GSI PNEG-1181 User Manual
GSI Network Portable
Dryer Models
Troubleshooting and Reference Manual
PNEG-1181
Date: 09-18-07
PNEG-1181
2 PNEG-1181 Portable Dryer Troubleshooting
Table of Contents
Contents
Chapter 1 Safety .................................................................................................................................................. 5
Safety Guidelines ............................................................................................................................... 5
Dryer Safety Instructions and Information .......................................................................................... 6
Safety Precautions ........................................................... ... ... .... ... ... ... ... ............................................ 7
Chapter 2 Decals .................................................................................................................................................9
Chapter 3 Operation Tips ................................................................................................................................. 11
Network Dryer Operation Tips .......... .......................................... ... ... ... ... .... ...................................... 11
Chapter 4 Setup Screens ................................................................................................................................. 13
Special Network Dryer Setup Screens ............................................................................................. 13
Chapter 5 Dryer Operation ............................................................................................................................... 14
Network Dryer Options Explanation ................................................................................................. 14
Chapter 6 Programming ................................................................................................................................... 16
Programming Instructions Using Palm Pilot ..................................................................................... 16
Programming Network Dryer Using Palm Pilot ............. ... ... .......................................... ... ... ............. 17
Programming Instructions Using Flash Programmer ....................................................................... 18
Programming Network Dryer Using Flash Programmer ................................................................... 19
Chapter 7 Board Hook Up ................................................................................................................................ 20
Programmer Hook Up Diagram ........................................................................................................ 20
Network Display Board ..................................................................................................................... 21
Input/Output Board ........................................................................................................................... 22
Chapter 8 Troubleshooting Tips ...................................................................................................................... 23
Possible Safety Circuit Shut Down Messages ................................................................................. 23
Input/Output Errors ........................................................................................................................... 27
Master Display Generated Errors ..................................................................................................... 29
PNEG-1181 Portable Dryer Troubleshooting 3
Table of Contents
Chapter 9 Wiring Reference ............................................................................................................................. 31
2 Fan Network Dryer Internal Wiring ................................................................................................ 31
2 Fan Network Dryer Internal Jumper Wiring ................................................................................... 32
Upper Control Back Panel Wiring .................................................................................................... 33
Network Upper Control Panel Wiring (220 Volt 3PH) ........................ ... ....... ...... ....... ...... ....... ...... ..... 34
Network Upper Control Panel Wiring (380, 460 and 575 Volt 3PH) ................................................. 35
2 Fan Network Power Circuit Diagram (220 Volt 1PH) (1 of 2) ........................................................ 36
Network Power Circuit Diagram (220 Volt 1PH) (2 of 2) .................................................................. 37
2 Fan Network Power Circuit (220 Volt 3PH) (1 of 2) ...................................................................... 38
Network Power Circuit (220 Volt 3PH) (2 of 2) ................................................................................. 39
2 Fan Network Power Circuit Diagram (440 Volt 3PH) (1 of 2) ........................................................ 40
Network Power Circuit Diagram (440 Volt 3PH) (2 of 2) .................................................................. 41
Network Control Circuit (Main Display Board) (1 of 4) ..................................................................... 42
Network Control Circuit (Input/Output Board) (2 of 4) ................. ..................................................... 43
Network Control Circuit (Meter Roll Sensor-SCR Board) (3 of 4) .................................................... 44
Network Control Circuit (Fan/Heater Board) (4 of 4) ........................................................................ 45
Upper Terminal Strip ........................................................................................................................ 46
Network Upper Terminal Strip (With Moisture Manager Hookup/Relay) .......................................... 47
Moisture Manager Hookup (Network or Competitor) ....................................................................... 48
Input/Output Board Voltage Testing (Located in Upper Control Box) .............................................. 49
Lower Control Box Back Panel Wiring ............................................................................................. 50
Network Fan/Heater Interface (Located in Heater Control Box) .................... ... .... ... ... ..................... 51
Network Fan/Heater Computer Pinouts ........................................................................................... 52
Fan/Can Control Box Wiring (Example: Single Phase Power) ....................... .......... ......... .......... ..... 53
Lower Junction Box Wire Routing .................................................................................................... 54
Upper Junction Box (Wiring) ............................................................................................................ 55
Network Dryer Meter Roll Sensor Rearview (Wiring) ....................................................................... 56
Testing Procedures and Location of Grain Temperature Sensors .................................................. 57
Procedure for Locating, Testing and Replacing a Defective Grain Temperature Sensor ................ 58
Sensor Chart .................................................................................................................................... 60
Procedure for Locating, Testing and Replacing a Defective Plenum Temperature Sensor ............. 61
Procedures for Replacing Network SCR Board .................................................... ... ........................ 63
Chapter 10 Dryer Parts ..................................................................................................................................... 64
Dryer Front Panel (Part Locations) ................................................................................................ 64
Dryer Fan/Can Side View (Part Locations) .................................................................................... 65
Plenum and Grain High Limit Locations ......................................................................................... 66
Chapter 11 Air Switch Tip ................................................................................................................................ 67
Network Series Air Switch Adjustment ........................................................................................... 67
Chapter 12 SCR Board Setup .......................................................................................................................... 69
SCR Board Terminals and Min./Max. Adjustment Locations ......................................................... 69
Setting SCR Board Maximum Voltage ........................................................................................... 70
Setting SCR Board Minimum Voltage ............................................................................................ 71
Chapter 13 Cross Reference ............................................................................................................................ 72
Overload Cross Reference Chart ................................. ... ... .... ... ... .......................................... ........ 72
Motor Cross Reference Chart ........................................................................................................ 74
Chapter 14 Warranty ......................................................................................................................................... 75
4 PNEG-1181 Portable Dryer Troubleshooting
1. Safety
Safety Guidelines
This manual contains information that is important for you, the owner/operator, to know and understand.
This information relates to protecting personal safety and preventing equipment problems. It is the
responsibility of the owner/operator to inform anyone operating or working in the area of this equipment
of these safety guidelines. To help you recognize this information, we use the symbols that are defined
below. Please read the manual and pay attention to these sections. Failure to read this manual and its
safety instructions is a misuse of the equipment and may lead to serious injury or death.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, may
result in property damage.
NOTE indicates information about the equipment that you
should pay special attention.
WARNING! BE ALERT!
Personnel operating, working or servicing portable dryers should read this manual.
Failure to read this manual and its safety instructions is a misuse of the equipment.
PNEG-1181 Portable Dryer Troubleshooting 5
1. Safety
Dryer Safety Instructions and Information
Thank you for choosing a GSI Network Portable Grain Dryer. It is designed to provide excellent
performance and service for many years.
This manual refers to the troubleshooting of the Network Dryer models. Different models are available
for liquid propane or natural gas fuel supply, with either single phase 230 volt, or three phase 230, 460,
575 volt electrical power. (Also 380 volt 50 Hz).
The GSI Group recommends contacting the local power company and having a representative survey
the installation so that wiring is compatible with the system and adequate power is supplied.
Our foremost concern is your safety and the safety of others associated with this equipment. We want
to keep you as a customer. This manual is to help you understand safe operating procedures and some
problems which may be encountered by the operator and other personnel.
As owner and/or operator, it is your responsibility to know what requ irements, hazards and p recautions
exist, and to inform all personnel associated with the equipment or in the area . Safety precautions may
be required from the personnel. Avoid any alterations to the equipment. Such alterations may produce
a very dangerous situation, where SERIOUS INJURY or DEATH may occur.
This equipment shall be installed in accordance with the current installation codes and applicable
regulations which should be carefully followed in all cases. Authorities having jurisdiction should be
consulted before installations are made.
Figure 1A
6 PNEG-1181 Portable Dr yer Troubleshooting
1. Safety
Safety Precautions
READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE
SAVE FOR FUTURE REFERENCE
1. Read and understand the operating manual before attempting to operate the dryer.
2. Power supply should be OFF for service of electrical components. Use CAUTION in checking
voltage or other procedures requiring the power to be ON.
3. Check for gas leaks at all gas pipe connections. If any leaks are detected, DO NOT operate the
dryer. Shut down and repair before further operation.
4.
NEVER
5. Set pressure regulator to avoid excessive gas pressure applied to the burner during ignition and
when the burner is in operation. DO NOT exceed maximum recommended drying temperature.
6. Keep the dryer clean. DO NOT allow fine material to accumulate in the plenum or drying chamber.
Clean grain is easier to dry. Fine material increases resistance to airflow and requires removal of
extra moisture.
7. Use CAUTION in working around high speed fans, gas burners, augers and auxiliary conveyors
which START AUTOMATICALLY.
attempt to operate the dryer by jumping or otherwise bypassing any safety devices on the unit.
8. DO NOT operate in any area where combustible material will be drawn into the fan.
9. BEFORE attempting to remove or reinstall any propeller, make sure to read the recommended
procedure listed within the servicing chapter of the fan manual.
This product is intended for the use of grain handling only. Any other use is considered a misuse
of the product.
Some edges of the product components can be sharp. Inspect each component to determine
what specific safety considerations to be taken. Any and all necessary personal protective
equipment should be worn at all times when handling, assembling, installing and operating the
product and/or components.
NOTE:
Throughout this manual, guards are removed for illustration purposes only. All guards must be
in place before and during operation.
PNEG-1181 Portable Dryer Troubleshooting 7
1. Safety
Use Caution in the Operation of this Equipment
The design and manufacture of this dryer is targeted to maximize operator safety. However, grain
dryers have inherently hazardous components: a gas burner, high voltage electrical equipment, high
speed rotating parts, etc. It is not possible to fully safeguard against all hazards without impeding
efficient operation and reasonable access to components. Therefore, a careful and knowledgeable
owner/operator is the best insurance against an accident.
Use extreme caution when working around high speed fans, gas-fired heaters, augers and auxiliary
conveyors, which may start without warning when the dryer is operating on automatic control.
Keep the dryer clean. Not allow fine material to accumulate in the plenum chamber or surrounding the outside of the dryer.
Continued safe, dependable operation of automatic equipment depends, to a great degree, upon the
owner. For a safe and dependable drying system, follow the recommendations within the Owner’s
Manual, and make it a practice to regularly inspect the operation of the unit for any developing problems
or unsafe conditions.
Take special note of all safety precautions before attempting to operate the dryer.
8 PNEG-1181 Portable Dr yer Troubleshooting
2. Decals
ROTATING AUGER
KEEP HANDS, FEET, HAIR AND
CLOTHING AWAY FROM INTAKE.
DO NOT REMOVE OR MODIFY
ANY GUARDS.
KEEP CHILDREN AWAY.
FAILURE TO DO SO WILL
RESULT IN SERIOUS
INJURY OR DEATH.
Safety decals should be read and understood by all people in and around the dryer area. If the following safety
decals are not displayed on your dryer, or if they are damaged, contact GSI for replac eme nt.
GSI Decals
1004 E. Illinois St.
Assumption, IL. 62510
Phone: 217-226-4421
WARNING
Flame and pressure beyond
door can cause serious
injury. Do not operate with
service door removed. Keep
head and hands clear.
DC-1227
WARNING
ROTATING AUGER
Stay clear of rotating
blade. Blade could start
automatically. Can cause
serious injury. Disconnect
power before servicing.
DC-1225
WARNING!
FAILURE TO DO SO WILL
PNEG-1181 Portable Dryer Troubleshooting 9
RESULT IN SERIOUS
INJURY OR DEATH.
KEEP HANDS, FEET, HAIR AND
CLOTHING AWAY FROM INTAKE.
DO NOT REMOVE OR MODIFY
ANY GUARDS.
KEEP CHILDREN AWAY.
High speed belt drive
operating overhead.
Can cause serious injury.
Keep head and hands
clear. Do not enter when
dryer is running.
DC-1064
2. Decals
Rotating auger will crush
and cut. Auto equipment
can start at anytime. Do not
enter until electric power is
locked in off position. Failure
to do so will result in serious
injury or death.
DC-974
Moving parts can crush
and cut. Keep hands
clear. Do not operate
without guards in place.
Failure to do so could
result in serious injury.
DC-972
10 PNEG-1181 Portable Dryer Troubleshooting
3. Operation Tips
Network Dryer Operation Tips
Important Software and Troubleshooting Tips (Software Version 1.08 and Up).
Present Software Version Numbers: Display 1.19 Heater 1.19 Input/Output 1.18
1. Stuck register value. After installing a new display board and “flashing” the software in, an error
message with “garbage” characters or a negative number for the temperature may appear. To
correct this, hard reboot the system by holding down the reset key and turning the power ON.
Always perform a hard boot after installing a new Display board.
2. If after a hard rebot the screen is still blank, the contrast may need to be adjusted. See tip #6 under
General Tips and Suggestions to adjust the contrast.
3. When flashing new software to the Input/Output board, turn OFF the leveling auger breaker. Due
to design, the leveling auger will run whenever the Input/Output board is being flashed.
4. If only the load and unload augers will not run check to make sure the 110 volt breaker on the Input/
Output board is turned ON.
5. The newest display boards (5/01/02) can now be used on either a Top Dry or Portable Dryer.
In the past a dryer display board had to have wires soldered in place for the meter roll speed
potentiometer. The newest boards have a six pin connector that connects to the meter roll
speed potentiometer.
6. The metering roll speed potentiometer connection at the potentiometer is correct when the visible
copper on the connector is in the bottom.
7. As dryers age, the contacts in the safeties start reducing the amount of DC voltage passed through
and may need to be replaced. Check the voltage if repeated error warnings are received from what
appears to be a good safety.
General Tips and Suggestions
1. In software version 1.19, the moisture control differential was reduced from 4° to 2°. As a result, the
dryer will cycle quicker and control moisture better.
2. In software version 1.18, the ability to calibrate bushels readings was added.
3. In software version 1.17 and greater, holding down the UP and DOWN arrow keys while changing
the timer or delay setting will start changing the setting at a much faster rate.
4. In version 1.17 and greater, pressing reset while changing a timer or delay setting will return the
setting to its default setting.
5. To enter the switch and keypad test function for diagnostic purposes, press and hold the HELP
button in. Turn ON the control power and release the HELP button. Turn any of the switches or
press any of the keypad buttons, and the one that you activated will be displayed on the screen.
6. To enter the screen adjustment mode, press the SCREENS button while turning the control power
on. Use the UP and DOWN arrow keys to adjust the current level of contrast. NOTE: Continued
depression of the arrow keys (UP or DOWN) will not adjust the contrast. Instead, each press and
release of the arrow keys (UP or DOWN) will adjust the contrast slightly. Because of this, adjusting
the contrast from a dark or blank screen to a visible screen will require many (100 or more) repeated
presses of the arrow keys.
PNEG-1181 Portable Dryer Troubleshooting 11
3. Operation Tips
Network Dryer Operation Tips (Continued)
7. To return all options and settings to the factory defaults, press and hold the RESET button. Turn
the control power ON and release the RESET button. NOTE: ALL settings will be erased and all
options will return to the factory defaults.
8. To disable the air pressure switches, press and hold both the GRAIN and PLENUM buttons. Turn
ON the control power and release the buttons.
9. To erase all shut downs in the computer history, press and hold both the DRY and COOL buttons
and turn ON the control power. Release the buttons.
10. To view the shut down history of the dryer, press the UP and DOWN arrow buttons at the same
time, prior to pressing the START switch on the dryer. 256 dryer shut downs are stored in memory.
Performing this keystroke sequence while changing a timer or a delay setting, will change the
setting to 0.01.
11. Press the SCREENS button while the dryer is running to access the following data:
A. Out of Grain - View “Out of Grain” Timer
Set “Out of Grain” Timer
Check “Last Load” Time
B. View Grain Temps
C. User Hour Meter (Hour meter can be reset here also).
D. Meter Roll Speed Average. (Monitors the percentage of time the meter rolls spend on both high
and low speed.)
12. Press the
A. Enter the BPH factor (software version 1.18)
B. Reset batch counter
C. Clear total bushels
D. Change user message
13. Press DELAYS button before pressing start on the dryer in order to access the following Delays:
A. Load Delay
B. Out of Grain
C. Fan Delay
D. Unload Clean Out Delay
SETUP
button, before pressing start on the dryer in order to change the following settin gs:
12 PNEG-1181 Portable Dryer Troubleshooting
4. Setup Screens
Special Network Dryer Setup Screens
There are certain dryer features that rarely need to be changed a nd which should be carefully considered
before adjusting. To access these advanced features, with the power OFF, press and hold the
button and then turn ON the control power for the dryer. Release the
MODIFY
button and the advanced
feature screens will be available.
Pressing ENTER after releasing the Modify button will allow you to view and/or change the special setup
screens in the following sequential order:
Option Select
1. Turn Meter Rolls OFF No——Yes
2. Air Switch Testing Yes——No
3. Meter Roll Reverse No——Yes
A. Reverse Time 5 Minutes, but is adjustable
B. Forward Time 55 Minutes, but is adjustable
4. Select Unload Method 2 Speed——3 Speed
5. Select Dryer Address 01——for use with the Watchdog program only
6. Attempt to Refill No——Yes
7. Enter Model Number Dryer Model Number NOTE: Dryer Model Number mu st
be exact in order for the dryer to operate properly.
8. Temperature Scale Fahrenheit——Celsius
9. Change Burner Setup Enter to Change——Reset to Bypass
A. High/Low Fire or ON/OFF Fire High/Low Fire——ON/OFF Fire
B. Active or Inactive Active——Inactive
10. Set Time and Date Time and Date
1 1. Load System End Fill——Center Fill——Dual Fill
12. Unit of Measure Bushels——Metric Tons
13. Change Burner Differential Enter to Change——Reset to Bypass
A. Set Burner Differential in Degrees Default is 3 Deg rees in High/Low and 1° in ON/OFF Fire
This default is not effecti ve unt i l software version 1.16
MODIFY
Selections in bold are the default settings
Series 2000 Fan and Heater Dip Switch Settings:
NOTE: These are set at the factory but will need to be reset when changing out a board.
Fan 1 #1 OFF / All Others ON
Fan 2 #2 OFF / All Others ON
Fan 3 #1 and #2 OFF / All Others ON
Fan 4 #3 OFF / All Others ON
Fan 5 #1 and #3 OFF / All Others ON
Fan 6 #2 and #3 OFF / All Others ON
PNEG-1181 Portable Dryer Troubleshooting 13
5. Dryer Operation
Network Dryer Options Explanation
Turn Meter Rolls OFF
This option does not actually turn off the metering rolls. Changing this setting to YES removes the
sensor board from the circuit and allows the dryer to operate normally, but without any meter roll
information displayed on the screen. This is useful in the event of a sensor board failure. The sensors
on the rear of the dryer and the computer monitor whether or not the metering rolls are turning when the
UNLOAD is running. They also calculate the RPM, total bushels and Bushels Per Hour (BPH) of the
grain flowing across the meter rolls. If the meter rolls do not show movement in a two-minu te period, the
computer will shut down the dryer with a Meter Roll Drive System Failure. If, upon restarting the dryer
the meter rolls work properly, the drive system itself is okay and the problem is the sensor board itself.
Run the dryer normally by switching this setting to YES. Replace the board as soon as possible and
return this setting to ON when possible.
Air Switch Testing
Setting this option to NO allows the dryer to run without proving airflow. When a fan starts, it has
20 seconds to develop air pressure in the plenum of the dryer. If pressure develops, the dryer operates
normally. If no pressure develops, the dryer will shut down with a Loss of Airflow Shut Down error
message. Changing this setting to NO allows the user to run the fan on the dryer if a switch becomes
defective. It also allows the user to run the fan on the dryer without grain inside of it. This option resets
every time there is a dryer power loss of the dryer control power is shut OFF. Therefore, when restarted,
the setting will default back to YES and require proof of airflow again. Change this option to NO to run the
fan on the dryer without grain or with a defective switch until it is replaced.
Meter Roll Reverse
When set to YES, the meter rolls will run in the normal direction but, will occasionally slow to a stop and
then run in the reverse direction for a short period of time. The amount of time the meter rolls run in
forward and in reverse is adjustable and programmable. This option will not be used regularly but is
useful when grain conditions are very poor.
Select Unload Method
The Select Unload Method is set to a default of 2 Speed. In this setting, meter rolls will speed up and
slow down as needed to maintain constant grain moisture at the discharge of the dryer. While a
3 Speed option is under development, it is not available on this software and this setting should, remain
on 2 Speed.
Select Dryer Address
Most owners will not use this setting as it requires the use of the GSI Watchdog software program to
operate. This option allows the user to assign an address for each dryer on the network to be monitored
by the Watchdog program. The system can monitor up to 10 dryers and log dryer functions whenever
any of the dryers are running.
Attempt to Refill
Setting this option to YES enables the dryer to monitor the Out of Grain Timer. When the dryer runs low
and the Out of Grain Timer runs down, the dryer will go into a “hold” mode instead of shutting down. In
the “hold” mode, the unload auger shuts down, the burner turns off and the fan and the load auger
continue to run. If the dryer fills back up with grain, the burner will turn on again and the unload auger
will start up as well.
14 PNEG-1181 Portable Dryer Troubleshooting
5. Dryer Operation
Dyer Model Number
This setting is critical to proper function of the dryer. The actual model number of the dryer is located
here and that number contains a great deal of valuable information about the dryer, including: number
of fans, number of modules, and the length of the dryer. This data is used by the computer to operate
the dryer properly. If any of this information is incorrect, the dryer will not operate properly and may not
operate at all. Use tremendous caution when changing this setting.
Temperature Scale
This option allows the user to toggle the temperature scale between Fahrenheit to Celsius.
Change Burner Set-Up
This setting controls the operation of each fan/heater unit on the dryer. Users can run any burner, or any
combination of burners, on either High/Low Fire or On/OFF Fire. This setting also allows users to render
a problem fan/heater inactive, thereby removing it from the programming of the dryer and allowing the
remainder of the dryer to continue running until the problem fan/heater can be repaired or replaced.
Set Time and Date
Use this setting to enter, store and adjust the time and date information.
Select Load System
While most dryers use the end fill option, GSI dryers also have the ability to run center fill and dual fill
modes if needed.
Unit of Measure
This setting allows the dryer to perform calculations in metric tons instead of bushels. This option is
useful for applications in foreign countries.
Change Burner Differential
The burner differential is the number of degrees that a fan/heaters temperature must drop before it will
cycle. Proper burner cycling means three (3) to four (4) times a minute the fan/heater should cycle from
high to low pressure. For this to happen, the burner must first reach the set point. The set point is the
desired running temperature for the plenum, usually around 220 degrees. When this temperature is
reached, the burner will shut off one solenoid and divert all of the gas through the low pressure ball
valve and the low pressure solenoid. Turn down the low pressure ball valve far enough to allow the
temperature to start to fall. When the temperature falls the number of degrees set by the differential, the
burner will cycle back to high. Keep in mind the burner should cycle three (3) to four (4) times a minute.
PNEG-1181 Portable Dryer Troubleshooting 15
6. Programming
Programming Instructions Using Palm Pilot
There are three (3) boards to program on the Network Dryer: Display Board (lower control box),
Input/Output Board (upper control box), and Heater Interface Board (by Fan/Can housing).
1. Turn the control power on the dryer to the OFF position.
2. Locate the programming jack on each individual board:
• Display Board (lower control panel) - (DB-9) located at bottom of board.
• Input/Output Board (upper panel) - (DB-9) located at bottom of board.
• Heater Interface Board (by fan/can housing) - (J2 connector) located on back of board.
NOTE: Refer to See Figure 6A on Page 17.
3. If programming the Input/Output Board or Display Board, connect the DB-9 connector from the
Palm Pilot to the board.
4. If programming the Heater Interface Board, connect the J2 connector on the series 2000 cable to
the J2 connector on the back of the board.
5. Unplug the network connection (yellow and blue wires) to the board being programmed.
6. On the Palm Pilot, select the program for that particular board and select it by “tapping” on it.
7. Turn the dryer control power back ON.
8. The programming process begins by erasing the present program and starting the new program.
9. The screen will display a confirmation screen when the transfer of the software is complete.
10. Turn the dryer control power OFF and remove the connector from the board. Plug the network wires
back into the board being programmed.
11. Turn ON the dryer and the opening screens on the dryer will indicat e the latest version of software.
There are two Palm Pilot kits available from GSI for order:
Ref # Part # Description
D03-0692 (Palm Flash Program Kit Deluxe)
1 D01-1771 Series 2000 Programming Cable
2 D03-0688 Palm Pilot IIIC (color)
3 D03-0694 Palm Pilot Hot Sync Cable
4 D03-0695 Palm Flash 9 Pin M-M Adapter
5 D03-0709 Disk, CD-ROM Palm Flash Software
D03-0693 (Palm Flash Program Kit Economy)
6 D01-1771 Series 2000 Programming Cable
7 D03-0689 Palm Pilot M100 (black & white)
8 D03-0695 Palm Flash 9 Pin M-M Adapter
9 D03-0709 Disk, CD-ROM Palm Flash Software
16 PNEG-1181 Portable Dryer Troubleshooting
Programming Network Dryer Using Palm Pilot
6. Programming
Figure 6A
PNEG-1181 Portable Dryer Troubleshooting 17
6. Programming
Programming Instructions Using Flash Programmer
There are three (3) boards on the Network Dryer to program: Display Board (lower control box),
Input/Output Board (upper control box), and the Heater Interface Board (Fan/Can housing).
1. Turn the control power on the dryer to the OFF position.
2. Locate the programming jack on each individual board:
• Display Board (lower control panel) - (DB-9) located at bottom of board.
• Input/Output Board (upper panel) - (DB-9) located at bottom of board.
• Heater Interface Board (by fan/can housing) - (J2 connector) located on back of board.
NOTE: Refer to See Figure 6B on Page 19.
3. If programming the Input/Output Board or Display Board, connect the DB-9 connector from the
Flash Programmer to the board.
4. If programming the Heater Interface Board, connect the J2 connector on the series 2000 cable to
the J2 connector on the back of the board.
5. Unplug the network connection (yellow and blue wires) to the board being programmed.
6. Make sure the rotary switch on the programmer is set to position 8.
7. Turn the dryer control power back ON.
8. The four lights on the programmer will come ON, then three will go out leaving only the power light
still illuminated.
9. Push the Start button on the programmer to start the transfer of software.
10. The Busy light will flash until the transfer process is complete.
11. When completed, the Pass light will illuminate, indicating a successful transfer.
12. After a successful transfer, turn control power OFF, remove connector from the board and plug the
network wires back into the board being programming.
13. If the Fail light flashes, check the connection and repeat the above process.
14. Turn ON the dryer and the opening screens of the dryer should indicate the latest version of software.
18 PNEG-1181 Portable Dryer Troubleshooting
Programming Network Dryer Using Flash Programmer
6. Programming
Figure 6B
*The Flash Programmer can still be used to program the dryer but the programmable chip for it is no
longer available. Therefore, GSI recommends using a Palm Pilot for programming.
PNEG-1181 Portable Dryer Troubleshooting 19
7. Board Hook Up
Programmer Hook Up Diagram
(Located in Heater Control Box) (Back of Heater Board)
Figure 7A
20 PNEG-1181 Portable Dryer Troubleshooting
Network Display Board
(Located in the lower control panel) (Back of Board)
7. Board Hook Up
Network
Terminal connections
(blue and yellow wires)
DB-9 Connector
This is used for
programming the board.
Figure 7B
PNEG-1181 Portable Dryer Troubleshooting 21
DB-9 Connector
This is used for
Watchdog Program
.
7. Board Hook Up
Input/Output Board
(Located in Upper Control Panel)
Network
Terminal connections
(blue and yellow wires)
Figure 7C
22 PNEG-1181 Portable Dryer Troubleshooting
DB-9 Connector
This is used for
programming the board.
8. Troubleshooting Tips
Possible Safety Circuit Shut Down Messages
Viewing the Shut Down History
The shut down history can store up to 200 shut down warnings. When the dryer exceeds this amount,
the oldest shut down will be erased and replaced with the current shut down warning.
To view the shut down history (Warnings):
• Turn the Control Power to ON.
• Wait until the time and date screen appears and then press the START button.
• Press the increase and decrease buttons at the same time while the dryer is stopped. Then,
scroll through the history by pressing either the increase or decrease buttons. Press enter
to exit this screen or press stop to clear the shut down warning.
Shut Down Message Listing
The following is a list of all possible shut down messages for the network dryer. They are broken down
with their associated controller where the error originated. The message on the screen will show
WARNING at the top followed by the error, time, date and in which fan/heater the error occurred.
FAN X LOSS OF AIRFLOW
Fan 1 Loss of Airflow: The contacts in the air switch have opened due to insufficient air pressure in
the plenum. The message will identify which plenum caused the shut down.
Hints
Verify that the fan is running and that the dryer is completely full of grain. If the air pressure switch is
sensing air pressure, the blue light in the fan switch will come on after the fan has reached half speed. If
it does not, adjust the air switch using a straight blade screw driver to turn the adjusting screw on the air
switch counter-clockwise.This will make it more sensitive to air pressure. If this does not solve the problem,
inspect the wiring circuit of the air pressure switch. Each air pressure switch is wired to the Network
fan/heater Interface located on each individual fan/can box. Use a voltmeter on the following terminals:
Black Probe (J7-10) DC Negative
Red Probe (J7-09) 0 VDC Fan Running Red Probe (J7-09) 5 VDC Fan Stopped
Red Probe (J7-11) 5 VDC Fan Running Red Probe (J7-11) 0 VDC Fan Stopped
If operating correctly, the voltmeter should display the reading listed above.
Any other reading may indicate a bad switch, computer board, air pressure
switch or wiring.
If all this fails to work, remove the wires from the air pressure switch and remove the switch from the
dryer. Blow into the air tube to simulate air pressure in the plenum. The switch should have an open
circuit. Blow into the switch to close it. If it fails to close try adjusting it or replacing it.
Remember
1. Dryer must be full of grain. (Make sure fill is keeping up with unload.)
2. Check to see if light comes ON when fan is running.
3. Make sure the bulb is good. It is a 110 VAC.
PNEG-1181 Portable Dryer Troubleshooting 23
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