GSI Group PNEG - 1711 User manual

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Digital Thermostat Owner s Manual
Installation and Operation Manual
PNEG – 1711
Date: 2009
Digital Moisture
Control Thermostat

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Digital Thermostat Owner s Manual
READ THESE INSTRUCTIONS BEFORE
INSTALLATION and OPERATION.
SAVE FOR FUTURE REFERENCE.
Thank you for choosing a GSI Vision Series grain dryer. These units are among the finest grain dryers ever
built; designed to give you excellent operating performance and reliable service for many years. This manual
describes the installation and operation for all standard production model dryers. These dryers are available with
liquid propane or natural gas fuel supply, single phase 230 volt, three phase 230 or 460 volt (60Hz) electrical
power.
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 cannot be completely safeguarded against without interfering with efficient operation
and reasonable access to components. Use extreme caution in working around high speed fans, gas-fired
heaters, augers and auxiliary conveyors which may start without warning when the dryer is operating on
automatic control.
Continued safe dependable operation of automatic equipment depends, to a great degree, upon the owner.
For a safe and dependable drying system, follow the recommendations within the manual and make it a practice
to regularly inspect the operation of the unit for any developing problems or unsafe conditions. Take special note
of the Operating Precautions listed below before attempting to operate the dryer.
Keep the dryer clean. Do not allow fine material to accumulate in the plenum chamber.
A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENT.
OPERATING PRECAUTIONS
1. Read and understand the operation manual before attempting to operate the unit.
2. Keep ALL guards, safety decals, and safety devices in place. Never operate dryer while guards are removed.
3. Keep visitors, children and untrained personnel away from dryer at all times.
4. Never attempt to operate the dryer by jumping or otherwise bypassing any safety devices on the unit.
5. Always set the main power supply disconnect switch to OFF and lock it in the OFF position using a padlock
before performing any service or maintenance work on the dryer or the auxiliary conveyor equipment.
6. Before attempting to remove and reinstall the fan blade, make certain to read recommended procedure listed
within the SERVICING section of the manual.
7. Keep the dryer and wet holding equipment CLEAN. Do not allow fine material to accumulate.

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8. Set pressure regulator to avoid excessive gas pressure applied to a burner during ignition and when burner is
in operation. See page 19 for operating gas pressures. Do not exceed maximum recommended drying
temperatures.
9. Do not operate the dryer if any gas leak is detected. Shut down and repair before further operation.
10. Clean grain is safer and easier to dry. Fine material can be highly combustible, and it also requires removal
of extra moisture.
11. Use CAUTION in working around high-speed fans, gas burners, augers, and auxiliary conveyors which can
start automatically.
12. Be certain that capacities of auxiliary conveyors are matched to dryer auger capacities.
13. Do not operate in an area where combustible material will be drawn into the fan.
14. The operating and safety recommendations in this manual pertain to the common cereal grains as indicated.
When drying any other grain or products, consult the factory for additional recommendations.
15. Routinely check for any developing gas plumbing leaks. Check LP vaporizer for contact with burner vanes.

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Table of Contents
TABLE OF FIGURES ........................................................................................................................................................ 9
1. CONTENTS ..............................................................................................................................................................10
2. INSTALLATION .........................................................................................................................................................10
3. OPERATION .............................................................................................................................................................13
4. EXAMPLE SETUP ....................................................................................................................................................18
5. TROUBLESHOOTING GUIDE ...................................................................................................................................18
6. DRILL DIMENSIONS TO SCALE ...............................................................................................................................19
7. WARRANTY .............................................................................................................................................................21

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Table of Figures
Figure 1 - Drill Pattern ......................................................................................................................................................11
Figure 2 - A1 through A3 Connections...............................................................................................................................12
Figure 3 - B1 through B6 Connections...............................................................................................................................12
Figure 4 - Assembly Drawing ............................................................................................................................................13
Figure 5 - Default Hi / Lo Screen .......................................................................................................................................15
Figure 6 - Default On / Off Screen .....................................................................................................................................16
Figure 7 - Engaged Mode, notice the temperature to the left ..............................................................................................17
Figure 8 - Disengaged Mode, notice the temperature to the right .......................................................................................17

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1. Contents
1.1 Digital Thermostat Contents
Qty
GSI Part Number
Des ription
1 D03-0852 Digital Moisture Control Thermostat
4 S-8570 2.5” #10-24 Machine Screw, Pan Head Phillip Stainless Steel
4 S-2010 Nut, Nylock #10-24 Zinc
2. Installation
2.1 Mounting in Control Panel
1. Turn the Main Power Disconnect to the “OFF” position.
2. Use the following table to document the wiring of the Honeywell that is being replaced, as this will be
referenced later in the manual.
# on Honeywell
Wire Des ription
(RTD) 1
(RTD) 2
(NO) 4
(SRC) 5
(110 VAC) 8
(NEUTRAL) 9
3. Remove the Honeywell controller from the control panel door. Loosen the flat head screw at the bottom of the
face of the dial. Grab the edges of the controller on the front of the control panel door and pull away from the
control panel. The controller should slide out, leaving a shell in the 1/4 din cut-out.
On the left and the right side of the shell, there is a flat head screw. Loosen these screws until you are able to
remove the shell from the control panel door.
4. Holes need to be drilled in the control panel door for mounting new thermostat. This is a two person job, as the
door needs to be open at least 90 degrees from closed when the drill breaks through to avoid damaging
internal circuitry. Refer to Figure 1 for drilling dimensions. Make sure all wires and human limbs are out of the
way when drilling. Section 6 is a drawing to scale that can be removed from this manual to be used as a guide
for drilling the holes.

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Figure 1 - Drill Pattern
5. Before mounting the GSI moisture control to the panel door, attach the necessary wiring. Be sure to kill power
when installing. Table 1 depicts the relation between the Honeywell controller and the GSI moisture control.
Refer to Figure 2 and Figure 3 for connections of the GSI moisture control. For example, if a wire is attached
to the connection labeled “1” on the Honeywell controller, that wire would need to be attached to “A1” on the
GSI moisture control. Remove the four Phillip head screws from the corner of the controller to access the
connections on the GSI controller.
Table 1 - Honeywell to GSI relation
Honeywell
Conne tion #
GSI
Conne tion #
1 A1
2 A2
4 B3
5 B4
8 B1
9 B2

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Figure 2 - A1 through A3 Conne tions
Figure 3 - B1 through B6 Conne tions

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6. Once the control has been wired, refer to Figure 4 for mounting the new controller to the control panel door.
The S-7931 nuts are already installed in the bottom assembly (Figure 3). There are recessions on the bottom
of the corners of the box that fit the nuts. Make sure to place the gasket between the two box pieces.
Figure 4 - Assembly Drawing
7. The GSI Digital Thermostat is now ready for operation. Refer to Section 3 for operation instructions.
3. Operation
3.1 Setting Temperature Setpoint
Press and release the “SET” button to enter the temperature setpoint menu. Here the user may press and release the “UP”
or “DOWN” button to adjust the setpoint accordingly, incrementing/decrementing by one. The setpoint can be adjusted
rapidly by holding the “UP” or “DOWN” button. To accept the setpoint, press and release the “SET” button. The controller is
still running in the background while in this menu and the new setpoint is not accepted until the “SET” button is pressed.
While in the setpoint menu, if the user allows approximately twenty-five seconds to pass without pressing a button, the menu
is exited and the new setpoint is not saved.

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3.2 Configuration Menu
To access the configuration menu, press and hold the “SET” button until the configuration menu appears, approximately five
seconds. Once in the menu structure, us “UP” and “DOWN” to browse through the options and “SET” to enter the sub menu.
While in the configuration, if the user allows approximately twenty-five seconds to pass without pressing a button, the
configuration menu is exited and no changes will be saved. The following are the menu options.
3.2.1 Save and Exit
No modifications will actually be accepted until the user selects the “Save and Exit” option. Once selected, the
controller returns to the default screen with all of the new parameters being used and stored to a non-volatile EEPROM
(will not be erased on power down).
3.2.2 Operation Sele t
The Thermostat has four modes of operation. The factory default is “No Operation” to prevent accidental operation on
initial install.
3.2.2.1 No Operation
Relays are set to an open state.
3.2.2.2 Hi / Lo Operation (Plenum Temperature Control)
See Section 3.3.1
3.2.2.3 On / Off Operation (Plenum Temperature Control)
See Section 3.3.2
3.2.2.4 Dryer / TopDry Operation (Grain Temperature / Moisture Control)
See Section 3.3.3
3.2.3 Units Sele t
Choose between Standard (°F) and Metric (°C) units for the controller to use.
3.2.4 Sensor Sele tion
The controller can use one of two sensors, one being a BetaTherm Bolt Thermistor (HF-7236) and the other a
Honeywell RTD (D03-0045). See wiring diagram for installation.
3.2.5 Hi-Limit Differential
This is only applicable when the controller is in Hi / Lo mode. See Section 3.3.1 for behavior. Range from 10 to 30
degrees.
3.2.6 Temperature Differential
See descriptions of mode operations for behavior. Range from 1 to 10 degrees.

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3.3 Operating Modes
3.3.1 Hi / Lo Operation (Plenum Temperature Control)
There are three states the burner can assume when Hi / Lo operation is selected: High, Low, and Off.
Anytime the sensor temperature is below the temperature setpoint minus the differential, the controller will engage the
“High” state. Once the sensor temperature rises above the setpoint plus the temperature differential, the Thermostat
will enter “Low” mode and will remain in this state until one of two things happen:
1. The sensor temperature falls below the setpoint minus the temperature differential. At which point the
controller returns to “High” mode. This should be normal operation.
2. The sensor temperature rises above the temperature setpoint plus the temperature differential plus the hi-
limit differential. If this occurs the controller will switch the “Off” position until the sensor temperature drops
below the temperature setpoint minus the temperature differential.
The relay position in each state is depicted below.
Table 2 - Hi / Lo Controller States
Controller State
Relay 1
Relay 2
High Closed (0 Ω) Closed (0 Ω)
Low Closed (0 Ω) Open (∞ Ω)
Off Open (∞ Ω) Open (∞ Ω)
The default screen displays current state of controller, current sensor temperature, and current setpoint.
Figure 5 - Default Hi / Lo S reen
3.3.2 On / Off Operation (Plenum Temperature Control)
There are two states the controller can assume using On / Off operation: On and Off.
Anytime the sensor temperature is below the setpoint minus the temperature differential, the Thermostat will be in the
“On” state. If the sensor temperature rises above the setpoint plus the differential, the Thermostat will be in the “Off”
state.
The relay position in each state is depicted below.

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Table 3 - On / Off Controller States
Controller State
Relay 1
Relay 2
On Closed (0 Ω) Closed (0 Ω)
Off Open (∞ Ω) Open (∞ Ω)
The default screen displays current state of controller, current sensor temperature, and current setpoint.
Figure 6 - Default On / Off S reen
3.3.3 Dryer / TopDry Operation (Grain Temperature / Moisture Control)
There are two states the controller can assume using Dryer / TopDry operation: Engaged and Disengaged.
Anytime the sensor temperature is below the setpoint minus the temperature differential, the Thermostat will be in the
“Engaged” state. If the sensor temperature rises above the setpoint plus the differential, the Thermostat will be in the
“Disengaged” state.
The relay position in each state is depicted below.
Table 4 - Dryer / TopDry Relay States
Controller State
Relay 1
Relay 2
Engaged Closed (0 Ω) Closed (0 Ω)
Disengaged Open (∞ Ω) Open (∞ Ω)
The default screen displays the current setpoint on the top line and the current sensor temperature on the bottom line.
If the controller is in the “Engaged” mode, the current sensor temperature is displayed on the left side of the screen
(see Figure 7). If the controller is in the “Disengaged” mode, the current sensor temperature is displayed on the right
side of the screen (see Figure 8).

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Figure 7 - Engaged Mode, noti e the temperature to the left
Figure 8 - Disengaged Mode, noti e the temperature to the right

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4. Example Setup
Once the thermostat has been wired and secured to the control panel door, turn the power on. The display will show “GSI
Group, LLC” for approximately ten seconds while the thermostat is booting. The next screen will display “No Operation”,
provided this is the first time the controller has been used.
1. Press and hold the “SET” button until the configuration menu appears, approximately five seconds. You can press
and release “UP” or “DOWN” to navigate through the menus. Since “No Operation” is selected, the menus are
limited to “Operation Selection” and “Save and Exit”. Once an operation mode is selected other than “No
Operation”, more menus will be available depending on the mode.
2. “Operation Selection” is the first menu that is displayed in the configuration menu. While “Operation Selection” is
visible, press and release “SET” to enter the menu.
3. Press and release “UP” twice, or until “Dryer / TopDry” is displayed. Press and release “SET” to accept the
operation mode and return to the list of menus. You can now scroll through the menus to see the options that are
available for that mode of operation. Refer to Section 3.2 for an explanation of what each menu controls. Scroll
through the menus until “Exit and Save” is visible and press and release “SET” to save and exit the configuration
menu.
4. The controller should now display the default screen for “Dryer / TopDry” (Figure 7 and 8). Press and release the
“SET” button to enter the “Temperature Setpoint” menu. Use the “UP” and “DOWN” buttons to adjust the setpoint
to the desired temperature. Holding “UP” or “DOWN” will change the temperature rapidly. Once the desired
setpoint is displayed, press and release “SET” to accept the new setpoint.
5. The controller is now setup and ready to go. Refer to Section 3.3.3 for the behavior of the controller in this mode.
5. Troubleshooting Guide
# Symptom Fix
1 “System Error EEPROM Failure” is displayed Replace controller
2 “THERMISTOR ERROR” is displayed 1. Check the A2 and A3 connections on the controller
2. Check Thermistor that is attached
3 “RTD ERROR” is displayed 1. Check the A1 and A2 connections on the controller
2. Check the RTD that is attached
4 Nothing is displayed on the LCD Check the input power of the controller
5 Relay(s) does not open and close as
described in this manual
Replace controller
If problem is not resolved above, contact GSI Service Department at [phone].

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6. Drill Dimensions to S ale

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