Brock MEYER ENERGY MISER ME1000S

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document is a comprehensive manual for the BROCK® MEYER® Energy Miser Tower Dryer, specifically covering models ME1000S/SG-ME2650S/SG. It provides schematics, fault codes, and operational guidelines, emphasizing safety and proper installation by licensed and qualified electricians.

Function Description

The BROCK® MEYER® Energy Miser Tower Dryer is designed for efficient grain drying. It integrates an Intui-DRY® Controller, which serves as the "brain" of the dryer, managing various functions including burner control, motor operation, and safety systems. The dryer utilizes Allen-Bradley PowerFlex 525 drives for motor control, allowing for precise speed and torque management. Honeywell burner controls are employed for safe and efficient ignition and flame management. The system incorporates linear limit switches and set-reset L/R thermostats for temperature control and safety. The Intui-DRY® Controller provides alarms, levels, color codes, and fault codes displayed on its screen, aiding in diagnostics and troubleshooting.

Important Technical Specifications

The manual details setup parameters for Allen-Bradley PowerFlex 525 drives for various motor configurations:

5 HP 230V: Motor NP FLA 13.4, Motor NP RPM 1800, Accel/Decel Time 1 30, Maximum Freq 120.
5 HP 380V: Motor NP Volts 380, Motor NP Hertz 50, Motor NP FLA 13.4, Motor NP RPM 1440, Accel/Decel Time 1 30, Maximum Freq 120.
5 HP 400V: Motor NP Volts 400, Motor NP Hertz 50, Motor NP FLA 7.66, Motor NP RPM 1450, Accel/Decel Time 1 30, Maximum Freq 100.
5 HP 460V: Motor NP FLA 6.7, Motor NP RPM 1800, Accel/Decel Time 1 30, Maximum Freq 120.
5 HP 600V: Motor NP FLA 5.2, Motor NP RPM 1755, Accel/Decel Time 1 30, Maximum Freq 120.
15 HP 230V Drive, Single Phase Input, 5 HP Motor: Motor NP FLA 13.4, Motor NP RPM 1800, Accel/Decel Time 1 30, Maximum Freq 120.

These parameters include settings for motor nominal full load amps (FLA), nominal RPM, torque performance mode, acceleration and deceleration times, maximum frequency, start sources, speed references, digital input terminal block configurations, relay output selection, safety open enable, Ethernet IP address configuration, subnet configuration, and various preset frequencies.

The Honeywell burner control system utilizes blink codes (e.g., 1-1 Low AC Line Voltage, 2-1 Unexpected Flame Signal, 4-3 Flame Amplifier Problem) and keyboard display module messages (e.g., INITIATE, STANDBY, PURGE, PILOT IGN, MAIN IGN, RUN) to indicate operational status and fault conditions.

Usage Features

The dryer's operation is primarily managed through the Intui-DRY® Controller, which provides a user-friendly interface for monitoring and control. The Allen-Bradley PowerFlex 525 drives feature a keypad with display and control keys for viewing and editing parameters. Key functions include:

Basic Display (b): Shows commonly viewed drive operating conditions.
Basic Program (P): Accesses commonly used programmable functions.
Terminal Blocks (t): Configures programmable terminal functions.
Communications (C): Manages programmable communication functions.
Logic (L): For PowerFlex 525 only, programmable logic functions.
Advanced Display (d): Shows advanced drive operating conditions.
Advanced Program (A): Accesses remaining programmable functions.
Network (N): Displays network functions when a comm card is used.
Modified (M): Shows functions with values changed from default.
Fault and Diagnostic (f): Lists specific fault conditions.
AppView and CustomView (G): Organizes functions for specific applications.

Navigation is intuitive with Up/Down Arrows for scrolling, Esc for backing out, Sel for selecting, Enter for saving, and dedicated Start/Stop/Reverse keys. A potentiometer allows for speed control.

The Honeywell Keyboard Display Module provides real-time status and hold messages, guiding the operator through the burner sequence (INITIATE, STANDBY, PURGE, PILOT IGN, MAIN IGN, RUN, POSTPURGE) and indicating any hold conditions (e.g., High Fire Switch not closed, Flame Detected, Pre-Ignition Interlock not closed).

Linear limit switches are crucial safety features, with indicator lights on the Intui-DRY® screen and a decal on the control panel door for easy reference. These limits are set for different dryer models (ME1000S to ME2650S) and correspond to specific wiring configurations.

Maintenance Features

The manual provides extensive troubleshooting guides for both Allen-Bradley PowerFlex 525 fault codes and Honeywell burner control faults.

Allen-Bradley PowerFlex 525 Fault Codes (F000-F127): These codes cover a wide range of issues from "No Fault" (F000) to "DSIFlashUpdatReq" (F127). Troubleshooting steps include checking wiring, verifying connections, inspecting components (fuses, fans, heat sinks, motors), adjusting parameters (Accel Time, Current Limit, Boost Select), and replacing faulty modules (drive, control module, encoder). For example, "Power Loss" (F003) requires monitoring the AC line, checking input fuses, and reducing load. "Motor Stalled" (F006) suggests increasing acceleration time or reducing load. "Ground Fault" (F013) necessitates checking motor and external wiring for grounded conditions.

Honeywell Burner Control Faults (Blink Codes and Hold Messages): These provide detailed diagnostics for burner-related issues. For blink codes, troubleshooting involves checking wiring, flame sensor, amplifier, purge card, and interlock switches. For hold messages, the manual outlines conditions that prevent the burner from advancing in its sequence. For instance, "STANDBY HOLD: F/G (Flame Detected)" indicates a flame is detected when not expected, requiring the flame signal to clear. "PURGE HOLD: T19 (High Fire Switch)" means the High Fire Switch is not closed, and the firing rate motor is driving to its PURGE rate position. Troubleshooting steps include inspecting switches, verifying connections, measuring voltages, and resetting the relay module.

Set-Reset L/R Thermostats: The manual describes how to access and adjust the HI-Limit and LO-Limit thermostats, which are critical for temperature control. Users can remove covers and push RESET tabs to address temperature-related trips.

Safety and Lockout/Tagout Procedures: A significant portion of the manual is dedicated to safety. It emphasizes that all electrical installations and testing must be performed by licensed and qualified electricians. It outlines a comprehensive Lockout/Tagout procedure to prevent accidental energization during maintenance. This includes:

Preparation for shutdown: Understanding the equipment, energy types, hazards, and control methods.
Machine or equipment shutdown: Orderly shutdown to avoid additional hazards.
Machine or equipment isolation: Physically isolating all energy sources.
Lockout/Tagout device application: Affixing devices to energy isolating devices to prevent operation.
Stored energy: Relieving, disconnecting, or restraining all potentially hazardous stored energy.
Verification of isolation: Operating controls to ensure equipment will not operate.
Release from Lockout/Tagout: Inspecting the work area, ensuring individuals are safely positioned, and notifying affected individuals before removing devices.
Lockout/tagout devices removal: Removal by the individual who applied them, or under authorized supervisor direction with specific procedures.

The manual also covers procedures for shift or personnel changes during Lockout/Tagout, group Lockout/Tagout, operator training, and periodic inspections to ensure compliance with safety protocols. It stresses the importance of using properly rated/insulated Personal Protective Equipment (PPE) and performing a SAFETY Systems checkout before initial startup and at the beginning of each season.