WatchDog Installation and Operation Manual PNEG-1745 Date: 06-07-10 PNEG-1745
PNEG-1745 WatchDog
Table of Contents Contents Chapter 1 Safety ..................................................................................................................................................... 4 Safety Guidelines .................................................................................................................................. 4 Dryer Operation .....................................................................................................................................
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 Operation Thank you for choosing a GSI product. It is designed to give excellent performance and service for many years. This manual describes the operation and service for all standard production model dryers. These models are available for liquid propane or natural gas fuel supply, with either 1 phase 230 volt, or 3 phase 230 or 440 volt electrical power. Our foremost concern is your safety and the safety of others associated with this equipment. We want to keep you as a customer.
1. Safety Safety Precautions READ THESE INSTRUCTIONS BEFORE INSTALLATION AND OPERATION SAVE FOR FUTURE REFERENCE 1. Read and understand the operating manual before attempting to operate the dryer. 2. NEVER operate the dryer while the guards are removed. 3. Power supply should be OFF for service of electrical components. Use CAUTION in checking voltage or other procedures requiring the power to be ON. 4. Check for gas leaks at all gas pipe connections. If any leaks are detected, DO NOT operate dryer.
1. Safety Use Caution in the Operation of this Equipment This dryer is designed and manufactured with operator safety in mind. However, the very nature of a grain dryer having a gas burner, high voltage electrical equipment and high speed rotating parts, presents hazards to personnel which cannot be completely safeguarded against without interfering with the efficient operation of the dryer and reasonable access to its components.
2. Introduction Description The WatchDog System allows for remote monitoring of a Vision dryer. There are two (2) configurations available: Internet Connection and Direct Connection. Internet Connection allows the user to view the dryer from any device that has a web browser. Internet Explorer and Mozilla Firefox were the only two (2) browsers tested, but other browsers should be able to view it without problem.
3. Installation Internet Connection (Part #: VIS-WATCH-IC) This option requires an active internet connection be present at the dryer via Ethernet (RJ-45 connection). It is recommended that either an Internet Service Provider (ISP) technician or someone versed in networking be present during installation. While GSI’s Technical Support group can offer suggestions, GSI is not responsible for the required connection. Package Contents The contents of this package are pictured in Figure 3A.
3. Installation Serial cable connector figures: (See Figure 3B and Figure 3C.
3. Installation Install Procedure This installation takes place in the lower control panel of the Vision system. Follow the steps listed below to install the components: 1. Turn OFF power to dryer and control panel. 2. If a cellular modem is being installed, first refer to Appendix A on Page 45 for a few extra instructions and then return here. 3. Place mounting plate with WatchDog circuit board attached over two (2) existing bolts on the right side of the lower control panel.
3. Installation 4. Connect the 3 position quick connector of Serial Cable #1 to the “AUX SERIAL PORT” on the Display I/O board located on the back of the touch screen. The connector is polarized so care should be taken to plug it in correctly. (See Figure 3E.
3. Installation 5. Plug the DB9 connector of Serial Cable #1 into the DB9 connector on the WatchDog circuit board. Tighten the two (2) screws to secure the connection. (See Figure 3F.) DB9 Connector Figure 3F 6.
3. Installation If a cellular modem is NOT being used, the bare leads of the WatchDog power cable should be connected to the moisture control board as follows: Black with faint white line lead - J1-1 “POWER SUPPLY+ (+12 VDC)” Black lead with faint white writing lead - J1-2 “POWER SUPPLY GROUND” Please refer to Figure 3H. Figure 3H 7. The barrel connector of the WatchDog power cable should be plugged into the power connector on the WatchDog circuit board. (See Figure 3H.) 8.
3. Installation Network Setup This section is intended to help ISP or network technicians install the WatchDog. If this section does not make sense to you, it is strongly advised to request the service of a network technician. Default Configuration The WatchDog’s Wide Area Network (WAN) port default is setup as a Dynamic Host Configuration Protocol (DHCP) client. The script to configure the port is only executed on start-up.
3. Installation The default password is default. The password is the same as is used to access the WatchDog. Therefore, if the user has changed the password, the setup password will be whatever they have changed it to. If the user forgets his/her password, see the user manual for resetting the password. Once logged in, Figure 3K should be displayed on the screen. Figure 3K The current setup is displayed to the left of this screen. The address will differ from Figure 3K.
3. Installation At first, neither DHCP or Static is selected. Choose one or the other depending on how you would like to setup the WatchDog’s network parameters. If “Static IP” is selected, the following fields are displayed for entry: IP Address, Subnet Mask, Default Gateway, DNS 1 and DNS 2. Figure 3M depicts these entries. Figure 3M Note that all fields are required when using the Static IP option.
3. Installation Configuring a Modem/Router If the WatchDog board is connected to a modem/router that is configurable, listed below are a few recommendations to assist with setup. The methods below do not cover every configuration that is available. If the modem is not configurable, refer to Page 17 for setting the WatchDog network to the static IP allocated by the service provider. Static IP This is the preferred method for installation. Acquire the LAN’s default gateway address of the modem/router.
3. Installation Accessing the WatchDog The WatchDog is accessed from any PC that has an internet connection and web browser. Some phones are available that view the graphics correctly; other phones will have to view the text version. 1. Make sure that the dryer is powered up and the Vision application is running. 2. On the PC or phone, open up a web browser, i.e. Internet Explorer, Mozilla Firefox, etc. 3. In the URL bar, enter the static IP address given by the ISP.
3. Installation Direct Connection (Part #: VIS-WATCH-IC) This option allows the user to connect their dryer directly to one Personal Computer (PC) using two (2) short-haul modems and four (4) wires, CAT5 is recommended. Text messaging and e-mail is not available with this option. Package Contents The contents of this package are pictured in Figure 3O. Please refer to Figure 3O during installation. Package contains: 1. WatchDog enclosure (white case). 2. Two (2) short-haul modems w/ power supplies. 3.
3. Installation Serial cable connector figures: (See Figures 3P, 3Q and 3R.
3. Installation Install Procedure This installation is split into two (2) steps. Some installation is done in the lower control panel of the Vision system at the dryer and the rest at the PC location. This manual does not cover running the wires between the two (2) locations, as this is the customer’s responsibility. CAT5 cable is recommended by GSI. Installation at the Dryer The following items will be installed at the dryer location: 1. One short-haul modem w/ power supply. 2.
3. Installation 3. Plug the DB25 connector of Serial Cable #2 to one of the short-haul modems. Care should be taken to make sure the switches on the short-haul modem match those in Figure 3U.
3. Installation 4. Now, the four (4) wires that run from the dryer to the PC location need to be connected to the short-haul modem. Use the following table to document what color is attached to which terminal. This will help in connecting the other end of the cable at the PC location. Table 1: Wire Colors at Dryer Terminal # at Dryer Wire Color 1 2 3 4 NOTE: The order of the colors in the picture are for illustrative purposes only. 5.
T-ON/R-ON DCE 4321 4321 SIM 3. Installation Dryer side SIM T-ON/R-ON DTE PC Side Figure 3V Connect the wires to the short-haul modem according the terminal numbers listed at the right of Table 2 on Page 24. 2. Plug the DB25 connector of Serial Cable #3 to the short-haul modem. Care should be taken to make sure the switches on the short-haul modem match those in Figure 3X on Page 26.
3. Installation PC side switch positions SIM DTE T-ON/R-ON 4 3 2 1 Figure 3X 3. Attach the DB9 connector of Serial Cable #3 to the DB9 connector on the WatchDog enclosure. RJ-45 Connector DB9 Connector Figure 3Y 4. Plug an Ethernet cable into the RJ-45 connector on the WatchDog enclosure. Please refer to Figure 3Y. 5. Attach the other end of the Ethernet cable to the Ethernet port on the PC.
3. Installation 6. The short-haul modem power supply should be plugged into a 120 VAC receptacle and the barrel connector into the short-haul modem. The red power light should come ON. 7. Plug the power cable from the WatchDog enclosure into a 120 VAC receptacle. Accessing the WatchDog The WatchDog is accessed from the PC that the WatchDog enclosure is attached to. This PC will be used in the section to connect to the dryer. 1. Make sure that the dryer is powered up and the Vision application is running.
4. WatchDog Operation Login Screen When the web browser initially makes contact with the WatchDog System, you will be presented with a screen requesting a password. (See Figure 4A.) Once the password has been entered, you must press the LOG IN button to accept the password. Default password is default. Figure 4A If you have forgotten the password, press the “Forgot Password” button shown in Figure 4A. This will bring up the screen shown in Figure 4B.
4. WatchDog Operation Default Operation Screen The screen in Figure 4C will be displayed, unless the dryer is shutdown, upon connection to the dryer if it is a tower dryer. This very closely resembles how the screen would appear at the dryer. All the buttons function exactly as they would if pressed on the dryer screen, except for the Setup and View buttons. These buttons on this screen allow changes to be made to the setup of the WatchDog System and to view information related to the WatchDog System.
4. WatchDog Operation Figure 4D Timer Button Pressing the button will display a screen similar to that in Figure 4E. The actual layout will vary depending on the type of dryer and its particular setup. Pressing any of these timer buttons will allow modification of that timer’s setpoint value.
4. WatchDog Operation For example, pressing the button will bring up the timer minutes modification dialog box shown in Figure 4F. Enter the number of minutes and press OK. Figure 4F Another dialog box will then appear prompting the second’s setpoint to be entered as shown in Figure 4G. Figure 4G Depending on the security settings of the particular browser you may have to temporally allow scripted windows. Using Internet Explorer, simply right click and select OK and press Timer button again.
4. WatchDog Operation Figure 4H Pressing the button will bring up a dialog requesting a new setpoint value to be entered. (See Figure 4H.) Once the new value has been entered, press the OK button to accept or CANCEL to keep the old value. All other temperature setpoints are set similarly. (See Figure 4I.
4. WatchDog Operation Setup Button Pressing the button will bring up the screen shown in Figure 4J. The Setup screen is not used to setup the dryer as it would at the dryer control, but it is used to further setup the WatchDog System. The Setup screen has been broken into six (6) distinct functions and these will be addressed in the following sections. Figure 4J Select Time Interval This set of radio buttons allows the user to select how often the WatchDog System contacts the dryer for information.
4. WatchDog Operation Metering Roll Speed Setpoint This portion of the Setup screen allows the user to adjust the metering roll speed setpoints. Only the setpoints required by the current setup are shown, so the screen may vary from the one shown in Figure 4L. Do not enter a percent (%) symbol, e.g. to enter 50% simply enter 50 and press OK. Figure 4L Shutdown Dryer Pressing the stop sign displayed on the Setup screen will shutdown the dryer.
4. WatchDog Operation Change Site Name The site name is displayed at the top of the webpage. This is a way to personalize the WatchDog remote monitoring system. It is especially useful when viewing more than one WatchDog on a single PC. This will identify which site the user is currently looking at. The site name is also included in the text messages and e-mails that are sent due to dryer shutdowns. (See Figure 4P.
4. WatchDog Operation M/C (Moisture Setpoint) Button Pressing the button will bring up a dialog box requesting to modify the current grain temperature setpoint or the moisture setpoint depending upon the setup of the dryer. For example, Figure 4R shows the dialog box that is presented when using temperature to control the moisture output of the dryer.
4. WatchDog Operation Text Version The text version of WatchDog leaves all of the fancy graphics behind and simply displays a few key parameters denoting the status of the dryer. This version was put in place to allow phones that cannot handle the graphics the ability to monitor the dryer. Shutdowns will still be displayed when using the text version. (See Figure 4T.) To access, scroll to the bottom of the webpage and click on the “Click Here for the Text Version” link.
5. WatchDog Software Update Process This process assumes the user is using Windows XP. 1. Make an SD card readable by your computer. This may require a special piece of equipment from a consumer electronics store. Below is an example of an SD card. (See Figure 5A.) Figure 5A 2. Download the “WatchDog Update Version 1.03 installation program” file from http://www.gsiag.com/ gsi/progs/watchdog/to a directory on your computer. 3. Execute the “WatchDog Update v103.
5. WatchDog Software Update 5. Click the “Next” button to proceed. (See Figure 5C.) Figure 5C 6. This will bring you to a list of changes made from the previous version. Click “Next” to proceed. (See Figure 5D.
5. WatchDog Software Update 7. Select the drive that your SD card is using and click “Next”. (See Figure 5E.) Figure 5E 8. Verify the correct drive has been selected and click “Next”. (See Figure 5F.
5. WatchDog Software Update 9. The installer is now ready to install the update to the SD card. Click “Next” to install. (See Figure 5G.) Figure 5G 10. Once the files have been transferred, the SD card installation is complete. Click “Finish” to exit the installer. (See Figure 5H.
5. WatchDog Software Update 11. After turning the WatchDog power OFF, insert the SD Card into the WatchDog board as shown in Figure 5I. Figure 5I 12. Once the SD Card is securely placed in the reader, return power to the WatchDog board and allow 3 minutes to pass. 13. After 3 minutes have passed, turn the WatchDog power OFF and then remove the SD Card from the board. 14. Return power to the WatchDog board and wait for the red “SYS” light to come ON. The WatchDog is now updated.
6. Troubleshooting Internet Connection Problems Problem Potential Fix 1. Check the current version of Vision. It should be 1.00 or newer. 2. Make sure the Vision is powered ON and the dryer application is running. 3. Check the connection points of the Serial Cable #1 between the WatchDog circuit board and Display I/O circuit board. “Check connection between WatchDog and Dryer. Also check Vision Version. Should be 1.00 or newer.” is being displayed. 4.
7. Technical Support This section lists the pertinent contact information to be used in the event of WatchDog System failure. There are three (3) possible options for help. Internet Provider If the WatchDog System is not accessible via the Internet please make sure the Internet Connection being used is viable. This can be done in a number of ways, but contacting the Internet Provider for assistance would probably be the best way to address this problem.
8. Appendix A Acquiring and Installing a BlueTree Cellular Modem To acquire a GSI recommended cellular modem, contact the following company: USAT Corporation www.usatcorp.com sales@usatcorp.com 919-942-4214 Ask for a GSI Group account manager. If you are installing a BlueTree modem acquired from USAT Corporation, there are a few extra installation steps for mounting. Perform the following list of instructions before returning to the “Install Procedure”: 1.
8. Appendix A 3. Connect one end of an Ethernet cable to the Ethernet connector on the cellular modem. Please refer to Figure 8C. 4. Run the antenna wire for the cellular modem through a knockout in the bottom of the control panel and connect the BNC connector to the modem. The antenna is magnetized and should be placed with the least obstructions to the nearest tower. Ethernet connector Antenna connector Figure 8C 5. Return to the “Install Procedure” on Page 11.
9. Warranty GSI Group, LLC Limited Warranty The GSI Group, LLC (“GSI”) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier.
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.gsiag.
