GSi COMPETITOR 2000 Series Operation manual

1
A N D S E R V I C E M A N U A L
DRYER OPERATION
20032003
20032003
2003
GSI GR A I N CO N D I T I O N I N G SY S T E M S
PNEG-552
COMPETITOR SERIES 2000
DRYER MODELS

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3
Warranty.......................................................................................................................4
Safety First...................................................................................................................5
Safety Alert Decals.......................................................................................................6
Safety Precautions.......................................................................................................7
Dryer Control Panel Featuring The Competitor Series 2000 Control System...................8
Special Features....................................................................................................12
Safety Circuit Shutdown Messages......................................................................12
Dryer Pre Start Checks...............................................................................................13
Pre Season Inspection..........................................................................................13
Dryer Start Up...................................................................................................................16
Fan And Heater Switch Settings...........................................................................16
100 Series Batch Timer Settings..............................................................................18
Full Start Up Check..............................................................................................19
Filling The Dryer...................................................................................................19
Starting The Dryer................................................................................................20
Adjusting The Temperature..................................................................................20
Full Heat-Continuous Flow Operation..................................................................21
100 Series Continuous Flow Metering Roll Settings............................................22
Adjusting The Moisture Control............................................................................23
Service........................................................................................................................24
Seasonal Inspection And Service.........................................................................25
Lubrication Instructions For Ball Bearing Motors..................................................25
Suggested Lubricants..........................................................................................26
Fan Propellor Removal And Installation...............................................................27
Fan Motor Removal And Installation....................................................................28
Heater Parts Removal And Installation.............................................................................29
Metering Roll Servicing........................................................................................30
How To Determine A Metering Roll Problem........................................................31
Wiring Diagrams...............................................................................................................32
Wiring Schematics...................................................................................................41
Trouble Analysis Procedure...................................................................................47
Notes...................................................................................................................51
TABLE OF CONTENTS
COMPETITOR DRYER OPERATION AND SERVICE

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WARRANTY
EXCEPT FOR THE ABOVE STATED EXPRESS LIMITED WARRANTIES, GSI MAKES NO WARRANTY
OF ANY KIND, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MER-
CHANTABILITYORFITNESSFORAPARTICULARPURPOSEORUSEINCONNECTIONWITH(i)PROD-
UCT MANUFACTURED OR SOLD BY GSI OR (ii) ANY ADVICE, INSTRUCTION, RECOMMENDATION OR
SUGGESTION PROVIDED BY AN AGENT, REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR
RELATEDTOTHECONFIGURATION,INSTALLATION,LAYOUT,SUITABILITYFOR A PARTICULAR PUR-
POSE, OR DESIGN OF SUCH PRODUCT OR PRODUCTS.
IN NO EVENT SHALL GSI BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL OR CONSEQUEN-
TIALDAMAGES, INCLUDING, WITHOUT LIMITATION, LOSS OF ANTICIPATED PROFITS OR BENEFITS.
PURCHASER'SSOLEAND EXCLUSIVE REMEDY SHALL BE LIMITEDTOTHAT STATED ABOVE, WHICH
SHALL NOT EXCEED THE AMOUNT PAID FOR THE PRODUCT PURCHASED. THIS WARRANTY IS
NOT TRANSFERABLE AND APPLIES ONLY TO THE ORIGINAL PURCHASER. GSI SHALL HAVE NO
OBLIGATION OR RESPONSIBILITY FOR ANY REPRESENTATIVE OR WARRANTIES MADE BY OR ON
BEHALF OF ANY DEALER, AGENT OR DISTRIBUTOR OF GSI.
GSIASSUMESNO RESPONSIBILITY FOR FIELD MODIFICATIONS OR ERECTIONDEFECTSWHICH
CREATE STRUCTURAL OR STORAGE QUALITY PROBLEMS. MODIFICATIONS TO THE PRODUCT
NOT SPECIFICALLY COVERED BY THE CONTENTS OF THIS MANUAL WILL NULLIFY ANY PRODUCT
WARRANTY THAT MIGHT HAVE BEEN OTHERWISE AVAILABLE.
THE FOREGOING WARRANTY SHALL NOT COVER PRODUCTS OR PARTS WHICH HAVE BEEN
DAMAGED BY NEGLIGENT USE, MISUSE, ALTERATION OR ACCIDENT. THIS WARRANTY COVERS
ONLY PRODUCTS MANUFACTURED BY GSI. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL
OTHER WARRANTIES EXPRESS OR IMPLIED. GSI RESERVES THE RIGHT TO MAKE DESIGN OR
SPECIFICATION CHANGES AT ANY TIME.
PRIOR TO INSTALLATION, PURCHASER HAS THE RESPONSIBILITY TO RESEARCH AND COM-
PLY WITH ALL FEDERAL, STATE AND LOCAL CODES WHICH MAY APPLY TO THE LOCATION AND
INSTALLATION.
THE GSI GROUP, INC. ("GSI") WARRANTS ALL PRODUCTS MANUFACTURED BY GSI TO BE FREE OF
DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDITIONS FOR A
PERIOD OF TWENTY-FOUR MONTHS AFTER RETAIL SALE TO THE ORIGINAL END USER OF SUCH
PRODUCTS. GSI'S ONLY OBLIGATION IS, AND PURCHASER'S SOLE REMEDY SHALL BE FOR GSI,
TO REPAIR OR REPLACE, AT GSI'S OPTION AND EXPENSE, PRODUCTS THAT, IN GSI'S SOLE JUDG-
MENT, CONTAIN A MATERIAL DEFECT DUE TO MATERIALS OR WORKMANSHIP. ALL DELIVERY AND
SHIPMENT CHARGES TO AND FROM GSI'S FACTORY WILL BE PURCHASER'S RESPONSIBILITY.
EXPENSES INCURRED BY OR ON BEHALF OF THE PURCHASER WITHOUT PRIOR WRITTEN AU-
THORIZATION FROM AN AUTHORIZED EMPLOYEE OF GSI SHALL BE THE SOLE RESPONSIBILITY OF
THE PURCHASER.

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ROOF WARNING, OPERATION & SAFETY
ROOF DAMAGE WARNING AND DISCLAIMER
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 con-
cerningyour personalsafety. Watch
for this symbol; it points out impor-
tant safety precautions. It means
"ATTENTION","WARNING","CAU-
TION", and "DANGER". Read the
message and be cautious to the
possibility of personal injury or
death.
SAFETY ALERT SYMBOL
GSI DOES NOT WARRANT ANY ROOF DAMAGE CAUSED
BY EXCESSIVE VACUUM OR INTERNAL PRESSURE
FROM FANS OR OTHER AIR MOVING SYSTEMS. AD-
EQUATE VENTILATION AND/OR "MAKEUP AIR" DEVICES
SHOULD BE PROVIDED FOR ALL POWERED AIR HAN-
DLINGSYSTEMS.GSI DOES NOT RECOMMEND THE USE
OF DOWNWARD FLOW SYSTEMS (SUCTION). SEVERE
ROOF DAMAGE CAN RESULT FROM ANY BLOCKAGE OF
AIR PASSAGES. RUNNING FANS DURING HIGH HUMID-
ITY/COLD WEATHER CONDITIONS CAN CAUSE AIR EX-
HAUST OR INTAKE PORTS TO FREEZE.
Thank you for choosing a GSI/
Airstream product. It is designed
to give excellent performance
and service for many years.
This manual describes the
operation and service for all stan-
dard Competitor Series 2000
single fan grain dryers. These
models are available for liquid
propane or natural gas fuel sup-
ply, with either single phase 230
volt, or three phase 220 or 440
volt electrical power.
Theprincipal concern ofthe GSI
Group, Inc. ("GSI") is your safety
and the safety of others associated
with grain handling equipment. This
manual is written to help you under-
stand safe operating procedures,
and some of the problems that may
be encountered by the operator or
other personnel.
As owner and/or operator, it is
your responsibility to know what
requirements, hazards and pre-
cautions exist, and to inform all
personnel associated with the
equipment, or who are in the dryer
area. Avoid any alterations to the
equipment. Such alterations may
produce a very dangerous situa-
tion, where serious injury or death
may occur.
DRYER OPERATION

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SAFETY ALERT DECALS
The GSI Group, Inc. recommends
contacting your local power company,
and having a representative survey
your installation so the wiring is com-
patible with their system, and ad-
equatepoweris suppliedto yourunit.
Safety decals should be read
and understood by all people in the
grain handling area. The bottom
rightdecalshould be present on the
inside bin door cover of the two ring
door, 24" porthole door cover and
the roof manway cover.
Ifa decal is damaged or ismiss-
ing contact:
The GSI Group, Inc.
1004 E. Illinois St.
Assumption, IL 62510
217-226-4421
Afreereplacementwillbesenttoyou.

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Three decals displayed on all Airstream Dryers. Belt drives, chain driven meter rolls
and combustible fuels must be treated as potential danger.
SAFETY ALERT DECALS

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1. Read and understand the operating manual before trying to operate the
dryer.
2. Never operate the dryer while the guards are removed.
3. Power supply should be OFF for service of electrical components.
Use CAUTION in checking voltage or other procedures requiring power
to be ON.
4. Check for gas leaks at all gas pipe connections. If any leaks are
detected, do not operate dryer. Shut down and repair before fur-
ther operation.
5. Never attempt to operate the dryer by jumping or otherwise bypassing
any safety devices on the unit.
6. Set pressureregulatorto avoidexcessive gaspressureapplied to burner
during ignition and when burner is in operation. See chart for operat-
ing procedures. Do not exceed maxi mum recommended drying tem-
perature.
7. Keep the dryer clean. Do not allow fine material to accumulate in
the plenum chamber.
8. Keep auger drive belts tight enough to prevent slippage.
9. Use CAUTION in working around high speed fans, gas burners, augers
and auxiliary conveyors which START AUTOMATICALLY.
10. Donotoperateinanyareawherecombustiblematerialwillbedrawninto
the fan.
11. Beforeattemptingto remove andreinstall any propellor,make certain to
read the recommended procedure listed within the servicing section of
the manual.
12. Becertain thatcapacities of auxiliaryconveyors arematchedto dryer
auger capacities.
13. Cleangrainiseasiertodry. Finematerialincreasesresistancetoairflow
and requires removal of extra moisture.
SAFETY PRECAUTIONS
USE CAUTION
IN THE OPERATION
OF THIS EQUIPMENT
The design and manufacture of this
dryer is directed toward operator
safety. However, the very nature of
a grain dryer having a gas burner,
high voltage electrical equipment
and high speed rotating parts, does
present a hazard to personnel,
which can not be completely safe-
guarded against, without interfering
with efficient operation and reason-
able access to components.
Use extreme caution in working
around high speed fans, gas-fired
heaters, augers and auxiliary con-
veyors, which may start without
warningwhenthe dryer is operating
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-
spectthe operationof theunit forany
developingproblemsor unsafe con-
ditions.
Take special note of the safety
precautions listed above before at-
tempting 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

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DRYER CONTROL PANEL
off to the moisture control. The light
beside the switch is illuminated when
the grain column temperature is be-
low the moisture control set point.
DRYER CONTROL PANEL FEATURING THE COMPETITOR
SERIES 2000 CONTROL SYSTEM
This is used to select the opera-
tion of the fill auger. In both the
auto and manual position the load
auger will operate if the dryer is low
on grain and will automatically shut
off when the dryer is full. In the auto
position only, the dryer will shut
down after a preset period of time
set on the out of grain timer.
The dryer outside light is turned on
or off here.
OUTSIDE LIGHT
The power to the Competitor 2000
Control System is turned on or off
with this switch.
CONTROL POWER
SWITCH
This switch turns the power on or
MOISTURE CONTROL
SWITCH
TheSeries 2000 Dryer has a built in
moisture control. It controls the
moisture level of discharged grain
bysensinggraincolumntemperature.
MOISTURE CONTROL
Thecontrolpanel provides easy ac-
cess to gauges and controls. The
Competitor Series 2000 Control
System is a computerized control
systemthat givesinstantinformation
regarding dryer operation.
DRYING MODE SWITCH
This is used to select staged batch
or continuous flow drying.
LOAD AUGER SWITCH
Figure 1: The grain dryer control panel.

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DRYER CONTROL PANEL
This is used to adjust the low speed
ofthe meteringroll whenthe2 speed
automatic moisture control feature
of the dryer is in use.
HIGH SPEED METERING
ROLL POTENTIOMETER
This is used to:
• Set the high speed of the meter-
ing roll when the two speed auto-
matic moisture control feature of
the dryer is utilized.
• Setthe speed of the meteringrolls
when the one speed automatic
moisture control feature of the
dryer is utilized.
• Set the speed of the metering rolls
during continuous flow operation
whenthemoisturecontrolisnotused.
• Settherateofgraindischargefrom
thedryer during theunloadcycle of
staged batch dryer operation.
DRYER POWER
START SWITCH
This switch starts and operates the
dryer based on switch settings. If
other switch settings are in the off
position, individual dryer compo-
nentscan beoperatedby turning the
drying mode switch to continuous
flow, pressing the dryer power start
button and then turning on the de-
sired dryer component.
LOW SPEED METERING
ROLL POTENTIOMETER
DRYER POWER
STOP SWITCH
Thisswitchstops all dryer functions.
If an automatic dryer shutdown oc-
curs, first determine and correct the
cause of the shutdown. Press the
dryer power stop button to reset the
dryer before restarting.
Note: If the load auxiliary motor
overload relay is being utilized in
the dryer control panel, this switch
will also control the operation of the
auxiliary equipment.
The unload switch turns the meter-
ing rolls and discharge auger on or
off, and selects the operation of the
metering rolls.
• Inthe2speed position if the mois-
ture control switch is on, and the
drying mode switch is turned to
continuous flow, the metering roll
speed will alternate between the
high speed metering roll potenti-
ometer setting and the low speed
meteringroll potentiometer setting
depending on the control signal
UNLOAD SWITCH
The fan is turned on or off with this
switch. The on position operates
the fan continuously during staged
batch and continuous flow modes.
The auto position operates the fan
in staged batch during the dry and
cool cycle. The light comes on only
when air pressure is sensed.
FAN SWITCH
This switch is used to turn the
burner on or off. The auto posi-
tion operates the burner in staged
batch during the dry cycle. The on
position will operate the burner
only when the fan is running. The
burner light comes on only when
flame is detected.
HEATER SWITCH
from the moisture control thermo-
stat. The discharge auger will op-
erate continuously.
• Inthe 1speedposition, ifthe mois-
ture control switch is on, and the
drying mode switch is turned to
continuous flow, the metering roll
speed will operate at the high
speedmeteringrollpotentiometer
settingor turnoff dependingon the
control signal from the moisture
controlthermostat. The discharge
auger will operate whenever the
metering rolls are operating.
• Inboththe1speed or the 2 speed
position, if the moisture control
switch is off, and the drying mode
switch is turned to continuous
flow, the metering roll speed can
be manually controlled by adjust-
ing the high speed metering roll
potentiometer. Thedischargeau-
ger will operate continuously.
• Ifthedrying mode switch is turned
tostaged batch, the unload switch
should be set to the 1 speed posi-
tion.The dischargeaugerand me-
tering rolls will only operate dur-
ing the unload cycle of the staged
batch operation, and the speed of
the metering rolls is adjusted us-
ing the high speed metering roll
potentiometer.
Note: If the unload auxiliary motor
overloadrelay is being utilized in the
dryercontrolpanel, the same switch
will also control the operation of the
auxiliary equipment.

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DRYER CONTROL PANEL
SERIES 2000
CONTROL SYSTEM
TURNING ON THE
SERIES 2000 CONTROL
SYSTEM
The 2000 Control System controls
all timing functions and safety cir-
cuit checks. It is designed to sim-
plify dryer operation by providing
messages and warnings on its liq-
uid crystal display (LCD).
Turn the control power switch to on.
Themonitorwilldisplay"GSI"andthe
current software version number.
SETTING THE DRY, COOL,
UNLOAD AND OUT OF
GRAIN TIMERS
These switches are used to set the
cycle times in the staged batch dry-
ing mode only. The drying mode
switch must be in the staged batch
position.Outofgrainsets the length
oftime the dryer will runbeforeshut-
ting down when the load switch is in
theauto position. Tochangethe set-
ting of these timers follow these in-
structions:
1. Pressthe PROGRAM(TIMERS)
The Airstream Competitor 2000 Series Dryer Control Panel.
buttonuntilthe"carrot"isabove
the timer you want to modify.
2. Usethe upand downarrowkeys
tochangefromthepresenttime
to the desired setting. The new
time is automatically accepted.
3. Keep pressing the PROGRAM
(TIMERS) button until the car-
rot disappears or press the
modeselectbuttononceto exit.
During the operation the remaining
time on each timer is displayed on
the screen. If the power goes out or
if the dryer is stopped, these times
are saved by the controller. When
The dryer LCD display.

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DRYER CONTROL PANEL
Figure 2: The Competitor Series 2000 Control System
the dryer is restarted the timers will
continue timing down. The timers
will return to their initial settings by
pressing and holding the "stop"
button for 5 seconds.
automatically entered.
3. Keep pressing the PROGRAM
(DELAYS) button until the car-
rot disappears or press the
modeselectbuttononceto exit.
SETTING THE LOAD AND
UNLOAD DELAYS
1. Press the PROGRAM (TEM-
PERATURES) button until the
carrot is under the temperature
setting to be changed.
2. Usethe upand downarrowkeys
tochange from the present tem-
perature to the new one. The
newtimeisautomaticallyentered.
3. Keep pressing the PROGRAM
(TEMPERATURES) button until
thecarrotdisappearsorpressthe
mode select button once to exit.
Press the up arrow key and the to-
tal hours on the machine are dis-
played.
CHECKING THE HOUR
METER
MONITORING GRAIN
TEMPERATURES, PLENUM
TEMPERATURE OR TIMERS
Usethe modeselectto decidewhich
of the modes you want to view.
DRYER SAFETY CIRCUIT
TheCompetitor Series 2000 Control
System continuously checks all
safety circuits on the dryer, and will
automatically shut the dryer down
shoulda problem occur. The cause
of the dryer shutdown will be shown
on the LCD display. To restart the
dryer after a safety shutdown, first
correctthereason for the shutdown,
andthenpressthedryer power stop
buttontoresetthe circuit. Press the
start button.
The load delay is used to delay the
starting of the load auger when the
dryerisunloadingto preventthe load
augerfrom starting and stopping too
often. The unload delay is used to
control the amount of time the un-
load auger runs after the metering
rollsstop to allowfor auger cleanout.
1. PressthePROGRAM(DELAYS)
buttonuntilthecarrot isunderthe
time delay to be changed.
2. Usethe upand downarrowkeys
tochangefromthepresenttime
to the new one. The new time is
SETTING THE MOISTURE
CONTROL AND PLENUM
SET POINT

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DRYER CONTROL PANEL
SPECIAL FEATURES
EMERGENCY COOLING
MODE runthe fanto helpcool thegrainand/
or plenum high limit back down to a
safelevel.After changing the switch
press the start button and only the
fan will run for approximately five
minutes.
By moving the third switch (num-
ber six) on the dip switch located in-
side the control box on the back of
thecomputercontrolboard,theburner
canbechanged fromahi-loburnerto
anon/offburneroperation.Theburner
will operate exactly the same as the
hi-lo burner, however, when the set
point is reached the burner is cycled
off instead of going to a lower pres-
sure. The vaporizer cools much
quickerandallowsustokeepacloser
tolerance on the set point.
The need has developed for an on/
off burner in recent years, due to
changing fuel conditions, and also
to aid in drying wheat or other low
temperature grains in hot weather.
Anemergencycooling mode can be
entered by switching the next to the
topswitch (numberseven) onthedip
switchlocatedinside the control box
on the back of the computer control
board.This willenable amode which
allows an operator to run the dryer
fan only, in the case there is a ple-
num temperature or grain high limit
warning. When either of these safe-
ties shuts down the dryer, you can
BURNER ON/OFF
OPERATION
VAPOR HIGH
TEMPERATURE
OUT OF GRAIN
SAFETY CIRCUIT SHUTDOWN MESSAGES
an oblong covered electrical box.
This control is set at 200°F and
MUST BE MANUALLY RESET.
The dryer has run low on grain, and
the out of grain timer has timed out,
shuttingthe dryer down. Theunload
auger will clean out the dryer if in
continuous flow operation.
The air switch contacts have closed
prior to the fan starting, indicating a
freewheeling blade or improper set-
ting of the air switch.
An over temperature condition has
occurred in one of the grain col-
umns causing the control to shut-
down the dryer. This control is set
at 210°F and automatically resets
itself when cool.
GRAIN HIGH
TEMPERATURE
AIR
An over temperature condition has
occurred inside the dryer plenum.
This control is a 300°F limit and auto-
matically resets itself when cool. See
emergency cooling mode above.
PLENUM HIGH
TEMPERATURE
The contacts in the air switch have
openeddueto insufficient airflow for
the burner to operate. The contacts
intheairswitchhave opened due to
the fan not turning, or the air switch
may need adjusting.
NO AIRFLOW
The temperature high limit located
on the fan/burner housing has
opened,indicating an over tempera-
ture condition has occurred toward
the rear of the fan/heater housing in
HOUSING HIGH
TEMPERATURE
The LP gas vapor temperature
sensor located in the gas pipe train
downstream from the vaporizer,
has opened indicating that the
vaporizor is running too hot and
must be readjusted. This sensor
is set at 200°F and automatically
resets itself when cool.
LOSS OF FLAME
The flame sensor has failed to de-
tect a burner flame indicating that
the burner has failed to light, there
is a problem with the flame sens-
ing circuitry or the dryer is not get-
ting burner fuel.
REAR DISCHARGE
WARNING
The lid on the grain discharge box
has opened, indicating that grain is
not being taken away fast enough
at the discharge box.
One of the thermal overloads on ei-
ther the fan, load, unload or auxiliary
motors has opened, indicating an
overcurrentcondition. Theoverloads
MUST BE MANUALLY RESET.
MOTOR OVERLOAD

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ERROR CONDITIONS
ERROR CODE BREAKDOWN
Grain temperature probe shorted.
This error occurs whenever one of the
grain probes or wires going to the
probes shorts together or to the frame
of the dryer.
code4
code5
Flame probe short. This error occurs
whenever the flame probe shorts to
ground or on the occasion the AC and
DC neutrals somehow get shorted
together. To try and fix this problem
the first thing to check and see of the
flame probe is actually shorted. If this
is not the case then you must diag-
nose the AC and DC neutral circuit.
These two circuits must be kept
separate. Pull the white J7-13 wire
loose from the circuit board. If this
removes the problem then go to the
temperature probes on the dryer and
start unwiring them one at a time
while continuing to check for the
shorted condition between the AC
and DC ground. If this does not
remove the short then replace the J7-
13 wire and recheck for a shorted
neutral condition. The best way to
check for an AC to DC ground short is
to set your meter for resistance
(usually about 200ohms) and place
one probe on terminal J7-20 and put
the other probe to the metal of the
dryer (dryer control box). There
should be an open circuit between
these two points.
LIMIT SWITCHES
Plenum temperature probe open.
This error occurs whenever one of the
plenum temperature probes or wires
going to the probe opens, and the
circuit has an infinite resistance.
Continuous flow to batch mode
change. This error occurs whenever
you try to change from continuous
flow mode to the batch mode without
shutting down the dryer first.
Plenum temperature probe shorted.
This error occurs whenever one of the
plenum temperature probes or wires
going to the probes shorts together or
to the frame of the dryer.
Grain temperature probe open. This
error occurs whenever one of the
grain temperature probes or wires
going to the probe opens, and the
circuit has an infinite resistance.
code1
code2
code3code6
Thefollowinglimit switch errors light
up individually on the LCD screen:
PLENUM, HOUSING, VAPOR,
TEMP HI LIMIT, REAR DIS-
CHARGE.
Note: When a shutdown does
occur due to an error condition, the
amount of time elapsed since the
shutdown can be viewed by press-
ingthe down arrowswitch(up to 218
hours).

15
DRYER PRE START CHECKS
PRE SEASON INSPECTION
INSPECT THE METERING
ROLLS
Open all metering roll access doors
and inspect each compartment for
any bolts, nuts or other foreign ma-
terial, that may cause possible jam-
ming of the metering rolls.
Before the dryer is filled, thoroughly
inspect the unit and check the op-
eration of the dryer as follows.
BEFORE ATTEMPTING TO
OPERATE THE DRYER MAKE
SURE ALL SAFETY SHIELDS
ARE IN PLACE, ALL BOTTOM
CLEANOUT AND REAR
ACCESS DOORS ARE CLOSED
AND ALL PERSONNEL ARE
CLEAR OF THE DRYER
Moisture Control Switch-ON
Moisture Control Thermostat-200°
Load Switch-OFF
Unload Switch-OFF
Fan Switch-OFF
Burner Switch-OFF
Out of Grain Timer-8 MINUTE
Load Delay-30 SECONDS
Unload Delay-30 SECONDS
Metering Roll Speed-LOW AND
HIGH SPEED SETTINGS PUT
ON ZERO
Dry Timer-60 MINUTE
Cool timer-20 MINUTE
Unload timer-10 SECONDS
ModeSwitch-CONTINUOUS FLOW
SET CONTROL SWITCHES
CONTROL POWER
SWITCH
Turn the control power switch to
on. The switch light comes on.
"GSI" and the software version will
appear. At this point the controller
will lock out all other dryer func-
tions and the dryer will perform its
safety circuit check. If a fault is
found, the cause will be displayed
on the LCD. If all safeties are
found safe, the controller will sup-
ply power to the electronic fuel shut
off valve (if so equipped). Press the
start button to initialize the com-
puter.
FUEL CHECK
ELECTRICAL POWER
Turn on the electrical power sup-
ply to the dryer, set all circuit
breakers to on, including the safety
disconnect handle mounted on
front of the dryer's power panel.
POWER START BUTTON
Push the dryer start button, and all
the toggle switches on the control
panel will be activated.
The Maxon safety shut off valve.
If using LP gas, make sure the tank
hasplenty of fuel and that theTANK
DOESNOTHAVE A REGULATOR
MOUNTED TO IT. If using natural
gas,make sure an adequate supply
is available.
If using LP gas, slowly open the
main fuel supply valve at the tank. If
using natural gas, turn on the valve
along the supply line. Then, open the
electronic shut off valve (Maxon
valve), if so equipped, or open the
manual shut off valve on the dryer to
allow fuel flow to the dryer. Inspect
all gas lines and connections for pos-
sibleleaks.ANYGAS LEAKSNEED
TO BE FIXED IMMEDIATELY!

16
DRYER PRE START CHECKS
METERING ROLL
OPERATION
Tocheckthe metering roll operation
turn either the low speed or high
speed knob clockwise, and the me-
tering roll speed should increase.
Turning either knob counterclock-
wisewilldecreasethespeed. Make
sure the drive chain tension is prop-
erly adjusted and all sections of the
metering rolls rotate. Turn the un-
load switch off after these checks
arecomplete. The bottom auger will
continue to run for 30 seconds after
the switch is turned off to allow for
cleanout.
Tochecktheburnersafetyfunction,
first make sure the main gas valve
is off. Turn the fan switch on and al-
low the fan to start. Then, turn the
BURNER SAFETY
Bump the fan switch and observe
the fan rotation. The fan should run
counterclockwise. Sometimes on
three phase models all motors on
the dryer will run backwards. They
can easily be reversed by inter-
changing two of three power supply
wires. Reverse the two outside
wires, L1 and L3, and leave the
middle one in the same position.
Note: If the dryer is empty, the
burner will not operate. The fans
cannot create enough static pres-
sure to engage the air switch. You
will receive a "no airflow" message.
To start the dryer when it is low
on grain, the airflow switches must
be turned off.
FAN SWITCH
Tocheck one speedoperationplace
the unload switch in the one speed
setting. Turnupthehighspeedme-
teringrolldialuntilthe metering rolls
start rotating. The bottom auger
should rotate counterclockwise as
viewed from the drive end. The
metering roll drive motor should ro-
tate clockwise as viewed from the
drive end of the gear box. If the dry
grain take away auxiliary is wired to
the dryer, it should start and rotate
in the proper direction.
With the grain supply shut off,
quickly bump the load auger switch
tomanual, and see if the load auger
rotatesclockwise asviewed fromthe
driveend,orcounterclockwiseifthe
dryerisa front load model. If the wet
grain supply auxiliary is wired to the
dryerit should also rotate in the cor-
rect direction at this time. Turn the
load auger switch to the auto posi-
tion. The top auger and wet grain
supply auxiliary should run for one
minute, and then the dryer will shut
down leaving the safety shutdown
message (out of grain) displayed.
Press the dryer power stop button
LOAD AUGER
The metering roll access area.
to reset the panel, then press the
start button to resume operation.
ONE SPEED OPERATION

17
DRYER PRE START CHECKS
The dryer fan and heater controls featuring: 1-pressure regulator, 2-lo-fire
ball valve, 3-high pressure solenoid, 4-low pressure solenoid, 5-hi-lo fire
thermostat (assembly includes thermometer), 6-fuel supply line, 7-LP
solenoid or supply ball valve(NG) and 8-air pressure switch.
3
421
7
5
8
6
To check the staged batch opera-
tion, turn the control power switchto
the on position. Open the main
STAGED BATCH CHECK
Test fire the burner by starting the
fan, and then turn the burner switch
to on. Turn on the fuel supply, and
theburnershould ignite after a short
purge delay of approximately 10
seconds. Gas pressure should be
shown on the gauge. At this time
set the hi-fire and lo-fire pressure
settings. Use the pressure regu-
lator for hi-fire and the ball valve
for lo-fire. The burner should cycle
between high and low fire, approxi-
mately 4 to 5 times per minute.
Approximate settings should be:
LP Gas Hi-Fire 6-15 lbs.
Lo-Fire 2-6 lbs.
Natural Gas Hi-Fire 6-10 lbs.
Lo-Fire 1-3 lbs.
If the burner remains on hi-fire
and does not cycle, increase the
regulator setting on the propane
models, or the supply valve on the
naturalgasmodelsinorder to reach
the thermostat setting. If the burner
remains in lo-fire and does not cycle,
slightlydeceasegaspressurewiththe
lo-fire control valve. If the gas pres-
sure is decreased too much a pop-
ping or fluttering sound will be heard.
Also,anytimethehigh pressureregu-
lator is adjusted the low pressure ball
valve side needs to be checked.
fuel supply valve at the tank on an
LP dryer or valve in the fuel supply
lineonanaturalgasdryer. Turnthe
drying mode switch to the staged
batch position. Turn on the electric
shut off valve to allow fuel flow to
the dryer, if so equipped. Turn the
load switch to auto, the unload
switchtoonespeedand the fan and
burner to on. Push the dryer power
startbutton andthecontroller willse-
quentiallystart all dryer components
intheirproper order. If any switches
are not in their correct position for
stagedbatch operation,the dryerwill
indicate improper switch position,
and will not start until the switches
are in the proper position. After
starting, all batch timers will time
downin sequence.Whenthe unload
cycleiscompletethe timers will auto-
matically reset to their original set-
tings, and start the dry timer again.
heaterswitch on. The dryer willshut
down after 20 seconds. The safety
message,"loss offlame" will appear.
Incase of emergencypushthe dryer
power stop button. The fan, burner
andallaugers will stop immediately.
EMERGENCY
BURNER TEST FIRE Toshutdown thedryer, firstclosethe
fuelsupplyvalve at the tank or valve
along the fuel line. If the burner is
operating, let the dryer run out of
fuel, and it will shutdown automati-
cally due to loss of flame. Close the
fuelvalve at the dryer, and pressthe
dryerpower stop button. Turnoffthe
safetydisconnect handleon thefront
of the power box, and turn off the
main power to the dryer.
DRYER SHUTDOWN

18
DRYER START UP
STAGED BATCH
OPERATION
1. Turnthecontrolpowerswitchtoon.
2. Make sure the drying mode
switchis turned to stagedbatch.
3. Openthe main fuel supply valve
on the tank if using LP gas, or
the valve in the fuel supply line
if using natural gas. Turn on the
electric shut off, Maxon valve
(if so equipped), or open the
manual shut off valve to allow
fuel flow to the dryer.
4. Set switches to the following
settings:
Load-Auto
Fan-Auto
Burner-Auto
Unload-1 speed
5. To start the drying operation
push the dryer power start but-
8. After purging for approxi-
mately 10 seconds the burner
will fire. For information con-
cerning burner adjustment
see the pre start section of this
manual.
9. To properly set the correct dry,
coolandunload time for various
moisturecontent grains.See the
chart on page 18.
10. If the dryer is being operated in
all heat, move the fan switch
to the on position. In this posi-
tion the fan will run continu-
ously during the dry, cool and
unload stages of the staged
batch operation. If the dryer
is being operated in the dry
and cool mode, the preferred
position for the fan switch is the
on position, so the fan will run
continuously. If desired, the fan
canbe turned off during the un-
ton. The controller will start all
the dryer components in their
proper order. If any of the se-
lected switches are improperly
positionedforstagedbatch dry-
ing, the display will indicate the
proper switch position, and will
not allow the dryer to operate
until the position of the switch is
corrected.
6. The dryer should already be
filled with grain. And the load
auger switch is set to auto. In
both the auto and manual po-
sition, the grain level switch will
automaticallykeepthedryerfull
of grain. In the auto position the
dryer will shut down after the
preset time period on the out of
grain timer, or if the grain flow
to the dryer is interrupted.
7. The fan will start and airflow is
checked.
FAN & HEATER SWITCH SETTINGS
Fan Setting
Auto
Auto
On
On
Fan Function
Fans stay on during dry and cool
cycle only
Fans stay on during dry and cool
cycle only
Fans are on continuously
Fans are on continuously
Heater Function
Burners stay on during dry timer cycle
only
Burners stay on during dry and cool
Burners are on continuously
Burners shut down at the end of the
dry cycle
At the end of the dry cycle in staged batch, the fans and heaters will continue running if the moisture control is "on", until
the preset temperature on the moisture control thermostat is reached.
Heater Setting
Auto
On
On
Auto

19
DRYER START UP
loadcycle ofthe dry-cool-unload
sequence by turning the fan
switch to auto.
11. If the dryer is being operated in
all heat, move the heater
switch to on. The burner will
operate whenever the fan is
operating. If the dryer is being
used in dry and cool, turn the
heater switch to auto and the
burner will automatically shut
down during the cooling and
unloading cycles.
12. The bottom auger and meter-
ing rolls will start automati-
cally during the unload cycle
of the dry-cool-unload mode,
along with any grain handling
equipment that is wired to the
dryer. The speed at which the
metering rolls operate during
the unload cycle is adjusted by
using the high speed metering
roll knob. Turning the dial
clockwise will increase the
grain discharge rate, and
counterclockwise will de-
crease the discharge rate.
13. To control the length of the dry
cycle using only the dry time set-
tingprogrammedintothesystem,
turn the moisture control setting
tooff.Tousetheautomaticmois-
turecontrol so thatthedry time is
determined, not only by the dry
time setting, but also by the
moisture content of the drying
grain, turn the moisture control
switch to on.
14. Toshutdownthedryer,close the
fuelsupplyvalveat the fuel tank
or fuel source. If the burner is
operating, let the dryer run out
of fuel causing an automatic
shutdowndue to a lossofflame.
Closethe fuel valve at thedryer,
and press the dryer power stop
button.Turnoff the dryer's main
circuit breaker located on the front
of the power panel. Turn off the
main power supply to the dryer.
15. In case of an emergency press
thedryer powerstop button.The
burner, fan and all augers will
stop immediately.

20
DRYER START UP
100 SERIES BATCH TIMER SETTINGS
Initial
Moisture
17%
18%
19%
20%
21%
22%
23%
24%
25%
26%
27%
28%
29%
30%
31%
32%
33%
34%
35%
Moisture
Removed
2 pts.
3 pts.
4 pts.
5 pts.
6 pts.
7 pts.
8 pts.
9 pts.
10 pts.
11 pts.
12 pts.
13 pts.
14 pts.
15 pts.
16 pts.
17 pts.
18 pts.
19 pts.
20 pts.
Approx.
Dry Time
16 min.
21 min.
26 min
31.5 min.
37 min.
41.5 min.
47 min.
51 min.
54 min.
58 min.
62 min.
66.5 min.
71.5 min.
76 min.
81 min.
86 min.
91 min.
96 min.
100 min.
Dry
6 min.
11 min.
16 min
21.5 min.
27 min.
31.5 min.
37 min.
47 min.
44 min.
48 min.
52 min.
56.5 min.
61.5 min.
66 min.
71 min.
76 min.
81 min.
86 min.
90 min.
Cool
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Unload*
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
Dry
18 min.
24 min.
30 min
35 min.
40 min.
45 min.
50 min.
55 min.
60 min.
65 min.
70 min.
75 min.
80 min.
85 min.
90 min.
95 min.
100 min.
105 min.
110 min.
Cool
18 min.
18 min.
18 min
18 min.
18 min.
18 min.
18 min.
18 min.
18 min.
18 min.
18 min.
18 min.
18 min.
18 min.
18 min.
18 min.
18 min.
18 min.
18 min.
Approx.
Dry Time
18 min.
24 min.
30 min
35 min.
40 min.
45 min.
50 min.
55 min.
60 min.
65 min.
70 min.
75 min.
80 min.
85 min.
90 min.
95 min.
100 min.
105 min.
110 min.
Unload*
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
10 min.
Full Heat
Fan & Burner Switches on Manual Dry & Cool
Fans on Manual Burners on Auto
These are approximate starting points.
*Set unload meter roll high speed setting to 999. If unload equipment cannot adequately keep up, lower the speed setting
and add time to the unload timer setting to completely unload the batch. In full heat mode, the time added to the unload
timer will need to be substracted from the dry timer. If fan is on auto and does not run during unload, set cool timer to 25
minutes.
New unload time calculation = present unload time  new dial setting
1000
Example
13.75 = 11 ÷ 800
1000