Network Dryer Operation & Service Manual Operation & Service Manual PNEG-950 Date: 1-30-2006 PNEG-950
Table of Contents Section 1 Warranty............................................................................7 Section 2 Safety First........................................................................9 Safety Alert Symbol...........................................................................................10 Emergency Stop................................................................................................10 Safety Alert Decals......................................................
Meter Roll Reverse.............................................................................................70 Select Unload Method........................................................................................71 Select Dryer Address.........................................................................................72 Attempt to Refill.................................................................................................72 Model Number..............................................
Introduction GSI Network Portable Dryers 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 1200 series two fan grain dryers. These models are available for liquid propane, natural gas, or fuel oil fuel supply, with either single phase 230 volt, three phase 220, 380, 440, or 575 volt electrical power. The principal concern of GSI Group, Inc.
2 Fan Network Dryer Manual GSI Group, Inc. All rights reserved. No parts of this work may be reproduced in any form or by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of the publisher. Products that are referred to in this document may be either trademarks and/or registered trademarks of the respective owners. The publisher and the auther make no claim to these trademarks.
Section 1 Warranty
THE GSI GROUP, INC. WARRANTY THE GSI GROUP, INC. (“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.
Section 2 Safety First
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 100 Series single fan grain dryers. These models are available for liquid propane or natural gas fuel supply, with either single phase 230 volt, or three phase 220 or 440 volt electrical power. The principal concern of the GSI Group, Inc.
The GSI Group, Inc. recommends contacting your local power company, and having a representative survey your installation so the wiring is compatible with their system, and adequate power is supplied to your 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: The GSI Group, Inc. 1004 E. Illinois St. Assumption, IL 62510 217-226-4421 A free replacement will be sent to you.
Decal: DC-972 Decal DC-972 is located on the bottom auger belt guard and the front bearing plate (which is visible when then 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. Decal: DC-971 Decal DC-971 is located on the bottom auger belt guard and the front bearing plate (which is visible when then bottom auger belt guard is removed).
Decal: DC-1227 Decal DC-1227 is located on the fan/heater access door. Decal: DC-1225 Decal DC-1225 is located on the fan/heater access door. Decal: DC-1229 Decal DC-1229 is located on each of the meter roll access doors.
Decal: DC-973 Decal DC-973 is located on the rear plenum access door (inside and outside). Decal: DC-388 Decal DC-388 is located on the hitch tongue. Decal: DC-1249 Decal DC-1249 is located on the hitch tongue.
READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE SAVE FOR FUTURE REFERENCE 1. Read and understand the operating manual before trying to operate the dryer. This manual contains important guidelines and sequence of events to help you install and operate your dryer safely and successfully. Follow the guide lines closely. 2. After towing the dryer, ensure it is parked on a level surface and that suitable precautions have been taken to prevent it from rolling, i.e. block the wheels in both directions. 3.
PNEG-950
Section 3 Control Panel
PNEG-950 Load Auger Outside Light Dryer Mode Control Power Moisture Control LCD Display SWITCH PANEL LAYOUT Meter Roll Adjustment Stop Start Unload Auger Heaters Fans Keypad
CONTROL POWER SWITCH The control power to energize the Network 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. Turn the Main Disconnect Handle to the OFF posistion prior to servicing any of the installed components. DRYING MODE SWITCH This is used to select staged batch or continuous flow drying.
MOISTURE CONTROL SWITCH This switch activates the moisture control circuit. It lights up when the grain column temperature is below the moisture control (grain temperature) set point. OUTSIDE LIGHT SWITCH The dryers outside service light is turned on or off here. It also may be set on auto, which turns the light on while the dryer is running and off if a shutdown occurs. RUN SWITCH This switch starts and operates the dryer based on switch settings.
SETUP BUTTON Pressing the button while the system is stopped, will give you four setup screens. These are: This screen is used to clear your batch counter. You may want to do this at the start of the drying season to keep an accurate count of the batches ran through your dryer during the drying season. Press the button to clear it or just press the button to keep your total batch count. The next screen allows you to clear the total amount of bushels that your dryer has recorded.
DELAY BUTTON The button will display four different setup screens.
Set Out of Grain The Out of Grain timer should be set to the maximum time it takes for your dryer to refill during continious or batch mode drying. If the dryer runs out of grain while the load auger switch is in the auto position, the out of grain timer automatically shuts off the dryer after the period of time preset on the timer. Press the button to edit the timer settings. Press the button to adjust the timer value. Press the button to accept the changes.
View Grain Temps Press the Then press the button and move the pointer to change your selection to View Grain Temps. button to accept the selection. Grain Temperatures This allows you to look at detailed temperature information on each fan and heater that is installed on your dryer. Press the button to toggle between the fan/heaters or press the to exit out of this screen. Meter Roll SP Avg Press the Then press the button and move the pointer to change your selection to Meter Roll SP Avg.
View MR Speed Average On this screen is information showing you how much time the metering roll system has spent on HI speed and LOW speed. The ideal values of course is at 50% each, although in real world situations this is very difficult to obtain. Having a 30% - 70% reading is not uncommon but anything over this may indicate that meter roll speed settings may need adjusting.
HELP BUTTON The button currently has no function. DRY BUTTON The button is used to change the Dry timer settings when you operate your dryer in the Batch mode. This button has no effect in the continous drying mode. Please refer to the Staged Batch section. COOL BUTTON The button is used to change the Cool timer settings when you operate your dryer in the Batch mode. This button has no effect in the continous drying mode. Please refer to the Staged Batch section for Batch operation.
STATS BUTTON Pressing the button will toggle the last line of the main display screen to 3 different views relating to the dryers approximated output rate. This screen shows the actual turning speed of the meter rolls in RPM. Pressing the button again shows an approximated Bushel per hour that have passed through the dryer using the above RPM readings as a reference.
PNEG-950
Section 4 Dryer Pre Season Checks
This section gives a series of checks to be carried out on the dryer before starting for the first time in the drying season. If any of the checks fail to produce the stated result, you should consult your dealer. YOU SHOULD NOT ATTEMPT TO USE THE DRYER UNLESS ALL THE PRE-START CHECKS HAVE BEEN SUCCESSFULLY COMPLETED.
LOAD AUGER With the grain supply shut off, quickly bump the load auger switch to manual, and see if the load auger rotates clockwise as viewed from the drive end, or counterclockwise if the dryer is a front load model. If the wet grain supply auxiliary is wired to the dryer it should also rotate in the correct direction at this time. Turn the load auger switch to the auto position.
Meter Roll 2 Speed Display • Set the speed of the metering roll when the two speed automatic moisture control feature of the dryer is utilized. If you turn the meter roll adjustment knob and the unload switch is in the two speed position, you can adjust your 2 speed settings. Notice that the numbers next to Low is flashing. This indicates that any adjustment you make with the meter roll know will only affect this setting. To change the High setting, press the meter roll adjusment knob until it clicks.
decreased too much a popping or fluttering sound will be heard. Also, anytime the high pressure side is adjusted, the low pressure side needs to be checked. Repeat the test for each fan/heater unit. DRYER SHUTDOWN To shut down the dryer, 1. Close the fuel supply valve at the tank or valve along the fuel line. 2. If the burner is operating, let the dryer run out of fuel, and it will shut down automatically due to loss of flame. 3. Close the fuel valve at the dryer, and press the dryer power stop button. 4.
PNEG-950
Section 5 Dryer Startup and Operation
FULL HEAT DRYING Full Heat Operation With this type of drying, the grain is discharged hot, with no cooling. Drying capacity is substantially higher with FULL HEAT than the DRY AND COOL process. Dryeration Process The full heat process is called “DRYERATION”. Recommended procedure is to temper the hot grain for 4 to 10 hours in a cooling bin or storage bin, then cool by an aeration fan at an air flow rate of 1/2 to 1 CFM per bushel of grain in the hot batch being cooled.
Load Delay The load delay is used to delay the starting of the load auger when the dryer is unloading to prevent the load auger from cycling to often. To change the setting of this delay follow these instructions: 1. Press the button. 2. Press the button. 3. Press the 4. Press the button to adjust the settings. button to accept the changes. Out of Grain Timer The Out of Grain timer should be set to the maximum time it takes for your dryer to refill during continious or batch mode drying.
3. Press the 4. Press the button to adjust the settings. button to accept the changes. If you want to view the out of grain timer while the dryer is running, perform the following steps: 1. Press the button the display will then show this selection screen: 2. Press the to view the OUT OF GRAIN TIME selection screen. 3. Press the button and move the pointer from the SET OUT OF GRAIN to the OUT OF GRAIN TMR position. 4.
1. Press the button. Press 2. Press the button. 3. Press the 4. Press the (enter twice) to bypass the other screens. button to adjust the settings. button to accept the changes. Unload Delay The unload delay is used to control the amount of time the unload auger runs after the metering rolls stop to allow the unload auger to clean itself out. To change the setting of this delay follow these instructions: 1. Press the button. Press (enter three times) to bypass the other screens. 2.
Setting Up The Temperature Set Points These set points are monitored by the computer to control certain features of the dryer. These can be adjusted from the keypad of the Dryer control panel using the button or the button. Moisture Control Setpoint Drying mode switch is in the Continuous position: If the moisture control temperature is below this set point and you have your unload switch set to two speed position then meter rolls will discharge the grain using the low speed meter roll setting.
Plenum Temperature Setpoint The plenum temperature set point will determine the average temperature of air entering the grain columns. To change the burner cycling mode, please refer to Fan/Heater Select topic section of the Initial Setup Parameters chapter. To change the setting of the plenum temperature follow these instructions: 1. Press the 2. Press 3. Press the 4. Press the temps button. to advance to the next plenum screen or to change the set point. button to adjust the settings.
ately start, and the load auger switch will light up. If additional loading equipment is wired to the dryer it will also start immediately. 6. When the dryer is full of grain the top auger will stop automatically, and any auxiliary loading equipment wired to the dryer will also stop. CONTINUOUS FLOW DRYING MODE Full Heat-Continuous Flow Operation 1. Turn the CONTORL POWER switch to on. 2. After the date and time appear on screen, press the 3. Turn the DRYING MODE switch to CONT. FLOW. 4.
12. Run the fan(s) and heater(s) for about 10% longer than the (APPROX. DRYING TIME) required for the moisture you are trying to dry. 13. Example: 10% removal would be about 54 minutes, 15% removal would be about 76 minutes and 20% removal would be about 100 minutes. Add 10 minutes to insure that the grain is dry. 14. After the time in step 12 turn the UNLOAD to 1 SPEED and set the METER ROLL SPEED, (HIGH SPEED). to the setting for 1 SPEED operation. Grain should begin to run at this time.
9. Look in the Drying Charts section in the back of this manual for the DRY AND COOL chart settings that correspond to your model of dryer. You will see the settings for (Initial Moisture) (Moisture Removed) (Approx. Dry Time) (1 Speed) (2 Speed Low) (2 Speed High) pick the line that has your initial starting moisture. These are the settings we will be referring to during this start up procedure. 10. Run the bottom fan(s) and heater(s) (to be used for cooling later) for about 20 minutes.
7. Start each burner by turning the HEATER switch to AUTO. After purging for approximately 10 seconds the burner will fire, and the heater switch will light up indicating that the flame sensing circuit is sensing burner flame. For information concerning burner adjustment see the pre start section of this manual. 8. To properly set the correct DRY, COOL and UNLOAD time for various moisture content grains, see the drying charts for your size of dryer. 9.
During operation the remaining time on each timer is displayed on the screen. If the power goes out or if the dryer is stopped, these times are saved by the controller. When the dryer is restarted the timers will continue timing down. The timers will return to their initial setting if the reset button is pushed. Use the dryer charts in the back of this manual for reference of a suggested timer settings. Dry Timer This timer controls how long the burner will operate.
Unload Timer This timer controls how long the unload auger will operate after the cool timer has expired. Use the dryer charts on page 77 of this manual for reference of a suggested timer settings. To change the setting of this timer follow these instructions: Press the timer button, press the Press the Press the button to edit the amount of cool time. button to adjust the settings. button to accept the new setting.
PNEG-950
Section 6 Safety Circuit Shutdown Messages
FAN AND HEATER GENERATED ERRORS The following is a list of errors that are generated with the fan and heater controller. Each fan and heater has there own set of safeties which are listed below. You will need to inspect the controller associated with the error. Example: If you get this error it is telling you the problem is with Housing 1 (bottom most fan) High Limit.
distinguish between which burner caused the shutdown. The reference to the number one (1) is telling you that it is burner number 1 which is the bottom most fan. Grain Temp Short x This error indicates there is a shorted condition with one of the grain temperature sensors located inside the left or right grain columns. This could be a shorted sensor or the sensor wires could be shorted.
Illegal Flame x This message is displayed when the flame detection circuit of your heater is sensing flame when the burner is supposed to be off. Example, if you shut down the dryer and the heater continues to burn due to a solenoid stuck in an open state, it will generate this type of error. Motor Overload x One of the thermal overloads on either the fan, load, unload or auxiliary motors has opened, indicating an overcurrent condition. The overloads must be manually reset.
Vapor x High Limit The LP gas vapor temperature sensor located in the gas pipe train downstream from the vaporizer, has opened indicating that the vaporizor is running too hot and must be readjusted. This sensor is set at 200°F (93°C) and automatically resets itself when cool. The message will distinguish between which burner caused the shutdown. The reference to the number one (1) is telling you that it is burner number 1 which is the bottom most fan/heater unit, is where the malfunction is located.
to reset this error. This is caused from the motor operating with to much of a work load, which in turn uses more current (amperage). If the problem reoccurs then check the motor to make sure it is not being overworked. You may need to call an electrician to measure the motors full load amps (FLA).
Unload Motor Overload The motor overload has tripped on the Unload Motor Overload located in the upper control box. This indicates that 12VDC has been lost to terminal J2-08 on the I/O board. Push the red button on the overload to reset this error. This is caused from the motor operating with to much of a work load, which in turn uses more current (amperage). If the problem reoccurs then check the motor to make sure it is not being overworked.
Network Failed I/O This error is generated whenever Input/Output board (upper control panel) has lost its communications link with the master (lower control panel door) and the fan/heater boards. Check the blue and yellow wires marked N1-01 and N1-02 on a 3 terminal plug to make sure they are plugged in tightly. There are 3 LED lights next to this plug, one indicates power and the other two indicate data being transmitted.
Section 7 Service and Maintanance
Before starting any repairs or maintenance on your dryer, observe the following safety steps: 1. Isolate the whole system from the electrical supply by switching off the power isolator and locking it. 2. Isolate the dryer from the gas supply by shutting off the main gas valve (if necessary lock the valve). 3. Keep the keys in your possesion. 4. Augers and drives to augers may be under some degree of tension. Avoid touching these parts with your hands until you are sure that they are free. 5.
Note: All of the auger and metering roll bearings are lifetime lubricated and do not require service relubrication. 1. Remove and clean the gas line strainers. Make certain gas valves are closed and that gas is purged from the system before attempting to disassemble anything. 2. Inspect the collector plate at the top of the burner casting and the burner cup for any accumulation of foreign material. Clean if required.
FAN REMOVAL AND INSTALLATION When reassembling parts, the cap screws must be installed through the untapped clearance holes as shown. This will cause the blade to be pulled forward onto the tapered bushing, thus locking the parts securely onto the motor shaft. When fan servicing requires removal and installation of the blade, make sure the blade is removed and reinstalled properly. 1. Lock out the fan power supply, and remove the fan guard and the venturi, as required on some models. 2.
3. Install two of the cap screws into the threaded holes in bushing, and turn them by hand until they bottom against the front surface of the blade. NOTE: The threaded holes within the bushing are provided for disassembly purposes only. Do not attempt to use these holes for reassembly. They will not allow the parts to lock onto the shaft thereby causing a hazardous operating condition. 4.
Note: When installing a liquid gas solenoid valve on LP models, do not over tighten the connection into the inlet side, as the inlet orifice may become partially blocked. 4. Main Gas Orifice: With fuel shut off and gas purged from system, proceed as follows: a. Disconnect the plumbing support brackets from the pipe train. b. Disconnect gas solenoid valve coils. Be sure to mark which one goes where. c.
The scale of adjustment is from 0 to 999 which represents the flow of grain past the metering rolls as a percent of the maximum grain discharge rate for the dryer. The maximum setting of 999 provides a maximum 100% discharge of 1960 BPH (50 MT / hr) for 1214, 2240 BPH (57 MT / hr) for 1216, 2520 BPH (64 MT / hr) for 1218, 2800 BPH (71 MT / hr) for 1220, 3080 BPH (78 MT / hr) for 1222, 3640 BPH (92 MT / hr) for 1226 model dryers.
This column cutoff damper is designed to insert through the grain column (from the inside of the dryer) immediately above the metering roll. This permits opening of the metering roll access door. For service or inspection without unloading the dryer, the plenum bottom closure panel and metering roll adjust damper must be removed prior to using service tool. TROUBLE ANALYSIS PROCEDURE A multimeter is required for some of the following checkout procedures.
PNEG-950 65
PNEG-950
PNEG-950 67
PNEG-950
Section 8 Special Setup Screens
By pressing and holding the button while the power is off. Continue to hold and turn on the control power for the dryer. You will be able to access certain dryer features that rarely need to be changed and if setup incorrectly, could cause your dryer not to operate properly or not at all.
To toggle this feature on or off use the changes. buttons then press the button to accept the You will activate 2 additional screens by selecting yes. Reverse time This screen changes the amount of time you want he meter rolls to run in the reverse (backwards) mode. 5 minutes is the default setting. Pr ess to change the reverse time or to jump to the next screen. Forward time This screen changes the amount of time you want he meter rolls to run before switching to the reverse mode.
SELECT DRYER ADDRESS This feature is used for networking several portable grain dryers together for monitoring on a PC with special software. Changing this value will have no effect on the operation of the dryer, only the monitoring software (Watchdog 2000). ATTEMPT TO REFILL Changing this setting to yes allows your dryer to pause its drying process in the event that the Out of Grain Timer has expired.
changes press the button to accept them. Note: If the wrong selection is made, your dryer will look for other safeties that will not be present causing the dryer to be inoperable. TEMPERATURE SCALE This screen is used to toggle the temperature scale from Celsius to Fahrenheit. To change the scale press the then press the to accept the changes. FAN/HEATER SELECT This screen allows you to change the burner characteristics from a Hi/Lo type of burner to a On/Off type burner.
On this screen you can disable a fan and heater out of the Network loop. This would be used if you have a fan/ heater computer that is malfunctioning and rather than preventing you from using the dryer at all, you can just ignore it. So you can continue to use your dryer until you can have the dryer serviced. To change the fan/heater to an inactive state, press the buttons to toggle between active or inactive. Then press the button to accept your changes.
CONTRAST ADJUSTMENT Press and hold the the button while the control power is off, then turn the control power on, then release button. Press the buttons to darken or lighten the contrast. Press the to accept the changes. Note: If the display is blank, keep pressing the increase button to bring up the contrast. A new installed display board may not have had the contrast set at the factory and defaults at no contrast.
PNEG-950
Section 9 Drying Charts
1200 Series Dryers 1200 Continuous Full Heat 78 PNEG-950
1200 Continuous Dry & Cool PNEG-950 79
1200 Staged Batch 80 PNEG-950
1200S 50/50 Split Dryers 1200S Continuous Full Heat PNEG-950 81
1200S Continuous Dry & Cool 82 PNEG-950
1200S Staged Batch PNEG-950 83
PNEG-950
Section 10 Technical Reference
CONTROL PANEL JUMPER WIRING Note: Wiring specifications are subject to change without notice.
CONTROL PANEL INTERNAL WIRING PNEG-950 87
LOWER CONTROL BOX BACK PANEL WIRING 88 PNEG-950
NETWORK FAN/HEATER INTERFACE GREEN - ELECTRICAL GROUND BLUE - N1 NETWORK YELLOW - N2 NETWORK WHITE - 110VAC NEUTRAL BLACK - 110VAC POWER WHITE - GRAIN TEMPERATURE SENSORS 2 WIRES BLACK - GRAIN TEMPERATURE SENSORS 2 WIRES YELLOW - GRAIN HI LIMIT SWITCH YELLOW - GRAIN HI LIMIT SWITCH ORANGE - GRAIN HI LIMIT SWITCH ORANGE - GRAIN HI LIMIT SWITCH WHITE - PLENUM TEMPERATURE SENSOR BLACK - PLENUM TEMPERATURE SENSOR GREY - PLENUM HI LIMIT SWITCH +12VDC GREY - PLENUM HI LIMIT SWITCH +12VDC WHITE - SOLENOID NEUT
FAN COMPUTER PINOUTS 90 PNEG-950
FAN CONTROL BOX PNEG-950 91
UPPER TERMINAL STRIP 92 PNEG-950
UPPER BACK PANEL CONTROL WIRING PNEG-950 93
NOTES ______________________________________________________________________________________________________ _______________________________________________________________________________________________________ ______________________________________________________________________________________________________ __________________________________________________________________________________________________________ _________________________________________________________________________________________
NOTES ______________________________________________________________________________________________________ _______________________________________________________________________________________________________ ______________________________________________________________________________________________________ __________________________________________________________________________________________________________ _________________________________________________________________________________________
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 installation occurs. The GSI Group, Inc. 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 217-226-4421 Fax: 217-226-4420 e-mail: gsisales@grainsystems.com internet: http://www.grainsystems.
