GSI PNEG-630 User Manual

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Page 1

GSI Competitor Portable Dryer Models

Troubleshooting and Reference Manual

& EMCS

2004 Revised Edition PNEG-630

Competitor Series 2000 Dryer

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Portable Dryer Troubleshooting

Safety..................................................................................................................................................................... 3

Safety Sign Off Sheet ............................................................................................................................................ 8

EMCS Portable Dryer (1993-1998)

Safety Voltage Check Points .................................................................................................................................9

Programming Instructions for EMCS Grain Dryers .............................................................................................. 10

EMCS Display Board ............................................................................................................................................ 11

Input/Output Board Identification .......................................................................................................................... 12

EMCS Switch Replacement.........................................................................................................................13

1100 Series Control Box W iring ............................................................................................................................. 14

1100 Series Control Box W iring (New) ................................................................................................................. 15

1200 Series Control Box Wiring............................................................................................................................. 16

1200 Series Control Box Wiring (New)................................................................................................................. 17

1100 Fan Lower Control Box Interconnect Strip................................................................................................... 18

1200 Fan Lower Control Box Interconnect Strip .................................................................................................. 19

Upper Control Box External Wiring....................................................................................................................... 20

Fan Housing and V apor Hi-Limit Circuit ............................................................................................................... 21

Plenum Hi-Temperature Switch ............................................................................................................................22

Fixed Grain Hi-Limit .............................................................................................................................................. 23

Grain & Plenum Hi-Limit Circuit........................................................................................................................... 24

T wo Fan Plenum and Grain Limit Switch Wiring ..................................................................................................25

Rear Discharge & Emergency Cooling Circuit ..................................................................................................... 26

Rear Discharge Mercury Switch...........................................................................................................................27

Adjustable Hi-Limit & Emergency Cooling Circuit ............................................................................................... 28

Motor Overloads .................................................................................................................................................... 29

Air Pressure Switch............................................................................................................................................... 30

Air Pressure Switch Drawing................................................................................................................................ 31

Out of Grain Safety Circuit....................................................................................................................................32

Out of Grain Safety Circuit Drawing..................................................................................................................... 33

Upper Junction Box Wiring.................................................................................................................................... 34

Meter Roll Sensor .................................................................................................................................................. 35

Meter Roll Sensor Wiring ......................................................................................................................................36

Meter Roll Reversing............................................................................................................................................. 37

Lower Junction Box Wiring ................................................................................................................................... 38

New Fenwal Board Wiring.......................................................................................................................... 39

New Fenwal Board Troubleshooting.............................................................................................................40

Flame Control Circuit............................................................................................................................................. 41

Fan Burner Circuit for Canadian Models .............................................................................................................. 42

Conversion Diagram for C Series Dryers to a Switchable Hi/Low or On/Off Burner ......................................... 43

Fan 28 LP Hi/Low-On/Off....................................................................................................................................44

Fan 28 LP On/Off Burner with Mercoid...............................................................................................................45

Fan 28 NG Hi/Low-On/Off ................................................................................................................................... 46

Fan 28 NG On/Off Burner with Mercoid .............................................................................................................. 47

Fan 42 LP Hi/Low-On/Off....................................................................................................................................48

Fan 42 LP On/Off Burner with Mercoid...............................................................................................................49

Fan 42 NG Hi/Low-On/Off ................................................................................................................................... 50

Fan 42 NG On/Off Burner with Mercoid .............................................................................................................. 51

SCR Drive Circuit.................................................................................................................................................. 52

RTD Temperature Sensor...................................................................................................................................... 53

Test Procedure for EMCS Dryers ......................................................................................................................... 54

Temperature Charts ............................................................................................................................................... 55

EMCS Troubleshooting Tips........................................................................................................................ 56

Table Of Contents

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Table Of Contents

Competitor Series 2000 Dryer (Picture of Dryer)(1995 to Present)......................................................65

220 Volt Single (1) Phase Power Drawing ............................................................................................................ 66

220 Volt Single (1) Phase Power Drawing (New Version) .................................................................................. 67

220 Volt Three (3) Phase Power Drawing ............................................................................................................ 68

220 Volt Three (3) Phase Power Drawing (New Version) ................................................................................... 69

220 Volt 1 Phase Power Circuit (Ladder Diagram)........................................................................................70

220 Volt 3 Phase Power Circuit (Ladder Diagram)........................................................................................71

440 Volt 3 Phase Power Circuit (Ladder Diagram)........................................................................................72

Upper Control Box Internal Wiring........................................................................................................................ 73

Series 2000 Control Box Wiring (New Version) .................................................................................................... 74

Series 2000 Control Box Wiring............................................................................................................................. 75

Series 2000 Control Box Wiring (380-460-575 3 Phase).................................................................................76

Upper Terminal Strip...................................................................................................................................77

Upper Terminal Strip (Moisture Control Hook-Up)........................................................................................78

Upper Terminal Strip (Moisture Control Relay Hook-Up)...............................................................................79

Moisture Manager to Dryer Wiring...............................................................................................................80

Input/Output Board & T erminal Strip .................................................................................................................... 81

Control Circuit (CPU/Display)(Ladder Diagram)......................................................................................... 82

Control Circuit (I/O Board)(Ladder Diagram)...............................................................................................83

Control Circuit (SCR Drive Board)(Ladder Diagram)....................................................................................84

SCR Board (Installing & Calibrating)............................................................................................................85

Upper Control Box External Wiring....................................................................................................................... 88

Input/Output Board 12 Volt .................................................................................................................................... 89

CPU Board Wiring.................................................................................................................................................90

Programming Instructions for Competitor Series Grain Dryers ............................................................................91

Programming Hook Up Diagram...........................................................................................................................92

Back of Switch Panel Layout ................................................................................................................................ 95

Back of Switch Panel Wiring................................................................................................................................. 96

Air Switch Assembly ............................................................................................................................................. 97

Air Switch Adjusting...................................................................................................................................98

Fixed Grain Hi-Limit & T emperature Sensor ........................................................................................................ 99

Out of Grain Sensor...................................................................................................................................100

Grain Temperature Sensor..........................................................................................................................101

Grain Sensor Testing..................................................................................................................................102

Grain Sensor (Locating,Testing,& Replacing)...............................................................................................103

Sensor Resistance/Temperature Chart.........................................................................................................105

Plenum Sensor (Locating,Testing & Replacing)............................................................................................106

Stern and Capacitor Diagram......................................................................................................................108

Operation Hints..........................................................................................................................................109

Series 2000 Error Conditions.......................................................................................................................111

Heater Circuit............................................................................................................................................113

Fan Burner Circuit for Canadian Models Only..............................................................................................114

Series 2000 LP 26"/28" Fan ........................................................................................................................115

Series 2000 Natural Gas 26"/28" Fan............................................................................................................116

Series 2000 LP 36"/42" Fan.........................................................................................................................117

Series 2000 Natural Gas 36"/42" Fan............................................................................................................118

Warranty....................................................................................................................................................119

Portable Dryer Troubleshooting

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Portable Dryer Troubleshooting

Dryer Safety

Instructions and

Information

Thank you for choosing an GSI

Grain Dryer. It is designed to provide excellent performance and service for many years.

This manual refers to the troubleshooting of the E.M.C.S.and Series 2000 Competitor 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 50Hz). The GSI Group Inc. recommends contacting your local power company, and having a representative survey your installation so the wiring is compatible with your system and adequate power is supplied.

The principal concern of the GSI

Group, Inc. ("GSI") is your safety and the safety of others associated with grain handling equipment. This manual is written to help you understand safe operating procedures, and some of the problems that may be encountered by the operator or 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 who are in the dryer area. Avoid any alterations to the equipment. Such alterations may produce a very dangerous situation, where serious injury or death may occur.

Safety

WARNING! BE ALERT!

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.

Safety Alert Symbol

The symbol shown is used to call your attention to instructions concerning your personal safety . Watch for this symbol; it points out important safety precautions. It means "ATTENTION",

"WARNING", "CAUTION", and "DANGER". Read the message and be cau-

tious to the possibility of personal injury or death.

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Safety

Portable Dryer Troubleshooting

Grain Systems, Inc. recommends you contact your local power company and have a representative survey your dryer installation, so your wiring will be compatible with their system and you will have adequate power supplied to your unit.

A CAREFUL OPERATOR

IS THE BEST INSURANCE

AGAINST AN ACCIDENT

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 Grain Systems, Inc. for replacement.

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Portable Dryer Troubleshooting

Safety

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Safety

Portable Dryer Troubleshooting

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Portable Dryer Troubleshooting

READ THESE INSTRUCTIONS

BEFORE OPERATION AND SERVICE

SAVE FOR FUTURE REFERENCE

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

2. Power supply should be OFF for service of electrical components. Use CAUTION in checking voltage or other procedures requiring 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 attempt to operate the dryer by jumping or otherwise bypassing any safety devices on the unit.

5. Set pressure regulator to avoid excessive gas pressure applied to burner during ignition and when 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.

Safety Precautions

Use Caution in the

Operation of this

Equipment

The design and manufacture of this dryer is directed toward operator safety. However, the very nature of a grain dryer having a gas burner, high voltage electrical equipment and high speed rotating parts, does present a hazard to personnel, which can not be completely safeguarded against, without interfering with efficient operation and reasonable access to 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.

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

8. Do not operate in any area where combustible material will be drawn into the fan.

9. Before attempting to remove and reinstall any propeller, make certain to read the recommended procedure listed within the servicing section of the manual.

10. Clean grain is easier to dry. Fine material increases resistance to airflow and requires removal of extra moisture.

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. It is recommended that each component of this product be examined to determine if there are any safety considerations to be taken. Any and all necessary personal protective equipment should be worn at all tines when handling, assembling, installing and operation of the product and/or components. Guards are removed for illustration purpose only. All guards must be in place before/during operation.

KEEP THE DRYER CLEAN

DO 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 this 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 the safety precautions listed at left before attempting to operate the dryer.

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Safety Sign-Off Sheet

Portable Dryer Troubleshooting

Date Employer’s Signature Employee

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Portable Dryer Troubleshooting

Safety Voltage Check Points

Wiring Reference

123456

FAN #

Error Message - + - + - + - + - + - + RESULT

Plenum # High Temperature J5-12 J1-11 J5-12 J1-12 J5-12 J2-11 J5-12 J2-12 J5-12 J3-11 J5-12 J3-12 12VDC

Burner # Flame not Detected J5-12 J1-9 J5-12 J1-10 J5-12 J2-9 J5-12 J2-10 J5-12 J3-9 J5-12 J3-10 12VDC

Fan # Housing High Tempera ture J5-12 J1-7 J5-12 J1-8 J5-12 J2-7 J5-12 J2-8 J5-12 J3-7 J5-12 J3-8 12VDC

Burner # Vapor High Temperature J5-12 J1-5 J5-12 J1-6 J5-12 J2-5 J5-12 J2-6 J5-12 J3-5 J5-12 J3-6 12VDC

Burner # Shutdown Loss of Airflow J5-12 J1-13 J5-12 J1-14 J5-12 J2-13 J 5-12 J2-14 J5-12 J3-13 J5-12 J3-14 Note 1

Fan # Failure No Airflow J5-12 J1-13 J5-12 J1-14 J5-12 J2-13 J 5-12 J2-14 J5-12 J3-13 J5-12 J3-14 Note 2

the fan is on.

in the closed postition. No voltage should be present if the

dryer is stopped.

3 The condition for this error will occur if the air switch is stuck

1100/1200/1300 2200/2300/2400 3300/3400/3600

Motor Ov er lo a d J5-12 J4-12 1 T his error will occur if the fan and bur ner were both operating and

Upper Fixed Grain J5-12 N/A J5-12 J 4-4 J5-12 J4-2

Middle Fixed Grain J5-12 N/A J5-12 N /A J5-12 J4-4

Misc E r rors

Upper Adjustable Grain J5-12 N/A J5-12 J4-8 J5-12 J4-6

Middle Adjustable Grain J5-12 N/A J5-12 N/A J5-12 J4-8

Lower or Left Fixed Grain J5-12 J1-19 J5-12 J1-19 J5-12 J1-19

Fan # cannot Start Check Air Switch J5-12 J1-13 J5-12 J1-14 J5-12 J2-13 J5-12 J2-14 J5-12 J3-13 J5-12 J3-14 Note 3

Lower Adjustable or Right Fixed Grain J5-12 J4-19 J5-12 J4-19 J5-12 J4-19

Auxilliary Safety Shutd o w n J5-12 J1-20 Note:

Grain Discharge Warning J5-12 J5-5 the air switch opens which indicates loss of static pressure.

Maxon Valve Shut Warning J5-12 J5-2 12 volts should be present if the fan is on.

Unknow n S a fe ty Er ror J5-12 J5-10 2 This error will occ ur if after the fan has started the air switc h does

20 Second Safety Circuit Failure J5-12 J5-6 not detect any static pressure. 12 volts should be present if

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Programming

Portable Dryer Troubleshooting

Programming Instructions for EMCS Grain Dryers

1. Turn Control Power on dryer to off.

2. Locate programming jack (P7) on back of computer. (See page 13).

3. Plug the DB-9 jack of the programmer into the computer's jack.

4. Be sure that the rotary switch on the programmer is set to position 8.

5. Turn on Control Power to the dryer .

6. The four (4) lights on the programmer will come on, then three (3) will go out leaving the power light still on.

7. Push the start button on the programmer to start the transfer of Software.

8. The busy light will flash until the transfer process is complete.

9. When completed the pass light will flash indicating a successful transfer.

10. If the fail light flashes then check your connections and repeat the above process.

11. T urn Control Power on dryer to off and remove the cable.

12. Turn on the dryer and the opening screens should indicate the newer version of software.

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Portable Dryer Troubleshooting

EMCS Display Board

COMPUTER

PROGRAMMING

JACK

PROGRAMMER

JACK (DB9)

SOUND

Programming

KEY PAD RIBBON

COMMUNICATIONS CABLE

TO I/O BOARD

TO STOP SW.

3 21

U12

BATTERY (TIC)

TO START &

TO START SW.

STOP SWS.

DISPLAY

RIBBON

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Wiring Reference

Portable Dryer Troubleshooting

Input/Output Board Identification

120 VOLT AC OUTPUTS12 VOLT DC INPUTS

+12 LIMIT OUTPUT 12 VOLT DC NEUTRAL METERING ROLL INPUT 12 VOLT DC NEGATIVE 12 VOLT DC NEGATIVE SAFETY CIRCUIT INPUT

+12 VOLT LIMIT OUTPUT

FLAME SENSOR RETURN OUT OF GRAIN SENSOR MAXON VALVE SENSOR

MERCOID SFTY FAN#1 (CAN)

MERCOID SFTY FAN#2 (CAN)

MERCOID SFTY FAN#4 (CAN) LOW MERCURY SWITCH (BO)

MOTOR OVERLOADS

MOISTURE CONTROL ADJ. GRAIN (MIDDLE) ADJ. GRAIN (UPPER) FIXED GRAIN (MIDDLE) FIXED GRAIN (UPPER)

BURNER #6 AUTO BURNER #6 ON FAN #6 AIR FAN #6 PLENUM FAN #6 FLAME DETECTION FAN #6 HOUSING HIGH LIMIT FAN #6 VAPOR HIGH LIMIT FAN #6 AUTO FAN #6 ON

17 15

16 14

8 6

5 3

4 2

9 7

8 6

5 3

10 8

7 5

4 2

+12 LIMIT OUTPUT 12 VOLT DC NEGATIVE 12 VOLT DC NEGATIVE 12 VOLT DC NEGATIVE +12 VOLT LIMIT OUTPUT +12 VOLT LIMIT OUTPUT REAR DISCHARGE M.C. THERMOSTAT N.O. TERM #4 M.C. THERMOATAT N.C. TERM #6

LOWER ADJ. GRAIN HIGH LIMIT 2 SPEED UNLOAD 1 SPEED UNLOAD UNLOAD BYPASS LOAD SWITCH AUTO LOAD SWITCH ON BATCH MODE CONTINUOUS FLOW MERCOID SAFTY FAN#3 (CAN) OUT OF GRAIN FOR LOAD #2

LO-HEAT THERMOSTAT (BO)HI-HEAT THERMOSTAT (BO) BURNER #5 AUTO BURNER #5 ON FAN #5 AIR FAN #5 PLENUM FAN #5 FLAME DETECTION FAN #5 HOUSING HIGH LIMIT FAN #5 VAPOR HIGH LIMIT FAN #5 AUTO FAN #5 ON

JUMPER J1-9 TO J5-6 IS A HARDWARE TIMER FOR THE FLAME SENSOR SHUTDOWN JUMPER J5-2 TO J5-20 IS A CONNECTION FOR THE MAXON VALVE SENS0R JUMPER J4-12 TO J5-10 IS A HARDWARE TIMER FOR THE SAFETY SHUTDOWNS

JUMPER J1-20 TO J5-8 IS A CONNECTION FOR THE USER SUPPLLIED SAFETY

JUMPERS MUST BE INSTALLED FOR THE INPUT/OUTPUT BOARD TO OPERATE!!

120VAC POWER (INPUT) AC NEUTRAL 120VAC POWER (INPUT) AC NEUTRAL AC NEUTRAL AC NEUTRAL AC NEUTRAL AC NEUTRAL FAN #1 POWER FAN #2 POWER

JUMPERS TO BE INSTALLED FOR E-COOL

INSTALL JUMPER FROM J6-13 TO J1-5 INSTALL JUMPER FROM J6-14 TO J1-19 INSTALL JUMPER FROM J6-16 TO J5-5 INSTALL JUMPER FROM J6-17 TO J4-19

FAN #3 POWER FAN #4 POWER FAN #5 POWER FAN #6 POWER UNLOAD POWER BUR # 4 NEUTRAL BUR # 3 NEUTRAL FAN # 4 NEUTRAL FAN # 3 NEUTRAL LOAD #2 NEUTRAL

11 13

14 16

16 18

120VAC POWER (OUTPUT) AC NEUTRAL 120VAC POWER (OUTPUT) AC NEUTRAL AC NEUTRAL AC NEUTRAL AC NEUTRAL BURNER #1 POWER BURNER #2 POWER BURNER #3 POWER

BURNER #4 POWER BURNER #5 POWER BURNER #6 POWER LOAD POWER SCR POWER FAN #1 NEUTRAL FAN #2 NEUTRAL UNLOAD NEUTRAL LOAD NEUTRAL SCR NEUTRAL

BURNER #4 AUTO BURNER #4 ON FAN #4 AIR FAN #4 PLENUM FAN #4 FLAME DETECTION FAN #4 HOUSING HIGH LIMIT FAN #4 VAPOR HIGH LIMIT FAN #4 AUTO FAN #4 ON

USER SUPPLIED SAFETY BURNER #2 AUTO BURNER #2 ON FAN #2 AIR FAN #2 PLENUM FAN #2 FLAME DETECTION FAN #2 HOUSING HIGH LIMIT FAN #2 VAPOR HIGH LIMIT FAN #2 AUTO FAN #2 ON

9 7

5 3

** IMPORTANT--JUMPERS LISTED ABOVE MUST BE INSTALLED

BURNER #3 AUTO BURNER #3 ON FAN #3 AIR FAN #3 PLENUM FAN #3 FLAME DETECTION FAN #3 HOUSING HIGH LIMIT FAN #3 VAPOR HIGH LIMIT FAN #3 AUTO FAN #3 ON

LOWER GRAIN HIGH LIMIT BURNER #1 AUTO BURNER #1 ON FAN #1 AIR FAN #1 PLENUM FAN #1 FLAME DETECTION FAN #1 HOUSING HIGH LIMIT FAN #1 VAPOR HIGH LIMIT FAN #1 AUTO FAN #1 ON

LOAD #2 POWER MAXON POWER BUR #6 NEUTRAL BUR #5 NEUTRAL FAN #6 NEUTRAL FAN #5 NEUTRAL

THERMOSTAT 110VAC (BO)

NC NC

SCR P1 & V1 FROM BR#1 (BO)

M.R.H POT 2

M.R.L POT 2 & HI SOLENOID BUR#2 (BO)

THERMOSTAT SENSOR S1 SENSOR 2 LOWER. SENSOR 2 UPPER ENERGENCY COOLING AUX #6 B-COMMON EMERGENCY COOLING

11 13

14 16

17 19

PROCESS LIGHT BURNER #1 NEUTRAL BURNER #2 NEUTRAL MAXON NEUTRAL AC NEUTRAL LO-HEAT POWER (BO) HI-HEAT POWER (BO) NC

M.R.H POT 3

M.R.L POT 3 & HIGH SOLENOID BUR#1 (BO)

SCR P3 & V1 FROM BR#2 (B SENSOR 1 LOWER SENSOR 1 UPPER THERMOSTAT SENSOR S2 AUX #6 A-N.C. EMERGENCY COOLING EMERGENCY COOLING NC NC

Page 14

Portable Dryer Troubleshooting

Switch Replacement for EMCS Dryer

Switch Replacement

Switch N/O Contact Block - Part No. D63-0006

Switch Light Block - D01-0455

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Wiring Reference

Portable Dryer Troubleshooting

1100 Series Control Box Wiring

1100 FAN TO CONTROL BOX WIRING

AIR PRESSURE SWITCH +12VDC

HOUSING HIGH LIMIT VAPOR HIGH LIMIT (LP ONLY)

FLAME DETECTION PLENUM

LEFT FIXED GRAIN HI LIMIT

SAFETY CIRCUIT

*REAR DISCHARGE RIGHT FIXED GRAIN HI LIMIT

AIR PRESSURE SWITCH BURNER POWER BURNER NEUTRAL BURNER LIGHT

USED ON SINGLE FAN NAT GAS ONLY

K OTHER SIDE

N/C) SAFETY

5-8 OR J5-9 --

MAXON POWER MAXON NEUTRAL

OUT OF GRAIN SENSOR

LEFT METERING ROLL SENSOR

RIGHT METERING ROLL SENSOR METERING ROLL 12 VOLTS

CUSTOMER SUPPLIED SAFETY METERING ROLL NEUTRAL

TEMP SENSORS TEMP SENSORS WORK LIGHT

DRYER SAFETY CIRCUIT ALWAYS STARTS ON J5-8 AND ENDS ON J4-12.USING THE J5-12 TERMINAL FOR NEGATIVE, THERE SHOULD BE 12 VOLTS DC ON EACH TERMINAL FROM J5-8 TO J4-12.

WHEN CHECKING FOR 12 VOLTS DC ALWAYS PUT THE NEGATIVE PROBE OF VOLT METER TO TERMINAL J5-12

SAFETY CIRCUIT IN BOLD IS FOR FLAME DETECTION ONLY. EACH OF THE TERMINALS CONNECTED TO IT CAN LOOSE 12 VDC FOR 20 SECONDS BEFORE A SHUTDOWN OCCURS. THIS GIVES THE BURNER CIRCUIT TIME TO SENSE FLAME. ALL OTHER SAFETY CONNECTIONS MUST HAVE 12 VDC PRESENT AT ALL TIMES TO OPERATE PROPERLY.

*LOCATED AT REAR OF DRYER

1100EW98.PRT REV. DATE 4/10/98

RELAY CONTACTS LOCATED IN DRYER FAN CAN BOX

MERCURY SWITCH LOCATED ON TOP OF DRYER

120VAC FOR AUX UNLOAD CONTACTOR COIL

120VAC FOR AUX LOAD CONTACTOR COIL

AUX CONTACT POINTS FOR LOAD AND UNLOAD SYSTEMS ALL VOLTAGE SUPPLIED BY USER

42 TOTAL TERMINALS

WIRINGDESCRIPTION

NEED JUMPER

YEL

RED BRN

RED

BLK

NEED JUMPER

RED RED

YEL

PUR OR BLU

OR OR

BLU BLK WHT BRN PUR WHT BLK YEL

BLU

RED

BLK

WHT BLK RED

ALL SAFETIES MUST BE CLOSED FOR DRYER TO OPERATE

J5-8 J5-8 J1-7

J1-5

J1-9 J1-11 J1-19

J5-5 J4-19 J4-12 J1-13

J9-16 J7-4

B1 J7-3

J7-8 J5-4 J5-16 J5-19 J5-9

J1-20

J5-12

-12VDC

S1 S2 L1

J8-16 J8-9 J8-18 J8-8

J8-12

J9-17

J8-20

J8-10

J6-1 SCR 2 J6-4 U-COM U-N/O L-COM L-N/O

12 VOLTS DC (RED) 12 VOLTS DC (RED) 12 VOLTS DC (RED) 12 VOLTS DC (RED) 12 VOLTS DC (RED) 12 VOLTS DC (RED)

12 VOLTS DC (RED) 12 VOLTS DC (RED)

12 VOLTS DC (RED)

MOTOR OVERLOADS

12 VOLTS DC (BLUE) 120 VAC (BLACK) 120 VAC NEUT (WHITE)

120 VAC (BLUE) 120 VAC (BLACK)

120 VAC NEUT (WHITE) 12 VOLTS DC (YELLOW) METER ROLL PULSE (PUR)

NO LONGER USED 12 VOLTS DC (RED)

12 VOLTS DC (RED)BLK

12 VOLTS DC NEG (WHITE)

TEMP SENSOR (ORANGE) TEMP SENSOR (ORANGE)

120 VAC (BLACK) 120 VAC NEUT (WHITE)J9-3 120 VAC (BLACK)AC 1 120 VAC NEUT (WHITE) 120 VAC (ORANGE) 120 VAC NEUT (WHITE) 120 VAC (YELLOW)

120 VAC NEUT (WHITE) 120 VAC (BLUE) 120 VAC NEUT (WHITE) 120 VAC (ORANGE)

CONTROL POT P1 (PUR) CONTROL POT P2 (PUR) CONTROL POT P3 (PUR)

UNLOAD AUX COM(ORANGE) UNLOAD AUX N/O(ORANGE) LOAD AUX COM (YELLOW) LOAD AUX N/O (YELLOW)

COLORVOLTAGE

Page 16

Portable Dryer Troubleshooting

1100 Series Control Box Wiring (New Version)

Wiring Reference

Page 17

Wiring Reference

1200 Series Control Box Wiring

DESCRIPTION

WIRING

Portable Dryer Troubleshooting

52 TOTAL TERMINALS

TERMINAL

COLORVOLTAGE

HOOK OTHER SIDE OF (N/C) SAFETY TO J5-8 OR J5-9 --

53 TOTAL TERMINALS

15 - RED 4 - BLUE 1 - WHITE/BLACK 3 - BLACK (1-16GA) 9 - WHITE (1-16GA 2 - BROWN 4 - PURPLE 4 - ORANGE)

*LOCATED AT REAR OF DRYER

1200EW98.PRT REV. DATE 3/5/98

AIR PRESSURE SWITCH +12VDC

FAN #2 HOUSING HIGH LIMIT FAN #2 VAPOR HIGH LIMIT

FAN #2 FLAME DETECTION FAN #1 HOUSING HIGH LIMIT

FAN #1 VAPOR HIGH LIMIT FAN #1 FLAME DETECTION

FAN #2 PLENUM

SAFETY CIRCUIT

FAN #1 PLENUM

FIXED GRAIN HIGH LIMIT *REAR DISCHARGE ADJ. GRAIN HIGH LIMIT

FAN #2 PRESSURE SWITCH FAN #1 PRESSURE SWITCH BURNER #2 POWER BURNER #2 NEUTRAL

BURNER #1 POWER BURNER #1 NEUTRAL BURNER #2 LIGHT

BURNER #1 LIGHT MAXON POWER MAXON NEUTRAL

OUT OF GRAIN SENSOR *LEFT METERING ROLL SENSOR *RIGHT METERING ROLL SENSOR METERING ROLL 12 VOLTS

CUSTOMER SUPPLIED SAFETY RED

METERING ROLL NEGATIVE

TEMP SENSOR TEMP SENSOR

RELAY CONTACTS LOCATED IN FAN CAN CONTROL BOX

MERCURY SWITCH LOCATED ON TOP OF DRYER

120VAC FOR AUX UNLOAD CONTACTOR COIL

120VAC FOR AUX LOAD CONTACTOR COIL

AUX CONTACT POINTS FOR LOAD AND UNLOAD SYSTEMS ALL VOLTAGE SUPPLIED BY USER

NEED JUMPER

RED

RED BRN RED

BLK

NEED JUMPER

RED

YEL

PUR OR

YEL

PUR OR YEL

BLU OR

OR RED

MOTOR OVERLOADS

BLU BLU BLK WHT BLK WHT

BRN BRN PUR

WHT BLK YEL

BLU

RED

BLK

WHT BLK

RED

ALL SAFETIES MUST BE CLOSED FOR DRYER TO OPERATE

J5-8 J5-8 J1-8 J1-6 J1-10 J1-7 J1-5 J1-9 J1-12 J1-11 J1-19 J5-5 J4-19

J4-12 J1-14 J1-13 J9-18 J7-6 J9-16

J7-4 B2 B1

J7-3

J7-8

J5-4

J5-16

J5-19

J5-9

J1-20

J5-12

-12VDC

L1 WORK LIGHT

J9-3

J8-16 J8-9 J8-18 J8-8 J8-14 J9-19

J8-12

J9-17

J8-20

J8-10

J6-1

SCR 2 J6-4 U-COM U-N/O L-COM

L-N/O

12 VOLTS DC (RED) 12 VOLTS DC (RED) 12 VOLTS DC (RED) 12 VOLTS DC (RED) 12 VOLTS DC (RED) 12 VOLTS DC (RED) 12 VOLTS DC (RED)

12 VOLTS DC (RED) 12 VOLTS DC (RED) 12 VOLTS DC (RED)

12 VOLTS DC (BLUE)

120 VAC (BLACK)

120 VAC NEUT (WHITE)

120 VAC (BLACK)

120 VAC NEUT (WHITE)

120 VAC (BROWN)

120 VAC (BLACK)

120 VAC NEUT (WHITE)

12 VOLTS DC (YELLOW)

METER ROLL PULSE (PUR)

NO LONGER USED

12 VOLTS DC (RED) 12 VOLTS DC (RED)

12 VOLTS DC NEG (WHITE)

TEMP SENSOR (ORANGE)

TEMP SENSOR (ORANGE) 120 VAC (BLACK) 120 VAC NEUT (WHITE) 120 VAC (BLACK)AC 1 120 VAC NEUT (WHITE)

120 VAC (ORANGE) 120 VAC NEUT (WHITE) 120 VAC (YELLOW) 120 VAC NEUT (WHITE) 120 VAC (BLUE) 120 VAC NEUT (WHITE) 120 VAC (BLUE) 120 VAC NEUT (WHITE) 120 VAC (ORANGE) CONTROL POT P1 (PUR) CONTROL POT P2 (PUR) CONTROL POT P3 (PUR)

UNLOAD AUX COM(ORANGE) UNLOAD AUX N/O(ORANGE) LOAD AUX COM (YELLOW) LOAD AUX N/O (YELLOW)

Page 18

Portable Dryer Troubleshooting

1200 Series Control Box Wiring (New Version)

Wiring Reference

Page 19

Wiring Reference

1100 Fan Lower Control Box Interconnect Strip

Portable Dryer Troubleshooting

J9-1

LOAD

LINE

AC-1

EMERGENCY COOLING JUMPERS INSTALL J6-13 TO J1-5 INSTALL J6-14 TO J1-19 INSTALL J6-16 TO J5-5 INSTALL J6-17 TO J4-19

L1 B1 S1 S2 SCR2 J1-5 J1-7 J1-9 J1-11 J1-13 J1-19 J1-20 J4-12 J4-19 J5-4 J5-5 J5-8 J5-9 J5-12 J5-16 J5-19 J6-1 J6-4 J7-3 J7-4 J7-8 J8-8 J8-9 J8-10 J8-12

J9-3

EMI FILTER D03-0181

BLACK - 120 VAC - OUTSIDE LIGHT BROWN - 120 VAC - BURNER #1 LIGHT ORANGE - TEMPERATURE SENSOR ORANGE - TEMPERATURE SENSOR PURPLE - CONTROL POT P2 RED - 12 VDC - FAN #1 VAPOR HIGH LIMIT RED - 12 VDC - FAN #1 HOUSING HIGH LIMIT RED - 12 VDC - FAN #1 FLAME DETECTION RED - 12 VDC - FAN #1 PLENUM HIGHT LIMIT BLUE - 12 VDC - FAN #1 AIR SWITCH RED - 12 VDC - LOWER FIXED GRAIN LIMIT RED - 12 VDC - USER SUPPLIED SAFETY RED - 12 VDC - MOTOR OVERLOADS RED - 12 VDC - LOWER ADJUSTABLE GRAIN HIGH LIMIT YELLOW - 12 VDC - OUT OF GRAIN SENSOR RED - 12 VDC - REAR DISCHARGE SWITCH RED - 12 VDC - 12 VOLT SUPPLY RED - 12 VDC - 12 VOLT SUPPLY WHITE - 12 VDC NEG - 12 VOLT SUPPLY NEGATIVE PURPLE -TIMING PULSE- LEFT METERING ROLL PULSE PURPLE -TIMING PULSE- RIGHT METERING ROLL PULSE PURPLE - CONTROL POT P1 PURPLE - CONTROL POT P3 BLACK - 120 VAC - MAXON POWER WHITE - AC NEUTRAL - BURNER NEUTRAL WHITE - AC NEUTRAL - MAXON NEUTRAL YELLOW - 120 VAC - LOAD POWER ORANGE - 120 VAC - UNLOAD POWER ORANGE - 120 VAC - SCR POWER WHITE - AC NEUTRAL - FAN #1 NEUTRAL

5VB1

J9-3

J8-16 WHITE - AC NEUTRAL - UNLOAD NEUTRAL J8-18 J8-20 J9-16 J9-17

WHITE - AC NEUTRAL - LOAD NEUTRAL WHITE - AC NEUTRAL - SCR NEUTRAL BLACK - 120 VAC - BURNER #1 POWER BLUE - 120 VAC - FAN #1 POWER

35 - D01-0531 ENTRELEC TERMINALS 2 - D01-0533 END STOPS 1 - D01-0532 BLANK PROTECTOR END

I/O BOARD JUMPERS INSTALL J1-9 TO J5-6 INSTALL J5-2 TO J5-20 INSTALL J4-12 TO J5-10 INSTALL J1-20 TO J5-8

Page 20

Portable Dryer Troubleshooting

1200 Fan Lower Control Box Interconnect Strip

Wiring Reference

J9-1

LOAD

J9-3

L1 B1 B2 S1 ORANGE - TEMPERATURE SENSOR S2 ORANGE - TEMPERATURE SENSOR SCR2 J1-5 J1-6 J1-7 J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 J1-14 J1-19 J1-20 J4-12 J4-19 J5-4 J5-5 J5-8 J5-9 J5-12 J5-16 J5-19 J6-1 J6-4 J7-3 J7-4

J7-8 J8-8 J8-9 J8-10 J8-12

J8-18 J8-20 J9-16

LINE

5VB1

EMI FILTER D03-0181

BLACK - 120 VAC - OUTSIDE LIGHT BROWN - 120 VAC - BURNER #1 LIGHT BROWN - 120 VAC - BURNER #2 LIGHT

PURPLE - CONTROL POT P2 RED - 12 VDC - FAN #1 VAPOR HIGH LIMIT RED - 12 VDC - FAN #2 VAPOR HIGH LIMIT RED - 12 VDC - FAN #1 HOUSING HIGH LIMIT RED - 12 VDC - FAN #2 HOUSING HIGH LIMIT RED - 12 VDC - FAN #1 FLAME DETECTION RED - 12 VDC - FAN #2 FLAME DETECTION RED - 12 VDC - FAN #1 PLENUM HIGHT LIMIT RED - 12 VDC - FAN #2 PLENUM HIGHT LIMIT BLUE - 12 VDC - FAN #1 AIR SWITCH BLUE - 12 VDC - FAN #2 AIR SWITCH RED - 12 VDC - LOWER FIXED GRAIN LIMIT RED - 12 VDC - USER SUPPLIED SAFETY RED - 12 VDC - MOTOR OVERLOADS RED - 12 VDC - LOWER ADJUSTABLE GRAIN HIGH LIMIT YELLOW - 12 VDC - OUT OF GRAIN SENSOR RED - 12 VDC - REAR DISCHARGE SWITCH RED - 12 VDC - 12 VOLT SUPPLY RED - 12 VDC - 12 VOLT SUPPLY WHITE - 12 VDC NEG - 12 VOLT SUPPLY NEGATIVE PURPLE -TIMING PULSE- LEFT METERING ROLL PULSE PURPLE -TIMING PULSE- RIGHT METERING ROLL PULSE PURPLE - CONTROL POT P1 PURPLE - CONTROL POT P3 BLACK - 120 VAC - MAXON POWER WHITE - AC NEUTRAL - BURNER #1 NEUTRAL WHITE - AC NEUTRAL - BURNER #2 NEUTRALJ7-6 WHITE - AC NEUTRAL - MAXON NEUTRAL YELLOW - 120 VAC - LOAD POWER ORANGE - 120 VAC - UNLOAD POWER ORANGE - 120 VAC - SCR POWER WHITE - AC NEUTRAL - FAN #1 NEUTRAL WHITE - AC NEUTRAL - FAN #2 NEUTRALJ8-14 WHITE - AC NEUTRAL - UNLOAD NEUTRALJ8-16 WHITE - AC NEUTRAL - LOAD NEUTRAL WHITE - AC NEUTRAL - SCR NEUTRAL BLACK - 120 VAC - BURNER #1 POWER BLUE - 120 VAC - FAN #1 POWERJ9-17 BLACK - 120 VAC - BURNER #2 POWERJ9-18 BLUE - 120 VAC - FAN #2 POWERJ9-19

AC-1

J9-3

EMERGENCY COOLING JUMPERS INSTALL J6-13 TO J1-5 INSTALL J6-14 TO J1-19 INSTALL J6-16 TO J5-5 INSTALL J6-17 TO J4-19

45 - D01-0531 ENTRELEC TERMINALS 2 - D01-0533 END STOPS 1 - D01-0532 BLANK PROTECTOR ENDS

I/O BOARD JUMPERS INSTALL J1-9 TO J5-6 INSTALL J5-2 TO J5-20 INSTALL J4-12 TO J5-10 INSTALL J9-1 TO J9-5

Page 21

Wiring Reference

Portable Dryer Troubleshooting

Upper Control Box External Wiring

BLACK FROM J9-16 TO L1 ON FENWAL BOARD 120VAC POWER WHITE FROM J7-04 TO L2 ON FENWAL BOARD 120VAC NEUTRAL

BROWN TO B1 FROM V1 ON FENWAL BOARD 120VAC ORANGE FROM J1-09 TO FLAME DETECTION RELAYS ORANGE FROM J5-08 TO FLAME DETECTION RELAYS

WHITE/BLACK STRIP J5-12 12VDC NEGATIVE YELLOW TO J1-07 FROM HOUSING HIGH LIMIT SWITCH RED FROM J5-08 TO HOUSING & VAPOR HIGH LIMIT SWITCHES PURPLE TO J1-05 FROM VAPOR HIGH LIMIT SWITCH

TO FAN CONTROL BOX

BLUE FROM J5-08 TO AIRSWITCH COMMON TERMINAL

BLUE TO J1-13 FROM AIRSWITCH N.O. TERMINAL

WHITE TO S1 FROM RIGHT GRAIN TEMPERATURE SENSOR BLACK TO S2 FROM RIGHT GRAIN TEMPERATURE SENSOR

RED FROM J1-11 TO LEFT GRAIN HIGH LIMIT SWITCH ORANGE TO J1-19 FROM LEFT GRAIN HIGH LIMIT SWITCH PURPLE J7-03 MAXON POWER 120VAC (NATURAL GAS ONLY) WHITE J7-08 MAXON 120VAC NEUTRAL (NATURAL GAS ONLY) BROWN FROM J1-19 TO REAR DISCHARGE SWITCH ORANGE TO J5-05 FROM REAR DISCHARGE SWITCH RED 16 GA. A+ SCR DRIVE MOTOR BLACK 16 GA. A- SCR DRIVE MOTOR GREEN 16 GA. SCR DRIVE MOTOR GROUND

BLACK FROM J5-09 TO LOAD MERCURY SWITCH BLACK TO J5-04 FROM LOAD MERCURY SWITCH

WHITE FROM J9-03 TO OUTSIDE LIGHT AC NEUTRAL RED FROM L1 120VAC TO OUTSIDE LIGHT POWER

TO AIRSWITCH ASSEMBLY

TO LOWER JUNCTION BOX

TO UPPER JUNCTION BOX

YELLOW FROM J1-05 TO PLENUM HIGH LIMIT SWITCH WHITE TO S1 FROM GRAIN TEMPERATURE SENSOR BLACK TO S2 FROM GRAIN TEMPERATURE SENSOR BLUE TO J1-11 FROM PLENUM HIGH LIMIT SWITCH YELLOW FROM J1-05 TO PLENUM HIGH LIMIT SWITCH RED FROM J5-05 TO RIGHT GRAIN HIGH LIMIT SWITCH ORANGE TO J4-19 FROM RIGHT GRAIN HIGH LIMIT SWITCH

TO PLENUM AND RIGHT FIXED GRAIN HIGH LIMIT SWITCHES AND TEMPERATURE SENSORS

Page 22

Portable Dryer Troubleshooting

Fan Housing and Vapor Hi-Limit Circuit

Wiring Reference

Page 23

Wiring Reference

Portable Dryer Troubleshooting

Plenum Hi-Temperature Switch

Page 24

Portable Dryer Troubleshooting

Fixed Grain Hi-Limit

Wiring Reference

Page 25

Wiring Reference

LOAD

MOTOR

Portable Dryer Troubleshooting

Grain & Plenum Hi-Limit Locations

LIMIT

GRAIN HIGH

LEFT FIXED

TEMP. SENSORS

GAS PIPE TRAIN

11XX

BOX

UPPER

JUNCTION

OUTSIDE LIGHT

LOAD MERCURY SWITCH

PLENUM HIGH LIMIT SWITCH

D03-0004 300 DEGREE

SOLENOID

BURNER

HI-LOW

THERMO

PLENUM

LIMIT

GRAIN HIGH

RIGHT FIXED

TEMP. SENSORS

AIR SWITCH

FAN

BOX

LOWER

JUNCTION

SCR

MOTOR

UNLOAD

BLUE J1-11

YELLOW J1-05

RIGHT GRAIN HIGH LIMIT SWITCH

D03-0005 210 DEGREE

BLUE J1-11

YELLOW J1-05

ORANGE J4-19

LEFT GRAIN HIGH LIMIT SWITCH

D03-0005 210 DEGREE

RED J5-05

TO UPPER CONTROL BOX

RED J1-11

ORANGE J1-19

TO LOWER JUNCTION BOX

Page 26

Portable Dryer Troubleshooting

Two Fan Plenum and Grain Limit Switch Wiring

LOAD

MOTOR

FIXED GRAIN

HI-LIMIT AND

THERMO SENSORS

Wiring Reference

MAXON

12XX

BOX

UPPER

JUNCTION

SOLENOID

LOAD MERCURY SWITCH

OUTSIDE LIGHT

BURNER #2

PLENUM #2

HI-LOW

THERMO

HI-LOW

BURNER #1

AIR

SWITCHES

FAN #2

THERMO

SOLENOID

PLENUM #1

LIMIT

ADJUSTABLE

GRAIN HIGH

TEMP. SENSORS

FAN #1

RED TO J1-11

SCR

MOTOR

UNLOAD

2FNLMTSW98.PRT REV. DATE 4/5/98

FAN #2

PLENUM HIGH LIMIT SWITCH

D03-0004 300 DEGREE

FIXED GRAIN HIGH LIMIT SWITCH

D03-0005 210 DEGREE

FAN #1

PLENUM HIGH LIMIT SWITCH

D03-0004 300 DEGREE

ORANGE TO J1-19

YELLOW TO J1-12 BLUE TO J1-11 RED TO J1-05

TO LOWER JUNCTION BOX

Page 27

Wiring Reference

Rear Discharge & Emergency Cooling Circuit

Portable Dryer Troubleshooting

Page 28

Portable Dryer Troubleshooting

Rear Discharge Mercury Switch

Wiring Reference

POSITIONED WITH LID CLOSED AND

SJOW 18/2 CORD POINTED TOWARDS

THE FRONT OF THE DRYER CONNECT

INSIDE METER ROLL BOX TO BROWN

AND ORANGE WIRES.

LOOSEN SCREWS ON BRACKET

TO CHANGE SENSITIVITY

OF REAR DISCHARGE SWITCH

CONNECT TO SJOW CORD

INSIDE LRL BOX

Page 29

Wiring Reference

Adjustable Hi-Limit & Emergency Cooling Circuit

Portable Dryer Troubleshooting

Page 30

Portable Dryer Troubleshooting

Wiring Reference

Motor Overloads

Page 31

Wiring Reference

12V DC SOURCE FROM MOTOR OVERLOADS

FAN #2 PRESSURE SWITCH

FAN #1 PRESSURE SWITCH

Air Pressure Switch

J5-8 J1-8

J1-6

J1-10

J1-7

J1-5

J1-9

J1-12

J1-11

J1-19

J6-14

J5-5

J4-19

BLUE

J6-17

J4-12

J1-14

J1-13

BLUE

Portable Dryer Troubleshooting

12 VOLT

1 1 12 VOLT SOURCE DC POSITIVE

DC NEGATIVE

INPUT/OUTPUT BOAR TERMINAL LOCATION

PRESSURE SWITCH SAFETY CIRCUIT

J 1

Page 32

Portable Dryer Troubleshooting

Air Pressure Switch Drawing

LOAD

MOTOR

LIMIT

LEFT FIXED

GRAIN HIGH

TEMP. SENSORS

Wiring Reference

GAS PIPE TRAIN

11XX

BOX

UPPER

JUNCTION

SOLENOID

LOAD MERCURY SWITCH

OUTSIDE LIGHT

PLENUM

LIMIT

GRAIN HIGH

RIGHT FIXED

TEMP. SENSORS

AIR SWITCH

FAN

BOX

LOWER

JUNCTION

SCR

MOTOR

UNLOAD

TO UPPER CONTROL BOX

BLUE J5-08 12VDC POSITIVE

BLUE J1-13 AIRFLOW (N.O.)

CALIBRATED WITH

DIAPHRAGM VERTICAL

C N.C. N.O.

HIGH

BACKVIEW OF AIR SWITCH ASSEMBLY

Page 33

Wiring Reference

Portable Dryer Troubleshooting

Out of Grain Safety Circuit

Page 34

Portable Dryer Troubleshooting

Out of Grain Safety Circuit Location

LOAD

MOTOR

LIMIT

GRAIN HIGH

LEFT FIXED

TEMP. SENSORS

Wiring Reference

GAS PIPE TRAIN

11XX

BOX

UPPER

JUNCTION

SOLENOID

LOAD MERCURY SWITCH

OUTSIDE LIGHT

BURNER

THERMO

HI-LOW

PLENUM

LIMIT

GRAIN HIGH

RIGHT FIXED

TEMP. SENSORS

AIR SWITCH

FAN

BOX

LOWER

JUNCTION

SCR

MOTOR

UNLOAD

LEADS MUST BE IN THIS POSITION

FOR PROPER OPERATION

SJOW 18/2 WIRE

EXITS THROUGH

BLACK

BOX COVER

WHITE

FRONT VIEW OF OPEN BOX

REMOVE THESE EARS

Page 35

Wiring Reference

LOAD

MOTOR

Portable Dryer Troubleshooting

Upper Junction Box Drawing

LIMIT

GRAIN HIGH

LEFT FIXED

TEMP. SENSORS

GAS PIPE TRAIN

11XX

BOX

UPPER

JUNCTION

SOLENOID

OUTSIDE LIGHT

LOAD MERCURY SWITCH

BURNER

HI-LOW

THERMO

PLENUM

LIMIT

GRAIN HIGH

RIGHT FIXED

TEMP. SENSORS

AIR SWITCH

FAN

BOX

LOWER

JUNCTION

SCR

MOTOR

UNLOAD

BLACK

WHITE

TO LOAD MERCURY SWITCH

WHITE

RED

J9-03

BLACK

WHITE

TO 12VDC J5-09

BLACK

J5-04

TO UPPER CONTROL BOX

TO OUTSIDE LIGHT FIXTURE

Page 36

Portable Dryer Troubleshooting

Wiring Reference

Meter Roll Sensor

RIGHT METER

ROLL SENSOR

RED

BLACK

BLUE

J5-19

J5-12

J5-09

NOTE:

RIGHT SENSOR IS

NO LONGER USED ON

DRYERS MANUFACTURED

AFTER MARCH 1, 1997

RED 12VDC POS

BLACK OR WHITE/BLACK STRIP 12VDC NEG

YELLOW LEFT METER PULSE RETURN

BLUE RIGHT METER PULSE RETURN

J5-19

J5-12

YELLOW

BLACK

LEFT METER

ORANGE REAR DISCHARGE RETURN

ROLL SENSOR

BROWN 12VDC TO DISCHARGE SWITCH

TO REAR

ORANGE

J5-09

RED

BROWN

J5-16

JUNCTION BOX

TO REAR DISCHARGE SWITCH

J1-19

J5-05

Page 37

Wiring Reference

Portable Dryer Troubleshooting

Meter Roll Sensor Wiring

J5-8

J1-7

J1-5

J1-9

J1-11

J1-19

J5-5

J4-19

J1-13

J4-12

J9-16

J7-4

J5-16

J5-19

J5-4

J7-8

J7-3

J5-9

J1-20

J5-12

J 1

Pulse

12 Volt +

12 Volt -

Pulse

Board

Meter Roll

Board

Meter Roll

T-2

T-1

T-3

METER ROLL SENSOR

12 Volt +

T-1

12 Volt -

T-2

T-3

1997 Dryers have only 1 meter roll board.

Remove one meter roll board and tie the

2 T-3 wires together.

Page 38

Portable Dryer Troubleshooting

Meter Roll Reversing

Wiring Reference

YOU MUST ENTER INTO THE DRYER PARMETER MODE BY PRESSING THE INCREASE AND DECREASE BUTTONS SIMULTANIOUSLY. YOU WILL HAVE THE FOLLOWING OPTIONS LISTED: SHUTDOWN HISTORY (PRESS ENTER) DRYER MODEL # (IE. 1112) FAN DELAY (DEFAULT = 5) FILL AUGER (DEFAULT = END) BPH FACTOR (DEFAULT = 1.0) TEST METER ROLL (DEFAULT = YES) TEST AIR SWITCH (DEFAULT = YES) M.R. REVERSE (DEFAULT = NO) <- CHANGE TO YES * REVERSE DELAY (DEFAULT = 60) * REVERSE TIME (DEFAULT = 1)

* DISPLAYED ONLY IF M.R. REVERSE IS CHANGED TO YES

REVERSE DELAY = METER ROLLS NORMAL ROTATION TIME (AMOUNT OF TIME METER ROLLS WILL OPERATE BEFORE THEY WILL BEGIN REVERSE ROTATION)

REVERSE TIME = METER ROLLS REVERSE ROTATION TIME (AMOUNT OF TIME METER ROLLS WILL OPERATE IN THE REVERSED ROTATION MODE)

EXAMPLE: REVERSE DELAY = 10 MINUTES REVERSE TIME = 1 MINUTE

NOTE: WHEN INSTALLING RELAY BASE NOTE POSITION OF SLOTS FOR RELAY!!

ORANGE

TO SCR DRIVE BOARD

A+

85 4

A-

PURPLE

JUMPER WIRES SHOULD GO BETWEEN: TERMINALS 4 AND 5 TERMINALS 1 AND 8

LOCATE THE ORANGE AND PURPLE WIRES COMING FROM THE SCR DRIVE BOARD GOING TO THE TERMINAL STRIP AND INSERT THE RELAY AS SHOWN

BLACK

J7-17

(110 VAC CONTROL)

PURPLE

IMPORTANT

YOU MUST ADD A JUMPER WIRE FROM J9-09 TO J7-16 IN THE LOWER CONTROL BOX.

14 12

A-

TO DC DRIVE MOTOR

(110 VAC NEUTRAL)

ORANGE

A+

WHITE

J8-20

Page 39

Wiring Reference

LOAD

MOTOR

Portable Dryer Troubleshooting

Lower Junction Box Wiring

LIMIT

GRAIN HIGH

LEFT FIXED

TEMP. SENSORS

GAS PIPE TRAIN

11XX

BOX

UPPER

JUNCTION

SOLENOID

LOAD MERCURY SWITCH

OUTSIDE LIGHT

WHITE S1

RED J1-11

BURNER

HI-LOW

THERMO

PLENUM

LIMIT

GRAIN HIGH

RIGHT FIXED

TEMP. SENSORS

AIR SWITCH

FAN

BOX

LOWER

JUNCTION

SCR

MOTOR

UNLOAD

TO LEFT FIXED

GRAIN HIGH LIMIT

AND TEMPERATURE

SENSORS

SJOW 18/2 WIRE

BLACK TO MAXON

PURPLE J7-03

WHITE TO MAXON

WHITE J7-08

NATURAL GAS DRYERS ONLY

WIRES GO TO UPPER

CONTROL BOX

BLACK S2

ORANGE J1-19

RED FROM J5-09 TO 12VDC POSITIVE TERMINAL ON METER ROLL SENSOR BLACK FROM J5-12 TO 12V NEGATIVE TERMINAL ON METER ROLL SENSOR YELLOW FROM J5-16 TO LEFT METER ROLL SENSOR BLUE FROM J5-19 TO RIGHT METER ROLL SENSOR BROWN FROM J1-19 TO DISCHARGE SWITCH ORANGE FROM J5-05 TO DISCHARGE SWITCH

RED 16 GA. A+ TO SCR DRIVE MOTOR BLACK 16 GA. A- TO SCR DRIVE MOTOR

GREEN 16 GA. TO SCR DRIVE GROUND

TO SCR

DRIVE MOTOR

TO REAR

OF DRYER

Page 40

Portable Dryer Troubleshooting

Wiring Reference

New Fenwal Board Wiring

The B. GND terminal is used to ground the burner and to complete the flame current signal circuit. This terminal is new for systems that used the older version of the Fenwal board. This terminal must be connected to the burner (chassis) ground not only to ensure the best, long term, stable flame signal, but also to ground the burner for proper sparking.

The use of a burner ground terminal eliminates the problem of loss of flame sense signal due to a missing or loose neutral or ground (green) wire at the 120 V AC power source. The new board has been designed such that reversing the polarity of the 120 V AC line does not cause a loss of flame signal. Thus providing a more reliable flame signal along with a reduction of nuisance lockouts, due to its design and the use of the B. GND terminal.

NEU.

HOT

BURNER

120

VAC

H.V.

B. GND

GAS

VALVE

BURNER

HOT

NEU.

120

VAC

S1 E2

L2 V2

(A) L1

(B) V1

H.V.

GAS

VALVE

Old version with Remote Flame Sense.

New version with Remote Sense using existing

spark and remote sense electrodes.

Note that terminal E2 on the old version has been replaced by terminal B.GND on the new board.

IGNITOR

Part No. HF-4624

Flame Safety Board

BURNER GROUND (B. GND)

FLAME ROD

Page 41

Wiring Reference

Portable Dryer Troubleshooting

Fenwal Board Troubleshooting

On-Board Diagnostics

The LED will flash on for 0.2 seconds then off for 0.2 seconds to indicate an error condition. The pause time between error codes will be 2.5 to 3.0 seconds. During power-up, the LED will light for one second and then turn off to indicate normal operation.

LED Indication Fault Mode

Steady on Internal Control Failure 2 Flashes Flame Fault** 3 Flashes Ignition Lockout Fault

** May indicate either that a flame was detected during

pre- or post-purge, or that there is a flame sensing error.

If a lockout occurs, the board will have to be reset

by shutting off the power to the board.

Measure Flame Current

Micro Amp Meter

BURNER

YES NO

BURNER

Flame

Test

Flame

Test

FC+

FC-

BURNER

Page 42

Portable Dryer Troubleshooting

Flame Control Circuit

TER. 6-8 (110 VOLTS AC)

WHT

TER. 1-5 (12 VOLTS DC)

WHT

BRN

WHT

Coil

BRN

COIL

COMMON

BLK

Normal Closed

Wiring Reference

COMMON

BLK

Coil

Neutral

WHT

Normal Closed

FLAME

SENSOR

IGNITOR

TIME

DELAY

FENWAL BOARD

WHT

Neutral

WHT

BLK

BRN

BLK

BRN

WHT

120 VOLTS AC

NEUTRAL

120 VOLTS AC

BURNER LIGHT

12 VOLTS DC

20 SEC SAFETY

20 SEC INPUT

MAIN CONTROL BOX

ALL WIRES COME FROM

Page 43

Wiring Reference

Fan Burner Circuit for Canadian Models Only

* MERCOID TERMINALS

J4-20 FOR 1 FAN DRYERS

J4-18 FOR 2 FAN DRYERS

SOLENOIDS

HIGH

BROWN

VAPOR

HONEYWELL THERMOSTAT

PART# D03-0047

LOW

Portable Dryer Troubleshooting

HOUSING

GREY BROWN

FLAME

SENSOR

MERCOID

SWITCH

WIRING

TIME

DELAY

BLACK

LIQUID

WHITE

BROWN

WHT

BLK

TER. 1-7 (12 VOLTS DC)

TER. 8-10 (110 VOLTS AC)

BLK

L1 BURNER

WHITE

BROWN

YELLOW

BLACK

PURPLE

7654321

ORG

YEL

BRN

PUR

VAPOR LIMIT

ORG

RED

YEL

ORG

12 VOLTS DC

20 SEC INPUT

20 SEC SAFETY

HOUSING LIMIT

PNK

MERCOID SAFETY PNK

ORG

MERCOID SAFETY

RELAY

GREY

WHITE

BROWN

ORG

BLK

ORG

WHITE WHITE

BLACK

IGNITOR

E2 S1

FENWAL PART# HF-4624

110 VOLTS AC

NEUTRAL- - - - WHT

TO BURNER CIRCUIT

L1V1

BURNER LIGHT - BRN

BLK

BRN

N/C

N/O

COM

MERCOID

PRESSURE SWITCH

SWITCH CLOSES WHEN

BROWN

PRESSURE IS SENSED

Page 44

Portable Dryer Troubleshooting

Conversion Diagram For C Series Dryers To A Switchable

Hi/Low Burner Or A On/Off Burner

Wiring Reference

Page 45

Wiring Reference

Portable Dryer Troubleshooting

Fan 28 LP Hi/Low-On/Off

Page 46

Portable Dryer Troubleshooting

Fan 28 LP Hi/Low-On/Off Burner With Mercoid

Wiring Reference

Page 47

Wiring Reference

Portable Dryer Troubleshooting

Fan 28 NG Hi/Low-On/Off

Page 48

Portable Dryer Troubleshooting

Fan 28 NG Hi/Low-On/Off Burner With Mercoid

Wiring Reference

Page 49

Wiring Reference

Portable Dryer Troubleshooting

Fan 42 LP Hi/Low-On/Off

Page 50

Portable Dryer Troubleshooting

Fan 42 LP Hi/Low-On/Off Burner With Mercoid

Wiring Reference

Page 51

Wiring Reference

Portable Dryer Troubleshooting

Fan 42 NG Hi/Low-On/Off

Page 52

Portable Dryer Troubleshooting

Fan 42 NG Hi/Low-On/Off Burner With Mercoid

Wiring Reference

Page 53

Wiring Reference

Portable Dryer Troubleshooting

SCR Drive Circuit

To Coil

BLK

SCR

CONTACTOR

T2 L2

6 8

A2 A1

COIL

BLK

1 2 3 F + F L 1 L 2 A + A -

L 1

L 2

Fuse

220 Volt

L1T1

5 7

S C R Board

J6-1

SCR 2

J8-10

J8-20

SCR P2

SCR P1

SCR POWER

SCR NEUTRAL

J6-4

SCR P3

To SCR Drive Motor

PUR

A -

A +

TO TERMINAL ON

WITH POWER WIRES

UPPER POWER STRIP

Page 54

Portable Dryer Troubleshooting

RTD Temperature Sensor

LOAD

MOTOR

LIMIT

GRAIN HIGH

LEFT FIXED

TEMP. SENSORS

Wiring Reference

GAS PIPE TRAIN

11XX

BOX

UPPER

JUNCTION

SOLENOID

OUTSIDE LIGHT

LOAD MERCURY SWITCH

BLACK S2

WHITE S1

BURNER

HI-LOW

THERMO

PLENUM

LIMIT

GRAIN HIGH

RIGHT FIXED

TEMP. SENSORS

TO UPPER CONTROL BOX

AIR SWITCH

FAN

BOX

LOWER

JUNCTION

BLACK S2

SCR

MOTOR

UNLOAD

WHITE S1

TO LOWER JUNCTIONL BOX

BLACK 20 GA.

WHITE 20 GA.

FRONT

INSIDE GRAIN COLUMN CONDUIT

SOLDERED AND INSULATED INSIDE CONDUIT

REAR

BLACK 20 GA.

WHITE 20 GA.

FRONT

INSIDE GRAIN COLUMN CONDUIT

SOLDERED AND INSULATED INSIDE CONDUIT

REAR

Page 55

)

Wiring Reference

USING OHM METER BEGIN CHECKING

THE SENSORS FOLLOWING FIG. 1

Portable Dryer Troubleshooting

Test Procedure for E.M.C.S. Dryers

IF OHMS DOES NOT = 3.4 K

CHECK LOWER AND UPPER TERMINAL

STRIP (ON SINGLE MODULES CHECK S1 & S2

(ON DOUBLE OR TRIPLE MODULES

CHECK J6-9 TO J6-6 = 3.4 AND

CHECK J6-11 TO J6-8 = 3.4)

IF MEASUREMENTS DO NOT = 3.4 K

CHECK CONNECTIONS IN WHITE

JUNCTION BOX ON FAR LEFT AND

RIGHT SIDES FACING THE FAN END.

IF NONE OF THE MEASUREMENTS = 3.4 K,

THEN CHECK EACH INDIVIDUAL SENSOR.

FIG.1

J5-3

E.M.C.S. PORTABLE DRYERS

CONTROL

MOISTURE

THERMOSTAT

9 8

3 2 1

3.4 ON 20K

SCALE AT

70 DEGREES

Page 56

Portable Dryer Troubleshooting

Temperature Charts

We use two (2) different types of sensors (NTC thermistor on the Competitor Series 2000, and an encapsulated sensor on the E.M.C.S dryer) in our dryers. The resistance of the sensors varies according to the outside temperature. For example, on the E.M.C.S. dryers, for every one (1) degree rise in temperature the resistance increases 4.8 ohms. However, on the Competitor Series 2000 dryer , the sensor reacts just the opposite, the resistance rises with colder temperatures. The charts displayed above will help when troubleshooting any sensor problems.

Page 57

Troubleshooting Tips

Portable Dryer Troubleshooting

DC Drive Metering Roll System

Symptoms: Metering Roll will not turn,

dryer shutdown-"Metering Roll Drive Failure"

Metering Roll Operation

• The DC drive system on the portable dryer is used to control the output of grain from the dryer. It is adjusted from the front of the control box using the high and low metering roll potentiometers. Components used in this circuit are the SCR contactor, SCR drive board, DC motor/ gear box, and the input/output board from the Electronic Monitoring Control System.

• All voltage for the drive system comes from terminals 1-(L1) and 3-(L2) of the SCR contactor. There should be 220 volts AC across these two points even if the unload system is turned off. If this voltage is zero, check your incoming main power.

in the 2 Speed position. If this is present then the SCR contactor and input/output board are okay.

• If 220 volts AC is present across input of the SCR drive board (L1 and L2) then check for voltage across the output of the board. Change your voltmeter to check for DC voltage at a range above the 200 volt scale. Put the leads across A+ and A-. The voltage across these two points will vary depending on where the speed control potentiometer is turned. Also try turning the potentiometer up and down. The voltage should go from zero to approximately 180 Volts DC. If zero voltage is present across the A+ and Aterminal, first try to disconnect the wires from these two points and then check for DC volts again. If the voltage returns, suspect a bad motor or a problem in the wiring to the motor. If the voltage does not return, suspect a bad DC drive board.

• When the unload system is turned on you should be able to observe the SCR contactor energizing. The power to the contactor should turn on and off with the unload switch. You can check for power by putting an AC voltmeter across terminals

A1 and A2. Across these points you should read 120 Volts AC. Also on the top

of the contactor you can see a plunger pulling in whenever the contactor coil gets power. When the contactor is energized, power is transferred from terminals L1 and L2 to terminals T1 and T2. Understand that L1 and L2 are the Input of the SCR contactor and T1 and T2 are the

Output of the contactor.

Check the SCR Drive Board

• Next if all the above checks out okay, put your voltmeter across terminal L1and L2 of the SCR drive board. You should get 220 Volts AC across these points when the Unload Switch Is

Check the Motor

• The wires attached to A+ and A- go directly to the DC drive motor on the dryer. You may remove the top cover of the motor and check for the same DC voltages mentioned above at the motor. If the voltage is not present try to disconnect the wires, then check for DC volts again. If you do not get any voltage then look for a broken or loose wire between the motor and the drive board terminals.

• If the voltage is present suspect the motor or the gear box. Removing the motor from the gear box and trying to run the motor only is one way of narrowing down the problem, or you may want to remove the chain and see if the metering rolls are froze up. Using a pipe wrench is an easy way to try and rotate the metering rolls.

Page 58

Portable Dryer Troubleshooting

Troubleshooting Tips

Fenwal Ignition System

Symptoms: Burner will not light, dryer

shutdown for "Loss of Flame"

Fenwal Ignition Operation

• The Fenwal Ignition System ignites the

Fenwal Ignition Operation

burner and monitors the flame. Once 120 VAC is applied to the Fenwal, the solenoids are powered up and the transformer begins ignition through the ignitor. If flame is sensed during the ignition period (about 4 seconds), the transformer is turned off, but the solenoids stay on. If no flame is detected after the ignition period, both the solenoids and transformer lose power and the dryer begins a shutdown sequence.

• All voltage for the Fenwal Ignition System is derived from the input/output board of the Electronic Monitoring Control System. For ignition to occur:

1. The fan must be turned on.

2. The pressure switch in the plenum

must indicate the fan is operating.

3. The burner switch must be in the

auto or manual position.

4. The dryer must go through a 10

second purge delay, which is indicated

ing

on the LCD screen. These steps must take place before troubleshooting of the Fenwal System can occur. The following assumes the above steps have been taken.

Fenwal Troubleshooting

• The Fenwal Board located in the fan can control box on the dryer has seven(7) terminals. They are L1, L2, V1, V2, S1, S2 and E2. L1 and L2 are considered the input to the board. After the 10 second purge delay, an AC voltmeter connected Across L1 and L2 should read 120 Volts AC. If this is true, you can assume the input/output board is operating properly and the problem is in the

Fenwal Ignition System. If no voltage is present after the 10 second purge delay, check for voltage going through the auxiliary switch mounted on the side of the fan contactor for that burner. This switch has to close before the Fenwal gets power. If this is OK, check the appropriate output on the input/output board for that burner.

• If voltage is present across L1 and L2, check for voltage across the Output of the Fenwal board. The output terminals are V1 and V2, and they will also have

120 VAC across them for approximately four(4) seconds. The four(4)

seconds is the amount of time the Fenwal has to ignite and sense flame or it concludes no flame is detected and begins a "Loss of Flame" shutdown. If you have power on the in put terminals and no voltage on the output terminals, unload the secondary (take the wires off of V1 and V2) and recheck for voltage. If no voltage is present then suspect a bad Fenwal

board. If power returns, look for a bad solenoid valve or a problem in the wiring.

Note: All of the above voltage checks can be bypassed if you can hear one or more of the solenoids on the gas train snap on after the 10 second purge delay. This is true because the solenoids are connected across V1 and V2, and for the solenoids to come on, power must be going through the Fenwal board. Also during the four(4) second ignition period the transformer is energized and you should be able to observe sparking across the ignitor. If the solenoids snap, but no ignition takes place, check for loose ignitor wires or check the ignitor condition/ignition gap even if flame is sensed the sparking will discontinue after the ignition period (4 seconds).

(1/8 " to 3/16"). Remember

Continued on page 55.

Page 59

Troubleshooting Tips

Portable Dryer Troubleshooting

Fenwal Ignition System continued...

Hints

• Hearing the solenoids snap on after the 10 second purge delay means that power is coming to and through the Fenwal board. The Fenwal board is probably okay.

• If flame is sensed, the power to the solenoids stays on but the power to the ignitor always goes off after about four(4) seconds.

• Power to the low pressure solenoid is always on anytime flame is sensed. This is because the power to the low solenoid is hooked directly across terminals V1 and V2 of the Fenwal board.

• Power to the high pressure solenoids is controlled by the Plenum thermostat. One side of the solenoid is hooked to V2(neutral) and the other side is run through the normally closed switch of the thermostat and then back to V1. This is how the burner is made to cycle. When the plenum is below temperature, power is run through the ther mostat to the high pressure solenoid. When temperature is reached, the thermostat opens and the high solenoid loses power.

Ignitor Tips

• Make sure that the ignitors are mounted correctly through an opening in the burner skirting. Also, make sure that they are not close enough to the edges of the opening to cause a spark to jump the skirting, instead of between the ignitors.

• Be sure that the ignitor tips are no more than 1/8" apart from each other.

• Make sure that the wire connections on the ignitors are good and tight.

• On stubborn lighting burners reverse the direction the ignitor tips are facing. Instead of having the tips pointing toward the fan or burner, change the direction so the tips are facing the exhaust end of the dryer. (This is especially true on burners with no burner cone installed (i.e. Natural Gas).

• L2 and V2 are connected internally in the Fenwal, and they must be nuetral.

Page 60

Portable Dryer Troubleshooting

Troubleshooting Tips

Metering Roll Sensors

Symptoms: No BPH, Total Bushels, RPM dis-

played on LCD or dryer shutdown with metering

roll problems

Metering Roll Sensor Operation

• Each metering roll on the portable dryer has a sensor mounted to read pulses as the metering roll is turning. These pulses are transmitted to the input/output board of the Electronic Monitoring Control System. The computer interprets this information and then displays the data on the LCD screen.

• All voltage for the metering roll sensors is derived from the input/output board of the Electronic Monitoring Control System. The sensors are operated with

12 Volts DC from terminals J5-9 and J512 on the board. When checking for volt-

age the negative or black probe (-)of a voltmeter should always go to terminal J5-12.

Always use j5-12 for the negaitve anytime you check for any DC voltage on the dryer.

Then put the red probe (+) of the voltmeter on terminal J5-9. Across these two points there should be 12 volts DC. This voltage needs to be checked, but you can be reasonably assured the 12 volts DC is present if the rest of the dryer is operating. Check for this voltage on the terminal strip in the upper control box.

the incoming 12 volts DC (the T1-+12V and T2-GND terminals), and one is a pulsing 12 volts DC back to the input/output board (the T3 out terminal). Checking across T1 and T2 will verify that 12 volts DC is getting to the sensor.

• The T3 (out) terminal is what delivers the metering roll information back to the input/output board in the main control box. The information for the metering roll on the left side of the dryer is sent on a yellow wire and goes to terminal J5-16. The information for the metering roll on the right side is sent on a blue wire and goes to terminal J5-19.

• You can use a DC voltmeter to observe this pulsing voltage. The best place to check for this voltage is directly on the input/output board located in the very back of the lower control box on the dryer. Check for a pulsing voltage from J5-16 to J5-12 (negative) and J5-19 to J5-12 (negative). Across each of these test points you should be able to observe a pulsing DC voltage when the metering rolls are turning. You should be able to speed up or slow down the pulses by turning the speed of the metering rolls up or down.

Note: Because a digital voltmeter cannot react fast enough you may not see a full 12 volts DC, instead you may see a pulsing from zero to about eight(8) volts.

• 12 volts DC is transmitted from J5-8 and J5-12 directly to the metering roll sensors located on the back of the dryer. Each of the metering rolls is enclosed in a white plastic box mounted to the back of the metering rolls. Inside each box is the metering roll sensor and the metering roll wheel.

• Each sensor has three(3) wires connected to it. Two(2) of these wires are

Hints

• When checking for a pulsing voltage on J5-16 or J5-19 you should always leave the voltmeter across the terminals for about 30 seconds. Watch the meter closely. Each pulse should be about the same length and about the same time apart. If this is not true, suspect a problem with the sensor on the back of the dryer.

Page 61

Troubleshooting Tips

Portable Dryer Troubleshooting

Air Pressure System

• When inspecting the sensor make sure that the wheel going through the sensor is positioned in the center and is not touching either side. If the sensor is scratched it is either bad or will probably go bad.

Airflow Operation

Symptoms: Dryer will indicate a "Loss of Airflow"

• After turning on a fan the computer must get a signal from the air pressure switch telling it that the fan is actually running and the plenum has been pressurized. If the switch does not show the air pressure within 20 seconds a "Loss of Airflow" shutdown occurs.

Troubleshooting: "Loss of Airflow"

driver and turn the adjusting screw counterclockwise. Turning it this way makes the switch more sensitive to pressure and will turn on the light easier.

• If adjusting the screw does not solve your problem consult the layout diagram of the input/output board. Look for the input for the problem switch. Example: Fan #1 switch's input is J1-13. This is a 12 volt DC input and it can be checked with a DC voltmeter. One of the following conditions will exist when checking this input.

NO AIR PRESSURE---ZERO VOLTS

HAS AIR PRESSURE---12 VOLTS DC Remember when checking for 12 volts DC you should always use one of the DC

negatives for the black probe(-) of your voltmeter. Some of the terminals that may be used for the negative(-) are J5-11, J5-12 or J5-13.

• This error message indicates that the fan is running and the air pressure in the plenum did not pressurize. First, verify that the fan is running, and the dryer is full of grain. There must be grain in the dryer or no pressure will develop. If the fan does come on and the dryer is full of grain, but a "Loss of Airflow" shutdown still occurs, check the air pressure switch circuit.

• W atching the blue light in the fan switch is the easiest way to tell if the air pressure switch is sensing air pressure. Each air pressure switch has a light in the fan switch that will only come on if air pressure has developed. Turn on the fan and after it has run up to about one half of its operating speed the light should go on. If the fan light is not coming on then the air pressure circuit is not sensing pressure.

• Try adjusting the air switch on the front of the plenum to see if it is just out of adjustment. Use a straight blade screw-

• To check fan #1 for air pressure with a voltmeter:

1. Turn on the dryer.

2. Place the black probe(negative) of

your voltmeter on J5-11 or J5-12.

3. Place the red probe(positive) of your

voltmeter on J1-13. At this point there should be zero volts here because the fan is not running.

4. Turn on the fan and watch your volt-

meter.

• If the air switch is adjusted properly you should have zero volts across these test points when you first turn on the fan. After the fan has run up to about one half of its normal operating speed you should see the voltmeter change from zero volts to 12 volts DC. This also works in reverse when turning off the fan. After the fan is first turned off, the voltmeter should still show 12 volts DC until the fan has slowed down to about one half of its operating speed. This is because even though the fan is turned off it is still turning and developing some pressure in the plenum.

Page 62

Portable Dryer Troubleshooting

Troubleshooting Tips

• If all the above fails to work then remove the two wires while blowing into the air tube. Blowing into the switch is the same as having air pressure in the plenum. You should have an open circuit until you blow into the switch, then it should close. If the switch does not close try adjusting it, or replace it with a known good one.

Hints

1. Dryer must be full of grain.

2. Light in the fan switch can be used exactly like a voltmeter to test.

3. Make adjustments of the pressure in one quarter turns.

4. Make sure the air tube in the plenum is not plugged after sitting over the summer.

5. Check the bulb in the fan light. It is a 12 volt bulb.

Vapor High Temperature

Symptoms: Dryer runs for only a short period of time, then a shutdown occurs.

erature Operation

• This message indicates that the vaporizer on

an LP Dryer is not properly adjusted. LP (liquified petroleum) must be vaporized before the burner can operate properly. If LP is being fed to the dryer it must run through a vaporizer before it can be burned. If the vaporizer is getting the fuel too hot it will cause a Vapor High Limit shutdown.

• The vaporizer is located in the fan/heater

unit. It is wrap of pipe mounted inside the fan can directly in front of the burner. It can be seen by looking through the inspection door on the side of the burner.

• T o properly adjust the vaporizer a 1/2"

wrench is needed. Knowing that the gas can get too hot, you must feel the pipe train before the regulator to check this temperature. This point may be very hot so be careful while checking the temperature.

The temperature before the regulator must be warm to the touch. This point cannot be

hot, nor can it be cold...only warm. Use the 1/2" wrench to loosen the hold down bracket on the vaporizer. Move the vapor izer away from the flame to cool down the pipe train or move it closer to the flame to make the pipe train warmer.

Troubleshooting: Vapor High

Temperature

• The dryer will shutdown but will probably

restart as soon as the computer is reset. This is because the high limit is an automatic reset and after the dryer shuts down it allows the pipe train to cool down.

• After the dryer is reset, it will run from a

few seconds to a few minutes and then shutdown again. This is because the Vapor High Limit is heating up again as

Page 63

Troubleshooting Tips

Portable Dryer Troubleshooting

soon as the burner is turned on. The vaporizer must be adjusted to solve this problem.

Using J5-11 as the negative test point for all voltage tests, check for 12 volts DC using the following termi-

nals to help diagnose the problem:

Fan #1-J1-5 Fan #2-J1-6 Fan #3-J2-5 Fan #4-J2-6 Fan #5-J3-5 Fan #6-J3-6

Remember that each of these input terminals is part of the main safety circuit of the dryer, and each must

have 12 volts DC on it before the dryer will operate.

Vapor High Limit Hints

1. Anytime you adjust the Vapor High you should wait and be sure that the pipe train temperature stays constant. It may slowly allow the pipe train to get hotter or colder the longer the dryer runs.

2. If a dryer is shutting down constantly from a Vapor High Limit, it may also be caused from a gas line that is exposed to direct sunlight. If the fuel line to the dryer is exposed to direct sunlight, the liquid in the line will start to vaporize before it even gets to the dryer. Then, when it runs through the vaporizer it gets too hot and causes a shutdown (no matter where you try and adjust the vaporizer). This problem can be helped by insulating the gas line from outside heat.

The two wrap has less surface area and it will not heat the LP quite as much. This may also be true in colder climates where a two wrap will not heat up enough. In this case, the pipe train may develop frost or even freeze the solenoids open.

4. The Vapor High Limit is an automatic reset safety device. It will reset itself as soon as its temperature drops below 190° F. Because the pipe train of the burner cools down rapidly when there is a dryer shut down, the V apor High Limit will generally be cool before the operator gets back to the dryer. As soon as he hits the stop button to reset the computer, it comes back up to normal operation. It appears that the dryer is shutting down for no apparent reason. Usually if this happens the dryer will shut down again a short while after restarting the dryer.

5. If the LP tank feeding the dryer is getting very low on fuel, it can also cause the dryer to shutdown on a Vapor High Limit. Before adjusting the vaporizer always check the fuel level in the customers tank. If the fuel pressure is very low, try suggest ing that the tank be refilled. Usually this will solve the problem.

3. In extreme cases the vaporizer may have to be changed before it will run the proper temperature. Example: If a dryer has a burner with a three wrap vaporizer and the dryer is located in the southern United States, you may have problems adjusting thevaporizer far enough from the flame. In this case, you may have to install a two wrap vaporizer.

Page 64

Portable Dryer Troubleshooting

Troubleshooting Tips

Out Of Grain Warning Shutdown

Out Of Grain Warning

• This message indicated that the dryer has

run low on grain. The shutdown occurs when the loading equipment has run longer than the time the operator has set on the Out of Grain timer. The mercury

switch located on top of the dryer tells the computer when the dryer is full or calling for grain. The shutdown usually occurs

when the loading equipment is having trouble keeping up with the output of the dryer.

Possible Solution

• Look at the loading equipment to see if this

is the problem. Remember, the top hopper of the dryer should always have grain in it. If any of the side screens are opening up at anytime, then you are losing heat along with efficiency. This indicates that you are not filling fast enough. Speed up the

loading equipment to the dryer.

2. Before setting the Out of Grain timer, monitor how long it takes the dryer to refill for shrink. Then, set the Out of Grain timer accordingly . Example: If a dryer takes six minutes to refill for shrink, add an additional five minutes to this, and use this as the amount of time to program into the Out of Grain timer. The additional five minutes is to avoid any nuisance shutdowns. A lot of customers don't want their fill augers to run empty if the source of grain runs out. They may want to set the Out of Grain timer closer than the additional five minutes. (this is fine, but caution the customer that it may cause some nuisance shutdowns.)

3. For the Out of Grain warning to work properly , the fill equipment must be large enough to handle the capacity of the dryer. You do not want the side columns to get low on grain. This will allow the airflow to escape from the dryer through the side screens. If this happens you lose efficiency and may start having a loss of airflow shutdown.

• Using J5-11 for the test point ground, test

for 12 volts on J5-4 to test the load mercury switch. This switch should have 12 volts DC

on it when the dryer is calling for grain and has zero volts on it when thedryer is full.

Out of Grain Hints

1. The out of grain timer is only in use when the fill switch is in the auto position. In the manual position the top mercury switch will still shut off the fill auger , but the dryer will not shutdown if the source of grain to the fill auger is depleted.

Page 65

Troubleshooting Tips

Portable Dryer Troubleshooting

Motor Overload Shutdown

This indicates that one of the Motor Overloads has tripped, shutting down the dryer. Each of the Motor Overloads is located in the upper main power control box. They are all wired into a single series circuit that goes to the input/output board on terminal J4-12. Before the dryer will start terminal J4-12 must have 12 volts DC present, or the Motor Overload shutdown will occur.

V isually inspect each of the overloads. Y ou can tell by looking at them if a trip has occurred. Simply press the reset handle on the overload to reset it. After resetting the overloads press the stop button to clear the error.

If no overloads are tripped try the following voltage tests: Using terminal J5-11 as the negative terminal for all DC voltage checks. Look for 12 volts DC on terminal J-419. This is the terminal that feeds power to the Motor Overloads. If the 12 volts DC is present then check for voltage on J4-12. During a Motor Overload shutdown J4-12 should have zero volts. If you have power going to and not returning to J4-12 inspect the siring from J4-19 to the overloads and then back to J4-

12. If the wiring is okay , turn off all power to the dryer and do a continuity check from J4-19 to J4-12. This must be closed circuit to operate properly .

Motor Overload Helpful Hints

1. Each of the Motor Overload is run in a series circuit. This means, if any of the Motor Overloads trip, a shutdown will occur. Visually inspect the overload to tell

which has caused the shutdown.

2. Even though GSI uses ambient compensated overloads, hot weather or positioning the dryer control box in the sunlight may cause a Motor Overload shutdown to occur. This can usually be tested by trying to run the dryer with the control box door open a little bit.

3. Each of the overloads has an adjustable trip setting that can set up to 115 %. At 115% the overload will hold in longer before it trips.

4. Always check amperages on the motors to be sure that the problem is not in the motor itself.

5. Remember that each motor has a built-in service factor. This allow the motor to actually run over the rated full load amps. The motor manufacturers have allowed GSI, on a number of applications, to run motors over the full load amp rating. this is possible because they are being used in an air over application.

Page 66

Portable Dryer Troubleshooting

Competitor Series 2000 Portable

Page 67

Competitor Wiring Reference

220 Volt Single (1) Phase Power Drawing

INPUT

MAIN

BREAKER

220V FUSES

SCR

CONTACTOR

3FO

1F0

16GA BLACK

110X0

Portable Dryer Troubleshooting

SCR BOARD ASSEMBLED D03-0104

KBIC BARRIER TERMINAL BOARD

8 AMP

25 AMP

LINE FUSE

ACCEL

MIN

MAX

P3 P2P1 I1 F+F- L1 L2

ARM FUSE

A+ A-

SCR BOARD

RESISTOR

SCR BOARD RESISTOR VALUES

1108-1112 (1/3H.P. 240V) #D03-0039

1114-1126 (3/4H.P. 240V) #D33-0001

AC-1

J6-02

BLOCK

DISTRIBUTION

1FI

3FI

FAN #1

BREAKER

LOADUNLOAD

BREAKER

1FO3F0

FAN #1

CONTACTOR

LOADUNLOAD

CONTACTORCONTACTOR

FAN #1

LOAD

LOAD AUX

UNLOAD

220 VAC INPUT

110 VAC OUTPUT

OVERLOAD

TRANSFORMER

109

MOTOR

TO FAN #1

MOTOR

TO LOAD

MOTOR

TO AUX LOAD

MOTOR

TO UNLOAD

BREAKER

UNLOAD AUX

OVERLOAD

MOTOR

TO AUX UNLOAD

Page 68

Portable Dryer Troubleshooting

220 Volt Single (1) Phase Power Drawing (New Version)

Competitor Wiring Reference

Page 69

Competitor Wiring Reference

220 Volt Three (3) Phase Power Drawing

MAIN

BREAKER

220V FUSES

120V FUSES

Portable Dryer Troubleshooting

SCR

CONTACTOR

1FO

BLOCK

DISTRIBUTION

110X0

FAN 1 BREAKER

AC1

3FO

FAN #1

CONTACTOR

220 VAC INPUT

110 VAC OUTPUT

FAN #1

OVERLOAD

LOAD

OVERLOAD

TRANSFORMER

AC-1

AC NEUTRAL

15 1413

MOTOR

TO FAN #1

12 1110

MOTOR

TO LOAD

LOAD BREAKER

UNLOAD

BREAKER

LOADUNLOAD

CONTACTORCONTACTOR

OVERLOAD

LOAD AUX

UNLOAD

OVERLOAD

UNLOAD AUX

987

MOTOR

TO AUX LOAD

6 5

MOTOR

TO UNLOAD

321

MOTOR

TO AUX UNLOAD

Page 70

Portable Dryer Troubleshooting

220 Volt Three (3) Phase Power Drawing (New Version)

Competitor Wiring Reference

Page 71

Competitor Wiring Reference

Portable Dryer Troubleshooting

COMPETITOR POWER CIRCUIT

( 220 VOL T 1PH )

Page 72

Portable Dryer Troubleshooting

COMPETITOR POWER CIRCUIT ( 220 VOL T 3PH )

Competitor Wiring Reference

Page 73

Competitor Wiring Reference

Portable Dryer Troubleshooting

COMPETITOR POWER CIRCUIT

( 440 VOL T 3PH )

Page 74

Portable Dryer Troubleshooting

Upper Control Box Internal Wiring

Competitor Wiring Reference

USER SAFETY +12 VDC HOUSE HI LIMIT VAPOR HI LIMIT +12 VDC LEFT GRAIN HI RIGHT GRAIN HI PLENUM HI LIMIT +12 VDC REAR DISCHARGE +12 VDC OUT OF GRAIN +12 VDC MOTOR OVERLOAD AIRSWITCH N.O. AIRSWITCH COM. AIRSWITCH N.C. FLAME DETECT FLAME DETECT PLENUM TEMP GRAIN/PLENUM GRAIN TEMP 120 AC NEUTRAL 120 AC POWER MAIN SOL NEUT MAIN SOL PWR CYCLE SOL NEUT CYCLE SOL PWR UNLOAD NEUTRAL UNLOAD POWER LOAD NEUTRAL LOAD POWER FAN NEUTRAL FAN POWER IGNITION NEUTRAL IGNITION POWER MAXON NEUTRAL MAXON POWER SCR CONT NEUTRAL SCR CONT POWER SCR P1 SCR P2 SCR P3 WORK LIGHT NEUT WORK LIGHT PWR MERCOID SWITCH USER INSTALLED USER INSTALLED USER INSTALLED USER INSTALLED

J1-17 J7-08 J7-02 J1-13

NONE NONE J7-01

J7-03

J7-05

J7-04 J7-09 J7-10 J7-11 J7-19 J7-20

J7-13

J6-02 AC 1

J6-13

M-SOL

J6-15

J6-14

J3-02

J3-01

J3-12

J3-11 J3-14

J6-03

J6-07

J6-06

J3-03

J3-04

J3-18

J6-09

J4-02

SCR2 J4-01 J6-18 LITE J1-16

UNLD COM UNLD N/O

LOAD N/O

RED RED

RED

RED RED RED BLU WHT BLU GRY GRY YELJ7-12 WHT ORGJ7-14 WHT BLK WHT

BLK WHT BLK

BLU WHT BLK

WHT BLK

P WHT BLK (CANADA ONLY)

ORG ORG YELLOAD COM YEL

TERMINAL ON

UPPER STRIP

LOAD AUX.UNLOAD AUX.

AC1

J6-02

A+

OR PUR

A-

OVERLOADOVERLOADOVERLOAD

FAN #1LOADUNLOAD

ORG ORG

YEL YEL

J6-12 (BLK)

COM N/O N/C

COM N/O

N/C

LOADUNLOAD

FAN #1

J3-01

J3-02

J3-12

J6-03

J3-11

J3-14

WHT

YEL

BREAKER BREAKER BREAKER

FAN #1 LOADUNLOAD

WHT

BLU

WHT

DISTRIBUTION

BLOCK

TRANSFORMER

110XO

AC1

BREAKER

3FI

MAIN

1FI

F-F+L1L2A+

A-

321

DRIVE

SCR

CONTACTOR

SCR

3FO

1FO

Page 75

Competitor Wiring Reference

Series 2000 Control Box Wiring (New Version)

Portable Dryer Troubleshooting

Page 76

Portable Dryer Troubleshooting

Upper Control Box Wiring

Competitor Wiring Reference

220 Volt 1PH

Page 77

Competitor Wiring Reference

Portable Dryer Troubleshooting

Upper Control Box Wiring

380, 460 & 575 3PH

Page 78

Portable Dryer Troubleshooting

Series 100 Control Box Wiring

Competitor Wiring Reference

2 WIRES 2 WIRES -

16 GA WIRES

1 - END PROTECTOR# D01-0532 48 - COMPRESSION TERM.# D01-0531 2 - ENDSTOP# D01-0533 4 - GROUND TERMINAL# D01-0534 13" DIN RAIL# D03-0013

NO CONNECTION (12VDC CNTR TAP) +12 VOLTS

HOUSING HIGH LIMIT

VAPOR HIGH LIMIT

+12 VOLTS

LEFT GRAIN HIRIGHT GRAIN HI PLENUM HIGH LIMIT

+12 VOLTS

REAR DISCHARGE

+12 VOLTS

OUT OF GRAIN

RED YEL

- - PURP RED

2 WIRES ORG 2 WIRES RED

- -BLUE BRN

ORG BLK BLK

NO CONNECTION (12 VDC CNTR TAP)

NO CONNECTION AIRFLOW AIR GND

2 WIRES WHT/BLK NO AIRFLOW FLAME DETECT FLAME DETECT PLENUM TEMPERATURE

GRAIN/PLENUM GND GRAIN TEMPERATURE

BLUE GRY

ORG WHT

YEL

WHT/BLK

BLK

NO CONNECTION NO CONNECTION

MAIN SOLENOID NEUTRAL MAIN SOLENOID POWER CYCLE SOLENOID POWER

UNLOAD AUGER NEUTRAL UNLOAD AUGER POWER

LOAD AUGER NEUTRAL LOAD AUGER POWER FAN NEUTRAL FAN POWER

IGNITION NEUTRAL-----IGNITION POWER

-WHT BLK

BRN WHT BLK WHT BLK

WHT BLK WHT BLK

MAXON POWER ---------- PUR MAXON NEUTRAL -------- WHT SCR CONTACTOR NEUTRAL

SCR CONTACTOR POWER -

WHT

ORG METERING ROLL POT BLK METERING ROLL POT METERING ROLL POT WORK LIGHT NEUTRAL WORK LIGHT POWER

BLK BLK WHT

RED MERCOID SWITCH (CANADA ONLY) USER INSTALLED USER INSTALLED USER INSTALLED USER INSTALLED

REMOVE SCREW TO ACTIVATE USER SAFETY TERMINAL CONNECT WIRE FROM J7-08 THRU USER SAFETY SWITCH BACK TO USER SAFETY TERM.

RED - - - -J1-17 USER SAFETY RED - - - -J7-08 RED - - - -J7-02 RED - - - -J1-13 NO CONNECTION (12 VDC CENTER TAP) NO CONNECTION NO CONNECTION RED - - - -J7-01 NO CONNECTION (12 VDC CENTER TAP) RED - - - -J7-03 NO CONNECTION (12 VDC CENTER TAP) RED - - - -J7-05 (MOTOR OVERLOAD-49) RED - - - -J7-04 (MOTOR OVERLOAD-35) BLUE- - - -J7-09 WHT - - - -J7-10 BLUE- - - -J7-11 GREY- - - -J7-19 WHT - - - -J7-20 YEL - - - -J7-12 WHT - - - -J7-13 ORG - - - -J7-14 WHT - - - -J6-02 BLK - - - -AC-01 WHT - - - -J6-13 BLK - - - -M-SOL BLK - - - -J6-14 WHT - - - -J3-02 ORG - - - -J3-01 WHT - - - -J3-12 YEL - - - -J3-11 WHT - - - -J3-14 BLUE- - - -J6-03 WHT - - - -J6-07 BLK - - - -J6-06 BLK - - - -J3-03 WHT - - - -J3-04 WHT - - - -J3-18 ORG - - - -J6-09 PUR - - - -J4-02 PUR - - - - SCR2 PUR - - - -J4-01 WHT - - - -J6-18 BLK - - - - LITE PINK------------ J1-16 ORG - UNLOAD AUX COM ORG - UNLOAD AUX N/O YEL - LOAD AUX COM YEL - LOAD AUX N/O

100STRIP98.PRT REV. DATE 3/12/98

Page 79

Competitor Wiring Reference

With Moisture Control Hook Up

Portable Dryer Troubleshooting

Upper T erminal Strip

Page 80

Portable Dryer Troubleshooting

With Moisture Control Relay Hook Up

Competitor Wiring Reference

Upper T erminal Strip

Page 81

Competitor Wiring Reference

Moisture Manager to Dryer Wiring

Portable Dryer Troubleshooting

(Upper Control Box)

Page 82

Portable Dryer Troubleshooting

Input/Output Board & Terminal Strip

Competitor Wiring Reference

J6-1

LINE

CORCOM

LOAD

AC1

J6-02

5VB1

EMI FILTER

J6-02

RED --- J1-17

RED --- J1-13

PNK --- J1-16 - - CANADIAN MODELS ONLY

D03-0181

PNK

RED

WHT --- J3-04

BLK --- J3-03

ORG --- J3-01

YEL --- J3-11

WHT --- J3-02

RED

PUR --- J4-01

PUR --- J4-02

WHT --- J3-18

WHT --- J3-14

WHT --- J3-12

RED

PUR

BLK --- J6-06

BLU --- J6-03

WHT --- J6-13

BLK --- J6-12

ORG --- J6-09

WHT --- J6-07

RED --- J7-03

RED --- J7-02

WHT --- J6-18

WHT --- J6-15

BLK --- J6-14

RED --- J7-01

BLU --- J7-11

WHT/BLK J7-10

BLU --- J7-09

RED --- J7-08

RED --- J7-05

RED --- J7-04

YEL

BLK

BLK --- LITE

WHT --- J7-20

GRY --- J7-19

ORG --- J7-14

WHT/BLK J7-13

YEL --- J7-12

PUR --- SCR2

WHT

3 AMP FUSE

ORG

BLUE-3

BLACK-4

WHITE-6

WIRES

TO DOOR:

RED-2

ORANGE-1

TO I/O BOARD:

RED-6

WHITE-5

YELLOW-1

ORANGE-2

GREY-1

BLACK-1

PURPLE-2

WHT/BLK-2

Page 83

Competitor Wiring Reference

Portable Dryer Troubleshooting

Competitor Control Circuit

CPU/Display Board

Page 84

Portable Dryer Troubleshooting

Competitor Control Circuit

Competitor Wiring Reference

I/O Board

Page 85

Competitor Wiring Reference

Portable Dryer Troubleshooting

Competitor Control Circuit

SCR Drive Board

Page 86

Portable Dryer Troubleshooting

Competitor Wiring Reference

* The SCR board is located in the upper control box.

RESISTOR

MIN

MAX

* Terminals L1 and L2 are the input terminals. When the unload system is turned on there should be 220 Volts AC accross these terminals.

* Terminals A+ and A- are the ouput terminals. The voltage across these terminals is DC and will vary depending on where the speed control potentiometer is set.

* The item circled at the bottom right of the SCR board in the photograph is the minimum set potentiometer. This will be used in the SCR board set up to set minimum DC voltage.

* The item circled at the bottom left of the SCR board in the photograph is the maximum set potentiometer. This will be used in the SCR board set up to set maximum DC voltage.

P3 P2 P1 L1 L2 A-A+

IMPORT ANT: After the new board has been installed be sure to remove the resistor

(shown in the photograph above) from the old board and install it in the new board. Just

pull the resistor from the two pin socket and install in the same socket on the new board.

Resistor for 1/3 Hp

Meter Roll motors

used on 12 ft dryers

and shorter . (part

no. D03-0039)

Drying Mode

Switch

Resistor for 3/4 Hp Meter Roll motors used on 14 ft dryers and longer. (part no. D33-0001)

Control panel switch locations.

Moisture Control Switch

Unload Switch

Metering Roll Speed (High)

Metering Roll Speed (Low)

Page 87

Competitor Wiring Reference

Setting SCR Board Maximum Voltage

Before starting the procedure set the dryer up as follows:

1. All fan and heater switches to off position and load switch to off position.

2. Control power to on position.

3. Push the dryer power switch.

4. Dryer mode switch to cont. flow position.

5. Moisture control switch to on position.

6. Unload switch to 2 speed position.

Portable Dryer Troubleshooting

1. Set the low metering roll speed to 050 on the dial indicator shown in the photograph on the left. Set the high metering roll speed to 999.

Metering Roll Speed (Low) set to 050

Unload Switch to 2 speed position

Metering Roll Speed (High) set to 999

2. Switch the Unload switch to the 2 speed position.

3. Switch the Moisture Control switch to the off position. This will put the meter roll rotation speed to the high setting.

4. Use a voltmeter set at the 200 volt DC range and probe terminal A+ with the red voltmeter probe and Awith the black voltmeter probe. If the display on your voltmeter reads 180 volts DC no maximum adjustment is needed. If your voltmeter does not read 180 VDC, then use a small screw driver and adjust the max set petentiometer until the voltage is 180 VDC.

A+

MAX

A-

Page 88

Portable Dryer Troubleshooting

Competitor Wiring Reference

Setting SCR Board Minimum Voltage

1. Switch the Moisture Control Switch back to the on position. This will put the meter roll rotation speed at the low setting.

2. Use a voltmeter set at the 20 volt DC range and probe terminal A+ with the red voltmeter probe and A- with the black voltmeter probe. Use a small screw driver and adjust the min set potentiometer until the voltage is 9 VDC.

The SCR board is now set and dryer is ready for normal operation at desired settings.

SCR Drive Board (Part No. D03-0104)

MIN

A-A+

Page 89

Competitor Wiring Reference

Upper Control Box External Wiring

Portable Dryer Troubleshooting

ORANGE J7-19 FLAME DETECTION TO FLAME PROBE WHITE J7-20 FLAME DETECTION TO FLAME PROBE BASE WHITE J6-07 IGNITION TRANSFORMER 120VAC NEUTRAL 16 GA. WIRE BLACK J6-06 IGNITION TRANSFORMER 120VAC POWER 16 GA. WIRE BLACK J6-12 MAIN SOLENOID 120VAC POWER WHITE/BLACK STRIP J7-10 12VDC NEGATIVE WHITE J6-13 MAIN/CYCLE SOLENOID 120VAC NEUTRAL BROWN J6-14 CYCLE SOLENOID 120VAC POWER YELLOW J7-02 FROM HOUSING HIGH LIMIT SWITCH RED J7-08 12VDC INPUT POWER TO HOUSING & VAPOR HIGH LIMIT SWITCHES PURPLE J7-13 FROM VAPOR HIGH LIMIT SWITCH

BLUE J7-09 CONNECTS TO AIRSWITCH N.O. TERMINAL WHITE/BLACK STRIP J7-10 CONNECTS TO AIRSWITCH COMMON TERMINAL GREY J7-11 CONNECTS TO AIRSWITCH N.C. TERMINAL

TO FAN CONTROL BOX

TO AIRSWITCH ASSEMBLY

WHITE J7-13 PLENUM/GRAIN TEMPERATURE SENSOR COMMON BLACK J7-14 RIGHT GRAIN TEMPERATURE SENSOR

RED 12VDC TO LEFT GRAIN HIGH LIMIT SWITCH ORANGE 12VDC FROM LEFT GRAIN HIGH LIMIT SWITCH PURPLE J3-03 MAXON POWER 120VAC (NATURAL GAS ONLY) WHITE J3-04 MAXON 120VAC NEUTRAL (NATURAL GAS ONLY) BROWN 12VDC TO REAR DISCHARGE SWITCH ORANGE J7-03 FROM REAR DISCHARGE SWITCH RED 16 GA. A+ SCR DRIVE MOTOR BLACK 16 GA. A- SCR DRIVE MOTOR GREEN 16 GA. SCR DRIVE MOTOR GROUND

BLACK 12VDC TO LOAD MERCURY SWITCH BLACK J7-05 FROM LOAD MERCURY SWITCH

WHITE J6-18 OUTSIDE LIGHT AC NEUTRAL RED LITE 120VAC OUTSIDE LIGHT POWER

YELLOW J7-12 PLENUM TEMPERATURE SENSOR WHITE J7-13 PLENUM/GRAIN TEMPERATURE SENSOR COMMON BLACK J7-14 GRAIN TEMPERATURE SENSOR BLUE FROM PLENUM HIGH LIMIT SWITCH TO J7-01 RED TO PLENUM HIGH LIMIT SWITCH ORANGE TO RIGHT GRAIN HIGH LIMIT SWITCH RED FROM RIGHT GRAIN HIGH LIMIT SWITCH

TO LOWER JUNCTION BOX

TO UPPER JUNCTION BOX

TO PLENUM AND RIGHT FIXED GRAIN HIGH LIMIT SWITCHES AND TEMPERATURE SENSORS

Page 90

Portable Dryer Troubleshooting

Input/Output Board 12 Volt

UNLOAD AUGER POWER

MAXON VALVE/DRYER RUNNING LIGHT

PROOF OF FLAME LIGHT

PROOF OF AIRFLOW LIGHT

MOISTURE CONTROL HOLDING LIGHT

LOAD POWER

TRIAC SPARE

N.C. (TIED TO J3-19)

120V INPUT FROM CPU

120 VOLT AC OUTPUT

2 4

101214161820

19 17 15 13 11 9 7

Competitor Wiring Reference

UNLOAD AUGER NEUTRAL AC NEUTRAL

AC NEUTRAL AC NEUTRAL

AC NEUTRAL LOAD AUGER NEUTRAL FAN NEUTRAL AC NEUTRAL AC NEUTRAL AC NEUTRAL

3 AMP FUSE

12 VDC FAN ON

BURNER ON

UNLOAD 1 SPEED

101214161820

LOAD ON

CONTINUOUS FLOW

VAPOR HIGH LIMIT INPUT

SPARE

12 VOLT DC INPUT

USER SAFETY INPUT

12 VDC

19 17 15 13 11 9 7

RL1-A COMMON TO POT INPUT ON SCR BOARD RL1-B COMMON TO POT INPUT ON SCR BOARD

RL1-B N.C. LOW SPEED POT A RL1-B N.O. HIGH SPEED POT A RL1-A N.C. LOW SPEED POT B

RL1-A N.O. HIGH SPEED POT B

12 VDC FAN AUTO BURNER AUTO UNLOAD 2 SPEED LOAD AUTO DRYER EMPTY (BATCH ONLY) MOISTURE CONTROL ON MERCOID SAFETY INPUT SPARE 12 VDC

DATA INTERLINK CABLE CONNECTION

THESE JUMPERS MUST BE INSTALLED

J1-1 TO J1-17 - USER SAFETY

J1-1 TO J1-16 - MERCOID SAFETY

Page 91

Competitor Wiring Reference

Cpu Board Wiring

MAIN SOL PWR 120VAC

CYCLE SOL PWR 120VAC

RL3 N.C.

NO CONNECTION

RL1 N.C.

AC NEUTRAL INPUT

IGN TRANS PWR 120VAC

Portable Dryer Troubleshooting

SPARE AC OUTPUT

LIGHT AC NEUTRAL

120VAC TO I/O BOARD

FUSE

TRANSFORMER

RS485 COM PORTS

FLAME PROBE A

RL1 N.O.

110VAC IN

RL1 COMMON

TEMP SENSOR (GROUND)

+ 12VDC OUTPUT

RL3 COM SCR IN

IGN TRAN NEUTRAL

RL3 N.O. SCR DRIVE OUT

STOP SWITCH

N/C AIRSWITCH (5 VDC)

N/O AIRSWITCH (5 VDC)

NNN

MAIN SOL NEUTRAL

AC NEUTRAL

LOAD COIL NEUTRAL

CYCLE SOL NEUTRAL

110V NEUTRAL

OUT OF GRAIN SWITCH

REAR DISCHARGE SWITCH

GRAIN/PLENUM HIGH LIMIT SWITCH

12 VDC GROUND

MONITORING

DISPLAY

171513

FLAME PROBE B

975

161412

+ 12VDC OUTPUT

12VDC NEGATIVE

GRAIN TEMP SENSOR

PLENUM TEMP SENSOR

AIRSWITCH COM (DC NEG)

321

864

START SWITCH

+12VDC OUTPUT

MOTOR OVERLOAD

HOUSING HI-LIM

Page 92

Portable Dryer Troubleshooting

Competitor Wiring Reference

Programing Instructions for Competitor Series Grain Dryers

1. Turn Control Power on dryer to the off position.

2. Locate programming jack (J2) on back of computer . (See next page). There will be a cable plugged into this jack that comes from the other computer board. Unplug this cable to plug the programmer into the jack.

3. Plug the series 2000 cable into programming jack and into programmers DB-9 jack.

4. Be sure that the rotary switch on the programmer is set to position 8.

5. Turn on Control Power to the dryer .

6. The four (4) lights on the programmer will come on, then three (3) will go out leaving the power light still on.

7. Push the start button on the programmer to start the transfer of Software.

8. The busy light will flash until the transfer process is complete.

9. When completed, the pass light will flash indicating a successful transfer .

10. If the fail light flashes then check your connections and repeat the above process.

11. T urn Control Power on dryer to off and remove the cable.

12. Turn on the dryer and the opening screens should indicate the newer version of software.

Page 93

Competitor Wiring Reference

Programmer Hook Up Diagram

Portable Dryer Troubleshooting

J2 CONNECTOR

DB9 JACK

PLUG THIS INTO

FUSE

THE PROGRAMMER

468

1012141618

1113151719

SERIES 2000 CABLE

PROGRAMMING JACK TO UPDATE

SOFTWARE ON EPROM PLUG

PROGRAMMER INTO THIS JACK

TRANSFORMER

87654321

MONITORING

DISPLAY

RS485

COM

PORTS

DIP SWITCHS

DIP SWITCH #8 = AIR SWITCH TEST ON OR OFF

DIP SWITCH #6 = BURNER CYCLE HI-LO (OFF) OR ON-OFF (ON)

DIP SWITCH #5 = NO LOAD DURING LOW FIRE CYCLE (BATCH ONLY)

DIP SWITCH #7 = EMERGENCY COOLING MODE

123

Page 94

Portable Dryer Troubleshooting

Competitor Wiring Reference

Programming Instructions Using Palm Pilot

On the Competitor Dryer there is only one board to program. This board is called the CPU Display board. It is mounted to the door of the lower box. T o access, open the door and the programming jack is located on the back of this board. T o program, follow the instructions below .

1. Turn the control power on the dryer to the off position.

2. Locate the programming jack (J2 connector) on back of board.

3. Unplug the communications cable that is connected to that connector. This is the cable that runs from the CPU/Display board and IO Board.

4. Connect the DB-9 connector from the Palm Pilot to the series 2000 cable.

5. On the Palm Pilot select the program for that particular board and tap on it.

6. Turn the dryer control power back on.

7. The programming process should begin, it will erase the present program and start the new program.

8. A screen will come up telling you when the transfer of software is complete.

9. When the process is complete turn dryer control power off, remove the connector from the board and plug the communications cable back on to the CPU/Display board.

10. Turn on the dryer and the opening screens should indicate the latest version of software.

Refer to next page for more information on programming the Series 2000 board.

If ordering Palm Pilot from GSI there are two kits available:

D03-0692 ( Palm Flash Program Kit Deluxe )

D01-1771 Series 2000 Programming Cable D03-0688 Palm Pilot IIIC (color) D03-0694 Palm Pilot Hot Sync Cable D03-0695 Palm Flash 9 Pin M-M Adapter D03-0709 Disk, CD-Rom Palm Flash Software

D03-0693 ( Palm Flash Program Kit Economy )

D01-1771 Series 2000 Programming Cable D03-0689 Palm Pilot M100 (black & white) D03-0695 Palm Flash 9 Pin M-M Adapter D03-0709 Disk, CD-Rom Palm Flash Software

Page 95

Programming Competitor

Programming Competitor Dryer Using Palm Pilot

Palm Pilot

D03-0689 (M100)

D03-0688 (IIIC)

Portable Dryer Troubleshooting

Hot Sync Cable

D03-0694

DB-9 M-M Ad a p te r

D03-0695

DB-9 Connector

(

Connects to the

DB-9 M-M adapter)

Palm

Side

D ryer

Side

DB-9 Connector

J2 Connector

(

Connects to the back

of CPU/Displa y bo ard)

Series 2000 Prog ram min g Cabl e

D01-1771

(Use on CPU/Board)

Page 96

Portable Dryer Troubleshooting

Back of Switch Panel Layout

JUMPERS:

ORANGE-5

BLACK-1

PURPLE-4

BROWN-3

BLUE-3

YELLOW-3

GREY-1

FROM I/O BOARD:

RED J1-16 TO J1-20

RED J3-19 TO J6-16

WHITE J3-04 TO J6-17

BLACK J6-05 TO J6-11

BLACK J6-01 TO J6-05

Competitor Wiring Reference

AC1

LITE

CONNECTS TO

TERMINAL STRIP

ON BACK PANEL

BLACK-1

RED-1

WHITE-1

BLUE-1

TO DISPLAY:

TRANSFORMER

YELLOW-1

FUSE

MONITORING

DISPLAY

CONTROL POWER

BATCHCF

TWO POS

OUTSIDE LIGHT

J1-11

J3-03

BLK

DRYING MODE

J1-09J1-10

19 20

LOAD

J3-11

J1-03

FAN

J1-04

J1-06 J1-05

J4-03

J4-05

J3-07

1920

CONNECT J6-05

TO J6-01.

J3-05

J1-08

J3-01

J1-14

MOISTURE CONTROL

J3-09

THREE POS

UNLOAD BURNER

START

J1-07

com

J3-03

STOP METERING ROLL SPEED

com

J4-06

J4-04

SCR-2

PRPRPR

Page 97

Competitor Wiring Reference

Back of Switch Panel Wiring

Portable Dryer Troubleshooting

BLACK

J6-01

FUSE

TRANSFORMER

MONITORING

DISPLAY

J6-01 (AC POWER) BLACK

J6-02 (AC NEUTRAL)

WHITE

1920

19 20

1 2

CONTROL POWER

J6-02

BATCHCF

GREY

DRYING MODE

J6-02

LOAD AUGER

FAN

J6-02 J6-2 J6-02

HEATER

OUTSIDE LIGHT

J7-15 J7-15

J7-15

RED

J7-15

REQUIRED JUMPERS:

RED J3-19 TO J6-16

WHT J3-04 TO J6-17

BLK J6-01 TO J6-05

WHITE

MOISTURE CONTROL

RED

THREE POS

UNLOAD

START

J7-06

BLU

J7-15

com

J6-02

METERING ROLL SPEED

J6-02

STOP

com

RED

J7-07

YEL

Page 98

Portable Dryer Troubleshooting

Air Switch Assembly

LOAD

MOTOR

LIMIT

LEFT FIXED

GRAIN HIGH

TEMP. SENSORS

Competitor Wiring Reference

GAS PIPE TRAIN

BOX

UPPER

JUNCTION

1XX

LOAD MERCURY SWITCH

SOLENOID

OUTSIDE LIGHT

PLENUM

LIMIT

GRAIN HIGH

RIGHT FIXED

TEMP. SENSORS

AIR SWITCH

FAN

BOX

LOWER

JUNCTION

SCR

MOTOR

UNLOAD

TO UPPER CONTROL BOX

GREY J7-11 NO AIRFLOW (N.C.)

WHITE/BLACK STRIP J7-10 AIRFLOW GROUND

BLUE J7-09 AIRFLOW (N.O.)

CALIBRATED WITH

DIAPHRAGM VERTICAL

C N.C. N.O.

HIGH

BACKVIEW OF AIR SWITCH ASSEMBLY

Page 99

Air Switch Adjustment

Air Switch location.

Portable Dryer Troubleshooting

Competitor Air Switch Adjustment

Air Switch assembly.

IMPORTANT: T o adjust the air switch the grain columns

need to be full of grain so that the plenum can build up air

pressure and close the air switch.

With the Load Auger, Fan, Heater, and Unload switches in the off position turn

1. on the Control power then push the Dryer Power Start switch.

With power now applied to the dryer flip the fan switch to the on position and

2. watch the light right above that switch. If the light illuminates when the fan reaches half its full speed, then no adjustment is required. However, if the light does not illuminate until the fan is running at full speed or the light does not illuminate at all and the dryer shuts down the air switch is adjusted too high (skip to step 3a). If the light illuminates before the fan reaches half its full speed the air switch is adjusted too low (skip to step 3b

3a.

If the light above the fan switch illuminates after the fan reaches full speed or did not illuminate at all and the dryer shut down then the air switch needs to be made more sensitive. Turn adjustment screw in the more sensitive direction (counter clockwise). Make this adjustment on the air switch 1/4 turn at a time and each time restart the fan and watch to see when the light illuminates.

If the light above the fan switch illuminates before the fan reaches half its full speed

3b.

then the air switch needs to be less sensitive. Turn adjustment screw in the less sensitive direction (clockwise). Make this adjustment on the air switch 1/4 turn at a time and each time restart the fan and watch to see when the light illuminates.

4. Flip the fan switch to the off position and watch the light. Now it should go out when the fan is about half its full speed. Adjust the air switch if necessary . Remember that less sensitive (clockwise adjustment) will require a higher fan speed to close the air switch, and more sensitive (counter clockwise adjustment), the switch can close at a slower fan speed.

AUTO

FAN

OFF

Page 100

Portable Dryer Troubleshooting

Fixed Grain Hi-Limit & Temperature Sensor

Competitor Wiring Reference

GAS PIPE

TRAIN

LOAD

MOTOR

BOX

UPPER

JUNCTION

1XX

LOAD MERCURY

SWITCH

SOLENOID

OUTSIDE LIGHT

RIGHT FIXED

LEFT FIXED

GRAIN HIGH

LIMIT

GRAIN HIGH

LIMIT

TEMP. SENSORS

FAN

PLENUM

TEMP.

SENSORS

AIR SWITCH

BOX

LOWER

JUNCTION

MAXON

UNLOAD

SCR

MOTOR

TO LEFT FIXED

GRAIN HIGH LIMIT

AND TEMPERATURE

SENSORS

SJOW 18/2 WIRE

BLACK TO MAXON

WHITE TO MAXON

NATURAL GAS DRYERS ONLY

WIRES GO TO UPPER

CONTROL BOX

RED

WHITE J7-13

ORANGE

BLACK J7-14

PURPLE J3-03

WHITE J3-04

BROWN FROM 12VDC TO DISCHARGE SWITCH ORANGE FROM J7-03 TO DISCHARGE SWITCH

RED 16 GA. A+ TO SCR DRIVE MOTOR BLACK 16 GA. A- TO SCR DRIVE MOTOR GREEN 16 GA. TO SCR DRIVE GROUND

TO SCR

DRIVE MOTOR

TO REAR

OF DRYER

GSI PNEG-630 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual