GSI PNEG-1755 User Manual

PLC WatchDog

Installation and Operation Manual

PNEG-1755

Date: 07-28-10

PNEG-1755

2 PNEG-1755 PLC WatchDog

Table of Contents

Contents

Chapter 1 Safety ..................................................................................................................................................... 4

Safety Guidelines .................................................................................................................................. 4

Dryer Operation ..................................................................................................................................... 5

Emergency Stop Switch ................................... ... ... ... .... ... ... ... .... ... ... ..................................................... 5

Safety Precautions .................................... ... .... .......................................... ... ........................................ 6

Chapter 2 Introduction .......................................................................................................................................... 8

Description ............................................................................................................................................ 8

Features ................................................................................................................................................ 8

Chapter 3 Installation ............................................................................................................................................ 9

PLC WatchDog Connection ................................................................................................................... 9

Package Contents ........................................................................................................................... 9

Install Procedure ............................................................................................................................ 10

Network Setup ............................................................................................................................... 10

Configuring a Modem/Router ................ ... ... .... ... ... ... .... ... .......................................... ... ... ... .... 10

DHCP Reservations ........................................................................................................ 10

DHCP Pool ......................................................................................................................11

Accessing the PLC WatchDog ...................................................................................................... 11

Chapter 4 PLC WatchDog Operation ................................................................................................................. 12

GSI PLC WatchDog ............................................................................................................................ 12

View Data ............................................................................................................................................ 12

Password ...................................... ................................ .................................... ............................. 13

PLC WatchDog .............................................................................................................................. 14

Set Time and Date ........................................... ... .... ... ... ... .... ......................................... .... ............. 15

Editing Variables ............................................................................................................................ 16

View Logs ............................................................................................................................................ 17

Remote View ................................................................. ... ... ... .... ... ... ... ... ............................................. 19

Editing Passwords ......................................................................................................................... 19

Verify Password Button ................................................................................................................. 21

Password Status Indicator ......................................................................................................21

Change Password Button .............................................................................................................. 22

Dryer Display Button .................................. ... ... ... .... ... ... ... .... ... .......................................... ............. 24

Main Display ... .......................................... ... .......................................... .... ............................. 24

Stop Button ............................................................................................................................. 24

Auto/Manual Button ................................................................................................................ 24

Email On/Off Button ............................................................................................................... 24

Main Menu Button .......... .... ... .......................................... ... .......................................... ... ....... 25

Log Off Button ................ .... ... .......................................... ... .......................................... .......... 25

System Variables Button ............................................................................................................... 25

Email Settings Button ................ ... ... ... .......................................... ... .............................................. 26

Time Settings Button ..................................................................................................................... 27

Chapter 5 Troubleshooting ................................................................................................................................. 29

Chapter 6 Technical Support .............................................................................................................................. 30

Chapter 7 Appendix A ......................................................................................................................................... 31

Acquiring and Installing a BlueTree Cellular Modem .......................................................................... 31

Chapter 8 Appendix B ......................................................................................................................................... 32

Common List of SMS Carriers and Account Formatting ..................................................................... 32

Chapter 9 Appendix C ......................................................................................................................................... 33

Chapter 10 Warranty ............................................................................................................................................ 35

PNEG-1755 PLC WatchDog 3

1. Safety

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.

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.

DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.

Personnel operating or working around electric fans should read this manual. This manual
must be delivered with the equipment to its owner. Failure to read this manual and its
safety instructions is a misuse of the equipment.

WARNING! BE ALERT!

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.

4 PNEG-1755 PLC WatchDog

1. Safety

Dryer Operation

Thank you for choosing a GSI product. It is designed to give excellent performance and service for
many years.

This manual describes the operation and service for all standard production model dryers. T hese models
are available for liquid propane or natural gas fuel supply, with either 1 phase 230 volt, or 3 phase
230 or 440 volt electrical power.

Our foremost concern is your safety and the safety of others associated with this equipment. We want to
keep you as a customer. 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 requirements, hazards and precautions
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.

Emergency Stop Switches

The Emergency Stop switches are located on the power panel and the control panel. Pushing the
Emergency Stop switches will interrupt the control power and stop all dryer functions.

Pushing the Emergency Stop Switches does not interrupt the main power to the power panel.

PNEG-1755 PLC WatchDog 5

1. Safety

Safety Precautions

READ THESE INSTRUCTIONS BEFORE INSTALLATION AND OPERATION

SAVE FOR FUTURE REFERENCE

1. Read and understand the operating manual before attempting to operate the dryer.

2. NEVER operate the dryer while the guards are removed.

3. Power supply should be OFF for service of electrical components. Use CAUTION in checking voltage
or other procedures requiring the power to be ON.

4. Check for gas leaks at all gas pipe connections. If any leaks are detected,
Shutdown and repair before further operation.

5. NEVER attempt to operate the dryer by jumping or otherwise bypassing any safety devices on
the unit.

6. Set pressure regulator to avoid excessive gas pressure being applied to the burner during ignition
and when the burner is in operation. DO NOT exceed maximum recommended drying temperature.

7. Keep the dryer clean. DO NOT allow fine material to accumulate in the plenum chamber.
Clean grain is easier to dry. Fine material increases resistance to airflow and requires removal
of extra moisture.

8. Keep auger drive belts tight enough to prevent slippage.

9. Use CAUTION in working around high speed fans, gas burners, augers and auxiliary conveyors
which can START AUTOMATICALLY.

10. Keep area around air inlet to the fan clear of any obstacles and combustible materials.

11. BEFORE attempting to remove and reinstall any propeller, make sure to read the
recommended procedure.

12. Make sure that capacities of auxiliary conveyors are matched to dryer auger capacities.

13. DO NOT operate in an area where combustible material will be drawn into the fan.

DO NOT

operate dryer.

14. The operating and safety recommendations in this manual pertain to the common cereal
grains as indicated. When drying any other grain or products, consult the factory for
additional recommendations.

15. Routinely check for any developing gas plumbing leaks. Check LP vaporizer for contact with
burner vanes.

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1. Safety

Use Caution in the Operation of this Equipment

This dryer is designed and manufactured with operator safety in mind. However, the very nature of a
grain dryer having a gas burner, high voltage electrical equipment and high speed rotating parts, presents
hazards to personnel which cannot be completely safeguarded against without interfering with the efficient
operation of the dryer and reasonable access to its components.

Use extreme caution in 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.

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 unit for any developing problems or unsafe conditions.

Take special note of the Safety Precautions on Page 6 before attempting to operate the dryer.

PNEG-1755 PLC WatchDog 7

2. Introduction

Description

The PLC WatchDog system allows for remote monitoring of a tower dryer.
An internet connection allows the user to view the dryer from any device that has a web browser. Currently,

the only supported browser is Microsoft’s Internet Explorer.

Features

1. Remote monitoring of dryer

2. Remote shutdown of dryer

3. Remote drying parameter adjustment (Plenum and grain temperature setpoints, unload rate, etc.)

4. Web browser is the only software needed by the customer

5. Text message and/or email can be sent to alert customers of shutdowns

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3. Installation

1

2

3

4

PLC WatchDog Connection (Part #: GT4-5073)

This requires an active internet connection be present at the dryer via Ethernet (RJ-45 connection). It is
recommended that either an Internet Service Provider (ISP) technician or someone versed in networking
be present during installation. While GSI’s Technical Support group can offer sugg estions, GSI is not

responsible for the required connection.

Package Contents

The contents of this package are pictured in Figure 3A. Please refer to Figure 3A during installation.
Package contains:

1. Red Lion Controller

2. 24 VDC Power Supply

3. CF memory card

4. Cable #CBLAB001

Figure 3A

PNEG-1755 PLC WatchDog 9

3. Installation

Install Procedure

This installation takes place in the power panel of the tower dryer system. Follow the steps listed below to
install the components; also refer to Figure 3A on Page 9.

1. Turn OFF power to the dryer and control panel.

2. Attach the Red Lion controller and the 24 VDC power supply to the DIN rail.

3. Wire the 120 VAC supply power from the power panel terminal “L1.1”, to the 24 VDC power supply
terminal “L”.

4. Wire the white NEUTRAL wire from the power panel terminal “L2”, to the 24 VDC power supply
terminal “N”.

5. Wire the GROUND from the power panel terminal strip, to the 24 VDC power supply terminal “ ”.

6. Wire the 24 VDC power supply terminal “+”, to the Red Lion terminal “+24”.

7. Wire the 24 VDC power supply terminal “-”, to the Red Lion terminal “COMM”.

8. If a cellular modem is being installed, first refer to Appendix A on Page 31 for additional instructions
and then return here.

9. Plug the RJ12 end of the Pacific Cable #CBLAB001 into the RS232 port of the Red Lion controller
and the DB9 end into the SLC serial port.

10. Plug the Ethernet cable with a live internet connection into the ETHERNET port on the Red
Lion controller.

NOTE: Use cable ties to secure wires.

11. Turn ON power to the dryer and the power panel. A green LED should illuminate on the 24 VDC
power supply indicating power.

12. A green LED, labeled “STS”, should illuminate on the Red Lion unit indicating the controller is
operating properly.

13. A red LED, labeled “CF”, should illuminate verifying a valid CompactFlash card is installed.

Network Setup

This section is intended to help ISP or network technicians install the PLC WatchDog. If this section does
not make sense to you, it is strongly advised to request the service of a network technician.

SECURITY NOTE: Ultimately, it is the End User’s responsibility to make sure the PLC WatchDog is

properly placed behind a secured network security system.

Configuring a Modem/Router

If the PLC WatchDog is connected to a modem/router that is configurable, listed below are a few
recommendations to assist with setup. The methods below do not cover every configuration that
is available.

DHCP Reservations

This is the preferred method for installation. A reservation can be an option in the configuration of a
modem/router. It can be set to serve a given MAC address with a certain IP address when it is introduced
to the network. As mentioned above, the MAC address of the PLC WatchDog can be found on a label on
the front of the Red Lion controller.

Once the IP address has been setup for the MAC address, forward incoming requests on ports 21 and 80.

10 PNEG-1755 PLC WatchDog

3. Installation

DHCP Pool

If the modem/router does not have DHCP reservations, the controller can be allowed to pull an IP address
from the DHCP server’s IP range. This method is only recommended when the PLC WatchDog is the only
node on the network.

Reduce the IP range of the DHCP server down to one IP address. This will be the only IP address that the
DHCP server is allowed to serve to the network. Once the range has been narrowed to one, forward
incoming requests on ports 21 and 80 to the single IP address.

Accessing the PLC WatchDog

The tower dryer PLC WatchDog is accessed from any PC that has an internet connection and web
browser. Some phones are available that view the graphics correctly.

1. Make sure that the dryer is powered up and the PLC application is running.

2. On the PC or phone, open up a web browser, i.e. Internet Explorer.

3. In the URL bar, enter the IP address given by your network administrator. There is no need to put
“www”, simply enter the number sequence. The IP address shown in the Figure 3B is just for
illustration purposes. The IP address you enter will be different.

4. The “GSI PLC WatchDog” should now appear. If it does not, run back through the install procedure
to verify everything is connected properly.

Figure 3B

5. Once the “GSI PLC WatchDog” appears, move on to Chapter 4 “PLC WatchDog Operation”

on Page 12.

PNEG-1755 PLC WatchDog 11