GSI
Competitor & EMCS
Portable Dryer
Models
Troubleshooting and
Reference Manual
2004 Revised Edition
PNEG-630
Competitor Series 2000 Dryer
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Ta b le Of Co n t e n t s
Po rt a b le Drye r Tro u b le sh o o t in g
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
2
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Sa fe t y
Po rt a b le Drye r Tro u b le sh o o t in g
Dryer Safety
Instructions and
Information
Thank you for choosing an GSI
Grain Dryer. It is designed to pro-
vide excellent performance and ser-
vice for many years.
This manual refers to the trouble-
shooting of the E.M.C.S.and Series
2000 Competitor models. Different
models are available for liquid pro-
pane or natural gas fuel supply, with
either single phase 230 volt, or three
phase 230, 460, 575 volt electrical
power. (Also 380 volt 50Hz).
The GSI 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
and adequate power is supplied.
The principal concern of the GSI
Group, Inc. ("GSI") is your safety
and the safety of others associated
with grain handling equipment. This
manual is written to help you un-
derstand safe operating proce-
dures, and some of the problems
that may be encountered by the op-
erator or other personnel.
As owner and/or operator, it is your responsibility to know what requirements, hazards and precautions 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 situation, where serious injury or death may
occur.
Safety Alert Symbol
WARNING! BE ALERT!
The symbol shown is used to call your
Personnel operating or working
attention to instructions concerning your
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.
personal safety. Watch for 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.
3
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Sa fe t y
Po rt a b le Drye r Tro u b le sh o o t in g
Grain Systems, Inc. recommends
you contact your local power com-
pany and have a representative sur-
vey your dryer installation, so your
wiring will be compatible with their
system and you will have adequate
power supplied to your unit.
A CAREFUL OPERATOR
IS THE BEST INSURANCE
AGAINST AN ACCIDENT
Safety decals should be read and
understood by all people in and
around the dryer area. If the follow-
ing safety decals are not displayed
on your dryer, or if they are dam-
aged, contact Grain Systems, Inc. for
replacement.
4
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Sa fe t y
Po rt a b le Drye r Tro u b le sh o o t in g
5
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Sa fe t y
Po rt a b le Drye r Tro u b le sh o o t in g
6
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Sa fet y Preca u t ion s
Po rt a b le Drye r Tro u b le sh o o t in g
READ THESE INSTRUCTIONS
BEFORE OPERATION AND SERVICE
SAVE FOR FUTURE REFERENCE
Use Caution in the
Operation of this
Equipment
1. Read and understand the operating manual before trying to operate the
dryer.
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.
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.
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.
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.
KEEP THE DRYER CLEAN
DO NOT ALLOW FINE
MATERIAL TO ACCUMULATE
IN THE PLENUM CHAMBER
OR SURROUNDING THE
8. Donotoperateinanyareawherecombustiblematerialwillbedrawninto
the fan.
OUTSIDE OF THE DRYER
9. Before attempting to remove and reinstall any propeller, make certain to
read the recommended procedure listed within the servicing section of
the manual.
Continued safe, dependable opera-
tion of automatic equipment de-
10. Clean grain is easier to dry. Fine material increases resistance to airflow pends, to a great degree, upon the
and requires removal of extra moisture.
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.
This product is intended for the use of grain handling only. Any other
use is considered a misuse of the product.
Some edges of the product components can be sharp. It is recommended
that each component of this product be examined to determine if there
areanysafetyconsiderationstobetaken. Anyandallnecessarypersonal
protective equipment should be worn at all tines when handling, 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.
Take special note of the safety pre-
cautions listed at left before attempt-
ing to operate the dryer.
7
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Sa fe t y Sig n -Off Sh e e t
Po rt a b le Drye r Tro u b le sh o o t in g
Date
Employer’s Signature
Employee
________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________
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_______________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________
8
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Safety Voltage Check Points
9
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Po rt a b le Drye r Tro u b le sh o o t in g
Pro g ra m m in g
Programming Instructions for EMCS Grain Dryers
1. Turn Control Power on dryer to off.
2. Locate programming jack (P7) on back of computer. (See page 13).
3. Plug the DB-9 jack of the programmer into the computer's jack.
4. Be sure that the rotary switch on the programmer is set to position 8.
5. Turn on Control Power to the dryer.
6. The four (4) lights on the programmer will come on, then three (3) will go out leaving the power light still on.
7. Push the start button on the programmer to start the transfer of Software.
8. The busy light will flash until the transfer process is complete.
9. When completed the pass light will flash indicating a successful transfer.
10. If the fail light flashes then check your connections and repeat the above process.
11. Turn Control Power on dryer to off and remove the cable.
12. Turn on the dryer and the opening screens should indicate the newer version of software.
10
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Pro g ra m m in g
Po rt a b le Drye r Tro u b le sh o o t in g
EMCS Display Board
11
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Input/Output Board Identification
12 VOLT DC INPUTS
120 VOLT AC OUTPUTS
120VAC POWER (INPUT)
120VAC POWER (OUTPUT)
AC NEUTRAL
1
2
+12 LIMIT OUTPUT
20
18
19
17
15
13
11
AC NEUTRAL
3
4
12 VOLT DC NEUTRAL
METERING ROLL INPUT
12 VOLT DC NEGATIVE
+12 LIMIT OUTPUT
120VAC POWER (INPUT)
AC NEUTRAL
120VAC POWER (OUTPUT)
AC NEUTRAL
5
6
12 VOLT DC NEGATIVE
12 VOLT DC NEGATIVE
12 VOLT DC NEGATIVE
16
14
7
8
AC NEUTRAL
AC NEUTRAL
9
10
12
14
16
18
20
12 VOLT DC NEGATIVE
SAFETY CIRCUIT INPUT
+12 VOLT LIMIT OUTPUT
12
10
J9
J5
AC NEUTRAL
AC NEUTRAL
11
13
15
+12 VOLT LIMIT OUTPUT
+12 VOLT LIMIT OUTPUT
9
AC NEUTRAL
AC NEUTRAL
8
6
7
5
3
1
AC NEUTRAL
BURNER #1 POWER
BURNER #2 POWER
BURNER #3 POWER
FLAME SENSOR RETURN
OUT OF GRAIN SENSOR
MAXON VALVE SENSOR
REAR DISCHARGE
FAN #1 POWER
FAN #2 POWER
M.C. THERMOSTAT N.O. TERM #4
M.C. THERMOATAT N.C. TERM #6
17
19
4
2
MERCOID SFTY FAN#1 (CAN)
MERCOID SFTY FAN#2 (CAN)
MERCOID SFTY FAN#4 (CAN)
LOWER ADJ. GRAIN HIGH LIMIT
2 SPEED UNLOAD
20
18
16
14
12
10
8
19
17
15
13
11
JUMPER J1-9 TO J5-6 IS A HARDWARE TIMER FOR THE FLAME SENSOR SHUTDOWN
1 SPEED UNLOAD
UNLOAD BYPASS
LOAD SWITCH AUTO
LOAD SWITCH ON
BATCH MODE
JUMPER J5-2 TO J5-20 IS A CONNECTION FOR THE MAXON VALVE SENS0R
LOW MERCURY SWITCH (BO)
MOTOR OVERLOADS
MOISTURE CONTROL
ADJ. GRAIN (MIDDLE)
ADJ. GRAIN (UPPER)
JUMPER J4-12 TO J5-10 IS A HARDWARE TIMER FOR THE SAFETY SHUTDOWNS
JUMPER J1-20 TO J5-8 IS A CONNECTION FOR THE USER SUPPLLIED SAFETY
J4
9
JUMPERS MUST BE INSTALLED FOR THE INPUT/OUTPUT BOARD TO OPERATE!!
7
5
CONTINUOUS FLOW
6
JUMPERS TO BE INSTALLED FOR E-COOL
FIXED GRAIN (MIDDLE)
FIXED GRAIN (UPPER)
MERCOID SAFTY FAN#3 (CAN)
OUT OF GRAIN FOR LOAD #2
3
1
4
2
INSTALL JUMPER FROM J6-13 TO J1-5
INSTALL JUMPER FROM J6-14 TO J1-19
INSTALL JUMPER FROM J6-16 TO J5-5
INSTALL JUMPER FROM J6-17 TO J4-19
FAN #3 POWER
FAN #4 POWER
FAN #5 POWER
FAN #6 POWER
UNLOAD POWER
BUR # 4 NEUTRAL
BUR # 3 NEUTRAL
FAN # 4 NEUTRAL
FAN # 3 NEUTRAL
LOAD #2 NEUTRAL
BURNER #4 POWER
BURNER #5 POWER
BURNER #6 POWER
LOAD POWER
HI-HEAT THERMOSTAT (BO)
BURNER #6 AUTO
BURNER #6 ON
LO-HEAT THERMOSTAT (BO)
BURNER #5 AUTO
BURNER #5 ON
1
2
20
18
16
14
12
10
8
19
3
4
17
15
13
11
5
6
FAN #6 AIR
FAN #5 AIR
7
8
SCR POWER
FAN #6 PLENUM
FAN #5 PLENUM
9
10
12
14
16
18
20
J8
J3
FAN #1 NEUTRAL
FAN #2 NEUTRAL
UNLOAD NEUTRAL
LOAD NEUTRAL
SCR NEUTRAL
FAN #6 FLAME DETECTION
FAN #6 HOUSING HIGH LIMIT
FAN #6 VAPOR HIGH LIMIT
FAN #6 AUTO
FAN #5 FLAME DETECTION
FAN #5 HOUSING HIGH LIMIT
FAN #5 VAPOR HIGH LIMIT
FAN #5 AUTO
11
13
15
9
7
5
3
1
6
17
19
4
2
FAN #6 ON
FAN #5 ON
LOAD #2 POWER
MAXON POWER
BUR #6 NEUTRAL
BUR #5 NEUTRAL
PROCESS LIGHT
BURNER #1 NEUTRAL
BURNER #2 NEUTRAL
MAXON NEUTRAL
AC NEUTRAL
20
18
16
14
12
10
8
19
1
2
BURNER #4 AUTO
BURNER #4 ON
BURNER #3 AUTO
BURNER #3 ON
17
15
13
11
3
4
5
6
FAN #4 AIR
FAN #3 AIR
7
8
FAN #4 PLENUM
FAN #3 PLENUM
FAN #6 NEUTRAL
FAN #5 NEUTRAL
9
10
12
J2
J7
FAN #4 FLAME DETECTION
FAN #4 HOUSING HIGH LIMIT
FAN #4 VAPOR HIGH LIMIT
FAN #4 AUTO
FAN #3 FLAME DETECTION
FAN #3 HOUSING HIGH LIMIT
FAN #3 VAPOR HIGH LIMIT
FAN #3 AUTO
9
LO-HEAT POWER (BO)
HI-HEAT POWER (BO)
NC
11
13
15
7
5
14
16
18
20
THERMOSTAT 110VAC (BO)
6
NC
NC
3
1
4
2
17
19
FAN #4 ON
FAN #3 ON
M.R.H POT 3
SCR P1 &
M.R.L POT 3 &
V1 FROM BR#1 (BO)
HIGH SOLENOID BUR#1 (BO)
1
2
USER SUPPLIED SAFETY
BURNER #2 AUTO
BURNER #2 ON
LOWER GRAIN HIGH LIMIT
BURNER #1 AUTO
BURNER #1 ON
20
18
16
14
12
10
8
19
M.R.H POT 2
SCR P3 & V1 FROM BR#2 (B0
SENSOR 1 LOWER
SENSOR 1 UPPER
THERMOSTAT SENSOR S2
AUX #6 A-N.C.
3
4
17
15
13
11
5
6
M.R.L POT 2 & HI SOLENOID BUR#2 (BO)
THERMOSTAT SENSOR S1
FAN #2 AIR
7
8
FAN #1 AIR
SENSOR 2 LOWER.
SENSOR 2 UPPER
9
10
12
14
16
18
20
FAN #2 PLENUM
FAN #1 PLENUM
J6
J1
11
13
15
FAN #2 FLAME DETECTION
FAN #2 HOUSING HIGH LIMIT
FAN #2 VAPOR HIGH LIMIT
FAN #2 AUTO
FAN #1 FLAME DETECTION
FAN #1 HOUSING HIGH LIMIT
FAN #1 VAPOR HIGH LIMIT
FAN #1 AUTO
9
ENERGENCY COOLING
AUX #6 B-COMMON
EMERGENCY COOLING
EMERGENCY COOLING
EMERGENCY COOLING
NC
7
5
6
17
19
3
1
4
2
NC
FAN #2 ON
FAN #1 ON
NC
** IMPORTANT--JUMPERS LISTED ABOVE MUST BE INSTALLED
12
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Sw it ch Re p la ce m e n t
Po rt a b le Drye r Tro u b le sh o o t in g
Switch Replacement for EMCS Dryer
Switch N/O Contact Block - Part No. D63-0006
Switch Light Block - D01-0455
13
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
1100 Series Control Box Wiring
42 TOTAL TERMINALS
1100 FAN TO CONTROL BOX WIRING
WIRING
DESCRIPTION
VOLTAGE
COLOR
J5-8
RED
RED
YEL
AIR PRESSURE SWITCH +12VDC
NEED JUMPER
12 VOLTS DC
12 VOLTS DC
12 VOLTS DC
(RED)
J5-8
HOUSING HIGH LIMIT
OR
(RED)
(RED)
J1-7
J1-5
VAPOR HIGH LIMIT (LP ONLY)
RELAY CONTACTS LOCATED
IN DRYER FAN CAN BOX
PUR
OR
YEL
FLAME DETECTION
PLENUM
12 VOLTS DC
(RED)
J1-9
BLU
12 VOLTS DC
12 VOLTS DC
(RED)
(RED)
J1-11
J1-19
RED
BRN
LEFT FIXED GRAIN HI LIMIT
OR
*REAR DISCHARGE
12 VOLTS DC
(RED)
J5-5
OR
OR
RED
RIGHT FIXED GRAIN HI LIMIT
12 VOLTS DC
12 VOLTS DC
(RED)
(RED)
J4-19
J4-12
J1-13
MOTOR OVERLOADS
AIR PRESSURE SWITCH
BURNER POWER
BLU
BLK
12 VOLTS DC
(BLUE)
120 VAC
(BLACK)
J9-16
WHT
BURNER NEUTRAL
120 VAC NEUT (WHITE)
J7-4
B1
120 VAC
120 VAC
(BLUE)
BRN
BURNER LIGHT
MAXON POWER
MAXON NEUTRAL
(BLACK)
J7-3
PUR
WHT
USED ON SINGLE FAN
NAT GAS ONLY
120 VAC NEUT (WHITE)
12 VOLTS DC (YELLOW)
J7-8
J5-4
J5-16
MERCURY SWITCH LOCATED
ON TOP OF DRYER
OUT OF GRAIN SENSOR
BLK
YEL
BLU
RED
*
LEFT METERING ROLL SENSOR
RIGHT METERING ROLL SENSOR
METERING ROLL 12 VOLTS
METER ROLL PULSE (PUR)
NO LONGER USED
OK OTHER SIDE
*
J5-19
J5-9
(N/C) SAFETY
J5-8 OR J5-9 --
BLK
12 VOLTS DC
12 VOLTS DC
(RED)
(RED)
BLK
BLK
J1-20
J5-12
CUSTOMER SUPPLIED SAFETY
METERING ROLL NEUTRAL
12 VOLTS DC NEG (WHITE)
NEED JUMPER
-12VDC
TEMP SENSORS
TEMP SENSORS
WORK LIGHT
WHT
BLK
S1
TEMP SENSOR
(ORANGE)
(ORANGE)
S2
TEMP SENSOR
120 VAC (BLACK)
RED
L1
J9-3
AC 1
J8-16
J8-9
120 VAC NEUT (WHITE)
120 VAC (BLACK)
120 VAC NEUT (WHITE)
120 VAC (ORANGE)
120 VAC NEUT (WHITE)
120 VAC (YELLOW)
120 VAC NEUT (WHITE)
120 VAC (BLUE)
120 VAC NEUT (WHITE)
120 VAC (ORANGE)
120VAC FOR AUX UNLOAD CONTACTOR COIL
120VAC FOR AUX LOAD CONTACTOR COIL
J8-18
J8-8
DRYER SAFETY CIRCUIT ALWAYS STARTS ON J5-8 AND ENDS
J8-12
J9-17
ON J4-12.USING THE J5-12 TERMINAL FOR NEGATIVE,
THERE SHOULD BE 12 VOLTS DC ON EACH TERMINAL FROM
J5-8 TO J4-12.
J8-20
J8-10
J6-1
WHEN CHECKING FOR 12 VOLTS DC ALWAYS PUT THE
NEGATIVE PROBE OF VOLT METER TO TERMINAL J5-12
CONTROL POT P1 (PUR)
CONTROL POT P2 (PUR)
CONTROL POT P3 (PUR)
SCR 2
J6-4
SAFETY CIRCUIT IN BOLD IS FOR FLAME DETECTION ONLY.
EACH OF THE TERMINALS CONNECTED TO IT CAN LOOSE
12 VDC FOR 20 SECONDS BEFORE A SHUTDOWN OCCURS.
THIS GIVES THE BURNER CIRCUIT TIME TO SENSE FLAME.
ALL OTHER SAFETY CONNECTIONS MUST HAVE 12 VDC
PRESENT AT ALL TIMES TO OPERATE PROPERLY.
UNLOAD AUX COM(ORANGE)
UNLOAD AUX N/O(ORANGE)
LOAD AUX COM (YELLOW)
LOAD AUX N/O (YELLOW)
U-COM
U-N/O
L-COM
L-N/O
AUX CONTACT POINTS FOR LOAD AND UNLOAD SYSTEMS
ALL VOLTAGE SUPPLIED BY USER
*LOCATED AT REAR OF DRYER
1100EW98.PRT REV. DATE 4/10/98
ALL SAFETIES MUST BE CLOSED FOR DRYER TO OPERATE
14
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
1100 Series Control Box Wiring (New Version)
15
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
1200 Series Control Box Wiring
52 TOTAL TERMINALS
DESCRIPTION
WIRING
VOLTAGE
COLOR
TERMINAL
AIR PRESSURE SWITCH +12VDC
FAN #2 HOUSING HIGH LIMIT
RED
RED
J5-8
J5-8
J1-8
J1-6
J1-10
J1-7
NEED JUMPER
OR
12 VOLTS DC
12 VOLTS DC
12 VOLTS DC
12 VOLTS DC
12 VOLTS DC
12 VOLTS DC
12 VOLTS DC
(RED)
(RED)
(RED)
(RED)
(RED)
(RED)
(RED)
YEL
PUR
OR
FAN #2 VAPOR HIGH LIMIT
RELAY CONTACTS LOCATED
IN FAN CAN CONTROL BOX
RED
OR
FAN #2 FLAME DETECTION
FAN #1 HOUSING HIGH LIMIT
YEL
FAN #1 VAPOR HIGH LIMIT
RELAY CONTACTS LOCATED
PUR
OR
J1-5
IN FAN CAN CONTROL BOX
RED
FAN #1 FLAME DETECTION
FAN #2 PLENUM
J1-9
YEL
J1-12
J1-11
J1-19
J5-5
12 VOLTS DC
(RED)
FAN #1 PLENUM
12 VOLTS DC
12 VOLTS DC
(RED)
(RED)
BLU
OR
RED
BRN
RED
FIXED GRAIN HIGH LIMIT
*REAR DISCHARGE
12 VOLTS DC
12 VOLTS DC
(RED)
(RED)
OR
ADJ. GRAIN HIGH LIMIT
J4-19
RED
12 VOLTS DC
(RED)
J4-12
J1-14
J1-13
J9-18
J7-6
MOTOR OVERLOADS
12 VOLTS DC
12 VOLTS DC
(BLUE)
(BLUE)
BLU
BLU
BLK
WHT
FAN #2 PRESSURE SWITCH
FAN #1 PRESSURE SWITCH
BURNER #2 POWER
120 VAC
(BLACK)
BURNER #2 NEUTRAL
120 VAC NEUT (WHITE)
120 VAC (BLACK)
120 VAC NEUT (WHITE)
BURNER #1 POWER
BURNER #1 NEUTRAL
BURNER #2 LIGHT
BLK
J9-16
J7-4
B2
WHT
BRN
BRN
120 VAC
120 VAC
(BROWN)
(BROWN)
B1
BURNER #1 LIGHT
MAXON POWER
MAXON NEUTRAL
120 VAC
(BLACK)
J7-3
PUR
WHT
120 VAC NEUT (WHITE)
12 VOLTS DC (YELLOW)
J7-8
MERCURY SWITCH LOCATED
ON TOP OF DRYER
OUT OF GRAIN SENSOR
BLK
YEL
BLU
J5-4
*LEFT METERING ROLL SENSOR
J5-16
METER ROLL PULSE (PUR)
NO LONGER USED
*RIGHT METERING ROLL SENSOR
J5-19
HOOK OTHER SIDE
OF (N/C) SAFETY
TO J5-8 OR J5-9 --
BLK
METERING ROLL 12 VOLTS
CUSTOMER SUPPLIED SAFETY
RED
RED
12 VOLTS DC
12 VOLTS DC
(RED)
(RED)
J5-9
J1-20
BLK
12 VOLTS DC NEG (WHITE)
J5-12
METERING ROLL NEGATIVE
NEED JUMPER
-12VDC
TEMP SENSOR
TEMP SENSOR
120 VAC
(ORANGE)
(ORANGE)
(BLACK)
WHT
BLK
TEMP SENSOR
TEMP SENSOR
S1
S2
WORK LIGHT
RED
L1
J9-3
AC 1
J8-16
J8-9
120 VAC NEUT (WHITE)
120 VAC (BLACK)
120 VAC NEUT (WHITE)
120 VAC (ORANGE)
120 VAC NEUT (WHITE)
120 VAC (YELLOW)
120 VAC NEUT (WHITE)
120 VAC (BLUE)
120 VAC NEUT (WHITE)
120 VAC (BLUE)
120 VAC NEUT (WHITE)
120 VAC (ORANGE)
120VAC FOR AUX UNLOAD CONTACTOR COIL
120VAC FOR AUX LOAD CONTACTOR COIL
J8-18
J8-8
J8-14
J9-19
J8-12
J9-17
53 TOTAL TERMINALS
15 - RED
4 - BLUE
J8-20
J8-10
1 - WHITE/BLACK
3 - BLACK (1-16GA)
9 - WHITE (1-16GA
2 - BROWN
CONTROL POT P1 (PUR)
CONTROL POT P2 (PUR)
J6-1
SCR 2
4 - PURPLE
4 - ORANGE)
CONTROL POT P3 (PUR)
J6-4
UNLOAD AUX COM(ORANGE)
U-COM
UNLOAD AUX N/O(ORANGE)
LOAD AUX COM (YELLOW)
LOAD AUX N/O (YELLOW)
U-N/O
L-COM
L-N/O
AUX CONTACT POINTS FOR LOAD AND UNLOAD SYSTEMS
ALL VOLTAGE SUPPLIED BY USER
*LOCATED AT REAR OF DRYER
ALL SAFETIES MUST BE CLOSED FOR DRYER TO OPERATE
1200EW98.PRT REV. DATE 3/5/98
16
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
1200 Series Control Box Wiring (New Version)
17
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
1100 Fan Lower Control Box Interconnect Strip
J9-1
AC-1
J9-3
EMERGENCY COOLING JUMPERS
INSTALL J6-13 TO J1-5
5 V B 1
J9-3
INSTALL J6-14 TO J1-19
INSTALL J6-16 TO J5-5
EMI FILTER
D03-0181
INSTALL J6-17 TO J4-19
L1
BLACK - 120 VAC - OUTSIDE LIGHT
B1
S1
BROWN - 120 VAC - BURNER #1 LIGHT
ORANGE - TEMPERATURE SENSOR
S2
ORANGE - TEMPERATURE SENSOR
SCR2
J1-5
J1-7
J1-9
J1-11
J1-13
J1-19
J1-20
J4-12
J4-19
J5-4
J5-5
J5-8
J5-9
J5-12
J5-16
J5-19
J6-1
J6-4
J7-3
J7-4
J7-8
J8-8
J8-9
J8-10
J8-12
J8-16
J8-18
J8-20
J9-16
J9-17
PURPLE - CONTROL POT P2
RED - 12 VDC - FAN #1 VAPOR HIGH LIMIT
RED - 12 VDC - FAN #1 HOUSING HIGH LIMIT
RED - 12 VDC - FAN #1 FLAME DETECTION
RED - 12 VDC - FAN #1 PLENUM HIGHT LIMIT
BLUE - 12 VDC - FAN #1 AIR SWITCH
RED - 12 VDC - LOWER FIXED GRAIN LIMIT
RED - 12 VDC - USER SUPPLIED SAFETY
RED - 12 VDC - MOTOR OVERLOADS
RED - 12 VDC - LOWER ADJUSTABLE GRAIN HIGH LIMIT
YELLOW - 12 VDC - OUT OF GRAIN SENSOR
RED - 12 VDC - REAR DISCHARGE SWITCH
RED - 12 VDC - 12 VOLT SUPPLY
RED - 12 VDC - 12 VOLT SUPPLY
WHITE - 12 VDC NEG - 12 VOLT SUPPLY NEGATIVE
PURPLE -TIMING PULSE- LEFT METERING ROLL PULSE
PURPLE -TIMING PULSE- RIGHT METERING ROLL PULSE
PURPLE - CONTROL POT P1
PURPLE - CONTROL POT P3
BLACK - 120 VAC - MAXON POWER
WHITE - AC NEUTRAL - BURNER NEUTRAL
WHITE - AC NEUTRAL - MAXON NEUTRAL
YELLOW - 120 VAC - LOAD POWER
ORANGE - 120 VAC - UNLOAD POWER
ORANGE - 120 VAC - SCR POWER
WHITE - AC NEUTRAL - FAN #1 NEUTRAL
WHITE - AC NEUTRAL - UNLOAD NEUTRAL
WHITE - AC NEUTRAL - LOAD NEUTRAL
WHITE - AC NEUTRAL - SCR NEUTRAL
BLACK - 120 VAC - BURNER #1 POWER
BLUE - 120 VAC - FAN #1 POWER
I/O BOARD JUMPERS
INSTALL J1-9 TO J5-6
INSTALL J5-2 TO J5-20
INSTALL J4-12 TO J5-10
INSTALL J1-20 TO J5-8
35 - D01-0531 ENTRELEC TERMINALS
2
1
- D01-0533 END STOPS
- D01-0532 BLANK PROTECTOR END
18
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
1200 Fan Lower Control Box Interconnect Strip
J9-1
AC-1
5 V B 1
J9-3
J9-3
EMI FILTER
D03-0181
L1
BLACK - 120 VAC - OUTSIDE LIGHT
B1
B2
S1
BROWN - 120 VAC - BURNER #1 LIGHT
BROWN - 120 VAC - BURNER #2 LIGHT
ORANGE - TEMPERATURE SENSOR
S2
ORANGE - TEMPERATURE SENSOR
SCR2
J1-5
J1-6
J1-7
J1-8
PURPLE - CONTROL POT P2
RED - 12 VDC - FAN #1 VAPOR HIGH LIMIT
RED - 12 VDC - FAN #2 VAPOR HIGH LIMIT
RED - 12 VDC - FAN #1 HOUSING HIGH LIMIT
RED - 12 VDC - FAN #2 HOUSING HIGH LIMIT
RED - 12 VDC - FAN #1 FLAME DETECTION
RED - 12 VDC - FAN #2 FLAME DETECTION
RED - 12 VDC - FAN #1 PLENUM HIGHT LIMIT
RED - 12 VDC - FAN #2 PLENUM HIGHT LIMIT
BLUE - 12 VDC - FAN #1 AIR SWITCH
BLUE - 12 VDC - FAN #2 AIR SWITCH
RED - 12 VDC - LOWER FIXED GRAIN LIMIT
RED - 12 VDC - USER SUPPLIED SAFETY
RED - 12 VDC - MOTOR OVERLOADS
RED - 12 VDC - LOWER ADJUSTABLE GRAIN HIGH LIMIT
YELLOW - 12 VDC - OUT OF GRAIN SENSOR
RED - 12 VDC - REAR DISCHARGE SWITCH
RED - 12 VDC - 12 VOLT SUPPLY
J1-9
J1-10
J1-11
J1-12
J1-13
J1-14
J1-19
J1-20
J4-12
J4-19
J5-4
J5-5
J5-8
J5-9
RED - 12 VDC - 12 VOLT SUPPLY
J5-12
J5-16
J5-19
J6-1
WHITE - 12 VDC NEG - 12 VOLT SUPPLY NEGATIVE
PURPLE -TIMING PULSE- LEFT METERING ROLL PULSE
PURPLE -TIMING PULSE- RIGHT METERING ROLL PULSE
PURPLE - CONTROL POT P1
J6-4
PURPLE - CONTROL POT P3
J7-3
BLACK - 120 VAC - MAXON POWER
J7-4
J7-6
J7-8
J8-8
WHITE - AC NEUTRAL - BURNER #1 NEUTRAL
WHITE - AC NEUTRAL - BURNER #2 NEUTRAL
WHITE - AC NEUTRAL - MAXON NEUTRAL
YELLOW - 120 VAC - LOAD POWER
J8-9
ORANGE - 120 VAC - UNLOAD POWER
ORANGE - 120 VAC - SCR POWER
J8-10
J8-12
J8-14
J8-16
J8-18
J8-20
J9-16
J9-17
J9-18
J9-19
WHITE - AC NEUTRAL - FAN #1 NEUTRAL
WHITE - AC NEUTRAL - FAN #2 NEUTRAL
WHITE - AC NEUTRAL - UNLOAD NEUTRAL
WHITE - AC NEUTRAL - LOAD NEUTRAL
WHITE - AC NEUTRAL - SCR NEUTRAL
BLACK - 120 VAC - BURNER #1 POWER
BLUE - 120 VAC - FAN #1 POWER
BLACK - 120 VAC - BURNER #2 POWER
BLUE - 120 VAC - FAN #2 POWER
I/O BOARD JUMPERS
INSTALL J1-9 TO J5-6
INSTALL J5-2 TO J5-20
INSTALL J4-12 TO J5-10
INSTALL J9-1 TO J9-5
EMERGENCY COOLING JUMPERS
INSTALL J6-13 TO J1-5
INSTALL J6-14 TO J1-19
INSTALL J6-16 TO J5-5
INSTALL J6-17 TO J4-19
45 - D01-0531 ENTRELEC TERMINALS
2
1
- D01-0533 END STOPS
- D01-0532 BLANK PROTECTOR ENDS
19
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Upper Control Box External Wiring
BLACK FROM J9-16 TO L1 ON FENWAL BOARD 120VAC POWER
WHITE FROM J7-04 TO L2 ON FENWAL BOARD 120VAC NEUTRAL
BROWN TO B1 FROM V1 ON FENWAL BOARD 120VAC
ORANGE FROM J1-09 TO FLAME DETECTION RELAYS
ORANGE FROM J5-08 TO FLAME DETECTION RELAYS
TO FAN CONTROL BOX
WHITE/BLACK STRIP J5-12 12VDC NEGATIVE
YELLOW TO J1-07 FROM HOUSING HIGH LIMIT SWITCH
RED FROM J5-08 TO HOUSING & VAPOR HIGH LIMIT SWITCHES
PURPLE TO J1-05 FROM VAPOR HIGH LIMIT SWITCH
BLUE FROM J5-08 TO AIRSWITCH COMMON TERMINAL
BLUE TO J1-13 FROM AIRSWITCH N.O. TERMINAL
TO AIRSWITCH ASSEMBLY
WHITE TO S1 FROM RIGHT GRAIN TEMPERATURE SENSOR
BLACK TO S2 FROM RIGHT GRAIN TEMPERATURE SENSOR
RED FROM J1-11 TO LEFT GRAIN HIGH LIMIT SWITCH
ORANGE TO J1-19 FROM LEFT GRAIN HIGH LIMIT SWITCH
PURPLE J7-03 MAXON POWER 120VAC (NATURAL GAS ONLY)
WHITE J7-08 MAXON 120VAC NEUTRAL (NATURAL GAS ONLY)
BROWN FROM J1-19 TO REAR DISCHARGE SWITCH
ORANGE TO J5-05 FROM REAR DISCHARGE SWITCH
RED 16 GA. A+ SCR DRIVE MOTOR
TO LOWER JUNCTION BOX
BLACK 16 GA. A- SCR DRIVE MOTOR
GREEN 16 GA. SCR DRIVE MOTOR GROUND
BLACK FROM J5-09 TO LOAD MERCURY SWITCH
BLACK TO J5-04 FROM LOAD MERCURY SWITCH
TO UPPER JUNCTION BOX
WHITE FROM J9-03 TO OUTSIDE LIGHT AC NEUTRAL
RED FROM L1 120VAC TO OUTSIDE LIGHT POWER
YELLOW FROM J1-05 TO PLENUM HIGH LIMIT SWITCH
WHITE TO S1 FROM GRAIN TEMPERATURE SENSOR
BLACK TO S2 FROM GRAIN TEMPERATURE SENSOR
BLUE TO J1-11 FROM PLENUM HIGH LIMIT SWITCH
YELLOW FROM J1-05 TO PLENUM HIGH LIMIT SWITCH
TO PLENUM AND RIGHT
FIXED GRAIN HIGH LIMIT
SWITCHES AND TEMPERATURE
SENSORS
RED FROM J5-05 TO RIGHT GRAIN HIGH LIMIT SWITCH
ORANGE TO J4-19 FROM RIGHT GRAIN HIGH LIMIT SWITCH
20
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Fan Housing and Vapor Hi-Limit Circuit
21
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Plenum Hi-Temperature Switch
22
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Fixed Grain Hi-Limit
23
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Grain & Plenum Hi-Limit Locations
RED J1-11
ORANGE J1-19
RED J5-05
BLUE J1-11
YELLOW J1-05
ORANGE J4-19
24
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Two Fan Plenum and Grain Limit Switch Wiring
RED TO J1-11
ORANGE TO J1-19
YELLOW TO J1-12
BLUE TO J1-11
RED TO J1-05
25
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Rear Discharge & Emergency Cooling Circuit
26
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Rear Discharge Mercury Switch
27
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Adjustable Hi-Limit & Emergency Cooling Circuit
28
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Motor Overloads
29
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Air Pressure Switch
J5
12 VOLT
DC NEGATIVE
1 1
12 VOLT SOURCE
DC POSITIVE
8
J5-8
J1-8
J1-6
J1-10
12
J4
J1-7
J1-5
INPUT/OUTPUT BOARD
TERMINAL LOCATIONS
J1-9
J1-12
J1-11
J1-19
J6-14
J3
12V DC SOURCE FROM
MOTOR OVERLOADS
J5-5
J4-19
J6-17
J4-12
BLUE
BLUE
BLUE
FAN #2 PRESSURE SWITCH
FAN #1 PRESSURE SWITCH
J1-14
J1-13
J2
BLUE
1413
J 1
30
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Air Pressure Switch Drawing
31
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Out of Grain Safety Circuit
32
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Out of Grain Safety Circuit Location
33
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Upper Junction Box Drawing
BLACK
L1
TO 12VDC J5-09
J5-04
BLACK
J9-03
BLACK
WHITE
34
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Meter Roll Sensor
J5-19
J5-12
J5-09
J 5 - 1 2
J 5 - 1 9
J 5 - 0 9
J 1 - 1 9
J 5 - 0 5
J 5 - 1 6
35
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Meter Roll Sensor Wiring
B o a r d
M e t e r R o l l
B o a r d
M e t e r R o l l
36
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Meter Roll Reversing
YOU MUST ENTER INTO THE DRYER
PARMETER MODE BY PRESSING THE
INCREASE AND DECREASE BUTTONS
SIMULTANIOUSLY. YOU WILL HAVE
THE FOLLOWING OPTIONS LISTED:
SHUTDOWN HISTORY (PRESS ENTER)
DRYER MODEL # (IE. 1112)
TO
SCR DRIVE
BOARD
A+
A-
FAN DELAY
FILL AUGER
BPH FACTOR
(DEFAULT = 5)
(DEFAULT = END)
(DEFAULT = 1.0)
ORANGE
PURPLE
TEST METER ROLL (DEFAULT = YES)
TEST AIR SWITCH (DEFAULT = YES)
M.R. REVERSE (DEFAULT = NO) <- CHANGE TO YES
* REVERSE DELAY (DEFAULT = 60)
* REVERSE TIME (DEFAULT = 1)
* DISPLAYED ONLY IF M.R. REVERSE
IS CHANGED TO YES
8
5
1
JUMPER WIRES SHOULD
GO BETWEEN:
TERMINALS 4 AND 5
TERMINALS 1 AND 8
REVERSE DELAY = METER ROLLS NORMAL ROTATION TIME
(AMOUNT OF TIME METER ROLLS WILL OPERATE BEFORE
THEY WILL BEGIN REVERSE ROTATION)
REVERSE TIME = METER ROLLS REVERSE ROTATION TIME
(AMOUNT OF TIME METER ROLLS WILL OPERATE IN THE
REVERSED ROTATION MODE)
4
EXAMPLE: REVERSE DELAY = 10 MINUTES
REVERSE TIME
=
1 MINUTE
LOCATE THE ORANGE AND
PURPLE WIRES COMING FROM
THE SCR DRIVE BOARD GOING
TO THE TERMINAL STRIP AND
INSERT THE RELAY AS SHOWN
NOTE:
WHEN INSTALLING RELAY
BASE NOTE POSITION OF
SLOTS FOR RELAY!!
BLACK
WHITE
14
12
13
9
J7-17
(110 VAC CONTROL)
J8-20
(110 VAC NEUTRAL)
PURPLE
ORANGE
IMPORTANT
YOU MUST ADD A JUMPER WIRE
FROM J9-09 TO J7-16 IN THE
LOWER CONTROL BOX.
A-
A+
TO
DC DRIVE
MOTOR
37
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Lower Junction Box Wiring
RED FROM J5-09 TO 12VDC POSITIVE TERMINAL ON METER ROLL SENSOR
BLACK FROM J5-12 TO 12V NEGATIVE TERMINAL ON METER ROLL SENSOR
YELLOW FROM J5-16 TO LEFT METER ROLL SENSOR
BLUE FROM J5-19 TO RIGHT METER ROLL SENSOR
BROWN FROM J1-19 TO DISCHARGE SWITCH
ORANGE FROM J5-05 TO DISCHARGE SWITCH
RED 16 GA. A+ TO SCR DRIVE MOTOR
BLACK 16 GA. A- TO SCR DRIVE MOTOR
GREEN 16 GA. TO SCR DRIVE GROUND
38
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Po rt a b le Drye r Tro u b le sh o o t in g
New Fenwal Board Wiring
Wirin g Re fe re n ce
The B. GND terminal is used to ground the burner and to complete the flame current signal circuit. This terminal is
new for systems that used the older version of the Fenwal board. This terminal must be connected to the burner
(chassis) ground not only to ensure the best, long term, stable flame signal, but also to ground the burner for
proper sparking.
The use of a burner ground terminal eliminates the problem of loss of flame sense signal due to a missing or loose
neutral or ground (green) wire at the 120 VAC power source. The new board has been designed such that reversing
the polarity of the 120 VAC line does not cause a loss of flame signal. Thus providing a more reliable flame signal
along with a reduction of nuisance lockouts, due to its design and the use of the B. GND terminal.
NEU.
L2
120
VAC
H.V.
V2
(A) L1
S1
BURNER
GAS
VALVE
HOT
B. GND
HOT
NEU.
L1
V2
L2
(B) V1
120
VAC
BURNER
H.V.
S1
E2
GAS
VALVE
E1
V1
NC
New version with Remote Sense using existing
spark and remote sense electrodes.
Old version with Remote Flame Sense.
Note that terminal E2 on the old version has been replaced by terminal B.GND on the new board.
IGNITOR
BURNER
GROUND
(B. GND)
FLAME ROD
Part No. HF-4624
Flame Safety Board
39
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Po rt a b le Drye r Tro u b le sh o o t in g
Fenwal Board Troubleshooting
Wirin g Re fe re n ce
On-Board Diagnostics
The LED will flash on for 0.2 seconds then off for 0.2 seconds to indicate an error condition.
The pause time between error codes will be 2.5 to 3.0 seconds. During power-up, the LED will light
for one second and then turn off to indicate normal operation.
LED Indication
Steady on
2 Flashes
Fault Mode
Internal Control Failure
Flame Fault**
3 Flashes
Ignition Lockout Fault
** May indicate either that a flame was detected during
pre- or post-purge, or that there is a flame sensing error.
If a lockout occurs, the board will have to be reset
by shutting off the power to the board.
Measure Flame Current
Flame
S1 Test
Flame
Test
S1
FC+
+
FC-
-
Micro Amp Meter
BURNER
BURNER
BURNER
NO
YES
NO
40
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Flame Control Circuit
C O M M O N
C O M M O N
41
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Fan Burner Circuit for Canadian Models Only
42
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Conversion Diagram For C Series Dryers To A Switchable
Hi/Low Burner Or A On/Off Burner
43
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Fan 28 LP Hi/Low-On/Off
44
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Fan 28 LP Hi/Low-On/Off Burner With Mercoid
45
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Fan 28 NG Hi/Low-On/Off
46
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Fan 28 NG Hi/Low-On/Off Burner With Mercoid
47
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Fan 42 LP Hi/Low-On/Off
48
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Fan 42 LP Hi/Low-On/Off Burner With Mercoid
49
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Po rt a b le Drye r Tro u b le sh o o t in g
Wirin g Re fe re n ce
Fan 42 NG Hi/Low-On/Off
50
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Fan 42 NG Hi/Low-On/Off Burner With Mercoid
51
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Wirin g Re fe re n ce
SCR Drive Circuit
T1
T2
6
L1
L2
5
8
7
A2
A1
COIL
1
2
3
F +
F -
L 1
L 2
A +
A -
J 8 - 1 0
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Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
RTD Temperature Sensor
BLACK S2
BLACK S2
WHITE S1
WHITE S1
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Wirin g Re fe re n ce
Test Procedure for E.M.C.S. Dryers
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Te m p e ra t u re Ch a rt s
We use two (2) different types of sensors (NTC thermistor on the Competitor Series 2000, and an
encapsulated sensor on the E.M.C.S dryer) in our dryers. The resistance of the sensors varies according to the
outside temperature. For example, on the E.M.C.S. dryers, for every one (1) degree rise in temperature the
resistance increases 4.8 ohms. However, on the Competitor Series 2000 dryer, the sensor reacts just the opposite,
the resistance rises with colder temperatures. The charts displayed above will help when troubleshooting any
sensor problems.
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in the 2 Speed position. If this is present
then the SCR contactor and input/output board
are okay.
DC Drive Metering Roll System
Symptoms: Metering Roll will not turn,
dryer shutdown-"Metering Roll Drive Failure"
•
If 220 volts AC is present across input of
the SCR drive board (L1 and L2) then
check for voltage across the output of the
board. Change your voltmeter to check for
DC voltage at a range above the 200 volt
scale. Put the leads across A+ and A-. The
voltage across these two points will vary
depending on where the speed control poten-
tiometer is turned. Also try turning the poten-
tiometer up and down. The voltage should go
from zero to approximately 180 Volts DC. If
zero voltage is present across the A+ and A-
terminal, first try to disconnect the wires from
these two points and then check for DC volts
again. If the voltage returns, suspect a bad
motor or a problem in the wiring to the motor.
If the voltage does not return, suspect a bad
DC drive board.
Metering Roll Operation
•
The DC drive system on the portable
dryer is used to control the output of grain
from the dryer. It is adjusted from the
front of the control box using the high and
low metering roll potentiometers. Compo-
nents used in this circuit are the SCR
contactor, SCR drive board, DC motor/
gear box, and the input/output board from
the Electronic Monitoring Control System.
•
•
All voltage for the drive system comes
from terminals 1-(L1) and 3-(L2) of the
SCR contactor. There should be 220 volts
AC across these two points even if the
unload system is turned off. If this voltage
is zero, check your incoming main power.
When the unload system is turned on you
should be able to observe the SCR
Check the Motor
contactor energizing. The power to the
contactor should turn on and off with the
unload switch. You can check for power by
putting an AC voltmeter across terminals
A1 and A2. Across these points you
should read 120 Volts AC. Also on the top
of the contactor you can see a plunger pulling
in whenever the contactor coil gets power. When
the contactor is energized, power is transferred
from terminals L1 and L2 to terminals T1 and
T2. Understand that L1 and L2 are the Input
of the SCR contactor and T1 and T2 are the
Output of the contactor.
•
The wires attached to A+ and A- go directly to
the DC drive motor on the dryer. You may
remove the top cover of the motor and check
for the same DC voltages mentioned above at
the motor. If the voltage is not present try to
disconnect the wires, then check for DC volts
again. If you do not get any voltage then look
for a broken or loose wire between the motor
and the drive board terminals.
•
If the voltage is present suspect the motor
or the gear box. Removing the motor from
the gear box and trying to run the motor only
is one way of narrowing down the problem, or
you may want to remove the chain and see if
the metering rolls are froze up. Using a pipe
wrench is an easy way to try and rotate the
metering rolls.
Check the SCR Drive Board
•
Next if all the above checks out okay, put
your voltmeter across terminal L1and L2 of the
SCR drive board. You should get 220 Volts AC
across these points when the Unload Switch Is
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Fenwal Ignition System. If no voltage is
present after the 10 second purge delay,
check for voltage going through the auxil-
iary switch mounted on the side of the fan
contactor for that burner. This switch has
to close before the Fenwal gets power. If
this is OK, check the appropriate output
on the input/output board for that burner.
Fenwal Ignition System
Symptoms: Burner will not light, dryer
shutdown for "Loss of Flame"
Fenwal Ignition Operation
•
The Fenwal Ignition System ignites the
F en wa l Ign ition Op er a tion
burner and monitors the flame. Once 120
•
If voltage is present across L1 and L2,
check for voltage across the Output of
the Fenwal board. The output terminals
are V1 and V2, and they will also have
120 VAC across them for approxi-
VAC is applied to the Fenwal, the solenoids
are powered up and the transformer begins
ignition through the ignitor. If flame is
sensed during the ignition period (about
4 seconds), the transformer is turned off,
but the solenoids stay on. If no flame is det-
ected after the ignition period, both the solenoids
and transformer lose power and the dryer
begins a shutdown sequence.
mately four(4) seconds. The four(4)
seconds is the amount of time the Fenwal
has to ignite and sense flame or it concludes
no flame is detected and begins a "Loss of
Flame" shutdown. If you have power on the in
put terminals and no voltage on the output ter-
minals, unload the secondary (take the wires off
of V1 and V2) and recheck for voltage. If no
voltage is present then suspect a bad Fenwal
board. If power returns, look for a bad so-
lenoid valve or a problem in the wiring.
•
All voltage for the Fenwal Ignition
System is derived from the input/output
board of the Electronic Monitoring
Control System. For ignition to occur:
1. The fan must be turned on.
2. The pressure switch in the plenum
must indicate the fan is operating.
3. The burner switch must be in the
auto or manual position.
Note: All of the above voltage checks can be
bypassed if you can hear one or more of the
solenoids on the gas train snap on after the 10
second purge delay. This is true because the so-
lenoids are connected across V1 and V2, and
for the solenoids to come on, power must be
going through the Fenwal board. Also during
the four(4) second ignition period the trans-
former is energized and you should be able to
observe sparking across the ignitor. If the sole-
noids snap, but no ignition takes place, check
for loose ignitor wires or check the ignitor con-
dition/ignition gap (1/8 " to 3/16"). Remember
even if flame is sensed the sparking will discon-
tinue after the ignition period (4 seconds).
4. The dryer must go through a 10
second purge delay, which is indicated
on the LCD screen.
in g
These steps must take place before troubleshooting
of the Fenwal System can occur. The following
assumes the above steps have been taken.
Fenwal Troubleshooting
•
The Fenwal Board located in the fan can
control box on the dryer has seven(7)
terminals. They are L1, L2, V1, V2, S1, S2
and E2. L1 and L2 are considered the input
to the board. After the 10 second purge delay,
an AC voltmeter connected Across L1 and
L2 should read 120 Volts AC. If this is true,
you can assume the input/output board is
operating properly and the problem is in the
Continued on page 55.
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Fenwal Ignition System continued...
Ignitor Tips
Hints
•
Make sure that the ignitors are mounted
correctly through an opening in the burner
skirting. Also, make sure that they are not close
enough to the edges of the opening to cause a
spark to jump the skirting, instead of between
the ignitors.
•
Hearing the solenoids snap on after the
10 second purge delay means that power
is coming to and through the Fenwal
board. The Fenwal board is probably okay.
•
•
If flame is sensed, the power to the sole-
noids stays on but the power to the ignitor
always goes off after about four(4) seconds.
•
•
•
Be sure that the ignitor tips are no more than
1/8" apart from each other.
Make sure that the wire connections on the
ignitors are good and tight.
Power to the low pressure solenoid is al-
ways on anytime flame is sensed. This is
because the power to the low solenoid is
hooked directly across terminals V1 and
V2 of the Fenwal board.
On stubborn lighting burners reverse the
direction the ignitor tips are facing. Instead of
having the tips pointing toward the fan or burner,
change the direction so the tips are facing the ex-
haust end of the dryer. (This is especially true on
burners with no burner cone installed (i.e. Nat-
ural Gas).
•
Power to the high pressure solenoids is
controlled by the Plenum thermostat. One
side of the solenoid is hooked to V2(neutral)
and the other side is run through the nor-
mally closed switch of the thermostat and
then back to V1. This is how the burner is
made to cycle. When the plenum is below
temperature, power is run through the ther
mostat to the high pressure solenoid. When
temperature is reached, the thermostat opens
and the high solenoid loses power.
•
L2 and V2 are connected internally in the
Fenwal, and they must be nuetral.
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the incoming 12 volts DC (the T1-+12V and
T2-GND terminals), and one is a pulsing
12 volts DC back to the input/output board
(the T3 out terminal). Checking across T1
and T2 will verify that 12 volts DC is getting
to the sensor.
Metering Roll Sensors
Symptoms: No BPH, Total Bushels, RPM dis-
played on LCD or dryer shutdown with metering
roll problems
Metering Roll Sensor Operation
•
The T3 (out) terminal is what delivers
the metering roll information back to
the input/output board in the main con-
trol box. The information for the meter-
ing roll on the left side of the dryer is
sent on a yellow wire and goes to termi-
nal J5-16. The information for the me-
tering roll on the right side is sent on a
blue wire and goes to terminal J5-19.
•
Each metering roll on the portable dryer
has a sensor mounted to read pulses as
the metering roll is turning. These
pulses are transmitted to the input/out-
put board of the Electronic Monitoring
Control System. The computer inter-
prets this information and then displays
the data on the LCD screen.
•
All voltage for the metering roll sensors
is derived from the input/output board
of the Electronic Monitoring Control
System. The sensors are operated with
12 Volts DC from terminals J5-9 and J5-
12 on the board. When checking for volt-
age the negative or black probe (-)of a
voltmeter should always go to terminal
J5-12.
•
You can use a DC voltmeter to observe
this pulsing voltage. The best place to
check for this voltage is directly on the
input/output board located in the very
back of the lower control box on the
dryer. Check for a pulsing voltage from
J5-16 to J5-12 (negative) and J5-19 to
J5-12 (negative). Across each of these
test points you should be able to ob-
serve a pulsing DC voltage when the
metering rolls are turning. You should
be able to speed up or slow down the
pulses by turning the speed of the me-
tering rolls up or down.
Always use j5-12 for the negaitve anytime you
check for any DC voltage on the dryer.
Then put the red probe (+) of the volt-
meter on terminal J5-9. Across these
two points there should be 12 volts DC.
This voltage needs to be checked, but
you can be reasonably assured the 12
volts DC is present if the rest of the dryer
is operating. Check for this voltage on
the terminal strip in the upper control
box.
Note: Because a digital voltmeter cannot
react fast enough you may not see a full
12 volts DC, instead you may see a pulsing
from zero to about eight(8) volts.
•
12 volts DC is transmitted from J5-8
and J5-12 directly to the metering
roll sensors located on the back of the
dryer. Each of the metering rolls is en-
closed in a white plastic box mounted to the
back of the metering rolls. Inside each box
is the metering roll sensor and the metering
roll wheel.
Hints
•
When checking for a pulsing voltage on
J5-16 or J5-19 you should always leave
the voltmeter across the terminals for
about 30 seconds. Watch the meter
closely. Each pulse should be about the
same length and about the same time
apart. If this is not true, suspect a prob-
lem with the sensor on the back of the dryer.
•
Each sensor has three(3) wires con-
nected to it. Two(2) of these wires are
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driver and turn the adjusting screw coun-
terclockwise. Turning it this way makes
the switch more sensitive to pressure and
will turn on the light easier.
Air Pressure System
•
When inspecting the sensor make sure
that the wheel going through the sensor is
positioned in the center and is not touch-
ing either side. If the sensor is scratched
it is either bad or will probably go bad.
•
If adjusting the screw does not solve your
problem consult the layout diagram of the
input/output board. Look for the input for
the problem switch. Example: Fan #1
switch's input is J1-13. This is a 12 volt
DC input and it can be checked with a DC
voltmeter. One of the following conditions
will exist when checking this input.
NO AIR PRESSURE---ZERO VOLTS
HAS AIR PRESSURE---12 VOLTS DC
Remember when checking for 12 volts DC
you should always use one of the DC
negatives for the black probe(-) of your
Airflow Operation
Symptoms: Dryer will indicate a "Loss of Airflow"
•
After turning on a fan the computer must
get a signal from the air pressure switch
telling it that the fan is actually running
and the plenum has been pressurized. If
the switch does not show the air pressure
within 20 seconds a "Loss of Airflow"
shutdown occurs.
voltmeter. Some of the terminals that
may be used for the negative(-) are J5-11,
J5-12 or J5-13.
Troubleshooting: "Loss of Airflow"
•
To check fan #1 for air pressure with a
voltmeter:
1. Turn on the dryer.
•
This error message indicates that the fan
is running and the air pressure in the ple-
num did not pressurize. First, verify that
the fan is running, and the dryer is full of
grain. There must be grain in the dryer or
no pressure will develop. If the fan does
come on and the dryer is full of grain, but
a "Loss of Airflow" shutdown still occurs,
check the air pressure switch circuit.
2. Place the black probe(negative) of
your voltmeter on J5-11 or J5-12.
3. Place the red probe(positive) of your
voltmeter on J1-13. At this point
there should be zero volts here be-
cause the fan is not running.
4. Turn on the fan and watch your volt-
meter.
•
Watching the blue light in the fan switch
is the easiest way to tell if the air pres-
sure switch is sensing air pressure. Each
air pressure switch has a light in the fan
switch that will only come on if air pres-
sure has developed. Turn on the fan and
after it has run up to about one half of its
operating speed the light should go on. If
the fan light is not coming on then the air
pressure circuit is not sensing pressure.
•
If the air switch is adjusted properly you
should have zero volts across these test
points when you first turn on the fan. Af-
ter the fan has run up to about one half of
its normal operating speed you should see
the voltmeter change from zero volts to 12
volts DC. This also works in reverse when
turning off the fan. After the fan is first
turned off, the voltmeter should still show
12 volts DC until the fan has slowed down
to about one half of its operating speed.
This is because even though the fan is
turned off it is still turning and developing some
pressure in the plenum.
•
Try adjusting the air switch on the front
of the plenum to see if it is just out of ad-
justment. Use a straight blade screw-
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•
If all the above fails to work then remove
the two wires while blowing into the air
tube. Blowing into the switch is the same as
having air pressure in the plenum. You
should have an open circuit until you blow
into the switch, then it should close. If the
switch does not close try adjusting it, or
replace it with a known good one.
Vapor High Temperature
Symptoms: Dryer runs for only a short period of
time, then a shutdown occurs.erature Operation
•
This message indicates that the vaporizer on
an LP Dryer is not properly adjusted. LP
(liquified petroleum) must be vaporized
before the burner can operate properly. If
LP is being fed to the dryer it must run
through a vaporizer before it can be burned.
If the vaporizer is getting the fuel too hot it
will cause a Vapor High Limit shutdown.
Hints
1. Dryer must be full of grain.
2. Light in the fan switch can be used exactly
like a voltmeter to test.
•
•
The vaporizer is located in the fan/heater
unit. It is wrap of pipe mounted inside the
fan can directly in front of the burner. It
can be seen by looking through the inspec-
tion door on the side of the burner.
3. Make adjustments of the pressure in one
quarter turns.
4. Make sure the air tube in the plenum is
not plugged after sitting over the summer.
5. Check the bulb in the fan light. It is a 12
volt bulb.
To properly adjust the vaporizer a 1/2"
wrench is needed. Knowing that the gas
can get too hot, you must feel the pipe train
before the regulator to check this tempera-
ture. This point may be very hot so be
careful while checking the temperature.
The temperature before the regulator must
be warm to the touch. This point cannot be
hot, nor can it be cold...only warm. Use the
1/2" wrench to loosen the hold down
bracket on the vaporizer. Move the vapor
izer away from the flame to cool down the
pipe train or move it closer to the flame to
make the pipe train warmer.
Troubleshooting: Vapor High
Temperature
•
•
The dryer will shutdown but will probably
restart as soon as the computer is reset.
This is because the high limit is an auto-
matic reset and after the dryer shuts down it
allows the pipe train to cool down.
After the dryer is reset, it will run from a
few seconds to a few minutes and then
shutdown again. This is because the
Vapor High Limit is heating up again as
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soon as the burner is turned on. The
vaporizer must be adjusted to solve this
problem.
The two wrap has less surface area and it
will not heat the LP quite as much. This
may also be true in colder climates where a
two wrap will not heat up enough. In this
case, the pipe train may develop frost or
even freeze the solenoids open.
Using J5-11 as the negative test point for all voltage
tests, check for 12 volts DC using the following termi-
nals to help diagnose the problem:
4.
The Vapor High Limit is an automatic reset
safety device. It will reset itself as soon as
its temperature drops below 190° F. Be-
cause the pipe train of the burner cools
down rapidly when there is a dryer shut
down, the Vapor High Limit will generally
be cool before the operator gets back to the
dryer. As soon as he hits the stop button to
reset the computer, it comes back up to
normal operation. It appears that the dryer
is shutting down for no apparent reason.
Usually if this happens the dryer will shut
down again a short while after restarting the
dryer.
Fan #1-J1-5
Fan #3-J2-5
Fan #5-J3-5
Fan #2-J1-6
Fan #4-J2-6
Fan #6-J3-6
Remember that each of these input terminals is part of
the main safety circuit of the dryer, and each must
have 12 volts DC on it before the dryer will operate.
Vapor High Limit Hints
1.
2.
Anytime you adjust the Vapor High you
should wait and be sure that the pipe train
temperature stays constant. It may slowly
allow the pipe train to get hotter or colder
the longer the dryer runs.
5.
If the LP tank feeding the dryer is getting
very low on fuel, it can also cause the
dryer to shutdown on a Vapor High Limit.
Before adjusting the vaporizer always
check the fuel level in the customers tank.
If the fuel pressure is very low, try suggest
ing that the tank be refilled. Usually this
will solve the problem.
If a dryer is shutting down constantly from
a Vapor High Limit, it may also be caused
from a gas line that is exposed to direct
sunlight. If the fuel line to the dryer is
exposed to direct sunlight, the liquid in
the line will start to vaporize before it
even gets to the dryer. Then, when it runs
through the vaporizer it gets too hot and
causes a shutdown (no matter where you
try and adjust the vaporizer). This prob-
lem can be helped by insulating the gas
line from outside heat.
3.
In extreme cases the vaporizer may have
to be changed before it will run the proper
temperature. Example: If a dryer has a
burner with a three wrap vaporizer and the
dryer is located in the southern United
States, you may have problems adjusting
thevaporizer far enough from the flame.
In this case, you may have to install a two
wrap vaporizer.
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2.
Before setting the Out of Grain timer,
Out Of Grain Warning Shutdown
Out Of Grain Warning
monitor how long it takes the dryer to
refill for shrink. Then, set the Out of
Grain timer accordingly. Example: If a
dryer takes six minutes to refill for
•
This message indicated that the dryer has
run low on grain. The shutdown occurs
when the loading equipment has run
longer than the time the operator has set on
the Out of Grain timer. The mercury
switch located on top of the dryer tells the
computer when the dryer is full or calling
for grain. The shutdown usually occurs
when the loading equipment is having
trouble keeping up with the output of the
dryer.
shrink, add an additional five minutes to
this, and use this as the amount of time to
program into the Out of Grain timer. The
additional five minutes is to avoid any
nuisance shutdowns. A lot of customers
don't want their fill augers to run empty if
the source of grain runs out. They may
want to set the Out of Grain timer closer
than the additional five minutes. (this is
fine, but caution the customer that it may
cause some nuisance shutdowns.)
Possible Solution
3.
For the Out of Grain warning to work
properly, the fill equipment must be large
enough to handle the capacity of the
dryer. You do not want the side columns
to get low on grain. This will allow the
airflow to escape from the dryer through
the side screens. If this happens you lose
efficiency and may start having a loss of
airflow shutdown.
•
Look at the loading equipment to see if this
is the problem. Remember, the top hopper
of the dryer should always have grain in it.
If any of the side screens are opening up at
anytime, then you are losing heat along
with efficiency. This indicates that you are
not filling fast enough. Speed up the
loading equipment to the dryer.
•
Using J5-11 for the test point ground, test
for 12 volts on J5-4 to test the load mercury
switch. This switch should have 12 volts DC
on it when the dryer is calling for grain and has
zero volts on it when thedryer is full.
Out of Grain Hints
1.
The out of grain timer is only in use when
the fill switch is in the auto position. In
the manual position the top mercury
switch will still shut off the fill auger, but
the dryer will not shutdown if the source
of grain to the fill auger is depleted.
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Motor Overload Helpful Hints
Motor Overload Shutdown
1.
2.
Each of the Motor Overload is run in a
series circuit. This means, if any of the
Motor Overloads trip, a shutdown will
occur. Visually inspect the overload to tell
which has caused the shutdown.
This indicates that one of the Motor Overloads
has tripped, shutting down the dryer. Each of the Motor
Overloads is located in the upper main power control
box. They are all wired into a single series circuit that
goes to the input/output board on terminal J4-12. Be-
fore the dryer will start terminal J4-12 must have 12
volts DC present, or the Motor Overload shutdown will
occur.
Visually inspect each of the overloads. You can
tell by looking at them if a trip has occurred. Simply
press the reset handle on the overload to reset it. After
resetting the overloads press the stop button to clear the
error.
Even though GSI uses ambient compen-
sated overloads, hot weather or positioning
the dryer control box in the sunlight may
cause a Motor Overload shutdown to
occur. This can usually be tested by trying
to run the dryer with the control box door
open a little bit.
If no overloads are tripped try the following volt-
age tests: Using terminal J5-11 as the negative terminal
for all DC voltage checks. Look for 12 volts DC on
terminal J-419. This is the terminal that feeds power to
the Motor Overloads. If the 12 volts DC is present then
check for voltage on J4-12. During a Motor Overload
shutdown J4-12 should have zero volts. If you have
power going to and not returning to J4-12 inspect the
siring from J4-19 to the overloads and then back to J4-
12. If the wiring is okay, turn off all power to the dryer
and do a continuity check from J4-19 to J4-12. This
must be closed circuit to operate properly.
3.
Each of the overloads has an adjustable
trip setting that can set up to 115 %. At
115% the overload will hold in longer
before it trips.
4.
5.
Always check amperages on the motors to
be sure that the problem is not in the
motor itself.
Remember that each motor has a built-in
service factor. This allow the motor to
actually run over the rated full load amps.
The motor manufacturers have allowed
GSI, on a number of applications, to run
motors over the full load amp rating. this
is possible because they are being used in
an air over application.
64
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Co m p e t it o r Se rie s 2 0 0 0 Po rt a b le
Po rt a b le Drye r Tro u b le sh o o t in g
65
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Po rt a b le Drye r Tro u b le sh o o t in g
Co m p e t it o r Wirin g Re fe re n ce
220 Volt Single (1) Phase Power Drawing
SCR BOARD ASSEMBLED
D03-0104
KBIC BARRIER TERMINAL BOARD
LINE
FUSE
ARM
FUSE
ACCEL
MAXMIN
IR
CL
A+ A-
P3 PP21 I1 FF+- L1 L2
O V E R L O A D
O V E R L O A D
O V E R L O A D
O V E R L O A D
O V E R L O A D
66
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
220 Volt Single (1) Phase Power Drawing (New Version)
67
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Po rt a b le Drye r Tro u b le sh o o t in g
Co m p e t it o r Wirin g Re fe re n ce
220 Volt Three (3) Phase Power Drawing
68
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
220 Volt Three (3) Phase Power Drawing (New Version)
69
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
COMPETITOR POWER CIRCUIT
( 220 VOLT 1PH )
70
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
COMPETITOR POWER CIRCUIT
( 220 VOLT 3PH )
71
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
COMPETITOR POWER CIRCUIT
( 440 VOLT 3PH )
72
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Upper Control Box Internal Wiring
COM
ORG
ORG
R
R
OR
J3-01
N/O
N/C
R
R
WHT
J3-02
YEL
YEL
COM
YEL
R
N/O
N/C
R
R
R
J3-11
WHT
J3-12
BLU
J6-03
R
R
WHT
49
J3-14
USER SAFETY
RED
RED
J1-17
+12 VDC
J7-08
J7-02
HOUSE HI LIMIT
VAPOR HI LIMIT
+12 VDC
RED
RED
J1-13
LEFT GRAIN HI
RIGHT GRAIN HI
PLENUM HI LIMIT
+12 VDC
NONE
NONE
J7-01
RED
RED
REAR DISCHARGE
+12 VDC
J7-03
J7-05
OUT OF GRAIN
+12 VDC
RED
RED
35
MOTOR OVERLOAD
AIRSWITCH N.O.
AIRSWITCH COM.
AIRSWITCH N.C.
FLAME DETECT
FLAME DETECT
PLENUM TEMP
GRAIN/PLENUM
GRAIN TEMP
RED
J7-04
J7-09
BLU
WHT
J7-10
J7-11
J7-19
BLU
GRY
GRY
YEL
J7-20
J7-12
J7-13
J7-14
J6-02
AC 1
WHT
ORG
WHT
120 AC NEUTRAL
120 AC POWER
MAIN SOL NEUT
MAIN SOL PWR
CYCLE SOL NEUT
CYCLE SOL PWR
UNLOAD NEUTRAL
UNLOAD POWER
LOAD NEUTRAL
BLK
J6-13
M-SOL
J6-15
J6-14
J3-02
J3-01
J3-12
J3-11
WHT
BLK
WHT
BLK
W
OR
W
Y
LOAD POWER
FAN NEUTRAL
FAN POWER
J3-14
J6-03
W
BLU
IGNITION NEUTRAL
IGNITION POWER
J6-07
WHT
J6-06
J3-03
J3-04
J3-18
J6-09
BLK
WHT
BLK
MAXON NEUTRAL
MAXON POWER
SCR CONT NEUTRAL
SCR CONT POWER
SCR P1
W
O
P
J4-02
SCR2
J4-01
SCR P2
P
P
SCR P3
WORK LIGHT NEUT
WORK LIGHT PWR
MERCOID SWITCH
USER INSTALLED
USER INSTALLED
USER INSTALLED
USER INSTALLED
J6-18
LITE
WHT
BLK
J1-16
(CANADA ONLY)
ORG
UNLD COM
UNLD N/O
ORG
LOAD COM YEL
LOAD N/O
YEL
A+
A-
OR
PUR
73
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Po rt a b le Drye r Tro u b le sh o o t in g
Co m p e t it o r Wirin g Re fe re n ce
Series 2000 Control Box Wiring (New Version)
74
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Co m p e t it o r Wirin g Re fe re n ce
Upper Control Box Wiring
Po rt a b le Drye r Tro u b le sh o o t in g
220 Volt 1PH
75
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Upper Control Box Wiring
380, 460 & 575 3PH
76
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Series 100 Control Box Wiring
1 - END PROTECTOR# D01-0532
48 - COMPRESSION TERM.# D01-0531
2 - ENDSTOP# D01-0533
REMOVE SCREW TO ACTIVATE
USER SAFETY TERMINAL
CONNECT WIRE FROM J7-08
THRU USER SAFETY SWITCH
BACK TO USER SAFETY TERM.
4 - GROUND TERMINAL# D01-0534
13" DIN RAIL# D03-0013
NO CONNECTION (12VDC CNTR TAP)
RED - - - -J1-17 USER SAFETY
RED - - - -J7-08
RED - - - -J7-02
+12 VOLTS
HOUSING HIGH LIMIT
RED
YEL
RED - - - -J1-13
- - PURP
RED
2 WIRES ORG
VAPOR HIGH LIMIT
+12 VOLTS
LEFT GRAIN HI-
NO CONNECTION (12 VDC CENTER TAP)
NO CONNECTION
NO CONNECTION
RED - - - -J7-01
2 WIRES RED
RIGHT GRAIN HI
- -BLUE
PLENUM HIGH LIMIT
BRN
NO CONNECTION (12 VDC CENTER TAP)
+12 VOLTS
RED - - - -J7-03
NO CONNECTION (12 VDC CENTER TAP)
RED - - - -J7-05
(MOTOR OVERLOAD-49)
RED - - - -J7-04 (MOTOR OVERLOAD-35)
BLUE- - - -J7-09
WHT - - - -J7-10
BLUE- - - -J7-11
GREY- - - -J7-19
WHT - - - -J7-20
YEL - - - -J7-12
WHT - - - -J7-13
ORG - - - -J7-14
WHT - - - -J6-02
ORG
BLK
BLK
REAR DISCHARGE
+12 VOLTS
OUT OF GRAIN
NO CONNECTION (12 VDC CNTR TAP)
NO CONNECTION
AIRFLOW
AIR GND
NO AIRFLOW
FLAME DETECT
FLAME DETECT
PLENUM TEMPERATURE
BLUE
2 WIRES WHT/BLK
GRY
ORG
WHT
YEL
2 WIRES -
2 WIRES -
GRAIN/PLENUM GND WHT/BLK
BLK
GRAIN TEMPERATURE
NO CONNECTION
NO CONNECTION
BLK - - - -AC-01
MAIN SOLENOID NEUTRAL -WHT
WHT - - - -J6-13
BLK
BRN
WHT
BLK
WHT
BLK
WHT
BLK
WHT
MAIN SOLENOID POWER
CYCLE SOLENOID POWER
UNLOAD AUGER NEUTRAL
UNLOAD AUGER POWER
LOAD AUGER NEUTRAL
LOAD AUGER POWER
FAN NEUTRAL
FAN POWER
IGNITION NEUTRAL------
IGNITION POWER
BLK - - - -M-SOL
BLK - - - -J6-14
WHT - - - -J3-02
ORG - - - -J3-01
WHT - - - -J3-12
YEL - - - -J3-11
WHT - - - -J3-14
BLUE- - - -J6-03
WHT - - - -J6-07
BLK - - - -J6-06
16 GA WIRES
BLK
MAXON POWER ---------- PUR
MAXON NEUTRAL -------- WHT
BLK - - - -J3-03
WHT - - - -J3-04
SCR CONTACTOR NEUTRAL WHT
SCR CONTACTOR POWER - ORG
WHT - - - -J3-18
ORG - - - -J6-09
METERING ROLL POT
METERING ROLL POT
METERING ROLL POT
WORK LIGHT NEUTRAL
WORK LIGHT POWER
BLK
BLK
BLK
WHT
PUR - - - -J4-02
PUR - - - - SCR2
PUR - - - -J4-01
WHT - - - -J6-18
RED
BLK - - - - LITE
PINK------------ J1-16
ORG - UNLOAD AUX COM
ORG - UNLOAD AUX N/O
YEL - LOAD AUX COM
YEL - LOAD AUX N/O
MERCOID SWITCH (CANADA ONLY)
USER INSTALLED
USER INSTALLED
USER INSTALLED
USER INSTALLED
100STRIP98.PRT REV. DATE 3/12/98
77
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Po rt a b le Drye r Tro u b le sh o o t in g
Upper Terminal Strip
Co m p e t it o r Wirin g Re fe re n ce
With Moisture Control Hook Up
78
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Upper Terminal Strip
With Moisture Control Relay Hook Up
79
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Po rt a b le Drye r Tro u b le sh o o t in g
Moisture Manager to Dryer Wiring
Co m p e t it o r Wirin g Re fe re n ce
(Upper Control Box)
80
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Input/Output Board & Terminal Strip
LINE
LOAD
19
20
J2
1
2
J1
J4
19
20
1
2
J3
81
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Po rt a b le Drye r Tro u b le sh o o t in g
Co m p e t it o r Wirin g Re fe re n ce
Competitor Control Circuit
CPU/Display Board
82
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Co m p e t it o r Wirin g Re fe re n ce
Competitor Control Circuit
Po rt a b le Drye r Tro u b le sh o o t in g
I/O Board
83
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Competitor Control Circuit
SCR Drive Board
84
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
* The SCR board is located in the
upper control box.
* Terminals L1 and L2 are the input
terminals. When the unload system
is turned on there should be 220
Volts AC accross these terminals.
RESISTOR
* Terminals A+ and A- are the ouput
terminals. The voltage across these
terminals is DC and will vary de-
pending on where the speed con-
trol potentiometer is set.
MIN
* The item circled at the bottom right
of the SCR board in the photograph
is the minimum set potentiometer.
This will be used in the SCR board
set up to set minimum DC voltage.
MAX
* The item circled at the bottom left
of the SCR board in the photograph
is the maximum set potentiometer.
This will be used in the SCR board
set up to set maximum DC voltage.
P3
P2 P1
L1
L2 A+
A-
IMPORTANT: After the new board has been installed be sure to remove the resistor
(shown in the photograph above) from the old board and install it in the new board. Just
pull the resistor from the two pin socket and install in the same socket on the new board.
Resistor for 1/3 Hp
Meter Roll motors
used on 12 ft dryers
and shorter. (part
no. D03-0039)
Resistor for 3/4 Hp
Meter Roll motors
used on 14 ft dryers
and longer. (part
no. D33-0001)
Control panel switch locations.
Moisture
Control
Switch
Unload
Switch
Metering Roll
Speed (High)
Drying Mode
Switch
Metering Roll
Speed (Low)
85
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Po rt a b le Drye r Tro u b le sh o o t in g
Co m p e t it o r Wirin g Re fe re n ce
Setting SCR Board Maximum Voltage
Before starting the procedure set the dryer up as follows:
1. All fan and heater switches to off position and load switch to off position.
2. Control power to on position.
3. Push the dryer power switch.
4. Dryer mode switch to cont. flow position.
5. Moisture control switch to on position.
6. Unload switch to 2 speed position.
1. Set the low metering roll speed to 050 on the dial
indicator shown in the photograph on the left. Set the
high metering roll speed to 999.
Unload
Switch to 2
speed
2. Switch the Unload switch to the 2 speed position.
3. Switch the Moisture Control switch to the off position.
This will put the meter roll rotation speed to the high
setting.
position
4. Use a voltmeter set at the 200 volt DC range and
probe terminal A+ with the red voltmeter probe and A-
with the black voltmeter probe. If the display on your
voltmeter reads 180 volts DC no maximum adjustment
is needed. If your voltmeter does not read 180 VDC,
then use a small screw driver and adjust the max set
petentiometer until the voltage is 180 VDC.
Metering Roll
Speed (High) set to
999
Metering Roll
Speed (Low) set to
050
A+
A-
MAX
86
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Po rt a b le Drye r Tro u b le sh o o t in g
Co m p e t it o r Wirin g Re fe re n ce
Setting SCR Board Minimum Voltage
1. Switch the Moisture Control Switch back to the on position. This will put the meter roll rotation
speed at the low setting.
2. Use a voltmeter set at the 20 volt DC range and probe terminal A+ with the red voltmeter probe
and A- with the black voltmeter probe. Use a small screw driver and adjust the min set potentiom-
eter until the voltage is 9 VDC.
The SCR board is now set and dryer is ready for normal operation at desired settings.
SCR Drive Board (Part No. D03-0104)
MIN
A+
A-
87
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Po rt a b le Drye r Tro u b le sh o o t in g
Co m p e t it o r Wirin g Re fe re n ce
Upper Control Box External Wiring
ORANGE J7-19 FLAME DETECTION TO FLAME PROBE
WHITE J7-20 FLAME DETECTION TO FLAME PROBE BASE
WHITE J6-07 IGNITION TRANSFORMER 120VAC NEUTRAL 16 GA. WIRE
BLACK J6-06 IGNITION TRANSFORMER 120VAC POWER 16 GA. WIRE
BLACK J6-12 MAIN SOLENOID 120VAC POWER
WHITE/BLACK STRIP J7-10 12VDC NEGATIVE
TO FAN CONTROL BOX
WHITE J6-13 MAIN/CYCLE SOLENOID 120VAC NEUTRAL
BROWN J6-14 CYCLE SOLENOID 120VAC POWER
YELLOW J7-02 FROM HOUSING HIGH LIMIT SWITCH
RED J7-08 12VDC INPUT POWER TO HOUSING & VAPOR HIGH LIMIT SWITCHES
PURPLE J7-13 FROM VAPOR HIGH LIMIT SWITCH
BLUE J7-09 CONNECTS TO AIRSWITCH N.O. TERMINAL
WHITE/BLACK STRIP J7-10 CONNECTS TO AIRSWITCH COMMON TERMINAL
GREY J7-11 CONNECTS TO AIRSWITCH N.C. TERMINAL
TO AIRSWITCH ASSEMBLY
WHITE J7-13 PLENUM/GRAIN TEMPERATURE SENSOR COMMON
BLACK J7-14 RIGHT GRAIN TEMPERATURE SENSOR
RED 12VDC TO LEFT GRAIN HIGH LIMIT SWITCH
ORANGE 12VDC FROM LEFT GRAIN HIGH LIMIT SWITCH
PURPLE J3-03 MAXON POWER 120VAC (NATURAL GAS ONLY)
WHITE J3-04 MAXON 120VAC NEUTRAL (NATURAL GAS ONLY)
BROWN 12VDC TO REAR DISCHARGE SWITCH
ORANGE J7-03 FROM REAR DISCHARGE SWITCH
RED 16 GA. A+ SCR DRIVE MOTOR
TO LOWER JUNCTION BOX
BLACK 16 GA. A- SCR DRIVE MOTOR
GREEN 16 GA. SCR DRIVE MOTOR GROUND
BLACK 12VDC TO LOAD MERCURY SWITCH
BLACK J7-05 FROM LOAD MERCURY SWITCH
TO UPPER JUNCTION BOX
WHITE J6-18 OUTSIDE LIGHT AC NEUTRAL
RED LITE 120VAC OUTSIDE LIGHT POWER
YELLOW J7-12 PLENUM TEMPERATURE SENSOR
WHITE J7-13 PLENUM/GRAIN TEMPERATURE SENSOR COMMON
BLACK J7-14 GRAIN TEMPERATURE SENSOR
BLUE FROM PLENUM HIGH LIMIT SWITCH TO J7-01
RED TO PLENUM HIGH LIMIT SWITCH
TO PLENUM AND RIGHT
FIXED GRAIN HIGH LIMIT
SWITCHES AND TEMPERATURE
SENSORS
ORANGE TO RIGHT GRAIN HIGH LIMIT SWITCH
RED FROM RIGHT GRAIN HIGH LIMIT SWITCH
88
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Input/Output Board 12 Volt
UNLOAD AUGER NEUTRAL
AC NEUTRAL
UNLOAD AUGER POWER
MAXON VALVE/DRYER RUNNING LIGHT
AC NEUTRAL
PROOF OF FLAME LIGHT
PROOF OF AIRFLOW LIGHT
MOISTURE CONTROL HOLDING LIGHT
LOAD POWER
AC NEUTRAL
AC NEUTRAL
LOAD AUGER NEUTRAL
FAN NEUTRAL
AC NEUTRAL
TRIAC SPARE
N.C. (TIED TO J3-19)
AC NEUTRAL
N.C. (TIED TO J3-19)
AC NEUTRAL
120V INPUT FROM CPU
RL1-A COMMON TO POT INPUT ON SCR BOARD
RL1-B COMMON TO POT INPUT ON SCR BOARD
RL1-B N.C. LOW SPEED POT A
RL1-B N.O. HIGH SPEED POT A
RL1-A N.C. LOW SPEED POT B
RL1-A N.O. HIGH SPEED POT B
12 VDC
12 VDC
FAN ON
FAN AUTO
BURNER AUTO
UNLOAD 2 SPEED
LOAD AUTO
BURNER ON
UNLOAD 1 SPEED
LOAD ON
DRYER EMPTY (BATCH ONLY)
MOISTURE CONTROL ON
MERCOID SAFETY INPUT
SPARE
CONTINUOUS FLOW
VAPOR HIGH LIMIT INPUT
SPARE
USER SAFETY INPUT
12 VDC
12 VDC
89
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Po rt a b le Drye r Tro u b le sh o o t in g
Co m p e t it o r Wirin g Re fe re n ce
Cpu Board Wiring
F U S E
90
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Programing Instructions for Competitor Series Grain Dryers
1. Turn Control Power on dryer to the off position.
2. Locate programming jack (J2) on back of computer. (See next page). There will be a cable plugged into
this jack that comes from the other computer board. Unplug this cable to plug the programmer into the jack.
3. Plug the series 2000 cable into programming jack and into programmers DB-9 jack.
4. Be sure that the rotary switch on the programmer is set to position 8.
5. Turn on Control Power to the dryer.
6. The four (4) lights on the programmer will come on, then three (3) will go out leaving the power light still on.
7. Push the start button on the programmer to start the transfer of Software.
8. The busy light will flash until the transfer process is complete.
9. When completed, the pass light will flash indicating a successful transfer.
10. If the fail light flashes then check your connections and repeat the above process.
11. Turn Control Power on dryer to off and remove the cable.
12. Turn on the dryer and the opening screens should indicate the newer version of software.
91
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Po rt a b le Drye r Tro u b le sh o o t in g
Co m p e t it o r Wirin g Re fe re n ce
Programmer Hook Up Diagram
F U S E
8
7
6
5
4
3
2
1
O N
92
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Po rt a b le Drye r Tro u b le sh o o t in g
Co m p e t it o r Wirin g Re fe re n ce
Programming Instructions Using Palm Pilot
On the Competitor Dryer there is only one board to program. This board is called the CPU
Display board. It is mounted to the door of the lower box. To access, open the door and the pro-
gramming jack is located on the back of this board. To program, follow the instructions below.
1. Turn the control power on the dryer to the off position.
2. Locate the programming jack (J2 connector) on back of board.
3. Unplug the communications cable that is connected to that connector. This is the cable that
runs from the CPU/Display board and IO Board.
4. Connect the DB-9 connector from the Palm Pilot to the series 2000 cable.
5. On the Palm Pilot select the program for that particular board and tap on it.
6. Turn the dryer control power back on.
7. The programming process should begin, it will erase the present program and start the new
program.
8. A screen will come up telling you when the transfer of software is complete.
9. When the process is complete turn dryer control power off, remove the connector from the
board and plug the communications cable back on to the CPU/Display board.
10. Turn on the dryer and the opening screens should indicate the latest version of software.
Refer to next page for more information on programming the Series 2000 board.
If ordering Palm Pilot from GSI there are two kits available:
D03-0692 ( Palm Flash Program Kit Deluxe )
D01-1771 Series 2000 Programming Cable
D03-0688 Palm Pilot IIIC (color)
D03-0694 Palm Pilot Hot Sync Cable
D03-0695 Palm Flash 9 Pin M-M Adapter
D03-0709 Disk, CD-Rom Palm Flash Software
D03-0693 ( Palm Flash Program Kit Economy )
D01-1771 Series 2000 Programming Cable
D03-0689 Palm Pilot M100 (black & white)
D03-0695 Palm Flash 9 Pin M-M Adapter
D03-0709 Disk, CD-Rom Palm Flash Software
93
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Po rt a b le Drye r Tro u b le sh o o t in g
Pro g ra m m in g Co m p e t it o r
Programming Competitor Dryer Using Palm Pilot
Hot Sync Cable
D03-0694
Palm Pilot
D03-0689 (M100)
D03-0688 (IIIC)
Palm
Side
DB-9 M-M Adapter
D03-0695
Dryer
Side
DB-9 Connector
J2 Connector
(Connects to the back
of CPU/Display board)
DB-9 Connector
(Connects to the
DB-9 M-M adapter)
Series 2000 Programming Cable
D01-1771
(Use on CPU/Board)
94
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Back of Switch Panel Layout
F U S E
95
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Po rt a b le Drye r Tro u b le sh o o t in g
Co m p e t it o r Wirin g Re fe re n ce
Back of Switch Panel Wiring
F U S E
96
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Co m p e t it o r Wirin g Re fe re n ce
Po rt a b le Drye r Tro u b le sh o o t in g
Air Switch Assembly
97
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Po rt a b le Drye r Tro u b le sh o o t in g
Competitor Air Switch Adjustment
Air Sw it ch Ad ju st m e n t
Air Switch location.
Air Switch assembly.
IMPORTANT: To adjust the air switch the grain columns
need to be full of grain so that the plenum can build up air
pressure and close the air switch.
1.
2.
With the Load Auger, Fan, Heater, and Unload switches in the off position turn
on the Control power then push the Dryer Power Start switch.
With power now applied to the dryer flip the fan switch to the on position and
watch the light right above that switch. If the light illuminates when the fan
reaches half its full speed, then no adjustment is required. However, if the light
does not illuminate until the fan is running at full speed or the light does not
illuminate at all and the dryer shuts down the air switch is adjusted too high
(skip to step 3a). If the light illuminates before the fan reaches half its full
speed the air switch is adjusted too low (skip to step 3b).
3a. If the light above the fan switch illuminates after the fan reaches full speed or did not
illuminate at all and the dryer shut down then the air switch needs to be made more
sensitive. Turn adjustment screw in the more sensitive direction (counter clock-
wise). Make this adjustment on the air switch 1/4 turn at a time and each time restart
the fan and watch to see when the light illuminates.
FAN
3b. If the light above the fan switch illuminates before the fan reaches half its full speed
then the air switch needs to be less sensitive. Turn adjustment screw in the less
sensitive direction (clockwise). Make this adjustment on the air switch 1/4 turn at a
time and each time restart the fan and watch to see when the light illuminates.
OFF
4.
Flip the fan switch to the off position and watch the light. Now it should go out when
the fan is about half its full speed. Adjust the air switch if necessary. Remember that
less sensitive (clockwise adjustment) will require a higher fan speed to close the air
switch, and more sensitive (counter clockwise adjustment), the switch can close at
a slower fan speed.
AUTO
O N
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Po rt a b le Drye r Tro u b le sh o o t in g
Fixed Grain Hi-Limit & Temperature Sensor
BROWN FROM 12VDC TO DISCHARGE SWITCH
ORANGE FROM J7-03 TO DISCHARGE SWITCH
RED 16 GA. A+ TO SCR DRIVE MOTOR
BLACK 16 GA. A- TO SCR DRIVE MOTOR
GREEN 16 GA. TO SCR DRIVE GROUND
99
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Out of Grain Sensor
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Po rt a b le Drye r Tro u b le sh o o t in g
Grain Temperature Sensor
YELLOW J7-12
WHITE/BLACK STRIP J7-13
WHITE/BLACK STRIP J7-13
BLACK J7-14
BLACK J7-14
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Grain Sensor Testing
F U S E
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Gra in Se n so r
Po rt a b le Drye r Tro u b le sh o o t in g
Procedure for Locating, Testing and Replacing
a Defective Grain Temperature Sensor
Symptoms of a bad sensor may include:
·
Temperature readings that are not consistent with the ambient outside temperature or with any
known verified grain temperatures entering the dryer.
·
·
Grain temp open or grain temp short on Network dryers
Display readings of 255° or –127°.
Grain Thermistor Sensor
Troubleshooting:
1.
2.
3.
Locate the left and right grain sensor electrical boxes on the dryer (see drawing below)
Open each box by removing the lid. They are held in place by 4 phillips head bolts and nuts.
Once inside the box, determine which wires you need to test by identifying the wire routing.
Mounting Screws
Grain Thermal
Overheat wires
Sensor wires
(Small white
26 ga.)
Sensor Wires
(Small white
26 ga.)
Grain Thermal
Overheat wires
4.
The grain sensor wires are small white (26 ga.) and are connected to a 18 ga. white and a 18 ga.
black wire with 2 of the smaller (26 ga.) grain sensor wires butt connected together.
The grain thermal overheat switch is a black disk mounted on a silver bracket with 2 black 18 ga.
wires connected to 2 colored wires.
5.
6.
7.
8.
Disconnect the white and black 18 ga. wires from the smaller white grain sensor wires.
Strip back about 1/4 inch from the end of each 26 ga. sensor wire.
With a ohm meter, set your scale to 20k (if its not a autorange model).
9.
Place the black lead into the still butt connected wire connection with the 2 – 26 ga. wires.
10. Connect the red lead to either of the disconnected 26 ga. wires and make note of the reading.
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Gra in Se n so r
Procedure for Locating, Testing and Replacing
a Defective Grain Temperature Sensor. (continued)
11.
12.
13.
Now move the red lead to the other disconnected 26 ga. wire and make note of this reading.
Go to the other side of the dryer and repeat steps 6 through 11.
You will notice that 3 readings will be very close to the same, but one reading will be different. This
is your defective sensor. (Compare readings to Resistance/Temperature chart page 62.)
If you don’t have a replacement sensor, jump to How to Bypass the Grain Temperature Sensor
14.
Sensor Replacement:
15.
16.
17.
The grain sensors are mounted to the grain overheat capillary and need to be removed together.
To remove the overheat switch disconnect the grain thermal overheat wires.
Then remove the 2 self tapping screws and slide the bracket, overheat switch and sensors out of
conduit.
18.
19.
20.
Remove the tape surrounding the defective grain sensor then remove it.
Place your new sensor upon the capillary then apply tape to secure the sensor.
Slide the overheat switch and sensors back into the conduit until the bracket for the overheat switch
is in the same mounting position as before.
21.
22.
23.
24.
25.
26.
27.
Replace both mounting screws back into the overheat switch mounting bracket.
Butt connect together one wire from each of the grain sensors.
Connect one of the remaining grain sensor wires to the Black 18 ga. wire.
Connect the other remaining grain sensor to the White 18 ga. wire.
Connect one of the grain overheat switch wire to each one of the colored wires.
Reconnect the other side of the dryer following steps 22 through 24.
Double check the wire connections then replace the covers on the boxes.
How to Bypass the Grain Temperature Sensor:
The following instructions are for situations where you don’t have an extra grain sensor to replace the
defective one. So now, we are going to rewire the sensors so that instead of using 4 sensors to monitor the
grain temperature with, we are only going to use one. The dryer will operate fine with only one sensor with
the exception of only being able to monitor one small section of the grain columns.
1.
On the side of the dryer in which sensor is defective, leave this sensor and the joining sensor
disconnected from the white and black 18 ga. wires. Be sure to cap these 18 ga. wires off.
On the other side of the dryer, take one of the small white grain sensor wires and connect it to the
white 18 ga. wire.
2.
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Se n so r Ch a rt
Procedure for Locating, Testing and Replacing
a Defective Grain Temperature Sensor. (continued)
3. From the same sensor that you connected to the white 18 ga. wire, connect the other small white
grain sensor wire to the black 18 ga. wire.
4. Double check the wire connections then replace the covers on the boxes.
Resistance / Temperature Chart
°F
Ohms
°F
Ohms
°F
Ohms °F
Ohms °F
Ohms °F
Ohms °F
Ohms
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
36,601 62
35,565 63
34,562 64
33,591 65
32,650 66
31,739 67
30,856 68
30,000 69
29,171 70
28,368 71
27,590 72
26,835 73
26,104 74
25,394 75
24,707 76
24,040 77
23,394 78
22,767 79
22,159 80
21,569 81
20,997 82
20,442 83
19,903 84
19,380 85
18,873 86
18,380 87
17,902 88
17,438 89
16,988 90
16,551 91
16,126 92
15,714 93
15,313 94
14,924 95
14,546
14,179
13,822
13,475
13,139
12,811
12,493
12,184
11,884
11,591
11,307
11,031
10,762
10,501
10,247
10,000
9,760
9,526
9,298
9,077
8,862
8,652
8,448
8,249
8,056
7,868
7,685
7,506
7,333
7,164
6,999
6,839
6,682
6,530
96
97
98
99
6,382
6,238
6,097
5,960
130 3,047 164 1,565
198 855.7
199 841.4
200 827.3
201 813.6
202 800.1
203 786.8
204 773.8
205 761.1
206 748.6
207 736.3
208 724.3
209 712.5
210 700.9
211 689.6
212 678.4
213 667.5
214 656.8
215 646.2
216 635.9
217 625.8
218 615.8
219 606.1
220 596.5
221 587.1
222 577.9
223 568.8
224 559.9
225 551.2
226 542.6
227 534.2
228 525.9
229 517.8
230 509.8
231 502
232 494.3
233 86.8
234 479.4
235 472.1
236 464.9
237 457.9
238 451
239 444.2
240 437.6
241 431
131 2,985
132 2,925
133 2,865
134 2,807
135 2,751
136 2,696
137 2,642
138 2,589
139 2,537
140 2,487
141 2,438
142 2,390
143 2,343
144 2,297
145 2,252
146 2,208
147 2,165
148 2,123
149 2,082
150 2,042
151 2,003
152 1,965
153 1,927
154 1,890
155 1,855
156 1,820
157 1,785
158 1,752
159 1,719
160 1,687
161 1,655
162 1,624
163 1,594
165 1,536
166 1,508
167 1,480
168 1,453
169 1,427
170 1,401
171 1,375
172 1,350
173 1,326
174 1,302
175 1,279
176 1,256
177 1,234
178 1,212
179 1,190
180 1,169
181 1,149
182 1,129
183 1,109
184 1,089
185 1,070
186 1,052
187 1,034
188 1,016
189 998.3
190 981.2
191 964.4
192 947.9
193 931.8
194 915.9
195 900.4
196 885.2
197 870.3
100 5,826
101 5,696
102 5,569
103 5,446
104 5,325
105 5,208
106 5,093
107 4,981
108 4,872
109 4,766
110 4,663
111 4,562
112 4,463
113 4,367
114 4,273
115 4,182
116 4,093
117 4,006
118 3,921
119 3,838
120 3,757
121 3,678
122 3,601
123 3,526
124 3,453
125 3,381
126 3,311
127 3,243
128 3,176
129 3,111
242 424.6
243 418.3
244 412.1
245 406
246 400
247 394.1
248 388.3
249 382.7
250 377.1
105
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Ple n u m Se n so r
Po rt a b le Drye r Tro u b le sh o o t in g
Procedure for Locating, Testing and Replacing
a Defective Plenum Temperature Sensor
Symptoms of a bad sensor may include:
Temperature readings that are not consistent with the ambient outside temperature or
with a verified plenum temperature that has been taken with a thermometer.
Erratic plenum display readings.
Plenum temp open or plenum temp short.
Troubleshooting:
1. The process of checking the sensor is similar to that of the grain sensors, but you
only have one sensor to check.
2. The actual plenum sensor is located in the plenum just inside the rear access door
to the right. (Facing the rear of the dryer)(See picture on next page)
3. Start at the CPU/Display board, it is located on the door of the lower box.(See below)
4. The wires from the sensor (which are butt connected at the sensor) go through a
conduit in the plenum section of the dryer.(See next page) That conduit terminates at
a white plastic 4"x4" junction box. This box is located on the front of the dryer to the left
of the fan/heater. (Facing the front of the dryer.) From that point to the CPU/Display board.
5. The wires are connected to terminals J7-12 (white wire) and J7-13 (black wire) on the
back of the Cpu/Display board.(see picture below)
6. Unhook those wires
7. What you will be checking is resistance in relationship to a known temperature.
(See resistance/temperature chart on previous page.)
8. With a ohm meter, set your scale to 20k (if it’s not a autorange model).
9. Place one probe of your meter on one wire going out to the sensor and the other
probe to the other wire.
10. The meter should read close to the resistance/temperature chart on previous page.
11. Assuming you have checked the wiring from the CPU/Display board to the sensor and
it is OK. But the resistance is not close to what is on the chart. You probably have a bad
plenum bolt sensor.
Plenum Sensor
Plenum Bolt
Connected to
Sensor
J7-12 & J7-13
(Part No. HF-7236)
Back of Door on Lower Box
CPU/Display Board
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Ple n u m Se n so r
Po rt a b le Drye r Tro u b le sh o o t in g
Procedure for Locating, Testing and Replacing
a Defective Plenum Temperature Sensor
The picture below is of the plenum bolt sensor in the plenum of the dryer. See previous
page for more information.
Plenum Bolt Sensor (Part No. HF-7236)
View of back side of the plenum bolt sensor, as it is mounted in the conduit fitting.
(Located inside the dryer plenum, to the right, just inside the rear access door.)
View of the 4"x4" plastic junction box. This is located to the left of the fan/heater
facing the front of the dryer. It contains the plenum overheat and a juction point
where the wires from the plenum bolt sensor are butt connected together.
Plenum 300 Degree Overheat (10' Length)(Part No.D03-0004)
Plenum 300 Degree Overheat (24' Length)(Part No. D03-0377)
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Co m p e t it o r Wirin g Re fe re n ce
Stern and Capacitor Diagram 10-17 HP 1Phase
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Po rt a b le Drye r Tro u b le sh o o t in g
OPERATION HINTS FOR COMPETITOR DRYERS
Op era t ion Hin t s
Present Software version is 2.19
1. BURNER CYCLING
Keep Low pressure setting as low as possible without shutting down dryer or popping. Approx. 1 to 2 lb.
Cycle on average 4 times per minute. 3 -5 times per minute is acceptable.
2. ERRORS
01 User switched from continuous flow to batch while dryer was running.
02 Grain Temperature Sensor Open. One or both leads are off (Open Circuit.).
03 Grain Temperature Sensor Leads are shorted together.
04 Plenum Temperature Sensor Open. One or both leads are off (Open Circuit).
05 Plenum Temperature Sensor Leads are shorted together.
06 Flame Probe Shorted to ground.
07 Illegal Flame Sense. Most likely caused by stuck open gas solenoid.
Error 7 will not shut down fan until loss of flame is detected by control. May occur if 1 of the 12 volt DC limits is
shorted to AC ground, or to the communication port for the air switch or either temperature sensor is shorted to
AC ground.
08 No safety circuit voltage.
09 I/O board communication failure. I/O board and Master board have lost communication.
10 User supplied safety. A safety connected to J7 -8 and J1-17.
11 Canadian Mercoid sensor. In USA jump J7-8 to J1-16.
BATCH ERRORS
BRN on the screen means the Burner Switch is turned off or there is a loose wire in its circuit.
FAN on the screen means the Fan Switch is turned off or there is a loose wire in its circuit.
Presently the Load Switch and the Unload Switch are not monitored by the Dryer Controls.
999 on the screen is not a n Error. It means the board has never had software loaded. This will come up when you
turn on the power just after GSI appears. This means the latest software must be down loaded.
3. DIP SWITCHES
1. Dip Switch 8 = Air Switch Test Bypass. WARNING! Bypassing this test will allow burner to come on
without the Fan running.
2. Dip Switch 7 = Emergency Cooling Mode. Fan will run alone for 5 minutes when the Start button is pushed with
switch on.
3. Dip Switch 6 = Allows Off/On Burner operation instead of High/Low as is standard.
4. Dip Switch 5 = (In Software Ver. 2.11 and up) Adds Low Temp Timer to a nd low Temp finish dry like dual temp.
Batch Dryer.
5. Dip Switch 4 = (In Software Ver. 2.14 and up) Adds Low Temp finish tripped by Grain Temperature to Batch
Mode.
4. SHUTDOWNS
If both the GRAIN and PLENUM HIGH TEMPERATURE warnings appear on the screen at the same time one of
the two mechanical temperature sensors are kicked out. NOTE Emergency Cooling will NOT work if these are
kicked out. These temperature limits are in addition to the electronics high limits and are located in the same
electrical conduits as the electronic thermister sensors. Note that J7-01 is the terminal the computer checks for
12 volts.
5. SPECIAL KEY USAGE
1. Pushing the UP arrow key will gives the Dryers Hour Meter reading. Two successive screens Hours x 100 |
Balance of hours.
In software vers. 2.14 and above it reads in 5 successive screens Total Hours x 100 | Balance of hours | Balance of
minutes | Batch Count | Minutes since last shutdown. So 5 | 23 | 12 | 144 | 188 would be Timer = 523 hours 12
minutes, 144 Batches dumped and 3 hours and 8 minutes since the last shutdown.
2. Pushing the DOWN arrow key while an error is on the screen will tell how long ago the shutdown occurred.
3. Pushing the MODE SELECT key exits any mode back to the main screen.
4. Holding the STOP button for 4 seconds or longer causes the Dry, Cool, and Unload timers to be reset to the
values programmed by the user. This also forces new times.
5. Holding down the HOURS key and turning on the power resets the NOVRAM or does what is called a HARD
BOOT.
6. Holding down the DOWN key while turning on the power restores the factory default settings.
7. In software vers. 2.19 and above Holding down the Up Arrow Key while powering up resets the Total Batch
Counter .
109
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OPERATION HINTS FOR COMPETITOR DRYERS
Op era t ion Hin t s
6. OPERATION HINTS
1. If you set a new timer setting which is lower then the present setting it becomes effective immediately. If it is
7. OPTIONAL WIRING POINTS
1. J7-10, J7-13 and J7-18 are 12 volt ground points for use with a tester.
There are no 12 volt ground connections on the IO board.
2. J1-17 - User Supplied Safety. If 12 volts is interrupted from J7-18 the User Supplied Safety Warning, ERROR 10
results.
3. J1-16 - Canadian Mercoid Sensor. If 12 volts in interrupted from J7-18 the Canadian Mercoid Warning, ERROR
11 results.
4. J1-15 - Discharge Hold Function – First available in Version 2.19 - operates in Batch Mode only.
If 12 volts is applied to J1-15 before the unload cycle is reached, when it does reach the unload cycle the dryer will
turn off the Fan and or the Heater (Only if the switches are in the AUTO position) and not allow the Dryer to unload
until the 12 volts is removed from J1-15. When 12 volts is not detected the dryer will resume normal operation and
immediately unload the Dryer and continue drying. This function cannot be activated if the unload cycle has
already begun. If you are running Dry and Cool and want the Dryer to continue cooling while in Discharge Hold put
the Fan switch in the Manual position. Otherwise both the Fan and Heater Switches should be in the AUTO
position.
5. J7-15, J7-16 and J7-17 are 12 volt Positive source points.
8. Temperature Sensor Testing
1. You can find charts with the Resistance readings at various Temperatures in the following manuals
The Competitors use the Thermister type sensors, the bolt style for the Plenum and the round style for the Grain
Temperature.
Located in Resource 2003 CD in the “Resources – Manuals” Folder
PNEG-630 Portable Dryer – Trouble Shooting
PNEG-377 Fan & Heater – Service Manual Feb 2000.pdf Page 50 (Fans and Heaters | Trouble Shooting Guide)
9. TROUBLESHOOTING TIPS
1. If some 110 volt contactor control devices work and some do not check the fuse on the IO board to see if it has
failed.
Likely devices that will not work are the Load Auger, Unload Auger and SCR drive.
110
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Error Codes
Po rt a b le Drye r Tro u b le sh o o t in g
Series 100 Error Conditions
111
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Co m p e t it o r Wirin g Re fe re n ce
Series 100 Error Conditions
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Po rt a b le Drye r Tro u b le sh o o t in g
Heater Circuit
PART# HH-1093
IGNITION TRANSFORMER
TYPE 312-24A402V
CODE D97T
PRI V SEC V HZ PRI A SEC A
120 10,000 60 2.2 .023
SECONDARY MIDPOINT GROUNDED
Webster
113
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Co m p e t it o r Wirin g Re fe re n ce
Fan Burner Circuit For Canadian Models Only
114
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Po rt a b le Drye r Tro u b le sh o o t in g
Series 100 LP 26"/28" Fan
WIRES:
2 - PURPLE
2 - YELLOW
3 FEET LONG
FROM OUTSIDE
OF BOX
PURPLE
PURPLE
BLACK
BLACK
YELLOW
YELLOW
J7-19 ORG
J7-20 WHT
J6-07 WHT
J6-06 BLK
J6-12 BLK
J6-13 WHT
J6-14 BRN
J7-13 PUR
J7-08 RED
BLACK
WHITE
BROWN
PURPLE
PURPLE
BROWN
YELLOW
WHITE
BLACK
YELLOW
J7-02 YEL
J7-10 WHT/BLK
WIRES:
1 - WHITE
1 - BLACK
1 - BROWN
1 FOOT LONG
FROM OUTSIDE
OF BOX
S228LP.PRT
115
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Co m p e t it o r Wirin g Re fe re n ce
Series 100 Natural Gas 26"/28" Fan
WIRES:
2 - YELLOW
3 FEET LONG
FROM OUTSIDE
OF BOX
BLACK
BLACK
YELLOW
YELLOW
J7-19 ORG
J7-20 WHT
J6-07 WHT
J6-06 BLK
J6-12 BLK
J6-13 WHT
BLACK
BLACK
WHITE
BROWN
J6-14 BRN
J7-08 RED
YELLOW
BROWN
YELLOW
J7-02 YEL
WHITE
BLACK
J7-10 WHT/BLK
WIRES:
1 - WHITE
1 - BLACK
1 - BROWN
1 FOOT LONG
FROM OUTSIDE
OF BOX
S228NG.PRT
116
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Po rt a b le Drye r Tro u b le sh o o t in g
Series 100 LP 36"/42" Fan
WIRES:
2 - PURPLE
2 - YELLOW
3 FEET LONG
FROM OUTSIDE
OF BOX
BLACK
WHITE
PURPLE
BROWN
YELLOW
WIRES:
1 - BROWN
1 - WHITE
1 - BLACK
PART# HH-1093
IGNITION TRANSFORMER
TYPE 312-24A402V CODE D97T
PRI V SEC V HZ PRI A SEC A
120 10,000 60 2.2 .023
1 FEET LONG
FROM OUTSIDE
OF BOX
SECONDARY MIDPOINT GROUNDED
WIRES:
1 - WHITE
1 - BLACK
Webster
12 FEET LONG
FROM OUTSIDE
OF BOX
S242LP.PRT
117
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Co m p e t it o r Wirin g Re fe re n ce
Series 100 Natural Gas 36"/42" Fan
WIRES:
2 - YELLOW
3 FEET LONG
FROM OUTSIDE
OF BOX
BLACK
WHITE
BROWN
YELLOW
WIRES:
1 - BROWN
1 - WHITE
1 - BLACK
PART# HH-1093
1 FEET LONG
FROM OUTSIDE
OF BOX
IGNITION TRANSFORMER
TYPE 612-6A7
CODE J94E
PRI V SEC V HZ PRI A SEC A
120 10,000 60 2.2 .023
MIDPOINT GROUNDED
Webster
S242NG.PRT
118
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Wa rra n t y
Po rt a b le Drye r Tro u b le sh o o t in g
THE GSI GROUP, INC. ("GSI") WARRANTS ALL PRODUCTS MANUFACTURED BY GSI TO BE
FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDI-
TIONS 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 JUDGMENT, 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 AUTHORIZATION FROM AN AUTHORIZED EMPLOYEE
OF GSI SHALL BE THE SOLE RESPONSIBILITY OF THE PURCHASER.
EXCEPT FOR THE ABOVE STATED EXPRESS LIMITED WARRANTIES, GSI MAKES NO WAR-
RANTY OF ANY KIND, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WAR-
RANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN CON-
NECTION WITH (i) PRODUCT MANUFACTURED OR SOLD BY GSI OR (ii) ANY ADVICE, INSTRUC-
TION, RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT, REPRESENTATIVE OR
EMPLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION, INSTALLATION, LAY-
OUT, SUITABILITY FOR A PARTICULAR PURPOSE, OR DESIGN OF SUCH PRODUCT OR PROD-
UCTS.
IN NO EVENT SHALL GSI BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL OR CON-
SEQUENTIAL DAMAGES, INCLUDING, WITHOUT LIMITATION, LOSS OF ANTICIPATED PROF-
ITS OR BENEFITS. PURCHASER'S SOLE AND EXCLUSIVE REMEDY SHALL BE LIMITED TO THAT
STATED ABOVE, WHICH SHALL NOT EXCEED THE AMOUNT PAID FOR THE PRODUCT PUR-
CHASED. THIS WARRANTY IS NOT TRANSFERABLE AND APPLIES ONLY TO THE ORIGINAL
PURCHASER. GSI SHALL HAVE NO OBLIGATION OR RESPONSIBILITY FOR ANY REPRESEN-
TATIVE OR WARRANTIES MADE BY OR ON BEHALF OF ANY DEALER, AGENT OR DISTRIBU-
TOR OF GSI.
GSI ASSUMES NO RESPONSIBILITY FOR FIELD MODIFICATIONS OR ERECTION DEFECTS
WHICH CREATE STRUCTURAL OR STORAGE QUALITY PROBLEMS. MODIFICATIONS TO THE
PRODUCT NOT SPECIFICALLY COVERED BY THE CONTENTS OF THIS MANUAL WILL NUL-
LIFY 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
COMPLY WITH ALL FEDERAL, STATE AND LOCAL CODES WHICH MAY APPLY TO THE LOCA-
TION AND INSTALLATION.
119
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