GSI Network Portable Dryer Models Troubleshooting and Reference Manual PNEG-1181 Date: 09-18-07 PNEG-1181
PNEG-1181 Portable Dryer Troubleshooting
Table of Contents Contents Chapter 1 Safety .................................................................................................................................................. 5 Safety Guidelines ............................................................................................................................... 5 Dryer Safety Instructions and Information .......................................................................................... 6 Safety Precautions ................
Table of Contents Chapter 9 Wiring Reference ............................................................................................................................. 31 2 Fan Network Dryer Internal Wiring ................................................................................................ 31 2 Fan Network Dryer Internal Jumper Wiring ................................................................................... 32 Upper Control Back Panel Wiring .......................................
1. Safety Safety Guidelines This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections.
1. Safety Dryer Safety Instructions and Information Thank you for choosing a GSI Network Portable Grain Dryer. It is designed to provide excellent performance and service for many years. This manual refers to the troubleshooting of the Network Dryer models. Different models are available for liquid propane or natural gas fuel supply, with either single phase 230 volt, or three phase 230, 460, 575 volt electrical power. (Also 380 volt 50 Hz).
1. Safety Safety Precautions READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE SAVE FOR FUTURE REFERENCE 1. Read and understand the operating manual before attempting to operate the dryer. 2. Power supply should be OFF for service of electrical components. Use CAUTION in checking voltage or other procedures requiring the power to be ON. 3. Check for gas leaks at all gas pipe connections. If any leaks are detected, DO NOT operate the dryer. Shut down and repair before further operation. 4.
1. Safety Use Caution in the Operation of this Equipment The design and manufacture of this dryer is targeted to maximize operator safety. However, grain dryers have inherently hazardous components: a gas burner, high voltage electrical equipment, high speed rotating parts, etc. It is not possible to fully safeguard against all hazards without impeding efficient operation and reasonable access to components. Therefore, a careful and knowledgeable owner/operator is the best insurance against an accident.
2. Decals Safety decals should be read and understood by all people in and around the dryer area. If the following safety decals are not displayed on your dryer, or if they are damaged, contact GSI for replacement. GSI Decals 1004 E. Illinois St. Assumption, IL. 62510 Phone: 217-226-4421 WARNING Flame and pressure beyond door can cause serious injury. Do not operate with service door removed. Keep head and hands clear. DC-1227 WARNING Stay clear of rotating blade. Blade could start automatically.
2. Decals Rotating auger will crush and cut. Auto equipment can start at anytime. Do not enter until electric power is locked in off position. Failure to do so will result in serious injury or death. DC-974 10 Moving parts can crush and cut. Keep hands clear. Do not operate without guards in place. Failure to do so could result in serious injury.
3. Operation Tips Network Dryer Operation Tips Important Software and Troubleshooting Tips (Software Version 1.08 and Up). Present Software Version Numbers: Display 1.19 Heater 1.19 Input/Output 1.18 1. Stuck register value. After installing a new display board and “flashing” the software in, an error message with “garbage” characters or a negative number for the temperature may appear. To correct this, hard reboot the system by holding down the reset key and turning the power ON.
3. Operation Tips Network Dryer Operation Tips (Continued) 7. To return all options and settings to the factory defaults, press and hold the RESET button. Turn the control power ON and release the RESET button. NOTE: ALL settings will be erased and all options will return to the factory defaults. 8. To disable the air pressure switches, press and hold both the GRAIN and PLENUM buttons. Turn ON the control power and release the buttons. 9.
4. Setup Screens Special Network Dryer Setup Screens There are certain dryer features that rarely need to be changed and which should be carefully considered before adjusting. To access these advanced features, with the power OFF, press and hold the MODIFY button and then turn ON the control power for the dryer. Release the MODIFY button and the advanced feature screens will be available.
5. Dryer Operation Network Dryer Options Explanation Turn Meter Rolls OFF This option does not actually turn off the metering rolls. Changing this setting to YES removes the sensor board from the circuit and allows the dryer to operate normally, but without any meter roll information displayed on the screen. This is useful in the event of a sensor board failure. The sensors on the rear of the dryer and the computer monitor whether or not the metering rolls are turning when the UNLOAD is running.
5. Dryer Operation Dyer Model Number This setting is critical to proper function of the dryer. The actual model number of the dryer is located here and that number contains a great deal of valuable information about the dryer, including: number of fans, number of modules, and the length of the dryer. This data is used by the computer to operate the dryer properly. If any of this information is incorrect, the dryer will not operate properly and may not operate at all.
6. Programming Programming Instructions Using Palm Pilot There are three (3) boards to program on the Network Dryer: Display Board (lower control box), Input/Output Board (upper control box), and Heater Interface Board (by Fan/Can housing). 1. Turn the control power on the dryer to the OFF position. 2. Locate the programming jack on each individual board: • Display Board (lower control panel) - (DB-9) located at bottom of board. • Input/Output Board (upper panel) - (DB-9) located at bottom of board.
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6. Programming Programming Instructions Using Flash Programmer There are three (3) boards on the Network Dryer to program: Display Board (lower control box), Input/Output Board (upper control box), and the Heater Interface Board (Fan/Can housing). 1. Turn the control power on the dryer to the OFF position. 2. Locate the programming jack on each individual board: • Display Board (lower control panel) - (DB-9) located at bottom of board. • Input/Output Board (upper panel) - (DB-9) located at bottom of board.
6. Programming Programming Network Dryer Using Flash Programmer Figure 6B *The Flash Programmer can still be used to program the dryer but the programmable chip for it is no longer available. Therefore, GSI recommends using a Palm Pilot for programming.
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7. Board Hook Up Network Display Board (Located in the lower control panel) (Back of Board) Network Terminal connections (blue and yellow wires) DB-9 Connector DB-9 Connector This is used for programming the board. This is used for Watchdog Program.
7. Board Hook Up Input/Output Board (Located in Upper Control Panel) Network Terminal connections (blue and yellow wires) DB-9 Connector This is used for programming the board.
8. Troubleshooting Tips Possible Safety Circuit Shut Down Messages Viewing the Shut Down History The shut down history can store up to 200 shut down warnings. When the dryer exceeds this amount, the oldest shut down will be erased and replaced with the current shut down warning. To view the shut down history (Warnings): • Turn the Control Power to ON. • Wait until the time and date screen appears and then press the START button.
8. Troubleshooting Tips Possible Safety Circuit Shut Down Messages (Continued) 4. Make adjustments on air pressure switch one quarter turn at a time. 5. Clean air pressure switch tube to make sure it is not plugged. 6. More on how to adjust air switch on Page 57. AIR SWITCH X STUCK Air Switch 1 Stuck: Air pressure switch contacts have closed prior to the fan starting, indicating a freewheeling blade or improper adjustment of the air switch. The error message will show on which fan the error occurred.
8. Troubleshooting Tips Possible Safety Circuit Shut Down Messages (Continued) VAPOR X HIGH LIMIT Vapor 1 High Limit: The LP gas vapor temperature sensor, located in the gas pipe train downstream from the vaporizer, has opened indicating that the vaporizer is running too hot and must be adjusted. This sensor is set at 200°F and will automatically reset itself when cool. Adjust the vaporizer coil away from the burner flame. Make sure the LP tank has fuel in it.
8. Troubleshooting Tips Possible Safety Circuit Shut Down Messages (Continued) PLENUM TEMP SHORT X Plenum Temp Short 1: This error indicates a shorted condition with the plenum temperature sensor located inside the plenum chamber. This could be a short in the sensor or the sensor wires. These sensors are wired to a fan/heater interface, which sensor contains the short depends on number of plenums. The error message will show in which plenum the short occurred.
8. Troubleshooting Tips Possible Safety Circuit Shut Down Messages (Continued) ILLEGAL FLAME X Illegal Flame 1: This message is displayed when the flame detection circuit of the heater senses flame when the burner is supposed to be OFF. Example, after being shut down, the dryer and the heater continue to burn due to a solenoid stuck open. The error message will show in which heater the illegal flame has occurred.
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8. Troubleshooting Tips Possible Safety Circuit Shut Down Messages (Continued) METER ROLLS FAILED This is usually caused by either a defective meter roll sensor or the meter rolls not turning because of a broken drive chain, jammed meter roll, bad motor or gear case. The meter roll sensor is located in a white plastic box on the rear of the dryer. The box is mounted on the end of the meter roll drive shaft.
8. Troubleshooting Tips Possible Safety Circuit Shut Down Messages (Continued) NETWORK FAILED: Input/Output This error occurs when the Input/Output Board (upper control panel) has lost its communications link with the Master Display Board (lower control panel) and the fan/heater Boards. Check the blue and yellow wires marked N1-01 and N1-02 on a three (3) terminal plug to make sure they are plugged in tightly.
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9. Wiring Reference Testing Procedures and Location of Grain Temperature Sensors The grain sensors terminate at the Heater Board located by the fan/can housing. Single module with two fans, grain sensors are wired to bottom heater board. On a stack dryer with multiple fan/heaters, the sensors will be terminated on the bottom Heater Board of the second module. It does not matter if the second module has one fan/heater or two fan/heaters. If a bad sensor is suspected, always check the heater board first.
9. Wiring Reference Procedure for Locating, Testing and Replacing a Defective Grain Temperature Sensor Symptoms of a bad sensor may include: • Temperature readings that are not consistent with the ambient outside temperature or with any known or verified grain temperatures entering the dryer. • Grain temperature open or grain temperature short on network dryers. • Display readings of 255°F or -127°C. Figure 9A Grain Thermistor Sensor Troubleshooting: 1.
9. Wiring Reference Procedure for Locating, Testing and Replacing a Defective Grain Temperature Sensor (Continued) 7. Strip back about 1/4 inch from the end of each 26 Ga. sensor wire. 8. With an ohm meter, set the scale to 20k (if it is not an autorange model). 9. Place the black lead into the butt connected wire connection with the 2-26 Ga. wires. 10. Connect the red lead to either of the disconnected 26 Ga. wires and note the reading. 11. Move the red lead to the other disconnected 26 Ga.
9. Wiring Reference Sensor Chart Resistance and Temperature Chart 60 °F Ohms °F Ohms °F Ohms °F Ohms °F Ohms °F Ohms °F Ohms 28 36,601 62 14,546 96 6,382 130 3,047 164 1,565 198 855.7 232 494.3 29 35,565 63 14,179 97 6,238 131 2,985 165 1,536 199 841.4 233 86.8 30 34,562 64 13,822 98 6,097 132 2,925 166 1,508 200 827.3 234 479.4 31 33,591 65 13,475 99 5,960 133 2,865 167 1,480 201 813.6 235 472.
9. Wiring Reference Procedure for Locating, Testing and Replacing a Defective Plenum Temperature Sensor Symptoms of a bad sensor may include: • Temperature readings that are not consistent with the ambient outside temperature or with a verified plenum temperature that has been taken with a thermometer. • Erratic plenum display readings. • Plenum temp open or plenum temp short. Troubleshooting: 1. There is only one sensor to check for each plenum.
9. Wiring Reference Procedure for Locating, Testing and Replacing a Defective Plenum Temperature Sensor (Continued) 8. With an ohm meter, set the scale to 20k (if it is not an autorange model). 9. Place one probe of the meter on one wire going out to the sensor and the other probe to the other wire. 10. The meter should read close to the Resistance/Temperature Chart on Page 60. 11.
9. Wiring Reference Procedures for Replacing Network SCR Board The following three pages will explain how to calibrate the SCR board on a Network Dryer. Remember when replacing a SCR board on a Network Dryer that it takes a special top board. Not replacing it with the proper board could cause damage to the Dryer’s Input/Output board. The necessary part numbers are listed below: 1. D03-0679-SCR Drive Board (complete top and bottom board without resistor) (Network Only) 2.
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10. Dryer Parts Dryer Fan/Can Side View (Part Locations) 1 3 2 4 5 6 1. Fan/can Box: Fan motor contactor and overload - ignition transformer - igniter and flame probe wire connections. 2. LP Pipe Train. 3. Air Switch. 4. Access Door: Flame probe - igniter. 5. 4" x 4" White Plastic Junction Box: Plenum (bolt) sensor wire connection - Plenum high limit. 6. Fan Heater Control Box: Heater interface board.
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11. Air Switch Tip Network Series Air Switch Adjustment 1. With the Load Auger, Fan, Heater, and Unload switches in the OFF position, turn ON the Control power then push the Dryer Power Start switch. 2. With power applied to the dryer, flip one of the fan switches to the ON position and watch for the light to illuminate the fan switch knob. If the light illuminates when the fan reaches half its full speed, then no adjustment is required.
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12. SCR Board Setup SCR Board Terminals and Min./Max. Adjustment Locations MIN Resistor MAX +12 SIG COM L1 L2 A+ A- Figure 12A * The SCR board is located in the upper control box. * Terminals L1 and L2 are the input terminals. When the unload system is turned on, there should be 220 volts AC across these terminals. * Terminals A+ and A- are the output terminals. The voltage across these terminals is DC and will vary depending on where the speed control potentiometer is set.
12. SCR Board Setup Setting SCR Board Maximum Voltage 1. At the METER ROLL SETTINGS screen on the display set the High to 1000 and the Low to 50. (NOTE: Pressing the meter roll speed control knob toggles between High and Low settings, and turning the knob will adjust the settings.) 2. Switch the Moisture Control Switch to the OFF position. This will put the meter roll rotation speed at the high setting. 3.
12. SCR Board Setup Setting SCR Board Minimum Voltage 1. Switch the Moisture Control Switch back to the ON position. This will put the meter roll rotation speed at the low setting. 2. Use a voltmeter set at the 20 VDC range and probe terminal A+ with the red voltmeter probe and A- with the black voltmeter probe. Use a small screw driver and adjust the minimum setting for the potentiometer until the voltage is 9 VDC. The SCR board is now set and the dryer is ready for normal operation at desired settings.
13. Cross Reference Overload Cross Reference Chart CR124 STANDARD AND AMBIENT COMPENSATED BLOCK OVERLOADS 1 PHASE FOR CR124C 27 AMP OVERLOAD FOR CR124D 45 AMP OVERLOAD Motor FLA GE # GSI # New GE # Motor FLA GE # GSI # New GE # .30-.33 .34-.37 .38-.41 .42-.46 .47-.52 .53-.57 .58-.61 .62-.67 .68-.75 .76-.84 .85-.94 .95-1.03 1.04-1.14 1.15-1.30 1.31-1.42 1.43-1.61 1.62-1.72 1.73-1.93 1.94-2.10 2.11-2.34 2.35-2.64 2.65-2.86 2.87-3.13 3.14-3.32 3.33-3.68 3.69-4.08 4.09-4.61 4.62-5.21 5.22-5.62 5.63-6.12 6.
13. Cross Reference Overload Cross Reference Chart (Continued) CR324 STANDARD AND AMBIENT COMPENSATED BLOCK OVERLOADS 3 PHASE FOR CR324C 27 AMP OVERLOAD Motor FLA GE # .35-.39 GSI # FOR CR324D 45 AMP OVERLOAD New GE # Motor FLA GE # GSI # C054A RT12C 4.78-5.14 C630A D13-0001 .40-.42 C060A RT12C 5.15-5.63 C695A New GE # RT12L RT12L .43-.45 C066A RT12D 5.64-6.26 C778A D03-0008 RT12M .46-.51 C071A RT12D 6.27-7.15 C867A D33-0011 RT12M .52-.56 C078A RT12D 7.16-7.
13. Cross Reference Motor Cross Reference Chart 74 GSI # 100-1 D03-0309 200-1 300-1 500-1 712-1 1000-1 CD-0110 CD-0571 HP 1 1.5 2 3 5 7.5 10 10-12 15 RPM 1750 1750 1750 1750 1750 1750 1750 1750 1750 PHASE 1 1 1 1 1 1 1 1 1 VOLTS 230 230 230 230 230 230 230 230 230 FLA 6.5 9 14 15.
14. Warranty The GSI Group Warranty THE GSI GROUP (GSI) WARRANTS ALL PRODUCTS WHICH IT MANUFACTURES TO BE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDITIONS FOR A PERIOD OF 12 MONTHS AFTER RETAIL SALE TO THE ORIGINAL END USER. THE PURCHASER’S SOLE REMEDY AND GSI’S ONLY OBLIGATION SHALL BE TO REPAIR OR REPLACE, AT GSI’S OPTION AND EXPENSE, PRODUCTS THAT, IN GSI’S SOLE JUDGMENT, CONTAIN A MATERIAL DEFECT DUE TO MATERIALS OR WORKMANSHIP.
This equipment shall be installed in accordance with the current installation codes and applicable regulations which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made. GSI Group 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.grainsystems.
