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Dryer Master DM510 Installation Manual

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INSTALLATION GUIDE
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Dryer Master DM510
Installation Guide
©Dryer Moisture Systems Inc.
115 Ardelt Avenue, Kitchener, Ontario
Phone 519.725.4700 • Fax 519.885.4300
USA and Canada – Toll free at 1-888-318-0009
E-mail: [email protected]
Reminder
Remember to register your DM510 at dryermaster.com
Simply by registering your new DM510 you automatically
extend your warranty from 1 year to 2 years.
February 28, 2015
January 15, 2016
January 31, 2017 March 30, 2018
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What is in this guide
In this guide you will find the information you will need in order to install a Dryer Master DM510. There is information on both the physical installation and the wiring connections.
Before you start the installation, review the information in this manual as there are a few key decisions you should make before starting the actual installation.
Specifically, you will need to determine where to install the DM510 panel and the two moisture sensors. It is extremely important for the proper functioning of the DM510 that the sensors be installed according to the instructions and requirements outlined in this guide. There are several examples shown in this guide, but each situation can be somewhat unique, so if you have questions ask us before beginning the installation.
Once you have completed the installation, the next step will be to use the Commissioning Guide to tailor the DM510 to your particular dryer. Do not attempt to use the DM510 to control your dryer
before completing the commissioning process.
If you have questions call us at the Dryer Master Customer Support Centre
One of the benefits you receive with the DM510 is access to support from the Dryer Master Support Center where we have experts in the theory (application to drying), installation and operation of the DM510. Personnel are available to answer questions about the material in this manual and other questions you have pertaining to drying. You can call the support center toll free from the USA
or Canada at 1-888-318-0009, or directly at 519-725-4700.
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Index
Index .......................................................................................................................... 4
Table of figures ................................................................................................................................ 6
Dryer Moisture Systems Inc. – About Us ................................................................ 8
DM510 - A Brief Description ..................................................................................... 9
DM510 - How it Works .............................................................................................. 9
System Components ............................................................................................... 10
DM510 Control Panel including I/O:.................................................................................................... 10
Printer (optional): ................................................................................................................................... 10
Inlet Moisture and Temperature Sensor: ........................................................................................... 10
Outlet Moisture and Temperature Sensor & Chute with Rotary Feed: .......................................... 10
Calibration Push Button: ...................................................................................................................... 10
Drying Air Temperature Sensor or Temperature Signal Converter: ............................................... 10
Internet Connectivity Capability: ......................................................................................................... 10
Installation Configurations (printer optional) ..................................................... 11
Configuration with Integrated I/O and APT sensor ........................................................................... 11
Configuration with Remote I/O and APT sensor ............................................................................... 12
Configuration with Integrated I/O and Temperature Signal Converter ......................................... 13
Project Manager Guide and Checklist .................................................................. 14
Installation Overview............................................................................................................................. 14
Situation 1 Overview: Installation on new dryer when purchased from dryer manufacturer ... 14
Situation 2 Overview: Retrofit onto an existing dryer ...................................................................... 15
Installation Checklist ............................................................................................. 16
DM510 Control Panel ............................................................................................................................ 16
Dryer Master I/O system ........................................................................................................................ 16
Inlet Moisture Sensor ............................................................................................................................ 17
Outlet Moisture Sensor......................................................................................................................... 17
Sample Station (calibration push button) .......................................................................................... 17
Air Plenum Temperature probe (Temperature Option A) ............................................................... 17
Temperature Signal Converter (Temperature Option B) ................................................................. 18
Relay (Motor Speed Control Option A) ............................................................................................... 18
Speed Control Interface (Motor Speed Control Option B) ................................................................... 18
Internet connection ............................................................................................................................... 18
Electrical Installation Guidelines .......................................................................... 19
General .................................................................................................................................................... 19
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Wiring ...................................................................................................................................................... 19
Component Summary ............................................................................................ 21
DMSI supplied components and services .......................................................................................... 21
Customer supplied components and services .................................................................................. 21
Dryer Master Moisture Sensors ............................................................................ 22
Sensor Types .................................................................................................................................. 22
Inlet Moisture Sensor Installation ........................................................................ 23
Sensor Location ............................................................................................................................. 23
Sensor Installation ........................................................................................................................ 24
Outlet Moisture Sensor Installation ..................................................................... 27
Sensor Types .......................................................................................................................................... 27
Outlet sensor mounting requirements: ............................................................................................. 27
Outlet sensor installation options .............................................................................................. 28
Option 1 By-Pass Method – Details ..................................................................................................... 28
Option 1a - Bypass Using Sampling Auger ......................................................................................... 31
Option 2 In-Line Method – Details....................................................................................................... 33
DM510 Control Panel Installation ......................................................................... 35
Control Panel Location .......................................................................................................................... 35
Control Panel Installation ..................................................................................................................... 35
I/O Panel Installation ............................................................................................. 37
Power and Grounding Requirements ................................................................... 39
DM510 Control Panel ............................................................................................................................ 39
Moisture Sensors ................................................................................................................................... 44
AC Motor Speed Control Interface ...................................................................................................... 44
DC Motor Speed Control Interface ...................................................................................................... 44
Control Wiring Requirements ................................................................................ 45
Motor Controller and Ground Wiring Specifications ........................................................................ 45
Multi-Cable Specifications .................................................................................................................... 45
Typical System Multi-Cable Requirements ......................................................................................... 46
Installing Conduit and Pulling Wires ................................................................................................... 47
Wiring Instructions (Cable Terminations) ............................................................ 48
Tools Required ....................................................................................................................................... 48
General Wiring Procedure .................................................................................................................... 48
Overview: Typical DM510 wiring connections: .................................................................................. 49
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I/O board Jumper locations and functions ......................................................................................... 52
Motor Speed Control Interface Wiring Instructions (for DC drives)................................................ 54
Local/Remote Status Wiring Instructions ........................................................................................... 56
Fan Status Wiring Instructions ............................................................................................................. 58
Drying Air Temperature Wiring Instructions ...................................................................................... 59
Connecting to a Drying Air Temperature Controller......................................................................... 61
Calibration Button Wiring Instructions ............................................................................................... 63
Remote Alarm Control .......................................................................................................................... 64
Appendix 1: Motor speed control wiring diagrams ............................................. 65
Sample wiring diagrams ....................................................................................................................... 65
Appendix 2: Complete instructions for programming and wiring Omega
TXDIN70-24V Signal Converter .............................................................................. 68
Appendix 3. Sensor Chutes w/ Rotary Feed .......................................................... 72
Installation Considerations: ................................................................................................................. 72
Appendix 4. Round Cell Sensor .............................................................................. 75
Table of figures
FIGURE 1- INSTALLATION SCHEMATIC – DM510 W/ INTEGRATED I/O AND APT SENSOR .................... 11
FIGURE 2 - INSTALLATION SCHEMATIC - DM510 WITH REMOTE I/O ......................................................... 12
FIGURE 3- APPLICATION SCHEMATIC ............................................................................................................... 13
FIGURE 4 - FIN TYPE MOISTURE SENSOR (FRONT AND BACK VIEWS) ...................................................... 22
FIGURE 5 - SAMPLE INLET SENSOR INSTALLATION ON A GRAIN HANDLER DRYER ............................ 23
FIGURE 6 - SENSOR AND MOUNTING PLATE DIMENSIONS .......................................................................... 25
FIGURE 7 - ALTERNATE LOCATION FOR INLET SENSOR ON COLUMN DRYER ....................................... 26
FIGURE 8 - ROUND DRYER INSTALLATION LOCATION ................................................................................. 26
FIGURE 9 – OUTLET FIN IN CHUTE PHOTO ....................................................................................................... 28
FIGURE 10 - BY-PASS WITH ROTARY METERING ............................................................................................ 29
FIGURE 11 – EXAMPLE INSTALLATIONS OF BY-PASS WITH ROTARY METERING ................................. 30
FIGURE 12 - BY-PASS AUGER INSTALLATION ................................................................................................. 32
FIGURE 13 - BY-PASS AUGER INSTALLATION ................................................................................................. 32
FIGURE 14 – INLINE CHUTE INSTALLATION .................................................................................................... 33
FIGURE 15 – INLINE CHUTE GRAPHIC ................................................................................................................ 33
FIGURE 16 – DRYER MASTER ROTARY FEED CHUTE – INLINE VERSION ................................................. 34
FIGURE 17 – EXAMPLE OF GSI/ZIMMERMAN CHUTE INSTALLATION ....................................................... 34
FIGURE 18 - DM510 PRODUCT DIMENSIONS ..................................................................................................... 36
FIGURE 19 - I/O ASSEMBLY REMOVAL .............................................................................................................. 37
FIGURE 20 - COMMUNICATIONS WIRE LAYOUT ............................................................................................. 38
FIGURE 21 - STAR POINT GROUNDING SYSTEM ................................ .............................................................. 40
FIGURE 22 - EFFECTS OF SURGE CURRENT IN A STAR POINT GROUND SYSTEM ................................... 41
FIGURE 23 - EFFECTS OF SURGE CURRENT IN A CONVENTIONAL GROUND SYSTEM .......................... 42
FIGURE 24 - DRYER MASTER INTERNAL GROUNDING .................................................................................. 43
FIGURE 25 – MULTI-CABLE DIAGRAM ............................................................................................................... 45
FIGURE 26 - WIRE PLACEMENT ........................................................................................................................... 46
FIGURE 27 - WIRE ENTRY LOCATIONS............................................................................................................... 46
FIGURE 28 - DM510 TYPICAL WIRING CONNECTIONS.................................................................................... 49
FIGURE 29 - SENSOR HOOK-UP PHYSICAL ........................................................................................................ 51
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FIGURE 30 - SENSOR HOOK-UP SCHEMATIC .................................................................................................... 51
FIGURE 31 – I/O BOARD JUMPER LOCATION .................................................................................................... 52
FIGURE 32 – I/O BOARD DIGITAL OUT JUMPER CONFIGURATION DESCRIPTION. .................................. 52
FIGURE 33 – I/O BOARD DIGITAL INPUT JUMPER CONFIGURATION DESCRIPTION. .............................. 52
FIGURE 34 – I/O BOARD ANALOG INPUT JUMPER CONFIGURATION DESCRIPTION. ............................. 53
FIGURE 35- DM510 TO MSC INTERFACE............................................................................................................. 54
FIGURE 36 - DM510 TO MSC INTERFACE............................................................................................................ 55
FIGURE 37 - MSCI TO DC MOTOR......................................................................................................................... 55
FIGURE 38 - MSC DC ISOLATION HOOKUP ........................................................................................................ 56
FIGURE 39 - LOCAL/REMOTE STATUS WIRING ................................................................................................ 57
FIGURE 40 - FAN STATUS ...................................................................................................................................... 58
FIGURE 41 - TEMPERATURE SIGNAL CONVERTER ......................................................................................... 59
FIGURE 42 - AIR PLENUM TEMPERATURE SENSOR ........................................................................................ 59
FIGURE 43 - DRYING AIR TEMPERATURE SENSOR WIRING ......................................................................... 60
FIGURE 44 - APT CONTROLLER ANALOG CONNECTION ............................................................................... 61
FIGURE 45 - DM510 TO SIGNAL CONVERTER WIRING .................................................................................... 62
FIGURE 46 - CALIBRATION PUSH BUTTON ....................................................................................................... 63
FIGURE 47 - REMOTE ALARM ............................................................................................................................... 64
FIGURE 48 - DM510 TO MITSUBISHI FR-D700 .................................................................................................... 65
FIGURE 49 - DM510 TO GENERIC VFD (O-10 VDC) ........................................................................................... 66
FIGURE 50 - DM510 TO ALLEN BRADLEY POWERFLEX40 ............................................................................. 66
FIGURE 51 - DM510 TO BALDOR SERIES H2 ...................................................................................................... 67
FIGURE 52 - DM510 TO ALTIVAR 31 .................................................................................................................... 67
FIGURE 53 - WIRING DIAGRAM FOR SIGNAL CONVERTER CONNECTIONS .............................................. 69
FIGURE 54 – BYPASS CHUTE DESCRIPTION ...................................................................................................... 72
FIGURE 55 – INLINE CHUTE DESCRIPTION ....................................................................................................... 73
FIGURE 56 – INLINE CHUTE GRAPHIC ................................................................................................................ 73
FIGURE 57 – INLINE CHUTE INSTALLATION .................................................................................................... 73
FIGURE 58 – CHUTE MOTOR ROTATION CHANGE GRAPHIC ........................................................................ 74
FIGURE 59 - ROUND CELL SENSOR ..................................................................................................................... 75
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Dryer Moisture Systems Inc. – About Us
Dryer Moisture Systems Inc. (DMSI) is a process engineering company specializing in on-line product and total process optimization. We offer the benefits of many years of professional process expertise in a broad range of industries and technologies, from food processing to engineered wood products to pharmaceuticals, from basic control and monitoring systems to sophisticated advanced control systems.
Our engineering staff are experts in the design of real time advanced control systems, specifically tailored to the optimization of engineered processes. These control systems are provided on industry standard platforms that are extremely flexible and readily configured by the end user.
In support of our real-time advanced control systems, DMSI provides a full range of hardware and software, engineering services, system commissioning, operator training and over the phone remote support. We deliver proven solutions resulting in increased yields, improved and consistent product quality, maximized plant efficiency and more effective use of your operations personnel. DMSI also provides services that allow the monitoring of your process or plant operations from locations on or off site.
The Dryer Master DM510 from DMSI continues the commitment to excellence that has made the Dryer Master name the industry standard in grain drying technologies. With your assistance, the DM510 can help:
• Reduce product shrinkage due to over drying
• Reduce energy costs
• Produce a consistent and better product
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DM510 - A Brief Description
The Dryer Master DM510 from DMSI is the ideal addition to your new or existing continuous flow grain dryer. Simple and easy to operate, the DM510 uses advanced process control to automatically adjust your dryer discharge rate, drying grain more consistently and closer to your target moisture level.
The DM510 is a computer control system that controls grain drying. The standard configuration of the system comes complete with an operator panel, sensors to measure the grain moisture and temperature entering and exiting the dryer, a drying air temperature monitor, an outlet moisture sensor with rotary feed, and remote access via internet capability. An optional printer is also available. The system uses this and other information, to set the optimum grain discharge rate to control the moisture of the product within a narrow tolerance.
The DM510 is capable of being monitored and controlled remotely through a web browser on your smart phone, tablet or desktop PC through DM-Mobile. Simply connect the DM510 to an internet enabled router and then access many of the DM510 functions through your web browser at my.dryermaster.com. DM-Mobile can also be configured to provide you with text on alarm messages so that you can be aware of an issue without having to be at the DM510 panel.
The DM510 provides quick payback by reducing over and under drying, resulting in increased yields, energy savings, and providing a better quality dried product.
DM510 - How it Works
As an operator you know that grain drying is a very difficult process to control. You know that your dryer dries faster or slower depending upon drying conditions. Ambient air temperature, wind speed and direction, humidity, time of day, the variety of the grain being dried, and of course, the moisture of the grain all can affect dryer operation.
The Dryer Master DM510 uses sophisticated on-line moisture measurement and moisture control technology to overcome these difficulties. The DM510 uses specially designed on-line moisture and temperature sensors located at the inlet and the outlet of the dryer. These sensors provide continuous moisture and temperature readings to the computer located in the DM510 control panel.
The computer uses this information to build an operating model of your dryer. As inlet moistures and drying conditions change throughout the day the DM510 continuously calculates and automatically adjusts to the optimum discharge rate for current conditions.
The DM510 has three important advantages. First, in all modes, the systems is always monitoring the dryer. Second, in automatic mode, it continually watches the dryer. It doesn’t have to help unload trucks, load trains, or do other jobs around the elevator. The dryer receives its full attention. Third, it has the benefit of continuous moisture information from both the inlet and the outlet of the dryer, giving it a complete picture of all the grain in the dryer, and the grain exiting the dryer.
With this information, the DM510 does not have to wait to react to changes in the outlet moisture. It is able to adjust the discharge rate as the incoming moisture changes. For example, as wetter grain comes into the dryer, the DM510 begins to slow down the discharge rate just as the wetter grain reaches the hot zone.
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System Components
The DM510 system includes the following components:
• DM510 control panel (with remote I/O option)
• Inlet and outlet grain moisture sensors with integral product temperature sensors
• Calibration push button
• Outlet moisture sensor chute with rotary feed (bypass or inline version)
• Drying air temperature sensor or signal converter (to access dryer’s temp reading)
• Internet connectivity capability (or optional modem connectivity)
An optional printer for continuous reporting of dryer operation and results is also available.
DM510 Control Panel including I/O:
The DM510 is a computer system complete with user interface keypad and the display screen, I/O system and the capability to provide real time information through an internet connection to a network capable device. The DM510 Control Panel is typically installed in a location near the dryer where the operators spend much of their time. The I/O can be located remotely using a wired connection for short distances or a wireless connection for longer distances (requires optional wireless modems). See I/O Panel Installation page 37
Printer (optional):
The DM510 uses the printer to provide reports such as: continuous averages, hourly and daily reports, and bin summaries. These are tools that can be used to manage the total drying process.
Inlet Moisture and Temperature Sensor:
The inlet moisture and temperature sensor is installed in the flow of the product before it enters the drying zone (hot zone) of the dryer, typically in the garner or holding bin above the hot zone.
Outlet Moisture and Temperature Sensor & Chute with Rotary Feed:
The outlet moisture and temperature sensor is typically installed in a sensor chute with rotary feed (either the bypass or inline version) which is placed after the product flow exits the dryer.
Calibration Push Button:
The calibration button is installed near the operator sampling point for product exiting the dryer, in close proximity to the outlet moisture sensor.
Drying Air Temperature Sensor or Temperature Signal Converter:
A temperature sensor is installed in the heating chamber in close proximity to the dryer’s existing drying air temperature sensor to monitor the drying air temperature. Some systems will instead use a temperature signal converter to use the dryer’s temperature reading.
Internet Connectivity Capability:
Connect your DM510 to an internet enabled router or wireless hotspot (via Ethernet cable) and you access your system remotely via a desktop PC, smartphone or tablet. Simply use your browser to go to my.dryermaster.com and login using the login information that came with your system.
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Installation Configurations (printer optional)
Configuration with Integrated I/O and APT sensor
Figure 1- Installation Schematic – DM510 w/ Integrated I/O and APT sensor
Printer
Inlet Moisture &
Temperature
Sensor
Outlet Moisture & Temperature Sensor
Moisture Sample Start Button
Dryer Control Panel
(Discharge Speed)
DRYER
DM510 Control Panel
5
6
7
2
3
1
4
Instrumentation
cables
Ground
cables
Internet connected router or wireless access point (WAP)
8
1) Inlet Sensor
2) Outlet Sensor
3) Push Button
4) Drying Air Temperature Sensor
5) Rate Sense and Rate Control
6) Local/Remote Control andLocal/Remote Status
7) Fan Status
8) Spare
Drying Air
Temperature
Sensor
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Configuration with Remote I/O and APT sensor
See - Figure 19 - I/O assembly removal
Printer
Inlet Moisture &
Temperature
Sensor
Outlet Moisture &
Temperature Sensor
Moisture Sample Start Button
Dryer Control Panel
(Discharge Speed)
DRYER
DM510 Control Panel
Remote I/O Box
cables
Instrumentation
Internet Router or
Wireless Access
Point (WAP)
10
11
Communicatons and Power Cable
Spare
1
5
3
2
6
87
1) Inlet Sensor
2) Outlet Sensor
3) Push Button
4) Drying Air Temperature Sensor
5) Rate Sense and Rate Control
6) Local/Remote Control andLocal/Remote Status
7) Fan Status
8) Spare
9) Remote Alarm (Optional)
10) Communications and Power Wire
11) Spare Communications and Power Wire
Ground
Cables
Drying Air
Temperature
Sensor
4
Figure 2 - Installation Schematic - DM510 with Remote I/O
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Configuration with Integrated I/O and Temperature Signal Converter
Figure 3- Application Schematic
Printer
Inlet Moisture &
Temperature
Sensor
Outlet Moisture &
Temperature Sensor
Moisture Sample Start Button
Dryer Control Panel
(Discharge Speed)
DRYER
DM510 Control Panel
5 6
7
2
3
1
4
Instrumentation
cables
Ground
cables
Internet connected
router or wireless
access point (WAP)
8
1) Inlet Sensor
2) Outlet Sensor
3) Push Button
4) Plenum Temperature Signal Converter
5) Rate Sense and Rate Control
6) Local/Remote Control andLocal/Remote Status
7) Fan Status
8) Spare
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Project Manager Guide and Checklist
Installation Overview
Introduction:
This section is a guide for site managers. Its purpose is to detail responsibilities in the installation of the Dryer Master DM510 computerized drying control system and a checklist is included to help you track completion of the required steps.
The rest of this manual is intended to cover most standard installations and includes sensor and electrical installation guidelines
If at any time you have any questions with either the details in this document or the installation please contact the Dryer Master Support Centre toll free at 1-888-318-0009
If you are installing the DM510 on a new dryer refer to situation #1. For all other situations please refer to situation #2.
Situation 1 Overview: Installation on new dryer when purchased from dryer manufacturer
DMSI Responsibilities:
• To ship the equipment to site upon receipt of a purchase order
• To provide over the phone assistance during the installation process and during system
start-up
• To assist the site operator(s) by phone during the drying season
Dryer Supplier / System Installer Responsibilities:
• To mount the inlet moisture sensor, the outlet moisture sensor, the drying air temperature
sensor (or temperature signal converter), the sample button, and the Dryer Master I/O system
• To install conduit and wire the above devices to the Dryer Master I/O system located in the
DM510 or the dryer panel or a separate I/O enclosure
• To connect the field devices (sensors) to the Dryer Master I/O system
Site Responsibilities (please see enclosed checklist and the physical installation guide and conduit and wiring guide for more detailed information):
• To mount the DM510 panel
• To install conduit and run wiring from the dryer panel or I/O enclosure box to the DM510
panel
• To terminate communication cable at the Dryer Master I/O device at the DM510 panel
• To start-up the system with over the phone assistance from the Dryer Master Support
Centre
• To arrange an over the phone commissioning time with the Dryer Master Support Centre
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Situation 2 Overview: Retrofit onto an existing dryer
DMSI Responsibilities:
• To ship the equipment to site
• To provide over the phone assistance during the installation process and during the system
start-up
• To assist the site operator(s) by phone during the drying season
Site Responsibilities (please see enclosed checklist and the installation manual for more detailed information):
• To mount the inlet moisture sensor, the outlet moisture sensor, the drying air temperature
sensor (or temperature signal converter), the sample button, and Dryer Master I/O system (if not retained in the DM510 cabinet)
• To mount the DM510 panel
• To install conduit and run wiring from the DM510 panel to the Dryer Master I/O system (If
applicable)
• To install conduit and run wiring from the field devices to the Dryer Master I/O system
• To terminate connections at the field devices, the Dryer Master I/O system (if so equipped)
and at the DM510 panel
• To start-up the system with over the phone assistance from the Dryer Master Support
Centre
• To arrange an over the phone commissioning time with the Dryer Master Support Centre
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Installation Checklist
The following checklist will help to ensure all steps in the installation process are covered. Once you have completed all the items on this checklist you can move on to Commissioning the DM510. There is a dedicated DM510 Commissioning Manual (included with the manual package) to guide you through the process, but as always you can call the Dryer Master Support Center with any questions. There are some portions of the Commissioning process that can be handled more easily over the phone, so do not hesitate to call us.
DM510 Control Panel
The DM510 control panel is mounted in a “NON HAZARDOUS” environment. The ambient
temperature during operation should be maintained between 40° and 105°F (5° to 41°C). The system can function outside of these limits but it may impact product longevity. The system requires an 110VAC or 220VAC 50-60HZ grounded circuit. A circuit with isolated ground in conjunction with approved surge protection equipment will afford extra surge and lightning protection. Surge protection and/or a UPS if power is unstable may be of benefit.
The DM510 control panel is to be located in the control room from where the operators currently control operations. For viewing ease it is recommended that the DM510 control panel be mounted so that the bottom of its display screen is at or slightly above average eye level.
Meets environmental requirements Meets electrical requirements Panel installed as described in a NON HAZARDOUS environment
Dryer Master I/O system
The Dryer Master I/O system can be left in the DM510 panel or it can be separately mounted in a “NON HAZARDOUS” environment. The I/O board can be installed in the dryer control panel or an electrical enclosure in close proximity to the dryer control panel. The I/O system will function throughout the standard industrial temperature range of 0° to 140°F (-20° to 60°C). The I/O system is powered from the DM510 panel and requires no external power source.
Meets environmental requirements Panel installed as described in a NON HAZARDOUS environment For the wireless I/O option only, plug in the supplied power supply to power the
. wireless modem and the Dryer Master I/O
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Inlet Moisture Sensor
The inlet sensor is to be mounted in a location that will provide a representative sample of grain entering the dryer. It should be located where there will be a regular flow of product past the sensor (at no faster than 1 inch per second – slower is fine), and in an area where debris is unlikely to accumulate.
Communication with DMSI Engineering personnel could result in revisions to the installation method if readings are not representative. DMSI Project Engineering can advise you of modifications to the required installation.
Installed the inlet moisture sensor as specified Connected the inlet moisture sensor as specified Installed in a Non Hazardous location
Outlet Moisture Sensor
The sensor is to be mounted in a chute that will provide product flow at a rate of approximately 0.5" to 1" (1.25cm to 2.5cm) per second. The Dryer Master inline and bypass chutes with rotary feed are designed to meet these requirements. If an alternate configuration is used specifications for the chute dimensions and product conveyance methods are provided in separate mechanical drawings.
Communication with DMSI Engineering personnel could result in revisions to the installation method if the flow rate is not within specification. DMSI Project Engineering can advise you of modifications to the required installation.
Installed the sensor chute as specified Installed the outlet moisture sensor as specified Connected the outlet moisture sensor as specified Installed in a Non Hazardous location
Sample Station (calibration push button)
The Sample Station consists of a Normally Open Push Button Contact and a 24 VDC LED Lamp. The Sample Station should be placed in close proximity to the outlet Moisture Sensor. The purpose of the station is to signal the DM510 control panel that a moisture sample has been taken and to tell the operator for how long to take a sample.
Installed the Sample Station (Push Button and 24VDC Lamp) as specified Connected the Sample Station (Push Button and 24VDC Lamp) as specified
Air Plenum Temperature probe (Temperature Option A)
The DM510 control panel's hot air plenum temperature sensor is to be installed within 6-12" of the dryer's air plenum temperature sensor.
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Installed the hot air temperature sensor as specified Connected the hot air temperature sensor as specified
Temperature Signal Converter (Temperature Option B)
The signal converter translates the dryer temperature reading for use by the DM510. Each signal converter comes pre-configured by DMSI with enclosed wiring instructions. A copy of the wiring and programming instructions (if required) can be found in Appendix 2
Installed temperature signal converter as specified
Relay (Motor Speed Control Option A)
The wiring of the DM510 to the dryer’s motor speed control can vary depending upon the make of the drive. Instructions for several common drives are included in Appendix 1. If your drive is not shown contact DMSI to obtain a wiring diagram for your drive.
Connected the motor speed control / relay / DM510 as specified.
Speed Control Interface (Motor Speed Control Option B)
A number of installations of the DM510 on older dryers with DC drives require the use of the DM510 motor speed control interface. The interface provides isolation and signal conditioning between the DM510 and the speed control.
The interface is located in the dryer control panel near the motor speed limit Installed the motor speed control interface as specified Connected the motor speed control interface as specified
Internet connection
If you want to make use of DM-Mobile for remote access through your smartphone, tablet or PC to your DM510 you will need to connect your DM510 to an internet enabled router or WAP (wireless access point). It is also possible to connect through a wireless hot spot (additional equipment required) – though you should contact the Support Center if you would like to use this route.
Plug one end of the provided Ethernet cable (if you have a longer distance you will need to purchase a longer cable) into the bottom of the DM510 in the location labelled “Router”. Plug the other end into your router or WAP. DM-Mobile should automatically connect if the DM510 is turned on.
Connected the DM510 to an internet router or WAP.
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Electrical Installation Guidelines
General
1. Analog signals from the field must be separated from other signal types and run in conduit
2. Metal conduit is required for electrical noise shielding
3. Communications cables must be run in conduit in plant environments. Surface wiring is
permissible in office environments
4. Ensure all field components are identical to those shown on electrical drawings
5. Ensure all field mounted level switches have been installed at specified elevations
6. Ensure all field devices are labelled with their appropriate nameplates
7. All manuals associated with instrumentation are to be available at site and are to be the
English version
8. Ensure that all field wiring is tagged at each end
9. All field wiring should be continuity tested. With the panel powered down, each field wire
should be individually connected to ground. The continuity to ground can then be measured from the panel
10. Once continuity testing has been done successfully, power can be applied to the panel
Wiring
Eight (8) 4-wire instrumentation cables need to be pulled from the dryer to the DM510 I/O panel to the field instrumentation for the integrated I/O solution. Three (3) 16 AWG (minimum) ground wires should be pulled from the DM510 chassis ground to specific field instrumentation and Dryer’s Control panel.
For the remote I/O: two instrument cables (one as a spare) need to be pulled between the remote I/O panel and the DM510 panel plus a 16 AWG (minimum) ground wire. It is recommended that the grounding be a star configuration. (See Figure 21 - Star Point Grounding)
Instrumentation cable for each of the following:
1. from the Inlet Moisture Sensor to DM510 panel
2. from the Outlet Moisture Sensor to DM510 panel
3. from the Sample Station (Calibration Push button) to DM510 panel
4. from the Air Plenum Temperature sensor high temperature wire junction box to DM510
panel (if using an APT sensor). If the signal converter is used, from the signal converter to the DM510 panel.
5. from the Dryer speed control interface to DM510 panel (rate in/out)
6. from the Dryer speed control interface to DM510 panel (local/remote)
7. from the fan status contacts to the DM510 panel (if used)
8. spare from Dryer Electrical panel to DM510 panel (optional)
9. from the remote alarm to the DM510 panel (optional)
10. for Remote I/O: communications and power wire from remote I/O to DM510 panel
11. for Remote I/O: optional spare communications and power wire from remote to I/O to
DM510 panel
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Ground wire for each of the following, to DM510 Panel:
#G1 from the Inlet Moisture Sensor to DM510 panel
#G2 from the Outlet Moisture Sensor to DM510 panel
#G3 from the Dryer electrical panel to DM510 panel
#G4 from the remote I/O panel to DM510 panel if configured this way
The conduit must enter the DM510 control panel through the supplied entry plug on the bottom right, or bottom, of the cabinet. Any other entry may damage equipment and void warranty.
Flexible (liquid tight) conduit is to be used at the moisture sensors so that they can be easily removed for servicing.
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Component Summary
DMSI supplied components and services
Control Panel
DM510 Display panel, Ethernet cable Printer (optional), power supply and cable,
Sensors
DMSI Inlet Moisture sensor DMSI Outlet Moisture sensor Sample Station (Calibration Push Button) Air Plenum Temperature Sensor or Temperature Signal Converter
Other
Motor speed control interface (optional) or relay User Guide Installation Guide Commissioning Guide Laminated Quick Guide Instrumentation wire (1000') Sensor chute (bypass or inline version)
Support
Telephone assistance for installation and setup and system support. The support staff can be reached at 1-888-318-0009.
Customer supplied components and services
Hardware
Connection to an internet enabled router or WAP (wireless access point) for DM-Mobile functionality
Site
Mill work required to install equipment Equipment Installation Electrical installation includes running of conduit and pulling of wire Setup of customer supplied equipment
Miscellaneous
Phone commissioning assistance (start-up and setup of equipment)
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Dryer Master Moisture Sensors
Sensor Types
The vast majority of new Dryer Master DM510 installations use the Fin Type moisture sensor at both the inlet and outlet to the dryer. The two sensors provided with a standard system are identical and can be used interchangeably. In some unique situations, a Round-Cell sensor design may be used in place of the fin sensor either at the inlet or the outlet.
Note:
It is important that you read all of the directions before proceeding with the installation.
The correct operation of the sensor and the Dryer Master depends on the correct
installation of the moisture sensors.
Caution!
Welding on or welding near the sensor while it is mounted will invalidate the warranty
Figure 4 - Fin Type moisture sensor (front and back views)
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Inlet Moisture Sensor Installation
Sensor Location
The Inlet Sensor should be placed vertically at the inlet to the grain dryer (in or near the garner bin). See Figure 7 - Alternate location for inlet sensor on column dryer and Figure 8 - Round dryer installation location for details.
There are two conditions that must be met for the Inlet Sensor to operate correctly.
1. The Inlet Sensor must be completely covered by compacted grain at all times.
2. The Inlet Sensor must also receive a good (representative) sample of the grain.
These two conditions are usually met if the Inlet Sensor is located near the centre of the longest vertical side of the garner bin.
However DO NOT locate the Inlet Sensor directly under the inlet spout. Grain that is
erratically compacted will dynamically change the relative readings of the inlet sensor contributing to false readings. Inaccurate or false readings of the inlet sensor will adversely affect control of the dryer.
Installation should minimize the probability of steam reaching the sensor. Install the Inlet Sensor at a level higher above the hot zone than the width of the hot zone. For example if the hot zone is a foot wide leave at least a foot between the hot zone and the sensor. If this is not done, the static pressure in the hot zone can force moisture-laden air past the sensor. Due to the cold state of the sensor, moisture will condense from the air onto the sensor resulting in false readings. Inaccurate or false readings of the inlet sensor will adversely affect control of the dryer.
If the sensor is placed in a location such that it will get an excess of fines or trash this will contribute to errors or false readings. Inaccurate or false readings of the inlet sensor will adversely affect control of the dryer.
Install the Inlet Sensor in a place where water cannot run down the surface of the sensor. In the dryers which have an open top allowing rain to penetrate the grain (or excessive cold) will cause condensation to form on a fin sensor. The sensor needs to be moved to the surge hopper or other
more appropriate location.
Figure 5 - Sample inlet sensor installation on a Grain Handler dryer
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Sensor Installation
1. Refer to Figure 7 - Alternate location for inlet sensor on column dryer and Figure 8 - Round
dryer installation location.
2. Cut an opening through the side of the garner bin the same size or slightly larger than the
opening in the mounting plate (Figure 6 - Sensor and mounting plate dimensions) making sure that the completed installation will be level.
3. Weld or bolt the mounting frame to the outside wall of the garner bin to cover the hole such
that the sensor can be mounted through the plate without binding.
4. Bolt the Sensor to the mounting frame. Make sure that the sensor is mounted such that the
wire entry will be down.
If you are unsure of where to locate the sensor contact the Dryer Master Support Center.
It is preferable to do it right the first time.
Note:
Locate the sensor where it is in constant contact with the compacted grain. If the sensor is not
in constant contact with compacted grain and becomes empty or becomes partially empty,
the DM510 will trigger an alarm condition. The DM510 may (as a result of the alarm)
relinquish automatic control.
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Inlet Sensor Dimensions
8 1/2
6 “
Mounting Plate
Inlet Sensor
10 “
11
Mounting Frame Dimensions
Figure 6 - Sensor and mounting plate dimensions
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Additional Sensor Location Diagrams
Figure 7 - Alternate location for inlet sensor on column dryer
Figure 8 - Round dryer installation location
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Outlet Moisture Sensor Installation
Sensor Types
The standard fin type outlet moisture sensor for new installations is identical to the inlet fin sensor. The two sensors are typically interchangeable.
The sensor is designed to fit into a 6" X 6" chute. It will also fit the standard GSI/Zimmerman chute (with only a slight modification to the chute).
Dryer Master also offers a Round Cell moisture sensor with a restrictor plate (see Appendix 4. Figure 59 ­Round Cell Sensor) This may be appropriate for some installations. If you are in doubt about which sensor to use call us at the Dryer Master Support Center and we will go over the pros and cons of each option with you.
There are a number of installation requirements which are outlined below. If at any time you have questions about the preferred option for installing the outlet sensor contact us at the Dryer Master Support Center.
Outlet sensor mounting requirements:
Dryer Master offers 2 versions of its outlet sensor chute with a rotary feed. The two versions (“Bypass” and “In-line”) are explained in Appendix 3. The use of one of these chute options is strongly recommended and will greatly simplify the installation.
Any outlet sensor installation needs to fulfill a number of requirements as outlined below:
1. The chute needs to hold a compacted yet flowing sample of grain (minimum possible airspace between kernels)
2. Sample size needs to be large enough to have statistical relevance
3. Sensor needs to be mounted in a vertical position to minimize the influence of fines on the
moisture reading
4. Operator must be able to physically confirm the product flow through the sensor chute
5. Operator needs to be able to sample product at the sensor for calibration purposes
6. Operator should be able to shut the flow of grain off in the sensor chute to service the sensor
and/or clear debris
7. Operator should use a rotary metering device to restrict/meter flow or have several restrictor plates with varying hole sizes to be able to adjust the flow rate to accommodate changing kernel size or a change in commodity
8. Flow rate must be fast enough to keep the measured sample relevant yet slow enough to ensure product compaction and minimize mechanical wear (less than 1” per second)
9. When using restrictor plates to adjust the flow rate the restrictor plate should be 6+ inches below the sensor fin to minimize the fines building up into the sensing area and influencing the moisture readings
10. Sensor chute must remain completely full and overflowing to give consistent readings, even at the lowest unload rate expected in use.
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Outlet sensor installation options
Option 1 By-Pass Method – Details
With the bypass method, a portion of the grain leaving the dryer is bypassed from the main stream to where it passes by the sensor and then is returned to the main flow.
The Dryer Master rotary feed bypass chute accomplishes this. The chute requires 16.5 inches, 42 cm of vertical space. For this type of installation see Appendix 3, Option1. The Dryer Master chute flows approximately 50 - 75 cubic feet, 1.4 – 2.1 cubic meters per hour.
Install the chute so that there will be a continuous flow of grain and the chute will remain full.
Ensure that the grain flowing through the chute is a good representative sample of the grain to be tested. Place the sensor in a location where it will NOT get an excess of fines or trash as this will
Figure 9 – Outlet Fin in chute photo
Warning:
Welding on or near the sensor while it is mounted will invalidate the warranty
Note:
The installation of the outlet sensor is critical. A poorly installed outlet sensor will reduce the
effectiveness of the DM510. Locate the sensor where it will stay full. If the sensor becomes empty,
incorrect moisture will be recorded, resulting in poor control of the drying process.
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contribute to errors or false readings. Inaccurate or false readings of the outlet sensor will adversely affect control of the dryer by the Dryer Master.
Locate the Sensor so it can be safely accessed for cleaning and taking grain samples.
Installation Procedure
1. Remove the Outlet Sensor from the 6” square chute before welding or bolting the chute in
place.
2. Make the necessary changes to the discharge system of the dryer so that there is room for
the chute; rotary feeder or slide restrictor.
3. Install the shut off slide gate above the sensor to shut off the flow to the sensor to allow
cleaning out and or servicing the sensor.
4. Install bars across the opening to the sensor in the direction of grain flow. This will prevent
large objects from entering the sensor.
5. Mount the chute in a vertical position.
6. Bolt the fin sensor back into the chute.
Do not cut holes in the Outlet Sensor. Use only the existing wire entry location. Entry at any other location voids the warranty.
Ensure the sensor chute empties completely when shutting down. Make electrical connections such that the chute power is tied to the elevator control circuit. The elevator is typically the last item shut down in the shutdown sequence.
Main Product Flow
Sample access
Moisture Sensor
Rotary metering device
Grain Sample Return
Shutoff slide
9 5/8",
24.5cm
6 5/8",
16.8cm
Figure 10 - By-Pass with rotary metering
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See also Appendix 3 for additional information on the Dryer Master bypass chute with rotary feed installation.
Figure 11 – Example installations of By­Pass with rotary metering
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Option 1a - Bypass Using Sampling Auger
The moisture sensor is installed in a by-pass where a portion of the grain is directed through the bypass. The grains flows through the sensor and then back into the system (see Figure 12 - By-Pass auger installation Error! Reference source not found.for more details). This method is used when
there is less than 18” of vertical space at the bottom of the dryer. The fin sensor is provided with a
square chute. A small slow moving auger restricts the flow of grain so the chute remains full of compacted grain at all times.
1. Install the chute so that there will be a continuous flow of grain.
2. Make sure that the chute will always be full of grain.
3. Make sure that the grain flowing through the chute is a good representative sample of the
grain to be tested. Placing the sensor in a location where it will NOT get an excess of fines or trash which will contribute to errors or false readings. Inaccurate or false readings of the outlet sensor will adversely affect control of the dryer by the Dryer Master.
4. The flow of grain through the chute should be approximately ½ inches per second or about
50 cubic feet, 1.4 cubic meters per hour.
5. Locate the Outlet Sensor so it can be safely accessed for cleaning out, and taking grain
samples.
A four-inch sampling auger is recommended. Several other options are available; see Table 1: Gear reductions for metering devices. All gear reductions given are based on a chute that is six inches by six inches. For the best flow characteristics, it is recommended that the auger be opened to the full width of the chute. This will also reduce transition complexity. Verify the auger flow and gear box required. The table is an approximate guideline.
Installation Procedure
1. Remove the Outlet Sensor from the 6” square chute while installing and welding the
transitions
2. Make the necessary changes to the discharge system of the dryer so that there is room for
the chute, sampling auger and slide gate.
3. Install the slide gate above the sensor to shut off the flow to the sensor to allow cleaning out
and or servicing the sensor
4. Install the Chute and Sensor so the operator can inspect and clean the sensor. It must be
possible to do these tasks easily and safely while the dryer is operating.
5. Install bars across the opening to the sensor in the direction of grain flow. This will prevent
large objects from entering the sensor.
6. Mount the chute in a vertical position.
7. Install the sampling auger as horizontally as possible.
8. For greatest sensitivity and accuracy, it is recommended to bolt the chute such that the fin of
the sensor will be oriented in the same direction as the shaft of the auger.
Metering Device
Approximate
rpm
Gear reduction
for 150 rpm
motor
6” screw conveyor
standard pitch
6.5
270:1
6” screw conveyor ½ pitch
13
135:1
4” screw conveyor
standard pitch
20
88:1
4” screw conveyor ½ pitch
40
44:1
4” flex screw conveyor
20
88:1
Table 1: Gear reductions for metering devices
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9. Run grain through the sampling chute and ensure the grain flows evenly past the fin. Also
ensure that the auger is drawing grain from all areas of the chute.
Figure 12 - By-Pass auger installation
Figure 13 - By-Pass auger installation
Dry
Grain
Leg
Dry Grain Drag
Bypass Chute
Viewing Window
Sample Return Auger
Moisture sensor
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Option 2 In-Line Method – Details
The Dryer Master In-Line chute with rotary feed is designed so that the moisture of the grain can be measured without having to divert a portion into a bypass. (see Appendix 3, Option 2.) Some dryer manufacturers can supply a chute that will fit under their dryer to accommodate an outlet fin sensor to get a similar effect. A similar type device can be fabricated on site.
A moisture sensor is installed in a 6” x 6” chute mounted within a larger chute that handles the full flow of grain from the dryer. The flow through the sensor chute is restricted and metered using
either a rotary feed or a slide gate restrictor. The grain that does not flow through the sensor chute flows past in the main part of the chute. This method requires a minimum of 16” of vertical space not including necessary transitions. Normally the sensor is installed under the dryer between it and the dry grain auger or drag.
Install the Chute and Sensor in a continuous flow of grain and where the sensor will remain full.
Install the Chute and Sensor so the operator can inspect and clean the sensor. It must be possible
to do these tasks easily and safely while the dryer is operating.
Installation Procedure
Note for the Dryer Master In-Line chute with rotary feed additional photos are in Appendix 3, Option 2.
1. If necessary, adjust the discharge system of the dryer so that a chute 16” high by (minimum)
16” square can be installed (Size will depend upon bushels being discharged).
2. Make sure that the centre of the flow of grain is directed at the Sensor’s location and will
keep the sensor full.
3. Weld or Bolt the sensor chute to the bottom of the dryer.
4. Create a transition between the bottom of the chute and the dry grain drag or auger.
5. Bolt the Sensor to the outside surface of the frame. See Figure 17 – for an example.
6. An access is provided for the operator to safely inspect and clean out the sensor and take
moisture samples without turning off the dryer discharge.
Figure 14 – Inline Chute installation
Figure 15 – Inline Chute Graphic
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Do not cut holes in the outlet sensor. Use only the existing wire entry location. Entry at any other location voids the warranty.
Calibration Push Button
Bypass Fin in Chute
Resrtictor Slide Gate
Dry grain Drag
Discharge Hopper of
Zimmerman Dryer
Zimmerman Chute
Figure 16 – Dryer Master rotary feed chute – inline version
Figure 17 – Example of GSI/Zimmerman chute Installation
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DM510 Control Panel Installation
Control Panel Location
The DM510 Control Panel must be located in a reasonably well-controlled and secure environment. Use the following guidelines to locate the best position for the DM510 Control Panel where:
• It is protected from the weather. (And is as free from dust as possible if the optional printer
is used).
• The ambient temperature during operation will be between 40° and 105°F (5° and 40°C).
• Someone can hear the alarm buzzer.
• The bottom of the display screen (LCD) is slightly above average eye level.
• Locate DM510 in a room where the dryer operators will spend most of their time or will be
processing moisture samples.
• If the DM510 is mounted against an uninsulated outside wall, provide ½" (12.7mm) insulating
panel (wood).
Control Panel Installation
Refer to Figure 21 – DM510 Control Panel Dimensions while doing the following:
1. Drill all holes and insert ¼" (6mm) bolts with washers into bottom holes. Leave space
between washer and wall
2. Slide cut-out slots in bottom mounting tab on Controller under washers
3. Align top holes. Insert screws and washers in top mounting tab, level the box and tighten all
screws
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Caution
Do not cut holes in the DM510 Control Panel. Cuttings getting inside the panel can cause serious
damage. Use only existing wire entry locations. The warranty is void if additional holes are made in
the DM510 Control Panel.
15"
14"
12"
0.5"
0.38 typ
0.5"
Eye Level
1" Flange Top and bottom
Figure 18 - DM510 Product Dimensions
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I/O Panel Installation
The DM510 may be operated with the I/O panel remotely located. Mounting the DM510 I/O panel in a remote enclosure creates a remote I/O panel.
Mount this panel in such a way that:
• The wiring from the sensors can be easily completed without discomfort.
• It is protected from the weather in a NEMA 4 box or in the dryer control panel.
• The ambient temperature during operation will be between 40° and 105°F (5° and 40°C).
• The I/O panel is away from high potential voltage and all unprotected Multi-cables coming in
from remote sensors are not near high power cable areas. Or it is physically protected with metal shielding.
• Wiring is done in accordance with local electrical codes and environmental conditions.
Single nut fastener to remove I/O panel
I/O system power and communication cable
Figure 19 - I/O assembly removal
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The cables required between the DM510 and I/O panel are 2 Multi-cables. One for communications, one for a spare and a minimum 16-gauge green ground wire from the DM510 chassis ground to the DM510 I/O Panel chassis ground.
The communication cable is created by removing the connections from the cable present in the DM510, noting the positions. Note the location of the individual conductors (see Figure 19 - I/O assembly removal) Remove the end connectors. Cut two Multi-cables that are long enough to reach between the DM510 and the location of the I/O panel. One will replace the current cable and the second will be a spare. Mark them to identify them from each other. Pull these cables along with a 16 awg. Green ground wire into the conduit between the DM510 and the I/O panel. Rewire the end connectors as noted below and connect them to the noted location as they were connected in the original configuration. See Figure 23 – Communications Wire Layout for details.
Conduit required to house the cables between the DM510 and the I/O panel is ½”. The wire entry points in the bottom of the DM510 are sized for a ¾ “ conduit.
Figure 20 - Communications Wire Layout
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Power and Grounding Requirements
DM510 Control Panel
Power
The DM510 can be powered with 85 to 264 VAC, 47 to 440 Hz or 120 to 370 VDC. The Dryer Master requires less than 175 watts that should be provided with a dedicated, isolated grounded circuit.
Grounding AC Power
The DM510 must be provided with a good earth ground. It is recommended that a UPS (Uninterruptible Power Supply) be used for best surge and lightning protection. An isolated ground connected directly into the control panel will assure the equipment is grounded even if it is unplugged. Damage caused by electrical surges and lightning are not warranted.
System Grounding Configuration
A typical electrical installation includes a number of electrical devices or equipment each with its own ground connection. The relationship between these ground connections will affect the overall performance of the system especially during a transient event such as lightning strikes.
Important:
All electrical installations must meet local electrical code requirements.
Note:
Although the information in this section is provided in an attempt to reduce damage to the Dryer
Master due to lightning strikes, it will not necessarily eliminate all lightning damage.
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Star Point Grounding
If all the devices in an electrical system are connected to a common point from which a cable runs to ground, the result is a star-point earth ground system. This is illustrated in Figure 21 - Star Point Grounding. For simplicity, only the ground wiring is shown and not other wiring that normally interconnects the devices.
Drying Air Temperature Sensor
Inlet Moisture &
Temperature
Sensor
Outlet Moisture & Temperature Sensor
Moisture Sample Start Button
DM510 Control Panel
Dryer Control Panel (Discharge Speed)
Ground Rod
Figure 21 - Star Point Grounding System
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The purpose of any ground system is to keep all connected equipment at the same ground potential. Figure 22 - Effects of surge current in a Star Point ground system illustrates the effect of a surge event in one of the connected devices. The current flow (i) induces a voltage across the ground conductor (V) between the device and the star connection. This voltage potential will be impressed on all devices connected to the star but will be small in magnitude in a well-designed system. A larger voltage will be seen on the conductor between the star connection and the earth ground connection but will have little consequence on the connected equipment as each device will see an equal rise in ground potential. This limits current conduction through sensitive equipment due to differences in ground potential
Figure 22 - Effects of surge current in a Star Point ground system
Drying Air Temperature Sensor
Inlet Moisture &
Temperature
Sensor
Outlet Moisture & Temperature Sensor
Moisture Sample Start Button
DM510 Control Panel
Dryer Control Panel (Discharge Speed)
Ground Rod
Surge Current
V
i
Z
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When ground connections are made at various points along a ground conductor the effect is much different. Figure 23 - Effects of surge current in a conventional ground system illustrates that current flow in the ground wiring results in increasing differences in ground potential in each piece of equipment connected downstream from the surge event. The result can be current flow between devices as a result of a difference in ground potential.
Equipment
Equipment
Equipment
Equipment
Equipment
i
V=i(Z1+Z2+Z3+Z4)
Surge Current
i
Z1
Z2
Z3
Z4
Z5
i
i
Figure 23 - Effects of surge current in a conventional ground system
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The conclusion is that ground system configuration plays an important role in surge protection. Therefore, Dryer Master installations must attempt to minimize the effects of improper grounding by ideally installing the grounds as a star-point system.
Figure 24 - Dryer Master internal grounding shows the internal grounding that is installed in the DM510. This is done to enhance the grounding capabilities by connecting the ground wires that power the remote sensors to the ground lug in the DM510 chassis. It is important that these wires remain in place along with the new wires placed at these locations during the installation process. These wires provide an extra path for surge current to dissipate.
Figure 24 - Dryer Master internal grounding
GND
+24VDC
Temp
GND
Com
Com
Rate Out
Output 2
GND
Com
Com
Com
RATE IN
GND
Speed
Sense
Speed
Control
Air
Temp
Rate Out
GND
AO 2
+24VDC
TEMP
GND
Input
DI 1
DI 2
DI 3
DI 4
120V MAX. 120V MAX.120V MAX.120V MAX.
DO 1
NO/NC
COM
Local/
Remote
Outlet 2
Calibrate
Fan
Status
Local/
Remote
Status
Outlet 1
Calibrate
Input
Input
Output
Input
GND
Moisture
+24
Gnd
Temp
Outlet 2
+24V
---
COM
T3
M3
__
Com
DO 2
NO/NC
COM
Outlet 1
Calibrate
Lamp
Output
Rate In
B
A
B
A
B
A
B
A
Note: Pre 2015 I/O Jumpers must be installed connecting ‘GND’ to the ‘B’ terminals of the used digital inputs and the ‘Com’ terminals of the used digital outputs.
All the ‘Com’ and ‘B’ terminals are shown connected to ‘GND’ in this drawing.
Moisture
+24
Gnd
Temp
Outlet 1
+24V
---
COM
T2
M2
__
Moisture
+24
Gnd
Temp
Inlet
+24V
---
COM
T1
M1
__
Com
DO 3
NO/NC
COM
Outlet 2
Calibrate
Lamp
Output
Com
DO 4
NO/NC
COM
Remote
Alarm
Output
GND
+24VDC
Temp
GND
Com
Com
Rate Out
Output 2
GND
Com
Com
Com
RATE IN
GND
Speed
Sense
Speed
Control
Air
Temp
Rate Out
GND
AO 2
+24VDC
TEMP
GND
Input
DI 1
DI 2
DI 3
DI 4
120V MAX. 120V MAX.120V MAX.120V MAX.
DO 1
NO/NC
COM
Local/
Remote
Outlet 2
Calibrate
Fan
Status
Local/
Remote
Status
Outlet 1
Calibrate
Input
Input
Output
Input
GND
Moisture
+24
Gnd
Temp
Outlet 2
+24V
---
COM
T3
M3
__
Com
DO 2
NO/NC
COM
Outlet 1
Calibrate
Lamp
Output
Rate In
B
A
B
A
B
A
B
A
Moisture
+24
Gnd
Temp
Outlet 1
+24V
---
COM
T2
M2
__
Moisture
+24
Gnd
Temp
Inlet
+24V
---
COM
T1
M1
__
Com
DO 3
NO/NC
COM
Outlet 2
Calibrate
Lamp
Output
Com
DO 4
NO/NC
COM
Remote
Alarm
Output
Note: Post 2015 I/O Jumpers have been replaced with high current Traces on the circuit board.
For the DI & DO pin jumpers are provided behind the connector to isolate the circuits if required.
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Moisture Sensors
Power
The low voltage power required by the moisture sensors is supplied by the DM510.
Grounding
The sensors require a good ground to function dependably. Run a minimum 16-gauge green ground wire from each sensor chassis ground to the DM510 I/O Panel. These grounds should be connected to the green ground wire located in the vertical wire channel beside the I/O assembly.
AC Motor Speed Control Interface
Most AC Motor Speed Controls can provide a 0-5V or 0-10V output for speed monitoring and a 0-10V input for remote speed control. These signals are normally isolated and can be connected directly to the DM510 Control Panel. Refer to the motor speed control manufacturer's manual for details.
Local/Remote Control
A 24V relay is required to switch between the local control signal and the DM510 speed input.
DC Motor Speed Control Interface
Discharge Rate Monitoring
The Motor Speed Control Interface converts the 0 to 90/180 VDC output from the motor speed control to an isolated 0 to 5 V signal for the DM510 Discharge Rate Sense input.
Discharge Rate Control
The Motor Speed Control Interface converts the 0 to 10 VDC grounded signal supplied by the DM510 Control Panel to an isolated 0 to 10 V signal to remotely set the customer motor speed control. The existing speed dial on the dryer motor controller must operate between 0 and 10 volts maximum.
Local/Remote Control
The Motor Speed Control Interface provides local/remote switching facility that can disconnect the manual speed dial on the dryer and allow the DM510 to control the discharge rate. Power for this purpose is provided from the DM510 Control Panel.
Note:
This method is used for non-isolated DC speed controls only.
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Control Wiring Requirements
Motor Controller and Ground Wiring Specifications
Use approved wire meeting local electrical code requirements between the Motor Speed Control Interface and the motor speed controller. 16-gauge wire is sufficient for all ground wires.
Multi-Cable Specifications
One multi-cable with the following specifications is required between each sensor and the DM510 Control Panel. See below for details.
• Two-pair shielded, minimum 22 AWG (.644 mm or 23 SWG) stranded tinned copper
conductors and drain wire (e.g. Beldon #8723).
• PVC jacket rated for 140°F (60°C). The Dryer Master supplied wire is rated to 105°C.
• Colour code: black, red, green, white (recommended).
• In areas where the temperature will exceed 140°F, use a wire with a higher jacket
rating (e.g. Beldon #88723).
Figure 25 – Multi-Cable Diagram
Note:
All electrical installations must meet local electrical code requirements
Caution
All multi-cable must be run in areas where the maximum temperature does not exceed 105°C
(220°F). Use Teflon coated wires in areas that exceed this limit.
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Typical System Multi-Cable Requirements
See Figure 26 - Wire placement for a list of the multi-cable requirements and wire placement for a
DM510 system with ALL options. To accommodate this number of cables (10 cables at .170” or
4.318 mm diameter) a ¾ “, 19.05mm conduit is required. There are two cable entry locations at the
bottom right hand side of the cabinet sized for a ¾ “, 19.05mm conduit for ease of installation. See Figure 27 - Wire Entry Locations
Number
Quantity
From
To
1
1 Multi-Cable + 1 ground
Inlet Moisture Sensor
DM510 Control Panel
2
1 Multi-Cable + 1 ground
Outlet Moisture Sensor
DM510 Control Panel
3
1 Multi-Cable
Remote Calibration Button
DM510 Control Panel
4
2 Multi-Cables
Drying Air Temperature Sensor
DM510 Control Panel
5 and 6
2 Multi-Cables + 1 ground
Motor Speed Control Interface and Local/Remote Status
DM510 Control Panel
7
1 Multi-Cable
Fan Status (optional)
DM510 Control Panel
8
1 Multi-Cable
Spare
DM510 Control Panel
9
1 Multi-Cable
Remote alarm (optional)
DM510 Control Panel
10 and 11
2 Multi-Cable
I/O Panel
DM510 Control Panel
1 If your system came with a supplied drying air temperature sensor (Figure 29 - Air Plenum Temperature Sensor) install it near the existing temperature sensor and use High Temperature Teflon coated wire where necessary. If your systems came with a signal converter (Figure 30 - Temperature Signal Converter) install the signal converter as per the instructions in Appendix 2.
Figure 26 - Wire placement
Figure 27 - Wire Entry Locations
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Installing Conduit and Pulling Wires
It is recommended that you use metal conduit for electrical noise shielding and mechanical protection although approved cable tray is also acceptable. A ¾ “, 19.05mm conduit is adequate for the number of wires required (10 cables at .170” or 4.318 mm diameter). Refer to Figure 1­Installation Schematic – DM510 w/ Integrated I/O and APT sensor for typical conduit layout. When installing the conduit, follow these guidelines:
• Install all wiring in accordance with local electrical codes and environmental
conditions.
• Tag each wire with the same number at each end (See figure 11). This will aid with
identifying the routing and connections during installation and service.
• Install the conduit into the DM510 Control Panel through the supplied entry plug.
See Figure 27 - Wire Entry Locations
Remember that it is easy to damage Multi-Cable when pulling into a conduit. Careful installation when doing this will save time and money.
When cutting Multi-Cable and placing it in the conduit, allow:
• An extra 24” (75 cm) at the DM510 Control Panel end
• An extra 12” (30 cm) at the Sensor end
It is recommended that you install a spare Multi-Cable for future upgrades and options.
Caution
Do not place Multi-Cables in any conduit that is carrying electrical power. Do not run unprotected
Multi-Cable in or near high power cable areas.
Caution Warranty Information
Entry through any other way voids the warranty, and may allow condensation from the conduit to
drip into the DM510 Control Panel, or metal shavings may cause a short circuit on the DM510
system board
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Wiring Instructions (Cable Terminations)
Tools Required
You will need the following tools to prepare and terminate the Multi-Cable:
• Wire Strippers
• Cable Strippers
• Side Cutters
• Small needle nose pliers
• Crimping tool for insulated connectors
• Small screwdriver 1/8" (3mm)
General Wiring Procedure
The following steps demonstrate how to prepare the Multi-Cable without causing damage to the individual conductors.
1. At the DM510 Control Panel end, cut all Multi-Cables so that each will reach 3" (7 cm) past
the furthest connector on the interface board making sure that all the wire numbers are placed such that they will be visible for reference.
2. Use the wire strippers to remove ½" of the PVC outer jacket and expose the ripcord (if the
cable is so equipped). Use the needle nose pliers to pull ripcord so the desired length of wire is exposed. Cut off the original ½" of the cable as it may have been nicked when the PVC jacket was removed and could cause problems at a later date.
3. Remove the insulation using cable strippers. The use of a knife is not recommended because
of the risk of damaging the insulation of the conductors.
4. Use the side cutters to trim the jacket, ripcord and foil shield. DO NOT CUT OFF THE DRAIN
WIRE at the DM510 Control Panel end. Use the side cutters to cut the rest of the wires to a uniform length.
5. When all wiring has been completed, join all the drain wires together at the DM510 Control
Panel end. The shields should be connected to the grounding pigtail provided in the vertical cable tray located beside the I/O board within the DM510 cabinet. Only one end of the shield wire is to be connected to ground. Connect all these wires to the ground wire provided by the DM510 Control Panel.
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Overview: Typical DM510 wiring connections:
GND
+24VDC
Temp
GND
Com
Com
Rate Out
Output 2
Gnd.
Com
Com
Com
RATE IN
GND
Speed
Sense
Rate In
Speed
Control
Air Temp
Rate Out
GND
Output 2
+24VDC
TEMP
GND
Input
Local/
Remote
Outlet 2
Calibrate
Fan
Status
Local/
Remote
Status
Outlet 1
Calibrate
Input
Input
Output
Input
GND
Moisture
+24
Gnd
Temp
Outlet 2
+24V
---
COM
T3
M3
__
Moisture
+24
Gnd
Outlet 1
+24V
---
COM
T2
M2
__
Moisture
+24
Gnd
Inlet
+24V
---
COM
T1
M1
__
Com
Outlet 1
Calibrate
Lamp
Output
Com
Outlet 2
Calibrate
Lamp
Output
Com
Remote
Alarm
Output
Temp
Temp
Inlet Moisture1
Drying Air Temperature4
Outlet Moisture2
Calibration Button3
Rate Sense/Control5
Local/Remote/Status6
Fan Status7
Spare8
Shield drain wires, twist and wire nut to drain wire provided in vertical cable tray
Signal Ground
Sensor Ground wires
Green
Green
Green
Green
Green
Green
Red
Red
Red
Red
Red
Red
Black
Black
Black
Black
Black
Black
White
White
White
White
White
White
White
Com
Input
Com
Input
Com
Input
Com
Input
Com
Output
Com
Output
Com
Output
Com
Output
Figure 28 - DM510 typical wiring connections
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Moisture Sensors Wiring Instructions
While wiring the sensors refer to Figure 30 - Sensor hook-up schematic. Both the Inlet and Outlet Moisture Sensor Multi-Cables should be wired as follows:
The Moisture Sensor End
1. Follow the instructions given in the section “General Wiring Procedure” to strip the PVC
jacket and expose 4" (10 cm) of wire.
2. Cut off the foil shield and the drain wire at the sensor end of the cable.
3. Tape over the exposed ends of the foil shield and drain wire so that they are insulated from
contact with the metal work and the circuit board.
4. Strip ½" (7mm) and twist (colour to colour) and crimp to the wires exposed in the moisture
sensor using the crimp connectors provided in the sensor.
5. Join the ground wire in the moisture sensor to the ground wire from the DM510 Control
Panel using a wire nut.
The DM510 Control Panel End
1. The Multi-Cables from the Moisture Sensors connect to the DM510 Control Panel
termination. Attach them using the connectors as indicated in Figure 29 - Sensor hook-up physical
2. Connect the Multi-Cable drain wire and the 18-gauge ground wire from the Moisture Sensors
to the ground wire in the DM510 Control Panel.
Notes:
Sensor Signal specification
Red = 18 to 28 vdc, 20mA Black = Signal return & dc Gnd. Green = Moisture signal White = Temperature signal
Maximum Wire length DM510 to sensor = 300 meters, 1000 feet. Additional lightning protection is recommended when exceeding 60 meters, 200 feet.
Important
During the following procedures, the drain must be grounded at the DM510 I/O Panel and isolated
from the ground at the field end.
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DM510 Control Panel
Figure 30 - Sensor hook-up schematic
Moisture
24V
GND
Temp
Inlet
Moisture +24VDC
GND
Temp
Outlet 1
M1
+24V
---
__
GND
T1
M2
+24V
---
GND
T2
__
Inlet
Sensor
Moisture
+ 24 V Gnd.
Temp.
Green
Red
Black
White
Outlet
Sensor
Moisture + 24 V
Gnd.
Temp.
Black
Red
Green
Green Red
Black White
Green
Red
Black
White
1
2
1
White
2
Shield
To pigtail in vertical
wire tray
Figure 29 - Sensor hook-up physical
Dryer Master Control Panel
Moisture Sensor
Electrical Tape
(insulate shield
from ground)
Wire Nut ground cable to ground wire in Sensor
Ground
GREEN RED
BLACK WHITE
Moisture
+24 VDC
Ground
Temperature
Conduit
Flex conduit
Green White
Black Red
Shield
To pigtail in vertical
wire tray
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I/O board Jumper locations and functions
These jumpers are found on the I/O board next to the terminal connections. These Jumpers are in the correct position by default. No adjustments are required for standard configurations.
Digital output Jumpers
Digital input jumpers
Analog input jumpers
Contact Configuration Jumpers. Shown in
default N.O. (Normally Open) configuration. Contact closes on activation. Optionally, N.C. (Normally Closed) configuration. Contact opens on activation.
Contact outputs +24 VDC or is dry contact.
Shown in default position. Contact closes
and +24 volts is present at Output.
Contact output dry contact or tied to GND. Shown in default position, tied to GND.
Figure 32 – I/O board Digital Out jumper configuration description.
Digital Input Configuration Jumpers.
Shown in default GND, grounded
configuration. Moving the jumper to COM
isolates the inputs from ground and from
each other.
Figure 33 – I/O board Digital Input jumper configuration description.
Figure 31 – I/O board jumper location
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Analog Input Configuration Jumpers. Shown in default 10V position for the first 7 channels. Channel 8 the temperature channel is in the 5V position by default.
Figure 34 – I/O board Analog Input jumper configuration description.
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Motor Speed Control Interface Wiring Instructions (for DC drives)
Note: Dryers with discharge systems powered by DC motors may have speed controls where the speed signals and potentiometer signals are live to power. These systems make use of the Dryer Moisture Systems Inc. Motor Speed Control Interface to isolate the speed control signals.
If the Dryer Master Motor Speed Control Interface is used, it should be mounted near the motor speed control for the dryer. The dimensions of the interface are 3" x 5". it is usually mounted inside the dryer's control panel. Make sure that the installation is in a dry, weather-tight area.
DC Motor Speed Control Interface
Local/Remote Control
The Local/Remote Control allows the DM510 Control Panel to initiate switching of the motor speed control between local speed pot and the DM510 Control Panel. Below is a list of the multi-cable requirements for a DM510 system with ALL options.
Connections from DM510 to Motor Speed Control Interface:
Function
From: DM510
To: Motor Speed Control Interface
Local/Remote Relay
DM510 Local/Remote Output
MSC Interface Local/Remote T3
Local/Remote Relay
DM510 Outlet 2 GND
MSC Interface Local/Remote T4
Rate Sense
DM510 Speed Sense Rate In.
MSC Interface Rate Sense T1
Rate Sense
DM510 Speed Sense GND.
MSC Interface Rate Sense T2
Rate Control
DM510 Speed Control Rate Out
MSC Interface Rate Control T5
Rate Control
DM510 Speed Control GND
MSC Interface Rate Control T6
The DM510 Speed Sense must be set to 0-5 VDC or 0-10 VDC depending what is being sent from the Dryers speed control. Most frequency drives output 0-10 volts as a speed signal. Changing the range is accomplished by placing the jumper on J26. Shorting pins 1 and 2 selects a 0-5 volt range while shorting pins 2 and 3 selects a 0-10 volt range. The default is 0-10 volt range.
The Local/Remote output must be set for 24 VDC, NO output. Placing the jumpers on J5 and J6 does this. Shorting pins 1 and 2 of J5 will give the 24 VDC while shorting pins 2 and 3 of J6 gives the NO condition.
Figure 35- DM510 to MSC Interface
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DM510 to Motor Speed Control Interface Wiring
MOTOR SPEED CONTROL INTERFACE
Rate Sense Out Adjustment
(Clockwise To Increase)
GND
+24VDC
Temp
GND
Com
Com
Rate Out
Output 2
GND
Com
Com
Com
RATE IN
GND
Speed
Sense
Speed
Control
Air Temp
Rate Out
GND
Output 2
+24VDC
TEMP
GND
Input
Output
COM
Local/
Remot
e
Outlet 2
Calibrate
Fan
Status
Local/
Remote
Status
Outlet 1
Calibrate
Input
Input
Output
Input
GND
5
6
RED
5
6
RED
RED
BLACK
BLACK
BLACK
RED
GREEN
WHITE
GREEN
WHITE
BLACK
Dryer Master DM510
GREEN
GREEN
Input
COM
Input
COM
Input
COM
Input COM
Rate IN
T1 T2
T3 T4
T5 T6
T7
T8
T9
T10
T11
T12
T13
T14
P 2
P 1
Rate Sense
OUT GND
LOC/REM Control
Rate Control
IN
GND
Shield
To pigtail in vertical
wire tray
Shield
Figure 36 - DM510 to MSC Interface
Connections from Motor Speed Control Interface to Motor Speed Control:
Function
From: DMSI Motor Speed Control
Interface
To: Motor Speed Control
Rate Sense Input (If DC Motor is 180 VDC)
MSC Interface ARM 180 VDC T14
DC Motor Speed Control A+
Rate Sense Input (If DC Motor is 90 VDC)
MSC Interface ARM 90VDC T13
DC Motor Speed Control A+
Rate Sense Common
MSC Interface ARM T12
DC Motor Speed Control A-
Rate Control
MSC Interface Wipe Out T9
DC Motor Speed Control Pot Input Wipe
Rate Control
MSC Interface Wipe In T8
Speed Pot Wipe
Rate Control
MSC Interface Com T7
DC Motor Speed Control Pot Input Low Speed Pot Low
Figure 37 - MSCI to DC Motor
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DC Motor Speed Control Interface Wiring
AC Motor Speed Control Interface
Most AC Motor Speed Controls can provide a 0-5V output for speed monitoring and a 0-10V input for remote speed control. If these signals are isolated they can be connected directly to the DM510 Control Panel
Local/Remote Status Wiring Instructions
The Motor Speed Control Interface provides a local/remote switching facility that can disconnect the manual speed dial on the dryer and allow the DM510 to control the discharge rate. It is necessary for the DM510 to understand the status of this functionality. This is achieved by wiring up the spare dry contact from the local/remote relay used to switch local control signal and the DM 510 speed input in the case of an AC motor.
Figure 38 - MSC DC Isolation Hookup
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AC Motor Local/Remote Status Wiring
GND
+24VDC
Temp
GND
Moisture
+24VDC
GND
Temp
Outlet 2
Com
Com
Rate Out
Output 2
GND
Com
Com
Com
Com
+24V ---
GND
T3
M3
__
RATE IN
GND
Speed
Sense
Rate In
Speed
Control
Air Temp
Rate Out
GND
Output 2
+24VDC
Temp
GND
Input
NO/NC
COM
NO/NC
COM
Outlet 1
Calibrate
Lamp
Local/
Remote
Inlet 2
Calibrate
Fan
Status
Local/
Remote
Status
Outlet 1
Calibrate
Input
Input
Output
Input
Output
Green
5 L/R Status NO
1 NC
6
6
13 A1 Coil +
Black
Local/Remote Relay
Finder 55.32, Carlo
Gavazzi RMIA2-10024DC
Dryer Master DM510
GND
Red
SHIELD
9 L/R Com
A2 Coil - 14
To VFD 12
NC Rate From Dryer 4
NO Rate Out 8
Input
COM
Input
COM
Input
COM
Input
COM
To pigtail in vertical
wire tray
Red
Green
Black
This is an optional feature.
If it is used the software must be configured to use this signal.
Figure 39 - Local/Remote Status Wiring
If you are using the Dryer Master Motor Speed Control Interface, the local/remote status function is provided at T10 and T11
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Fan Status Wiring Instructions
It is necessary for the DM510 to realize the status of the Dryer Fans. This is to inform the Dryer Master what drying state the dryer is operating in. This is achieved by wiring up a spare dry contact (if no dry contact is available use a second relay) from the fan starter to the Dryer Master fan status in the manner demonstrated in the drawing Figure 40 - Fan Status
GND
+24VDC
Temp
GND
Moisture
+24VDC
GND
Temp
Outlet 2
Com
Com
Rate Out
Output 2
GND
Com
Com
Com
Com
+24V ---
GND
T3
M3
__
RATE IN
GND
Speed
Sense
Rate In
Speed
Control
Air Temp
Rate Out
GND
Output 2
+24VDC
Temp
GND
Input
NO/NC
COM
NO/NC
COM
Outlet 1
Calibrate
Lamp
Local/
Remote
Inlet 2
Calibrate
Fan
Status
Local/
Remote
Status
Outlet 1
Calibrate
Input
Input
Output
Input
Output
Green
5 NO 1 NC
6
6
13 A1 Coil
Customer supplied
Dryer Running Relay
Dryer Master DM510
GND
SHIELD
9 Com
A2 Coil - 14
COM 12
NC 4
NO 8
Input
COM
Input
COM
Input
COM
Input
COM
To pigtail in vertical
wire tray
This is an optional feature.
If it is used the software must be configured to use this signal.
To Customer equipment for dryer fan running status
White
Figure 40 - Fan Status
Page 59
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Drying Air Temperature Wiring Instructions
There are three options for providing the DM510 with a drying air temperature reading. In most cases the decision about which option to use is made at the time of ordering the DM510 system.
1. A Dryer Master Air Plenum Temperature Sensor to be located in the dryer
2. A signal converter that utilizes the dryer temperature information
3. Using a signal from a temperature controller with a digital or analog output
Caution
All multi-cable must be run in areas where the maximum temperature does not exceed 105°C
(220°F). Use Teflon coated wires in areas that exceed this limit.
Figure 42 - Air Plenum Temperature Sensor
Figure 41 - Temperature Signal Converter
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Connecting to a Drying Air Temperature Sensor
GND
+24VDC
Temp
GND
Rate Out
Output 2
Gnd.
Rate In
GND
Speed
Sense
Rate In
Speed
Control
Air Temp
Rate Out
GND
Output 2
+24VDC
TEMP
GND
GND
Drying Air Temperature4
RED
BLACK
WHITE
GROUND
SHIELD
GROUND
Drying Air
Temperature
Sensor
4
RED
BLACK
WHITE
To pigtail in vertical
wire tray
Solid State Temperature probe Signal specification Red = 18 to 30 vdc, 2mA Black = Gnd. White = Temperature signal
Dryer Master DM510
This device measures the temperature of the drying air in the air plenum. If the temperature controller for the dryer does not have a scaled output use the Drying Air Temperature Sensor supplied with the DM510. For both options remember to attach the Multi-cable shield to ground at Dryer Master end and insulate it on the other end.
Mount the Drying Air Temperature Sensor within one foot of the existing temperature sensor in the hot zone of the dryer. Both sensors should be at the same height. Use high temperature wire from the Drying Air Temperature Sensor to the outside of the hot zone. At this point the standard two pair shielded cable can be used.
Hint
Caulk the conduit entry into the hot zone of the dryer with silicone. This avoids a hot draft
heating up the conduit near your splice.
Figure 43 - Drying Air Temperature Sensor Wiring
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Connecting to a Drying Air Temperature Controller
There are two possible methods to connect to a Temperature Controller within the dryer control panel. First is a direct analog connection and second is a RS485 connection. Consult your Temperature Controller manual to determine which one you have. Run one Multi-cable between the Dryer Master and the Temperature Controller. Check the temperature controller manual for the correct termination.
Connecting to a Temperature Controller with an analog output.
GND
+24VDC
Temp
GND
Rate Out
Output 2
Gnd.
Rate In
GND
Speed
Sense
Rate In
Speed
Control
Air Temp
Rate Out
GND
Output 2
+24VDC
TEMP
GND
GND
GREEN
WHITE
SHIELD
Dryer Master DM510
Drying Air Temperature4
Drying Air Temperature 4
To pigtail in vertical
wire tray
185.5
Consult device
manual for function
availability and setup
Consult Figure 37 – I/O board Analog Input jumper configuration description for setting the input jumpers to the correct input scaling.
Figure 44 - APT Controller analog connection
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Temperature controller to DM510 via signal converter
Existing Plenum Temperature
Controler
Omegaette
TXDIN70-24V
Rate Out
RATE IN
GND
Speed
Sense
Speed
Control
Air Temp
GND
Output 2
+24VDC
TEMP
GND
Local/
Remote
Status
GND
Outlet 2
+24V
---
COM
T3
M3
__
Outlet 1
+24V
---
COM
T2
M2
__
Green
White
Black
Precision
250Ω Resistor
Red
Note: This device requires 24VDC supply. DO NOT connect to 120VAC supply! Damage caused by incorrect supply voltage is not covered under warranty!
Red
DM 510 Dryer Master to Omega TXDIN70-24V converter
1 2 3 4
5 6 7 8
13 14 15 16
9 10 11 12
Existing J-type Thermocouple
White
+
-
Channel 1 Output Channel 2 Output
Channel 1 Input
Channel 2 Input
+24VDC
Temp
GND
Input Com
Moisture
+24VDC
GND
Temp
Moisture
+24VDC
GND
Temp
Rate In
GND
Rate Out
Output 2
+24VDC
GND
Temp
GND
Input
COM
Figure 45 - DM510 to signal converter wiring
For complete programming and install instructions see Appendix 2.
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Calibration Button Wiring Instructions
Rate Out
Rate In
GND
Speed
Sense
Speed
Control
Air Temp
GND
Output 2
+24VDC
TEMP
GND
Local/
Remote
Status
GND
Outlet 2
+24V
---
COM
T3
M3
__
Green
White
Black
Red
DM 510 Dryer Master
Input
Com
Moisture
+24VDC
GND
Temp
Rate In
GND
Rate Out
Output 2
+24VDC
GND
Temp
GND
Input
COM
Input
Com
Input
COM
Input
Com
Input
COM
Input
Com
Input
COM
Outlet 1
Calibrate
Fan
Status
Outlet 2
Calibrate
Output
Com
Output
COM
Output
Com
Output
COM
Outlet 1
Calibrate
Lamp
Local/
Remote
X2
X1
NO
NO
Calibration Button3
Calibration Button 3
White
Green
Red
Black
Calibration Button
SHIELD
To pigtail in vertical
wire tray
Button Lamp and Signal specification
Red = 18 to 30 VDC, 40mA (When Active) Black = GND Green = N.O. contact + 18 to 30 VDC, 2 mA (When Active) White = N.O. contact + 18 to 30 VDC
Figure 46 - Calibration Push Button
Mount the button where the operators normally take their off-line sample. During the calibration operation, the button is pushed and it flashes. The operators should be able to see the light while they are taking the manual sample. Run one multi-cable between the button and the Dryer Master and terminate as per the above diagram.
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Remote Alarm Control
Rate Out
Rate In
GND
Speed
Sense
Speed
Control
Air Temp
GND
Output 2
+24VDC
TEMP
GND
Local/
Remote
Status
GND
Outlet 2
+24V
---
COM
T3
M3
__
Black
Red
DM 510 Dryer Master
Input Com
Moisture
+24VDC
GND
Temp
Rate In
GND
Rate Out
Output 2
+24VDC
GND
Temp
GND
Input
COM
Input Com
Input
COM
Input Com
Input
COM
Input Com
Input
COM
Outlet 1
Calibrate
Fan
Status
Outlet 2
Calibrate
Output
Com
Output
COM
Output
Com
Output
COM
Outlet 1
Calibrate
Lamp
Local/
Remote
SHIELD
To pigtail in vertical
wire tray
Output
Com
Output
COM
Output
Com
Output
COM
Outlet 2
Calibrate
Lamp
Remote
Alarm
5 NO
1 NC
13 A1 Coil +
Alarm Relay Finder
55.32, Carlo Gavazzi RMIA2-10024DC
9 Com
A2 Coil - 14
Com 12
NC 4
NO 8
Red
Black
Power Source For remote alarm device
Figure 47 - Remote Alarm
DM510 Control Panel supplies a set of relay contacts to be used if an external alarm is desired. Run one multi-cable between the 24 VDC control relay and the Dryer Master and terminate as in Figure 47 - Remote Alarm. The Alarm Control Relay is activated when alarm parameters (set by the operator) are exceeded. See the DM510 Users’ Guide for further details.
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Appendix 1: Motor speed control wiring diagrams
Included in this section are wiring diagrams for some common motor speed controls. If your motor speed control diagram is not included here and you need guidance with the connections contact the Dryer Master Support Center for assistance.
Sample wiring diagrams
1. Mitsubishi FR-D700
2. Generic VFD (0-10 vdc)
3. Allen Bradley PowerFlex40
4. Baldor Series H2
5. Altivar 31
Rate Out
GND
+24VDC
Temp
GND
Com
Com
Rate Out
Output 2
Gnd.
Com
Com
Com
RATE IN
GND
Speed
Sense
Rate In
Speed
Control
Air Temp
GND
AO 2
R1/APT
R3
R2/GND
Input
DI 1
DI 2
DI 3
DI 4
120V MAX.
A
A
A
A B
B
B
B
120V MAX.
120V MAX.
120V MAX.
DO 1
NO/NC COM
Local/
Remote
Outlet 2
Calibrate
Fan
Status
Local/
Remote
Status
Outlet 1
Calibrate
Input
Input
Output
Input
GND
Moisture
+24
Gnd
Temp
Outlet 2
+24V
---
COM
T3
M3
__
Moisture
+24
Gnd
Outlet 1
+24V
---
COM
T2
M2
__
Com
DO 2
NO/NC COM
Outlet 1
Calibrate
Lamp
Output
Com
DO 3
NO/NC COM
Outlet 2
Calibrate
Lamp
Output
Com
DO 4
NO/NC COM
Remote
Alarm
Output
Temp
A1A2
9
1
5
12
4
8
Green
White
Black
Red
Red Black
2
5
4
Existing Speed
Potentiometer
White
Mitsubishi FR-D700
series inverter
Terminals
White
AM
10
X
coil coil
3
2
1
The default reference voltage for the speed setting potentiometer is 5 Volts at terminal 10. Therefore the input signal at terminal 2 is also configured for 0 to 5 volt. This can be set with Parameter 73. By default parameter 73 is set to 1, setting parameter 73 to 0 will set the input signal range to 0 10 volts. This will also require using terminal 10E, the 10 volt reference for the speed setting potentiometer. Ether configuration is suitable with Dryer Mster
Note: The Dryer Master speed setting signal is wired into the same terminal as the manual speed setting potentiometer, The relay serves to connect either the Speed potentiometer or the Dryer Master to terminal 2. Therefore the speed potentiometer wire connection to terminal 2 of the speed control is now routed through the relay. With the relay not energized the Speed Potentiometer is in control.
DM 510 Dryer Master to Mitsubishi FR-D700 series inverter
Figure 48 - DM510 to Mitsubishi FR-D700
Page 66
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coil coil
A1 A2
9
1
5
12
4
8
Com
Speed
Sense
Rate In
Local/
Remote
Output
0-10V input
Analog Common
Existing Speed
Potentiometer
Generic VFD
Analog Ouput
+10V
X
3
2
1
Note: To achieve the most flexibility and still maintain the use of a manual speed potentiometer for the just in case scenario the speed setting signal is wired into the same terminal as the manual speed setting potentiometer, The relay serves to connect either the speed potentiometer or the PLC speed signal to the input terminal. Therefore the speed potentiometer wire connection to the input terminal of the speed control is now routed through the relay. With the relay not energized the Speed Potentiometer is in control.
Generic DM510 to VFD voltage input (0-10 vdc)
ccw
cw
Rate Out
Speed
Control
GND
GND
4-20 mA input
Figure 49 - DM510 to Generic VFD (O-10 vdc)
Rate Out
GND
+24VDC
Temp
GND
Com
Com
Rate Out
Output 2
Gnd.
Com
Com
Com
RATE IN
GND
Speed
Sense
Rate In
Speed
Control
Air Temp
GND
AO 2
R1/APT
R3
R2/GND
Input
DI 1
DI 2
DI 3
DI 4
120V MAX.
A
A
A
A B
B
B
B
120V MAX.
120V MAX.
120V MAX.
DO 1
NO/NC COM
Local/
Remote
Outlet 2
Calibrate
Fan
Status
Local/
Remote
Status
Outlet 1
Calibrate
Input
Input
Output
Input
GND
Moisture
+24
Gnd
Temp
Outlet 2
+24V
---
COM
T3
M3
__
Moisture
+24
Gnd
Outlet 1
+24V
---
COM
T2
M2
__
Com
DO 2
NO/NC COM
Outlet 1
Calibrate
Lamp
Output
Com
DO 3
NO/NC COM
Outlet 2
Calibrate
Lamp
Output
Com
DO 4
NO/NC COM
Remote
Alarm
Output
Temp
A1A2
9
1
5
12
4
8
Green
White
Black
Red
Red
Black
13
16
12
Existing Speed
Potentiometer
Allen Bradley
PowerFlex® 40
White
14
X
coil coil
3
2
1
Note: The Dryer Master speed setting signal is wired into the same terminal as the manual speed setting potentiometer, The relay serves to connect either the Dryer Master or the Speed potentiometer to terminal 13. If the input is form a PLC this will be terminal 15. Therefore the speed potentiometer or PLC wire connection to terminal 13 or 15 of the speed control is now routed through the relay. With the relay not energized the Speed Potentiometer or PLC is in control.
DM 510 Dryer Master to Allen Bradley PowerFlex
®
40 series inverter
Analog Common
0-10V (or ±10V) Input
+10V DC
4-20mA Input
15
Analog Output
Drive Setup: Parameter AO65 > set to “0” for voltage output. AO66 > set to “100%” for 10VDC out at maximum speed. A123 > set to “0” for unipolar operation. A132 > set to “0” to ensure PID control is off.
From Speedpot wipe or PLC
Figure 50 - DM510 to Allen Bradley PowerFlex40
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GND
+24VDC
Temp
GND
Com
Com
Rate Out
Output 2
Gnd.
Com
Com
Com
RATE IN
GND
Speed
Sense
Rate In
Speed
Control
Air Temp
Rate Out
GND
AO 2
R1/APT
R3
R2/GND
Input
DI 1
DI 2
DI 3
DI 4
120V MAX.
A
A
A
A B
B
B
B
120V MAX.
120V MAX.
120V MAX.
DO 1
NO/NC COM
Local/
Remote
Outlet 2
Calibrate
Fan
Status
Local/
Remote
Status
Outlet 1
Calibrate
Input
Input
Output
Input
GND
Moisture
+24 Gnd Temp
Outlet 2
+24V
---
COM
T3
M3
__
Moisture
+24 Gnd
Outlet 1
+24V
---
COM
T2
M2
__
Com
DO 2
NO/NC COM
Outlet 1
Calibrate
Lamp
Output
Com
DO 3
NO/NC COM
Outlet 2
Calibrate
Lamp
Output
Com
DO 4
NO/NC COM
Remote
Alarm
Output
Temp
A1A2
9
1
5
12
4
8
finder
55.32.9.024.0040 Relay or
equivalent
CR DM
1 2 3 4 5 6 7
J1
1
Green
White
Black
Red
Baldor
Series H2
Control
Wiring
Terminal
Strip
existing rate
control wiring
from dryer control
panel
(removed from
terminal 2 of
Baldor drive)
DM510 to Baldor Series H2 Variable Frequency
Drive Wiring Schematic
Red
Black
Rate Out
GND
+24VDC
Temp
GND
Com
Com
Rate Out
Output 2
Gnd.
Com
Com
Com
RATE IN
GND
Speed
Sense
Rate In
Speed
Control
Air Temp
GND
AO 2
R1/APT
R3
R2/GND
Input
DI 1
DI 2
DI 3
DI 4
120V MAX.
A
A
A
A B
B
B
B
120V MAX.
120V MAX.
120V MAX.
DO 1
NO/NC COM
Local/
Remote
Outlet 2
Calibrate
Fan
Status
Local/
Remote
Status
Outlet 1
Calibrate
Input
Input
Output
Input
GND
Moisture
+24 Gnd Temp
Outlet 2
+24V
---
COM
T3
M3
__
Moisture
+24 Gnd
Outlet 1
+24V
---
COM
T2
M2
__
Com
DO 2
NO/NC COM
Outlet 1
Calibrate
Lamp
Output
Com
DO 3
NO/NC COM
Outlet 2
Calibrate
Lamp
Output
Com
DO 4
NO/NC COM
Remote
Alarm
Output
Temp
A1A2
9
1
5
12
4
8
finder
55.32.9.024.0040 Relay or
equivalent
Green
White
Black
Red
Red Black
AI1
COM AOV
Speed signal
from dryer control
panel
to auxilary dry
contacts on fan
starter
White
Green
Altivar 31
White
Figure 51 - DM510 to Baldor Series H2
Figure 52 - DM510 to Altivar 31
Page 68
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Appendix 2: Complete instructions for programming and wiring Omega TXDIN70­24V Signal Converter
Forward:
This appendix contains instructions on how to use an Omega part number TXDIN70-24V signal converter to share a dryer temperature thermocouple sensor with a Dryer Master DM510. Note
that the signal converter is typically provided already fully programmed.
Materials:
The following materials are required to accomplish this task:
1. Signal Converter, Omega part number TXDIN70-24V.(Green)
2. Programming/Display Adapter, w/ cable, (Black) Omega part number TXDIN70-
DISPLAY
3. Precision 250Ω resistor
4. Various hand tools and wire as indicated.
Procedure:
1) Mount the signal converter onto a DIN rail in the dryer panel.
2) If desired, mount the programming display to the DIN rail beside the converter.
3) Use the supplied USB cable to connect the display to the converter.
4) Use instrumentation cable to connect the converter signal output (terminal 5 (+),
terminal 6 (-)) and power wires (terminal 1 (+), terminal 2 (-)) to the Dryer Master as
shown in figure 1.
5) Using the appropriate thermocouple wire, jumper the thermocouple sensor signal
from the existing plenum temperature controller to the new converter. Connect the
positive wire (white) to terminal 15 and the negative wire (red) to terminal 14 of the
converter.
6) Install the 250Ω precision resistor inside the Dryer Master from the Air Temp
connector terminal “Temp” to terminal “GND”.
7) Program the converter.
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Note 1: The TXDIN70-24V converter is a two-channel device. The instructions above use channel 1. Channel 2 input uses terminals 10 and 11 while the output uses terminals 7 and 8.
Existing Plenum Temperature
Controler
Omegaette
TXDIN70-24V
Rate Out
RATE IN
GND
Speed
Sense
Speed
Control
Air Temp
GND
Output 2
+24VDC
TEMP
GND
Local/
Remote
Status
GND
Outlet 2
+24V
---
COM
T3
M3
__
Outlet 1
+24V
---
COM
T2
M2
__
Green
White
Black
Precision
250Ω Resistor
Red
Note: This device requires 24VDC supply. DO NOT connect to 120VAC supply! Damage caused by incorrect supply voltage is not covered under warranty!
Red
DM 510 Dryer Master to Omega TXDIN70-24V converter
1 2 3 4
5 6 7 8
13 14 15 16
9 10 11 12
Existing J-type Thermocouple
White
+
-
Channel 1 Output Channel 2 Output
Channel 1 Input
Channel 2 Input
+24VDC
Temp
GND
Input Com
Moisture
+24VDC
GND
Temp
Moisture
+24VDC
GND
Temp
Rate In
GND
Rate Out
Output 2
+24VDC
GND
Temp
GND
Input
COM
Note 2: If the 250Ω precision resistor is missing you can substitute four (4) 1000Ω 5% resistors commonly available at any electronic supply house. Twist the leads of all four resistors together to get 250Ω and install the resistors as instructed above. This may introduce a small error in the reading at the dryer master but should be reasonably close.
Figure 53 - Wiring diagram for signal converter connections
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Programming:
The following instructions will setup both channels identically. Should channel 1 fail for any reason, simply moving the appropriate wires to channel 2 will restore operation.
Note: If, when displaying a parameter there is inactivity on the keypad for more than about 20 seconds, the display exits the parameter setup. If this happens to you, simply return to step 1 and start over.
Note: You can only advance from one parameter to the next. If you enter the wrong value and advance to the next parameter you will need to advance through all the parameters and back to the temperature display screen in order to re-enter the parameters and correct your mistake.
Note: The programming/display unit will only show the temperature in degrees Celsius when connected to a thermocouple. For reference purposes, 100°C = 212°F, 0°C = 32°F and 21°C ≈ 70°F.
1) Press and hold the return key until the first parameter is displayed.
2) Set input channel 1 (InP1) to 3 for a T-type thermocouple or 5 for a J-type
thermocouple using the up and down arrows.
3) Press the return key to advance to the next parameter.
4) Set input channel 2 (InP2) to 3 for a T-type thermocouple or 5 for a J-type
thermocouple using the up and down arrows.
5) Press the return key to advance to the next parameter.
6) Set channel 1 scale low limit (SCL1) to -80.0.
7) Press the return key to advance to the next parameter.
8) Set channel 2 scale low limit (SCL2) to -80.0.
9) Press the return key to advance to the next parameter.
10) Set channel 1 scale high limit (SCH1) to 204.4.
11) Press the return key to advance to the next parameter.
12) Set channel 2 scale high limit (SCH2) to 204.4.
13) Press the return key to advance to the next parameter.
14) Set channel 1 input offset (Scb1) to 0.
15) Press the return key to advance to the next parameter.
16) Set channel 2 input offset (Scb2) to 0.
17) Press the return key to advance to the next parameter.
18) Set channel 1 digital filter (FIL1) to 30.
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19) Press the return key to advance to the next parameter.
20) Set channel 2 digital filter (FIL2) to 30.
21) Press the return key to advance to the next parameter.
22) Set retransmission channel assignment (OPn) to 1.
23) Press the return key to advance to the next parameter.
24) Set low limit of current retransmission of channel 1 (OPL) to 0.0.
25) Press the return key to advance to the next parameter.
26) Set high limit of current retransmission of channel 1 (OPH) to 200.
27) Press the return key to advance to the next parameter.
28) Set low limit of current retransmission of channel 2 (OPL2) to 0.0.
29) Press the return key to advance to the next parameter.
30) Set high limit of current retransmission of channel 1 (OPH2) to 200.
31) Do not change the remaining parameters.
32) Press the return key several more times to return to the temperature display screen.
Check the plenum temperature parameters on the Dryer Master as follows.
1. Press the “Settings” key.
2. Press “2” for installer setup.
3. Enter the password “4628”.
4. Press “Enter”.
5. Press “7” for Drying Temperature setup.
6. With the highlight bar on the slope value change the value (if required) to 0.5 and
press the “Enter” key. (If in degrees C use 0.2777)
7. Use the arrow keys to move the highlight bar to the offset value and change the
value (if required) to -112 and press the “Enter” key. (If in degrees C use -80)
8. Press the “Cancel” key several times to return to the main screen.
The Dryer Master should now read the same temperature as the dryer panel. When drying, if there is an error greater than 2-3 degrees change the offset value on the Dryer Master so the temperature displayed matches the dryer panel reading.
Note: The Programming/Display adapter can be removed when programming is complete as it is not required for system operation.
If problems arise, contact Dryer Master Support at 1-888-318-0009.
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Appendix 3. Sensor Chutes w/ Rotary Feed
Option 1: Bypass Method
The sensor chute is designed to be used in a bypass type installation of the outlet moisture sensor. In a bypass type installation only a portion of the total product flow passes by the sensor (See pages 28-29).
• Dimensions: 18 1/4” L x 8 1/2” W x 16 1/2” H
• Upper mounting flange 8 1/2” x 8 1/2”
• Built in sampling access
• Motor is IP66, 25W, 115VAC single phase,
0.43FLA reversible motor with 180:1 gear
reduction (230VAC also available if required)
• Sensor housing can be mounted in any
direction without impacting flow (must be
vertical)
Installation Considerations:
1. The sensor housing (top portion of the assembly) can be mounted in any direction. You can
unbolt the four bolts attaching the sensor housing to the rotary feed, then rotate the housing to the desired direction, and then bolt back together. The sensor can also be mounted where the viewing window is located (and then move the viewing window to the previous sensor location).
2. Ideally the sensor housing and chute assembly should be free of grain when the dryer is not
running. This avoids having stagnant grain gumming up the assembly. To do this the motor
for the rotary feed should be wired so that it is the last thing that shuts off after the dryer shuts down. Having the motor turn on and off with the dry conveyor will usually
accomplish this
3. To ensure proper flow, the transition piece mounted to the bottom of the chute should be
the same size as the hole leaving the chute (6”X6”).
Sensor Housing
Slide gate to close off flow for cleaning
Rotary feed Viewing
window
Sampling Access
Motor
Figure 54 – Bypass chute description
Page 73
Page | 73
Option 2: In-Line Method
The sensor chute is designed to be used in an inline type installation of the outlet moisture sensor. In an inline type installation a portion of the total product flow passes through the 6X6 chute with the rest flowing over the sides in the larger chute. (See pages 33-34).
• Overall 18.25” X 10”X 18.25” (HXWXD) (46.3
cm X 25.4 cm X46.3 cm)
• Inside chute 6”X6” (15.25 cm X 15.25 cm)
• Mounting plate is 18.25” X 10”
(46.3 cm X 25.4 cm)
• Motor is IP66, 25W, 115VAC single phase,
0.43FLA reversible motor with 180:1 gear reduction (230VAC also available)
• Slide gate to close off flow
• Sampling port and viewing window
6” X 6” chute
Rotary Feed
Sensor
Slide gate to close off flow
Sampling port and viewing window
Figure 55 – Inline chute description
Figure 56 – Inline Chute Graphic
Figure 57 – Inline Chute Installation
Page 74
Page | 74
The motor can run either clockwise (CW) or counter clockwise (CCW).
Move the black wire to change the direction of rotation
Figure 58 – Chute motor rotation change Graphic
Page 75
Page | 75
Appendix 4. Round Cell Sensor
In some cases a round cell sensor may be the most appropriate sensor choice. This may be the case where there is limited space for the standard fin sensor installation with a chute and slide gate or rotary valve.
Figure 59 - Round Cell Sensor
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