PLC WatchDog Installation and Operation Manual PNEG-1755 Date: 07-28-10 PNEG-1755
PNEG-1755 PLC 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 PLC WatchDog system allows for remote monitoring of a tower dryer. An internet connection allows the user to view the dryer from any device that has a web browser. Currently, the only supported browser is Microsoft’s Internet Explorer. Features 1. Remote monitoring of dryer 2. Remote shutdown of dryer 3. Remote drying parameter adjustment (Plenum and grain temperature setpoints, unload rate, etc.) 4. Web browser is the only software needed by the customer 5.
3. Installation PLC WatchDog Connection (Part #: GT4-5073) This 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 Install Procedure This installation takes place in the power panel of the tower dryer system. Follow the steps listed below to install the components; also refer to Figure 3A on Page 9. 1. Turn OFF power to the dryer and control panel. 2. Attach the Red Lion controller and the 24 VDC power supply to the DIN rail. 3. Wire the 120 VAC supply power from the power panel terminal “L1.1”, to the 24 VDC power supply terminal “L”. 4.
3. Installation DHCP Pool If the modem/router does not have DHCP reservations, the controller can be allowed to pull an IP address from the DHCP server’s IP range. This method is only recommended when the PLC WatchDog is the only node on the network. Reduce the IP range of the DHCP server down to one IP address. This will be the only IP address that the DHCP server is allowed to serve to the network.
4. PLC WatchDog Operation GSI PLC WatchDog When the web browser initially makes contact with the PLC WatchDog System, you will be presented with a screen displaying several links to other pages. (See Figure 4A.) Figure 4A From this page you may access the “View Data”, “View Logs” and “Remote View” pages. View Data The following pages allow the user to input data to be changed with the Remote View application. (See Figure 4B.
4. PLC WatchDog Operation Password Figure 4C Variables that may be edited here are: (See Figure 4C.) Enter Current Password - Enter current password to be verified. New Password - Enter only when changing passwords. Re-Enter New Password - Enter only when changing passwords. For additional information on verifying and changing your password information, refer to “Remote View” section on Page 19 of this manual.
4. PLC WatchDog Operation PLC WatchDog Figure 4D Variables that may be edited here are: (See Figure 4D.) IP Address - Address that the SMTP server is using to forward messages. SMTP Domain - Domain name of SMTP server. Email User - Email address to receive alarm messages. SMS Text User - Text messaging account information*. Grain Temp - °F setpoint for grain temperature. Unload Rate - Speed setpoint for unload conveyor. Dry Setpoint - Percent moisture setpoint for dry grain.
4. PLC WatchDog Operation Set Time and Date Figure 4E These variables allow the user to modify the date that the PLC stores. This information is also displayed on the Remote View Dryer Display. (See Figure 4E.) System Month - Month of the year stored in the PLC. System Day - Day of the week stored in the PLC. System Year - Current year to be stored in the PLC. System Hour - Hour of the day stored in the PLC. System Minute - Minute of the hour stored in the PLC.
4. PLC WatchDog Operation Editing Variables All of the previous listed variables can be changed by the following instructions; we will use Grain Temp as an example. Navigate to the GSI PLC WatchDog web page. - (See Figure 4A on Page 12.) Select “View Data”. - (See Figure 4B on Page 12.) Select “PLC WatchDog”. - (See Figure 4D on Page 14.) Select “Edit” next to the Grain Temp variable. In the box labeled “New Value”, enter your new setpoint. Figure 4F Click “OK”. (See Figure 4F.
4. PLC WatchDog Operation Figure 4G Select “Back” to return to the “View Data” web page. (See Figure 4B on Page 12.) Select “Back” to return to the “GSI PLC WatchDog” web page. (See Figure 4A on Page 12.) When editing variables, several may be edited before navigating to the “Remote View” page. Therefore perform as many edits as you need before returning to update any variables or settings.
4. PLC WatchDog Operation Figure 4H For example, if the dryer is running a TWOPOINT control then you would select the TWOPOINT link and the file list will be displayed. (See Figure 4I.) Figure 4I These files may then be downloaded and saved for future use by the user. These files are easily opened in Microsoft Excel and can be manipulated to show historical data from the dryer.
4. PLC WatchDog Operation Remote View The “Remote View” web page allows the customer remote access to view and modify certain variables and information for the dryer. (See Figure 4J.) Figure 4J To continue any further, the user will need to verify a password. This password must be entered into the “Enter Current Password” field on the “View Data - Password” web page. Editing Passwords Navigate to the “GSI PLC WatchDog” web page. - (See Figure 4A on Page 12.) Select “View Data”.
4. PLC WatchDog Operation Figure 4K Click “OK”. (See Figure 4K.) You will be re-directed back to the “Password” page. Verify your current password is now listed as the “Value”. (See Figure 4L.) Figure 4L Select “Back” to return to the “View Data” web page. (See Figure 4B on Page 12.) Select “Back” to return to the “GSI PLC WatchDog” web page. (See Figure 4A on Page 12.
4. PLC WatchDog Operation Verify Password Button Pressing the “Verify Password” button with a valid password entered will change the “Password Status” indicator from “Inactive”, Figure 4J on Page 19, to “Active” as in Figure 4M. Figure 4M Password Status Indicator An “Active” status allows the user to access other areas of the “Remote View” program.
4. PLC WatchDog Operation Change Password Button Password status must be active to enable this function. When changing a password, the user must first enter the desired change in the “New Password” field on the “View Data - Password” web page. The user must also re-type the new password in the “Re-Enter New Password” field. These values must match in order to complete the password change. After completing the variable edit, the user needs to return to the “Remote View” web page, Figure 4J on Page 19.
4. PLC WatchDog Operation Figure 4O After one minute the status will return to “Unchanged” to allow for additional changes in the future. If the attempt was unsuccessful the Status will still be “Unchanged”. The user will need to re-enter the new password information again on the View Data - Password web page to attempt the change again.
4. PLC WatchDog Operation Dryer Display Button Main Display Password status must be active to enable this function. Pressing the “Dryer Display” button will take the user to the screen displayed in Figure 4P which provides a continuous visual feedback on the current dryer status. Figure 4P Viewing Temperature/Moisture History Press the left and right arrows below the Temperature/Moisture History Chart to move backward and forward through the graph.
4. PLC WatchDog Operation Main Menu Button Pressing the “Main Menu” button will return the user back to the screen that is shown in Figure 4M on Page 21. Log Off Button Pressing the “Log Off” button changes the password status to inactive and will return the user back to the screen that is shown in Figure 4J on Page 19. System Variables Button Password status must be active to enable this function. Pressing the “System Variables” button will bring up the screen that is shown in Figure 4Q.
4. PLC WatchDog Operation If a change is to be made to the current settings of the system, the user should verify the information displayed under “New Settings” and then proceed to press the “Update System Variables” button. Upon pressing this button, the updated information will be sent to and stored in PLC. The updated information will also change on the web page. Figure 4R Pressing the “Return to Main Menu” button will return the user back to the screen that is shown in Figure 4M on Page 21.
4. PLC WatchDog Operation Figure 4S If a change is to be made to the current settings of the system, the user should verify the information displayed under “New Settings” and then proceed to press the “Update Settings” button. Upon pressing this button, the updated information will be sent to and stored in PLC WatchDog controller. The updated information will also change on the web page.
4. PLC WatchDog Operation Figure 4T If a change is to be made to the time and date of the system, the user should verify the time/date information displayed under “New Settings” and then proceed to press the “Update Time Settings” button. Upon pressing this button, the updated information will be sent to and stored in the PLC. The updated information will also change on the web page. Pressing the “Return to Main Menu” button will return the user back to the screen that is shown in Figure 4M on Page 21.
5. Troubleshooting Problem Potential Fix Green LED off on 24 VDC power supply. 1. Check the 120 VAC wiring to the unit. (See Figure 9A on Page 33.) Red STS LED off on the Red Lion controller. 1. Verify 24 VDC wiring to the unit. (See Figure 9B on Page 34.) 1. Verify all wiring connections to the Red Lion controller. Unable to connect to PLC WatchDog web site. 2. Verify proper IP address.
6. Technical Support This section lists the pertinent contact information to be used in the event of a 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. Contact your Internet Provider for assistance. Dealer If contacting your Internet Provider has not solved the problem, contact your dealer for the next steps.
7. 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. Attach the cellular modem to the DIN rail. 2.
8. Appendix B Common List of SMS Carriers and Account Formatting The following list is not all inclusive. If your carrier is not listed or if you are having problems with receiving text messages, please contact your local provider for further information. 32 Alaska Communications Systems number@msg.acsalaska.net Alltel Wireless (presently merging with Verizon Wireless) number@text.wireless.alltel.com AT&T Wireless domestic-number@txt.att.
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10. 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.
