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PNEG-950 - Network Dryer Operation and Service Manual - Dan-Corn

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4. 72 Model INUMID Seg mem 72 Sa ate eee Nee M east fee 73 73 Ser eto cdi 74 ContrasEAdustmelbib ze miS 75 DVINO CRAN 77 TZO0 SONICS E 78 12005 DOO Seco ces ARA RE CHARME E NH UMOR 81 Technical Reference 85 Coritrol PanelJurmiper WIrinNg zene cove Re a Los 86 Control Panel Internal 87 Lower Control Box Back Panel 0 88 Network Fan Heater 89 Fan Computer sasi ee 90 Fan ar Gohttol BOX din Misa ode M ub Sot te aet 91 Upper Terminal SIOIDo ne Aiea ne 92 Upper Control Back Panel 2 0012000000000 nnne 93 PNEG 950 Introduction GSI Network Portable Dryers Thank you for choosing a GSI product It is designed to give excellent perfor mance and service for many years This manual describes the operation and service for all standard 1200 se ries two fan grain dryers These models are available for liquid propane natural gas or fuel oil fuel supply with e
5. 33 Emergency Dryer 33 Dryer Startup and Operation 35 Initial Setup 36 en oe oa 41 Continuous Flow Drying 42 Staged Batch Drying 44 Operating Display SCreenS x isn 47 Safety Circuit Shutdown Messages 49 Fan and Heater Generated 8 50 Input Output Generated Errors arasinan en I EL 53 Master Display Generated 55 Service and 57 Seasonal Inspection and 5 58 ETE E E NONSE 58 Fan Blade Removal and 59 Motor Remova mpm 61 Heater Parts Removal and 61 Misusfntelelcs temer Q 62 Trouble Analysis 64 Special Setup 5 2 221 69 MiB x ET 70 SUNG MEE ETT EE 70 Section 9 Section 10 70 select Unload Method 71 Select Dryer 0 72 Atempo
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7. 814824220045 AUX LOAD CONTACTOR O 6 O GRY AND OVERLOAD N C O a Ol Ede t mR Z o amp 1 O Q 2906 Me H O_o LOAD neur WHT mc m m 22 8 i _ power yas ES elaela O 19 09 UNLOAD CONTACTER al 9 AND OVERLOAD Olay e REQ IT 29 04 a U 019 OLY OL UNLUAD NEUTRAL WHT s m Ss T UNLOAD COM ORG L DRG UNLOAD 0 m LI I I b o H UNL PAR Ps 8 o 9 11 8 A AUX UNLOAD CONTACTOR AND OVERLOAD N C t Of 9 2 Ol UN NEUT WHT 16 GA 16 GA WIRES x lt JUMPERS BRN TD 100300 DPOT RELAY RED T0 100301 RELAY BASE RED WHT PLR PUR r Yt2 14 4 8 gt Tee wem EI aes OO OW ORG RED RED 0 5 ORG BLK REO i 38 20 A al 39 ORG en BE E BLKAHT C gt oe MOVE JUMPERS TD co NEUTRALS mo STRIPE ACI LABEL GRAY es Mt e Vea 22 Ins J4 01 TO 4 02 LOAD POWER 8 25 i Pt T i resl mde 64 LOAD AUXILARY 1 m o LOAD 72 Mu ul TE EL SER POVERO E41 SCR CONTACTOR 22 POWER A INLOAD POWERS PS en UNLOAD 55 J8 20 NEUTRAL Wit Su 2 MRR 8 26 NET CONNECTION 1 RED ess YEL ams NET CONNECTION 2 BK MOS EH gel FES veL
8. 14 PNEG 950 READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE SAVE FOR FUTURE REFERENCE 1 Read and understand the operating manual before trying to operate the dryer This manual contains important guidelines and sequence of events to help you install and operate your dryer safely and successfully Follow the guide lines closely 2 After towing the dryer ensure it is parked on a level surface and that suitable precautions have been taken to prevent it from rolling i e block the wheels in both directions 3 Never operate the dryer while the guards are removed 4 BEFORE any maintenance switch the dryer OFF at the mains electricity and lock off This should include all associated conveyers augers and other associated equipment Maintenance requiring the power to be ON such as testing electrical circuits must be done by qualified personnel 5 Check for gas leaks at all gas pipe connections If any leaks are detected do not operate dryer Shut down and repair before further operation 6 Never attempt to operate the dryer by jumping or otherwise bypassing any safety devices on the unit 7 Set pressure regulator to avoid excessive gas pressure applied to burner during ignition and when burner is in operation Do not exceed maximum ended drying temperature 8 Keep the dryer clean Do not allow fine material to accumulate in the plenum chamber 9 Keep auger drive belts tight enough to prevent slippage 10 Never work in or
9. E gt 110X0 2 RED 5 uw vx Hu i 45 a ORG 50 2 01 OUT OF GRAIN YEL YEL amp NEL S e egez RED 65100 LOAD 0 YEL ORG bora z D i LIFI 5 LOAD COM YEL Weite Aeg cete one nente ee essen Dee wein ea ah or a a a 4 5 2 o RED BLU Network Connection 1 1 YEL Network Connection 2 J3 07 12700 REO beer 2312 13 AIR SYS FAILURE 2281 S i mE UNLOAD VO ORG 2 i a UNLOAD COM ORG 8 e 2181 PUR elle J4 02 SCR ORIVE Beo sR peo 3 25 sre 0 B 3 RPR O 5 PUR iB PLR 3 5 0 RELAY POVER i 0 i J8 18 e 7 Y EIL e 81180 IE 000000 0 1 1 BOG i m ME 3 2 Be Sl CONTROL TRANSFORMER USE GA WIRES 225 opg 55 TO LOVER CONTROL BOX PNEG 950 NOTES 94 PNEG 950 NOTES PNEG 950 95 This Equipment shall be installed in accordance with the current installation codes and applicable regulations which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installation occurs The GSI Group Inc 1004 E Illinois St Assumption IL 62510 0020 Phone 217 226 442 Fax 217 226 4420 e mail gsisales grainsystems com internet http www gra
10. 1 Press the 3 Press the d P button to adjust the settings 4 Press the button to accept the changes Unload Delay The unload delay is used to control the amount of time the unload auger runs after the metering rolls stop to allow the unload auger to clean itself out To change the setting of this delay follow these instructions 1 Press the the other screens 2 Press the MODIFY button 3 Press the button to adjust the settings 4 Press the button to accept the changes PNEG 950 39 Setting Up The Temperature Set Points These set points are monitored by the computer to control certain features of the dryer These can be adjusted from the keypad of the Dryer control panel using the button or the button Moisture Control Setpoint Drying mode switch is in the Continuous position If the moisture control temperature is below this set point and you have your unload switch set to two speed position then meter rolls will discharge the grain using the low speed meter roll setting If the moisture control temperature is above this set point and you have your unload switch set to two speed position then meter rolls will discharge the grain using the high speed meter roll setting Itis normal for the meter rolls to switch back and forth between high and low speed during the drying pro cess This regulates the speed of the grain being discharged from the dryer Drying mode switch is in the Bat
11. 10 PNEG 950 The GSI Group Inc recommends contacting your local power company and having a representative survey your installation so the wiring is compatible with their system and adequate power is supplied to your unit Safety decals should be read and understood by all people in the grain handling area If a decal is damaged or is missing contact The GSI Group Inc 1004 E Illinois St Assumption IL 62510 217 226 4421 free replacement will be sent to you Decal DC 1224 A DANGER Decal DC 1224 is located in two places on the fan heater control box One on the lid and one on the front of the fan heater control box Another location for this decal is inside the upper control box for the dryer High voltage Will cause serious injury or death Lockout power before servicing DC 1224 A DANGER H g h vol tage Decal DC 889 has two locations Wi cause 1 u ry One inside the fan heater control box and another on the dryer upper con death trol box door next to the main power Lockout power disconnect before servicing Decal DC 889 PNEG 950 11 Decal DC 972 AWARNING Moving parts can crush and cut Keep hands clear Do not operate without guards in place Failure to do so could result in serious injury DC 872 AWARNING Decal DC 971 Automatically controlled belt drive can start at anytime Keep hands clear Failure to do 50 could result in serious injury
12. If the dryer runs out of grain while the load auger switch is in the auto position the out of grain timer auto matically shuts off the dryer after the period of time preset on the timer 1 Pressthe button Press ENTER to bypass the first screen 2 Press the MODIFY button PNEG 950 37 38 3 Press the button to adjust the settings 4 Press the ENTER button to accept the changes If you want to view the out of grain timer while the dryer is running perform the following steps 1 Press the 3 Press the button and move the pointer from the SET OUT OF GRAIN to the OUT OF GRAIN TMR position 4 Press the to view the remaining time of the Out of Grain timer while the Load Auger is running The TIME LEFT is a countdown of time from the Out of Grain timer setting you have entered above and will decrement if your fill auger is running and the Load Auger switch is in the AUTO position The LAST LOAD TIME is the amount of time the load or fill auger operated until the fill auger mercury switch was activated indicating the dryer is full NOTE Anytime your TIME LEFT counter reaches zero your dryer will shut down with a Out of Grain warning Fan Sequence Delay The Fan Sequence Delay controls the amount of time between each fan startup to reduce the dryer startup amps Default setting is 5 seconds To change the setting of this delay follow these instructions PNEG 950
13. Press the buttons to darken or lighten the contrast Press the to accept the changes Note If the display is blank keep pressing the increase button to bring up the contrast A new installed display board may not have had the contrast set at the factory and defaults at no contrast PNEG 950 75 76 PNEG 950 Section Drying Charts 1200 Series Dryers 1200 Continuous Full Heat 78 Initial 1 18 19 2 21 22 23 24 25 25 27 21 29 30 31 32 23 24 25 2 pts 3 pts 4 pts 5 pts pts 7 pts pts 4 pts 10 pts 11 pts 12 pts 13 pts 14 pts 15 pts 16 pts 17 pts 18 pts 13 pts ZU pts Moisture Approx Moisture Removed Dry Time 1 Speed 15 min 21 min 26 31 5 min 3 min 41 5 min min 51 min 54 min So min min bh 5 min 715 min min 81 min Bh min H1 min Jh min 100 min p25 475 305 317 270 241 213 196 185 172 161 150 140 132 123 116 110 104 100 2 Speed 2 Speed Low 317 270 241 213 196 155 172 161 150 140 132 123 116 110 104 100 dh 5 2 High 875 775 B75 575 475 385 317 270 241 213 196 185 172 161 150 140 132 123 116 PNEG 950 1200 Continuous Dry amp Cool Initial Moisture Approx 2 Speed
14. buttons to toggle between active or inactive Then press the The display screen will then advance to the next fan and heater on your dryer You can easily configure your dryer to use both On Off burners and Hi Lo burners at the same time This depends on your particular drying situation Possible reasons for using On Off burner Low drying temperatures needed ie drying popcorn rice soybeans Very warm outside ambient temperatures Drying grain that already has low moisture content requiring only 1 to 5 point moisture removal May help prevent Vapor High Limit shutdowns Possible reasons for using Hi Lo burner e Higher drying temperatures needed ie Hard to dry varieties of corn e Colder outside ambient temperatures e High moisture content grain requiring 5 15 point removal SET TIME amp DATE Use this screen to set the computers time and date The time and date is preset at the factory but because of different time zones you may find the need to change it Just press the button to advance to the number on the line that needs to be changed or you can use the button to back up to the previous number on the line Use the to change the number directly above the flashing cursor Once you are satisfied with your changes press the button to accept them 74 PNEG 950 CONTRAST ADJUSTMENT Press and hold the button while the control power is off then turn the control power on then release button
15. 0 10 min 24 9 pts 55 min 55 min 18 min 10 min 54 min 44 min 0 min 25 10 pts min min 19 min 10 min 58 min 40 min min 25 11 pts min 65 min 18 min 10 min min 54 min min 27 12 pts 0 2D min 18 min 10 min bb 5 55 5 min min 28 13 pts min 5 min 18 min 10 min 1 5 min 61 5 min min 25 14 pts ol min 80 min 18 min 10 min fo min Bb min min 301 15 pts 05 min 85 min 18 min 10 min ol min 1 min 0 10 min 31 16 pts 90 min 90 min 18 min 10 min ob min 6 min 0 10 min 22 17 pts 95 min 95 min 18 min 10 min 91 min 81 min min 32 18 pts 100 min 100 min 18 10 min min ob min 10 min 24 19 pts 105 min 105 min 18 10 min 100 min 0 min 0 10 min 35 ZU pts 110 min 110 min 18 min 10 min PNEG 950 1200S 50 50 Split Dryers 1200S Continuous Full Heat Initial Moisture Approx 2 Speed 2 Speed Moisture Removed Dry Time 1 Speed Low High 17 2 pts 16 min 555 333 850 18 3 pts 21 min 499 283 760 19 4 pts 26 min 403 252 bl 20 5 pts 31 5 min 333 223 Sol 21 pts min 283 205 499 22 pts 415 min 252 194 403 21 B pts 417 min 223 181 333 24 9 pts 51 205 170 283 25 pts 54 min 184 158 202 25 11 pts 58 min 181 147 23 Ar Yo 12 pts 62 min 170 138 205 28 13 pts 66 5 min 158 128 194 29 14 pts 41
16. 149 C limit and automatically resets itself when cool The message will distinguish between which plenum caused the shut down PNEG 950 Vapor x High Limit The LP gas vapor temperature sensor located in the gas pipe train downstream from the vaporizer has opened indicating that the vaporizor is running too hot and must be readjusted This sensor is set at 200 F 93 C and automatically resets itself when cool The message will distinguish between which burner caused the shutdown The reference to the number one 1 is telling you that it is burner number 1 which is the bottom most fan heater unit is where the malfunction is located Try adjusting the vaporizer coils farther away from the burners flame You may also want to try switching the burner mode from Hi Lo to On Off especially on warmer days INPUT OUTPUT GENERATED ERRORS The following is a list of errors that are generated with the Input Output board located in the upper control box Air System Failure A shutdown has occurred due to a air system that was installed with an intergal safety switch that was in the unit The air system safety connections are located in the upper control box on the terminal strip This can occur if this safety looses 12VDC to terminal 42 13 on the I O board This input is jumpered on the terminal strip when it leaves the factory and is usually installed in the field by a qualified electrician Aux Load Overload The motor overload relay
17. 16 min 6 min 0 10 17 2 pts 18 min 18 min 18 min 10 min 21 min 17 min 0 10 min 18 3 pts 24 min 24 min 18 10 min 26 min 16 min min 19 4 pts 30 min 18 min min 31 5 min 21 5 min min 209 5 pts 35 min 35 18 min 10 min 3 min Z min min 21 pts 40 40 min 18 min 10 min 41 5 min 31 5 min 0 10 min 22 pts 45 min 45 min 18 min 10 min 47 min 24 min min 23 H pts 50 min 50 min 18 min 10 min 51 min 4 min min 24 pts 55 min 55 min 18 min 10 min 54 min 44 min 0 10 min 25 pts min min 18 min 10 min So min 40 min min 25 11 pts min 65 min 18 min 10 min 52min min 27 12 pts 0 2D min 18 min 10 min 5 min 56 5 min min 28 13 pts 5 min 5 min 18 min 10 min 1 5 min 61 5 min 0 10 min 25 14 pts ol min 80 min 18 min 10 min fo min 66 min 0 10 min 301 15 pts 05 min 85 min 18 min 10 min ol min 1 min min 31 16 pts 90 min 90 min 18 min 10 min ob min 6 min 0 10 min 22 17 pts 95 min 95 18 min 10 min 91 min 81 min min 32 18 pts 100 min 100 min 18 10 min min ob min min 24 18 pts 105 min 105 min 18 10 min 100 min 90 min 0 10 min 35 ZU pts 110 min 110 min 18 10 min PNEG 950 8
18. Decal DC 974 Auto equipment can start at anytime Do not enter until electric power is locked in off position Failure to do so will result in serious injury or death 12 Decal DC 972 is located on the bottom auger belt guard and the front bearing plate which is visible when then bottom auger belt guard is removed An alternate location would be atthe rear of the dryer for portable dryers equipped with the Front Discharge Option Decal DC 971 is located on the bottom auger belt guard and the front bearing plate which is visible when then bottom auger belt guard is removed An alternate location would be atthe rear of the dryer for portable dryers equipped with the Front Discharge Option Another location for decal DC 971 is the top auger belt guard one on the belt guard cover and one inside on the belt guard body visible when the belt guard cover is re move Decal DC 974 has several differentlocations Two are located on the front end panel below the fan heater Two are located on the rear end panel below the rear access door Two are located on the auger discharge box one on the outside top and one on the inside of the flapper lid next to the discharge mercury switch One more of these de cals is located inside the plenum on the rear plenum clo sure door just inside the rear access door PNEG 950 Decal DC 1227 A WARNING Flame and pressure beyond door Do not operate with Decal DC 1227 is loc
19. PART HH 1487 IGNITION TRANSFORMER TYPE 612 047 PRIV SELV HZ PRIA SECA 120 5 000 60 15 020 SECONDARY ENDPOINT GROUNDED 21910 MOTOR OVERLOAD 12 7 15 RD MOTOR OVERLOAD 12 7 04 WHITE NETURAL 6 15 BLACK HROWN REEN FLAME PROBE WIRE 17 19 RED CREEN STARTER COIL 110 6 03 IGNITION XFRIR LLOVAL 06 06 FLAME PROBE WIRE J7 20 ELECTRICAL GRILNI 91 PNEG 950 UPPER TERMINAL STRIP 92 GREEN ak To Tol 2 we 0 fol Ot m ud YELLOW o MODULE INTERCONNECT CONNECT THE 5 WIRES BUNDLED EITHER OF THESE TWO SETS OF TERMINALS gue E 7 BLACK 22 2 DO NUT DISCONNECT EXISTING Q WIRES IN THESE TERMINALS st en 1428 o Q OUTSIDE LIGHT CONNECTIONS ER 11219 MIN YALE eF CONNELT LENS I LIA 42 REAR DISCHARGE SWITCH CONNECTIONS 119 o 06 METER ROLL SENSOR jo 0 CONNECTIONS To fel o 11214 LISER INSTALLED SAFETY CONNECTIONS 2 MERCURY SWITCH VIRES _ am i 6 5 0 THESE 2 TERMINALS Hell e 1210 AIR SYSTEM CONNECTIONS MOISTURE SENSOR 9 o CONNECT 5 EJ E E E 110 VAC POWER SWITCHED LECTRICAL GROUND FROM LOWER CONTROL BOX GREEN 10 VAC POWER TO
20. RED TO SCR BOARD TERM P2 1200 S5 overs Bn ZR 8 17 AC PIER Eds TO TERM STRIP 18 20 AC NEUTRAL SCR BOARD TERM ol a5 METER RLL Neben 25 METER ROLL SENSOR RETLRN 56 CONNECTION dq USER SAFETY RED of BEY CONNECTION 2 a JUNPER 3 07 PT en 5 YEL RED S4 19 10 PR m 4559 DUTSIDE LIGHT POWER WHI BLK ST Io Ag ORG 1 1 w Io 1 1 e 1 1 1 48 48 20 NEUTRAL a fed 110VAC NEUTRAL i BK 110v AC PIER 69 27 3 1 M ja RR a Se i 9 05 MAXON POWER VHT lt gt lt mS 8 20 AC NEUTRAL 5 1 we 1 1 es Sj 1 2 9 88 58 N DAN 98 SYSTEM FAILURE YEL d UNS Om om J3 07 120 ili LOAD D L RED D Fo 826 ACTOR 9 2 05 REIR DISH SWT 5 28 1 UNLOAD 07L RED 008 om m 7 RED Gal LOWER MERCURY SWITCH ae 00 E REAR DISCHARGE i 33 07 1200 pes GRAIN DEM n 48 07 873 04 12406 ORAN PRESENT A A ri el EE 7 3 03 M R RETURN YEL 5 SO D YEL RG 1 RG 23 07 12V0C RED in Tat USER SAFETY 13 01 YEL S gt
21. UNLOAD time for various moisture content grains see the drying charts for your size of dryer 9 If the dryer is being operated in all heat turn each FAN switch to ON In this position the fan will run continuously during both the dry and unload stages of the staged batch operation If the dryer is being oper ated in the dry and cool mode the preferred position for the FAN switch is the ON position so the fan will run continuously If desired the fan can be turned off during the unload cycle of the dry cool unload sequence by turning the fan switch to auto 10 If the dryer is being operated in all heat turn each HEATER switch to ON The burner will operate when ever the fan is operating If the dryer is being used in dry and cool turn the HEATER switches to AUTO and the burner will automatically shut down during the cooling and unloading cycles 11 Turn the UNLOAD switch to the ONE SPEED position The bottom auger and metering rolls will start automatically during the unload cycle of the dry cool unload mode along with any grain handling equipment that is wired to the dryer The speed at which the metering rolls operate during the unload cycle is adjusted by using the high speed metering roll knob Turning the dial clockwise will increase the grain discharge rate and counterclockwise will decrease the discharge rate 12 To control the length of the dry cycle using only the dry time setting programmed into the system turn the moisture
22. access to components Use extreme caution in working around high speed fans gas fired heaters augers and auxiliary conveyers which may start without warning when the dryer is operating on automatic control Continued safe dependable operation of automatic equipment depends to a great degree upon the owner For a safe and dependable drying system follow the recommendations within 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 above before attempting to operate the dryer PNEG 950 15 16 PNEG 950 Section Control Panel EL EI jueunsn py NE i eee dois HEIS peojun SJ9 eoH Sue pedAsy TANVd HOLIMS Jacina fe en he ITA Ebates cer WIL ieri Ved lad TLS peo 1uBr1episino Spo 01 U0D 9Jn1SIo N eidsiq 21 PNEG 950 18 CONTROL POWER SWITCH The control power to energize the Network Control System is turned on or off with this switch Note This switch does not disconnect the power that is present at the breakers contactors transformer s fuses or other electrical components found in the upper and lower control boxes Turn the Main Dis
23. by pressing the button and goto the User Hour Meter screens User Hour Meter The User Hour Meter is a custom timer which can be used for several different scenarios For instance if you wanted to monitor the amount of time used between different hybrids of corn or if you have more then one user of the dryer Press the button to exit back to the main drying screen Reset User Hour Meter Pressing the button at this point will cause the to be reset back to O If this is not the desire action then press the ENTER button to exit back to the main drying screen PNEG 950 25 HELP BUTTON EE The HELP button currently has no function DRY BUTTON The A button is used to change the Dry timer settings when you operate your dryer in the Batch mode This button has no effect in the continous drying mode Please refer to the Staged Batch section COOL BUTTON The button is used to change the Cool timer settings when you operate your dryer in the Batch mode This button has no effect in the continous drying mode Please refer to the Staged Batch section for Batch operation UNLOAD BUTTON The A button is used to change the Unload timer settings when you operate your dryer in the Batch mode This button has no effect in the continous drying mode Please refer to the Staged Batch section for Batch operation PLENUM BUTTON The button allows you to view the plenum temperature of all the burners on
24. check the motor to make sure it is not being overworked You may need to call an electrician to measure the motors full load amps FLA User Safety A shutdown has occurred due to a user installed safety switch that was installed on the dryer The user installed safety connections are located in the upper control box on the terminal strip This also indicates that 12VDC has been lost to terminal J2 01 on the I O board This input is jumpered on the terminal strip when it leaves the factory and is usually installed in the field by a qualified electrician MASTER DISPLAY GENERATED ERRORS The following is a list of errors that are generated with the Master Display board located in the lower control box Cont Batch Mode Chng This error occurs when you switch the dryer mode switch from the Cont Flow to the Staged Batch position while the dryer is running in the Continous Flow Mode To avoid this shutdown stop the dryer before switching modes Press Stop to clear the error Network Failed FH x This error is generated whenever Fan Heater board has lost its communications link with the Input Output board upper control panel door and the Master Display board lower control panel Check the blue and yellow wires marked N1 01 and N1 02 on a 3 terminal plug to make sure they are plugged in tightly The reference to the number one FH1 is telling you that it is fan number 1 which is the bottom most fan PNEG 950 55 56 Network Faile
25. connector and unscrew the flame sensor out of its mounting bracket 2 Gas Solenoid valve coil s Unsnap either the plastic cap or the metal clip on the gas valve and slide the housing and coil off the valve stem and body Do not energize the coil when it is removed as the coil may become damaged due to excessive current flow 3 Regulator and gas solenoid valve s The gas regulator and solenoid valve s are directional and must be connected as indicated by the markings near the port openings Make sure gas is shut off and purged from the system before removing parts PNEG 950 61 Note When installing a liquid gas solenoid valve on LP models do not over tighten the connection into the inlet side as the inlet orifice may become partially blocked 4 Main Gas Orifice With fuel shut off and gas purged from system proceed as follows a Disconnect the plumbing support brackets from the pipe train b Disconnect gas solenoid valve coils Be sure to mark which one goes where c Lift pipe with orifice solenoid valve and other parts attached straight up and remove from fan heater housing Orifice and other parts can now be removed from pipe train if desired 5 Reassemble To reassemble parts reverse the disassembly procedure and check the following a Make sure all parts are thoroughly cleaned and open b Use a dependable brand of high temperature pipe caulking compound when assembling gas connections Apply only a light coati
26. control setting to off To use the automatic moisture control so that the dry time is determined not only by the dry time setting but also by the moisture content of the drying grain turn the MOISTURE CON TROL switch to ON and set the grain temperature set point to a setting of 135 F 57 C 13 To start the drying operation push the dryer POWER START button The controller will start all the dryer components in their proper order 14 To shutdown the dryer close the fuel supply valve at the fuel tank or fuel source If the burners are operat ing let the dryer run out of fuel causing an automatic shutdown due to a loss of flame Close the fuel valve at the dryer and press the dryer power stop button Turn off the dryer s main circuit breaker located on the front of the power panel Turn off the main power supply to the dryer 15 In case of an emergency press the dryer power stop button The burners fans and all augers will stop immediately Fan Setting Heater Setting Fan Function Heater Function Auto Auto Fans stay on during dry and cool cycle only Burners stay on during dry timer cycle only Auto On Fans stay on during dry and cool cycle only Burners stay on during dry and cool Un Fans are on continuously Burners are continuously Auto Fans are on continuously Burners shut down at the end of the dry cycle At the end of the dry cycle in staged batch the fans and heaters will continue running if in the Auto Auto setting
27. for obtaining the highest drying efficiency is to use the highest possible drying temperatures which will not adversely affect grain quality Dryer Shutdown Cooling Hot Grain If the dryer is to be shut down while filled with grain it is recommended that hot grain be cooled for 10 to 15 minutes especially in cold weather to prevent water vapor condensation and possible freezing of such condensate following shut down INITIAL SETUP PARAMETERS Timer and Delay Settings Turn the control power switch to on The monitor will display a copyright message and model number total running time in hours and minutes and the current time and date To activate the controller press es neser button a each setup screen orthe button to edit the delay currently on display The screens will display in the following order Load On Delay Out of Grain Timer Fan Sequencing Delay Unload Cleanout Delay 36 PNEG 950 Load Delay The load delay is used to delay the starting of the load auger when the dryer is unloading to prevent the load auger from cycling to often To change the setting of this delay follow these instructions 1 Press the button 2 Press the button 3 Pressthe button to adjust the settings 4 Pressthe button to accept the changes Out of Grain Timer The Out of Grain timer should be set to the maximum time it takes for your dryer to refill during continious or batch mode drying
28. has tripped on the Aux Load Motor circuit located in the upper control box This can occur if this safety looses 12VDC to terminal J2 10 on the I O board Push the red button on the overload to reset this error This is caused from the motor operating with to much of a work load which in turn uses more current amperage If the problem reoccurs then check the motor to make sure it is not being overworked You may need to call an electrician to measure the motors full load amps FLA Aux Unload Overload The motor overload relay has tripped on the Aux Unload Motor circuit located in the upper control box This can occur if this safety looses 12VDC to terminal 42 12 on the I O board Push the red button on the overload PNEG 950 53 54 to reset this error This is caused from the motor operating with to much of a work load which in turn uses more current amperage If the problem reoccurs then check the motor to make sure it is not being over worked You may need to call an electrician to measure the motors full load amps FLA Grain Discharge Warning The lid on the grain discharge box has opened indicating that either the grain is not being taken away fast enough from the discharge box or the take away auger system connected to the dryer may be causing the problem This can also occur if this safety looses 12VDC to terminal 42 05 on the board Load Motor Overload The motor overload has tripped on the Load Motor Overload loc
29. parameters are setup with the keypad Listed below is a description of the buttons used on the keypad RESET BUTTON On this screen is information on the version of software that is installed on your dryer Press the button to intialize the dryer The computer will run a series of tests on its internal components The dryer controls will not operate until this button has been pressed 20 PNEG 950 SETUP BUTTON button while the system is stopped will give you four setup screens These This screen is used to clear your batch counter You may want to do this at the start of the drying season to keep an accurate count of the batches ran through your dryer during the drying season Press the BEST button to clear it or just press the button to keep your total batch count The next screen allows you to clear the total amount of bushels that your dryer has recorded Press the This screen is used to customize your dryer with the name of your farm or company This message will contain the serial number of the dryer when it leaves the factory but can be changed to anything message DECREASE you like Use the cursor press the button to advance to the next character or the A button to back up to the previous Character on the line When you have finished entering your custom message press to accept the changes to change the character above the flashing cursor To move the
30. should also rotate in the correct direction at this time Turn the load auger switch to the auto position The top auger and wet grain supply auxiliary should run for eight 8 minutes and then the dryer will shutdown leaving the safety shutdown message out of grain warning dis played Press the dryer power stop button to reset the panel then press the start button UNLOAD ONE SPEED OPERATION To check one speed operation place the unload switch in the one speed setting Turn the metering roll dial until the metering rolls start rotating The bottom auger should rotate counterclockwise as viewed from the drive end The metering roll drive motor should rotate clockwise as viewed from the drive end of the gear box If the dry grain take away auxiliary is wired to the dryer it should start and rotate in the proper direction UNLOAD TWO SPEED OPERATION To check two speed operation move the unload switch to the two speed position change the low speed reading to 200 and high speed on 600 Adjust the moisture control grain temperature setpoint to a value lower then the ambient temperature or until the moisture control switch light comes on The metering roll speed is now controlled by the low speed setting Adjust the moisture control grain temperature setpoint to a value higher then the ambient temperature or until the light goes out leaves the metering rolls controlled by the high speed setting METERING ROLL OPERATION To check the metering ro
31. speeds if required Each time you make an adjustment to the moisture control it will take about the time shown in drying charts to see the results of this adjustment STAGED BATCH DRYING MODE 44 Continuous Batch Operation 1 Turn the control power switch to on 2 Make sure the DRYING MODE switch is turned to STAGED BATCH 3 After the date and time appear press the button 4 Open the main fuel supply valve on the tank if using LP gas or the valve in the fuel supply line if using natural gas Turn on the Maxon electric shut off valve if so equipped or open the manual shut off valve to allow fuel flow to the dryer 5 The dryer should already be filled with grain Turn the LOAD AUGER switch to AUTO In both the auto and manual position the grain level switch will automatically keep the dryer full of grain In the auto position the dryer will shut down after the preset time period on the out of grain timer or if the grain flow to the dryer is interrupted 6 Turn each FAN switch to AUTO The fan will start and the switch will light up when air pressure is de tected PNEG 950 7 Start each burner by turning the HEATER switch to AUTO After purging for approximately 10 seconds the burner will fire and the heater switch will light up indicating that the flame sensing circuit is sensing burner flame For information concerning burner adjustment see the pre start section of this manual 8 To properly set the correct DRY COOL and
32. staged batch during the dry cycle only The on position will operate the burner only when the fan is running The switch will light up only when the flame sensor detects the flame Note The bottom burner on your dryer is always Burner 1 UNLOAD SWITCH The unload switch turns the metering rolls and discharge auger on or off and selects the operation of the metering rolls e In the 2 speed position if the moisture control switch is on and the drying mode switch is turned to cont flow the metering roll speed will alternate between the high speed metering roll potentiometer setting and the low speed metering roll potentiometer setting depending on whether the grain temperature is above or below the grain temperature setpoint The discharge auger will operate continuously Inthe 1 speed position if the moisture control switch 1 on and the drying mode switch is turned to cont flow the metering roll speed will discharge grain at the high speed metering roll potentiometer setting or turn off the meter rolls depending on whether the grain temperature is above or below the grain temperature setpoint The discharge auger will operate whenever the metering rolls are operating n both the 1 speed or the 2 speed position if the moisture control switch is off and the drying mode switch is turned to cont flow the metering roll speed can be manually controlled by adjusting the high speed metering roll potentiometer The discharge auger will ope
33. that the blade is in balance Failure to do this could result in the blade running out of bal ance and potentially exploding Balancing the blade is a specialists job if in doubt contact GSI or your dealer The fan blade is secured to the motor shaft by the use of a taper lock bushing motor shaft key and three cap Screws CAUTION Although the taper lock method of retaining the blade onto the motor shaft is simple it is essential that the following points be read carefully and fully understood Improper installation can cause a loose flying blade and result in serious injury or death PNEG 950 59 FAN REMOVAL AND INSTALLATION When reassembling parts the cap screws must be installed through the untapped clearance holes as shown This will cause the blade to be pulled forward onto the tapered bushing thus locking the parts securely onto the motor shaft When fan servicing requires removal and installation of the blade make sure the blade is removed and reinstalled properly 1 Lockoutthe fan power supply and remove the fan guard and the venturi as required on some models e Bolts installed through threaded holes of bushing Split Taper Bushing Capscrews installed through threaded holes of bushing 60 PNEG 950 3 Install two of the cap screws into the threaded holes in bushing and turn them by hand until they bottom against the front surface of the blade NOTE The threaded holes wi
34. their stored values by pressing the button Cool Timer This timer controls how long the fan will operate after the dry timer has expired To change the setting of this timer follow these instructions Press the A timer button press the same button to edit the amount of cool time button to adjust the settings Press the Press the button to accept the new setting During dryer operation the remaining time on each timer is displayed on the screen unless reset to their stored values by pressing the PNEG 950 Unload Timer This timer controls how long the unload auger will operate after the cool timer has expired Use the dryer charts on page 77 of this manual for reference of a suggested timer settings To change the setting of this timer follow these instructions Press the timer button pressthe button to edit the amount of cool time Press the button to adjust the settings Press the ENTER button to accept the new setting During dryer operation the remaining time on each timer is displayed on the screen unless reset to their stored values by pressingthe LE Ir pl OPERATING DISPLAY SCREENS Main Display Screen This is the normal operating screen you will be viewing after you press the start button The top line on the screen indicates your system has been started by pressing the green run button is running The next two lines represents the curr
35. to hold and turn on the control power for the dryer You will be able to access certain dryer features that rarely need to be changed and if setup incorrectly could cause your dryer not to operate properly or not at all Pressing will allow you to enter the customer setup screens in the following sequential order Meter Roll Disable Disable Air Switches Meter Roll Reverse Select Select Unload Method Select Dryer Address Attempt to Refill Model Number Temperature Scale Select Fan and Heater Select Set Time amp Date Adjustable Grain High Limit Note To bypass any or all of these screens without changing the current settings just press METER ROLL DISABLE This option allows you to shut off the monitoring of the meter roll sensor located in the rear of the dryer This should be only used in the event of a failure of the sensor itself This sensor is used for calculation of the bushel per hour total bushels and meter roll rpm s To toggle this feature on or off use the buttons then press the ENTER button to accept the changes AIR SWITCH TESTING This option allows you to disable the testing of the air switch This is useful if you are doing a pre season check on your dryer and you want to start the fan and heater with no grain in the columns or you are having air switch problems The computer will ignore the state of the air switch if you change the selection to NO DEGREE To toggle this feature on or off use th
36. your dryer Press ing the MODIFY button allows you to change the plenum set point of the burner being viewed Press E to advance to the next screen burner or to accept any changes you may have made HCREASE 7 S AIN BUTTON The button allows you to view or modify the moisture control grain temperature set point which determines the final moisture content of the grain being discharged from the dryer Press the button to make any changes Press to advance to the next screen or to accept any changes you may have made MODIFY BUTTON When viewing a screen with settings that can be changed button will allow you to edit the values on this screen Otherwise this button will have no function available INCREASE and DECREASE BUTTONS m DECREE are used when you are editing temperature time values or for scrolling up and PPa down the different screen selections ENTER BUTTON Use the button to accept any changes you may have made to timer delay or setup screens It is also used to advance to the next screen 26 PNEG 950 STATS BUTTON Pressing the button will toggle the last line of the main display screen to 3 different views relating to the dryers approximated output rate This screen shows the actual turning speed of the meter rolls in RPM Pressing the button again shows an approximated Bushel per hour that have passed through the dryer using the above RPM readi
37. 2 JB 02 Jb 01 11119 A Hitt J7 18 J7 14 J7 DB i 9 9 0 0 0 0 JUMPER N ES T 0101010 E Ie 0501 g EM JUMPER E m 2 5250105 J7 15 17 04 46 15 J5 03 J6 06 J7 20 J7 18 0000000 inani siie GREEN ELECTRICAL GROUND BLUE N1 NETWORK YELLOW N2 NETWORK WHITE 110VAC NEUTRAL WHITE GRAIN TEMPERATURE SENSORS 2 WIRES BLACK GRAIN TEMPERATURE SENSORS 2 WIRES YELLOW GRAIN HI LIMIT SWITCH 4 YELLOW GRAIN HI LIMIT SWITCH ORANGE GRAIN HI LIMIT SWITCH 1 NEXT FAN CONTROLLER UPPER CONTROL BOX WHITE PLENUM TEMPERATURE SENSOR BLACK PLENUM TEMPERATURE SENSOR GREY PLENUM HI LIMIT SWITCH 12VDC GREY PLENUM HI LIMIT SWITCH 12VDC JUNCTION BOX GRAIN HI LIMIT WHITE SOLENOID NEUTRAL 110VAC NEUTRAL GREY LP LIQUID SOLENOID 110VAC 5 BLACK MAIN SOLENOID 110VAC BROWN CYCLE SOLENOID 110VAC GREEN ELECTRICAL GROUND PLENUM SENSOR BOX YELLOW HOUSING HI LIMIT YELLOW HOUSING HI LIMIT PURPLE VAPOR HI LIMIT PURPLE VAPOR HI LIMIT BLUE AIRSWITCH COMMON DC NEGATIVE TP BLUE AIRSWITCH NORMALLY OPEN SOLENOIDS RED MOTOR OVERLOAD 12VDC RED MOTOR OVERLOAD 12VDC 7 WHITE 110VAC NEUTRAL FOR FAN BOX BLACK STARTER COIL 110VAC 6 BROWN IGNITION TRANFORMER 110VAC WHITE FLAME PROBE GROUND
38. 2 Speed Moisture Removed Dry Time 1 Speed Low High 1 2 pts 18 min 363 187 650 18 3 pts 24 min 27 2 153 550 19 4 pts 3l min 218 145 450 21 5 pts 35 min 187 131 263 21 pts 40 min 163 119 2 2 22 pts 45 min 145 109 210 23 pts 50 min 131 101 107 24 pts 55 min 118 93 163 26 10 pts min 109 57 145 25 11 pts 65 min 101 32 131 27 12 pts Z0 min d3 118 28 13 pts 5 min oF 3 109 21 14 pts 80 min 32 101 30 15 pts 85 min fi 65 d3 21 16 pts 90 min h1 32 17 85 min 57 92 22 18 pts 100 min 55 nf 24 19 pts 105 min 49 3 25 20 pts min 59 45 950 1200 Staged Batch 80 Full Heat Dry amp Cool Fan amp Burner Switches on Manual Fans on Manual Burners on Auto Approx Initial Moisture Approx Dry Time Dry Cool Unload Moisture Removed Dry Dry Cool Unload 16 min 6 min min 17 2 pts 18 min 18 min 18 min 10 min 21 min 17 min 0 min 18 3 pts 24 min 24 min 18 10 min 26 min 16 min min 19 4 pts 30 min min 18 min 10 min 31 5 21 5 min min 20 5 pts 35 min 35 min 18 min 10 min 3 min Z min 10 min 21 pts 40 40 min 18 min 10 min 41 5 min 31 5 min 0 10 min 22 pts 45 min 45 min 18 min 10 min 47 min 37 min min 21 9 pts 50 min 50 min 18 min 10 min 51 min 4 min
39. 4 PNEG 950 Section Technical Reference PNEG 950
40. 5 min 147 122 181 30 15 pts 138 115 170 31 16 pts Bl min 129 109 158 22 17 pts Bb min 122 105 147 22 pts 81 min 115 99 138 24 19 pts 96 min 109 d3 128 35 20 pts 100 min 105 zh 122 PNEG 950 1200S Continuous Dry amp Cool 82 Initial 1 18 19 2 21 22 23 24 25 25 27 21 29 30 31 32 23 24 25 Moisture Moisture Removed Dry 1 Speed 2 pts 3 pts 4 pts 5 pts pts 7 pts pts 4 pts 10 pts 11 pts 12 pts 13 pts 14 pts 15 pts 16 pts 17 pts 18 pts 13 pts ZU pts 18 min 24 rin 30 min 35 min AU 45 min min 55 min BO min BS min min 78 min min B min g0 min 95 min 100 min 105 min 110 min 293 220 176 151 132 117 106 dh Hin H1 75 70 59 55 50 40 2 Speed 2 Speed Low 151 132 117 106 dh H1 5 0 59 56 53 50 48 45 42 3d High 420 370 320 270 220 176 151 132 117 106 88 81 75 70 66 62 59 56 PNEG 950 1200S Staged Batch Full Heat Dry amp Cool Fan amp Burner Switches on Manual Fans on Manual Burners on Auto Approx Initial Moisture Approx Dry Time Dry Cool Unload Moisture Removed Dry Time Dry Cool Unload
41. All All of season Continuous high ambient temperatures dirty ar moist 1 5 to to 28 8 months locations high vibrations or when shaft end gets hot 50 to 150 57 5 to 111 3 3 months The bearings have been lubricated at the factory thus no lubrication should be added before start up 58 PNEG 950 Insulation Class Consistency Grease Frame Type B Medium Palyurea Shell Dolum R 2157 amp Smaller A amp B Medium Polyurea Shell Dolum E 254 amp Larger Medium Polyurea Shell Dalium All Note All of the auger and metering roll bearings are lifetime lubricated and do not require service relubrication 1 Remove and clean the gas line strainers Make certain gas valves are closed and that gas is purged from the system before attempting to disassemble anything 2 Inspect the collector plate at the top of the burner casting andthe burner for any accumulation of foreign material Clean if required Foreign material in the burner cup or casting will not burn out and will impair burner operation If required inspect ignitor plug and clean the electrodes Use an ignition point file to remove carbon and rust between the electrode surfaces Ignitor gap should be about 1 4 3 mm 4 Inspect flame sensors for possible damage or poor connections Flame sensor wires must be in good condi tion 5 Inspect and manually rotate the top auger paddle assembly The paddle unit must rotate freely without any indic
42. E MOISTURE CONTROL IT WILL TAKE SEVERAL HOURS TO WORK ITSELF OUT 17 After the run time in step 14 you are ready to set up the moisture control Now turn the MOISTURE CONTROL to the ON position Set the temperature to about 100 deg 18 Turn the UNLOAD to 2 SPEED Set the METER ROLL SPEED LOW SPEED and HIGH SPEED to the settings listed for them Let the dryer run on these settings before trying to adjust moisture or meter roll settings These settings will not have your grain moisture adjusted exactly where you want it but will be a good place to start initially A little different moisture at the bottom of the storage bin is not usually a problem as long as you have full floor aeration 19 After the run time in step 18 you are ready to adjust the moisture control and the meter roll speeds if required Each time you make an adjustment to the moisture control it will take about the time shown in the drying charts to see the results of this adjustment Dry and Cool Continuous Flow Operation Turn the control power switch to on 2 After the date and time appear on screen press the button 3 Turn the DRYING MODE switch to CONT FLOW 4 Make sure the UNLOAD switch is OFF 5 Make sure the MOISTURE CONTROL switch is OFF 6 Open the main fuel supply valve on the tank if using LP gas or open the fuel supply line if using natural gas Turn on the Maxon electric shut off valve if so equipped or open the manual shut off valve to allow f
43. FAN CONTROL BOX BLACK 110 VAC NEUTRAL TO FAN CONTROL BOX WHITE ETWORK WIRE TO FAN CONTROL YELLOW WIRE TO FAN CONTROL BLUE LELTRICAL GROUND FROM LOWER CONTROL BOX GREEN 10 VAC POWER FROM LOWER CONTROL BOX BLACK 110 VAC NEUTRAL FROM LOWER CONTROL BUX WHITE NETWORK WIRE FROM LOWER CONTROL YELLOW WIRE FROM LOWER CONTROL BLUE 110 VAC POWER TO LIGHT RED 110 VAC NEUTRAL TO LIGHT WHITE 110 VAC POWER MAXON VALVE PURPLE 110 VACNEUTRAL VALVE WHITE 12 VDC TO REAR DISCHARGE WITH FROM J3 11 ORANGE 12 FROM REAR DISCHARGE SWITCH J2 05 ORANGE 12 VDC RED 12 NEGATIVE FROM 03 04 CWHITE BLACK METER ROLL SENSOR RETURN 03 03 YELLOW 12 VDC RED USER SAFETY INPUT J3 01 RED 12 RED LOAD MERCURY SWITCH TO J2 01 YELLOW LOAD N O YELLOW COMMON C YELLOW 12 VDC FROM J3 07 RED AIR SYSTEM FAILURE J2 03 YEL UNLOAD SWITCH VO ORANGE UNLOAD SWITCH COMMON ORANGE ELECTRICAL GROUND GREEN TO TERMINAL J4 02 RED TO TERMINAL 4 01 BLACK SCR 1 TO DN SCR BOARD PURPLE SCR 2 P2 SCR BOARD PURPLE SCR 3 TO ON SCR BOARD PURPLE 110 VAC POWER J8 19 110 VAC NEUTRAL TO 48 20 TO LOWER CONTROL BOX PNEG 950 UPPER BACK PANEL CONTROL WIRING
44. GED PATCH as amp I Da JL 13 FAN Z LANP EN 12 19 MOISTURE CONTROL NIS 5 cn 6 amp 5 65 65 UN E 25 4 11 FAN L LANP ON T li EX JL 08 START LANP EN re 41 07 NOISTURE LAMP ON n Las turst e Le ON 219 Fe Thy Ao ex D as Len Sears E SS QDR ca gt vu les vu 3 m c d a S LL LJ gt C I aus a c a n gt 25 c2 oe ae I N D S M PD 950 87 LOWER CONTROL BOX BACK PANEL WIRING je 1 7 LI FROM 218 AC Neutral See Moxon Yalve Terminal To 1 19 lol LIGHT 2172 01 EE Se NN 88 J8 20 WHITE 9 05 PURPLE HACK OUTSIDE LIBRI NI 02 YELLIN PNEG 950 NETWORK FAN HEATER INTERFACE S E 1000 1
45. Grain Timer e Set Out of Grain will allow you to change your Out of Grain Timer settings e Out of Grain Tmr view the Out of Grain timer e Last Load Time displays the amount of time it took for the fill paddle switch to become activated or the dryer filled Pressing the ENTER button again on the Set Out of Grain allows you to adjust the time it takes for your dryer to run whenthe load paddle switch has not been activated If this timer expires your dryer will shut down giving you a out of grain warning If you have a slow fill auger system you would probably want to set this setting to a high value 22 PNEG 950 Set Out of Grain The Out of Grain timer should be set to the maximum time it takes for your dryer to refill during continious or batch mode drying If the dryer runs out of grain while the load auger switch is in the auto position the out of grain timer auto matically shuts off the dryer after the period of time preset on the timer w Press the button to edit the timer settings Press the button to adjust the timer value Press the ENTER button to accept the changes Out of Grain Timer From this screen you can view the amount of time left on your Out of Grain timer and view the amount of time it took to load your dryer the time before See Out of Grain Timer for more information Last Load Timer This screen shows you how much time the load or fill auger operated
46. H 92 MT hr for 1226 model dryers Note When the control is set to the maximum discharge rate 999 the metering roll speed should be 17 5 RPM for 8 20 cm discharge auger 2 DCelectric motor The direct current DC motor provides the drive for the metering roll and is located on the front left hand side of standard model dryers The output shaft of the motor is connected directly to the gear box assembly The DC motor requires no operational adjustment as it is completely controlled from the control box 3 Speedreducer gear box The direct drive gear box providesthe required speed reduction and transmits power to the metering rolls through a drive chain arrangement The gear box does not require adjustment The drive chain should also be periodically lubricated and retensioned as necessary 4 Unload auger time delay The delay controls the bottom auger system and causes the unload auger and any connected auxiliary unloading conveyors to continue operating for a programmed amount of time even after the metering rolls stop This feature permits the cleanout of grain within the unloading equipment at the end of all discharge cycles 5 Ifa foreign object becomes lodged the metering rolls and jams the system the unloading auger will stay in motion However the metering roll drive will stop and the DC motor should stall out The Network Control System will shut down the dryer after a two minute period To determine if the meteri
47. HI TEMP RED FLAME PROBE TIP WIRE HI TEMP GREEN ELECTRICAL GROUND 5 Pp 9 HOUSING HI LIMIT ADD J7 17 RED ADD J7 06 PINK CANADIAN ONLY i BOX 89 PNEG 950 FAN COMPUTER PINOUTS 3aVds WALEN 3dVds JVAOcT WAOCI dhd 05 3DAJ JIVAOCT did IOS AS LON IN I N TI INI WALAN JV 50 9 OL 10 9 SHNI JU KH 9 ADT 0 0 011097 xa 01 9 ANTT LON WANN LON NA LIWII IH WALTAN 1138 LINT VALAN 1159 HILIMS LIWII IH NIY AS LEN NL E 19 CAS JON O N EW LON S HILIMSAIV WALEN 2011 XOA TOA S 2 DA DESEE INIT ANIS dal WINTIe MIT AMUd 10A eHAUd INANI ep FAIA dil 39 m 0 JMB 10 2 Oy MAOTHA 20 9 10 1 ol T AY ldsIl CAWAUASNVAL JST 91139 IWI 1 81138 SOVU BAD 1809 01039 3ALLESUd NAN WI HILIMAIV WING Id 931 OL 20 ANE dW3l NIVeB 5 38049 H PNEG 950 90 FAN CONTROL BOX lo J SZ 1 SS SSeS __ 2 2 19
48. Network Dryer Operation amp Service Manual Operation amp Service Manual PNEG 950 Date 1 30 2006 a division of THE GSI GROUP Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 PNEG 950 Table of Contents Warranty rp 7 SaIEIV en 9 Safety Alen 10 Emergency 0 etr 10 Safety Alert Decals sense 11 Safety 15 E 17 SWILICH PanelLayOukse eee eee cere 18 Keypad see 20 Dryer Pre Season Checks 29 Inspectthe Metering UE 30 30 Control POWER ae ee een ee 30 RUM BUTOR Meet ee ee 30 Fuel CHECK 30 POAC ostendet deus senec E ssh EcL she 31 Unload One Speed 31 Unload Two Speed Operation cele Neel 31 Meter Roll 31 FAM OWI CIS uei ecce LIPS Ae a PA 32 32 B rner lest 32 Diver
49. Operation FULL HEAT DRYING Full Heat Operation With this type of drying the grain is discharged hot with no cooling Drying capacity is substantially higher with FULL HEAT than the DRY AND COOL process Dryeration Process The full heat process is called DRYERATION Recommended procedure is to temper the hot grain for 4 to 10 hours in a cooling bin or storage bin then cool by an aeration fan at an air flow rate of 1 2 to 1 CFM per bushel of grain in the hot batch being cooled The process of tempering and slow cooling provides higher quality in shelled corn because of less stress cracking of kernels and less breakage during subsequent handling of the grain Final Moisture From 1 to 396 apparant moisture is usually removed in the cooling process so hot shelled corn is removed from the dryer at about 17 moisture if the final desired moisture content is 15 DRYING TEMPERATURES Shelled Corn For shelled corn with an initial moisture content of 25 3095 the recommended maximum drying temperature is 220 240 F 104 116 C for the top fan and 170 190 F 7788 C for the bottom fan For lower initial moisture content lower drying temperatures are recommended Small Grain For drying small grain wheat oats milo 150 F 66 C is suggested Rice Soybeans Drying temperatures are critical in drying rice and soybeans A temperature of 130 F 54 C is recommended to keep grain temperature low Drying Efficiency The general rule
50. Press the button to accept the new setting PNEG 950 21 DELAY BUTTON button will display four different setup screens The screens will display in the following order Load On Delay amount of time before fill auger starts once fill switch has been activated see Out of Grain Timer amount of time fill auger will run until fill switch has been activated Fan Sequencing Delay minimum amount of time between each fan startup Unload Cleanout Delay amount of time unload continues to run once meter rolls have stopped SCREENS BUTTON Pressthe button and the display will then show a menu selection screen This allows you to select between 3 different choices e Out of Grain Time allows you to view or change the Out of Grain Timer or view how long it took for your dryer to fill e View Grain Temps allows you to view your grain temperatures on different modules if so equipped e Meter Roll SP Avg shows you the percentage of time that the speed of the meter rolls system has spent on HI or Low speed DECREASE Press the buttons to move the pointer and allow you to select any of the three choices and then press the ENTER button to jump to the next menu selection Out of Grain Time a Press the button and move the pointer to change your selection or just press the ENTER Thi RE A button on the Out of Grain Time selection gives you an additional 3 choices relating to your Out of
51. ROL PANEL INTERNAL WIRING 41 14 BURNER 2 LA L 12 BIRNER LA 41 10 JI O8 LAM 1 06 LAMP C gt e ele
52. S OR UNAUTHORIZED MODIFICATIONS TO PRODUCTS WHICH IT MANUFACTURED MODIFICATIONS TO PRODUCTS NOT SPECIFICALLY DELINEATED IN THE MANUAL ACCOMPANYING THE EQUIPMENT AT INITIAL SALE WILL NULLIFY THE PRODUCT WARRANTY THAT MIGHT HAVE BEEN OTHERWISE AVAILABLE THE FOREGOING WARRANTY SHALL NOT EXTEND TO PRODUCTS OR PARTS WHICH HAVE BEEN DAMAGED BY NEGLIGENT USE MISUSE ALTERATION OR ACCIDENT THIS WARRANTY EXTENDS SOLELY TO ONLY PRODUCTS MANUFACTURED BY GSI THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED GSI RESERVES THE RIGHT TO MAKE DESIGN OR SPECIFICATION CHANGES AT ANY TIME PRIOR TO INSTALLATION PURCHASER HAS THE RESPONSIBILITY TO COMPLY WITH ALL FEDERAL STATE AND LOCAL CODES WHICH MAY APPLY TO THE LOCATION AND INSTALLATION OF PRODUCTS MANUFACTURED OR SOLD BY GSI PHLEGAL 1832020 v1 139LG01 DOC revised December 2005 Section Safety First DRYER OPERATION Thank you for choosing a GSI product It is designed to give excellent performance and service for many years This manual describes the operation and service for all standard 100 Series single fan grain dryers These models are available for liquid propane or natural gas fuel supply with either single phase 230 volt or three phase 220 or 440 volt electrical power 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
53. TAIN MATERIAL DEFECT DUE TO MATERIALS OR WORKMANSHIP ALL DELIVERY AND SHIPMENT CHARGES TO AND FROM GSI S FACTORY WILL BE PURCHASER S RESPONSIBILITY EXPENSES INCURRED BY OR ON BEHALF OF THE PURCHASER WITHOUT PRIOR WRITTEN AUTHORIZATION FROM AN AUTHORIZED EMPLOYEE OF GSI SHALL BE THE SOLE RESPONSIBILITY OF THE PURCHASER EXCEPT FOR THE LIMITED WARRANTY EXPRESSED ABOVE GSI MAKES NO FURTHER WARRANTY OF ANY KIND EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN CONNECTION WITH 1 PRODUCT MANUFACTURED OR SOLD BY GSI OR II ANY ADVICE INSTRUCTION RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION INSTALLATION LAYOUT SUITABILITY FOR A PARTICULAR PURPOSE OR DESIGN OF SUCH PRODUCTS GSI SHALL NOT BE LIABLE FOR ANY DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION LOSS OF ANTICIPATED PROFITS OR BENEFITS PURCHASER S SOLE AND EXCLUSIVE REMEDY IS AS SET FORTH IN THE LIMITED WARRANTY EXPRESSED ABOVE WHICH SHALL NOT EXCEED THE AMOUNT PAID FOR THE PRODUCT PURCHASED THIS WARRANTY IS NOT TRANSFERABLE AND APPLIES ONLY TO THE ORIGINAL PURCHASER GSI SHALL HAVE NO OBLIGATION OR RESPONSIBILITY FOR ANY REPRESENTATIONS OR WARRANTIES MADE BY OR ON BEHALF OF ANY DEALER AGENT OR DISTRIBUTOR OF GSI GSI ASSUMES NO RESPONSIBILITY FOR CLAIMS RESULTING FROM ERECTION DEFECT
54. ated in the upper control box This can occur if this safety looses 12VDC to terminal 42 12 on the I O board Push the red button on the overload to reset this error This is caused from the motor operating with to much of a work load which in turn uses more current amperage If the problem reoccurs then check the motor to make sure it is not being overworked You may need to call an electrician to measure the motors full load amps FLA Meter Rolls Failed If you have the meter roll speed adjustment turned too low not turning this will cause this error message It also could indicate that you have a defective meter roll sensor the metering roll drive system has failed to turn or broken chain or jammed metering roll is a possibility This can occur if the input is not receiving a 5 volt pulse on terminal 43 03 on the board Out of Grain The dryer has run low on grain and the out of grain timer has timed out shutting the dryer down The unload auger will continue to run so it can clean out the remaining grain before shutting down PNEG 950 Unload Motor Overload The motor overload has tripped on the Unload Motor Overload located in the upper control box This indicates that 12VDC has been lost to terminal 42 08 on the I O board Push the red button on the overload to reset this error This is caused from the motor operating with to much of a work load which in turn uses more current amperage If the problem reoccurs then
55. ated on the fan heater access door service door removed Keep head and hands clear cause serious injury DC 1227 Decal DC 1225 AWARNING Stay clear rotating blade Blade could start automatically Can cause serious injury Disconnect power before servicing DC 1225 Decal DC 1225 is located on the fan heater access door Decal DC 1229 A WARNING Rotating metering roll Decal DC 1229 is located on Equipment can start each of the meter roll access doors automatically Keep hands clear Can cause serious injury Disconnect power before servicing DC 1229 PNEG 950 13 Decal DC 973 DANGER Decal DC 973 is located on the rear plenum access door inside and outside Automatic equipment can start at anytime Do not enter until fuel is shut off and electrical power is locked in off position Failure to do so will result in serious injury or death DC 973 Decal DC 388 ACAUTION Hitch pin must be securely fastened and Decal DC 388 is located on the no less than 3 4 in diameter Failure to follow installation instructions may result property damage hitch tongue HUB TEMPERATURE NO GREATER THAN 150 F TIGHTEN TO 90FT LBS Dryer must be towed empty and with state and provincial 50 regulations AFTER 50 MILES AND EVERY 200 MILES Decal DC 1249 is located on the hitch tongue
56. ation of sticking or binding 6 Inspect the top auger and bottom auger drive lines for proper adjustment and condition Re adjust line tension as required 7 Operate dryer clean out levers and check clean out hatch mechanism for proper operation With hatch open inspect and remove any accumulation of dirt fines and foreign material from the bottom auger trough area Note Do not allow high moisture material to collect within the trough area It may adversely affect metal parts 8 Inspect entire dryer for loose worn or damaged parts Include check of auger flighting metering rolls and other internal parts Check that temperature sensors within air plenum chamber are secured within insulated clamps and do not chafe on other metal parts 9 Make sure all dryer guards and warning decals are securely installed Make certain guards do not interfere with moving parts If guards or warning decals are missing contact your dealer for a free replacement 10 Test fire the dryer several weeks ahead of the drying season Check for possible gas leaks See burner test fire section FAN BLADE REMOVAL AND INSTALLATION When working on or around the fan blade be aware that it may free wheel and could cause serious injury It may be helpful to gently wedge the propeller to prevent this from occuring However do remember to remove the wedge before restarting the fan If at any stage the blade has become damaged it is important that it is repaired and
57. blade 2 Remove cover from fan heater control box and disconnect the motor lead wires from within the box Note Tag or otherwise identify wires for ease of reassembly 3 Remove motor mount bolts If there are shims between the motor and its base note their location so they can be properly installed during reassembly 4 Disconnect the upper end of the motor conduit then carefully pull the wires through the hole in the fan heater housing Remove motor from the fan heater unit with the conduit still attached If motor requires service take it to an authorized service station 5 Toreinstall motor slide onto motor base plate and replace shims if required between motor base and plate Reinstall motor mount bolts and washer but do not fully tighten at this time 6 Reinstall conduit and wires through hole in fan heater housing and carefully connect all electrical wiring 7 Adjust position of motor by temporarily mounting fan blade on motor shaft Rotate fan blade by hand making the necessary adjustments so the tip clearance between blade and housing is uniform If required remove the fan blade and fully tighten all four motor mount bolts Note Make sure to install and tighten the blade in accordance with previous instructions HEATER PARTS REMOVAL AND INSTALLATION Most of the heater parts can be removed by simply identifying any attached wiring and then disconnecting the obvious mounting parts 1 Flame sensor Disconnect the wire
58. ch position If the moisture control temperature is below this set point and the Dry Timer has reached zero the heater will continue to fire until the moisture control set point has been reached During this cycle the moisture control light will flash and a message on the display will read TEMPERATURE HOLD To change the setting of the moisture control temperature follow these instructions 1 Press the temp button 2 Pressthe 23 button 3 Pressthe 4 Pressthe button to accept the changes button to adjust the settings PNEG 950 Plenum Temperature Setpoint The plenum temperature set point will determine the average temperature of air entering the grain columns To change the burner cycling mode please refer to Fan Heater Select topic section of the Initial Setup Parameters chapter To change the setting of the plenum temperature follow these instructions 1 Pressthe temps button 2 Press ENTER to advance to the next plenum screen or to change the set point 3 Press the button to adjust the settings f INGREAZE 4 Press the ENTER button to accept the changes STARTUP Startup Procedure At the beginning of each harvest and before filling the dryer with grain make sure to inspect the dryer for rodent damage proper belt and chain tension and missing or damaged safety shields Test operate the dryer using the pre start check procedures 1 Before attempting to operate t
59. connect Handle to the OFF posistion prior to servicing any of the installed components DRYING MODE SWITCH This is used to select staged batch or continuous flow drying The switch will light only after the Network Control System has been turned on the safety circuit is okay and the pressed LOAD AUGER SWITCH This is used to select the operation of the fill auger In both the auto and manual position the load auger will operate if the dryer is low on grain and will automatically shut off when the dryer is full In the auto position only the dryer will shut down after a preset period of time set on the out of grain timer or if grain flow is interrupted to the dryer The switch will light whenever the load auger is operating button on the control panel has been Note If the load auxiliary controls are being used this switch will also control the operation of the auxil lary equipment FAN SWITCH Each fan is turned on or off with this switch The on position operates the fan continuously during staged batch and continuous flow modes The auto position operates the fan in staged batch during the dry and cool cycle but the fan will not operate during the unload cycle The switch will light up whenever the air pressure switch is sensing air pressure and the dryer is full of grain Note The bottom fan on your dryer is always Fan 1 HEATER SWITCH Each burner is turned on or off with this switch The auto position operates the burner in
60. controller Each fan and heater has there own set of safeties which are listed below You will need to inspect the controller associated with the error Ex ample If you get this error itis telling you the problem is with Housing 1 bottom most fan High Limit 50 Air Switch x Stuck The air switch contacts have closed prior to the fan starting indicating a freewheeling blade or improper setting of the air switch The message will distinguish between which fan caused the shutdown This indicates that 12VDC has been lost to terminal J7 09 on the Fan Heater board Fan x Loss of Airflow This error message is displayed when airflow air pressure has been established but was lost for some reason This could happen if while during the dryers operation the grain has settled or shrinkage in the grain columns causing a loss of air pressure in the plenum chamber Fan x No Airflow Contacts in the air switch have never opened due to the fan not turning or the air switch may need adjust ment The message will distinguish between which fan caused the shutdown Flame Loss x The flame sensor has failed to detect a burner flame which had been established but was lost for some reason and there is a problem with the flame sensing circuitry or the dryer is not getting burner fuel The message will PNEG 950 distinguish between which burner caused the shutdown The reference to the number one 1 is telling you that itis burner numb
61. d I O This error is generated whenever Input Output board upper control panel has lost its communications link with the master lower control panel door and the fan heater boards Check the blue and yellow wires marked N1 01 and N1 02 on a 3 terminal plug to make sure they are plugged in tightly There are 3 LED lights next to this plug one indicates power and the other two indicate data being transmitted These two labeled RXD and TXD should be flashing randomly back and forth indicating network activity Network Failed Mast This error is generated whenever Master Display board lower control panel has lost its communications link with the Input Output board upper control panel door and the fan heater boards Check the blue and yellow wires marked N1 01 and N1 02 on a 3 terminal plug to make sure they are plugged in tightly PNEG 950 Section Service and Maintanance Before starting any repairs or maintenance on your dryer observe the following safety steps 1 Isolate the whole system from the electrical supply by switching off the power isolator and locking it 2 Isolate the dryer from the gas supply by shutting off the main gas valve if necessary lock the valve 3 Keep the keys in your possesion 4 Augers and drives to augers may be under some degree of tension Avoid touching these parts with your hands until you are sure that they are free 5 Do not reconnect the power supply until all work is completed and a
62. d an the fan burner housing has opened indicating an over temperature condition has occurred towards the rear of the faniheater housing This control is 200 F 93 C limit control that must be manually reset The cover an the grain discharge box has opened indicating that grain is backing Up inta the discharge box An aver temperature condition has occurred inside the grain columns This limitis adjustable in your parameter setup which may need ta be increased if a prablem is nat found in the grain columns An aver temperature condition has occurred inside the grain columns This control is a 21078 9970 thermal overheat switch which will reset automatically when it cools The dryer has run low on grain and the aut of grain timer has timed out shutting the dryer down The Unload auger will then clean aut dryer if the Unload switch is on during continuous flaw operation Check the aut of grain timer setting and if necessary adjust Also before restarting inspect load equipment for possible damage or adjustment An over temperature condition has occurred inside the dryer plenum This control is 300 F 149 C limit which automatically resets when it cools The air switch contacts have opened indicating insufficient air pressure for the burner to operate 65 Problem Display shows FAM x AIRF LOY message Display shows AIR SWITCH x STUCK message Fan motor wi
63. d trademarks of the respective owners The publisher and the auther make no claim to these trademarks While every precaution has been taken in the preparation of this document the publisher and the author assume no responsibility for errors or omissions or for damages resulting from the use of information con tained in this document or from the use of programs and source code that may accompany it In no event shall the publisher and the author be liable for any loss of profit or any other commercial damage caused or alleged to have been caused directly or indirectly by this document Printed May 2002 in Assumption Illinois History 1988 Portable Dryer line introduced 15 models produced 1989 71 dryers produced 1990 102 dryers produced 1991 94 dryers produced 1992 116 dryers produced 1993 Computerized controls introduced 220 dryers produced 34 were old style controls 1995 Competitor dryer introduced 1999 Network dryer introduced EMCS controller discontinued PNEG 950 Section Warranty THE GSI GROUP INC WARRANTY THE GSI GROUP INC GSI WARRANTS ALL PRODUCTS WHICH IT MANUFACTURES TO BE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDITIONS FOR A PERIOD OF 12 MONTHS AFTER RETAIL SALE TO THE ORIGINAL END USER THE PURCHASER S SOLE REMEDY AND GSI S ONLY OBLIGATION SHALL BE TO REPAIR OR REPLACE AT GSI S OPTION AND EXPENSE PRODUCTS THAT IN GSI S SOLE JUDGMENT CON
64. dryer operate by using a jumper wire to bypass a defective safety component Problem Possible Cause Check that main power and circuit breakers are turned an Check for tripped breaker Check for blown 5 amp fuses Defective transformer or wiring Check for a defective power Switch Check wiring between fuses and inputiautput board Refer to wiring diagram test locations Control power switch light aff 4 to This indicates control power is present at 1 inputrautput board hut na power is being transferred through the VO board Display nat finished initial setup The monitor will display a copyright message and model number 4 total running time in hours and minutes and then the current date and time Press the reset button to activate the controller Inputrautnut board The inputtoutput board has Control power light is on reset button has been pressed drying made light aff developed a problem that requires its replacement Mo display an LCD screen 1 Check for a defective power Switch 3 Check wiring between fuses and ingputoutput board 3 Check for 120 volts AC between paints 18 20 and J8 18 AC 1 4 The display may have a malfunction requiring its replacement Control power light is an drving mode light is an Inad auger fan heater unload auger 1 Press the dryer power start button will nat operate Refer to the prablem listed far load auger fan 2 heater and unload auger in
65. e buttons then press the ENTER button to accept the changes Note If the dryer s control power is lost this option will toggle back to its factory state of YES METER ROLL REVERSE This feature allows the meter rolls to temporarily reverse themselves for a programmed amount of time to help remove any debris that may have built up around this area This is very useful if you are drying grain with alot of trash This will help prevent the grain from not moving in the grain columns then causing the dryer to shutdown with grain overheat error 70 PNEG 950 To toggle this feature on or off use the buttons then press the ENTER button to accept the changes You will activate 2 additional screens by selecting yes Reverse time This screen changes the amount of time you want he meter rolls to run in the reverse backwards mode 5 minutes is the default setting Press MODIFY to change the reverse time or to jump to the next screen Forward time This screen changes the amount of time you want he meter rolls to run before switching to the reverse mode 5 minutes is the default setting Press to change the reverse time or to jump to the next screen Note This feature is only available on software version 1 03 or higher SELECT UNLOAD METHOD This is a feature that has not been implemented yet into the dryer software leave this setting at 2 speed Chang ing it to 3 speed may cause your dryer unload system to
66. e the two outside wires L1 and L3 and leave the middle one in the same position Note The bottom fan on your dryer is always refered to as Fan 1 BURNER SAFETY To check the burner safety function first make sure the main gas valve is off Turn the fan switch on and allow the fan to start Then turn the heater switch on for that fan The dryer will shut down after 20 seconds The safety message Ignition Failure x will appear Reset the dryer and repeat for the other fan heater s BURNER TEST FIRE Test fire each burner by starting the fan Then turn the burner switch to on Turn on the fuel supply and the burner should ignite after a short purge delay of approximately 10 seconds Gas pressure should be shown on the gauge At this time adjust the plenum set point to 200 F 93 C causing the burner to operate on hi fire Observe the gas pressure on gauge and lower the plenum set point until it causes the burner to cycle into lo fire When the plenum temperature set point is met the gas pressure should show a noticeable drop indicating that the cycling solenoid is closed and the burner is being supplied with less gas through the bypass valve At this time set the hi fire and lo fire pressure settings Use the pressure regulator for hi fire and the cycling solenoid needle valve for lo fire The computer should cycle the burners between high and low approximately 4 to 5 times per minute Only use pressure required to obtain desired te
67. ective points ar a burned out coil Inspect connections and check voltage applied to matar leads in motor junction box ta determine if motor is defective Check that the mercury switch box is in the proper position Check that the bottom auger circuit breaker is an Check that the unload switch is an 1 or speedy Verity closing af botom auger contactor check voltage an load side of contactor Ift using the moisture control check for proper setting PNEG 950 Problem Grain nat moving through columns 1 Uneven dring Some kernels appear brown while others are under dried Uneven heat 1 exiting from dryer columns 2 Display shows METER ROLL DRIVE 1 SYSTEM FAILURE message 2 Burner will nat fire with fan operating 1 Heater switch light and gas solenoids go on and erratically The light blinks an and off 1 while the salenaids chatter Possible Cause Check the dryer for fine material buildup inside the Columns Avoid leaving the dryer columns full tar lang periods at a time 2 3 days while not operating the dryer or during rainy weather Empty the dryer Keep the dryer clean Do not allow fine material ta gather in the plenum chamber It may necessary to open the strike off plates in the affected columns in half inch intervals Check plenum temperature setting Some varieties of grain are mare sensitive to higher operating temperatures It may be necessary to lower the plenum operating te
68. ent wired to the dryer will also stop CONTINUOUS FLOW DRYING MODE Full Heat Continuous Flow Operation 1 Turn the CONTORL POWER switch to on VET 2 Afterthe date and time appear on screen press the button Ws Ei 1 L m 3 Turn the DRYING MODE switch to CONT FLOW 4 Make sure the UNLOAD switch is OFF 5 Make sure the MOISTURE CONTROL switch is OFF 6 Open the main fuel supply valve on the tank if using LP gas or open the fuel supply line if using natural gas Turn on the Maxon electric shut off valve if so equipped or open the manual shut off valve to allow fuel flow to the dryer 7 Push the DRYER POWER START switch 8 The dryer should already be filled with grain Turn the LOAD AUGER switch to the AUTO position In both the auto and manual positions the dryer grain level switch will automatically keep the dryer full of grain In the auto position the dryer will shut down after a preset time period using the out of grain timer 9 Lookin the Drying Charts section in the back of this manual for the FULL HEAT chart settings that corre spond to your model of dryer You will see the settings for Initial Moisture Moisture Removed Approx Dry Time 1 Speed 2 Speed Low 2 Speed High pick the line that has your initial starting moisture These are the settings we will be referring to during this start up procedure 10 Turn each FAN switch to ON The fan will start and the switch will ligh
69. ent plenum temperature and the current grain temperature The bottom line indicates the speed of the meter roll Notice the PLEN1 line has 2 numbers listed The first one is the actual temperature of Plenum 1 and the second one in parenthesis is the plenum set point In this case the actual plenum temperature is 84 F and the set point is 180 F Notice the this indicates that the burner is currently in high fire mode This will switch to an L whenever the burner switches to low fire mode The plenum set point can be adjusted by pressing the button The next line indicates the grain temperature is at 68 F and the grain set point is at 77 F The grain set point can be adjusted by pressing the button During the drying process you may want to view the plenum temperatures of the different burners 5 DECREAEE i y Pressing the buttons will toggle between the available plenum temperatures on your main screen If your dryer shuts down with a Grain Discharge or the Unload Motor Overload the unload auger will continue to run until the Unload Cleanout Delay has expired This allows the unload auger to empty itself and prevent unnecessary load on the unload auger if you were to start it when its full of grain PNEG 950 47 48 PNEG 950 Section Safety Circuit Shutdown Messages FAN AND HEATER GENERATED ERRORS The following is a list of errors that are generated with the fan and heater
70. er 1 which is the bottom most fan Grain Temp Short x This error indicates there is a shorted condition with one of the grain temperature sensors located inside the left or right grain columns This could be a shorted sensor or the sensor wires could be shorted Grain x Overheat An over temperature condition has occurred in one of the grain columns causing the control to shutdown the dryer This control is set at 210 F 99 C and automatically resets itself when cool This can be caused from a grain column plugged with trash or your meter rolls may be adjusted to slow Feel the grain columns to determine which one may be causing the problems If all the columns are hot to the touch then you will probably need to check your meter roll settings If not then examine the column that feels hot make sure you can see the grain moving down the column screens For more information on service see Meter Roll Servic Ing Housing x High Limit The temperature high limit located on the fan burner housing has opened indicating an over temperature condition has occurred towards the rear of the fan heater housing This control is set at 200 F 93 C and must be manually reset The message will distinguish between which fan housing caused the shutdown The reference to the number one 1 is telling you that it is fan number 1 which is the bottom most fan Ignition Failure x This condition happens during the intial ignition of the burner If t
71. fail PNEG 950 71 SELECT DRYER ADDRESS This feature is used for networking several portable grain dryers together for monitoring on a PC with special software Changing this value will have no effect on the operation of the dryer only the monitoring software Watchdog 2000 ATTEMPT TO REFILL Changing this setting to yes allows your dryer to pause its drying process in the event that the Out of Grain Timer has expired Instead of the dryer shutting down with a Out of Grain error message the following sequence of events will happen Load will continue to run Fan will continue to run Burner will stop drying Unload will stop The dryer will continue in this mode until the fill switch paddle switch on the load auger has changed its state to indicate the dryer is full of grain again At this point the dryer will Load will stop running Burner will purge and relight to continue drying Unload will start discharging grain again Out of Grain timer will reset MODEL NUMBER This screen tells the computer in your Network dryer what model of dryer it is Do not change any information in this screen unless you are directed to either by a GSI service technician or engineer Just press the LN button to advance to the number on the line that needs to be changed or you can use the button toback up to the previous number on the line Use the to change the number directly above the cursor Once you are sa
72. he burner fails to light check to make sure that your gas has been turned on and or the maxon valve has been turned on The reference to the number one 1 is telling you that it is burner number 1 which is the bottom most fan PNEG 950 51 32 Illegal Flame x This message is displayed when the flame detection circuit of your heater is sensing flame when the burner is supposed to be off Example if you shut down the dryer and the heater continues to burn due to a solenoid stuck in an open state it will generate this type of error Motor Overload x One of the thermal overloads on either the fan load unload or auxiliary motors has opened indicating an overcurrent condition The overloads must be manually reset The message will distinguish between which fan overload caused the shutdown The reference to the number one 1 is telling you that it is fan number 1 which is the bottom most fan Plenum Temp Open x This error indicates there is a open condition with the plenum temperature sensor located inside the plenum chamber This could be a open sensor or the sensor wires could have a open connection Plenum Temp Short x This error indicates there is a shorted condition with the plenum temperature sensor located inside the plenum chamber This could be a shorted sensor or the sensor wires could be shorted Plenum x Overheat An over temperature condition has occurred inside the dryer plenum This control is 300 F
73. he dryer make sure that all safety shields are in place all plenum bottom closure panel doors are closed all rear access doors are closed and all personnel are clear of the grain dryer and grain handling machinery 2 Turn all selector switches on the control panel to the off position on the electrical power supply to the dryer and move the safety disconnect handle mounted on the dryer s upper power box to on 4 Turn the control power switch to on The switch will light up A copyright message model number total running time in hours and minutes current date and time will appear At this point the controller will lock out all FE x other dryer functions Once the time and date screen appears press the button and the dryer will perform its safety circuit checks If a fault is found the cause will be displayed on the LCD If all safeties do not detect a problem the controller will allow the electronic fuel shutoff valve Maxon to be manually opened if so equipped and the drying mode switch will light up indicating that the dryer is ready to be started 5 Move the load auger switch to manual and push the dryer power start switch The top auger will immedi PNEG 950 4 ately start and the load auger switch will light up If additional loading equipment is wired to the dryer it will also start immediately 6 Whenthe dryer is full of grain the top auger will stop automatically and any auxiliary loading equipm
74. insystems com Copyright O 2006 by The GSI Group Printed in the USA
75. ither single phase 230 volt three phase 220 380 440 or 575 volt electrical power The principal concern of 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 prob lems that may be encountered by operator or other personel As owner and or operator it is your responsibility to know what require ments hazards and precautions exist ant to inform all personnel associ ated with the equipment or who are in the dryer area Avoid any alterations to the equipment Such alterations may produce a very dangerous situa tion where serious injury or death may occur This dryer is designed solely for the purpose of drying agricultural corn grain and seeds Use of this dryer in any ways or under configurations other than those indicated in this manual is a misuse of the machine will invalidate the warranty and may lead to serious injury or death If in any doubt contact GSI or your dealer PNEG 950 5 2 Fan Network Dryer Manual GSI Group Inc All rights reserved No parts of this work may be reproduced in any form or by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems with outthe written permission of the publisher Products that are referred to in this document may be either trademarks and or registere
76. justments press the ENTER button The screen will also return to the main display if you don t turn or press the knob for about 8 seconds PNEG 950 31 Meter Roll 2 Speed Display Set the speed of the metering roll when the two speed automatic moisture control feature of the dryer is utilized If you turn the meter roll adjustment knob and the unload switch is in the two speed position you can adjust your 2 speed settings Notice that the numbers next to Low is flashing This indicates that any adjustment you make with the meter roll know will only affect this setting To change the High setting press the meter roll adjusment knob until it clicks You screen should now flash the numbers next to the High setting Any adjust ment made at this point will only affect this setting If you are finished with your adjustments press the ENTER button The screen will also return to the main display if you don t turn or press the knob for about 8 seconds Note This screen is only available if the moisture control switch is on and the unload switch is in the 2 speed position FAN SWITCHES Momentarily turn each fan switch to on and observe the fan rotation The fan should run counterclockwise Some times on three phase models all motors will run backwards They can easily be reversed by interchanging two of the three power supply wires All power should be switched and locked off before attempting to reverse the connections Revers
77. lenum bottom closure panel Insert the service tool above the metering roll GARIN COLUMN PLEHUM CLOSURE PAWEL METER ROLL ADJUST CAMPER METER ROLL ACCESS DOOR COLUMN CUT OFF DAMPER PNEG 950 63 This column cutoff damper is designed to insert through the grain column from the inside of the dryer imme diately above the metering roll This permits opening of the metering roll access door For service or inspection without unloading the dryer the plenum bottom closure panel and metering roll adjust damper must be re moved prior to using service tool TROUBLE ANALYSIS PROCEDURE A multimeter is required for some of the following checkout procedures Before performing any tests check if the dryer power supply is 1 phase 230 volt or 3 phase 230 380 460 and 575 volt he burner circuit is 120 volts AC on all standard U S production models The control circuit to the motor starters is 120 volts The safety circuit is 12 volts DC When checking these circuits measure voltage between the circuit test location and to ground e DC circuits should be measured between the test location and its respective DC ground Refer to wiring diagrams and the parts list for identification of parts and the electrical terminals CAUTION When making high voltage tests with live circuits be extremely careful Follow established safety practices Turn power on for testing only Do not attempt to make the
78. ll guards are correctly refitted SEASONAL INSPECTION AND SERVICE The dryer is made of weather resistant material and is designed to require a minimum of service However each season we recommend the following items be checked before the unit is used and any damaged or questionable parts replaced These checks will help eliminate possible failures and assure dependable operation of the equip ment 1 Shutoff electrical power Open power box and control box and inspect for moisture rodent damage or accu mulated foreign material Remove any foreign material present Inspect and tighten any loose terminal connec tions Replace any damaged or deteriorated wiring 2 Check each blade for freedom of rotation and uniform tip clearance They should also be inspected for dirt and grain dust especially inside the hub Any additional weight can seriously effect the balance and result in harmful vibrations and a short bearing life 3 Check each blade for free play Any side play is an indication of defective motor bearings which should be replaced to prevent a complete motor failure Make sure motor mount bolts are tight 4 Motor bearings should be lubricated periodically depending on operating conditions Under normal usage it is desirable to have the motor cleaned checked and bearings repacked by an authorized service station every two to three seasons If the unit is operated continuously through most of the year this service should be perfo
79. ll not start Tap auger will nat start Bottom auger will nat start 66 Possible Cause The air switch contacts have opened indicating the fan may be turning arthe air switch may need adjustment The air switch contacts have closed prior to the fan starting indicating a freewheeling blade or Improper setting of air switch Check that the fan circuit breaker and the fan switch are on Also check for defective switch or bad wiring connections If lighted switch does nat light the air switch needs adjustment or the bulb may be burned aut Verify clasing af fan motor contactor Check voltage on load side of contactor See appropriate power wiring far defective points ar a burned aut Inspect connections and check voltage applied to the motor leads in the fan heater box to determine if the motor is defective Check capacitors on single phase motors and replace if defective If matar starts slowly check for low voltage during starting due ta excessive voltage drap in power Check that the tap auger circuit breaker and the load auger switch are turned on Check position of the Upper auger paddle switch It must be down to start auger Inspectfor secure mounting and wiring af mercury Switch in the terminal box an the top auger paddle Switch shaft Include check for a defective mercury Switch Verity closing ofthe tap auger contactor Check voltage load side of contactor Inspect contactor for def
80. ll operation turn the knob clockwise and the metering roll speed should increase Turning either knob counterclockwise will decrease the speed Make sure the drive chain tension is properly adjusted and all sections of the metering rolls rotate Turn the unload switch off after these checks are complete The bottom auger will continue to run for 60 seconds default cleanout delay setting after the switch is turned off to allow for cleanout Note Due to the nature of the DC drive motor used on the meter rolls it is possible for the brushes inside the motor to become corroded if the dryer has not been operated for several months This will cause the meter rolls not to function To fix this problem use a rubber mallet or a piece of wood to tap the DC drive motor The shock is usually all the motor needs to start working again You should not have any more problems with this during the rest of your drying season Meter Roll 1 Speed Display This is used to adjust the speed of the metering roll when the single speed automatic moisture control feature of the dryer is in use This is used to Set the speed of the metering rolls when the one speed automatic moisture control feature of the dryer 15 utilized Set the speed of the metering rolls during continuous flow operation Just turn the meter roll adjustment knob and put the is in the single speed position your display will now show the following If you are finished with your ad
81. me will appear At this point the controller will lock out all other dryer functions Once the date and time appear press the button and the dryer will perform a safety circuit check If a fault is found the cause will be displayed on the LCD If all are found safe the controller will supply power to the electronic fuel shut off valve Maxon if so equipped and the drying mode switch will light up indicat ing that the dryer is ready to be started RUN BUTTON Push the dryer run button and all the selector switches on the control panel will be activated FUEL CHECK If using LP gas make sure the tank has plenty of fuel and that the tank must not have a regulator mounted on the liquid line Slowly open the main fuel supply valve at the tank Then open the electronic shut off valve Maxon valve if so equipped or open the manual shut off valve on the dryer to allow fuel flow to the dryer If using natural gas make sure an adequate supply is available Turn on the valve along the supply line Then open the electronic shut off valve Maxon valve Inspect all gas lines and connections for possible leaks Any gas leaks must be fixed immediately 30 PNEG 950 LOAD AUGER With the grain supply shut off quickly bump the load auger switch to manual and see if the load auger rotates clockwise as viewed from the drive end or counterclockwise if the dryer is a front load model If the wet grain supply auxiliary is wired to the dryer it
82. mperature Approximate settings should be LP Gas Hi Fire 6 15 PSI 41 102 kPa Lo Fire 2 6 PSI 14 41 kPa Natural Gas Hi Fire 6 10 PSI 41 69 kPa Lo Fire 1 3 PSI 7 20 kPa If the burner remains on hi fire and does not cycle increase the regulator setting on the propane models or the supply valve on the natural gas models in order to reach the plenum set point If the burner remains in lo fire and does not cycle slightly decease gas pressure with the cycling solenoid needle valve If the gas pressure is 32 PNEG 950 decreased too much a popping or fluttering sound will be heard Also anytime the high pressure side is adjusted the low pressure side needs to be checked Repeat the test for each fan heater unit DRYER SHUTDOWN To shut down the dryer 1 Close the fuel supply valve at the tank or valve along the fuel line 2 If the burner is operating let the dryer run out of fuel and it will shut down automatically due to loss of flame 3 Close the fuel valve at the dryer and press the dryer power stop button 4 Turn off the control power 5 Turn off the safety disconnect handle on the front of the power box and turn off the main power to the dryer EMERGENCY DRYER SHUTDOWN In case of emergency push the dryer stop button or the emergency stop button This will interupt power to the control panel and the fan burner and all augers will stop immediately PNEG 950 33 34 PNEG 950 Section Dryer Startup and
83. mperature to accommodate this Check for proper burner alignment side to Side Vibration during shipment may have caused misalignment The metering roll drive system has failed to turn within twa minutes A faulty D C matar broken chain ar jammed is a possible cause ofthis message The Meter Roll Sensor located atthe back of the dryer has failed and needs replaced Burner switch must on The blinking light indicates the flame sensor is detecting flame Check for loose wires flame sensor replace or repair wires Sensor Burner will natfire HMa gas pressure with fan operating atleast 15 seconds igas supply 1 or fan heater malfunction Burner will nat fire But gauge shows gas pressura PNEG 950 Check gas supply Also check gas filter and gas line far possible obstruction ar closed valves Refill tank replace or repair parts as required Inspect gas solenoid valves including liquid valve on LP units far defective coils ar improper wiring Replace valve ar coil ifvalve will nat open with proper voltage applied 120 volts Check thatthe ignitar is properly gapped to 118 125mm and that it has a strong spark Inspectihe porcelain and electrodes for damage or cracking Replace or clean if necessary 67 68 Problem Burner maintains desired drying temperature but cycles from hi fire ta off without going to lo fire Burner aperates But will nat cycle f
84. ng onto male threaded end of fittings c Solenoid valves and gas regulators are directional and must be properly installed Do not attempt to connect gas solenoid valve by applying force to the valve core stem as it may ruin the unit d Make sure all electrical wires are properly connected Refer to wiring diagrams Pressure Guage Firing Valve Main Solenoid 3 SA 24 kane Cycle Solenoid Bypass Valve__ Adjustment Relief Valve N i X 1 3 Vapor High Limit Regulator LP pipe train METER ROLL SERVICING This dryer is equipped with SCR metering roll drive assembly The metering rolls are driven by a separate DC type electric motor The speed of the motor is variable and is controlled by an electric SCR control within the main control box MAIN CONTROLS 1 SCR speed control The metering roll speed pots on the front of the control box regulate the speed of the DC motor which drives the metering rolls 62 PNEG 950 The scale of adjustment is from 0 to 999 which represents the flow of grain past the metering rolls as a percent of the maximum grain discharge rate for the dryer The maximum setting of 999 provides a maximum 100 discharge of 1960 BPH 50 MT hr for 1214 2240 BPH 57 MT hr for 1216 2520 BPH 64 MT hr for 1218 2800 BPH 71 MT hr for 1220 3080 BPH 78 MT hr for 1222 3640 BP
85. ng problem is from blockage perform the following test with the power off Remove the drive chain by loosening the motor mounting bolts Refer to photo and place a pipe wrench on the hub of the roller chain sprocket on the left hand metering roll at the drive end of the dryer Apply up to 100 ft lbs 136 N m of force and attempt to rotate the roll toward the inside of the dryer If the metering roll will turn then repeat for right hand side If the metering roll will turn it can be assumed that no blockage exists and the problem is from some other cause Check for a break in the power train chain drive key pin etc CAUTION Keep hands away from sprocket teeth to avoid injury from chain backlash as a result of torsion build up in the system caused by the jam HOW TO CLEAR A JAMMED METERING ROLL Place a pipe wrench on the hub of the sprocket of the jammed metering roll and turn the roll First backward and then forward several times in an attempt to dislodge the object and clear it through the roll If this is not successful have an assistant turn the metering roll and attempt to locate the jam by sound Shut down the fan heater and eliminate any other noise when making this check Once the location is determined the roll can be reached from the outside by opening the access door to remove the foreign object causing the jam before opening doors see below The service tool must be inserted before opening doors First swing open the p
86. ngs as a reference This can vary depending on the cleanliness and test weight of the grain and or the position of the slide gates located directly above the turning metering rolls Pressing the button again shows an approximated Total Bushels that have passed through the dryer pm using the above RPM readings as a reference PNEG 950 27 28 PNEG 950 Section Dryer Pre Season Checks This section gives a series of checks to be carried out on the dryer before starting for the first time in the drying season If any of the checks fail to produce the stated result you should consult your dealer YOU SHOULD NOT ATTEMPT TO USE THE DRYER UNLESS ALL THE PRE START CHECKS HAVE BEEN SUCCESSFULLY COMPLETED BEFORE ATTEMPTING TO OPERATE THE DRYER MAKE SURE ALL SAFETY SHIELDS ARE IN PLACE ALL BOTTOM CLEANOUT AND REAR ACCESS DOORS ARE CLOSED AND ALL PERSONNEL ARE CLEAR OF THE DRYER INSPECT THE METERING ROLLS Open all metering roll access doors and inspect each compartment for any bolts nuts or other foreign material that may cause possible jamming of the metering rolls ELECTRICAL POWER Turn on the electrical power supply to the dryer set all circuit breakers to on including the safety disconnect handle mounted on front of the dryer power panel CONTROL POWER SWITCH Turn the control power switch to on The switch will light up A copyright message model number total running time in hours and minutes current date and ti
87. on the dryer while it is on or when the electrical supply is on as the fans augers and burners may start automatically 11 Keep the air inlet to the fan clear of any obstructions and free from combustible materials 12 Before attempting to remove and re install any blade make certain to read the recommended procedure listed within the servicing section of the manual 13 Be certain that capacities of auxiliary conveyers are matched to dryer auger capacities 14 Clean grain is easier to dry Fine material increases resistance to airflow and requires removal of extra moisture 15 Never enter the dryer plenum chamber unless a The electrical power is locked off and the key is in your possession b The gas is shut off from the gas supply The dryer has stopped operating and is cool 16 Dust and noise are inherent hazards with this type of machine which can be harmful to your health To reduce risks a Avoid working around the dryer b When around the dryer wear suitable ear defenders and a dust mask suited to protection against grain dust 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 reason able
88. rate continuously f the drying mode switch is turned to staged batch the unload switch should be set to the 1 speed position The discharge auger and metering rolls will only operate during the unload cycle of the staged batch operation and the speed of the metering rolls is adjusted using the high speed metering roll potentiometer Note If the unload auxiliary controls are being used this switch will also control the operation of the auxiliary equipment PNEG 950 19 MOISTURE CONTROL SWITCH This switch activates the moisture control circuit It lights up when the grain column temperature is below the moisture control grain temperature set point OUTSIDE LIGHT SWITCH The dryers outside service light is turned on or off here It also may be set on auto which turns the light on while the dryer is running and off if a shutdown occurs RUN SWITCH This switch starts and operates the dryer based on switch settings If other switch settings are in the off position individual dryer components can be operated by turning the drying mode switch to continuous flow pressing the dryer power run button and then turning on the desired dryer component STOP SWITCH This switch stops all dryer functions If an automatic dryer shutdown occurs first determine and correct the cause of the shutdown Then press the dryer power stop button to reset the dryer before restarting KEYPAD LAYOUT All of the timer settings delays and operational dryer
89. rmed each year Note If on site bearing relubrication is to be performed see lubrication instructions for ball bearing motors To keep motor bearings properly lubricated and dispel any accumulation of moisture within the windings the fan and auger motors should be operated for 15 to 30 minutes each month LUBRICATION PROCEDURE If the motors are equipped with an alemite fitting clean the tip of the fitting and grease with a grease gun Use 1 or 2 full strokes on motors in NEMA 215 frame and smaller Use 2 to 3 strokes on NEMA 254 through NEMA 365 frame Use 3 to 4 strokes on NEMA 404 frames and larger On motors having drain plugs remove drain plug and operate motor for 20 minutes before replacing drain plug On motors equipped with slotted head grease screw remove screw and apply grease tube to hole Insert 5 to 8 cm length of grease string into each hole on motors in NEMA frame and smaller Insert 8 to 13 cm length on larger motors On motors having grease drain plugs remove plug and operate motor for 20 minutes before replacing drain plug SUGGESTED LUBRICANT s AND SCHEDULES Suggested Hours of Service per Year HP Range kW Range Lube Interval 5000 178 to r 172 to 5 6 5 years 10 to 40 7 5 to 28 8 years 50 to 150 37 3to 111 8 1 year Continuous Mormal Applications 1 8 107 1 2 to 5 6 1 year 10 to 40 7 5 ta 28 8 3 years 50 toa 150 37 3 10 111 3 4 months 1 year beginning Seasonal Service motor is idle for months or more
90. rn the bottom heater OFF cool this section for about 20 minutes Set the upper plenum thermostats to the decreed temperature 190 230 F 14 Turn the UNLOAD to 1 SPEED and set the METER ROLL SPEED HIGH SPEED to the setting for 1 SPEED operation Run time for this is about 10 longer than the APPROX DRYING TIME required for the moisture you are trying to dry This allows the moisture in the dryer to reach an even gradient top to bottom without having any highs or lows in it It will however over dry some of the corn a little 15 DO NOT TRY TO ADJUST THE DRYER FOR MOISTURE DURING THIS PROCESS OR YOU WILL ESTABLISH HIGH AND LOW SWINGS IN THE MOISTURE CONTROL IT WILL TAKE SEVERAL HOURS TO WORK ITSELF OUT 16 After the run time in step 14 you are ready to set up the moisture control Now turn the MOISTURE CONTROL to the ON position Set the temperature to about 130 deg 17 Turn the UNLOAD to 2 SPEED Set the METERING ROLL SPEED LOW SPEED and HIGH SPEED to the settings listed for them Let the dryer run on these settings before trying to adjust moisture or meter roll settings These settings will not have your grain moisture adjusted to exactly where you want it but it will be a good starting place to adjust from A little different moisture at the bottom of the storage bin is not usually a problem as long as you have full floor aeration 18 After the run time in step 17 you are ready to adjust the moisture control and the meter roll
91. rom hi fire ta la fire Burner aperates But will nat cycle from la fire ta hi fire Possible Cause The burner has been setup ta work as a ON OFF burner Change the burner setup ta HI LO type of hurner Check the gas pressure reading on the gauge Problem may be due to insufficient gas regulator setting Temporarily decrease the plenum temperature set point and cause the burner to cycle If Burner will cycle atthe reduced plenum set point setting itindicates thatthe problem was due to insufficient heatto satisty the original setting Increase the gas regulator setting for additional heat output Do not exceed the maximum pressure listed in this manual Check for an excessive lo fire qas pressure setting Observe pressure setting shown an gauge and compare reading with recommended law pressure settings listed in this manual Readjustlo tire setting an flow control valve if necessary Temporarily increase the plenum temperature set point setting Ifthe heater will still nat cycle check for problem in the control wire connections Check for improperly connected or faulty hi fire qas vapor solenoid valve Correct any poor connections or defective wiring Ifwiring appears proper problem may caused burned out valve coil defective valve Replace hi fire solenoid valve ar its coil if defective PNEG 950 Section Special Setup Screens By pressing and holding the button while the power is off Continue
92. 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 ALERT SYMBOL The symbol shown is used to call your attention to instructions con WARNING BE ALERT cerning your personal safety Watch Personnel operating or working around for this symbol it points out impor electric fans should read this manual tant safety precautions It means AT TENTION WARNING CAU TION and DANGER Read the message and be cautious to the This manual must be delivered with the equipment to its owner Failure to read this manual and its safety instructions is misuse of the equipment possibility of personal injury or death EMERGENCY STOP Decal DC 1317 Stop DC 1317 The emergency stop switch is located on the lower control box on the upper right hand side and is labeled with decal DC 1317 Pushing the emergency stop switch will interrupt the control power and stop all dryer functions WARNING Pushing the emergency A stop switch does not interrupt the main power to the upper control box panel
93. t up when air pressure is detected 11 Start each burner by turning the HEATER switch to ON After purging for approximately 10 seconds the burner will fire and the heater switch will light up This indicates that the flame sensing circuit is sensing burner flame For information concerning burner adjustment see the Dryer pre start checks section of this manual 42 PNEG 950 12 Run the fan s and heater s for about 10 longer than the APPROX DRYING TIME required for the moisture you are trying to dry 13 Example 1096 removal would be about 54 minutes 1596 removal would be about 76 minutes and 2096 removal would be about 100 minutes Add 10 minutes to insure that the grain is dry 14 After the time in step 12 turn the UNLOAD to 1 SPEED and set the METER ROLL SPEED HIGH SPEED to the setting for 1 SPEED operation Grain should begin to run at this time Run time for this is about 1096 longer than the APPROX DRYING TIME required for the moisture you are trying to dry This allows the moisture in the dryer to reach an even gradient top to bottom without having any highs or lows in it It will however over dry some of the corn a little 15 Increase the drying temperature to 190 deg for single fans or for multiple fan dryers set the heat cham bers 30 to 60 degrees apart Hottest at the top most cool at the bottom 16 DO NOT TRY TO ADJUST THE DRYER FOR MOISTURE DURING THIS PROCESS OR YOU WILL ESTABLISH HIGH AND LOW SWINGS IN TH
94. the following sections Display shows 12 vOLT POWER SUPPLY The fuse located on the inputiautput board ofthe WARMING message Network Control System has blown The thermal overload on the fan motor load motor Display shows MOTOR OVERLOAD x Unload motor or an auxiliary motor has opened message indicating an overloaded motor The overloads must be manually reset 64 PNEG 950 Problem Display shows VAPOR x HIGH LIMIT Inessamgae Display shows IGNITIGM FAILURE x Display shows HOUSING x HIGH LIMIT message Display shows GRAIN DISCHARGE WARNING message Display shows ADJ GRAIN x message Display shows GRAIN x OVERHEAT message Display shows QUT OF GRAIN message Display shows QUT OF GRAIN UNLOAD CLEAMNGOGLIT message Display shows PLENUM x HIGH TEMPERATURE message Display shows BURNER x LOSS OF AIRFLOW message PNEG 950 Possible Cause The LP gas vapor temperature sensor located in the gas train downstream from the vaporizor has opened indicating that the vaporizer is running too hat and must readjusted This cantral is a 2007 33 C3 limit which automatically resets when it cools The flame sensor has failed ta detect a burner flame indicating that the burner has failed to light there is a problem with the flame sensing circuitry dryer is nat getting burner fuel The temperature high limit lacate
95. thin the bushing are provided for disas sembly purposes only Do not attempt to use these holes for reassembly They will not allow the parts to lock onto the shaft thereby causing a hazardous operating condition 4 Block blade to prevent it from turning and gradually turn the cap screws up to 1 4 turn at a time until the blade breaks loose from the bushing and motor shaft Carefully remove bushing and blade With the blade free from the bushing a wheel can be used to pull the bushing off of the motor shaft Re attach bushing onto blade to prevent the loss of parts Note During manufacturing the blade and bushing are balanced together and are marked with two small dots to identify their original alignment position Check the bushing and propeller to make sure they have alignment marks Mark the alignment of the propeller and bushing if necessary FAN MOTOR REMOVAL In the event of motor failure remove the motor as described and take it to the nearest service station An autho rized service station is the only place that can provide possible motor warranty Motor service and repair at other places will be at owners expense If the service station determines motor failure is caused by faulty material or workmanship within the warranty period repair will be covered under the warranty Motor failure caused by external sources will result in a charge to the owner for repair 1 Makecertain power is shut off and locked out Remove fan guard and
96. tisfied with your 2 PNEG 950 changes press the button to accept them Note If the wrong selection is made your dryer will look for other safeties that will not be present causing the dryer to be inoperable TEMPERATURE SCALE This screen is used to toggle the temperature scale from Celsius to Fahrenheit To change the scale EY press the FAN HEATER SELECT This screen allows you to change the burner characteristics from a Hi Lo type of burner to a On Off type burner The On Off burner mode can be useful when drying on very warm days which may cause the dryer to never cycle from the Lo cycle Pressing the button will allow you to change the configuration of individual burners from On Off to Hi Lo type burners To change the burner mode press button to accept the changes buttons to toggle the burner setting then press the PNEG 950 73 On this screen you can disable a fan and heater out of the Network loop This would be used if you have a fan heater computer that is malfunctioning and rather than preventing you from using the dryer at all you can just ignore it So you can continue to use your dryer until you can have the dryer serviced To change the fan heater to gt an inactive state press the ENTER button to accept your changes IMPORTANT NOTE It is possible to change all your fan and heaters to an inactive state which would cause your dryer to be unable to dry grain
97. uel flow to the dryer 7 Push the DRYER POWER START switch 8 The dryer should already be filled with grain Turn the LOAD AUGER switch to the AUTO position In both the auto and manual positions the dryer grain level switch will automatically keep the dryer full of grain In the auto position the dryer will shut down after a preset time period on the out of grain timer PNEG 950 43 9 Lookin the Drying Charts section in the back of this manual for the DRY AND COOL chart settings that correspond to your model of dryer You will see the settings for Initial Moisture Moisture Removed Approx Dry Time 1 Speed 2 Speed Low 2 Speed High pick the line that has your initial starting moisture These are the settings we will be referring to during this start up procedure 10 Run the bottom fan s and heater s to be used for cooling later for about 20 minutes This will start the bottom drying so we can cool it before we begin to discharge grain 11 Take the remaining number of burners to be started divide that into the total drying time required working up start each burner that many minutes apart Run them about 10 longer than the APPROX DRYING TIME total required for the moisture you are trying to dry 12 Example 10 removal would be about 60 minutes 15 removal would be about 85 minutes and 20 removal would be about 110 minutes Add 10 minutes to insure that the grain is dry 13 After the required drying time tu
98. until being deactivated by the fill auger mercury switch This information can be useful for determining the amount of time you need to place into your setting See Out of Grain Timer for more information PNEG 950 23 View Grain Temps Press the button and move the pointer to change your selection to View Grain Temps Then press the ENTER button to accept the selection Grain Temperatures This allows you to look at detailed temperature information on each fan and heater that is installed on DEGREE your dryer Press the button to toggle between the fan heaters or press the ENTER to exit out of this screen button and move the pointer to change your selection to Meter Roll SP Avg Then press the ENTER button to accept the selection Meter Roll Speed Ave Selection Press the ENTER button to accept the View MR Speed Ave selection 24 PNEG 950 View MR Speed Average On this screen is information showing you how much time the metering roll system has spent on HI speed and LOW speed The ideal values of course is at 5096 each although in real world situations this is very difficult to obtain Having a 3096 7096 reading is not uncommon but anything over this may indicate that meter roll speed settings may need adjusting This can vary throughout the day due to a number of condi tions including drying wetter grain or ambient temperature changes of 1080 more button or you can exit out of this function
99. until the preset temperature for the moisture control is reached Continuous Batch Operation If you are going to operate your dryer in continuous flow drying mode then you can skip this section and jump to Special Setup Screens These switches are used to set the cycle times in the staged batch drying mode only The drying mode switch must be in the staged batch position The current setting on these three timers is displayed directly above each timer button PNEG 950 45 46 During operation the remaining time on each timer is displayed on the screen If the power goes out or if the dryer is stopped these times are saved by the controller When the dryer is restarted the timers will continue timing down The timers will return to their initial setting if the reset button is pushed Use the dryer charts in the back of this manual for reference of a suggested timer settings Dry Timer This timer controls how long the burner will operate If the moisture control switch is turned on and the dry time reaches zero then the burner will continue to burn as long as the grain temperature has not reached the moisture control set point To change the setting of this timer follow these instructions Press the A timer button press the MODIFY button to edit the amount of dry time Pressthe Press the ENTER button to accept the new setting During dryer operation the remaining time on each timer is displayed on the screen unless reset to

PNEG-950 - Network Dryer Operation and Service Manual - Dan-Corn

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