnel Changes When a shift or personnel change occurs, a designated individual shall ensure the continuity of Lockout/Tagout protection. The designated individual shall provide for the orderly transfer of Lockout/Tagout devices between off-going and on-coming individuals to minimize risk from stored energy. In general, if a piece of equipment is locked out at shift change, the person on the next shift must apply their lock before the individual who is leaving can remove their lock. In the event that no authorized individual or supervisor is available to transfer the Lockout/Tagout device, a designated department lock can be used to lockout the equipment during this time frame. As soon as the next shift authorized individual is available, he/she must ensure the equipment is properly de-energized and then place their own Lockout/Tagout device on the equipment. At this point in time the department lock should be removed and returned to its designated storage location. The department lock is never to be used as an individual lockout protection device while servicing or repairing equipment. Group Lockout/Tagout If more than one individual is servicing or setting up the machinery, each individual will use their own lock on the lockout. This prevents undue exposure to a potential hazard. The last individual working on the machinery will remove his/her lock and the tag indicating the work has been completed. The locks should remain on the switch until all work has been completed unless it is necessary for the machinery to be operable between servicing and/or maintenance and does not expose the worker or operator to any unnecessary danger. Operator Training The owner must provide effective initial training and retraining as necessary and must certify that such training has been given to all workers and operators covered by these minimum procedures. The certification must contain each worker and/or operator’s name and dates of training. For the purposes of these minimum procedures, there are three types of individuals — authorized, affected, and other. The amount and kind of training that each individual should receive is based upon (1) the relationship of that individual’s responsibilities in relation to the machine or equipment being locked and tagged out, and (2) the degree of knowledge relevant to hazardous energy that he or she must possess. For example, the owner’s training program for authorized individuals (those who are charged with the responsibility for implementing the energy control procedures and performing the service and maintenance) must cover, at minimum, the following areas: (1) details about the type and magnitude of the hazardous energy sources present in the workplace; and (2) the methods and means necessary to isolate and control those energy sources (i.e., the elements of the energy control procedures). By contrast, affected individuals (usually the machine operators or users) and all other individuals who have access to such machines and/or equipment must be able to: (1) recognize when the control procedure is being implemented; and (2) understand the purpose of the procedure and the importance of not attempting to start up or use the machinery and/or equipment that has been locked or tagged out. Because an ìaffectedî individual is not one who is performing the service or maintenance, that individual’s responsibilities under these minimum procedures are more simple (i.e., whenever there is a Lockout/Tagout device in place on an energy-isolating device, the affected individual must leave it alone and never attempt to operate the machinery and/or equipment). Every training program must ensure that all authorized and affected individuals understand the purpose, function and restrictions of these minimum energy control procedures and that authorized individuals possess the knowledge and skills necessary for the safe application, use, and removal of energy controls. Training programs used for compliance with these minimum procedures and/or other more stringent applicable procedures, which are performanceoriented, should deal with the equipment, type(s) of energy, and hazard(s) specific to the environment being covered. Retraining must be provided, as required, whenever there is a change in work and/or operational assignments, a change in machines, equipment or processes that present a new hazard, or a change in minimum energy control procedures. Additional retraining must be conducted whenever a periodic inspection reveals, or whenever the relevant authorized supervisor has reason to believe, that there are deviations from or inadequacies in the authorized individual’s knowledge or use of the minimum required energy control procedure. Periodic Inspection A periodic inspection is done, looking at the minimum energy control procedures performed to ensure that such minimum procedures and requirements are being followed. The inspection should be performed monthly by the authorized supervisor with the intent of evaluating the authorized individuals at least once per year. This information should be recorded on a Lockout/Tagout Inspection Sheet / Log. All original copies should be maintained by the owner of the equipment and/or machinery. Outside personnel (contractors, etc.) The owner and any third party contractor engaged to perform installation, maintenance or operation of the equipment and/or machinery must advise each other of their respective minimum Lockout/Tagout procedures. Each party must ensure that his or her personnel must understand and comply with all restrictions and / or prohibitions of the other party’s minimum energy control procedures. Administrative Duties The authorized supervisors are responsible for the daily follow-through of the required minimum procedures for each applicable piece of equipment and/or machinery. Violation of the required minimum procedures set by the owner must be addressed appropriately by the owner and/or authorized supervisor. The owner of the applicable equipment and/or machinery must review and update the required minimum procedures as necessary. Rev. 09/18/07 78 MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation SQ Series Specifications Electrical Symbols MFH1956E 79 SQ Series Specifications 80 BROCK® SUPERB® Low Profile Grain Dryers SQ Installation MFH1956E BROCK® SUPERB® Low Profile Grain Dryers SQ Installation MFH1956E SQ Series Specifications 83 Different by Design™ BROCK GRAIN SYSTEMS A Division of CTB Inc. Grain Conditioning Division 1750 W. State Road 28 • Frankfort IN 46041 Phone (765) 654-8517 • Fax (765) 654-8510 Toll Free (800) 541-7900 e-mail: [email protected] • Internet: www.ctbworld.com or www.graindryers.com and P.O. Box 2000 • Milford, Indiana 46542-2000 • U.S.A. Phone (574) 658-4191 • Fax (574) 658-4133 e-mail: [email protected] • Internet: http://www.brockgrain.com and 7400 East Thirteenth Street • Kansas City, Missouri 64126 • U.S.A. Phone (816) 968-6101 Fax (816) 968-6272 Printed in the U.S.A. Brock Grain Systems reserves the right to change specifications of, or to improve any of its machines, equipment or attachments thereto at any time without assumption of responsibility to equipment previously sold. Changes this issue: Pages 53-58: An exterior Vapor Relief Valve was added. The First-Stage Regulator part number changed from 2449-00030 to 2449-00032. Page 58: There is now a single Solenoid. There were miscellaneous additions and corrections. Changes last issue: There were miscellaneous additions; metric conversions were added. Revisions from the August 2011 Supplement MFH1932E-2 were incorporated into this issue: Page 63: Electrical Schematic 3724-00050A changed to 3724-00085. Page 67: Electrical Schematic 3724-00049A changed to 3724-00081. Page 74: The Electrical Specifications Chart changed. NOTE: The original, authoritative version of this Manual is the [English] version produced by CTB, Inc. or any of its subsidiaries or divisions, (hereafter collectively referred to as "CTB"). Subsequent changes to any Manual made by any third party have not been reviewed nor authenticated by CTB. Such changes may include, but are not limited to, translation into languages other than [English], and additions to or deletions from the original content. CTB disclaims responsibility for any and all damages, injuries, Warranty claims and/or any other claims associated with such changes, inasmuch as such changes result in content that is different from the authoritative CTB-published [English] version of the Manual. For current product installation and operation information, please contact the Customer Service and/or Technical Service Departments of the appropriate CTB subsidiary or division. Should you observe any questionable content in any Manual, please notify CTB immediately in writing to: CTB Legal Department, P.O. Box 2000, Milford, IN 46542-2000 USA. February 2014 MFH1956E

Continuous Flow Low Profile Sq Series Grain Dryers 2014

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