GSI Outdoors PNEG-630 User manual

2004RevisedEdition
PNEG-630
Troubleshooting and
Reference Manual
GSI
Competitor &EMCS
Portable Dryer
Models
CompetitorSeries2000Dryer

Portable Dryer Troubleshooting
1
Table Of Contents
Safety..................................................................................................................................................................... 3
Safety Sign Off Sheet ............................................................................................................................................ 8
EMCS Portable Dryer (1993-1998)
Safety Voltage Check Points ................................................................................................................................. 9
Programming Instructions for EMCS Grain Dryers .............................................................................................. 10
EMCS Display Board ............................................................................................................................................ 11
Input/Output Board Identification .......................................................................................................................... 12
EMCS Switch Replacement.........................................................................................................................13
1100 Series Control Box Wiring .............................................................................................................................14
1100 Series Control Box Wiring (New) .................................................................................................................15
1200 Series Control Box Wiring............................................................................................................................. 16
1200 Series Control Box Wiring (New) .................................................................................................................17
1100 Fan Lower Control Box Interconnect Strip................................................................................................... 18
1200 Fan Lower Control Box Interconnect Strip .................................................................................................. 19
Upper Control Box External Wiring....................................................................................................................... 20
Fan Housing and Vapor Hi-Limit Circuit ...............................................................................................................21
Plenum Hi-Temperature Switch ............................................................................................................................ 22
FixedGrain Hi-Limit .............................................................................................................................................. 23
Grain & Plenum Hi-Limit Circuit ...........................................................................................................................24
Two Fan Plenum and Grain Limit Switch Wiring .................................................................................................. 25
Rear Discharge & Emergency Cooling Circuit .....................................................................................................26
Rear Discharge Mercury Switch...........................................................................................................................27
Adjustable Hi-Limit & Emergency Cooling Circuit ............................................................................................... 28
Motor Overloads ....................................................................................................................................................29
Air Pressure Switch............................................................................................................................................... 30
Air Pressure Switch Drawing................................................................................................................................ 31
Out of Grain Safety Circuit.................................................................................................................................... 32
Out of Grain Safety Circuit Drawing..................................................................................................................... 33
Upper Junction Box Wiring.................................................................................................................................... 34
Meter Roll Sensor .................................................................................................................................................. 35
Meter Roll Sensor Wiring ...................................................................................................................................... 36
Meter Roll Reversing............................................................................................................................................. 37
Lower Junction Box Wiring ................................................................................................................................... 38
New Fenwal Board Wiring.......................................................................................................................... 39
New Fenwal Board Troubleshooting.............................................................................................................40
Flame Control Circuit ............................................................................................................................................. 41
Fan Burner Circuit for Canadian Models .............................................................................................................. 42
Conversion Diagram for C Series Dryers to a Switchable Hi/Low or On/Off Burner .........................................43
Fan 28 LP Hi/Low-On/Off.................................................................................................................................... 44
Fan 28 LP On/Off Burner with Mercoid...............................................................................................................45
Fan 28 NG Hi/Low-On/Off ................................................................................................................................... 46
Fan 28 NG On/Off Burner with Mercoid .............................................................................................................. 47
Fan 42 LP Hi/Low-On/Off.................................................................................................................................... 48
Fan 42 LP On/Off Burner with Mercoid...............................................................................................................49
Fan 42 NG Hi/Low-On/Off ................................................................................................................................... 50
Fan 42 NG On/Off Burner with Mercoid .............................................................................................................. 51
SCR Drive Circuit.................................................................................................................................................. 52
RTD Temperature Sensor...................................................................................................................................... 53
Test Procedure for EMCS Dryers......................................................................................................................... 54
Temperature Charts ............................................................................................................................................... 55
EMCS Troubleshooting Tips........................................................................................................................ 56

Portable Dryer Troubleshooting
2
Table Of Contents
Competitor Series 2000 Dryer (Picture of Dryer)(1995 to Present)......................................................65
220 Volt Single (1) Phase Power Drawing ............................................................................................................ 66
220 Volt Single (1) Phase Power Drawing (New Version) .................................................................................. 67
220 Volt Three (3) Phase Power Drawing ............................................................................................................ 68
220 Volt Three (3) Phase Power Drawing (New Version) ................................................................................... 69
220 Volt 1 Phase Power Circuit (Ladder Diagram)........................................................................................70
220 Volt 3 Phase Power Circuit (Ladder Diagram)........................................................................................71
440 Volt 3 Phase Power Circuit (Ladder Diagram)........................................................................................72
Upper Control Box Internal Wiring........................................................................................................................ 73
Series 2000 Control Box Wiring (New Version) ....................................................................................................74
Series 2000 Control Box Wiring............................................................................................................................. 75
Series 2000 Control Box Wiring (380-460-575 3 Phase).................................................................................76
Upper Terminal Strip...................................................................................................................................77
Upper Terminal Strip (Moisture Control Hook-Up)........................................................................................78
Upper Terminal Strip (Moisture Control Relay Hook-Up)...............................................................................79
Moisture Manager to Dryer Wiring...............................................................................................................80
Input/Output Board & Terminal Strip .................................................................................................................... 81
Control Circuit (CPU/Display)(Ladder Diagram)......................................................................................... 82
Control Circuit (I/O Board)(Ladder Diagram)...............................................................................................83
Control Circuit (SCR Drive Board)(Ladder Diagram)....................................................................................84
SCR Board (Installing & Calibrating)............................................................................................................85
Upper Control Box External Wiring....................................................................................................................... 88
Input/Output Board 12 Volt.................................................................................................................................... 89
CPU Board Wiring.................................................................................................................................................90
Programming Instructions for Competitor Series Grain Dryers ............................................................................91
Programming Hook Up Diagram...........................................................................................................................92
Back of Switch Panel Layout ................................................................................................................................ 95
Back of Switch Panel Wiring................................................................................................................................. 96
Air Switch Assembly ............................................................................................................................................. 97
Air Switch Adjusting...................................................................................................................................98
Fixed Grain Hi-Limit & Temperature Sensor ........................................................................................................ 99
Out of Grain Sensor...................................................................................................................................100
Grain Temperature Sensor..........................................................................................................................101
Grain Sensor Testing..................................................................................................................................102
Grain Sensor (Locating,Testing,& Replacing)...............................................................................................103
Sensor Resistance/Temperature Chart.........................................................................................................105
Plenum Sensor (Locating,Testing & Replacing)............................................................................................106
Stern and Capacitor Diagram......................................................................................................................108
Operation Hints..........................................................................................................................................109
Series 2000 Error Conditions.......................................................................................................................111
Heater Circuit............................................................................................................................................113
Fan Burner Circuit for Canadian Models Only..............................................................................................114
Series 2000 LP 26"/28" Fan ........................................................................................................................115
Series 2000 Natural Gas 26"/28" Fan............................................................................................................116
Series 2000 LP 36"/42" Fan.........................................................................................................................117
Series 2000 Natural Gas 36"/42" Fan............................................................................................................118
Warranty....................................................................................................................................................119

Portable Dryer Troubleshooting
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
attentiontoinstructions concerning your
personalsafety. Watchfor this symbol;
it points out important safety precau-
tions. It means "ATTENTION",
"WARNING", "CAUTION", and "DAN-
GER". Read the message and be cau-
tious to the possibility of personal in-
jury or death.
Safety Alert Symbol
Thank you for choosing an GSI
Grain Dryer. It is designed to pro-
videexcellentperformanceandser-
vicefor many years.
Thismanualreferstothetrouble-
shootingoftheE.M.C.S.and Series
2000 Competitor models. Different
models are available for liquid pro-
paneornaturalgas fuel supply, with
eithersingle phase 230 volt, or three
phase 230, 460, 575 volt electrical
power. (Also 380 volt50Hz).
TheGSI 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
andadequate power issupplied.
Theprincipal concern of theGSI
Group, Inc. ("GSI") is your safety
andthe safety ofothersassociated
withgrainhandlingequipment.This
manual is written to help you un-
derstand safe operating proce-
dures, and some of the problems
thatmaybeencounteredbytheop-
eratoror other personnel.
Dryer Safety
Instructions and
Information
Asowner and/or operator,it isyour responsibility toknow what requirements,hazards and precautionsexist,
andto informall personnelassociated withthe equipment,or whoare inthe dryerarea. Avoid anyalterations to
the equipment. Such alterations may produce a very dangerous situation, where serious injury or death may
occur.

Portable Dryer Troubleshooting
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,contactGrain Systems, Inc. for
replacement.
A CAREFUL OPERATOR
IS THE BEST INSURANCE
AGAINST AN ACCIDENT
Grain Systems, Inc. recommends
you contact your local power com-
pany and have a representative sur-
vey your dryer installation, so your
wiringwillbe compatiblewiththeir
system and you will have adequate
power supplied to your unit.

Portable Dryer Troubleshooting
5
Safety

Portable Dryer Troubleshooting
6
Safety

Portable Dryer Troubleshooting
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 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
plenum or drying chamber.
7. Use CAUTION in working around high speed fans, gas burners, augers
and auxiliary conveyors which START AUTOMATICALLY.
8. Donotoperateinanyareawherecombustiblematerialwillbedrawninto
the fan.
9. Before attempting to remove and reinstall any propeller, make certain to
read the recommended procedure listed within the servicing section of
the manual.
10. Clean grain is easier to dry. Fine material increases resistance to airflow
and requires removal of extra moisture.
This product is intended for the use of grain handling only. Any other
use is considered a misuse of the product.
Someedgesoftheproductcomponentscanbesharp. Itisrecommended
that each component of this product be examined to determine if there
areanysafetyconsiderationstobetaken. Anyandallnecessarypersonal
protectiveequipment shouldbewornat all tineswhenhandling, 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.
Use Caution in the
Operation of this
Equipment
The design and manufacture of this
dryer is directed toward operator
safety. However, the very nature of
a grain dryer having a gas burner,
high voltage electrical equipment
and high speed rotating parts, does
present a hazard to personnel, which
can not be completely safeguarded
against, without interfering with 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.
READ THESE INSTRUCTIONS
BEFORE OPERATION AND SERVICE
SAVE FOR FUTURE REFERENCE
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-
cautionslisted at left before attempt-
ing to operate the dryer.
KEEP THE DRYER CLEAN
DO NOT ALLOW FINE
MATERIAL TO ACCUMULATE
IN THE PLENUM CHAMBER
OR SURROUNDING THE
OUTSIDE OF THE DRYER
Safety Precautions

Portable Dryer Troubleshooting
8
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Safety Sign-Off Sheet

Portable Dryer Troubleshooting
9
FAN # 12345 6
Error Message - + - + - + - + - + - + RESULT
Fan # Housing High Temperature J5-12 J1-7 J5-12 J1-8 J5-12 J2-7 J5-12 J2-8 J5-12 J3-7 J5-12 J3-8 12VDC
Burner # Vapor High Temperature J5-12 J1-5 J5-12 J1-6 J5-12 J2-5 J5-12 J2-6 J5-12 J3-5 J5-12 J3-6 12VDC
Burner # Flame not Detected J5-12 J1-9 J5-12 J1-10 J5-12 J2-9 J5-12 J2-10 J5-12 J3-9 J5-12 J3-10 12VDC
Plenum # High Temperature J5-12 J1-11 J5-12 J1-12 J5-12 J2-11 J5-12 J2-12 J5-12 J3-11 J5-12 J3-12 12VDC
Burner # Shutdown Loss of Airflow J5-12 J1-13 J5-12 J1-14 J5-12 J2-13 J5-12 J2-14 J5-12 J3-13 J5-12 J3-14 Note 1
Fan # Failure No Airflow J5-12 J1-13 J5-12 J1-14 J5-12 J2-13 J5-12 J2-14 J5-12 J3-13 J5-12 J3-14 Note 2
Fan # cannot Start Check Air Switch J5-12 J1-13 J5-12 J1-14 J5-12 J2-13 J5-12 J2-14 J5-12 J3-13 J5-12 J3-14 Note 3
1100/1200/1300 2200/2300/2400 3300/3400/3600
Lower or Left Fixed Grain J5-12 J1-19 J5-12 J1-19 J5-12 J1-19
Lower Adjustable or Right Fixed Grain J5-12 J4-19 J5-12 J4-19 J5-12 J4-19
Middle Fixed Grain J5-12 N/A J5-12 N/A J5-12 J4-4
Middle Adjustable Grain J5-12 N/A J5-12 N/A J5-12 J4-8
Upper Fixed Grain J5-12 N/A J5-12 J4-4 J5-12 J4-2
Upper Adjustable Grain J5-12 N/A J5-12 J4-8 J5-12 J4-6
Misc Errors
Auxilliary Safety Shutdown J5-12 J1-20 Note:
Motor Overload J5-12 J4-12 1 This error will occur if the fan and burner were both operating and
Grain Discharge Warning J5-12 J5-5 the air switch opens which indicates loss of static pressure.
Maxon Valve Shut Warning J5-12 J5-2 12 volts should be present if the fan is on.
Unknown Safety Error J5-12 J5-10 2 This error will occur if after the fan has started the air switch does
20 Second Safety Circuit Failure J5-12 J5-6 not detect any static pressure. 12 volts should be present if
the fan is on.
3 The condition for this error will occur if the air switch is stuck
in the closed postition. No voltage should be present if the dryer is stopped.
Wiring Reference
Safety Voltage Check Points