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GSI Outdoors PNEG-630 Clothes Dryer User Manual

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5. 5 o LI e elere S ssa 2 e o 5 kama S 6 Bu Rr 5 12 TO LOWER CONTROL BIX sS Sop Bou Bes 825 eee GO uj do PON 5 E e y 1000 IM ma fcc S p FI ECCO lt ele om Ole LER 5 E HORTS X Ob o 2 E OE C gt ei Oca m 55 i 2007 B e giles KAJ L JO oue pio L O Ol Feb Polo cuore tp gel Ore NEN Go m ES miis 8 m A ep h cq je s wami e o 25 e Ae 5 m x ET J G oreto o o E L C D 7 E T E re a To p o lol 9 LG o 9 E 3 I 2 So e TO 19 9 AD CONNECTION T Ae o AO CONECTION Le L o RED J i e e AD CONNECTION 1 fo 19 e RED J see o AO CONECTION o o RED J7 05 8 se e o MOTOR OVERLOAD 49 lol 9 RED
6. 2 a WISS 30 0 3 1 DI 2 e WE SI XN 330 r MIO He e IIN X I TH 0 2 5 o Tel Oo 338 02 e e UN Wa e AIS Ji e F INLLIH NMA AN D Hio e s als ova n jl xig WOE 40 NN T O VIH dl BC NY NITB 2 2 SHN Reference iring Portable Dryer Troubleshooting Fan 28 LP Hi Low On Off Burner With Mercoi
7. CL C C C 00000 N OG I O lt 00 UJ UJ 2705245522 8 A WIRES 2 PURPLE 2 YELLOW 3 FEET LONG SiS 9166 sS FROM OUTSIDE O OF BOX ssp I 339 AAA SSSSSSSSSS SG O BLACK WHITE BROWN M PURPLE VMV YELLOW NNN Il N WIRES 1 BROWN z 2 f 2 f 1 WHITE 1 BLACK PART HH 1093 IGNITION TRANSFORMER TYPE 312 24M402V 0977 1 FEET LONG PRIV SECV HZ PRIA SECA FROM OUTSIDE 10 10000 60 224 OF BOX SECONDARY MIDPOINT GROUNDED WIRES Webster 1 WHITE 1 BLACK M m CES 12 FEET LONG FROM OUTSIDE S242LP PRT OF BOX 117 Competitor Wiring Reference Portable Dryer Troubleshooting Series 100 Natural Gas 36 42 Fan
8. Tom Ex i Li ecd gt C gt oos A 131 Hll li FQ 17 Oe L1 2 a 2 Ji emo 2 E 35508 eS oulo YES 5 NE s ss sssi tte eme m J Dt wene 39 505 Gen Bil ES O JUMPER Wiring Reference Fan 42 Hi Low On Off Burner With Mercoi Portable Dryer Troubleshooting 51 XU8 30 3015110 NOB NOT 1333 cl 9661 N38 8230 038 Y nose 099 Z y sa
9. o c gt HOLOW HOO YOLOW HOLON YOLON OL avol oL qvo1Xnv OL OL OL lt 01 6 8 1 9 S v z n 20 9 S 1000 660 092 921 9101 ERAN ED N E o 6600 6008 2111 8011 SANA 4019634 04109 HOS HOISISSY 0408 HS gt g U U amp 8 Liy z 2 o 9 EN 3 H3WHO4ASNVHL 2 e u a Sozo 1NdLNO OWA OL 5 85 EG o o i 8 209 9 m gin mn n 1 OWA 022 x E o o E T avol avown avo T 2 031 n aG O 3 O8 E 03 B E 21 amp 8 O Ol HOLOVINOO HOLOVINOO HOLOVINOO a O ol H NVd dyol QVOTNQ gt HOLOV NOO p g b uos ost 046 un s p u3xvaua NV avol Qvomn D gt LII ITT eo gt trr Q Q N o N E i x S3Snd Adez 32018 o Q LNdNI S Competitor Wiring Reference 220 Vol
10. 5 04 Uy zu gt Jeget 25 5 l C ooooo 4 LA T cC E faa Ll c e p lt 5 LL Ga TH E EX t C lt Nae a gt gt lt ton are L J LE i Co a Cl LL pas Qe bsp C cc E c az LI Ll ENI lt CaA N CX LI EV N G CC gt lt i E EI iF ae fere x o tol ca ey eee ie Eo cl I C7 x ool o a fel pe BOCAS Bj Ojoca eoo pese do C22 5 re ele gt lt u o tol e L LI En ER L I u o 1 5 LO i ca r E E t GA 9 ier d loot AZ iP ojo Coffe co 1 5 hy OSTEO Tae go os L ES E olo 1 Ie9 o lys e 0 0 o s as Competitor Wiring Reference Portable Dryer Troubleshooting COMPETITOR POWER CIRCUIT 220 VOLT 1PH 2 GND DIST 102 BLOCK r 103 la FAN MOT
11. 31IHM e ND 3lHM uoc VE OME S di WW xov18 D QE c I 9o NMOU8 N GASNAS SI 905539 3LIHM N3HM 538070 HOLIMS OIN exo SS Woo mous WS O N HOLIMS 3ufisSadud d A133VS dIODYIN Jy Jy U Ar ya 4 A134VS GIOOSN 940 INdNI 235 02 8940 940 A134YS 938 02 MOTA GIG THA uL TA SLIOA ZL ONISNOH 5B qau aad SNISNOH a s Sia Fee und und LIN HOdVA MOHg NMOUB H 50049105 5 6 mee s 7 N dion MU 1 ya uaNuna 17 OV SLIOA 011 01 8 HAL Ho IA 1500 000 1 4 SLIOA 21 2 1 HAL LHOIM 1V1SONH3HI TI3WA3NOH JUHM IWHLNAN v29b 4H LHVd TWMNA4 9 OV SLIOA OLL i3 1InOHIO OL 34 O 15 ao Ov SLIOA OL wove ovun araa D HOLIMS QIOOE3A LEQ HOSN3S HOLINSI NMOUS A389 SH3Aud NVA Z 81 7 HOH 0c vf STVNINYAL GIOOU3N Reference iring Portable Dryer Troubleshooting Conversion Diagram For C Series Dryers To A Switchable Hi Low Burner Or Burner LOdE 30 01
12. B WIRES 2 YELLOW C 3 FEET LONG s ere o Qe O ae S E 5 sisle Seloso 6 BLACK WHITE BROWN YELLOW M DU JUN N WIRES 1 BROWN 2 f 2 1 WHITE 1 BLACK PART HH 1093 IGNITION TRANSFORMER 1 FEET LONG TYPE 612 6A7 CODE J94E FROM OUTSIDE PRIV SECV HZ PRIA SECA OF BOX 120 10 000 60 22 023 MIDPOINT GROUNDED Webster N A ATN Y S242NG PRT 118 Portable Dryer Troubleshooting Warranty THE GSI GROUP INC GSI WARRANTS ALL PRODUCTS MANUFACTURED BY GSI FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDI TIONS FOR A PERIOD OF TWENTY FOUR MONTHS AFTER RETAIL SALE TO THE ORIGINAL END USER OF SUCH PRODUCTS GSI S ONLY OBLIGATION IS AND PURCHASER S SOLE REMEDY SHALL BE FOR GSI TO REPAIR OR REPLACE AT GSI S OPTION AND EXPENSE PRODUCTS THAT IN GSI S SOLE JUDGMENT CONTAIN A 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 ABOVE STATED EXPRESS LIMITED WARRAN
13. 8 8 10 8 12 8 16 8 18 820 J9 16 SIS SIS SIS 49 17 HI HI PCI NI IPI 35 D01 0531 ENTRELEC TERMINALS 2 D01 0533 END STOPS 1 001 0532 BLANK PROTECTOR END 0v01 INN 0 LEAs J93 EMI FILTER D03 0181 BLACK 120 VAC OUTSIDE LIGHT BROWN 120 VAC BURNER 1 LIGHT ORANGE TEMPERATURE SENSOR ORANGE TEMPERATURE SENSOR PURPLE CONTROL POT P2 RED 12VDC FAN VAPOR HIGH LIMIT RED 12VDC HOUSING HIGH LIMI RED 12 0 FAN FLAME DETECTIO RED 12 0 FAN PLENUM HIGHT LIMIT BLUE 12VDC FAN AIR SWITCH LOWER FIXED GRAIN LIMIT 12 VDC USER SUPPLIED SAFETY 1 OVERLOADS 12 VDC LOWERADJUSTABLE GRAIN HIGH LIMIT YELLOW 12VDC OUT OF GRAIN SENSOR RED 12VDC REAR DISCHARGE SWITCH RED 12 0 12 VOLT SUPPLY RED 12 0 12 VOLT SUPPLY WHITE 12 VDC NEG 12 VOLT SUPPLY NEGATIVE PURPLE TIMING PULSE LEFT METERING ROLL PULSE PURPLE TIMING PULSE RIGHT METERING ROLL PULSE PURPLE CONTROL POT P1 PURPLE CON
14. 52 TOTAL TERMINALS DESCRIPTION WIRING TERMINAL VOLTAGE COLOR AIR PRESSURE SWITCH 12VDC RED J5 8 EED JUMPER J5 8 12VOLTSDC RED FAN 2 HOUSING HIGH LIMIT OR T YEL J1 8 12VOLTSDC RED VAPOR IM Lus Tui INFAN CONTROL BOK RED PUR J1 6 12VOLTSDC RED FAN 2 FLAME DETECTION OR mm 12VOLTSDC RED FAN 1 HOUSING HIGH LIMIT 2 E YEL J1 7 12VOLTSDC RED 52 FAN VAPORHIGHLIMT 5 RELAY CONTACT LOCATED PUR 1 5 12VOLTSDC RED gt FAN IFLAMEDETECTION C d OR m 12VOLTSDC RED 02 FANS2 PLENUM f VEL 92 PLENUM J1 12 12VOLTSDC RED app RU J1 11 12VOLTSDC RED FIXED GRAIN HIGH LIMIT OR J1 19 12VOLTSDC RED 3REAR DISCHARGE AU a J5 5 12VOLTSDC RED ADJ GRAIN HIGH LIMIT Ep J419 12VOLTSDC RED MOTOR OVERLOADS 4 12 12VOLTSDC RED FAN 2 PRESSURE SWITCH BLU J1 44 12 VOLTSDC BLUE FAN 1 PRESSURE SWITCH BLU J1 13 12VOLTS DC BLUE BURNER 42 POWER BLK 09 18 120VAC BLACK BURNER 2 NEUTRAL WHT J7 6 120 VACNEUT WHITE BURNER 1 POWER BLK J9 16 120VAC BLACK BURNER 1 NEUTRAL WHT J7 4 120 NEUT WHITE BURNER 2 LIGHT BRN B2 120VAC BROWN BURNER 1 LIGHT BRN 120 BROWN POWER PUR 3 120VAC BLACK MAXON NEUTRAL WHT J78 120 VAC NEUT WHITE OUT OF GRAIN SENSOR TTG BLK J5 4 12VOLTSDC YELLOW LEFT METERING ROLL SENSOR
15. HOLIMS E HOLON QvoNn 9 SuOSN3S dil HOIH 1H9lH SHOSN3S dN31 UWT NIVHO 1331 ONNH3HL MOTIH W3Nun HOLON WoT e gt X08 YaddN HOLIMS VOT 1830 339039 303 NOILISOd SIHLNI 38 LSNW SQV31 om 83 SSSHL SAOWSY P OJ LO 3409 X08 HONOYHL SLIX3 O 2 8 MOPS Q yov dn 40 40 LNOUS Portable Dryer Troubleshooting Reference iring Upper Junction Box Drawing Jdid SVO SHOSN3S dial UWT 1331 ONWd3H1 MOTIH u3Nung YOLON QvO Nn xog NOLLONnr 43M0 1 LILES HOLIMS NVA WANS Td SHOSN3S 99 15 1HOI8 3015110 HOMS 07 104109 OL 5 3ud 11XId 305110 OL ge VM lO aH e 3LIHM lol HOLIMS AYNOHSW GOT OL Refere
16. dH 3 UNIS Alco C2 Portable Dryer Troubleshooting 220 Volt Three 3 Phase Power Drawing HO1ON YOLON HO1ON 1 HO1ON L 3 OL avol1ol avo1xnv OL GVOINN OL QVOTINN Xnv OL Shel Eh ch H Ob 6 8 L 9 5 7 Elgit OV H3WHOdSNVud1L VOTH3AO VOTH3AO QvOTH3AO QvO183AO YOTHIN 109110 OWA OFF Ht NV Qvo1 Xnv qvo1 QVO INR xny avo Nn o OO IO OON OOO OWA 022 O
17. 05 15 SuOSN3S 380183931 NV NIVd9 Q3Xl3 144101 NOXVW OL 60 27 31dufd INOXVIN OL 3LIHM 80 31IHM 1081NO9 I d3ddf OL 09 S3uIM TRG 2 81 MOPS ANNO Su3AuQ SY9 1 Portable Dryer Troubleshooting Wiring Reference New Fenwal Board Wiring The B GND terminalis used to ground the burner and to complete the flame current signal circuit This terminal is new for systems that used the older version of the Fenwal board This terminal must be connected to the burner chassis ground not only to ensure the best long term stable flame signal but also to ground the burner for proper sparking The use of a burner ground terminal eliminates the problem of loss of flame sense signal due to a missing or loose neutral or ground green wire at the 120 VAC power source The new board has been designed such that reversing the polarity of the 120 VAC line does not cause a loss of flame signal Thus providing a more reliable flame signal along with a reduction of nuisance lockouts due to its design and the use of the B GND terminal Old version with Remote Flame Sense New version with Remote Sense using existing spark and remote sense electrodes Note that terminal E2 on the old version has been replaced by terminal B GND on the new board IGNITOR BURNER GROUND B GND OWN
18. MOTI YANN H 98 a Jdid SVO b d ZIRU RYE HOLIMS Goes YOLOW Li SYOSNAS dN LHOIY n x H 2195113065100 HOLIMS ANNOYS GOT b xog NOLLONA Yaddn YOLOW 0v01 334934 006 7000 00 HOLIMS O 10 NOILONAP H3MOT1O L RED J1 11 ORANGE J1 19 C 91 A lo 354930 Ole 9000 00 HOLIMS HOIH NIVHS 1331 X08 1 U3dd OL RED J5 05 YELLOW J1 05 BLUE J1 11 ORANGE J4 19 O SOI MOTISA ol zi o 354930 Ole 9000 00 HOLIMS HOIH NiVd9 1 Wiring Reference Portable Dryer Troubleshooting Two Fan Plenum and Grain Limit Switch Wiring 86 S 7 d31VQ Add 86 51 5 NOXVIN WS HOSN3S OWYSHL ONY LIATTIH NIVHO OWHSHL H uaNuna OWH3HL c
19. U BLKK 5 12 TO LOWER CONTROL BOX sj 0105 o 6 eG OL O 4 aon Or olor coro Qo i cp eg gis fe E oT olg icles Pil eej S K je B n 2 5 e oC o BEI o en 2 1 ee os 2 d 5 ES Que d ee ca e oe EO q gt VS co ES moo ges i Se t3 eq OL O r P o L Ww a sP LIT E Ss EE ES To Te e RED J m e 1 0 To e e 21 3 m eje e AD CONNECTION 120 3 T NI CONNECTION o e AD CONNECTION Fo f RED 0 ee e A CONNECTION 120 ol RED 03 Ao o o AD CONECTION 120 J fo o e RED 05 m 7S o MOTOR OVERLOAD 49 s e e RED X ze jet gs s o QO MWUBK Ss BLU 5 see e REY J a o e YE s O e F WVBK ele e IR 5 o 5 2 AK So lol Q W AK ao o e BLK dM so v e s o e e e o lel OQ o s fol Ot lo e lol EE A o ee F 5 e 18 eoe e Li OR 5 Ji 8 F CANADIAN ONLY 2 slo e of L0D CM 25 LILO s 2 08 o fol RED JI 17 US
20. 1nus jou Z 10413 plougjos uedo xonis Aq pesneo 1500 SI 10413 su s eB Yodda ULL Yodda Yodda Yodda Yodda LI Yodda Yodda Yodda Yodda Yodda Yodda Yodda punoi6 oY peuous egoid y ees peuous SI 10sues peuous sped 450 9 eJnje1eduie uinue d y eec unouro uedo Jio 409 10 euo uado s Josuas 1 uinue gd aanb ees peuous si Josues YO 1344260 peuous spee Josues p 3Hn9I4 33S uedo Jio uloq 10 euQ uedo 10sues eunjejeduie Buiuuni s J up yoq 0 MOJ snonumuoo SN 111 Portable Dryer Troubleshooting Competitor Wiring Reference Series 100 Error Conditions 31 40170 3111000 p 380913 NV 341913 33 1009 AON39U3IN3 N H3A80 3HL 1915 HAYN NOA NMOC 031000 N3HM ATIVOI YW 13994 S3HOLINS 3S3H1 CaddlHL SVH LIMS 3XI4 SHL 40 3NO FIN d JHL LYHL S31VOIONI AV 1dSIQ SIHL 1NOd 135 3814341 i M ANIA WOM 1 04 135 1081802 391181011 ABa 0001 ANAL 30443 000 NIU 31100 SIL AQ NI NOLLNE ONY A8N3SSV u08N
21. 9900 JHL HV ONY A I JHL UL 381A Y LJANI HLAS dE 3HL 30 01 NS ad SHE HOLLY ONY 038 JHL OL JIM Y 1900 NY NWI JHL 8 Odd AHL LIANOJ D 01 OS NADAB IONS OS IH OL ee W 1086 HL 30 4 NINOS UL JTM NAC SOUT SHE JHL JL USHIVLLY TILLS M ODE SHE STIHL JTM MUSS SAL AACN NHL GIN NWO ONY 331A Y SNIVINI TWNIWGAL HL 310007 UNDO WANGA TWNIWAAL 17 OL Ne NON L z ov 1091 13 NI 0911701 I c WNINGSL UL WNINGSL L OL UE HOLINS LOdE ND SSII 08009 WANS SHE A0 11 OL NJ FHL HILLY 1096 HE WNIWGSL UL 39 OOV IB Y 13 11 JADY ORV WANS dl 30 01 SSHVLIV HL NI ONIWO TDLINS 109 OL 38TH SIHL HDYLING 1 J 0 WNI J Y j alld HL Cu oL m Portable Dryer Troubleshooting Fan 28 LP Hi Low On Off Reference iring
22. auqa asa entente nette u pa asas 66 220 Volt Single 1 Phase Power Drawing New Version nan 67 220 Volt Three 3 Phase Power Drawing n 68 220 Volt Three 3 Phase Power Drawing New Version enne enne ense nene 69 220 Volt 1 Phase Power Circuit Ladder 70 220 Volt 3 Phase Power Circuit Ladder 71 440 Volt 3 Phase Power Circuit Ladder Diagram a 72 Upper Control Box Internal Wiring puq anna ui u tee m uqa pee Pte ded Ce u 73 Series 2000 Control Box Wiring New Version 7A series 2000 Control Wiring epe Re re oed p e eee 75 Series 2000 Control Box Wiring 380 460 575 3 Phase entente eterne 76 Upper Terminal Strip pet EE RETE yatai G uksa ee A boe iha pk petes TT Upper Terminal Strip Moisture Control 78 Upper Terminal Strip Moisture Control Relay Hook Up a 79 Moisture Manager to Dryer 1 80 Input Output Board amp Terminal 81 Control Circuit CPU Disp
23. NAO 033 8661 49049780 SUE OOO OO wa D TAQ xg SIS ESSI pror Q ov i sni INILVORN JOA 21 Wu A ARR of AJS OTIO BET 5 m e o ALBANS 38 02 MOX s eNA 1390 38 0 tte lel TH 9NISTIH eae mo e 3ALISDd 20 21 I pes S304 INSE am e e LG L 2nna JLH NOTA 0 X op D10243M 330 UD ON 82 00 08 30 301110 WEB NDT 1339 1351 IOSA DL SIXTA 47 Wiring Reference Portable Dryer Troubleshooting Fan 42 LP Hi Low On Off TO R TERMINAL DF THER TO 8 TERMINL OF THERM BLACK WHITE SULENUTD BLACK cet E gt ER UT LOQ ORE g5 A As SEES oO 17 101 Goll zie Sd c Ig n TII AM jun
24. Ht SHIM 3010 8 SHIM YOLOW Ou S SHIM err9 H diNV 06 6011 31 199 0911910 ANY 02 0671 41 1914 9 4 2vAO 6 5109 HOLIMS SNYWSLS SHOLOSNNOO HOLIMS ONY dV TW N33ML38 38IM V9 351 c 01081913 DIHAT0819313 2vOSZ 4165291 1 NHO 61 ONOGZ 4168291 HVWD N LZ 108 Portable Dryer Troubleshooting Operation Hints OPERATION HINTS FOR CONPETITOR DRYERS Present Software version is 2 19 1 BURNER CYCLING Keep Low pressure setting as low as possible without shutting down dryer or popping Approx 1 to 2 Ib Cycle on average 4 times per minute 3 5 times per minute is acceptable 2 ERRORS 01 User switched from continuous flow to batch while dryer was running 02 Grain Temperature Sensor Open One or both leads are off Open Circuit 03 Grain Temperature Sensor Leads are shorted together 04 Plenum Temperature Sensor Open One or both leads are off Open Circuit 05 Plenum Temperature Sensor Leads are shorted together 06 Flame Probe Shorted to ground 07 Illegal Flame Sense Most likely caused by stuck open gas solenoid Error 7 will not shut down fan until loss of flame is detected by control May occur if 1 of the 12 volt DC limits is shorted to AC ground or to the communication port for the air switch or either temperature sensor is shorted to AC ground 08 No safety circuit voltage 09 I O board communic
25. BLACK FROM 5 09 TO LOAD MERCURY SWITCH BLACK TO 5 04 FROM LOAD MERCURY SWITCH TOUPPER JUNCTION BOX WHITE FROM 49 03 TO OUTSIDE LIGHT AC NEUTRAL RED FROM Lt 120VAC TO OUTSIDE LIGHT POWER YELLOW FROM J1 05 TO PLENUM HIGH LIMIT SWITCH WHITE TO S1 FROM GRAIN TEMPERATURE SENSOR BLACK TO 2 FROM GRAIN TEMPERATURE SENSOR TOPLENUM AND RIGHT _ BLUE TO J1 t1 FROM PLENUM HIGH LIMT SWITCH FKED GRAN HIGH LIMIT _ SWITCHES AND TEMPERATURE YELLOW FROM J1 05 TO PLENUM HIGH LIMIT SWITCH pl RED FROM J5 05 TO RIGHT GRAIN HIGH LIMIT SWITCH ORANGE TO 4 19 FROM RIGHT GRAIN HIGH LIMIT SWITCH Portable Dryer Troubleshooting Wiring Reference Fan Housing and Vapor Hi Limit Circuit 5 12 VOT DC NEGATIVE FAN HOUSNG HHJMT 2 12 SOURCE FAN 2 VAPOR HHIMT _ 8 o 0000000000 1 HOUSING HHIMT gt 10 1 VAPOR HAMT 17 INPUI CUIPUT BOARD TERMINAL LOCATIONS JS 0000000000 0000000000 ay 000000000 21 Wiring Reference Portable Dryer Troubleshooting Plenum Hi Temperature Switch 12 DC SOURCE FROM 1 VAPOR SWICH
26. vu di FLAME ROD Part No HF 4624 Flame Safety Board 1 110V BDARD PDWER SUPPLY S ec SOLENOID 110V NEUTRA N 110 NEUTRAL SOLENOID 110 POWER SUPPLY u ALARM LISED Wiring Reference Portable Dryer Troubleshooting Fenwal Board Troubleshooting On Board Diagnostics The LED will flash on for 0 2 seconds then off for 0 2 seconds to indicate an error condition The pause time between error codes will be 2 5 to 3 0 seconds During power up the LED will light for one second and then turn off to indicate normal operation May indicate either that a was detected during pre or post purge or that there is a flame sensing error If a lockout occurs the board will have to be reset by shutting off the power to the board Measure Flame Current To measure flame current disconnect the input voltaqe and attach the leads from a multi meter with a DC microampere scale to FC and FC terminals to the 35 70 flame sense test pins Reconnect the input voltage and initiate a call for heat After spark ing is complete and the flame is established the meter should read 1 0 DC microamperes or higher If meter reads below O on the scale meter leads are reversed Disconnect power and reconnect meter leads for proper polarity Micro Amp Meter Flame Sensing Flame sensing is achieved using the principal of flame rectification Flame rectification relies on current passing from ground through the
27. SIH L OLNI YANWWVYHSDOdd NO AYVMLAOS ALVGddN OL ONIINIANVHOOHd iN 318vo 000z salu3s Portable Dryer Troubleshooting Competitor Wiring Reference Programming Instructions Using Palm Pilot On the Competitor Dryer there is only one board to program This board is calledthe CPU Display board It is mounted to the door of the lower box To access open the door and the pro gramming jack is located on the back of this board To program follow the instructions below 1 Turn the control power on the dryer to the off position 2 Locate the programming jack J2 connector on back of board 3 Unplug the communications cable that is connected to that connector This is the cable that runs from the CPU Display board and IO Board 4 Connect the DB 9 connector from the Palm Pilot to the series 2000 cable 5 On the Palm Pilot select the program for that particular board and tap on it 6 Turn the dryer control power back on 7 The programming process should begin it will erase the present program and start the new program 8 A screen will come up telling you when the transfer of software is complete 9 When the process is complete turn dryer control power off remove the connector from the board and plug the communications cable back on to the CPU Display board 10 Turn on the dryer and the opening screens should indicate the latest version of software Refer to next page for more information on p
28. 1 0 UR 5 P2 re o 1 0 re 6 01 e J5 02 Portable Dryer Troubleshooting Competitor Wiring Reference Upper Terminal Strip With Moisture Control Relay Hook Up ILIO REMOVE INSTALLED JUMPER TO ACTIVATE USER SAFETY FEATURE OL LL GL gL LA LL 606 TAT x B m mue RIGHT 77 Ta AUN DENIM HIGH LIMIT BLUE 12 VOLTS 2 o 2 2 D a o Fe fel pO joj o o o lol N o QO NEUTRAL e o o e o 0 1 Wi 2 Qa W Q o 2 a o I IB GA Fe je o Bi re 91 27 D MI D OAR o jo 2 Ot Lo 1 y Lo y je si 4 T o 2 716 GA WIRES TR TMETER POSITIVE MOISTURE ETER NEGATIVE NG ROL o e 7 CONTROL HUOKUP P TIT BLY ed No ROLL PD Qj PLR P3 C ID MOISTURE CONTROL Qj BLK MOIST POWER 6 11 C FROM MOISTURE CONTRO 27 BRN MCR POWER
29. RED EP m c J7 09 BLU w A c a 37 10 WHT Zu 5 O Q J711 BLU J719 GRY gt a lt gt 7 20 ony n5 gt h J7 12 YEL 9 743 9 hy 714 46 02 m BLK J6 13 WHT M SOL BLK Et EA 4645 WHT J amp 14 5 3 02 w 33 01 OR 342 w M J941 Y 3 14 w ES 1603 BLU 5 7 Wir 2606 43 03 33 4 BLK 318 w J6 09 0 P foe J4 02 SCR2 P lt gt me 4 01 P a x m J648 MM 2 LITE BLK uM J1 16 _ CANADA ONLY MH UNLD COM FORG UNLDNO LOAD COMLYEL sd kel poe 5 LOAD NO 1819191915199 EE 9 Lt o Zo So joue i s om lt i2 52 9g d me 2 2 OR Co p 59 gt 1 Competitor Wiring Reference Portable Dryer Troubleshooting Series 2000 Control Box Wiring New Version
30. JI M a e 55 ae nS ux al lol e oF 25 EL se el e E o ei o so e O e e slo o o Q gt o s o se e o s lol Qo O lo o o Em le a so Jol ed Mir 7 e e F lt CANADIAN OL Ad ol e 11 172 52 e RE JI B s ol RED JI 17 SER SAFETY e TR s el R D a o A e nen uid LEE o il HH 2 p o PJ Qoggg ER wal BLK MDIST POWER 6 11 z 131 o RELAY POWER Oo lol d WHT MOIST NEUTRAL 6 02 8 ET PR Jc ar amp z DA ums 8 A HIG E i 0 LLL DIG s 3 Tri PUR 14 02 PUR SCR2 76 Portable Dryer Troubleshooting Competitor Wiring Reference Series 100 Control Box Wiring 1 END PROTECTOR 001 0532 48 COMPRESSION TERM 001 0531 2 ENDSTOP 001 0533 4 GROUND TERMINAL 001 0534 13 DIN RAIL 003 0013 NO CONNECTION 12VDC CNTR TAP REMOVE SCREW TO ACTIVATE USER SAFETY TERMINAL CONNECT WIRE FROM J7 08 THRU USER SAFETY SWITCH BACK TO USER SAFETY TERM RED J1 17 USER SAFETY 12 VOLTS RED a HOUSING HIGH LIMIT YEL C VAPOR HIGH LIMIT
31. Even though GSI uses ambient compen sated overloads hot weather or positioning the dryer control box in the sunlight may cause a Motor Overload shutdown to occur This can usually be tested by trying to run the dryer with the control box door open a little bit Each of the overloads has an adjustable trip setting that can set up to 115 At 11596 the overload will hold in longer before it trips Always check amperages on the motors to be sure that the problem is not in the motor itself Remember that each motor has a built in service factor This allow the motor to actually run over the rated full load amps The motor manufacturers have allowed GSI on a number of applications to run motors over the full load amp rating this is possible because they are being used in an air over application Portable Dryer Troubleshooting Competitor Series 2000 Portable
32. 23 Gram amp Plenum Hi D amit Circuit 24 Two Fan Plenum and Grain Limit Switch Wiring n ener nennen tenerent enne 25 Rear Discharge amp Emergency Cooling Circuit 26 Rear Discharge Mercury Switch a eR e ee EE Le TO Ee CE DR 27 Adjustable Hi Limit amp Emergency Cooling Circuit 28 Motor Overloads itt cete La i Sata Da QS a Guau regelt do Leer ee y 29 Air Pressure SWICh icri a n ed enn deest ec mie te E ertet peer tiep ete dee o eee aaa 30 Ait Pressure Switch Drawing d aee p d gp uS dee abr ce pe tee a ieee 31 Out of Gram Safety Circuit a aka ananas a be ii atia suse eve avene oue 32 Out of Grain Safety Circuit Dra wine 1 5 i npe ee eee edes eve EL ob oa ben teet eec e a ento eben Doble 33 UpperJunction Box Wiring e t 34 Meter Roll Sensor iaa eed dale eti quidpiam ole ied ers 35 Meter Roll Sensor Wiring suysuna ukana t et RR ete ee ieget aa bande 36 Meter i tree tet e tee et Heer reb pega a dob de t dieta aleve u uq 37 LowerJuncton Box Wills eter det rhe tte ee ee bert et derer t eere dedere eate 38 New Fenwal Board Wiring beoe te teet Iosue ese rove ene petisse tao q te Iri ee eee dee 39 New Fenwal Board Troubleshooting 40 Plame Control Circuit yaa bte e h cet dere ede oe ci 41
33. HE zk x L1 BLACK L eee 17 1 E 2 c c Ji 05 PUR PIRO 5 Jo 5 08 RED mol o Tr EE PNIS II i fe Te ge 20 SEC SAFETY pr s EOC OJ J l WHI BK o e JUMPER Wiring Reference Fan 42 LP Hi Low On Off Burner With Mercoi Portable Dryer Troubleshooting XDB 0 3015110 WOX J SNOT 1333 211 8661 33843230 A ean wie I JUHA SIJIN X08 50 JOISLNO ONT 1334 1 a 038 a JLTHM NADSE gy 6 JLIHM 1 I SIJIN Dd e 5 X08 40 3015110 WOX s DADA ONTT 1333 ANTES 17 i MUTHA Jdid Z pg 08 0 O e 301 1 0 WD DN 1334 piOo2Jew JeUJ d 330 90 dl cy 904 Seanu Wiring Reference Portable Dryer Troubleshooting Fan 42 NG Hi Low On Off TO R TERMINAL OF THERMOSTAT B TERMIN OF THERMOSTAT
34. Place your new sensor upon the capillary then apply tape to secure the sensor Slide the overheat switch and sensors back into the conduit until the bracket for the overheat switch is in the same mounting position as before Replace both mounting screws back into the overheat switch mounting bracket Butt connect together one wire from each of the grain sensors Connect one of the remaining grain sensor wires to the Black 18 ga wire Connect the other remaining grain sensor to the White 18 ga wire Connect one of the grain overheat switch wire to each one of the colored wires Reconnect the other side of the dryer following steps 22 through 24 Double check the wire connections then replace the covers on the boxes How to Bypass the Grain Temperature Sensor The following instructions are for situations where you don t have an extra grain sensor to replace the defective one So now we are going to rewire the sensors so that instead of using 4 sensors to monitor the grain temperature with we are only going to use one The dryer will operate fine with only one sensor with the exception of only being able to monitor one small section of the grain columns 1 2 On the side of the dryer in which sensor is defective leave this sensor and the joining sensor disconnected from the white and black 18 ga wires Be sure to cap these 18 ga wires off On the other side of the dryer take one of the small white grain sensor wires an
35. 1 AIR SWITCH 1 14 BLUE 12VDC FAN 2 AIR SWITCH 1 19 RED 12VDC LOWER FIXED GRAIN LIMI 1 20 RED 12VDC USER SUPPLIED SAFETY 4 12 RED 12VDC MOTOR OVERLOADS 4 19 9 RED 12VDC LOWER ADJUSTABLE GRAIN HIGH LIMIT 54 YELLOW 12VDC OUT OF GRAIN SENSOR 5 5 9 RED 12VDC REAR DISCHARGE SWITCH 5 8 9 RED 12VDC 12VOLT SUPPLY 5 9 9 RED 12VDC 12VOLT SUPPLY 5 12 9 WHITE 12 VDC NEG 12 VOLT SUPPLY NEGATIVE 5 16 PURPLE TIMING PULSE LEFT METERING ROLL PULSE 5 19 PURPLE TIMING PULSE RIGHT METERING ROLL PULSE 6 1 9 PURPLE CONTROL POT P1 6 4 PURPLE CONTROL POT P3 7 3 BLACK 120 VAC MAXON POWER 7 4 WHITE AC NEUTRAL BURNER 1 NEUTRAL 7 6 WHITE AC NEUTRAL BURNER 2 NEUTRAL 7 8 WHITE NEUTRAL NEUTRAL 8 8 YELLOW 120 LOAD POWER 8 9 ORANGE 120 VAC UNLOAD POWER 8 10 ORANGE 120 SCRPOWER 8 12 WHITE NEUTRAL FAN 1 NEUTRAL 8 14 WHITE NEUTRAL FAN 2 NEUTRAL 8 16 9 WHITE AC NEUTRAL UNLOAD NEUTRAL 6 18 9 WHITE AC NEUTRAL LOAD NEUTRAL 8 20 WHITE AC NEUTRAL SCR NEUTRAL 9 16 BLACK 120 VAC BURNER 1 POWER 9 17 BLUE 120 1 POWER 9 18 BLACK 120 BURNER 2 POWER 9 19 9 BLUE 120VAC FAN 2 POWER EMERGENCY COOLING JUMPERS 1 0 BOARD JUMPERS INSTALL J6 13 TO J1 5 INSTALL J1 9 TO J5 6 INSTALL J6 14 TO J1 19 INSTALL J5 2 TO J5 20 INSTALL J6 16 TO J5 5 INSTALL
36. NEUTRAL TO CONTROL o 2 WHT MOIST NEUTRAL 5 02 Z pip A SCR 1 TO Pl DN SCR BOARD PURPLE YY OO UK LNL LLE PR SR SCR 2 TO P2 ON SCR BOARD PURPLE 9 BIOO nm SCR 3 TO P3 DN SCR BOARD PURPLE OYA a e E PURPLE CNG 86 t Z Portable Dryer Troubleshooting Competitor Wiring Reference Moisture Manager to Dryer Wiring Upper Control Box 10 vf 245 0 901113905 e EN l3 UN e 43090739 lavH OL JVA SIT 9 E SZ 7081309 03385 9313 IA AJS AJS 7 09 VU NH R VU INN I EM A mes DITS 3 t JOAcT gt gt DM Competitor Wiring Reference Portable Dryer Troubleshooting Input Output Board amp Terminal Strip MNO0STH0ONNVI VNVO TE gt imi E a ad 2995 311 18 0027 LHM
37. QAYOT o INOLLONAP H3M0101 WHITE 1 BLACK 2 I 10009 SCISNI Y9 02 3UIHM e J e 33 e Y9 004918 lg ld AINGNOD SGISN GALVINSNI N 030907108 TOHINOD H3ddN OL T AINCNOD NIVY9 Y90c 1 J e 1N0dd e dvdd Y90c OWE Fd fo 110009 305 GALVINSNI N 03030105 5338934 0 1V F1VOS 106 NOTE Portable Dryer Troubleshooting Reference iring YOSNAS TWACIAIGNI H0V3 393H9 1 A v SINIWIYNSYIN IHL dO INON d 3 ONIOWS 530195 1 NV 1 97 XO8 NOILONA ALIHM NI SNOLLOANNOO Xv LON OQ SIN3N3d SV3N dl P E 8 9f OL 1 9 MOIHI NV 9 9 OL 6 9f MOSH S31000N 31dlu1 318600 NO ZS 8 1 931100 319NIS NO 9131 TWNIWHSL H3ddf ONY 93 7 X v LON S304 Jl Test Procedure for E M C S Dryers Old 9NIMOTIO3 SHOSN3S JHL 9NDI93HO NI938 d313N WHO qu IVLSOWYSHL TOYLNOOD AYNLSIOW Portable Dryer Troubleshooting Temperature Charts E M C S DRYERS 3800 3700 3600 3500 3400 RESIST 33
38. 12 VOLTS RED 05 9 12VOLTSDC RED CUSTOMER SUPPLIED SAFETY BLK J1 20 12VOLTSDC RED METERING ROLL NEUTRAL BLK J5 12 12 VOLTS DC NEG WHITE NEED JUMPER L TEMP SENSORS WHT 81 TEMPSENSOR ORANGE TEMP SENSORS BLK 2 TEMPSENSOR ORANGE WORK LIGHT RED L1 120 VAC BLACK J9 3 120 VAC NEUT WHITE AC 1 120VAC BLACK J8 16 120 VAC NEUT WHITE 120VAC FOR AUX UNLOAD CONTACTOR COIL J8 9 120 ORANGE 48 18 120 VAC NEUT WHITE 120VAC FOR AUX LOAD CONTACTOR COIL lt SG ss J8 8 120VAC YELLOW DRYER SAFETY CIRCUIT ALWAYS STARTS ON J5 8 AND END u ON J4 12 USING THE J5 12 TERMINAL FOR NEGATIVE Jong 120 VAC NEUT WHITE THERE SHOULD BE 12 VOLTS DC ON EACH TERMINAL FROM J9 17 120VAC BLUE J5 8 TO J4 12 J8 20 120 VAC NEUT WHITE WHEN CHECKING FOR 12 VOLTS DC ALWAYS PUT THE J8 10 120 VAC ORANGE NEGATIVE PROBE OF VOLT METER TO TERMINAL J5 12 J6 1 CONTROL POT P1 PUR SAFETY CIRCUIT IN BOLD IS FOR FLAME DETECTION ONLY SCR2 CONTROL POT P2 PUR EACH OF THE TERMINALS CONNECTED TO IT CAN LOOSE J6 4 CONTROL POT P3 PUR 12 VDC FOR 20 SECONDS BEFORE A SHUTDOWN OCCURS THIS GIVES THE BURNER CIRCUIT TIME TO SENSE FLAME U COM UNLOAD AUX COM ORANGE ALL OTHER SAFETY CONNECTIONS MUST HAVE 12 VDC U N O UNLOAD AUX N O ORANGE PRESENT AT ALL TIMES TO OPERATE PROPERLY L COM LOADAUX YELLOW AUX CONTACT POINTS FOR LOAD AND UNLOAD SYSTEMS ALL VOLTAGE SUPPLIED BY USER L N O LOAD AUX N O YELLOW LOCATED AT REAR OF DRYER 1100
39. 201 11 CIRCUIT 12 LOAD AUGER MOTOR 13 4CB l4 LOAD AUX AUGER LOAD AUX AUGER ER CONTACTOR 115 5M m e gt s N DAD AUX AUGER MOTOR gg ui 116 Bs ps G SCB 117 UNLOAD AUX ALI NLDAD AUX AUGER CONTACTOR OV 18 e ies SMOL UNLOAD AUX AUGER oro MOTOR 65 VA MTR 119 224 G Wi Portable Dryer Troubleshooting Competitor Wiring Reference Upper Control Box Internal Wiring USER SAFETY 12 VDC HOUSE HI LIMIT VAPOR HI LIMIT 12 VDC LEFT GRAIN HI RIGHT GRAIN HI PLENUM HI LIMIT 12 VDC REAR DISCHARGE 12 VDC OUT OF GRAIN 12 VDC MOTOR OVERLOAD AIRSWITCH N O AIRSWITCH COM AIRSWITCH N C FLAME DETECT FLAME DETECT PLENUM TEMP GRAIN PLENUM GRAIN TEMP 120 AC NEUTRAL 120 AC POWER MAIN SOL NEUT MAIN SOL PWR CYCLE SOL NEUT CYCLE SOL PWR UNLOAD NEUTRAL UNLOAD POWER LOAD NEUTRAL LOAD POWER FAN NEUTRAL FAN POWER IGNITION NEUTRAL IGNITION POWER MAXON NEUTRAL MAXON POWER SCR CONT NEUTRAL SCR CONT POWER SCRP1 SCR P2 SCR WORK LIGHT NEUT WORK LIGHT PWR MERCOID SWITCH USER INSTALLED USER INSTALLED USER INSTALLED USER INSTALLED
40. 3L NIVHO 1fid1nO IGAEL 3ALVO3N 8 380ud 3 AV 1H 0 AOL 1100 a 004 ow HOLIMS H Ssh TWHLNAN 10S 31949 HOLIMS SDYVHOSIG HVdd O 90 JWHLNAN 105 NIV HOLIMS JO LNO O so SaO HOLIMS 4016 04 60 a a HOS ON STH OqA S HOLIMSHIV O N O 6 5i WHLR3N NVHL NOI OA S HOLIMSHIY 2IN so NONWNOO HH HOSN3S di 311 9812 LO 9 87 andino Be 380ud 3 vid O6 o Or In ad LO ov 1304 WOO 68 5 Avidsia a ONIYOLINOW 2 YAWYOSSNVYL e Portable Dryer Troubleshooting Competitor Wiring Reference Programing Instructions for Competitor Series Grain Dryers 1 Turn Control Power on dryer to the off position 2 Locate programming jack J2 on back of computer See next page There will be a cable plugged into this jack that comes from the other computer board Unplug this cable to plug the programmer into the jack 3 Plug the series 2000 cable into programming jack and into programmers DB 9 jack 4 Besure that the rotary switch on the programmer is set to position 8 5 Turn on Control Power to the dryer 6 The four 4 lights on the programmer will c
41. 7 WERE JO Fo Es 5 co ee o e cea 8 L 8 09 aE CRANES US esa C3 e PONS Igo t ond BLACK m 5 38 16 WATE sa Sz Sse de t e i ios SRT INA M RE m o 3 eH To LS o e 23e e m 5 ei e o ere 6 Es Ex D Fean um um pep At cco gt 2792 e m ss Z amp e e e o e e 2 e e m e e e 2 e v e e oe e e e e oe e c e 2 e 2 e 2 FER e 2 e s BIRNER 1 PONS T T ttt hh e e e e e e 2 o e e e e e Ei 2s e s D W 8LK STRIFE 5 12 e W 8LK STRIPE L2VOC NEUTRAL e IRG Ss e Ste e M i M lad ots A lu e s M wi L4 Sts M wi wi 1 e s M wi i e Ste Ste 2 s Te e 4 e J 1 sd LOAD CTN ole ol g ESSE 17 Wiring Reference Portable Dryer Troubleshooting 1100 Fan Lower Control Box Interconnect Strip EMERGENCY COOLING JUMPERS INSTALL J6 13 TO J1 5 INSTALL J6 14 TO J1 19 INSTALL J6 16 TO J5 5 INSTALL J6 17 TO J4 19 J9 1 J93
42. CANADA ONLY RED J7 08 RED J7 02 RED J1 13 NO CONNECTION 12 VDC CENTER TAP NO CONNECTION NO CONNECTION RED J7 01 NO CONNECTION 12 VDC CENTER TAP RED J7 03 NO CONNECTION 12 VDC CENTER TAP RED J7 05 MOTOR OVERLOAD 49 RED 7 04 MOTOR OVERLOAD 35 BLUE J7 09 WHT J7 10 BLUE J7 11 GREY J7 19 WHT J7 20 YEL J7 12 WHT J7 13 ORG J7 14 WHT J6 02 BLK AC 01 WHT J6 13 BLK M SOL BLK J6 14 WHT J3 02 ORG J3 01 WHT J3 12 YEL J3 11 WHT J3 14 BLUE J6 03 WHT J6 07 BLK J6 06 BLK J3 03 WHT J3 04 WHT J3 18 ORG J6 09 PUR J4 02 PUR SCR2 PUR J4 01 WHT J6 18 BLK LITE PINK J1 16 USER INSTALLED USER INSTALLED ORG UNLOAD AUX COM USER INSTALLED ORG UNLOAD AUX NO USER INSTALLED 100STRIP98 PRT REV DATE 3 12 98 S N ololololololololololololololololololololololololololololololololololololS ols oS olo YEL LOAD AUX COM YEL LOAD AUX N O Competitor Wiri
43. GRAIN HEUMIT SWICH Portable Dryer Troubleshooting Wiring Reference Motor Overloads e 5 18 Eae 12 VOLT SOURCE DC POSIME a 58 8 e J1 10 e ene e ud eye INPUTAOUIPUT BOARD 12V DC SOURCE FROM WS TERMINAL LOCATIONS ADJUSIABLE GRAIN 9 629 HHJMT 4 12 Jn e aly J1 19 AUX LOAD OVERIOAD T 7 _ RD 14 AKUNONDOWROB Z p SEEN UNOAD Z e 55 on Es ODORA lt 4419 20 2 Z 617 D FAN 1 RD 4 MdB ia ee _ K e 19 e e e e e e e e Wiring Reference Portable Dryer Troubleshooting Air Pressure Switch 12 VOLT DC NEGATIVE 12 VOLT SOURCE lt DC POSITIVE Ip Z 45 8 41 8 41 6 J1 10 za 549 INPUT OUTPUT BOARE Hs gt 3 TERMINAL LOCATIONS sie ee m J1 12 41 11 41 19 12V DC SOURCE FROM MOTOR OVERLOADS ind J4 19 gt BN J6 17 BLUE B 44 12 2 PRESSURE SWITCH 7 _ FAN 1 PRESSURE SWITCH 2 1 gt BLUE Wiring Reference Portable Dryer Troubleshooting Air Pressure Switch Drawin
44. High setto 999 Metering Roll Speed Low setto 050 MAX All fan and heater switches to off position and load switch to off position Control power to on position Push the dryer power switch Dryer mode switch to cont flow position Moisture control switch to on position Unload switch to 2 speed position 1 Setthe low metering roll speed to 050 on the dial indicator shown in the photograph on the left Set the high metering roll speed to 999 2 Switch the Unload switch to the 2 speed position 3 Switch the Moisture Control switch to the off position This will put the meter roll rotation speed to the high setting 4 Use a voltmeter set at the 200 volt DC range and probe terminal A with the red voltmeter probe and A with the black voltmeter probe If the display on your voltmeter reads 180 volts DC no maximum adjustment is needed If your voltmeter does not read 180 VDC then use a small screw driver and adjust the max set petentiometer until the voltage is 180 VDC Portable Dryer Troubleshooting Competitor Wiring Reference Setting SCR Board Minimum Voltage 1 Switch the Moisture Control Switch back to the on position This will put the meter roll rotation speed at the low setting 2 Use a voltmeter set at the 20 volt DC range and probe terminal A with the red voltmeter probe and A with the black voltmeter probe Use a small screw driver and adjust the min set potentiom eter until the volt
45. J18 J J1 10 JI 7 JS FAN 2 PLENUM SWICH FAN 1 PLENUM SMICH Do ____ Jr 12 SOURCE DC POSTIVE JI 12 J11 0000000000 12 VOT DC INPUT OUTPUT BOARD TERMINAL LOCATIONS 0000000000 0000000000 5 eee080000080 e e e 912 1 1099 70 e 5e e e A Portable Dryer Troubleshooting 12V DC SOURCE FROM FAN 7 1 PLENUM SWICH Fixed Grain Hi Limit Wiring Reference BLUE RED c EN FIXED GRAN HHIMT SMICH L ee e 1 12V e e LONGAM 12 SOURCE DC POME ach ve e 58 e J18 JI 10 e eye INPUT OUIPUI BOARD S e TERMINAL LOCATIONS e e J1 12 11 J1 19 e e 000000000 e Portable Dryer Troubleshooting Reference iring it Locations imi Grain amp Plenum Hi L SHOSN3S diac 03 13 1331
46. J4 12 TO J5 10 INSTALL J6 17 TO J4 19 INSTALL J9 1 TO J9 5 45 001 0531 ENTRELEC TERMINALS 2 D01 0533 END STOPS 1 D01 0532 BLANK PROTECTOR ENDS Wiring Reference Portable Dryer Troubleshooting Upper Control Box External Wiring BLACK FROM J9 16 TO L1 ON FENWAL BOARD 120VAC POWER WHITE FROM J7 04 TO L2 ON FENWAL BOARD 120VAC NEUTRAL BROWN TO Bt FROM V1 ON FENWAL BOARD 120VAC ORANGE FROM J1 09 TO FLAME DETECTION RELAYS ORANGE FROM 5 08 TO FLAME DETECTION RELAYS I TO FAN CONTROL BOX WHITEBLACK STRIP J5 12 12VDC NEGATIVE YELLOW TO J1 07 FROM HOUSING HIGH LIMIT SWITCH RED FROM J5 08 TO HOUSING amp VAPOR HIGH LIMIT SWITCHES PURPLE TO J1 05 FROM VAPOR HIGH LIMIT SWITCH BLUE FROM J5 08 TO AIRSWITCH COMMON TERMINAL 8 _ TO AIRSWITCH ASSEMBLY BLUE TO J1 13 FROM AIRSWITCH N O TERMINAL WHITE TO S1 FROM RIGHT GRAN TEMPERATURE SENSOR BLACK TO S2 FROM RIGHT GRAN TEMPERATURE SENSOR RED FROM 1 11 TO LEFT GRAN HGH LIMIT SWITCH ORANGE TO t 19 FROM LEFT GRAN HIGH LIMIT SWITCH PURPLE POWER 1200 NATURAL GAS ONLY gt WHITE MAXON 120VAC NEUTRAL NATURAL GAS ONLY TOLONER JUNCTIONBOX LR 8ROWNFROI Jt 19 TO REAR DISCHARGE SWITCH ORANGE TO 5 05 FROM REAR DISCHARGE RED 16 GA As SCR DRIVE MOTOR BLACK 16 GA A SCR DRIVE MOTOR GREEN SCR DRIVE MOTOR GROUND
47. SISIHL 3H1 3QISNI 3Hf SS3Ud 40 SS01V SALVOIGNI AVTdSIC SIHL O3480MU3A0 9NI38 14010 JHL 130 SHL addld1 LHL YOLOW JHL LOSdSNI NI GSHSNd SI LI SV S434371 JHL 30 dl FILON SAV HH QVOTYSAO 30 TIY NO SH3A31 038 JHL NI HSfld ONY Q3193NNOOSIG SI 3H1 SUNS 3000 X08 1081NOO YAdd JHL 90 ATIVONVIN 13539 38 LSAW AV T3H SIHL 3ddli1 SVH AV T3H QVO 1830 HOLON V LVHL S31VOIONI AV1dSI SIHL 61 300513 335 FOUVHOSIO JHL 03N3d0 SVH 3N03NOS HONONA 1SV4 LON SYM JHL 9NI1IX3 JHL A8 03910 SI SIHL C31VALLOV IHL 40 JHL NI 031 201 HOLIMS JHL LYHL S31VOIGNI AV1dSI SIHL 39N3f1038 NOILIN I NIYNG ALIN OL 313 SHL IN3INLSIPQY 40 100 38054 3WV14 1304 30 110 ONINNNY 09510 38 NYO SIHL 3NV14 9NISN3S 0399015 SVH 931909 JHL S31VOI NI AV1dSI SIHL 112 Competitor Wiring Reference Portable Dryer Troubleshooting t ircui ona Heater C dOdVA didfid MOTI3A 31du id gdOdVA 038 lt 1 80 MOTISA MOTISA ONISNOH 20 2P NMOWd 3LIHM 3918 15 9V T18 3LIHM 3ALLV93N 90701 ZP Xvid NMOUE 10S 719491 9 A
48. SUNB3HI 40 WNIN331 3 OL NWONG SOWMSHL 0 WNIN33I 8 OL 098 40 5 886 49449290 3018110 WOX TIONN UNIT 1334 21 MA i C NAL 1 d C WIC WIC OX SINT Q O ng Se pr lt e Pn ANI F a 4 3409 I OND 1004 I of K 07 fame 9 Ee MEN E JNO o ALS 235 02 MUSS P Re o A of 4 INIT IH NISH INFOS 07 01 E A e FALISOd IMA 21 1 l of TH som a Sd ANANG 1 3i e xw SININ m L 3LTHA JLH OTI 40 1 3015110 135 AN 3 N N TM 2 _ NOTA 2 D10349N usi jJU UU d BZ 903 STA XN 30 301S1N0 SNOT 1339 38Y ALJAS T0334 OL STA Wiring Reference Portable Dryer Troubleshooting Fan 28 NG Hi Low On Off LL c3 zc 21 LL lt 5 gt lt mo Se n gt af oo cn LG Iu az Oz 1 E3 82 uL oj e c ra ut dc tds ca 82 Ez 5 an F a 1 I os c Fe E TU HI SOLENOID YELLOW BLACK RELAY 2 gt p oo gt a ca e Hos A 25 25 co eu WHITE BLACK D RELA
49. YEL J5 16 METER ROLL PULSE PUR HOOK OTHER SIDE RIGHT METERING ROLL SENSOR I BLU J5 19 NO LONGER USED OF N C SAFETY METERING ROLL 12 VOLTS RED J59 12 VOLTSDC RED TO J5 8 OR J5 9 CUSTOMER SUPPLIED SAFETY RED J1 20 12VOLTS DC RED METERING ROLL NEGATIVE BLK J5 12 12 VOLTS DC NEG WHITE NEED JUMPER 5L TEMP SENSOR WHT St TEMPSENSOR ORANGE TEMP SENSOR BLK 52 TEMPSENSOR ORANGE WORK LIGHT RED 120VAC BLACK 49 3 120 VAC NEUT WHITE AC1 120VAC BLACK 18 16 120 VAC NEUT WHITE 120VAC FOR AUX UNLOAD CONTACTOR COIL 18 9 120 ORANGE J8 18 120 NEUT WHITE 120 FOR AUX LOAD CONTACTOR COIL dei 120VAC YELLOW 28 14 120 NEUT WHITE 79 19 120VAC BLUE 53 TOTAL TERMINALS J8 12 120 NEUT WHITE 15 RED 19 17 120VAC BLUE 4 BLUE 1 WHITE BLACK J8 20 120 NEUT WHITE 3 BLACK 1 16GA J8 10 120VAC ORANGE 9 WHITE 1 16GA J6 1 CONTROL POT P1 PUR 2 BROWN 4 PURPLE SCR2 CONTROL POT P2 PUR 4 ORANGE J6 4 CONTROL POT P3 PUR U COM UNLOAD AUX COM ORANGE UNO UNLOAD AUX N O ORANGE AUX CONTACT POINTS FOR LOAD AND UNLOAD SYSTEMS ALL VOLTAGE SUPPLIED BY USER L COM LOAD AUX COM YELLOW LN O LOAD AUX N O YELLOW LOCATED AT REAR OF DRYER ALL SAFETIES MUST BE CLOSED FOR DRYER TO OPERATE 1200EW98 PRT REV DATE 3 5 98 Portable Dryer Troubleshooting Wiring Reference 1200 Series Control Box Wiring New Version
50. have adequate power supplied to your unit A DANGER Do not operate with service door removed MAY CAUSE SERIOUS INJURY OR DEATH 1989 GRAIN SYSTEMS INC Portable Dryer Troubleshooting A DANGER Disconnect electricity before inspecting or servicing Keep guards and screens on exposed areas MAY CAUSE SERIOUS INJURY OR DEATH 1992 GRAIN SYSTEMS INC Safety decals should be read and understood by all people in and around the dryer area If the follow ing safety decals are not displayed on your dryer or if they are dam aged contact Grain Systems Inc for replacement A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENT A DANGER ROTATING AUGER V KEEP HANDS FEET HAIR AND CLOTHING AWAY FROM INTAKE DO NOT REMOVE OR MODIFY ANY GUARDS KEEP CHILDREN AWAY FAILURE TO DO SO WILL RESULT IN SERIOUS INJURY OR DEATH E High voltage Will cause serious injury or death Lockout power before servicing DC 1224 High speed belt dri operating overhead Can cause serious injury Keep head and hands clear Do not enter when dryer is running m Portable Dryer Troubleshooting DANGER Auto equipment can start at anytime Do not enter until electric power is locked in off position Failure to do so will result in serious injury or death DC 974 Safety AWARNING lt Moving parts can crush and cut Keep hands clear Do
51. iM i HM 81 Competitor Wiring Reference 203 N o 207 21 Competitor Control Circuit Portable Dryer Troubleshooting CPU Display Board 224 COMPETITOR CONTROL BOARD GRATING AIVELBUN HI LIMIT 3 HI LMT e SWITCH Yo JB 01 HOUSING HI LIMIT a AC NEUTRAL lt 16 62 _ FAN STARTER 7 17 03 J s d x e JB D4 15 05 EN IGNITION S MNTERIER 15 08 can e AC NEUTRAL STUP 6 2 x JB D7 ATR SWITCH WO SER CONTACTIR J 15 09 AIR SWITCH CON e 0 AIR SWITH VC 26211 M AUK E MIN A _ E EURA 7 13 48713 AL NEUTRAL 234 222 FLNE FREE 8D LAME PROBE QU S J5 20 POWER ON DUTSIDE LIGHT START LIGHT CF MODE LIGH BATCH MODE 3H FAN MOTOR IGNITIDN RANSFDRMER SCR CONTACTOR MAIN SOLENOID CYCLE SOLENOID Portable Dryer Troubleshooting Competitor Wiring Reference Competitor Control Circuit Board 212 218 221 COMPE 22 0 BOARD L n A 12VDC 4 Lt UNLOAD N UNLOAD e 5M 01 No MOTOR 23 E AC NEUTRAL FAN ON PAN gt 24 1 03 J3 03 FANN a es A
52. is shutting down for no apparent reason Usually if this happens the dryer will shut down again a short while after restarting the dryer If the LP tank feeding the dryer is getting very low on fuel it can also cause the dryer to shutdown on a Vapor High Limit Before adjusting the vaporizer always check the fuel level in the customers tank If the fuel pressure is very low try suggest ing that the tank be refilled Usually this will solve the problem Portable Dryer Troubleshooting Out Of Grain Warning Shutdown Out Of Grain Warning This message indicated that the dryer has run low grain The shutdown occurs when the loading equipment has run longer than the time the operator has set on the Out of Grain timer The mercury switch located on top of the dryer tells the computer when the dryer is full or calling for grain The shutdown usually occurs when the loading equipment is having trouble keeping up with the output of the dryer Possible Solution Look at the loading equipment to see if this is the problem Remember the top hopper of the dryer should always have grain in it If any of the side screens are opening up at anytime then you are losing heat along with efficiency This indicates that you are not filling fast enough Speed up the loading equipment to the dryer Using 5 11 for the test point ground test for 12 volts on J5 4 to test the load mercury switch This switch should have 12 volts DC on it wh
53. j amp D CONNECTION e s e D CONNECTION e a e e O CONNECTION 12VDC 2 e e ED J7 03 e CONNECTION 12v0C 2 e e J7 1 e lel 2 OTOR OVERLOAD 49 aS EE 2 e Lec o Is WHT 17 10 2 LU J7 11 a e e J7 e e e YEL 17 12 a 2 e 25 Sy 2 lel 2 WHT JB 02 a e c 01 e e 2 J5 13 MAIN SOL POWER lel e BLK MSOL e e e BK J5 14 UNLOAD NEUTRAL o o 33 02 M UNLDAD POWER a RG 01 M LOAD NEUTRAL o e WHT J3 12 LOAD POWER e e YEL J3 11 7 Wi FAN NEUTRAL o WAT J3 14 M M FAN POWER e o LU 6 03 M e WHT 5 07 e Te LK 6 06 e LK 3 03 e o WHT J3 04 SCR CUNT NEUTRAL 23 18 M SCR CONT POWER ole RG J6 08 M SCR P1 a o A D2 SCR P2 o US SCR T SCR P3 o UB O e WHT J6 18 e LK LITE 2 o INK 27 16 UNLOAD AUX COM o R UNL CIM 1 Fore I UNLOAD AUX 0 e e R WM MM M LDAD ALX CUM o YEL LOAD COM FT T M LDAD AUX 0 o MEE w y 0 co een B B Su HH Pe BH dee SEN PT 11111 11 ki 74 Portable Dryer Troubleshooting Competitor Wiring Reference Upper Control Box Wiring 220 Volt 1PH
54. mi BRANIE i YELLIN YELLOW 38 18 100 JHT ACE KI TI es 1 aE HE HE 08 2 Hoo Ah l lea PO OKI o oo o oo Moco sS s L jii SS s 60060 BOO fojojgjsjolo ISO Or olololololo g Oe oTo o SIM ororo dud 15 BE U H H Bu c o DES s DES be 2 599 so SIN 6539 1 elele elele E x y J HHS 3 RD REL R RE RD FA LOAD UNLOAD g gee H RANGE olelSlelSlelSlelelelelololelololololelolelolelelelolelelololololololelolololololelole WIE 6 pipe RH 1 DRYER SAFETY CIRCUIT ALWAYS STARTS N Lj COLOR DOB USING THE 5 10 SAFETY CIRCUIT IN BOLD TS RAE DETECTION ONLY EACH OF THE TERMINALS CONNECTED IT CAN LOOSE 12VOC FOR 20 SECONDS SHUTDOWN OCCURS THIS GIVES THE BURNER CIRCUIT TIME TO SENSE FLAME ALL OTHER SAFETY CONNEC TIONS MUST HAVE 12 VOC PRESENT AT ALL TIMES TU OPERATE PROPERLY Wiring Reference Portable Dryer Troubleshooting 1200 Series Control Box Wiring
55. not operate without guards in place Failure to do so could result in serious injury DC 972 Safety Portable Dryer Troubleshooting ACAUTION Hitch pin must be securely fastened and no less than 3 4 in diameter Failure to follow installation instructions may result in property damage DC 388 HUB TEMPERATURE NO GREATER THAN 150 F TIGHTEN TO 90FT LBS ACAUTION Dryer must be towed empty and in accordance with state provincial s aso 8Freguiations CHECK AFTER 50 MILES AND EVERY 200 MILES DC 1249 Portable Dryer Troubleshooting READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE SAVE FOR FUTURE REFERENCE 1 Read and understand the operating manual before trying to operate the dryer 2 Power supply should be OFF for service of electrical components Use CAUTION in checking voltage or other procedures requiring power to be ON 3 Check for gas leaks at all gas pipe connections If any leaks are de tected do not operate the dryer Shut down and repair before further operation 4 Never attempt to operate the dryer by jumping or otherwise bypassing any safety devices on the unit 5 Set pressure regulator to avoid excessive gas pressure applied to burner during ignition and when burner is in operation Do not exceed maxi mum recommended drying temperature 6 Keep the dryer clean Do not allow fine material to accumulate in the p
56. of between the ignitors Be sure that the ignitor tips are no more than 1 8 apart from each other Make sure that the wire connections on the ignitors are good and tight On stubborn lighting burners reverse the direction the ignitor tips are facing Instead of having the tips pointing toward the fan or burner change the direction so the tips are facing the ex haust end of the dryer This is especially true on burners with no burner cone installed i e Nat ural Gas Portable Dryer Troubleshooting Metering Roll Sensors Symptoms No BPH Total Bushels RPM dis played on LCD or dryer shutdown with metering roll problems Metering Roll Sensor Operation Each metering roll on the portable dryer has a sensor mounted to read pulses as the metering roll is turning These pulses are transmitted to the input out put board of the Electronic Monitoring Control System The computer inter prets this information and then displays the data on the LCD screen voltage for the metering roll sensors is derived from the input output board of the Electronic Monitoring Control System The sensors are operated with 12 Volts DC from terminals J5 9 and J5 12 on the board When checking for volt age the negative or black probe of a voltmeter should always go to terminal J5 12 Always use j5 12 for the negaitve anytime you check for any DC voltage on the dryer Then put the red probe of the volt meter termina
57. 00 3200 3100 3000 30 40 50 60 70 80 90 100 110 119 TEMP SERIES 2000 TEMP SENSOR 40000 35000 30000 25000 20000 RESIST 15000 10000 5000 30 40 50 60 70 80 90 100 110 119 TEMP We use two 2 different types of sensors NTC thermistor on the Competitor Series 2000 and an encapsulated sensor on the E M C S dryer in our dryers The resistance of the sensors varies according to the outside temperature For example on the E M C S dryers for every one 1 degree rise in temperature the resistance increases 4 8 ohms However on the Competitor Series 2000 dryer the sensor reacts just the opposite the resistance rises with colder temperatures The charts displayed above will help when troubleshooting any sensor problems Troubleshooting Tips DC Drive Metering Roll System Symptoms Metering Roll will not turn dryer shutdown Metering Roll Drive Failure Metering Roll Operation The DC drive system on the portable dryer is used to control the output of grain from the dryer It is adjusted from the front of the control box using the high and low metering roll potentiometers Compo nents used in this circuit are the SCR contactor SCR drive board DC motor gear box and the input output board from the Electronic Monitoring Control System All voltage for the drive system comes from terminals 1 L1 and 3 L2 of the SCR contactor There should be 220 volts AC across these two
58. 12 Ji 11 JI 19 4 414 556 JUMPER BROWN REAR DISCHARGE SMICH Wiring Reference Portable Dryer Troubleshooting Rear Discharge Mercury Switch MOPS OL LOANNOO A A Z HOLMS 398YHOSI HYH JO ALIAILISN3S 39NVH0 OL 13739 339 N3S001 SdHIM 39NVHO ANY OL YALAW 3GISNI LOANNOO H3AUQ 3H L HO LNOYS 3H L SqavMO GALNIOd 2 81 s Q3S0719 HLIM Q3NOILISOd gt 0000000000 8 INPUT OUTPUT BOARD TERMINAL LOCATIONS s 0000000000 m 5 0000000000 0000000000 3 0000000000 ss EMERGENCY COOLING CONTROL CIRCUIT FAN 1 Portable Dryer Troubleshooting 0000600000 8 o 0000000000 2000000000 s 000000000 3 3 0000000000 3000000000 0000000000 Adjustable Hi Limit amp Emergency Cooling Circuit Wiring Reference 12 SOURCE DC POSTIVE RED Z JB 10 J1 7 JI J9 JI 12 JI 19 4 J61 55 J419 J1 11 12V DC SOURCE FROM REAR DISCHARGE SWICH RED RD IMR J617 ADJUSTABLE
59. 12 VOLT LIMIT OUTPUT 12 VOLT LIMIT OUTPUT REAR DISCHARGE M C THERMOSTAT N O 4 M C THERMOATAT N C TERM 6 LOWER ADJ GRAIN HIGH LIMIT 120 VOLT AC OUTPUTS 120VAC POWER INPUT 1 o1 2 NEUTRAL 163 4 120VAC POWER INPUT ds 6 AC NEUTRAL I o 7 8 o AC NEUTRAL 1 10 AC NEUTRAL 11 12 AC NEUTRAL 9 13 14 AC NEUTRAL 1 15 16 o FAN 1 POWER 917 18 2 POWER 519 20 2 SPEED UNLOAD 1 SPEED UNLOAD UNLOAD BYPASS LOAD SWITCH AUTO LOAD SWITCH ON BATCH MODE JUMPER J1 9 TO J5 6 IS A HARDWARE TIMER FOR THE FLAME SENSOR SHUTDOWN JUMPER J5 2 TO J5 20 IS A CONNECTION FOR THE MAXON VALVE SENSOR JUMPER J4 12 J5 10 IS A HARDWARE TIMER FOR THE SAFETY SHUTDOWNS JUMPER J1 20 TO J5 8 IS A CONNECTION FOR THE USER SUPPLLIED SAFETY JUMPERS MUST BE INSTALLED FOR THE INPUT OUTPUT BOARD TO OPERATE CONTINUOUS FLOW MERCOID SAFTY FAN 3 CAN OUT OF GRAIN FOR LOAD 2 LO HEAT THERMOSTAT BO BURNER 5 AUTO BURNER 5 ON FAN 5 AIR FAN 5 PLENUM FAN 5 FLAME DETECTION FAN 5 HOUSING HIGH LIMIT FAN 5 VAPOR HIGH LIMIT FAN 5 AUTO FAN 5 ON BURNER 43 AUTO BURNER 3 ON FAN 3 AIR FAN 3 PLENUM FAN 3 FLAME DETECTION FAN 3 HOUSING HIGH LIMIT FAN 3 VAPOR HIGH LIMIT 3 AUTO 3 LOWER GRAIN HIGH LIMIT BURNER 1 AUTO BURNER 1 ON FAN 1 AIR FAN 1 PLENUM FAN 1 FL
60. 41990 1049 SIU eunjreJ Ajayes puooes Oz 10113 j9jes M InuS AA eBueuosiq ulei uMopinus Ajayes 10443 OSIIN ajqeisnipy ddn 9 ejgeisn py IPPIN 10 qe1sn pv 41901 437 10 1SA01 49940 Wels 1000 0 Safety Voltage Check Portable Dryer Troubleshooting L sr oN anpe Ici sn moiy jo 5507 uvopinus 1 Sf Ici sn papaq jou 4euing l1nsaad 9 r L NVA Programming Portable Dryer Troubleshooting 1O tA gt Q N Programming Instructions for EMCS Grain Dryers Turn Control Power on dryer to off Locate programming Jack P7 on back of computer See page 13 the DB 9 jack of programmer into the computer s jack Besure that the rotary switch on the programmer is set to position 8 Turn on Control Power to the dryer The four 4 lights on the programmer will come on then three 3 will go out leaving the power light still on Push the start button on the programmer to start the transfer of Software The busy light will flash until the transfer process is complete 9 When completed the pass light will flash indicating a successful transfer 10 If th
61. 5103 02 H i 9 3 AD 18 ug P T tHongasino HEH 901 33dSTOHBS9NB3W O 015 lt yO O EE FFH 107 0 SOJOWL HO HO HOLVg JA 19 ug dour O Q wm G wt C ser Dv T 49 XO 04 IHHL u3MOd 108109 COW ayol NVd uaNuna Qvo INn 1911 90 9 OL L0 9f MOVIE s F 11 9701 80 97 8 JE 1 9 OL 0 91 9701 61 6 08 1701 91 1 AR 2090 10NN09 sdis FS 5 SuaadlNnf B x lo ert re 19 ot x MOTI3A a L MOTT3A or Pus 907 ansa O t JIdYNd L 3LIHM L M9V 18 L Q3H G AONVYO L MOV 18 quvoa AV1dSIG OL 8 ee HO HO e 108109 3611501 Portable Dryer Troubleshooting Competitor Wiring Reference iring Back of Switch Panel W ov T8 NL E aay 09395 DNAS 015 1497305110 D T T m 38 N MM paler D 23 29 2097 m d 2097 69 D O D ASO 20974 0
62. 6127 69 1 17 940 5S 99 2 SS 99 o No TAA cM 18 LHM L A389 39NVHO L MOTT3A 9 d3H 9 31IHM v MOV1d eda HOOQ OL S3UIM c 3ldufid L MOV1d L MOTT3A S 3LIHM L 39NVHO e Qqad quvoa OL 940 9000000 J2 5 6 did lt 3d 3d 19 did OOOOOOOOOO OOOOOOOOOO NI sob If cc OPISI IFI GI PICC SS SS SSSSSSSSSSSSSSSS SQSSSSSSSSSSSSSS ANd N 3505 dV gt OOOOOO OOOOOOO OO J3 4 OOOOOOOOOO 099 1810 00 YL Td INS 9 1 5VB1 LINE LOAD CORCOM 09
63. 67 4 273 4 182 4 093 4 006 3 921 3 838 3 757 3 678 3 601 3 526 3 453 3 381 3 311 3 243 3 176 3 111 157 158 159 160 161 162 163 Ohms 3 047 2 985 2 925 2 865 2 807 2 751 2 696 2 642 2 589 2 537 2 487 2 438 2 390 2 343 2 297 2 252 2 208 2 165 2 123 2 082 2 042 2 003 1 965 1 927 1 890 1 855 1 820 1 785 1 752 1 719 1 687 1 655 1 624 1 594 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 Ohms 1 565 1 536 1 508 1 480 1 453 1 427 1 401 1 375 1 350 1 326 1 302 1 279 1 256 1 234 1 212 1 190 1 169 1 149 1 129 1 109 1 089 1 070 1 052 1 034 1 016 998 3 981 2 964 4 947 9 931 8 915 9 900 4 885 2 870 3 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 Ohms 855 7 841 4 827 3 813 6 800 1 786 8 773 8 761 1 748 6 736 3 724 3 712 5 700 9 689 6 678 4 667 5 656 8 646 2 635 9 625 8 615 8 606 1 596 5 587 1 577 9 568 8 559 9 551 2 542 6 534 2 525 9 517 8 509 8 502 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 Ohms 494 3 86 8 479 4 472 1 464 9 457 9 451 444 2 437 6 424 6 418 3 412 1 406 400 394 1 388 3 382 7 377 1 105 Ple
64. AME DETECTION FAN 1 HOUSING HIGH LIMIT FAN 1 VAPOR HIGH LIMIT FAN 1 AUTO FAN 1 ON IMPORTANT JUMPERS LISTED ABOVE MUST BE INSTALLED JUMPERS TO BE INSTALLED FOR E COOL INSTALL JUMPER FROM 6 13 TO J1 5 INSTALL JUMPER FROM J6 14 TO J1 19 INSTALL JUMPER FROM J6 16 TO J5 5 INSTALL JUMPER FROM J6 17 TO J4 19 FAN 3 POWER t 2 4 POWER _ 4 5 o 6 o7 UNLOAD _ gs 10 BUR 4NEUTRAL on BUR 3NEUTRAL eis FAN 4NEUTRAL 6 FAN 3NEUTRAL oy o LOAD 2NEUTRAL gio 20 o LOAD 2 _ o1 26 MAXON POWER___ _ 3 46 BUR 6NEUTRAL o5 6 BUR 5 NEUTRAL ROS 6 o9 10 e 5 ne THERMOSTAT 110VAC e 13 NC 16 o NC __ 17 18 19 20 1 amp VI FROM BR 1 91 26 MRHPOT2 4 MARL POT 2 amp HI SOLENOID BURH2 B0 e5 6 THERMOSTATSENSORSL 7 Po SENSOR2LOWER o too SENSOR 2 UPPER ENERGENCY COOLING 13 AUX 6 B COMMON 54s 16e EMERGENCY COOLING 99 20 120VAC POWER OUTPUT AC NEUTRAL 120VAC POWER OUTPUT AC NEUTRAL AC NEUTRAL AC NEUTRAL AC NEUTRAL BURNER 1 POWER BURNER 2 POWE
65. ATIVE o 14 13 o 12 VOLT DC NEGATIVE o 12 SAFETY CIRCUIT INPUT et 5 e 12 VOLT LIMIT OUTPUT o 71e FLAME SENSOR RETURN 5 e OUT OF GRAIN SENSOR o1 VALVE SENSOR o2 ia MERCOID SFTY FAN _ o 29 19 ot MERCOID SFTY FAN 2 _ o 18 MERCOID SFTY FAN 4 o 16 15 o LOW MERCURY SWITCH Bd 5 14 13 MOTOR OVERLOADS o 12 11 o MOISTURE CONTROL 9 ADJ GRAIN MIDDLE ot 1 ADJ GRAIN UPPER o6 5 FIXED GRAIN MIDDLE o4 e FIXED GRAIN UPPER o2 te HI HEAT THERMOSTAT BO _ 20 9 BURNER 6 AUTO o 18 17 o BURNER 6 ON o 16 15 FAN 6 AIR 14 13 e FAN 6 PLENUM o 12 6 FLAME DETECTION 3 FAN 6 HOUSING HIGH LIMIT Te FAN 6 VAPORHIGHLIMT FAN 6 AUTO S 6 o 20 19 0 BURNER 4 AUTO at 17 o BURNER 4 ON 16 15 ot FAN 44 AIR 2 dg FAN 4 PLENUM d 4 FLAME DETECTION lom 0 FAN 4 HOUSING HIGH LIMIT je FAN 4 VAPORHIGHLIMT 5 e FAN 4 AUTO o1 304 FAN 4 ON 1e USER SUPPLIED SAFETY o 20 19 o BURNER 2 AUTO 18 17 BURNER 2 ON 16 15 FAN 2 AIR 14 13 e 2 PLENUM o 12 11 o FAN 2 FLAME DETECTION 3o FAN 2 HOUSING HIGH LIMIT 6 FAN 2 VAPORHIGHLIMT o6 2 AUTO o4 30 FAN 2 ON 2 1 12 LIMIT OUTPUT 12 VOLT DC NEGATIVE 12 VOLT DC NEGATIVE 12 VOLT DC NEGATIVE
66. C NEUTRAL 3 04 NO E 4 5 BIRNER IN 5 ves PRIF IF FLUE E 3 0 LA BURNER 51 05 05 n lt G SWITCH o BURNER AUTO lt 1 05 3 06 PROOF 198 e 1 07 J3 07 o7 55 2 c 6 227 2 SPEED 9 J1 08 wom NOSTRE CORD S marsture ON se R Dj TUE NA LIG 2 avum Va N TS UAM g e 4 1 10 J3 10 EN DAD BATC 9M 31 MOTOR DRYER 100 229 MODE lt o I SWITCH F 91 11 3 1 SN 207 NEUTRAL Seely e e 1 12 13 12 77 vapor mm RUE N w 2 LIMI 1 13 J3 13 MOISTURE 5 MOISTURE AC NEUTRAL 231 CONTROL e Iss 35 SWITCH D 21 14 3 14 J1 15 3 15 232 MERCDID e AC NEUTRAL SAFETY ie 3 316 J3 USER USER SAFETY aay SAFETY N 337 e J1 18 234 e e 235 1 20 3 20 23 e 245 35 VEM e 245 J4 02 237 e J4 03 HGH lt SPEED 5 gt 23B 4 04 54705 gt gt 239 gt J4 05 E Competitor Wiring Reference Portable Dryer Troubleshooting Competitor Control Circuit SCR Drive Board lellelellelellellelelle 251 Portable Dryer Troubleshooting Competitor Wiring Reference The SCR board is located in the upper control box Terminals L1 and L2 are the input terminals When the unload system is turned on there should be 220 Volts AC accross these terminals RESISTOR Termin
67. D 16 GA A SCR DRIVE MOTOR BLACK 16 GA A SCR DRIVE MOTOR GREEN 16 GA SCR DRIVE MOTOR GROUND BLACK 12VDC TO LOAD MERCURY SWITCH BLACK J7 05 FROM LOAD MERCURY SWITCH WHITE J6 18 OUTSIDE LIGHT AC NEUTRAL RED LITE 120VAC OUTSIDE LIGHT POWER YELLOW J7 12 PLENUM TEMPERATURE SENSOR WHITE J7 13 PLENUM GRAIN TEMPERATURE SENSOR COMMON BLACK J7 14 GRAIN TEMPERATURE SENSOR BLUE FROM PLENUM HIGH LIMIT SWITCH TO J7 01 RED TO PLENUM HIGH LIMIT SWITCH ORANGE TO RIGHT GRAIN HIGH LIMIT SWITCH RED FROM RIGHT GRAIN HIGH LIMIT SWITCH E TOFAN CONTROL BOX TO AIRSWITCH ASSEMBLY L TO LOWER JUNCTION BOX TO UPPER JUNCTION BOX TO PLENUM AND RIGHT FIXED GRAIN HIGH LIMIT SWITCHES AND TEMPERATURE SENSORS DATA INTERLINK CABLE CONNECTION Portable Dryer Troubleshooting Competitor Wiring Reference Input Output Board 12 Volt e NO gt UNLOAD AUGER POWER CQ VALVEIDRYER RUNNING LIGHT 17 PROOF OF FLAME LIGHT gt PROOF OF AIRFLOW LIGHT 12s C5 MOISTURE CONTROL HOLDING LIGHT 17S LOAD TRIAC SPARE NC TIEDTOJ49 NC TIE
68. D TOJ3 19 120V INPUT FROM CPU CNI M ul e m m lt L e a 12 DC FANON BURNER ON B Er CONTINUOUS FLOW VAPORHIGHLIMITINPUT wm SPARE a USER SAFETY INPUT lt 12 VDC gt e gt UNLOAD AUGER NEUTRAL AC NEUTRAL AC NEUTRAL AC NEUTRAL AC NEUTRAL LOAD AUGER NEUTRAL FAN NEUTRAL AC NEUTRAL AC NEUTRAL AC NEUTRAL RL1 A COMMON TO POT INPUT ON SCR BOARD RL1 B COMMON TO POT INPUT ON SCR BOARD N C LOW SPEED POT A RLI BNO HIGH SPEED POT A RL1 A N C LOW SPEED POT B RLI ANO HIGH SPEED POT B 12 VDC FAN AUTO BURNER AUTO UNLOAD 2 SPEED LOAD AUTO DRYER EMPTY BATCH ONLY MOISTURE CONTROL ON MERCOID SAFETY INPUT SPARE 12 VDC THESE JUMPERS MUST BE INSTALLED J14 TO J1 17 USER SAFETY J14 1 16 MERCOID SAFETY Portable Dryer Troubleshooting Competitor Wiring Reference iring Cpu Board W LAdLNO OV 3dVdS WHLAAN OV LHONM Qquvoa OL OvAOCI OWA HMd 105 31949 OVAOZ I HMd TOS NIVIN 18 NOILOANNOO ON OVAOZL HMd SNVH L ON H 1 IVH LON OV SNISQNOH GVOTd3AO HOLOIN HOLIMS LYVLS 9GAZL 93N HOLIMSHIV HOSN3S dlIA3 L WANA 1d HOSN3S dl
69. ER SAFETY o IR NM s e Ot p EEMO E k s G ota Le 6 ft 4h o o il HE E eco o p els ele e BLK MOLST POWER 19 02 3 8B 82 e RELAY PONER so MTT NEUTRAL J5 D2 UE a Jn 90 1110 IHO OL QU URE PUR 4 02 PUR 2 Competitor Wiring Reference Portable Dryer Troubleshooting Upper Control Box Wiring 380 460 amp 575 3PH
70. EW98 PRT REV DATE 4 10 98 ALL SAFETIES MUST BE CLOSED FOR DRYER TO OPERATE Reference iring Portable Dryer Troubleshooting lon New Versi iring 1100 Series Control Box W TERMINAL NEGATIVE THERE SHILO EE 12 VOLTS OC ON EACH TERMINAL FROM J8 T 4 12 WHEN CHECKING FOR 12 VOLTS DC ALWAYS PUT THE NEGATIVE PROBE OF VOLT METER TO TERMINAL 5 12 1100 SERIES CONTROL BOX WIRING NEW REVISION 15 31 38 RNE RIN IRINE
71. Fan Burner Circuit for Canadian Models L 42 Conversion Diagram for C Series Dryers to a Switchable Hi Low or On Off Burner 43 Fan 28 LP HYLow On Of f u tente e doe Su He ree i 44 Fan 28 LP On Off Burner with Mercoid ii luas a Sa San aa nhu enhn etre trennen treten 45 Fan 28 NG HVEGOW OnD Ott Er ee eee ete Ple fedet ete ies e 46 Fan 28 NG On Off Burner with Mercoid an an sansaq nennen m Gagana u ays 47 42 LP 48 LP On Off B rner With Mercola esineeseen Pietre Etha tet d ee eee 49 42 NG HwLowsOn OIlt u earned e aa E e ote ie 50 Fan 42 NG On Off Burner with Mercoid eese neret rennen nre nennen tenente 51 SCR Drive Circuit mose chen a pU a idonee teer edge 52 RTD Temperature Sensor cen e eite etre ie opt queda s edet det de a eme aere Pod eee oen 53 Test Procedure for EMCS ee ER hetero erre ere on petet ed ede a eR 54 Temperat re Charts etit eee rede e e S eae E a Oea Ee EE E rete o ee n ei 55 EMCS Troubleshooting Tips nas n einen tre ere o eese de dead Paene tne hern tnn 56 Table Of Contents Portable Dryer Troubleshooting Competitor Series 2000 Dryer Picture of Dryer 1995 to Present 65 220 Volt Single 1 Phase Power Drawing
72. GSI Competitor amp EMCS Portable Dryer Models Troubleshooting and Reference Manual 2004 Revised Edition PNEG 630 Competitor Series 2000 Dryer Gs a division of THE GSI GROUP Portable Dryer Troubleshooting Table Of Contents NEW EU 3 Safety Sign Oft Sheet e et tere fte etm pete ine 8 EMCS Portable Dryer 1993 1998 satety Voltage Check Points pleri cuoc t itecto 9 Programming Instructions for EMCS Grain Dryers 10 EMCS Display Board 5 eee CERE RENE EA ee 11 Input Output Board Identification 1 12 EMCS Switch Replacement au a edet ode Tete eunte u u bleu A uu tra eb E 13 1100 Series Control BOX WINS ere rette Pe TEE E E EA 14 1100 Series Control Box Wiring NeW n an Pun h aa EE EEEE ais 15 1200 S ri s Control BOX Waitin etie te u 16 1200 Series Control Wiring asha aasawa e ea a aeeoa aeo aR ne ia 17 1100 Fan Lower Control Box Interconnect Strip 18 1200 Fan Lower Control Box Interconnect Strip 19 Upper Control Box External 20 Fan Housing and Vapor Hi Limit Circuit 21 Plenum Hi Temper t re S WIteh Xx eco oer erede secet ge de Ete E ee Fleet 22 Fixed Gram REC etri me Be p eda erre tates Ee PE o rer Les
73. ISNI 0z 30V18 YIM 30 OL 193NN09 9181 Xov T8 3LIHe YOSNIS diN31 WANSId 1008 101 Portable Dryer Troubleshooting Competitor Wiring Reference Grain Sensor Testing 1dd 96dN09 SHOSN3S NV4 SNI9Vd 305 1H9I8 1331 33 NO X08 91 099 61 40 9418 dOSN3S TWNCIAIGNI H0V3 X93H9 3LIHM NI SNOLLO3NNOO Y93H9 WNIWYSL 93990 ONY H3M01393H9 9NIMOTIO3 SHOSN3S 3HL SIN3A3UnSV3lN IHL dO INON 31 LON OQ SLNAWSYNSVSN dl LON 5304 SWHO 3l 938 8313 WHO 9334930 0 LV ame edL 31195 SA SDUSA Bed ees VNOOTL 90 AOL O 90 zi O s 1 1109 a bicis OL OVAOZL a Bee 90 OVAOZI Md 108 31940 ori N ES 9 OVA021 108 NHOS WOO ele 2100 9 O3N 90 WOO HOLIMSHIV ONE SO 1207 HOSNAS WANITA NOLLO3NNOO ON TO Md na HOSN3S dL NVH9 0 NONINOO LH uOSN3S d3L los OVA0ZI HMd SNYHL NOI O9 pe EO ON HH orl O SMEENK loji 3NLVO3N 1O novn
74. J6 12 BLK Q o BLACK 46 13 WHT o o d inn ES J6 14 BR BROWN PIP J7 13 PUR o tpr P J7 08 RED PURPLETETTOW J7 02 YEL o YELLOW UR J7 10 WHT BLK e WIRES 1 WHITE 2 P 1 BLACK 1 BROWN 1FOOTLONG FROM OUTSIDE OF BOX S228LP PRT 115 Competitor Wiring Reference Series 100 Natural Gas 26 28 Fan Portable Dryer Troubleshooting 116 TE g 3 T zu 5 8 x 285282 O C WIRES 2 5 8 2 YELLOW 2 BRA 3FEETLONG DEE FROM OUTSIDE OF BOX ii YELLOW BLACK YELLOW 79 ORG 5 so J120 WHT RENS 467 WHT 2 0 4606 BLK 1610 4 18 WHT i J6 14 BRI o 2 BROWN 17 08 RED J7 02 YEL E m J7A0 WHTIBLK O a WIRES 1 BLACK 1 BROWN 1 FOOTLONG FROM OUTSIDE OF BOX Portable Dryer Troubleshooting Competitor Wiring Reference Series 100 LP 36 42 Fan
75. Jb SNIS OH 20 2 k gula Set und ly HOIH HOdVA 81 2 OHOH 1048 8 JL H3MOd GION310S 31949 tl 9f 3UHM 1 510 41HM WHNLAN qION310S 310AO NIVI 9 somos Q Suo 39v 18 MOT yng H3MOd G ION310S NIVN Z 9f 1 5 2 18 H3MOd H3 HOJSNVH NOILIN I 90 9 H9S HM H3WHO4SNVH1 0 9 WHLNAN 98039 QUO 1HM WHLNANn 380ud dNV 1H 0 4 38IM ANOOMIS 38 Geo NOILO3113Q 3IAV 14 61 4 114 Portable Dryer Troubleshooting Competitor Wiring Reference Series 100 LP 26 28 Fan EET S x P E2835 3 Se 2 sx W Qu e N EH A a Quis COO WES RD 8 2 PURPLE 2 2 B gt Jy 2 YELLOW B S gt FEET LONG zT P FROM OUTSIDE OF BOX E PURPLE BLACK Em PURPLE m YELLOW O J7 19 ORG o J7 20 WHT lel ua J6 07 WHT Q o Q J6 06 BLK i
76. LIHM TWWHLAAN 105 319 A9 9NI VICE L 9P 9v 18 108 NIVIN zL 9P Xvid Xov T8 MOW1E YIMOd 190 9 ALIHM TVHLNAN 3808d 3HIM 3NOOhIIS 3I V 1H o 9999999999919 3LIHM 7TVBLON NOILIN9I 20 9f 3SV8 38044 OL 3LIHM 0c P 39NvuO NOLLO313Q 3I 61 17 15 9 9 9 9 9 ols e o S3HIM SOVLIO INOINIS PART 1093 IGNITION TRANSFORMER CODE D97T PRIV SECV HZ PRIA SECA TYPE 312 24M02V 120 10 000 60 22 023 SECONDARY MIDPOINT GROUNDED Webster UN m i p 113 Portable Dryer Troubleshooting Competitor Wiring Reference Models Only ian t For Canad ircui Fan Burner C X18 TWNINYSL II00d3N 30 3QISNI FO y0V18 HOLIMS QOO i385 NMOUg AV13u AL3SVS dIOOU3N HOLIMS SYNSSAYd CO DAO Y 3lIHM GIO JU JU 1 MOVIG ALIHM SALLWOAN OQACH 01 7 OSH Jp AL33VS GIOOH3W 91 17 MOTHA Ste
77. LLAR Wiring Reference Portable Dryer Troubleshooting 1100 Series Control Box Wiring 42 TOTAL TERMINALS DESCRIPTION WIRING VOLTAGE COLOR AIR PRESSURE SWITCH 12VDC RED J5 8 NEED LMES RED z J5 8 12VOLTSDC RED ll HOUSING HIGH LIMIT OR YEL J17 12VOLTS DC RED E VAPOR HIGH LIMIT LP ONLY Se 3 e Nt PUR DE rs e ies FLAME DETECTIO YEL OR 12VOLTSDC RED 1 J1 9 L gt PLENUM m m BLU 11 12VOLTSDC RED 3 LEFT FIXED GRAIN HILIMT OR ET 12VOLTSDC RED BRN REAR DISCHARGE 7 OR J5 5 12VOLTSDC RED RIGHT FIXED GRAIN HI LIMIT RED OR 4 19 12VOLTSDC RED 412 12VOLTSDC RED MOTOR OVERLOADS AIR PRESSURE SWITCH BLU J1 13 12VOLTSDC BLUE BURNER POWER BLK J9 16 120VAC BLACK BURNER NEUTRAL WHF 7 4 120 VAC NEUT WHITE BURNER LIGHT BRN B1 120VAC BLUE MAXON POWER PUR J7 3 120VAC BLACK MAXON NEUTRAL WHT J7 8 120VACNEUT WHITE OUT OF GRAIN SENSOR BLK J5 4 12 VOLTS DC YELLOW LEFT METERING ROLL SENSOR YEL J5 16 METER ROLL PULSE PUR OTHER SIDE NIG SAFETY RIGHT METERING ROLL SENSOR T BLU J5 19 NO LONGER USED 5 8 5 9 METERING ROLL
78. O NOILONAP dvO1 Portable Dryer Troubleshooting Competitor Wiring Reference Out of Grain Sensor YO LOW Qvo Nn O 3919 579 X08 NOILONAr Wu3MOT1 FEELS ES HOLIMS B NVd 5 5 5 d31 Q3xi3 1331 WANJA SHOSNAS diN31 HOIH 1 1 ISLNO 809 SIHL 38 LSNW SQV31 HOLIMS QvO1 XXI xog YOLOW 334099 HO SUVS SSSHL 34038 om LO 3409 X08 H NOHHL SLIXI O 2 81 MOPS S O O o 330 30 INOW 100 Competitor Wiring Reference Portable Dryer Troubleshooting Grain Temperature Sensor YOLOW V Qvo Nn GION3 TOS lo oJ oJ HOLIMS QVOT NOILONAP H3M01 OL x B a E a a 3 LINGNOO NA TIOO 30ISNI V9 0c 411 Xov TB 3LIHM N 9 020v 3ulM 30 0191 OL 193NNOO 033 YIM 3139 X08 1081409 OL YELLOW J7 12 WHITE BLACK STRIP J7 13 BLACK J7 144 lf MOTIBA VO 0c 4131 YOWTE SLIHM LINGNOD 3Q
79. ON HINTS 1 If you set a new timer setting which is lower then the present setting it becomes effective immediately If it is 7 OPTIONAL WIRING POINTS 1 J7 10 J7 13 and J7 18 are 12 volt ground points for use with a tester There are no 12 volt ground connections on the IO board 2 J1 17 User Supplied Safety If 12 volts is interrupted from J7 18 the User Supplied Safety Warning ERROR 10 results 3 J1 16 Canadian Mercoid Sensor If 12 volts in interrupted from J7 18 the Canadian Mercoid Warning ERROR 11 results 4 J1 15 Discharge Hold Function First available in Version 2 19 operates in Batch Mode only If 12 volts is applied to J1 15 before the unload cycle is reached when it does reach the unload cycle the dryer will turn off the Fan and or the Heater Only if the switches are in the AUTO position and not allow the Dryer to unload until the 12 volts is removed from J1 15 When 12 volts is not detected the dryer will resume normal operation and immediately unload the Dryer and continue drying This function cannot be activated if the unload cycle has already begun If you are running Dry and Cool and want the Dryer to continue cooling while in Discharge Hold put the Fan switch in the Manual position Otherwise both the Fan and Heater Switches should be in the AUTO position 5 J7 15 J7 16 and J7 17 are 12 volt Positive source points 8 Temperature Sensor Testing 1 You can find charts with the Resistance readings at vario
80. ONTROL 110 VAC NEUTRAL PURPLE ORANGE IMPORTAN YOU MUST ADD A JUMPER WIRE FROM 49 09 TO J7 16 IN THE 5 LOWER CONTROL BOX TO h DC DRIVE MOTOR Portable Dryer Troubleshooting Reference iring iring Lower Junction Box W 3dld SVO 3955 m SYOSNAS 4 31 HOIH 1331 xog H3MO1 ONWd3H1 HOLIMS B NVd fonsnos YOLOW GvO1Nn WANS d SHOSN3S dN31 LHON 3015110 s HDLIMS VOT YOLOW Qvo1 xog NOILONAr YaddN OH JONVYO 3484 30 33801 R ROLL SENSOR YOLOW 995 OL RED FROM J5 09 TO 12VDC POSITIVE TERMINAL ON METER ROLL SENSOR BLACK FROM J5 12 TO 12V NEGATIVE TERMINAL ON METER ROLL SENSOR YELLOW FROM J5 16 TO LEFT METER ROLL SENSOR BLUE FROM J5 19 TO RIGHT METI BROWN FROM J1 19 TO DISCHARGE SWITCH ORANGE FROM J5 05 TO DISCHARGE SWITCH RED 16 GA A TO SCR DRIVE MOTOR BLACK 16 GA A TO SCR DRIVE MOTOR GREEN 16 GA TO SCR DRIVE GROUND
81. OR 104 8 SCR IT BREAKER 2 0 UNLOAD AUGER OVERLOAD 08 DAD AUGER BREAKER Portable Dryer Troubleshooting Competitor Wiring Reference COMPETITOR POWER CIRCUIT 220 VOLT 3PH ON ON MAIN jo DISCONNECT 102 FAN CONTACTOR OVERLOAD 103 TNDL T C 9 p bM G EY 104 D gt Q G SCR BREAKER 105 108 UNLDAD AUGER BREAKER 107 ALIGER 108 2CB CONTROL 109 TRANSFORMER O j o a 2116 Bo SIE oo FS us g Ww 3 t 23 2 2 0 L o o 10 X4 111 DAD AUGER CONTACTOR 3M 112 al la LOAD AUGER M JR E 113 O S ve dert EB 114 LOAD AUX AUGER BREAKER 115 LDAD AUX AUGER MOTOR 116 i 117 UNLOAD AUX AUGER AK BREAKER UNLOAD ALX AUGER UNLOAD AUX AUGER CONTACTOR 118 SCB 71 Competitor Wiring Reference Portable Dryer Troubleshooting COMPETITOR POWER CIRCUIT 440 VOLT 3PH FAN BREAKER FAN 103 IM im e fe 104 4 1M x 105 28 SUR oe 244 CIRCUIT BREAKER SCR TRANSFORMER o 106 107 AUGER MOTOR 108 10 SES CONTROL EB TRANSFORMER 110 i 110 VAC
82. Oo jo o Jo jo Jo lo o Jo jo Jo lo HOLOVINOO Ql lol lo lloll Ql lol lo S00 T SO Ou vou 036 07 HOLOWLNOO YOLOWLNOO HOLOWLNOO LE NVA avol QVONQ LOW J dT T T T T R U3 V3H8 NV qvO1 OXOLL Qvo1Nn 89515 Adc 9 9 9 9 9 olo 89515 Adee 49018 Q Noumatsisid Yaad Q NIVIN Competitor Wiring Reference Portable Dryer Troubleshooting Competitor Wiring Reference 220 Volt Three 3 Phase Power Drawing New Version
83. PURP 12 VOLTS RED LEFT GRAIN HI 2WIRES ORG r RIGHT GRAIN 2 WIRES RED PLENUM HIGH LIMIT BLUE 12 VOLTS BRN REAR DISCHARGE ORG 12 VOLTS 1 OUT OF GRAIN BLK NO CONNECTION 12 VDC CNTR TAP NO CONNECTION I AIRFLOW BLUE AIR GND 2 WIRES WHT BLK 1 AIRFLOW GRY FLAME DETECT ORG FLAME DETECT WHT PLENUM TEMPERATURE YEL 2Wms GRAIN PLENUM GND WHT BLK wres GRAIN TEMPERATURE BLK NO CONNECTION NO CONNECTION MAIN SOLENOID NEUTRAL WHT MAIN SOLENOID POWER BLK CYCLE SOLENOID POWER BRN UNLOAD AUGER NEUTRAE WHT UNLOAD AUGER POWER BLK LOAD AUGER NEUTRAE WHT LOAD AUGER POWER BLK FAN NEUTRAL WHT FAN POWER BLK GNITION NEUTRAL WHT 16 GA WIRES IGNITION POWER BLK MAXON POWER PUR MAXON NEUTRAL WHT SCR CONTACTOR NEUTRAL WHT SCR CONTACTOR POWER ORG METERING ROLL POT BLK METERING ROLL BLK METERING ROLL POT BLK WORK LIGHT NEUTRAL WHT WORK LIGHT POWER RED MERCOID SWITCH
84. R BURNER 3 POWER BURNER 4 POWER BURNER 5 POWER BURNER 6 POWER LOAD POWER SCR POWER FAN 1 NEUTRAL 2 NEUTRAL UNLOAD NEUTRAL LOAD NEUTRAL SCR NEUTRAL PROCESS LIGHT BURNER 1 NEUTRAL BURNER 2 NEUTRAL MAXON NEUTRAL AC NEUTRAL LO HEAT POWER BO HI HEAT POWER BO NC M R H POT 3 M R L POT 3 amp HIGH SOLENOID BUR 1 BO SCR P3 amp V1 FROM BR 2 BC SENSOR 1 LOWER SENSOR 1 UPPER THERMOSTAT SENSOR S2 AUX 6 A N C EMERGENCY COOLING EMERGENCY COOLING NC NC Portable Dryer Troubleshooting Switch Replacement Switch Replacement for EMCS Dryer PRE 1996 SWITCH REPLACEMENT FOR DRYERS AND AUTOFLOW WITH EMCS CONTROLLERS NEW STYLE lt oD Ji NU LIE 2 Zu ANN ar he EI TL zx vi i oo 3 mS Ww nm Switch N O Contact Block Part No D63 0006 Switch Light Block D01 0455 PEN CONTROL BOX AND MAKE NOTES ON WIRE PLACEMENT ON 000 SWITCH RAISE IT TU DISSENGAGE THE SWITCH ASSEMBLY FROM THE LENS COLLAR JING THE LENS ASSEMBLY TO THE CONTROL PANE NG NOTCH IN THE MOLNTING HOLE WN ABOVE INTO THE LENS ASSEMBLY NEW SWITCH CLISE THE ABDVE EXAMPLE REFERENCE LLAR SILVER RING LOCATED ON THE COLORED PLASTIC LENS AND REMOVE EMOVED REMOVE THE COLORED LENS AND REPOSITION THE LENS SO IT MATCHES THE DECAL WHEN SWITCHED ING CO
85. RRANTY COVERS 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 RESEARCH AND COMPLY WITH ALL FEDERAL STATE AND LOCAL CODES WHICH MAY APPLY TO THE LOCA TION AND INSTALLATION 119 a division of THE GSI GROUP 1004 E Illinois St Assumption IL 62510 0020 Phone 217 226 4421 2004 Edition
86. TIES GSI MAKES NO WAR RANTY OF ANY KIND EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION WAR RANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN CON NECTION WITH 1 PRODUCT MANUFACTURED OR SOLD BY GSI OR 11 ANY ADVICE INSTRUC TION RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION INSTALLATION LAY OUT SUITABILITY FOR A PARTICULAR PURPOSE OR DESIGN OF SUCH PRODUCT OR PROD UCTS IN NO EVENT SHALL GSI BE LIABLE FOR ANY DIRECT INDIRECT INCIDENTAL OR CON SEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION LOSS OF ANTICIPATED PROF ITS OR BENEFITS PURCHASER S SOLE AND EXCLUSIVE REMEDY SHALL BE LIMITED TO THAT STATED ABOVE WHICH SHALL NOT EXCEED THE AMOUNT PAID FOR THE PRODUCT PUR CHASED THIS WARRANTY IS NOT TRANSFERABLE AND APPLIES ONLY TO THE ORIGINAL PURCHASER GSI SHALL HAVE NO OBLIGATION OR RESPONSIBILITY FOR ANY REPRESEN TATIVE OR WARRANTIES MADE BY OR ON BEHALF OF ANY DEALER AGENT OR DISTRIBU TOR OF GSI GSI ASSUMES NO RESPONSIBILITY FOR FIELD MODIFICATIONS OR ERECTION DEFECTS WHICH CREATE STRUCTURAL OR STORAGE QUALITY PROBLEMS MODIFICATIONS TO THE PRODUCT NOT SPECIFICALLY COVERED BY THE CONTENTS OF THIS MANUAL WILL NUL LIFY ANY PRODUCT WARRANTY THAT MIGHT HAVE BEEN OTHERWISE AVAILABLE THE FOREGOING WARRANTY SHALL NOT COVER PRODUCTS OR PARTS WHICH HAVE BEEN DAMAGED BY NEGLIGENT USE MISUSE ALTERATION OR ACCIDENT THIS WA
87. TROL POT P3 BLACK 120 VAC MAXON POWER WHITE AC NEUTRAL BURNER NEUTRAL WHITE AC NEUTRAL MAXON NEUTRAL YELLOW 120 LOAD POWER ORANGE 120 VAC UNLOAD POWER ORANGE 120 SCR POWER WHITE AC NEUTRAL FAN 1 NEUTRAL WHITE AC NEUTRAL UNLOAD NEUTRAL WHITE AC NEUTRAL LOAD NEUTRAL WHITE AC NEUTRAL SCR NEUTRAL BLACK 120 VAC BURNER 1 POWER BLUE 120 VAC 1 POWER 0 BOARD JUMPERS INSTALL J1 9 TO J5 6 INSTALL J5 2 TO J5 20 INSTALL J4 12 TO 5 10 INSTALL J1 20 J5 8 Portable Dryer Troubleshooting Wiring Reference 1200 Fan Lower Control Box Interconnect Strip 44 3 E i 3 EMIFILTER 03 0181 Li BLACK 120 VAC OUTSIDE LIGHT B1 BROWN 120 VAC BURNER 1 LIGHT B2 BROWN 120 VAC BURNER 2LIGHT 1 9 ORANGE TEMPERATURE SENSOR 2 ORANGE TEMPERATURE SENSOR SCR2 PURPLE CONTROL POT P2 15 RED 12VDC FAN 1 VAPOR HIGH LIMIT 1 6 RED 12VDC FAN 2 VAPOR HIGH LIMIT 17 9 RED 12VDC FAN 1 HOUSING HIGH LIMIT 1 8 RED 12VDC 2 HOUSING HIGH LIMIT 1 9 RED 12VDC FAN 1 FLAME DETECTION 1 10 9 RED 12VDC FAN 2 FLAME DETECTION 1 11 RED 12VDC FAN 1 PLENUM HIGHT LIMIT 1 12 RED 12VDC FAN 2 PLENUM HIGHT LIMIT 1 13 BLUE 12VDC FAN
88. V3 40 401 NO X08 HL 40 a SHLOLSM3HOS 2 MONY HOLMSSIHL a 000 93801 CaddlHL SVH HOLIMS LIN ISNOH JHL S3LVOIONI AYTdSIO SIHL 1404135 341 VES PE AVI30 WOM 1 04 135 1081802 391181017 AB 0101 3NLONI 31 30 100 31100 INL AQ NOH4 1109 NOLLISOd 430100 SNNY LI LYHLOS G3LSAPGY 38 OL SC33N 7109 000 JHL LVHL S3LVOIGNI AVTdSIC SIHL 1NOd 135 3ULVUIGNSL WANT 1 04 135 TOHLNO 3PSION 311000 sa N INIL AYO 100 HINL NIV 30 100 3HLNO INIL YNOA ISV382NI AHL O3H1dX3 SVH HINL 000 10 100 SHL LVHL S31VOIONI AVTdSIC SIHL wo YONA 180 0101 AVI30 WOM 1 04 135 TOHLNOO 391181017 AYO 0101 3M1 1009 30443 ON 1NOd 135 38 1Vd3d _ ATQ VONN 1NOd 135 106105 391191011 0001 INL YONN INL 30 100 311002 10883 1NOd 135 3HNLVUIANSL I N3ld X N Xe ABO VONN INOd 138 108LN09 340 02 1NOd 135 3UNLVUIANSL 1 04 138 TOHLNO9 3UPSION INL AYON INL 1009 INOI ABO VONN ABa 0 01 000 1NOd 135 3UNLVUSANSL 1404185104140 3 SION 0 VONN 180 0101 340914 339 JUNSSAUd OL 3ALLISN3S S3 0038 LI LYHL OS daLSNfAY 38 OL Q33N 097 HOLIMSHIV JHL H3AHQ SHL ACISNI 40 y0V1A8 aasnvo Amvnsn
89. Y WHITE BROWN ORANGE C Oo eO OO ae A v v ve rine OO OO TE WH f BROWN ie 1 bug ene RED JUMPER FAN 28 BLACK Reference iring Portable Dryer Troubleshooting Fan 28 NG Hi Low On Off Burner With Mercoi lYVISUNS3H 30 WNIWSSL d OL LWISOWASHL 30 WNINGI 8 OL X08 30 JOISIMO WS ONO 1333 cI NAGE C Sah 08 30 085 1003 T US TH D1 OTUNJ DS 039 XW JLIHM I SATA x08 dl JUSI NOH 9 07 1333
90. aa z SLTHM Sdn T xv 7i og 40 C un NOT 1354 NIB 038 mer CU er 1 1 gt 1 1 1 a e 152 olo X08 40 zm 3015110 sess 1354 i 1 het MUTHA 2 TEUER i3 d JLIHM l X 0 3015110 093 A389 1 2260 5225 lt ONDT 1334 E 1 p10249y JeUJng 440 YON cp YO4 eee 3391 m prog d OS asn4 HOA Occ Portable Dryer Troubleshooting t ircui SCR Drive C Wiring Reference gt S3dIA H3MOd dld1S d3MOd Y3ddN NO TVNINd31 OL To oot COIL YOLOVLNOO dos say IOON HOS OL g ya y i ror d HOS 4 zS zd HOS 4 m ld HOS 10901 lt 01 8 H3MOd uos N 0z 8n WHINAN YOS Reference iring Ww Portable Dryer Troubleshooting RTD Temperature Sensor HO1ON QvoiNn NIWHL SVD LEME HOLIMS SuOSN3S HOIH Q3xi3 1331 SuOSN3S Q3XI3 1 OWYSHL MOTIH 1H9I130IS1nO
91. age is 9 VDC The SCR board is now set and dryer is ready for normal operation at desired settings SCR Drive Board Part No D03 0104 MIN Competitor Wiring Reference Portable Dryer Troubleshooting Upper Control Box External Wiring ORANGE 19 FLAME DETECTION TO FLAME PROBE WHITE J7 20 FLAME DETECTION TO FLAME PROBE BASE WHITE J6 07 IGNITION TRANSFORMER 120VAC NEUTRAL 16 GA WIRE BLACK J6 06 IGNITION TRANSFORMER 120VAC POWER 16 GA WIRE BLACK J6 12 MAIN SOLENOID 120VAC POWER WHITEIBLACK STRIP J7 10 12VDC NEGATIVE WHITE J6 13 MAINICYCLE SOLENOID 120VAC NEUTRAL BROWN J6 14 CYCLE SOLENOID 120VAC POWER ELLOW J7 02 FROM HOUSING HIGH LIMIT SWITCH RED J7 08 12VDC INPUT POWER TO HOUSING amp VAPOR HIGH LIMIT SWITCHES PURPLE J7 13 FROM VAPOR HIGH LIMIT SWITCH BLUE J7 09 CONNECTS TO AIRSWITCH N O TERMINAL WHITEIBLACK STRIP J7 10 CONNECTS TO AIRSWITCH COMMON TERMINAL GREY J7 11 CONNECTS AIRSWITCH N C TERMINAL WHITE J7 13 PLENUM GRAIN TEMPERATURE SENSOR COMMON BLACK J7 14 RIGHT GRAIN TEMPERATURE SENSOR RED 12VDC TO LEFT GRAIN HIGH LIMIT SWITCH ORANGE 12VDC FROM LEFT GRAIN HIGH LIMIT SWITCH PURPLE J3 03 MAXON POWER 120VAC NATURAL GAS ONLY WHITE J3 04 MAXON 120VAC NEUTRAL NATURAL GAS ONLY P BROWN 12 00 TO REAR DISCHARGE SWITCH ORANGE J7 03 FROM REAR DISCHARGE SWITCH RE
92. als A and A are the ouput terminals The voltage across these terminals is DC and will vary de pending on where the speed con trol potentiometer is set MIN a J E j The item circled at the bottom right of the SCR board in the photograph is the minimum set potentiometer MAX Ad This will be used in the SCR board set to set minimum DC voltage The item circled at the bottom left ofthe SCR board in the photograph is the maximum set potentiometer Ame This will be used in the SCR board set up to set maximum DC voltage P3 P2 P1 L1 L2 A A IMPORTANT After the new board has been installed be sure to remove the resistor shown in the photograph above from the old board and install it in the new board Just pull the resistor from the two pin socket and install in the same socket on the new board Resistor for 3 4 Hp Meter Roll motors used on 14 ft dryers and longer part p no 033 0001 Control panel switch locations Resistor for 1 3 Hp Meter Roll motors used on 12 ft dryers and shorter part no D03 0039 Moisture Control Switch Unload Switch Metering Roll Speed High Drying Mode Switch Metering Roll Speed Low 85 Competitor Wiring Reference Portable Dryer Troubleshooting Setting SCR Board Maximum Voltage Before starting the procedure set the dryer up as follows O Q N speed position Metering Roll Speed
93. an and watch to see when the light illuminates 4 Flip the fan switch to the off position and watch the light Now it should go out when the fan is about half its full speed Adjust the air switch if necessary Remember that less sensitive clockwise adjustment will require a higher fan speed to close the air switch and more sensitive counter clockwise adjustment the switch can close at a slower fan speed Competitor Wiring Reference t amp Temperature Sensor imi Fixed Grain Hi L Portable Dryer Troubleshooting u3AdQ 30 uv3d OL uos F AVON e YOLOW SAIC TI 40801 3ddsvo EN NOLLONAP RED 16 GA TO SCR DRIVE MOTOR BLACK 16 GA A TO SCR DRIVE MOTOR GREEN 16 GA TO SCR DRIVE GROUND HOLIMS BROWN FROM 12VDC TO DISCHARGE SWITCH ORANGE FROM J7 03 TO DISCHARGE SWITCH Lj Z SHOSNAS AnaL Z a SuOSN3S e 1H9lH UE QION310OS e EFL URN vn SHOSNAS FUNLWHSdNSL NV 1IW1H9IHNIVdS E FTH 1031409 XX Q3XH 144101 uaddfi 01 09 S3ulM OLMS Ano qvo LJ 2 81 MOPS AINO SUAYA SV
94. ation failure board and Master board have lost communication 10 User supplied safety A safety connected to J7 8 and J1 17 11 Canadian Mercoid sensor In USA jump J7 8 to J1 16 BATCH ERRORS on the screen means the Burner Switch is turned off or there is a loose wire in its circuit FAN on the screen means the Fan Switch is turned off or there is a loose wire in its circuit Presently the Load Switch and the Unload Switch are not monitored by the Dryer Controls 999 on the screen is not an Error It means the board has never had software loaded This will come up when you turn on the power just after GSI appears This means the latest software must be down loaded 3 DIP SWITCHES 1 Dip Switch 8 Air Switch Test Bypass WARNING Bypassing this test will allow burner to come on without the Fan running 2 Dip Switch 7 Emergency Cooling Mode Fan will run alone for 5 minutes when the Start button is pushed with switch on 3 Dip Switch 6 Allows Off On Burner operation instead of High Low as is standard 4 Dip Switch 5 In Software Ver 2 11 and up Adds Low Temp Timer to a nd low Temp finish dry like dual temp Batch Dryer 5 Dip Switch 4 In Software Ver 2 14 and up Adds Low Temp finish tripped by Grain Temperature to Batch Mode 4 SHUTDOWNS If both the GRAIN and PLENUM HIGH TEMPERATURE warnings appear on the screen at the same time one of the two mechanical temperature sensors are kicked out NOTE Emergency Cooling will NOT w
95. ct the white and black 18 ga wires from the smaller white grain sensor wires 7 Strip back about 1 4 inch from the end of each 26 ga sensor wire 8 With a ohm meter set your scale to 20k if its not a autorange model 9 Place the black lead into the still butt connected wire connection with the 2 26 ga wires 10 Connectthe red lead to either of the disconnected 26 ga wires and make note of the reading Grain Sensor Portable Dryer Troubleshooting 104 11 12 13 14 Procedure for Locating Testing and Replacing a Defective Grain Temperature Sensor continued Now move the red lead to the other disconnected 26 ga wire and make note of this reading Go to the other side of the dryer and repeat steps 6 through 11 You will notice that 3 readings will be very close to the same but one reading will be different This is your defective sensor Compare readings to Resistance Temperature chart page 62 Ifyou don t have a replacement sensor jump to How to Bypass the Grain Temperature Sensor Sensor Replacement 15 16 17 18 19 20 21 22 23 24 25 26 27 The grain sensors are mounted to the grain overheat capillary and need to be removed together To remove the overheat switch disconnect the grain thermal overheat wires Then remove the 2 self tapping screws and slide the bracket overheat switch and sensors out of conduit Remove the tape surrounding the defective grain sensor then remove it
96. d 334HL m YIMOd TOHINOD qvo1 3 YONN 19115 N Z Wy N Z Y 5 VLAN 3v 20 97 HE JE JLIHM AE o g IE 9 o TOLNOO SUNLSION ESH OF L u3MOd OV 10 97 in M O 909701 1090 yg x OLTO P LHM 99 61 67 038 SHAAN qauino3d Competitor Wiring Reference Portable Dryer Troubleshooting Air Switch Assembly 3dld SV9 SHdOSN3S dW3L 1331 xog PERMIT HOLIMS YOLOW avoinn J WANITA SuOSN3S dW3L 4 1HOIH 60 7 3M8 01049 MOTHYIY 01 47 91915 NOV T8 3LIHM CIN MOV ON 11 10 A389 X08 1081NO9 Y3ddf OL A 18IN3SSV HOLIMS 30 M3lAMOVa Air Switch Adjustment Portable Dryer Troubleshooting Competitor Air Switch Adjustment Air Switch location Air Switch assembly IMPORTANT To adjust the air switch the grain columns need to be full of grain
97. d connect it to the white 18 ga wire Portable Dryer Troubleshooting 28 30 31 32 amp amp 5 588 50 51 52 55 57 59 61 Procedure for Locating Testing and Replacing Sensor Chart a Defective Grain Temperature Sensor continued 3 From the same sensor that you connected to the white 18 ga wire connect the other small white grain sensor wire to the black 18 ga wire 4 Double check the wire connections then replace the covers on the boxes Ohms 36 601 35 565 34 562 33 591 32 650 31 739 30 856 30 000 29 171 28 368 27 590 26 835 26 104 25 394 24 707 24 040 23 394 22 767 22 159 21 569 20 997 20 442 19 903 19 380 18 873 18 380 17 902 17 438 16 988 16 551 16 126 15 714 15 313 14 924 62 65 67 69 70 71 72 73 74 75 76 78 79 80 81 82 86 87 89 91 GRON Ohms 14 546 14 179 13 822 13 475 13 139 12 811 12 493 12 184 11 884 11 591 11 307 11 031 10 762 10 501 10 247 10 000 9 760 9 526 9 298 9 077 8 862 8 652 8 448 8 249 8 056 7 868 7 685 7 506 7 333 7 164 6 999 6 839 6 682 6 530 96 97 98 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 Resistance Temperature Chart Ohms 6 382 6 238 6 097 5 960 5 826 5 696 5 569 5 446 5 325 5 208 5 093 4 981 4 872 4 766 4 663 4 562 4 463 4 3
98. e fail light flashes then check your connections and repeat the above process 11 Turn Control Power on dryer to off and remove the cable 12 Turn on the dryer and the opening screens should indicate the newer version of software Programming Portable Dryer Troubleshooting EMCS Display Board MS 1 15 OL MS dOLS OL SMS dOLS LdV1S OL NO amp 88IH Vd Sd f e O o GNnOS _ E 2 T1 1784 ff OL 4 iT HAINdNOD 318VO SNOLLVOINnIWINOO ie 69 H3WAVHSOHd AV 1dSIG 11 Wiring Reference Portable Dryer Troubleshooting Input Output Board Identification 12 VOLT DC INPUTS 12 LIMIT OUTPUT 20 19 9 12 VOLT DC NEUTRAL 18 17 o METERING ROLL INPUT Se e4 12 VOLT DC NEG
99. e ignitor If flame is sensed during the ignition period about 4 seconds the transformer is turned off but the solenoids stay on If no flame is det ected after the ignition period both the solenoids and transformer lose power and the dryer begins a shutdown sequence voltage for the Fenwal Ignition System is derived from the input output board of the Electronic Monitoring Control System For ignition to occur 1 The fan must be turned on 2 The pressure switch in the plenum must indicate the fan is operating 3 The burner switch must be in the auto or manual position 4 The dryer must go through a 10 second purge delay which is indicated on the LCD screen These steps must take place before troubleshooting of the Fenwal System can occur The following assumes the above steps have been taken Fenwal Troubleshooting e Fenwal Board located in the fan can control box on the dryer has seven 7 terminals They are L1 L2 V1 V2 S1 52 and E2 L1 and L2 are considered the input to the board After the 10 second purge delay an AC voltmeter connected Across LI and L2 should read 120 Volts AC If this 1s true you can assume the input output board is operating properly and the problem is in the Troubleshooting Tips Fenwal Ignition System If no voltage is present after the 10 second purge delay check for voltage going through the auxil iary switch mounted on the side of the fan contactor for that bur
100. ed the sparking will discon tinue after the ignition period 4 seconds Continued on page 55 57 Troubleshooting Tips Fenwal Ignition System continued Hints Hearing the solenoids snap on after the 10 second purge delay means that power is coming to and through the Fenwal board The Fenwal board is probably okay If flame is sensed the power to the sole noids stays on but the power to the ignitor always goes off after about four 4 seconds Power to the low pressure solenoid is al ways on anytime flame is sensed This is because the power to the low solenoid is hooked directly across terminals V1 and V2 of the Fenwal board Power to the high pressure solenoids is controlled by the Plenum thermostat One side of the solenoid 1s hooked to V2 neutral and the other side is run through the nor mally closed switch of the thermostat and then back to V1 This is how the burner is made to cycle When the plenum is below tem perature power is run through the ther mostat to the high pressure solenoid When temperature is reached the thermostat opens and the high solenoid loses power L2 and V2 are connected internally in the Fenwal and they must be nuetral Portable Dryer Troubleshooting Ignitor Tips Make sure that the ignitors are mounted correctly through an opening in the burner skirting Also make sure that they are not close enough to the edges of the opening to cause a spark to jump the skirting instead
101. en the dryer is calling for grain and has Zero volts on it when thedryer is full Out of Grain Hints The out of grain timer is only in use when the fill switch is in the auto position In the manual position the top mercury switch will still shut off the fill auger but the dryer will not shutdown if the source of grain to the fill auger is depleted Troubleshooting Tips Before setting the Out of Grain timer monitor how long it takes the dryer to refill for shrink Then set the Out of Grain timer accordingly Example Ifa dryer takes six minutes to refill for shrink add an additional five minutes to this and use this as the amount of time to program into the Out of Grain timer The additional five minutes is to avoid any nuisance shutdowns A lot of customers don t want their fill augers to run empty if the source of grain runs out They may want to set the Out of Grain timer closer than the additional five minutes this is fine but caution the customer that it may cause some nuisance shutdowns For the Out of Grain warning to work properly the fill equipment must be large enough to handle the capacity of the dryer You do not want the side columns to get low on grain This will allow the airflow to escape from the dryer through the side screens If this happens you lose efficiency and may start having a loss of airflow shutdown Troubleshooting Tips Motor Overload Shutdown This indicates that one of the Motor Overl
102. eter up and down The voltage should go from zero to approximately 180 Volts DC If Zero voltage is present across the A and A terminal first try to disconnect the wires from these two points and then check for DC volts again If the voltage returns suspect a bad motor or a problem in the wiring to the motor If the voltage does not return suspect a bad DC drive board Check the Motor The wires attached to A and A go directly to the DC drive motor on the dryer You may remove the top cover of the motor and check for the same DC voltages mentioned above at the motor If the voltage is not present try to disconnect the wires then check for DC volts again If you do not get any voltage then look for a broken or loose wire between the motor and the drive board terminals If the voltage is present suspect the motor or the gear box Removing the motor from the gear box and trying to run the motor only is one way of narrowing down the problem or you may want to remove the chain and see if the metering rolls are froze up Using a pipe wrench is an easy way to try and rotate the metering rolls Portable Dryer Troubleshooting Fenwal Ignition System Symptoms Burner will not light dryer shutdown for Loss of Flame Fenwal Ignition Operation e The Fenwal Ignition System ignites the burner and monitors the flame Once 120 VAC is applied to the Fenwal the solenoids are powered up and the transformer begins ignition through th
103. f Airflow This error message indicates that the fan is running and the air pressure in the ple num did not pressurize First verify that the fan is running and the dryer is full of grain There must be grain in the dryer or no pressure will develop If the fan does come on and the dryer is full of grain but Loss of Airflow shutdown still occurs check the air pressure switch circuit Watching the blue light in the fan switch is the easiest way to tell if the air pres sure switch is sensing air pressure Each air pressure switch has a light in the fan switch that will only come on if air pres sure has developed Turn on the fan and after it has run up to about one half of its operating speed the light should go on If the fan light is not coming on then the air pressure circuit is not sensing pressure Try adjusting the air switch on the front of the plenum to see if it is just out of ad justment Use a straight blade screw Portable Dryer Troubleshooting driver and turn the adjusting screw coun terclockwise Turning it this way makes the switch more sensitive to pressure and will turn on the light easier If adjusting the screw does not solve your problem consult the layout diagram of the input output board Look for the input for the problem switch Example Fan 1 switch s input is J1 13 This is a 12 volt DC input and it can be checked with a DC voltmeter One of the following conditions will exist when checking
104. f it S not a autorange model 9 Place one probe of your meter one wire going out to the sensor and the other probe to the other wire 10 The meter should read close to the resistance temperature chart on previous page 11 Assuming you have checked the wiring from the CPU Display board to the sensor and itis OK But the resistance is not close to what is on the chart You probably have a bad plenum bolt sensor Plenum Bolt Sensor Part No HF 7236 Back of Door on Lower Box CPU Display Board Portable Dryer Troubleshooting Plenum Sensor Procedure for Locating Testing and Replacing a Defective Plenum Temperature Sensor The picture below is of the plenum bolt sensor in the plenum of the dryer See previous page for more information Plenum Bolt Sensor Part No HF 7236 View of back side of the plenum bolt sensor as it is mounted in the conduit fitting Located inside the dryer plenum to the right just inside the rear access door View of the 4 x4 plastic junction box This is located to the left of the fan heater facing the front of the dryer It contains the plenum overheat and a juction point where the wires from the plenum bolt sensor are butt connected together Plenum 300 Degree Overheat 10 Length Part 003 0004 Plenum 300 Degree Overheat 24 Length Part No D03 0377 Portable Dryer Troubleshooting Competitor Wiring Reference Stern and Capacitor Diagram 10 17 1Phase HOLOW
105. flame to the sense rod The minimum flame current necessary to keep the system operating is 1 0 DC microamperes Reference iring Ww Portable Dryer Troubleshooting t ircui Flame Control C lt JHM aoo ou MSS IO 2 169 Q wd up U oor 8 E LISS a 100 Nug 1109 q lt V 1HM zs uo TOH LNOO NIV HO 1HM JWOD S3UIM TV r dO lt J Jy ND INANI 23S 02 Su VIAL YO V NU NP A134VS OAS 02 SO oa soaz 20 wa TM SO SLIOA 010 8 9 HAL 188 Sie yng Gee JHM HM l H IA ya OV SLIOA 021 1HM TVH1n3N TVMN3d oy 51 01 IS INIL 2 HOSN3S HOLINDI Portable Dryer Troubleshooting Reference iring Models lan t for Canadi ircui Fan Burner C 9u0
106. g NIVH 3dld SV9 SHOSN3S dW3L 1331 xog o NoWLONnr H3NO1 HOLIMS B NVd YOLOW QvoNn YOLOW avol WANITA SuOSN3S diN31 Q3XI3 1 ii 1 SCISLNO o HOLIMS QVOT1 xog MO13HlV 3118 N ANLISOd 90AZ 80 6 3118 1081NO9 999101 19 35 HOLIMS 30 M3lAMOVa 31 Portable Dryer Troubleshooting Wiring Reference Out of Grain Safety Circuit TERMINAL LOCATIONS 12 SOURCE INPUI OUIPUI BOARD B 12 VOLT EGAM 3 8 3 0000000000 0000000000 a gt 0000000000 0000000000 D 716 4619 59 OUT OF GRAIN Wiring Reference Portable Dryer Troubleshooting lon it Locati Ircui Out of Grain Safety C 358 3419 SV X08
107. is supplied The principal concern of the GSI Group Inc GSI is your safety and the safety of others associated with grain handling equipment This manual is written to help you un derstand safe operating proce dures and some of the problems that may be encountered by the op erator or other personnel LN 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 WARNING BE ALERT Personnel operating or working around electric fans should read this manual This manual must be delivered with the equipment to its The symbol shown is used to call your attention to instructions concerning your personal safety Watch for this symbol it points out important safety precau tions It means ATTENTION owner Failure to read this manual WARNING CAUTION and DAN and its safety instructions is a GER Read the message and be cau misuse of the equipment tious to the possibility of personal in jury or death Safety Grain Systems Inc recommends you contact your local power com pany and have a representative sur vey your dryer installation so your wiring will be compatible with their system and you will
108. it ddNung fonanos XXcl HO1ON QvO INQ HANNITd E ae SHOSNAS diavisnrav YOLOW xog NOILONAr 3015100 HOLIMS QvOT NOLLONAP H4MO1 OL zB e B B OJ lo TUNE 339934 012 5000 00 HOLIMS Q3XH P d 334930 00 7000 600 HOLIMS WANSTd 338934008 7000 00 HOLIMS WANSTd ot NVA YELLOW TO J1 12 BLUE TO J1 11 RED TO J1 05 9 fo aH o o Portable Dryer Troubleshooting Wiring Reference Rear Discharge amp Emergency Cooling Circuit E T i INPUI OUIPUI BOARD TERMINAL LOCATIONS g 0000000000 5 e oeoooooo 3 0000000000 9 O s eeoeooooo 0000000000 5 0000000000 S 0000000000 1000000000 2000000000 lt 12 SOURCE DC POSIME d BLUE RED JI 10 JS J19 Jl 7 Ji
109. l J5 9 Across these two points there should be 12 volts DC This voltage needs to be checked but you can be reasonably assured the 12 volts DC is present if the rest of the dryer is operating Check for this voltage on the terminal strip in the upper control box 12 volts DC is transmitted from J5 8 and J5 12 directly to the metering roll sensors located on the back of the dryer Each of the metering rolls is en closed in a white plastic box mounted to the back of the metering rolls Inside each box is the metering roll sensor and the metering roll wheel Each sensor has three 3 wires con nected to it Two 2 of these wires are Troubleshooting Tips the incoming 12 volts DC the 1 12 and T2 GND terminals and one is a pulsing 12 volts DC back to the input output board the T3 out terminal Checking across T1 and T2 will verify that 12 volts DC is getting to the sensor The T3 out terminal is what delivers the metering roll information back to the input output board in the main con trol box The information for the meter ing roll on the left side of the dryer is sent on a yellow wire and goes to termi nal J5 16 The information for the me tering roll on the right side is sent on a blue wire and goes to terminal J5 19 e Youcanusea DC voltmeter to observe this pulsing voltage The best place to check for this voltage is directly on the input output board located in the very back ofthe lower control bo
110. lay Ladder Diagram a 82 Control Circuit I O Board Ladder Diagram esses eene neret eene nennen nens 83 Control Circuit SCR Drive Board Ladder Diagram ener 84 SCR Board Installmg amp CalHbratin9 khakakunayki lia reco 85 Upper Control Box External Waring sma 88 Inp t Output Board 12 Voltios eite RR E cepere ere I UL ee HERD eerte ladda 89 CPU Board Waitin ecoute edet dne ento ite db todo e 90 Programming Instructions for Competitor Series Grain Dryers 91 Programming Hook Up 92 Back of Switch Panel Eayout n stem He Heer 95 Back of Switch Panel Wiring ete ei ette Pee eL pie eese uhanay e RUE usay de 96 Air S Witch Assembly iiie oe o Te ue E REPE UE e e hapiq 97 Air Switch Adjust Ges n a HEP eek pecie eee te 98 Fixed Grain Hi Limit amp Temperature Sensor 99 Out Of Grain Sens r ie eeu up e Uie 100 Grain Temperature Sensory d esi eee eto e Ee dad e ke Ped auae eg 101 Grainy Sensor Testing eoe peer aee e e Pete tradet eet Caveats Se iter eerte as 102 Grain Sensor Locating Testing amp Replacing eese eene nn
111. lenum or drying chamber 7 Use CAUTION in working around high speed fans gas burners augers and auxiliary conveyors which START AUTOMATICALLY 8 Donotoperate inany area where combustible material will be drawn into the fan 9 Beforeattempting to remove and reinstall any propeller make certain to read the recommended procedure listed within the servicing section of the manual 10 Clean grain is easier to dry Fine material increases resistance to airflow and requires removal of extra moisture This product is intended for the use of grain handling only Any other use is considered a misuse of the product Some edges of the product components can be sharp Itis recommended that each component of this product be examined to determine if there are any safety considerations to be taken Any and all necessary personal protective equipment should be worn at all tines when handling assem bling installing and operation of the product and or components Guards are removed for illustration purpose only All guards must be in place before during operation Safety Precautions Use Caution in the Operation of this Equipment The design and manufacture of this dryer is directed toward operator safety However the very nature of a grain dryer having a gas burner high voltage electrical equipment and high speed rotating parts does present a hazard to personnel which can not be completely safeguarded against without interfering wi
112. nce iring Portable Dryer Troubleshooting Meter Roll Sensor HOLIMS 338 OL NS HOSNSS LHOIH CSUALOVAANYW 9380 OL 9313 1351 HOLIMS 398VHOSI OL NMOUB 31139 3984991 39NVu0 NYALSY 35109 4313 1 3018 3138 35709 8313 1 37 MOTISA DAN 9071 dld1S 39V 18 3 LIHM 504 00 0 du 16611 2 9140985 ALON Wiring Reference Portable Dryer Troubleshooting Meter Roll Sensor Wiring 9 o n 4 e tie Rae 5 gt a 5 5 OOQOQOOOOO an AN 2 i 919141212 515 5 5 515 555 51515 5 5 5 J lt 2 s 6 2 ales 2 h Q N 2 N A peog a DEIN peog J919IN I Ei gt lz m Q 1 E Remove one meter roll board and tie the 1997 Dryers have only 1 meter
113. ne nnne eene 103 Sensor Resistance Temperature Chart a 105 Plenum Sensor Locating Testing amp Replacing s enne enne nennen nere 106 Stern and Capacitor Diagram uidet dente e eet le e teet dee PEE PIE pepe eR 108 Operation Hints uei eed ac gi tr tee E e ERR t e VE ier 109 series 2000 Error Conditions iui Sau RR SERERE eee eiie 111 Cater Eric D PE 113 Fan Burner Circuit for Canadian Models 114 series 2000 LP 206 28 E3n iet reete ete o RE IDEE EE dede 115 Series 2000 Natural Gas 267 287 116 5211652000 EP 363 427 En di eet eee eri pa e bb eL th ELE P E 117 Series 2000 Natural Gas 36 42 Fan d ete 118 Warrantyu a ELLE 119 Portable Dryer Troubleshooting Dryer Safety Instructions and Information Thank you for choosing an GSI Grain Dryer It is designed to pro vide excellent performance and ser vice for many years This manual refers to the trouble shooting of the E M C S and Series 2000 Competitor models Different models are available for liquid pro pane or natural gas fuel supply with either single phase 230 volt or three phase 230 460 575 volt electrical power Also 380 volt 50Hz The GSI Group Inc recommends contacting your local power com pany and having a representative survey your installation so the wir ing is compatible with your system and adequate power
114. ner This switch has to close before the Fenwal gets power If this is OK check the appropriate output on the input output board for that burner If voltage is present across L1 and L2 check for voltage across the Output of the Fenwal board The output terminals are and V2 and they will also have 120 VAC across them for approxi mately four 4 seconds The four 4 seconds is the amount of time the Fenwal has to ignite and sense flame or it concludes no flame is detected and begins a Loss of Flame shutdown If you have power on the in put terminals and no voltage on the output ter minals unload the secondary take the wires off of V1 and V2 and recheck for voltage If no voltage is present then suspect a bad Fenwal board If power returns look for a bad so lenoid valve or a problem in the wiring Note All of the above voltage checks can be bypassed if you can hear one or more of the solenoids on the gas train snap on after the 10 second purge delay This is true because the so lenoids are connected across VI and V2 and for the solenoids to come on power must be going through the Fenwal board Also during the four 4 second ignition period the trans former is energized and you should be able to observe sparking across the ignitor If the sole noids snap but no ignition takes place check for loose ignitor wires or check the ignitor con dition ignition gap 1 8 to 3 16 Remember even if flame is sens
115. ng Reference Portable Dryer Troubleshooting Upper Terminal Strip With Moisture Control Hook Up 16 GA WIRES 10 DMC MOISTURE NEUTRA BLUE CONTROL SN RING ROLL PL LOVAC N BLK TO MOISTURE CONTROL TU M CONTROL 31 LL TL IST z E Z G 7 2 o Q RE 7 08 2 1 02 JI B CONNECTION 12V0L CONNECTION Q CONNECTION o RED J7 0l o o O U CONNECTION 12002 RED 77 03 NT CONNECT II 2 2 AP o 2 MOTOR OVERL lol QJ o H o 24 81 s REY YEL e Ol a Rh BLK A BLK e 1 Sry RG J o j HHT 3 14 Q o J6 03 2 6 07 2 BLK J6 06 Q 2p 3 03 BO QJ 3 18 RG J6 09 Q WHT J6 18 o g B REMOVE INSTALLED Q o M i Q o a JUMPER TO ACTIVA USER SAFETY FEATURE 2 16 eT o o o
116. num Sensor Portable Dryer Troubleshooting Procedure for Locating Testing and Replacing a Defective Plenum Temperature Sensor Symptoms of a bad sensor may include Temperature readings that are not consistent with the ambient outside temperature or with a verified plenum temperature that has been taken with a thermometer Erratic plenum display readings Plenum temp open or plenum temp short Troubleshooting 1 The process of checking the sensor is similar to that of the grain sensors but you only have one sensor to check 2 The actual plenum sensor is located in the plenum just inside the rear access door to the right Facing the rear ofthe dryer See picture on next page 3 Start atthe CPU Display board it is located on the door of the lower box See below 4 The wires from the sensor which are butt connected at the sensor go through a conduitin the plenum section of the dryer See next page That conduitterminates at a white plastic 4 x4 junction box This box is located on the front of the dryer to the left of the fan heater Facing the front of the dryer From that point to the CPU Display board 5 The wires are connected to terminals J7 12 white wire and J7 13 black wire on the back of the Cpu Display board see picture below 6 Unhook those wires 7 What you will be checking is resistance in relationship to a known temperature See resistance temperature chart on previous page 8 With a ohm meter set your scale to 20k i
117. o LNdNI WHINAN OV DZ ES s 020 8 38044 3AV1d o o f md ov 1404 WOO S8pSH T AV1dSIG d ONIHOLINOIN H3INHOJSNVHL g 102 Portable Dryer Troubleshooting Grain Sensor Procedure for Locating Testing and Replacing a Defective Grain Temperature Sensor Symptoms of a bad sensor may include Temperature readings that are not consistent with the ambient outside temperature or with any known verified grain temperatures entering the dryer Grain temp open or grain temp short on Network dryers Display readings of 255 or 127 Grain Thermistor Sensor Troubleshooting iP Locate the left and right grain sensor electrical boxes on the dryer see drawing below 2 Open each box by removing the lid They are held in place by 4 phillips head bolts and nuts 3 Once inside the box determine which wires you need to test by identifying the wire routing Grain Thermal Overheat wires Sensor wires Small white 26 ga Sensor Wires Small white 26 ga Grain Thermal Overheat wires 4 The grain sensor wires are small white 26 ga and are connected to a 18 ga white and a 18 ga black wire with 2 of the smaller 26 ga grain sensor wires butt connected together 5 The grain thermal overheat switch is a black disk mounted on a silver bracket with 2 black 18 ga wires connected to 2 colored wires 6 Disconne
118. oads has tripped shutting down the dryer Each of the Motor Overloads is located in the upper main power control box They are all wired into a single series circuit that goes to the input output board on terminal 14 12 Be fore the dryer will start terminal 14 12 must have 12 volts DC present or the Motor Overload shutdown will occur Visually inspect each of the overloads You can tell by looking at them if a trip has occurred Simply press the reset handle on the overload to reset it After resetting the overloads press the stop button to clear the error Ifnooverloads are tripped try the following volt age tests Using terminal J5 11 as the negative terminal for all DC voltage checks Look for 12 volts DC on terminal J 419 This is the terminal that feeds power to the Motor Overloads If the 12 volts DC is present then check for voltage on J4 12 During a Motor Overload shutdown J4 12 should have zero volts If you have power going to and not returning to J4 12 inspect the siring from J4 19 to the overloads and then back to J4 12 If the wiring is okay turn off all power to the dryer and do a continuity check from J4 19 to J4 12 This must be closed circuit to operate properly Portable Dryer Troubleshooting Motor Overload Helpful Hints Each of the Motor Overload is run in a series circuit This means if any of the Motor Overloads trip a shutdown will occur Visually inspect the overload to tell which has caused the shutdown
119. ome on then three 3 will go out leaving the power light still on 7 Push the start button on the programmer to start the transfer of Software 8 The busy light will flash until the transfer process is complete 9 When completed the pass light will flash indicating a successful transfer 10 If the fail light flashes then check your connections and repeat the above process 11 Turn Control Power on dryer to off and remove the cable 12 Turn on the dryer and the opening screens should indicate the newer version of software 91 Portable Dryer Troubleshooting Competitor Wiring Reference Programmer Hook Up Diagram HalWNINVHOOHd d OLNI SIH L Mover ead OLOANNODO cef Ol OS OL O6 OL or 919 060 O6 6L ood o wel AINO HO1V8 310A9 3413 GVO ON Sf HOLIMS did oat NO 44O NO 440 OTIH 31949 HANHNE 9 HOLIMS did Ms AGOW ONI1009 AON39U3IN3 HOLIMS did E 330 HO NO 1531 HOLIMS HIV 8 HOLIMS did e SLHOd oler SHOLIMS did O9 CES Or O 2 LO N Sc h Bee 9 Pr AV 1dSIGQ t5 ONIHOLINOMW m H3INHOJSNVH L Zf
120. ork if these are kicked out These temperature limits are in addition to the electronics high limits and are located in the same electrical conduits as the electronic thermister sensors Note that J7 01 is the terminal the computer checks for 12 volts 5 SPECIAL KEY USAGE 1 Pushing the UP arrow key will gives the Dryers Hour Meter reading Two successive screens Hours x 100 Balance of hours In software vers 2 14 and above it reads in 5 successive screens Total Hours x 100 Balance of hours Balance of minutes Batch Count Minutes since last shutdown So 5 23 12 144 188 would be Timer 523 hours 12 minutes 144 Batches dumped and 3 hours and 8 minutes since the last shutdown 2 Pushing the DOWN arrow key while an error is on the screen will tell how long ago the shutdown occurred 3 Pushing the MODE SELECT key exits any mode back to the main screen 4 Holding the STOP button for 4 seconds or longer causes the Dry Cool and Unload timers to be reset to the values programmed by the user This also forces new times 5 Holding down the HOURS key and turning on the power resets the NOVRAM or does what is called a HARD BOOT 6 Holding down the DOWN key while turning on the power restores the factory default settings 7 In software vers 2 19 and above Holding down the Up Arrow Key while powering up resets the Total Batch Counter 109 Operation Hints Portable Dryer Troubleshooting OPERATION HINTS FOR COMPETITOR DRYERS 6 OPERATI
121. ow into the switch then it should close If the switch does not close try adjusting it or replace it with a known good one Hints Dryer must be full of grain Light in the fan switch can be used exactly like a voltmeter to test Make adjustments of the pressure in one quarter turns Make sure the air tube in the plenum is not plugged after sitting over the summer Check the bulb in the fan light It is 12 volt bulb Troubleshooting Tips Vapor High Temperature Symptoms Dryer runs for only a short period of time then a shutdown occurs This message indicates that the vaporizer on an LP Dryer is not properly adjusted LP liquified petroleum must be vaporized before the burner can operate properly If LP is being fed to the dryer it must run through a vaporizer before it can be burned If the vaporizer is getting the fuel too hot it will cause a Vapor High Limit shutdown The vaporizer is located in the fan heater unit It is wrap of pipe mounted inside the fan can directly in front of the burner It can be seen by looking through the inspec tion door on the side of the burner To properly adjust the vaporizer a 1 2 wrench is needed Knowing that the gas can get too hot you must feel the pipe train before the regulator to check this tempera ture This point may be very hot so be careful while checking the temperature The temperature before the regulator must be warm to the touch This point cannot be hot no
122. points even if the unload system is turned off If this voltage is Zero check your incoming main power When the unload system is turned on you should be able to observe the SCR contactor energizing The power to the contactor should turn on and off with the unload switch You can check for power by putting an AC voltmeter across terminals Al and A2 Across these points you should read 120 Volts AC Also on the top of the contactor you can see a plunger pulling in whenever the contactor coil gets power When the contactor is energized power is transferred from terminals L1 and L2 to terminals T1 and T2 Understand that L and L2 are the Input of the SCR contactor and T and T2 are the Output of the contactor Check the SCR Drive Board Next if all the above checks out okay put your voltmeter across terminal Lland L2 of the SCR drive board You should get 220 Volts AC across these points when the Unload Switch Is Portable Dryer Troubleshooting in the 2 Speed position If this is present then the SCR contactor and input output board are okay If 220 volts AC is present across input of the SCR drive board L1 and L2 then check for voltage across the output of the board Change your voltmeter to check for DC voltage at a range above the 200 volt scale Put the leads across A and A The voltage across these two points will vary depending on where the speed control poten tiometer is turned Also try turning the poten tiom
123. r can it be cold only warm Use the 1 2 wrench to loosen the hold down bracket on the vaporizer Move the vapor izer away from the flame to cool down the pipe train or move it closer to the flame to make the pipe train warmer Troubleshooting Vapor High Temperature The dryer will shutdown but will probably restart as soon as the computer is reset This is because the high limit is an auto matic reset and after the dryer shuts down it allows the pipe train to cool down After the dryer is reset it will run from a few seconds to a few minutes and then shutdown again This is because the Vapor High Limit is heating up again as 61 Troubleshooting Tips soon the burner 15 turned on The vaporizer must be adjusted to solve this problem Using 75 11 as the negative test point for all voltage tests check for 12 volts DC using the following termi nals to help diagnose the problem Fan 1 J1 5 Fan 2 J1 6 Fan 3 J2 5 Fan 4 J2 6 Fan 5 J3 5 Fan 6 J3 6 Remember that each of these input terminals is part of the main safety circuit of the dryer and each must have 12 volts DC on it before the dryer will operate Vapor High Limit Hints 1 Anytime you adjust the Vapor High you should wait and be sure that the pipe train temperature stays constant It may slowly allow the pipe train to get hotter or colder the longer the dryer runs 2 If a dryer is shutting down constantly from a Vapor High Limit it may also be cau
124. rogramming the Series 2000 board If ordering Palm Pilot from GSI there are two kits available 003 0692 Palm Flash Program Kit Deluxe D01 1771 Series 2000 Programming Cable 003 0688 Palm Pilot color D03 0694 Palm Pilot Hot Sync Cable D03 0695 Palm Flash 9 Pin M M Adapter D03 0709 Disk CD Rom Palm Flash Software D03 0693 Palm Flash Program Kit Economy D01 1771 Series 2000 Programming Cable D03 0689 Palm Pilot M100 black amp white 003 0695 Palm Flash 9 Pin M M Adapter D03 0709 Disk CD Rom Palm Flash Software Programming Competitor Portable Dryer Troubleshooting Programming Competitor Dryer Using Palm Pilot Hot Sync Cable D03 0694 Palm Pilot D03 0689 M100 003 0688 DB 9 Adapter 003 0695 DB 9 Connector J2 Connector Connects to the back of CPU Display board DB 9 Connector Connects to the DB 9 M M adapter A Series 2000 Programming Cable D01 1771 Use on CPU Board Competitor Wiring Reference Back of Switch Panel Layout Portable Dryer Troubleshooting Hd 0 0 Sf 4 Tr Ud yg 0 m TANVd OVE NO dld1S TIVNIINH3 L i 01
125. roll board 2 T 3 wires together 12 Volt Portable Dryer Troubleshooting Wiring Reference Meter Roll Reversing YOU MUST ENTER INTO THE DRYER TO PARMETER MODE BY PRESSING THE INCREASE AND DECREASE BUTTONS SCR DRIVE SIMULTANIOUSLY YOU WILL HAVE THE FOLLOWING OPTIONS LISTED BOARD SHUTDOWN HISTORY PRESS ENTER DRYER MODEL E 1112 FANDELAY DEFAULT 5 FILLAUGER DEFAULT END BPHFACTOR DEFAULT 1 0 ORANGE PURPLE TEST METER ROLL DEFAULT YES TEST AIR SWITCH DEFAULT YES M R REVERSE DEFAULT NO lt CHANGE TO YES REVERSE DELAY DEFAULT 60 REVERSE TIME DEFAULT 1 DISPLAYED ONLY IF M R REVERSE b IS CHANGED TO YES JUMPER WIRES SHOULD REVERSE DELAY METER ROLLS NORMAL ROTATION TIME GO BETWEEN AMOUNT OF TIME METER ROLLS WILL OPERATE BEFORE TERMINALS 4 AND 5 THEY WILL BEGIN REVERSE ROTATION 4 1 TERMINALS 1 AND 8 REVERSE TIME METER ROLLS REVERSE ROTATION TIME AMOUNT OF TIME METER ROLLS WILL OPERATE IN THE REVERSED ROTATION MODE EXAMPLE REVERSE DELAY 10 MINUTES REVERSE TIME 1 MINUTE LOCATE THE ORANGE AND PURPLE WIRES COMING FROM THE SCR DRIVE BOARD GOING NOTE TO THE TERMINAL STRIP AND WHEN INSTALLING RELAY INSERT THE RELAY AS SHOWN BASE NOTE POSITION OF M x BLACK 14 WHITE SLOTS FOR RELAY 747 84 110 VAC C
126. sed from a gas line that is exposed to direct sunlight If the fuel line to the dryer is exposed to direct sunlight the liquid in the line will start to vaporize before it even gets to the dryer Then when it runs through the vaporizer it gets too hot and causes a shutdown no matter where you try and adjust the vaporizer This prob lem can be helped by insulating the gas line from outside heat 3 In extreme cases the vaporizer may have to be changed before it will run the proper temperature Example If a dryer has a burner with a three wrap vaporizer and the dryer is located in the southern United States you may have problems adjusting thevaporizer far enough from the flame In this case you may have to install a two wrap vaporizer Portable Dryer Troubleshooting The two wrap has less surface area and it will not heat the LP quite as much This may also be true in colder climates where a two wrap will not heat up enough In this case the pipe train may develop frost or even freeze the solenoids open The Vapor High Limit is an automatic reset safety device It will reset itself as soon as its temperature drops below 190 Be cause the pipe train of the burner cools down rapidly when there is a dryer shut down the Vapor High Limit will generally be cool before the operator gets back to the dryer As soon as he hits the stop button to reset the computer it comes back up to normal operation It appears that the dryer
127. so that the plenum can build up air pressure and close the air switch 1 With the Load Auger Fan Heater and Unload switches in the off position turn on the Control power then push the Dryer Power Start switch 2 With power now applied to the dryer flip the fan switch to the on position and watch the light right above that switch If the light illuminates when the fan reaches half its full speed then no adjustment is required However if the light does not illuminate until the fan is running at full speed or the light does not illuminate at all and the dryer shuts down the air switch is adjusted too high skip to step 3a If the light illuminates before the fan reaches half its full speed the air switch is adjusted too low skip to step 3b If the light above the fan switch illuminates after the fan reaches full speed or did not illuminate at all and the dryer shut down then the air switch needs to be made more sensitive Turn adjustment screw in the more sensitive direction counter clock wise Make this adjustment on the air switch 1 4 turn at a time and each time restart the fan and watch to see when the light illuminates 3b the light above the fan switch illuminates before the fan reaches half its full speed then the air switch needs to be less sensitive Turn adjustment screw in the less sensitive direction clockwise Make this adjustment on the air switch 1 4 turn at a time and each time restart the f
128. t Single 1 Phase Power Drawing New Version Portable Dryer Troubleshooting ONT 0 0 Hd 11 o X9 SN o QNI Yn ju num WA 011 a doe z TE T i T VINE WA 022 iii i eE EHE js hoon 0001 NO m ng 00 ER ue ono 9 072 E MIGNE m NOLITIGTSLSTU Ls Q
129. th ef ficient operation and reasonable ac cess to components Use extreme caution in working around high speed fans gas fired heaters augers and auxiliary con veyors which may start without warning when the dryer is operat ing on automatic control KEEP THE DRYER CLEAN DO NOTALLOW FINE MATERIAL TO ACCUMULATE IN THE PLENUM CHAMBER ORSURROUNDING THE OUTSIDE OF THE DRYER Continued safe dependable opera tion of automatic equipment de pends to a great degree upon the owner For a safe and dependable drying system follow the recom mendations within this manual and make it a practice to regularly in spect the operation of the unit for any developing problems or unsafe conditions Take special note of the safety pre cautions listed at left before attempt ing to operate the dryer Safety Sign Off Sheet Portable Dryer Troubleshooting Date Employer s Signature Employee Reference iring W ts In peddois si 1u s ud eq pinous oN uonisod pasoj y YANIS SI YOUMS y J 11990 20419 1 40 uoripuoo eu uO SI y 1ueseud eq p nous z eunsseJd omneis Aue 1 1 JOU eui 1 seu UP JI Jn290 JOE SIUL Z UO SI y Ji jueseJd eq SHOA Z L e1nssoJd oreis Jo sso sejeoipui suedo yms pue uloq pue eui
130. this input NO AIR PRESSURE ZERO VOLTS HAS AIR PRESSURE 12 VOLTS DC Remember when checking for 12 volts DC you should always use one of the DC negatives for the black probe of your voltmeter Some of the terminals that may be used for the negative are J5 11 J5 12 or J5 13 To check fan 1 for air pressure with a voltmeter 1 Turn on the dryer 2 Place the black probe negative of your voltmeter on J5 11 or J5 12 3 Place the red probe positive of your voltmeter on J1 13 At this point there should be zero volts here be cause the fan is not running 4 Turn on the fan and watch your volt meter If the air switch is adjusted properly you should have zero volts across these test points when you first turn on the fan Af ter the fan has run up to about one half of its normal operating speed you should see the voltmeter change from zero volts to 12 volts DC This also works in reverse when turning off the fan After the fan is first turned off the voltmeter should still show 12 volts DC until the fan has slowed down to about one half of its operating speed This is because even though the fan is turned off it is still turning and developing some pressure in the plenum Portable Dryer Troubleshooting If all the above fails to work then remove the two wires while blowing into the air tube Blowing into the switch is the same as having atr pressure in the plenum You should have an open circuit until you bl
131. us Temperatures in the following manuals The Competitors use the Thermister type sensors the bolt style for the Plenum and the round style for the Grain Temperature Located in Resource 2003 CD in the Resources Manuals Folder PNEG 630 Portable Dryer Trouble Shooting PNEG 377 Fan amp Heater Service Manual Feb 2000 pdf Page 50 Fans and Heaters Trouble Shooting Guide 9 TROUBLESHOOTING TIPS 1 If some 110 volt contactor control devices work and some do not check the fuse on the IO board to see if it has failed Likely devices that will not work are the Load Auger Unload Auger and SCR drive 110 Error Codes Series 100 Error Conditions Portable Dryer Troubleshooting seu 10 0W ou owej luil IU dwa uinu ld 10449 UO 19410 BY JO euo Jey sejeoipul siu Ajayes seb plone 1 150 pue eJnjrej pJeoq Ajejes ON punos6 oy peuous s Jsoues OY peuous S SHUI OG HOA 21 eui JO J nooo 25 s jod ueewjeq uedo jou 10151591 1Se eq 1015159 1 1 Aq pesneo eq osje 10413 SI JO SSO
132. x on the dryer Check for a pulsing voltage from J5 16 to J5 12 negative and J5 19 to J5 12 negative Across each of these test points you should be able to ob serve a pulsing DC voltage when the metering rolls are turning You should be able to speed up or slow down the pulses by turning the speed of the me tering rolls up or down Note Because a digital voltmeter cannot react fast enough you may not see a full 12 volts DC instead you may see pulsing from zero to about eight 8 volts Hints e When checking for a pulsing voltage J5 16 or J5 19 you should always leave the voltmeter across the terminals for about 30 seconds Watch the meter closely Each pulse should be about the same length and about the same time apart If this is not true suspect a prob lem with the sensor on the back of the dryer Troubleshooting Tips Air Pressure System When inspecting the sensor make sure that the wheel going through the sensor is positioned in the center and is not touch ing either side If the sensor is scratched it is either bad or will probably go bad Airflow Operation Symptoms Dryer will indicate a Loss of Airflow After turning on a fan the computer must get a signal from the air pressure switch telling it that the fan is actually running and the plenum has been pressurized If the switch does not show the air pressure within 20 seconds a Loss of Airflow shutdown occurs Troubleshooting Loss o

GSI Outdoors PNEG-630 Clothes Dryer User Manual

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