GSI Outdoors PNEG-630 User Manual
GSI
Competitor
Portable Dryer
Models
Troubleshooting and
Reference Manual
& EMCS
2004 Revised Edition
PNEG-630
Competitor Series 2000 Dryer
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
1
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
2
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.
3
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.
4
Portable Dryer Troubleshooting
Safety
5
Safety
Portable Dryer Troubleshooting
6
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.
7
Safety Sign-Off Sheet
Portable Dryer Troubleshooting
Date Employer’s Signature Employee
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8
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
9
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.
10
Portable Dryer Troubleshooting
EMCS Display Board
COMPUTER
PROGRAMMING
JACK
PROGRAMMER
JACK (DB9)
SOUND
S1
P5
Programming
KEY PAD RIBBON
P4
P7
P8
COMMUNICATIONS CABLE
TO I/O BOARD
P6
TO STOP SW.
P3
3
21
U12
BATTERY (TIC)
TO START &
TO START SW.
STOP SWS.
DISPLAY
RIBBON
P1
11
Wiring Reference
0
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
20
19
18
17
15
16
14
13
12
11
J5
9
10
7
8
6
5
3
4
2
1
20
19
18
17
16
15
14
13
12
11
J4
10
9
7
8
6
5
3
4
1
2
20
19
18
17
16
15
14
13
12
11
J3
9
10
8
7
5
6
3
4
2
1
+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
1
2
3
4
5
6
7
8
9
10
J9
12
11
13
14
16
15
18
17
20
19
1
2
3
4
5
6
7
8
9
10
J8
11
12
13
14
15
16
18
17
20
19
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
12
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
20
19
18
17
16
15
14
13
12
11
J2
10
9
7
8
5
6
3
4
1
2
20
19
18
17
16
15
14
13
12
11
J1
10
9
8
7
6
5
3
4
1
2
** 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
NC
1
2
3
4
5
6
7
8
9
10
J7
12
11
13
14
16
15
18
17
20
19
1
2
3
4
5
6
7
8
9
10
J6
12
11
14
13
16
15
18
17
19
20
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
Portable Dryer Troubleshooting
Switch Replacement for EMCS Dryer
Switch Replacement
Switch N/O Contact Block - Part No. D63-0006
Switch Light Block - D01-0455
13
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
OR
YEL
RED
BRN
RED
BLK
NEED JUMPER
RED
RED
YEL
PUR
OR
BLU
OR
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
14
Portable Dryer Troubleshooting
1100 Series Control Box Wiring (New Version)
Wiring Reference
15
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
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
RED
BRN
RED
BLK
NEED JUMPER
RED
RED
OR
YEL
PUR
OR
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
S1
S2
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 (RED)
12 VOLTS DC (RED)
12 VOLTS DC (RED)
12 VOLTS DC (BLUE)
12 VOLTS DC (BLUE)
120 VAC (BLACK)
120 VAC NEUT (WHITE)
120 VAC (BLACK)
120 VAC NEUT (WHITE)
120 VAC (BROWN)
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)
16
Portable Dryer Troubleshooting
1200 Series Control Box Wiring (New Version)
Wiring Reference
17
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
18
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
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
19
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
20
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
Portable Dryer Troubleshooting
Fan Housing and Vapor Hi-Limit Circuit
Wiring Reference
21
Wiring Reference
Portable Dryer Troubleshooting
Plenum Hi-Temperature Switch
22
Portable Dryer Troubleshooting
Fixed Grain Hi-Limit
Wiring Reference
23
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
24
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
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
25
Wiring Reference
Rear Discharge & Emergency Cooling Circuit
Portable Dryer Troubleshooting
26
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
27
Wiring Reference
Adjustable Hi-Limit & Emergency Cooling Circuit
Portable Dryer Troubleshooting
28
Portable Dryer Troubleshooting
Wiring Reference
Motor Overloads
29
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