Vision Hybrid for Portable Dryers Operation Manual PNEG-1935 Date: 06-04-13 PNEG-1935
PNEG-1935 Vision Hybrid for Portable Dryers
Table of Contents Contents Chapter 1 Safety .....................................................................................................................................................5 Safety Guidelines .................................................................................................................................. 5 Dryer Operation .....................................................................................................................................
Table of Contents View Button ......................................................................................................................................... 33 Table View.......................................................................................................................................33 Select Data Log Sample Time................................................................................................... 34 Graph View....................................................
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. Decals The GSI Group recommends contacting the local power company and having a representative survey the installation so the wiring is compatible with their system and adequate power is supplied to the unit. Safety decals should be read and understood by all people in the grain handling area. If a decal is damaged or is missing, contact: GSI Decals 1004 E. Illinois St. Assumption, IL. 62510 Phone: 1-217-226-4421 A free replacement will be sent to you.
2. Decals Decal: DC-972 WARNING Decal DC-972 is located on the bottom auger belt guard and the front bearing plate (which is visible when the bottom auger belt guard is removed). An alternate location would be at the rear of the dryer for portable dryers equipped with the Front Discharge Option. 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.
2. Decals Decal: DC-973 DANGER Decal DC-973 is located on the rear plenum access door (inside and outside). Automatic equipment can start at any time. Do not enter until fuel is shut off and electrical power is locked in off position. Failure to do so will result in serious injury or death. GSI Group 217-226-4421 DC-973 Decal: DC-1227 WARNING Flame and pressure beyond door. Do not operate with service door removed. Keep head and hands clear. Can cause serious injury.
2. Decals Decal: DC-1225 WARNING Decal DC-1225 is located on the fan/heater access door. Stay clear of rotating blade. Blade could start automatically. Can cause serious injury. Disconnect power before servicing. DC-1225 DC-1225 GSI Group 217-226-4421 Decal: DC-388 3/4" MINIMUM BOLT DIAMETER 16-17" Decal DC-388 is located on the hitch tongue. Hitch pin must be securely fastened and no less than 3/4" in diameter. Failure to follow installation instructions may result in property damage.
3. Vision Control Panel Heater switches Touch screen Fan switches Load switch Meter Roll Adjustment Unload switch Outside Light switch Control Power switch Start switch Stop button Figure 3A Control Power Switch The Vision control system is turned ON or OFF with this switch. NOTE: This switch does not disconnect the power that is present at the breakers, contactors, transformer(s), fuses or other electrical components found in the upper and lower control boxes.
3. Vision Control Panel Outside Light Switch The dryers outside service light is turned ON or OFF here. It also can be set on AUTO, which turns the light ON while the dryer is running and OFF if a shutdown occurs. Start Button Push the Start button and all of the selector switches on the control panel will be activated. Unload Switch The Unload switch turns the metering rolls and discharge auger ON or OFF and selects the operation of the metering rolls.
3. Vision Control Panel Here, you will find the following options: Speed Adjust buttons: These are used to adjust the setpoints if the Meter Roll Knob is disabled by the software. For instructions on doing this, see Operations Chapter on Page 21. Accept/Exit: To store the parameters and exit the screen. Cancel/Exit: To disregard the changes and exit the screen. Load Switch This is used to select the operation of the fill auger.
4. Boot Screen Boot Screen Description and Button Explanations Turning the Control Power switch to the ON position, will start the Vision computer. The first screen to appear will be the Boot Screen. Notice that there are four (4) buttons on the Boot Screen. (See Figure 4A.) Figure 4A 1. Start Dryer: This button accesses the dryer program. 2. Install Dryer Software: This button is used in updating the Vision software, which is described further in this chapter. 3.
4. Boot Screen Software Update Procedure 1. Cycle the Control Power switch. The Vision computer will start. (See Figure 4B.) Control Power switch Figure 4B 2. When the “Boot Screen” appears, touch the “Get Program From USB Flash” button. (See Figure 4C.
4. Boot Screen 3. Insert USB flash drive into USB port. 4. The display will now confirm that program files were found. Figure 4D Press “Yes” to copy. 5. After the program files are transferred, the “Boot Loader” screen will appear. (See Figure 4E.
4. Boot Screen Select the “Scan Network” button. This scan will check the dryer to make sure all parts of the control system are communicating directly. 6. After the scan is complete, the Display I/O, Main I/O, Moisture Control and the Fan/Heater(s) should be shown as “Nothing to Report”. (See Figure 4F.) NOTE: A Display I/O, Main I/O, Moisture Control and one entry for each Fan/Heater on the dryer should appear. Figure 4F Touch the “Exit” button. 7.
4. Boot Screen 8. Select the program file you wish to upload by touching the “Move Up” and “Move Down” buttons until the desired program file is highlighted. Then, choose the “Accept/Exit” button. 9. Touch the “Start Upload” button. 10. When the “Upload Progress” screen appears, select the “Start Upload” button. (See Figure 4H.) Figure 4H 11. The Vision computer will now begin programming each of the network circuit boards on the dryer.
5. Operations Operations NOTE: The following screenshots are taken from various models of portable dryers, explaining why the picture on the screen in this manual, may be different than that of the display. Default Operation Screen Dryer Status Dryer Operation Animation Dryer Status Charts Plenum(s) Configuration Buttons Figure 5A The “Operation Screen” is divided into five (5) sections. (See Figure 5A.) 1.
5. Operations Timers Button Select the button. A new screen will appear called the “Select Timer to Modify” screen. (See Figure 5B.) There are five (5) timers that can be modified. Figure 5B 1. Load Delay: (Default setting - 2 minutes) This delay is used to prevent the load auger from over-cycling. The load delay is active only when the Load switch is in the AUTO position. The timer starts when the dryer calls for grain. 2.
5. Operations Figure 5C Temp Button To adjust the temperature setpoints, touch the button at the bottom of the “Operation Screen”. A new screen will appear called the “Select Temperature Setpoint to Modify” screen. (See Figure 5D.
5. Operations Modify the setpoint for each of the temperatures by selecting the corresponding button. Plenum Temperature Setpoint - Press the “Plenum X Temp” button to change the individual plenum setpoints. The “X” refers to a number between 1 and 6. Plenum #1 refers to the heater closest to the ground. Grain Temperature Setpoint - This setpoint is used for all temperature based moisture control schemes. For more information, see the Moisture Control Options Chapter on Page 38.
5. Operations Setup Button The Setup screen will allow you to configure other parameters of the dryer. To access the “Select Hardware Setup Parameter to Modify” screen, also known as the “Setup Screen”, touch the button. (See Figure 5F.) Figure 5F The following list can be modified: 1. Drying Mode: The button will display the “Drying Mode Selection” window. Select continuous flow or staged batch. A check mark is displayed next to the currently selected drying mode. (See Figure 5G.
5. Operations 2. Moisture Control Setup: The moisture control setup operations are described in greater detail in the Moisture Control Options Chapter on Page 38. Figure 5H Figure 5I 3. Unload Parameters: a. Set Maximum Unload Rate: The meter roll speed setpoint cannot be set higher than this value. This prevents choking downstream augers. b. Set Minimum Unload Rate: The meter roll speed setpoint cannot be set lower than this value. (See Figure 5J.
5. Operations 4. Plenum Temp Manager: This will reduce the plenum temperature setpoint(s) if the unload rate reaches its maximum allowable value for the time specified by the “Time Between Steps” menu. Once the time has been exceeded, the dryer will reduce the temperature setpoint(s) by the value given in the “Size of Temperature Step”.
5. Operations The “Select Burner Mode” screen will allow the operator to select the type of burner operation for each burner. The user has three (3) options: HI/LO, ON/OFF and AUTO modes. a. HI/LO Mode (Default Setting): The burner will switch from high heat to low heat when the plenum temperature setpoint has been reached. b. ON/OFF Mode: The burner will shut OFF when the upper temperature setpoint has been reached and turn back on when the lower temperature setpoint has been met.
5. Operations 7. Extended Setup Screen The following list can be modified here: 1. Diagnostics: Figure 5N Check Light Outputs: Allow the user to verify the controller is attempting to illuminate each individual switch. If there is a check mark present on the Vision screen, the corresponding switch should be lit. If not, there is a wiring issue. Check Switch Wiring: Allows user to verify the controller is recognizing switch positions correctly.
5. Operations Figure 5O Example: If you have the temperature setpoint at 180°F and you select +/- 3° as the burner differential, then the burner will switch to low heat at 183°F and back to high heat at 177°F. To modify a burner differential setting, touch the plenum button you wish to modify, then select one of the five (5) differential setting buttons on the right side of the screen. The “Accept/Exit” button will save the settings and return to the “Setup Screen”. 3.
5. Operations 6. Set Time/Date: The (See Figure 5Q.) button will display the “Set Time/Date” window. Figure 5Q Use the “Up” and “Down” buttons to change each of the parameters. “Accept/Exit” will save settings and return to the “Setup Screen”. 7. Temp Scale: The button allows the user to select either English units or SI units. Depending on what temperature scale you are now operating, this button will display a pop-up window asking if you want to switch to SI (Celsius, metric tons, etc.
5. Operations 9. Data Logger Setup: By turning the data logger on, it records the following parameters of the dryer every 5 minutes. a. Dryer grain temperature b. Incoming grain temperature c. Incoming grain moisture d. Outgoing grain temperature e. Outgoing grain moisture f. Meter roll speed g. Bin number h. Hour i. Minute Figure 5S Looking Up Data Logger Records 1. Go to our website (www.grainsystems.com) and click on the “GRAIN DRYER VISION CONTROL” link at the right side of the page. 2.
5. Operations 10. User Saved Defaults: Here, you have the following options: Save Settings: Allows user to store the current setup of the dryer for retrieval later. Restore Settings: Restores the system to the settings last saved by pressing the “Save Settings” button. 11. Batches: This option allows the user to clear the batch counter. NOTE: This option will only appear if the system’s moisture control is set in stage batch mode. View Button Choose the button to open the “View Selection Window”.
5. Operations Select Data Log Sample Time Notice the “Sample Time” button in the upper left hand side of the dryer status chart. By touching this button, the sample time can be changed from the default (1 minute) to 5, 10 or 15 minutes. Select the desired sample time and touch “Accept/Exit” to exit. Also, notice that the chart can be cleared by selecting the “Clear Table” button at the bottom. (See Figure 5V.) Figure 5V 2. Graph View: This is the “Optional Operation Screen”. (See Figure 5W.
5. Operations 3. Owner’s Manual: This manual can be viewed on the Vision display screen. To view a manual, touch the “View” button. When the “View Selection Window” appears, choose the “Owner’s Manual” button. A new display will appear called an “Explorer Window”. The “Explorer Window” will show the manuals that are stored in the computer memory. To select a desired manual, “Double Tap” the corresponding manual icon, much like double clicking a mouse on the computer.
5. Operations 6. Software Version Info: This option will list the major software changes and additions in relation to the last software release. Figure 5Y M/C Button The button is used to change setpoints for the moisture controls. Pressing the button will access one of the following two (2) screens, depending on the drying scheme selected.
5. Operations Modifying Moisture Setpoint Figure 5AA Resetting Factory Defaults If the Vision system starts malfunctioning, sometimes restoring the factory defaults will alleviate the problem. NOTE: This will completely change the system setup, so this procedure is encouraged to be performed by a service technician. 1. Turn control power “OFF”. 2. Locate the “DEF” dipswitch on the Display I/O board. 3. Push the switch to the left. 4.
6. Moisture Control Options Moisture Control Options Moisture Control is used to regulate the moisture of the outgoing grain. For example, if a user is drying corn, the desired moisture content of the dried corn is usually around fifteen percent (15%). The moisture control schemes are designed to achieve that value with minimal effort from the user. These controls can be split into two (2) distinct modes of operation: Continuous Flow and Stage Batch.
6. Moisture Control Options 2 Speed Temperature When to Use: For use when good management is available and a quick reacting time is desired in all heat or dry and cool operation. How it Works: The user should stabilize the dryer with the Unload switch in the “MANUAL” position. It is imperative that the dryer is outputting the desired moisture content grain before switching the unload to the “AUTO” position.
6. Moisture Control Options 5 Speed Temperature When to Use: For use with a wider moisture variation spread and for when a close and quick reacting moisture control is desired in all heat or dry and cool operation. How it Works: The user should stabilize the dryer with the Unload switch in the “MANUAL” position. It is imperative that the dryer is outputting the desired moisture content grain before switching the unload to the “AUTO” position.
6. Moisture Control Options This scheme also has a feature called “Auto-Centering”. If the controller is staying in HI the majority of the time, it probably means the metering roll setpoint (MED) is set too low. To alleviate this problem, the unload rate is continually averaged. Once an hour, the controller changes the metering roll setpoint (MED) to the averaged value.
6. Moisture Control Options Moisture Controlled Schemes The moisture controlled schemes use the exiting moisture sensor as a reference parameter. As the grain moisture content varies, the controls adjust the unload rate accordingly. For example, our outgoing (dry) moisture setpoint will be set at 15%. If the outgoing moisture sensor reports a reading of 16%, the grain is 1% wetter than we desire.
6. Moisture Control Options This scheme also has a feature called “Auto-Centering”. If the controller is staying in HI the majority of the time, it probably means the metering roll setpoint (MED) is set too low. To alleviate this problem, the unload rate is continually averaged. Once an hour, the controller changes the metering roll setpoint (MED) to the averaged value.
6. Moisture Control Options Variable Moisture When to Use: For use when minimum moisture management is available and when large, quick changes in moisture are not expected. Can be used during all heat and dry and cool operation. How it Works: The user should stabilize the dryer with the Unload switch in the “MANUAL” position. It is imperative that the dryer is outputting the desired moisture content grain before switching the unload to the “AUTO” position.
6. Moisture Control Options Staged Batch Drying Stage batch drying is comprised of three (3) phases: Drying, Cooling and Unloading. 1. Drying Phase - All fans and burners are on during this phase. Unload is OFF. 2. Cooling Phase - All fans are on during this phase. Any burner in the “AUTO” position is turned OFF during this phase. If the burner is in the “ON” position, it will remain on for this period. The unload is OFF. 3.
6. Moisture Control Options How it Works: The user should stabilize the dryer with the Unload switch in the “MANUAL” position. It is imperative that the dryer is outputting the desired moisture content grain before switching the unload to the “AUTO” position. Single Plenum: The user enters two (2) parameters: Dry Timer and Plenum Setpoint(s). The drying phase consists of heating the plenum to the setpoints for the dry timer period. Once the dry timer expires, the controller moves on to cooling.
6. Moisture Control Options Setup Procedure 1. Press the “Stop” button on the control panel if the dryer is running. 2. From the “Setup” screen, select “Drying Mode”, then “Staged Batch”. 3. From the “Drying Mode Selection” screen, select “M/C Setup” to access “Staged Batch Setup”. 4. Select “Temperature” from the “Staged Batch Drying Criteria”. Make sure only the “Temperature” check box is selected, as it is possible to have “Time” and “Temperature” selected at the same time.
6. Moisture Control Options Setup Procedure 1. Press the “Stop” button on the control panel if the dryer is running. 2. From the “Setup” screen, select “Drying Mode”, then “Staged Batch”. 3. From the “Drying Mode Selection” screen, select “M/C Setup” to access “Staged Batch Setup”. 4. Select “Time” and “Temp” from the “Staged Batch Drying Criteria”. Make sure both the “Time” and “Temperature” check boxes are selected. 5. If desired, enable the “Max Time” and “Max Grain Temp” safety. 6.
6. Moisture Control Options Here is an example of how to calculate the Dry Time: Let’s say we have a 1/2-1/2 split dryer, so N will equal two. The wet grain has a moisture content of 21% and we want to dry it to 15%. We will use 5 minutes as our initial guess for the MPP. The Cool Time is set for 20 minutes and the Unload Time is set for 10 minutes.
6. Moisture Control Options Setup Procedure 1. Press the “Stop” button on the control panel if the dryer is running. 2. From the “Setup” screen, select “Drying Mode”, then “Staged Batch”. 3. From the “Drying Mode Selection” screen, select “M/C Setup” to access “Staged Batch Setup”. 4. Select “Moisture” from the “Staged Batch Drying Criteria”. 5. If desired, enable the “Max Grain Temp” safety. 6. Return to the “Default Operation Screen”. 7. Execute the equation above to determine the initial Dry Time value.
7. Initial Settings Check Dealer Suggested Initial Settings Check 1. Power on using the Control Power switch. Wait approximately 30 seconds. 2. Now viewing the “Boot Screen”, select “Start Dryer”. 3. Setup timers. 4. Using the “Extended Setup Screen”, select the following options to configure the dryer. Please use Operations Chapter on Page 21 as a reference guide. a.
8. Safety Circuit Shutdown Messages In the event of a dryer malfunction, the following error screen will appear: Figure 8A After you press the “Help” button, the “Shutdown Help File”, shown in Figure 8A, is displayed. It will display a picture of the part that may have caused the shutdown, along with a reason for the error. Fan/Heater Shutdown Messages “X” represents a number between 1 and 6 in the following message names.
8. Safety Circuit Shutdown Messages 0203 - Burner #X Vapor Temp High-Limit This message indicates that 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 readjusted. This sensor is set at 200°F (93°C) and automatically resets itself when cooled. The message will identify which burner caused the shutdown. Try adjusting the vaporizer coils farther away from the burner’s flame.
8. Safety Circuit Shutdown Messages 020C - Burner #X Grain Overheat (Thermistor) This error indicates that an over-temperature condition has occurred in one of the grain columns causing the control to shutdown the dryer. This control is set at 210°F (99°C) and automatically resets itself when cooled. This can be caused by a grain column plugged with trash or the meter rolls may be adjusted to run too slowly. Feel the grain columns to determine which one may be causing the malfunction.
8. Safety Circuit Shutdown Messages Main I/O Shutdown Messages 0E01 - Main I/O - Primary Unload Motor Overload This message indicates that the unload motor overload has been tripped in the upper control box. This indicates that 12 VDC has been lost to terminal J1-02 on the Input/Output board. Push the red button on the overload to reset this error. This is caused by the motor operating under too much load, which uses more current (amperage).
8. Safety Circuit Shutdown Messages 0E08 - Main I/O - Out of Grain Timer (OOG) Expired This message indicates that the dryer has run low on grain and the out of grain timer has timed out, shutting the dryer down. The unload auger will continue to run so it can clean out the remaining grain before shutting down.
8. Safety Circuit Shutdown Messages Moisture Control Shutdown Messages 0F01 - MC - Network Connection Failed This error is generated whenever the master display board (lower control panel) has lost its communications link with the moisture board (lower control panel or separate enclosure). Check the Ethernet cable jacks to make sure they are plugged in tightly. 0F02 - Max Drying Time Exceeded This safety can be used when drying in stage batch mode.
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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.com GSI is a worldwide brand of AGCO Corporation.
