GSi Grain PNEG-1509 User manual

Troubleshooting and
ReferenceManual
2006 Edition
PNEG-1509
PortableDryer
TouchScreen
Controls
PNEG-1509
Date:3-31-2006

DRYER SAFETY&DRYERINFORMATION...................................................................................................................................4
SPECIALSETUP SCREENS............................................................................................................................................................5
DRYERNETWORK LAYOUT...........................................................................................................................................................6
PROGRAMMINGINSTRUCTIONS...................................................................................................................................................7
PROGRAMMINGINSTRUCTIONS(cont’).......................................................................................................................................8
PROGRAMMINGINSTRUCTIONS(cont’).......................................................................................................................................9
PROGRAMMINGINSTRUCTIONS(cont’).....................................................................................................................................10
PROGRAMMINGINSTRUCTIONS(cont’).....................................................................................................................................11
PROGRAMMINGINSTRUCTIONS(cont’).....................................................................................................................................12
PROGRAMMINGINSTRUCTIONS(cont’).....................................................................................................................................13
PROGRAMMINGINSTRUCTIONS(cont’).....................................................................................................................................14
FRONTTOUCH SCREENDISPLAY..............................................................................................................................................15
FRONTTOUCH SCREENDISPLAY..............................................................................................................................................16
SETUPPARAMETERS..................................................................................................................................................................17
SELECTTIMERSCREEN..............................................................................................................................................................18
MODIFYTIMERSCREEN..............................................................................................................................................................19
MODIFYTEMPSCREEN................................................................................................................................................................20
MODIFYING PLENUMORGRAINSETPOINT..............................................................................................................................21
SELECTDRYERMODEL...............................................................................................................................................................22
SELECTBURNER MODE..............................................................................................................................................................23
MODIFYBURNER DIFFERENTIAL...............................................................................................................................................24
AIRSWITCHTESTINGSCREEN...................................................................................................................................................25
CHECK DISPLAYI/OSWITCH LITE OUTPUTS...........................................................................................................................26
CHECK DISPLAY I/OSWITCH INPUTS........................................................................................................................................27
MODIFY METERROLL SPEEDSETPOINT..................................................................................................................................28
SHUTDOWNERROR SCREEN......................................................................................................................................................29
SHUTDOWNHISTORY SCREEN...................................................................................................................................................30
SETTIME&DATE..........................................................................................................................................................................31
DISPLAYI/OBOARDERRORS.....................................................................................................................................................32
POSSIBLE MAINI/OBOARD ERRORS........................................................................................................................................33
POSSIBLEMAINI/OBOARD ERRORS(cont’)............................................................................................................................34
POSSIBLEMAINI/OBOARD ERRORS(cont’)............................................................................................................................35
POSSIBLE FAN&HEATERBOARD ERRORS(cont’)................................................................................................................36
Reference TableofContents
TABLEOFCONTENTS

HOWTOADJUSTAIRSWITCH.....................................................................................................................................................37
POSSIBLE FAN &HEATERBOARD ERRORS (cont’).................................................................................................................38
POSSIBLE FAN &HEATERBOARD ERRORS (cont’).................................................................................................................39
POSSIBLE FAN &HEATERBOARD ERRORS (cont’).................................................................................................................40
POSSIBLE FAN &HEATERBOARD ERRORS (cont’).................................................................................................................41
POSSIBLE FAN &HEATERBOARD ERRORS (cont’).................................................................................................................42
PROCEDUREFORDEFECTIVEPLENUMSENSOR....................................................................................................................43
TEMPERATURE/RESISTANCECHART......................................................................................................................................44
PROCEDURE FORDEFECTIVE GRAINSENSOR........................................................................................................................45
PROCEDUREFOR DEFECTIVE GRAINSENSOR (cont’)............................................................................................................46
PROCEDUREFOR DEFECTIVE GRAINSENSOR (cont’)............................................................................................................47
UPPER CONTROLPANEL WIRING (230 VOLT)..........................................................................................................................48
UPPER CONTROLPANEL WIRING (380,440 &575 VOLT)........................................................................................................49
UPPERTERMINALSTRIP..............................................................................................................................................................50
ACINPUTWIRING..........................................................................................................................................................................51
MAINI/OBOARD IDENTIFICATION..............................................................................................................................................52
FAN/HEATERBOXWIRING.........................................................................................................................................................53
FENWALBOARDWIRING.............................................................................................................................................................54
12 VDC WIRINGTOSWITCHES (2FAN)......................................................................................................................................55
12 VDC WIRINGTOSWITCHES (3FAN)......................................................................................................................................56
12 VDC WIRINGTOSWITCHES (4FAN)......................................................................................................................................57
12 VDC WIRINGTOSWITCHES (6FAN)......................................................................................................................................58
SWITCHINPUT WIRING(2FAN)...................................................................................................................................................59
SWITCHINPUT WIRING(3FAN)...................................................................................................................................................60
SWITCHINPUT WIRING(4FAN)...................................................................................................................................................61
SWITCHINPUT WIRING(6FAN)...................................................................................................................................................62
LAMPINPUTWIRING(2FAN).......................................................................................................................................................63
LAMPINPUTWIRING(3FAN).......................................................................................................................................................64
LAMPINPUTWIRING(4FAN).......................................................................................................................................................65
LAMPINPUTWIRING(6FAN).......................................................................................................................................................66
MOISTURECONTROLHOOKUP...................................................................................................................................................67
MOISTURE CONTROLBOARD IDENTIFICATION........................................................................................................................68
SWITCHI/OBOARDIDENTIFICATION.........................................................................................................................................69
Reference TableofContents
TABLEOFCONTENTS

ReferenceSafety
PnegXXXX -Troubleshooting
WARNING!BEALERT!
Personneloperating,workingor
servicing portabledryersshould
readthe ownersmanual.Failure
toread the manualanditssafety
instructionsisamisuseofthe
equipment.
Thesymbolshownisused tocall your
attentiontoinstructionsconcerningyour
personal safety.Watchforthissym-
bol;itpointsoutimportantsafetypre-
cautions.Itmeans "ATTENTION",
"WARNING", "CAUTION",and "DAN-
GER".Readthemessageandbe
cautioustothe possibilityofpersonal
injury ordeath.
SafetyAlertSymbol
ThankyouforchoosingaTouch
Screen Network GrainDryer.It isde-
signedtoprovide excellentperfor-
manceand serviceformanyyears.
Thismanualreferstothetrouble-
shootingofthe TouchScreen Net-
workDryermodels.Differentmodels
areavailable forliquid propaneor
naturalgasfuelsupply,witheither
singlephase230volt,orthree phase
230,460,575voltelectrical power.
(Also380volt50Hz).
The GSIGroup,Inc.recommends
contacting yourlocalpowercom-
pany,and havingarepresentative
surveyyourinstallation sothe wiring
iscompatiblewithyoursystemand
adequatepowerissupplied.
Asownerand/oroperator,itisyourresponsibilitytoknowwhatrequirements,hazardsandprecautions
exist, and toinformall personnelassociated withthe equipment,orwho arein the dryerarea.Avoidany
alterationstothe equipment. Suchalterationsmayproduceavery dangeroussituation,whereseriousinjuryor
deathmayoccur.
The principalconcernofthe GSIGroup,Inc.isyoursafetyand the safetyofothersassociated withgrain
drying equipment. Thismanualiswritten tohelpyou recognizesafeoperating,troubleshooting proceduresand
someofthe problemsthatmaybe encountered bythe operatororotherpersonnel.Thismanualisnota
subsituteforyourownersmanual.Pleaseread yourownersmanualindetail tohelpyou betterunderstand the
operation ofyourdryer.
DRYERSAFETY&DRYERINFORMATION

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SPECIALTOUCH SCREENSETUPSCREENS
Accessing variousscreenswill enableyou tomakechangeson howthe dryeroperates.
Someofthe featuresrarelyneed tobe changed oncethe dryerhasbeen setup. Mostof the
specialscreensareunderthe setup button on the maintouchscreen. Bytouching the setup
button,ascreen will appearwithmorebuttons. Asyou read thismanualyou will see thatthere
aremoreplacestoaccess morefeaturesand information byusing the touchscreen. Hereare
someexamplesbelow:
BurnerMode.........................On/Off orHi/Low
BurnerDifferential................Adjustablefrom1Degree to5Degrees
SetTime&Date....................Time&Date
AdjustableGrainHi-Limit....LowTempGrainApplications
DryerModel...........................MustSetupCorrectlyfortheDryertoRunProperly
DryerMode............................ContinuousFloworBatch
TemperatureScale...............FahrenheitorCelsius
MeterRoll Reverse...............55 Minutes&5MinutesReverse
Diagnostics...........................AirSwitch(EnableorDisableforTesting Dryer)
CheckDisplayI/OSwitchOutputs
CheckDisplayI/OSwitchLightOutputs
DataLoggerSetup...............AbilitytoLog ShutdownHistory
GrainMoisture&Temp

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Figure 4.1
Typicallayout ofVisionDryerNetwork.
The bootloadermasternode (DisplayI/O)connectstoaCPUhost(ICOP)viaan RS232
serialconnection toreceiveinstructionsand flashprogramdata.The masternode (Display
I/O)then consumesthesecommandsand dataitself, orpassesthemon tothe pertinent
slavenodes.Atypicallayoutof the Dryernetworkispresented below. The networkmaybe
maximallyexpanded toinclude 1Host(ICOP), 1DisplayI/O, 1MainI/O, 1MoistureControl
and up to6Fan / Heatersinterfaces. Eachone ofthesenodeswill requireupdatestobe
delivered byDryerbootloader.
Computer
Host
(ICOP) DisplayI/O
Board
MainI/O
Board Fan
Heater
Board
Moisture
Control
Board
Fan
Heater
Board
RS 232
PORT RS232 PORT
DRYERNETWORK LAYOUT

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PROGRAMMINGINSTRUCTIONS
USB
PORT
Figure2:USBPortLocation
2.)Locatethe USB porton the bottomofthe DryerControlComputer(see figure2).The DryerControl
Computerison the back side ofthe dryercontrolpanel.
CONTROLPOWER
SWITCH
Figure1:Control Panel
1.)Turnoff the controlpower. (see figure1).
DRYERCONTROL
COMPUTER

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8
5.)When the bootscreen appearstouchthe LookForNewProgramon FlashCard button.
NOTE:Touching the Update/ChangeProgram button will allowyou tochange toadifferentprogram
thatisalreadyon the computerharddrive.
Figure4:BootScreen
USB FLASH
DRIVE INSTALLED
Figure3:USBFlashDrive
insertedinUSBport
4.)Turnon the dryercontrolpower.(see figure1).The dryercontrolcomputerwill start.
3.)InsertUSB flashdriveintoUSB (see figure3).
PROGRAMMINGINSTRUCTIONS

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6.)The displaywill nowconfirm thatproramfileswerefound on USB flashdriveand thattheyare
being copied tothe dryercontrolcomputerharddrive.
Figure5:Copyingfiles
fromUSBflashdriveto
dryercontrol computer
7.)Afterthe programfilesaretransfered,the Bootloaderscreen will appear.Beginbytouching the
ScanNetwork button.Thisscan will check yourdryertomakesureall partsofthe controlsystemare
communicatingcorrectly.
SCANNETWORK
BUTTON
Fig.6:ScanNetwork
PROGRAMMINGINSTRUCTIONS

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10
SELECTPROGRAM
BUTTON
Figure.8:SelectProgram
9.)Touchthe SelectProgrambutton.
Figure.7:NetworkScan
Complete
8.)Afterthe scan iscompletethe DisplayI/O, MainI/O, MoistureControl,and the Fan/Heater(s)should
be shownasNothing ToReport(see figure7).Touchthe Exit button.
EXIT
BUTTON
PROGRAMMINGINSTRUCTIONS

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MOVE UP&
MOVE DOWN
BUTTONS
Figure. 9:SelectDryer
Program.
10.)Selectthe programfileyou wanttoupload bytouching the MoveUp and MoveDown buttonsuntil
the desired programfileishighlighted.Touchthe Accept/Exit button.
ACCEPT/EXIT
BUTTON
STARTUPLOAD
BUTTON
Figure.10:StartUpload
11.)Touchthe StartUpload button.
PROGRAMMINGINSTRUCTIONS

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12
13.)The computerwill nowbeginprogramming eachofthe networkcircuitboardson the dryer.The box
on the rightofthe screensliststhe networkcircuitboardsdetected inthe scan.Eachcircuitboardlisted
will havetobe reprogrammed,sothismaytakeafewminutes.Fileupload progress forcircuitboardthat
ishighlighted isdisplayed inthe boxabove(see figure12).
When thisstep iscompletethe bootloaderscreen will reappear.
Figure.11:StartUpload
12.)When the Upload Progress screen appearstouchthe StartUpload button.
Figure.12:UploadProgress
PROGRAMMINGINSTRUCTIONS

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EXITTODRYER
BUTTON
Figure.13:ExittoDryer
14.)The programupload procedurewassuccessful.Touchthe ExitToDryer button toexitbootloader
and startthe dryer.
15.)The dryerwill beginrunning the programthatwasjustinstalled.
Figure.13:Starting Dryer
PROGRAMMINGINSTRUCTIONS

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Figure.14:ProgramUploadComplete
16.)The dryercontrolisnowreadytooperatethe dryer.
PROGRAMMINGINSTRUCTIONS

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FRONTTOUCH SCREENDISPLAY
•SHOWINGDATACOLUMNMODE
•CHOOSE FREQUENCYOFSAMPLINGTIME
•VIEWTHEFOLLOWING:
√SAMPLETIME&DATE
√GRAINTEMPIN&OUT
√GRAINMOISTUREIN&OUT
√METERROLL OUTPUT%
√BACKWARD VIEWINGAVAILABLE

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FRONTTOUCH SCREENDISPLAY
•SHOWINGDATAGRAPHMODE
•CHOOSE FREQUENCYOFSAMPLINGTIME
•CHOICEOFWHICH TOVIEW:
√SAMPLINGTIME&DATE
√GRAINTEMPIN&OUT
√GRAINMOISTUREIN&OUT
√DRYERPLENUMTEMP
√METERROLL OUTPUT%
√BACKWARD VIEWINGAVAILABLE

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SETUPPARAMETERS
•THISSCREENCOMES AFTERSELECTINGSETUPONTOUCH SCREEN
•SELECTWHICH YOUWANTTO MODIFY

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SELECTTIMERSCREEN
•TOUCH TIMERSBUTTONONTHEMAINTOUCH SCREEN
•SELECTWHICH TIMERTO MODIFY
•MODIFYTIMERSCREENCOMES UP(NEXTPAGE)

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MODIFYTIMERSCREEN
•AFTERSELECTINGWHICH TIMERTOMODIFY
•SELECTDESIREDTIME
•TOUCH ACCEPT

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MODIFYTEMPSCREEN
•SELECTWHICH TEMPTOMODIFY
•MODIFYTEMPSCREENCOMES UP(NEXTPAGE)