GSI Outdoors PNEG-630 manual

2004 Revised Edition PNEG-630 T r oubleshooting and Refer ence Manual GSI Competitor & EMCS Portable Dryer Models Competitor Series 2000 Dryer[...]

Portable Dryer T r oubleshooting 1 T able Of Contents Safety ..................................................................................................................................................................... 3 Safety Sign Off Sheet ...................................................................................................[...]

Portable Dryer T roubleshooting 2 T able Of Contents Competitor Series 2000 Dryer (Picture of Dryer)(1995 to Present) ......................................................65 220 V olt Single (1) Phase Power Drawing ........................................................................................ .................... 6 6 220 V olt Single (1)[...]

Portable Dryer T roubleshooting 3 Safety WARNING! BE ALERT! Personnel operating or working around electric fans should read this manual. This manual must be delivered with the equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the equipment. The symbol shown is used to call your attention to instructions [...]

Portable Dryer T roubleshooting 4 Safety 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 Grain Systems, Inc. rec[...]

Portable Dryer T roubleshooting 5 Safety[...]

Portable Dryer T roubleshooting 6 Safety[...]

Portable Dryer T roubleshooting 7 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 op[...]

Portable Dryer T roubleshooting 8 Date Employer’s Signature Employee ________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________ ____________________________________[...]

Portable Dryer T roubleshooting 9 FAN # 123 4 5 6 Error Message - + - + - + - + - + - + RESULT Fa n # H ous ing High Te m pe r ature J5- 1 2 J1- 7 J5- 1 2 J1- 8 J5- 1 2 J2- 7 J5- 1 2 J 2- 8 J5- 1 2 J3- 7 J5- 1 2 J 3- 8 12V D C Burner # Vapor High Temperature J5-12 J1-5 J5-12 J1-6 J5-12 J2-5 J5-12 J 2-6 J5-12 J3-5 J5 -12 J 3-6 12VDC Burner # Flame n[...]

Portable Dryer T roubleshooting 10 Programming Instructions for EMCS Grain Dryers Programming 1. T urn Control Power on dryer to off. 2. Locate programming jack (P7) on back of computer . (See page 13). 3. Plug the DB-9 jack of the programmer into the computer's jack. 4. Be sure that the rotary switch on the programmer is set to position 8. 5.[...]

Portable Dryer T roubleshooting 11 TO STOP SW. TO START SW. TO START & STOP SWS. 3 2 1 DISPLAY RIBBON S1 U12 P3 COMMUNICATIONS CABLE TO I/O BOARD P5 P4 KEY PAD RIBBON SOUND BATTERY (TIC) P7 P8 P1 P6 COMPUTER PROGRAMMING JACK PROGRAMMER JACK (DB9) EMCS Display Board Programming[...]

Portable Dryer T roubleshooting 12 Wiring Reference Input/Output Board Identification 1 3 5 7 9 2 4 6 8 10 12 14 16 18 20 11 13 15 17 19 J1 1 3 5 7 9 2 4 6 8 10 12 14 16 18 20 11 13 15 17 19 J2 1 3 5 7 9 2 4 6 8 10 12 14 16 18 20 11 13 15 17 19 J3 1 3 5 7 9 2 4 6 8 10 12 14 16 18 20 11 13 15 17 19 J4 1 3 5 7 9 2 4 6 8 10 12 14 16 18 20 11 13 15 17 [...]

Portable Dryer T roubleshooting 13 Switch Replacement for EMCS Dryer Switch N/O Contact Block - Part No. D63-0006 Switch Light Block - D01-0455 Switch Replacement[...]

Portable Dryer T roubleshooting 14 Wiring Reference 1 100 Series Control Box W iring NEED JUMPER NEED JUMPER RED J5-8 120 VAC (BLACK) AC 1 120 VAC NEUT (WHITE) J9-3 USED ON SINGLE FAN NAT GAS ONLY SAFETY CIRCUIT RELAY CONTACTS LOCATED IN DRYER FAN CAN BOX SAFETY CIRCUIT IN BOLD IS FOR FLAME DETECTION ONLY. EACH OF THE TERMINALS CONNECTED TO IT CAN [...]

Portable Dryer T roubleshooting 15 Wiring Reference 1 100 Series Control Box W iring (New V ersion)[...]

Portable Dryer T roubleshooting 16 Wiring Reference 1200 Series Control Box Wiring 52 TOTAL TERMINALS SAFETY CIRCUIT NEED JUMPER NEED JUMPER RED 53 TOTAL TERMINALS 15 - RED 4 - BLUE 1 - WHITE/BLACK 3 - BLACK (1-16GA) 9 - WHITE (1-16GA 2 - BROWN 4 - PURPLE 4 - ORANGE) -12VDC AIR PRESSURE SWITCH +12VDC 1200EW98.PRT REV. DATE 3/5/98 HOOK OTHER SIDE OF[...]

Portable Dryer T roubleshooting 17 Wiring Reference 1200 Series Control Box W iring (New V ersion)[...]

Portable Dryer T roubleshooting 18 J8-16 WHITE - AC NEUTRAL - UNLOAD NEUTRAL 35 - D01-0531 ENTRELEC TERMINALS 2 - D01-0533 END STOPS 1 - D01-0532 BLANK PROTECTOR END J9-17 BLUE - 120 VAC - FAN #1 POWER 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 INSTALL J1-9 TO J5-6 INSTALL J5-[...]

Portable Dryer T roubleshooting 19 1200 Fan Lower Control Box Interconnect Strip S2 ORANGE - TEMPERATURE SENSOR S1 ORANGE - TEMPERATURE SENSOR B2 WHITE - AC NEUTRAL - UNLOAD NEUTRAL J8-16 45 - D01-0531 ENTRELEC TERMINALS 2 - D01-0533 END STOPS 1 - D01-0532 BLANK PROTECTOR ENDS BLUE - 120 VAC - FAN #2 POWER J9-19 WHITE - AC NEUTRAL - FAN #2 NEUTRAL [...]

Portable Dryer T roubleshooting 20 YELLOW FROM J1-05 TO PLENUM HIGH LIMIT SWITCH WHITE TO S1 FROM GRAIN TEMPERATURE SENSOR BLACK TO S2 FROM GRAIN TEMPERATURE SENSOR BLUE TO J1-11 FROM PLENUM HIGH LIMIT SWITCH YELLOW FROM J1-05 TO PLENUM HIGH LIMIT SWITCH ORANGE TO J4-19 FROM RIGHT GRAIN HIGH LIMIT SWITCH RED FROM J5-05 TO RIGHT GRAIN HIGH LIMIT SWI[...]

Portable Dryer T roubleshooting 21 Fan Housing and V apor Hi-Limit Circuit Wiring Reference[...]

Portable Dryer T roubleshooting 22 Plenum Hi-T emperature Switch Wiring Reference[...]

Portable Dryer T roubleshooting 23 Fixed Grain Hi-Limit Wiring Reference[...]

Portable Dryer T roubleshooting 24 Grain & Plenum Hi-Limit Locations PLENUM SCR UNLOAD MOTOR 11XX RIGHT FIXED GRAIN HIGH LIMIT OUTSIDE LIGHT TEMP. SENSORS LOAD MOTOR LOAD MERCURY SWITCH UPPER BOX JUNCTION FAN SOLENOID BURNER HI-LOW THERMO AIR SWITCH LEFT FIXED GRAIN HIGH LIMIT TEMP. SENSORS GAS PIPE TRAIN LOWER BOX JUNCTION TO LOWER JUNCTION BO[...]

Portable Dryer T roubleshooting 25 2FNLMTSW98.PRT REV. DATE 4/5/98 RED TO J1-05 BLUE TO J1-11 YELLOW TO J1-12 FAN #1 PLENUM HIGH LIMIT SWITCH D03-0004 300 DEGREE FIXED GRAIN HIGH LIMIT SWITCH D03-0005 210 DEGREE RED TO J1-11 ORANGE TO J1-19 FAN #2 PLENUM HIGH LIMIT SWITCH D03-0004 300 DEGREE TO LOWER JUNCTION BOX JUNCTION BOX UPPER LOAD MERCURY SWI[...]

Portable Dryer T roubleshooting 26 Rear Discharge & Emergency Cooling Circuit Wiring Reference[...]

Portable Dryer T roubleshooting 27 Rear Discharge Mercury Switch POSITIONED WITH LID CLOSED AND SJOW 18/2 CORD POINTED TOWARDS THE FRONT OF THE DRYER CONNECT INSIDE METER ROLL BOX TO BROWN AND ORANGE WIRES. CONNECT TO SJOW CORD INSIDE LRL BOX LOOSEN SCREWS ON BRACKET TO CHANGE SENSITIVITY OF REAR DISCHARGE SWITCH Wiring Reference[...]

Portable Dryer T roubleshooting 28 Adjustable Hi-Limit & Emergency Cooling Circuit Wiring Reference[...]

Portable Dryer T roubleshooting 29 Motor Overloads Wiring Reference[...]

Portable Dryer T roubleshooting 30 Air Pressure Switch J5-8 J1-8 J1-6 J1-7 J1-5 8 J5 1 1 12 VOLT DC NEGATIVE 12 VOLT SOURCE DC POSITIVE J2 J3 INPUT/OUTPUT BOAR D TERMINAL LOCATION S J1-10 J1-9 J1-12 J1-11 J1-19 J 1 J6-14 J5-5 J4-19 J6-17 J4-12 J4 12 J1-14 J1-13 14 12V DC SOURCE FROM MOTOR OVERLOADS FAN #2 PRESSURE SWITCH FAN #1 PRESSURE SWITCH 13 P[...]

Portable Dryer T roubleshooting 31 HIGH BACKVIEW OF AIR SWITCH ASSEMBLY TO UPPER CONTROL BOX BLUE J1-13 AIRFLOW (N.O.) BLUE J5-08 12VDC POSITIVE CALIBRATED WITH DIAPHRAGM VERTICAL C N.C. N.O. JUNCTION BOX LOWER GAS PIPE TRAIN TEMP. SENSORS LIMIT GRAIN HIGH LEFT FIXED AIR SWITCH SOLENOID FAN JUNCTION BOX UPPER LOAD MERCURY SWITCH MOTOR LOAD TEMP. SE[...]

Portable Dryer T roubleshooting 32 Out of Grain Safety Circuit Wiring Reference[...]

Portable Dryer T roubleshooting 33 Out of Grain Safety Circuit Location JUNCTION BOX LOWER GAS PIPE TRAIN TEMP. SENSORS LIMIT GRAIN HIGH LEFT FIXED AIR SWITCH THERMO HI-LOW BURNER SOLENOID FAN JUNCTION BOX UPPER LOAD MERCURY SWITCH MOTOR LOAD TEMP. SENSORS OUTSIDE LIGHT LIMIT GRAIN HIGH RIGHT FIXED 11XX MOTOR UNLOAD SCR PLENUM REMOVE THESE EARS SJO[...]

Portable Dryer T roubleshooting 34 Upper Junction Box Drawing RED WHITE TO OUTSIDE LIGHT FIXTURE BLACK BLACK J5-04 TO 12VDC J5-09 J9-03 L1 TO LOAD MERCURY SWITCH WHITE BLACK BLACK WHITE TO UPPER CONTROL BOX PLENUM SCR UNLOAD MOTOR 11XX RIGHT FIXED GRAIN HIGH LIMIT OUTSIDE LIGHT TEMP. SENSORS LOAD MOTOR LOAD MERCURY SWITCH UPPER BOX JUNCTION FAN SOL[...]

Portable Dryer T roubleshooting 35 Meter Roll Sensor J5-09 J5-12 J5-19 J5-16 J5-05 J1-19 TO REAR DISCHARGE SWITCH TO REAR JUNCTION BOX LEFT METER ROLL SENSOR RIGHT METER ROLL SENSOR J5-09 J5-12 J5-19 RED 12VDC POS BLACK OR WHITE/BLACK STRIP 12VDC NEG YELLOW LEFT METER PULSE RETURN BLUE RIGHT METER PULSE RETURN ORANGE REAR DISCHARGE RETURN BROWN 12V[...]

Portable Dryer T roubleshooting 36 Meter Roll Sensor Wiring 1997 Dryers have only 1 meter roll board. Remove one meter roll board and tie the 2 T-3 wires together. Board Meter Roll Board Meter Roll 12 Volt + 12 Volt - 12 Volt - 12 Volt + Pulse Pulse T-2 T-1 T-3 T-2 T-1 T-3 METER ROLL SENSOR J5-5 S2 S1 J5-12 J1-20 J5-9 J5-19 J5-16 J5-4 J7-8 J7-3 B1 [...]

Portable Dryer T roubleshooting 37 Meter Roll Reversing 14 9 13 12 1 4 85 TO DC DRIVE MOTOR ORANGE PURPLE J7-17 NOTE: WHEN INSTALLING RELAY BASE NOTE POSITION OF SLOTS FOR RELAY!! JUMPER WIRES SHOULD GO BETWEEN: TERMINALS 4 AND 5 TERMINALS 1 AND 8 A+ J8-20 A- ORANGE PURPLE WHITE BLACK YOU MUST ADD A JUMPER WIRE FROM J9-09 TO J7-16 IN THE LOWER CONT[...]

Portable Dryer T roubleshooting 38 Lower Junction Box Wiring WHITE S1 BLACK S2 RED J1-11 ORANGE J1-19 BROWN FROM J1-19 TO DISCHARGE SWITCH ORANGE FROM J5-05 TO DISCHARGE SWITCH RED 16 GA. A+ TO SCR DRIVE MOTOR BLACK 16 GA. A- TO SCR DRIVE MOTOR GREEN 16 GA. TO SCR DRIVE GROUND TO LEFT FIXED GRAIN HIGH LIMIT AND TEMPERATURE SENSORS WIRES GO TO UPPER[...]

Portable Dryer T roubleshooting 39 The B. GND terminal is used to ground the burner and to complete the flame current signal circuit. This terminal is new for systems that used the older version of the Fenwal board. This terminal must be connected to the burner (chassis) ground not only to ensure the best, long term, stable flame signal, but also t[...]

Portable Dryer T roubleshooting 40 Fenwal Board T roubleshooting On-Board Diagnostics The LED will flash on for 0.2 seconds then off for 0.2 seconds to indicate an error condition. The pause time between error codes will be 2.5 to 3.0 seconds. During power-up, the LED will light for one second and then turn off to indicate normal operation. LED Ind[...]

Portable Dryer T roubleshooting 41 Coil V1 20 SEC SAFETY 12 VOLTS DC 120 VOLTS AC WHT WHT FENWAL BOARD WHT WHT OR COMMON COMMON Neutral COIL Normal Closed Normal Closed WHT OR Coil WHT WHT BLK TER. 1-5 (12 VOLTS DC) TER. 6-8 (110 VOLTS AC) WHT BRN BLK Neutral BLK BRN 120 VOLTS AC 20 SEC INPUT OR OR MAIN CONTROL BOX ALL WIRES COME FROM BRN BURNER LI[...]

Portable Dryer T roubleshooting 42 IGNITOR SENSOR FLAME DELAY TIME E2 S1 L2 V2 L1 V1 FENWAL PART# HF-4624 12 VOLTS DC 20 SEC SAFETY VAPOR LIMIT HOUSING LIMIT VAPOR HOUSING LIQUID LOW HIGH 110 VOLTS AC NEUTRAL- - - - WHT L1 BURNER PUR RED YEL ORG WHITE BLK BLACK BLK BRN BROWN WHITE BLACK PURPLE PURPLE YELLOW YELLOW ORG ORG ORG ORG ORG YEL RED PUR WH[...]

Portable Dryer T roubleshooting 43 Conversion Diagram For C Series Dryers T o A Switchable Hi/Low Burner Or A On/Off Burner Wiring Reference[...]

Portable Dryer T roubleshooting 44 Fan 28 LP Hi/Low-On/Off Wiring Reference[...]

Portable Dryer T roubleshooting 45 Fan 28 LP Hi/Low-On/Off Burner With Mercoid Wiring Reference[...]

Portable Dryer T roubleshooting 46 Fan 28 NG Hi/Low-On/Off Wiring Reference[...]

Portable Dryer T roubleshooting 47 Fan 28 NG Hi/Low-On/Off Burner With Mercoid Wiring Reference[...]

Portable Dryer T roubleshooting 48 Fan 42 LP Hi/Low-On/Off Wiring Reference[...]

Portable Dryer T roubleshooting 49 Fan 42 LP Hi/Low-On/Off Burner With Mercoid Wiring Reference[...]

Portable Dryer T roubleshooting 50 Fan 42 NG Hi/Low-On/Off Wiring Reference[...]

Portable Dryer T roubleshooting 51 Fan 42 NG Hi/Low-On/Off Burner With Mercoid Wiring Reference[...]

Portable Dryer T roubleshooting 52 SCR Drive Circuit To Coil WITH POWER WIRES UPPER POWER STRIP TO TERMINAL ON CONTACTOR SCR S C R Board To SCR Drive Motor F + F - L 1 L 2 A - A + A - A + L 1 L 2 Fuse 220 Volt COIL L1 T1 T2 L2 A2 A1 PUR SCR 2 J6-4 J6-1 J8-20 SCR P3 SCR P2 SCR P1 SCR POWER SCR NEUTRAL J8-10 BLK BLK OR OR OR 3 2 1 7 5 8 6 P P P W Wir[...]

Portable Dryer T roubleshooting 53 R TD T emperature Sensor BLACK 20 GA. WHITE 20 GA. REAR FRONT INSIDE GRAIN COLUMN CONDUIT TO UPPER CONTROL BOX WHITE S1 BLACK S2 PLENUM SCR UNLOAD MOTOR 11XX RIGHT FIXED GRAIN HIGH LIMIT OUTSIDE LIGHT TEMP. SENSORS LOAD MOTOR LOAD MERCURY SWITCH UPPER BOX JUNCTION FAN SOLENOID BURNER HI-LOW THERMO AIR SWITCH LEFT [...]

Portable Dryer T roubleshooting 54 T est Procedur e for E.M.C.S. Dryers IF NONE OF THE MEASUREMENTS = 3.4 K, THEN CHECK EACH INDIVIDUAL SENSOR. IF MEASUREMENTS DO NOT = 3.4 K CHECK CONNECTIONS IN WHITE JUNCTION BOX ON FAR LEFT AND RIGHT SIDES FACING THE FAN END. IF OHMS DOES NOT = 3.4 K CHECK LOWER AND UPPER TERMINAL STRIP (ON SINGLE MODULES CHECK [...]

Portable Dryer T roubleshooting 55 T emperatur e Charts W e 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 ris[...]

Portable Dryer T roubleshooting 56 • 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 [...]

Portable Dryer T roubleshooting 57 Fenwal Ignition System Symptoms: Burner will not light, dryer shutdown for "Loss of Flame" Fenwal Ignition Operation 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 t[...]

Portable Dryer T roubleshooting 58 • 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 l[...]

Portable Dryer T roubleshooting 59 Hints Metering Roll Sensors Metering Roll Sensor Operation • 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. [...]

Portable Dryer T roubleshooting 60 Air Pressure System Symptoms: Dryer will indicate a "Loss of Airflow" 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 p[...]

Portable Dryer T roubleshooting 61 Symptoms: Dryer runs for only a short period of time, then a shutdown occurs. erature Operation • This message indicates that the vaporizer on an LP Dryer is not properly adjusted. LP (liquified petroleum) must be vaporized before the burner can operate properly . If LP is being fed to the dryer it must run thro[...]

Portable Dryer T roubleshooting 62 soon as the burner is turned on. The vaporizer must be adjusted to solve this problem. Using J5-1 1 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[...]

Portable Dryer T roubleshooting 63 Out Of Grain W arning • This message indicated that the dryer has run low on grain. The shutdown occurs when the loading equipment has run longer than the time the operator has set on the Out of Grain timer . The mer cury switch located on top of the dryer tells the computer when the dryer is full or calling for[...]

Portable Dryer T roubleshooting 64 T roubleshooting T ips This indicates that one of the Motor Overloads has tripped, shutting down the dryer . Each of the Motor Overloads is located in the upper main power control box. They are all wired into a single series circuit that goes to the input/output board on terminal J4-12. Be- fore the dryer will sta[...]

Portable Dryer T roubleshooting 65 Competitor Series 2000 Portable[...]

Portable Dryer T roubleshooting 66 220 V olt Single (1) Phase Power Drawing Competitor Wiring Reference OVERLOAD 110 VAC OUTPUT 220 VAC INPUT J6-02 AC-1 220V FUSES MOTOR TO FAN #1 MOTOR TO LOAD MOTOR TO AUX LOAD MOTOR TO UNLOAD MOTOR TO AUX UNLOAD CONTACTOR CONTACTOR CONTACTOR FAN #1 LOAD LOAD AUX UNLOAD UNLOAD AUX 10 9 8 7 6 5 4 3 2 1 TRANSFORMER [...]

Portable Dryer T roubleshooting 67 220 V olt Single (1) Phase Power Drawing (New V ersion) Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 68 110X0 AC1 3FO 1FO 120V FUSES 110 VAC OUTPUT 220 VAC INPUT AC NEUTRAL AC-1 220V FUSES CONTACTOR SCR TRANSFORMER MOTOR TO FAN #1 MOTOR TO LOAD MOTOR TO AUX LOAD MOTOR TO UNLOAD MOTOR TO AUX UNLOAD OVERLOAD OVERLOAD OVERLOAD OVERLOAD OVERLOAD CONTACTOR CONTACTOR CONTACTOR FAN #1 LOAD LOAD AUX UNLOAD UNLOAD AUX 15 14 [...]

Portable Dryer T roubleshooting 69 220 V olt Three (3) Phase Power Drawing (New V ersion) Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 70 COMPETITOR POWER CIRCUIT ( 220 VOL T 1PH ) Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 71 COMPETITOR POWER CIRCUIT ( 220 VOL T 3PH ) Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 72 COMPETITOR POWER CIRCUIT ( 440 VOL T 3PH ) Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 73 Upper Control Box Internal Wiring AC1 L1 L2 J6-02 3FO 1FO 110XO AC1 3FI 1FI 35 49 YEL YEL ORG ORG COM N/O N/C N/C COM N/O YEL LOAD N/O USER INSTALLED YEL LOAD COM USER INSTALLED ORG UNLD N/O USER INSTALLED ORG UNLD COM USER INSTALLED (CANADA ONLY) J1-16 MERCOID SWITCH BLK MAXON POWER J3-04 WHT MAXON NEUTRAL J3-03 [...]

Portable Dryer T roubleshooting 74 Series 2000 Control Box W iring (New V ersion) Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 75 Upper Control Box Wiring 220 V olt 1PH Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 76 Upper Control Box Wiring 380, 460 & 575 3PH Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 77 Competitor Wiring Reference Series 100 Control Box Wiring 100STRIP98.PRT REV. DATE 3/12/98 1 - END PROTECTOR# D01-0532 48 - COMPRESSION TERM.# D01-0531 2 - ENDSTOP# D01-0533 4 - GROUND TERMINAL# D01-0534 13" DIN RAIL# D03-0013 +12 VOLTS HOUSING HIGH LIMIT VAPOR HIGH LIMIT REAR DISCHARGE OUT OF GRAIN AIRFLOW A[...]

Portable Dryer T roubleshooting 78 Upper T erminal Strip With Moisture Control Hook Up Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 79 Upper T erminal Strip With Moisture Control Relay Hook Up Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 80 Moisture Manager to Dryer Wiring (Upper Control Box) Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 81 Input/Output Board & T erminal Strip PUR PUR RED RED --- J1-17 PUR --- SCR2 BLK --- LITE PUR --- J4-01 PUR --- J4-02 PNK RED RED --- J1-13 YEL BLK ORG RED WHT WHT WHT WHT WHT WHT --- J3-04 BLK --- J3-03 WHT --- J3-18 BLUE-3 BLACK-4 WHITE-6 RED-6 YELLOW-1 ORANGE-2 GREY-1 WHT/BLK-2 WIRES TO DOOR: RED-2 ORANGE-1 [...]

Portable Dryer T roubleshooting 82 Competitor Control Circuit CPU/Display Board Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 83 Competitor Control Circuit I/O Board Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 84 Competitor Control Circuit SCR Drive Board Competitor Wiring Reference[...]

Portable Dryer T roubleshooting 85 P3 P2 P1 L1 L2 A - A+ MIN MAX * The SCR board is located in the upper control box. * T erminals L1 and L2 are the input terminals. When the unload system is turned on there should be 220 V olts AC accross these terminals. * T erminals A+ and A- are the ouput terminals. The voltage across these terminals is DC and [...]

Portable Dryer T roubleshooting 86 A- A+ MAX Before starting the procedure set the dryer up as follows: 1. All fan and heater switches to off position and load switch to off position. 2. Control power to on position. 3. Push the dryer power switch. 4. Dryer mode switch to cont. flow position. 5. Moisture control switch to on position. 6. Unload swi[...]

Portable Dryer T roubleshooting 87 A- A+ MIN Setting SCR Board Minimum V oltage 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 [...]

Portable Dryer T roubleshooting 88 Upper Control Box External Wiring TO FAN CONTROL BOX TO AIRSWITCH ASSEMBLY TO LOWER JUNCTION BOX TO UPPER JUNCTION BOX TO PLENUM AND RIGHT FIXED GRAIN HIGH LIMIT SWITCHES AND TEMPERATURE SENSORS WHITE/BLACK STRIP J7-10 12VDC NEGATIVE PURPLE J7-13 FROM VAPOR HIGH LIMIT SWITCH RED J7-08 12VDC INPUT POWER TO HOUSING [...]

Portable Dryer T roubleshooting 89 Input/Output Board 12 V olt THESE JUMPERS MUST BE INSTALLED J1-1 TO J1-17 - USER SAFETY J1-1 TO J1-16 - MERCOID SAFETY AC NEUTRAL RL1-A N.O. HIGH SPEED POT B RL1-A N.C. LOW SPEED POT B RL1-B N.O. HIGH SPEED POT A RL1-B N.C. LOW SPEED POT A RL1-B COMMON TO POT INPUT ON SCR BOARD RL1-A COMMON TO POT INPUT ON SCR BOA[...]

Portable Dryer T roubleshooting 90 12 VDC GROUND - - - - MOTOR OVERLOAD PLENUM TEMP SENSOR OUT OF GRAIN SWITCH STOP SWITCH START SWITCH 12VDC NEGATIVE FLAME PROBE B FLAME PROBE A +12VDC OUTPUT AC NEUTRAL SPARE AC OUTPUT LIGHT AC NEUTRAL RL1 N.O. RL3 N.C. NO CONNECTION RL3 N.O. SCR DRIVE OUT RL3 COM SCR IN 120VAC TO I/O BOARD 110V NEUTRAL N 18 16 14[...]

Portable Dryer T roubleshooting 91 Programing Instructions for Competitor Series Grain Dryers Competitor Wiring Reference 1. T urn 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[...]

Portable Dryer T roubleshooting 92 Programmer Hook Up Diagram DB9 JACK PLUG THIS INTO THE PROGRAMMER J2 CONNECTOR SERIES 2000 CABLE PROGRAMMING JACK TO UPDATE SOFTWARE ON EPROM PLUG PROGRAMMER INTO THIS JACK RS485 COM PORTS J4 J5 J2 ON 8 7 6 5 4 3 2 1 DIP SWITCH #6 = BURNER CYCLE HI-LO (OFF) OR ON-OFF (ON) DIP SWITCH #5 = NO LOAD DURING LOW FIRE CY[...]

Portable Dryer T roubleshooting 93 Competitor Wiring Reference Programming Instructions Using Palm Pilot On the Competitor Dryer there is only one board to program. This board is called the CPU Display board. It is mounted to the door of the lower box. T o access, open the door and the pro- gramming jack is located on the back of this board. T o pr[...]

Portable Dryer T roubleshooting 94 P ro g ra m m in g C o m p e tit o r D r y e r U s in g P a lm P ilo t Pa lm Pilo t D 03- 0689 (M 100) D 0 3 - 0 6 8 8 ( IIIC ) Hot S ync C a ble D 03- 069 4 DB- 9 M -M Ada p t e r D 03- 069 5 J 2 C onn e c t or ( C o nnec ts to th e bac k o f CPU/ Di s p l a y b o a r d ) DB- 9 Co nn e ct o r Pa l m Si d e D r ye[...]

Portable Dryer T roubleshooting 95 Back of Switch Panel Layout MONITORING DISPLAY TRANSFORMER FUSE J6 19 20 12 J8 J6 1 1 3 3 J5 1 4 1 2 19 20 J7 START STOP METERING ROLL SPEED CONTROL POWER OUTSIDE LIGHT DRYING MODE BATCH CF com no com no LITE CONNECTS TO TERMINAL STRIP ON BACK PANEL J1-11 J1-09 J1-10 J3-11 J3-07 J1-04 J1-03 J3-01 J3-05 J1-08 J1-07[...]

Portable Dryer T roubleshooting 96 MONITORING DISPLAY TRANSFORMER FUSE J6 19 20 12 J8 J1 1 1 3 3 J5 1 4 1 2 19 20 J7 START STOP UNLOAD METERING ROLL SPEED HEATER CONTROL POWER OUTSIDE LIGHT DRYING MODE LOAD AUGER FAN J6-02 J6-02 J6-02 J6-2 J6-02 J6-02 J6-02 J7-15 J7-15 J7-15 J7-15 J7-15 BATCH CF com no com no J6-02 (AC NEUTRAL) WHITE J6-01 J6-01 (A[...]

Portable Dryer T roubleshooting 97 GREY J7-11 NO AIRFLOW (N.C.) PLENUM SCR UNLOAD MOTOR 1XX RIGHT FIXED GRAIN HIGH LIMIT OUTSIDE LIGHT TEMP. SENSORS LOAD MOTOR LOAD MERCURY SWITCH UPPER BOX JUNCTION FAN SOLENOID AIR SWITCH LEFT FIXED GRAIN HIGH LIMIT TEMP. SENSORS GAS PIPE TRAIN LOWER BOX JUNCTION C N.C. N.O. CALIBRATED WITH DIAPHRAGM VERTICAL WHIT[...]

Portable Dryer T roubleshooting 98 IMPOR T ANT : T o adjust the air switch the grain columns need to be full of grain so that the plenum can build up air pressure and close the air switch. With the Load Auger , Fan, Heater , and Unload switches in the of f position turn on the Control power then push the Dryer Power Start switch . With power now ap[...]

Portable Dryer T roubleshooting 99 Fixed Grain Hi-Limit & T emperature Sensor PLENUM SCR UNLOAD MOTOR 1XX RIGHT FIXED GRAIN HIGH LIMIT OUTSIDE LIGHT TEMP. SENSORS LOAD MOTOR LOAD MERCURY SWITCH UPPER BOX JUNCTION FAN SOLENOID AIR SWITCH LEFT FIXED GRAIN HIGH LIMIT TEMP. SENSORS GAS PIPE TRAIN LOWER BOX JUNCTION WHITE J7-13 BLACK J7-14 RED ORANG[...]

Portable Dryer T roubleshooting 100 Out of Grain Sensor JUNCTION BOX LOWER GAS PIPE TRAIN TEMP. SENSORS LIMIT GRAIN HIGH LEFT FIXED AIR SWITCH SOLENOID FAN JUNCTION BOX UPPER LOAD MERCURY SWITCH MOTOR LOAD TEMP. SENSORS OUTSIDE LIGHT LIMIT GRAIN HIGH RIGHT FIXED 1XX MOTOR UNLOAD SCR PLENUM REMOVE THESE EARS SJOW 18/2 WIRE EXITS THROUGH BOX COVER BL[...]

Portable Dryer T roubleshooting 101 Grain T emperature Sensor BLACK 20 GA. WHITE/BLACK STRIP 20 GA. REAR FRONT WHITE/BLACK STRIP J7-13 PLENUM TEMP SENSOR INSIDE GRAIN COLUMN CONDUIT TO LOWER JUNCTION BOX BLACK 20 GA. WHITE/BLACK STRIP 20 GA. REAR FRONT INSIDE GRAIN COLUMN CONDUIT TO UPPER CONTROL BOX CONNECT TO SHIELD OF WIRE CENTER WIRE CENTER WIR[...]

Portable Dryer T roubleshooting 102 Grain Sensor T esting SENSORS COMP98.PRT IF OHMS DOES NOT = 11.0 K CHECK LOWER AND UPPER TERMINAL STRIP (J7-13 GND & J7-14) IF MEASUREMENTS DO NOT = 11.0 K CHECK CONNECTIONS IN WHITE JUNCTION BOX ON FAR LEFT AND RIGHT SIDES FACING THE FAN END. IF NONE OF THE MEASUREMENTS = 11.0 K, THEN CHECK EACH INDIVIDUAL S[...]

Portable Dryer T roubleshooting 103 Grain Sensor Procedure for Locating, T esting and Replacing a Defective Grain T emperature Sensor Symptoms of a bad sensor may include: · T emperature readings that are not consistent with the ambient outside temperature or with any known verified grain temperatures entering the dryer . · Grain temp open or gra[...]

Portable Dryer T roubleshooting 104 Procedure for Locating, T esting and Replacing a Defective Grain T emperature Sensor . (continued) 1 1. Now move the red lead to the other disconnected 26 ga. wire and make note of this reading. 12. Go to the other side of the dryer and repeat steps 6 through 1 1. 13. Y ou will notice that 3 readings will be very[...]

Portable Dryer T roubleshooting 105 Procedure for Locating, T esting and Replacing a Defective Grain T emperature 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 boxe[...]

Portable Dryer T roubleshooting 106 Plenum Sensor Procedure for Locating, T esting and Replacing a Defective Plenum T emperature Sensor Symptoms of a bad sensor may include: T emperature 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[...]

Portable Dryer T roubleshooting 107 Procedure for Locating, T esting and Replacing a Defective Plenum T emperature 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 cond[...]

Portable Dryer T roubleshooting 108 Stern and Capacitor Diagram 10-17 HP 1Phase WIRE #8 FROM MOTOR WIRE #5 FROM MOTOR WIRE #1 FROM MOTOR 216-259uF, 250VAC CAPACITOR (ELECTROLYTIC) PART# TFH-2104 216-259uF, 250VAC CAPACITOR (ELECTROLYTIC) PART# TFH-2104 60uF, 370VAC CAPACITOR (OIL FILLED) FH-6448 STEARNS SWITCH PART# TF-1430 = 70 AMP PART# TF-1709 =[...]

Portable Dryer T roubleshooting 109 OPERA TION HINTS FOR COMPETITOR DR YERS 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 lb. Cycle on average 4 times per minute. 3 -5 times per minute is acceptable. 2. ERRORS 01 User switched from continuous fl[...]

Portable Dryer T roubleshooting 110 6. OPERA TION 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 S[...]

Portable Dryer T roubleshooting 111 Series 100 Error Conditions This indicates that one of the other on screen errors (vapor, plenum, housing temp hi-limit, flame out, no airflow, motor overload or rear discharge) has occured. Mercoid gas pressure safety. User supplied safety. I/O board communication failure I/O board and master have lost communica[...]

Portable Dryer T roubleshooting 112 Series 100 Error Conditions PLENUM ERROR THIS DISPLAY INDICATES A LOSS OF AIR PRESSURE INSIDE THE DRYER. THIS IS USUALLY CAUSED BY LACK OF GRAIN INSIDE THE DRYER. THE AIRSWITCH MAY ALSO NEED TO BE ADJUSTED SO THAT IT BECOMES MORE SENSITIVE TO AIR PRESSURE. (SEE FIGURE 1) THIS DISPLAY INDICATES THAT A MOTOR OVERLO[...]

Portable Dryer T roubleshooting 113 Heater Circuit J7-19 FLAME DETECTION ORANGE - J6-07-IGNITION NEUTRAL---WHITE J6-06-IGNITION POWER---BLACK J7-13-VAPOR-PURPLE J7-08-12V-RED J7-02-HOUSING-YELLOW J7-10-DC NEGATIVE - WHITE/BLACK STRIPE J6-12-MAIN SOL.-BLACK IGNITION TRANSFORMER TYPE 312-24A402V CODE D97T PRI V SEC V HZ PRI A SEC A 120 10,000 60 2.2 [...]

Portable Dryer T roubleshooting 114 J7-10 12VDC NEGATIVE WHITE/BLACK STRIP 1 PINK WHITE BROWN GREY J7-02 HOUSING HIGH LIMIT J6-14 CYCLE SOLENOID POWER J6-13 MAIN/CYCLE SOLENOID NETURAL WHT J7-19 FLAME DETECTION ORG J7-20 FLAME PROBE NEUTRAL WHT J6-07 IGNITION TRANSFORMER NEUTRAL J6-06 IGNITION TRANSFORMER POWER BLK FLAME PROBE (SILICONE WIRE) FLAME[...]

Portable Dryer T roubleshooting 115 S228LP.PRT J7-10 WHT/BLK J7-02 YEL J7-08 RED J7-13 PUR J6-14 BRN J6-13 WHT J6-12 BLK J6-06 BLK J6-07 WHT J7-20 WHT J7-19 ORG BROWN WHITE BLACK YELLOW YELLOW PURPLE PURPLE WIRES: 1 - WHITE 1 - BLACK 1 - BROWN 1 FOOT LONG FROM OUTSIDE OF BOX WIRES: 2 - PURPLE 2 - YELLOW 3 FEET LONG FROM OUTSIDE OF BOX BLACK WHITE B[...]

Portable Dryer T roubleshooting 116 Series 100 Natural Gas 26"/28" Fan S228NG.PRT J7-10 WHT/BLK J7-02 YEL J7-08 RED J6-14 BRN J6-13 WHT J6-12 BLK J6-06 BLK J6-07 WHT J7-20 WHT J7-19 ORG BROWN WHITE BLACK YELLOW YELLOW WIRES: 1 - WHITE 1 - BLACK 1 - BROWN 1 FOOT LONG FROM OUTSIDE OF BOX WIRES: 2 - YELLOW 3 FEET LONG FROM OUTSIDE OF BOX BLA[...]

Portable Dryer T roubleshooting 117 Series 100 LP 36"/42" Fan YEL PUR BLK WHT YEL PUR WHT BRN BLK BLK BLK J7-10 WHT/BLK J7-02 YEL J7-08 RED J7-13 PUR J6-14 BRN J6-13 WHT J6-12 BLK J6-06 BLK J6-07 WHT J7-20 WHT J7-19 ORG BROWN BLACK WHITE YELLOW PURPLE 12 FEET LONG FROM OUTSIDE OF BOX 1 FEET LONG FROM OUTSIDE OF BOX 3 FEET LONG FROM OUTSID[...]

Portable Dryer T roubleshooting 118 Series 100 Natural Gas 36"/42" Fan YEL BLK WHT YEL WHT BRN BLK BLK BLK J7-10 BLK/WHT J7-02 YEL J7-08 RED J6-14 BRN J6-13 WHT J6-06 BLK J6-12 BLK J6-07 WHT J7-20 WHT J7-19 ORG BROWN BLACK WHITE YELLOW 1 FEET LONG FROM OUTSIDE OF BOX 3 FEET LONG FROM OUTSIDE OF BOX WIRES: 1 - BROWN 1 - WHITE 1 - BLACK WIR[...]

Portable Dryer T roubleshooting 119 Warranty EXCEPT FOR THE ABOVE STATED EXPRESS LIMITED WARRANTIES, 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 (i) PRODUCT MANUFACTURED OR SOLD BY GSI OR (ii) ANY ADVICE, INS[...]

1004 E. Illinois St. Assumption, IL 62510-0020 Phone 217-226-4421 2004 Edition[...]