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Dryer Master DM510 User Manual

Computerized grain drying control system
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  • Page 2 USA & Canada – Toll Free – 1-888-318-0009 E-mail: info@dryermaster.com Reminder Remember to register your DM510 at dryermaster.com. Simply by registering your new DM510 you can automatically extend your warranty from 1 year to 2 years. March 24, 2003 March 11, 2005...

  • Page 3: Table Of Contents

    Operations Manual Dryer Moisture Systems Inc. – About Us ..............6 What is in this manual ..................... 7 DM510 - A Brief Description ..................8 DM510 - How it Works ....................9 Access to our Customer Support Centre ....................9 System Components ....................
  • Page 4 Setting Alarms ............................24 Description of Alarm Limits operation ..............26 Changing Products ....................27 What to expect when the DM510 is turned on ............ 27 The First Week of Drying ..................28 Calibrating the sensors......................... 28 Verifying the Throughput ........................28 Drying in Automatic ..........................
  • Page 5 Dryer Master DM510 Operations Manual ‘Bin’ key (Reports require optional printer) .................. 46 Switching Bins, Printing final Bin Report (the bin is full) ..............47 Switching Bins, No report to be printed at this time................ 47 Printing a bin report..........................48 Bin Summary Report.
  • Page 6 The moisture sensor won’t stay calibrated..................79 Appendix 4: Troubleshooting DM Mobile ............. 80 I can’t connect to the DM510: ......................80 What is my login information? ......................81 I can’t find the DM mobile web page....................81 I am not getting texts on alarms.

  • Page 7: Dryer Moisture Systems Inc. - About Us

    DMSI also provides services that allow the monitoring of your process or plant operations from location on or off site. The Dryer Master DM510 from DMSI continues the commitment to excellence that has made the Dryer Master name the industry standard in grain drying technologies. With your assistance, the...

  • Page 8: What Is In This Manual

    The DM510 is ideally suited to these operations as it devotes its attention full time to your dryer. The DM510 is a tool that helps the operators, by doing the menial tasks and frees them to make the executive decisions about the drying process. It should be noted that the DM510 Dryer Master only optimizes the dryer’s performance.

  • Page 9: Dm510 - A Brief Description

    DM-Mobile can also be configured to provide you with text on alarm messages so that you can be aware of an issue without having to be at the DM510 panel. The DM510 provides quick payback by reducing over and under drying resulting in increased yields, energy savings, and providing a better quality dried product.

  • Page 10: Dm510 - How It Works

    With this information, the DM510 does not have to wait to react to changes in the outlet moisture. It is able to adjust the discharge rate as the incoming moisture changes. For example, as wetter grain comes into the dryer, the DM510 begins to slow down the discharge rate just as the wetter grain reaches the hot zone.

  • Page 11: System Components

    This can be useful for customers not using the internet connectivity feature. DM510 Control Panel including I/O: The DM510 is a computer system complete with user interface keypad and the display screen, I/O system and the capability to provide real time information through an internet connection to an internet capable device.

  • Page 12: Equipment Schematic

    Dryer Control Panel Drying Rate, Rate setpoint & L/R control switching Note: DM510 systems come with either a drying air temp sensor (shown in diagram), or a signal Outlet converter which uses the dryer’s temperature Calibration Moisture button sensor signal. In the latter case the signal converter is...

  • Page 13: Dm510 User Interface

    Dryer Master DM510 Operations Manual DM510 User Interface The user interface incorporates three devices, an LCD display screen, status lights (LED’s) and the keypad. The following sections describe the operation and functionality of the three components of the user interface.

  • Page 14: Display Screen

    The moisture of the product at the top of the dryer as measured by the inlet moisture sensor. 3. Dryer discharge rate: The dryer unload rate as sent to the DM510 by the dryer’s unload system. 4. Outlet moisture sensor, product moisture: The moisture of the product leaving the dryer as measured by the moisture sensor.
  • Page 15 12. Print icon: The printer icon is displayed when a printing task has been initiated. This icon is displayed while the DM510 prepares the information to be printed and until it is sent to the printer. (Optional item) 13. Calibration in progress icon:...

  • Page 16: Operation Mode Descriptions

    Dryer Master DM510 Operations Manual Operation mode descriptions The sample screens show the DM510 drying corn in Local Mode, Manual Mode and Automatic mode. Local Mode: All items displayed on the Main Operations screen. Dryer discharge is controlled from the dryer panel.

  • Page 17: Automatic Mode

    Automatic Mode: All items displayed on the Main Operations screen. Dryer discharge is controlled automatically by the DM510, based on the moisture set-point. Figure 6 - Main Operations Screen (Automatic Mode) DM510 Keypad Figure 7 - DM510 Keypad Description of the Keys/Buttons usage and functions 1.
  • Page 18 Discharge Rate set-point menu. 8. Calibration: Accesses the moisture ‘sensor selection’ menu. Permits the entry of manual moisture samples for the purpose of calibrating the DM510 moisture sensors. 9. Alarms: Accesses the ‘Alarm’ menu. Permits setting, changing alarms and limits and to view the alarm summary.

  • Page 19: Dm510 Status Lights

    Operations Manual DM510 Status Lights The DM510 includes Alarm and Mode status lights located to the right and left side of the display. These status lights provide important alarm and operation mode indication at a glance. The intent is to supplement information already displayed on the display screen.
  • Page 20 ‘Automatic Mode’ as soon as the learn status light is lit. Great care must be used with this feature, as the DM510 Dryer Master may not have sufficient information to set the correct discharge or unload rate.

  • Page 21: Dm510 Dryer States

    (moisture displayed by the inlet moisture sensor). This is a temporary state. The DM510 Dryer Master will revert to local mode within 25 minutes and lock out both manual and automatic control from the DM510 Dryer Master as a safety precaution. The DM510 must be reset to clear this lockout.

  • Page 22: Using The Dm510

    Appendix 2 of this document. If at any time you have questions about the operation of the DM510 do not hesitate to contact the Dryer Master Support center at 519 746-0223 or toll free at 888-318-0009 (in North America).

  • Page 23: Changing Between Modes

    Remote Status light. Choosing a Moisture Setpoint The DM510 does two things based on the target moisture setpoint that you provide. First, it observes the discharge moisture in relation to the target to create an image of the drying conditions (dryer model) within the dryer.

  • Page 24: Calibrating The Dm510 Sensors

    The DM510 measures the moisture in slightly less than ¼ of a cubic foot (7 liters) of product, in corn at 56lbs/bushel (that equates to about 10lbs (4.5Kg) of corn. The bench top sample is usually less than 250 grams.

  • Page 25: Calibration Frequency

    A good way of seeing if the DM510 is in calibration is to keep a list of calibration pairs. Use two columns in which the first column is the bench top reading and the second column is the DM510 reading from the calibration data entry screen.
  • Page 26 Operator intervention is often required. If the DM510 cannot correct the situation, a critical alarm will be reached. This will return the DM510 to Manual or Local mode either immediately or after some time. The action is dependent on the nature of the situation.

  • Page 27: Description Of Alarm Limits Operation

    Let’s assume that your moisture target is 14.5%, and that you want to be notified if the moisture goes above 15.5%, and if the moisture reaches 16%, you want the DM510 to stop controlling and return to Manual mode. For this example you would set your high outlet moisture warning alarm at 15.5% and your high outlet moisture critical alarm at 16.0%.

  • Page 28: Changing Products

    What to expect when the DM510 is turned The start-up sequence of the DM510 takes 1 to 2 minutes. At this time the DM510 CPU tests various components and loads the DM510 Dryer Master system software. The alarm may sound momentarily, the alarm and mode status lights will sequence.

  • Page 29: The First Week Of Drying

    During the first 24 hours of drying we recommend that you take a minimum of 10 samples and input the results into the DM510. The DM510 should NOT be operated in automatic at this time. Follow the calibration procedure previously described for best results. This will help ensure that the DM510 moisture readings are in line with your Bench Top tester readings and it will also familiarize you with entering calibrations.

  • Page 30: A Typical Daily Routine

    2. Start your dryer as you have in the past from the dryer control panel. The DM510 panel will indicate that you are in ‘Local’ mode.

  • Page 31: A Typical Yearly Routine

    2) If you have the printer option, plug the printer into its power outlet and connect the printer cable to the “Printer” port at the bottom of the DM510 3) Turn the DM510 on. It will take the DM510 a few minutes to go through its start-up sequence.

  • Page 32: Dm510 Function & Usage

    Note: DM510 systems with ‘Auto Fast Start’ enabled can be switched to Automatic mode as soon as the DM510 determines the dryer is running. Should the DM510 select an inappropriate speed, return the system to Manual mode and wait until the 'Ready' status light is illuminated before selecting Automatic.

  • Page 33: Manual: Discharge Rate Control At The Dm510

    Figure 12- Manual Mode rate entry screen The DM510 Dryer Master is now setting the discharge rate at the selected value. To change the rate you can either repeat the steps or press the ‘Set-point’ key to display the ‘Set-point Entry menu’...

  • Page 34: Automatic: Discharge Rate Control At The Dm510

    Operations Manual Automatic: discharge rate control at the DM510 When the DM510 is ready for Automatic Mode, the Ready Status light will illuminate. To select Automatic Mode, press the ‘Mode’ key to display the ‘Select Control Mode’ menu. Press ‘2’ to ‘Request Automatic’ mode •...

  • Page 35: Local, Discharge Rate Control At The Dryer Panel

    Dryer Master DM510 Operations Manual For DM510s with Auto fast start enabled, selecting Automatic while the DM510 is not ready for Automatic, also indicated by the Ready Status light not illuminated, will display the ‘Auto Fast Start’ caution screen. This message is only displayed in DM510s with ‘Auto Fast Start’...

  • Page 36: 'Setpoint' Key

    The Discharge Rate setpoint can only be set/changed In ‘Manual’ mode (Manual control at the DM510). The Moisture Set-point can be changed in any operation mode. It will however not affect operation unless the system is in ‘Automatic’ (DM510 set the discharge rate).
  • Page 37 Dryer Master DM510 Operations Manual The ‘Discharge Rate’ setpoint entry screen • will display Press ‘Cancel’ to accept the displayed value • and return to the ‘Main Operations Screen’. Enter a new rate, press ‘Enter’ to accept the • new value and return to the ‘Main Operations Screen’.

  • Page 38: Set Moisture Setpoint

    Dryer Master DM510 Operations Manual Set Moisture Setpoint Press the ‘Setpoint’ key to display the ‘Select • Setpoint’ menu. Press ‘2’ to select ‘Moisture Setpoint’ • Press the ‘arrow’ keys to highlight the selection • followed by the ‘Enter’ key The ‘Moisture Setpoint’...

  • Page 39: Calibrate' Key

    The calibration sequence is started from the DM510 calibrate menu after sufficient time has passed for the product to reach the sensor. Calibration in progress Icon is displayed on the ‘Main Operations Screen’ when moisture calibrations are in process.

  • Page 40: Main Operations Screen With Calibration In Progress Icon

    ‘Enter’ key to accept the reading. In the event that the decimal is missed and the reading is entered as 162 the DM510 will record the value but will not affect the calibration upon returning to the ‘Main Operations Screen’. The incorrect entry will effectively be the same as canceling the calibration.

  • Page 41: Calibrate Key Hierarchy, (Calibration Not Started)

    Figure 28 - Calibration not started hierarchy The Calibration menus change slightly if a calibration has not been started. The inlet sensor has no calibration button and the inlet calibration is started at the DM510. Starting the Inlet Sensor Calibration Press the ‘Calibrate’...

  • Page 42: Calibrating The Inlet Sensor

    ‘Enter’ key to accept the reading. In the event that the decimal is missed and the reading is entered as 232 the DM510 will record the value but will not affect the calibration upon returning to the ‘Main Operations Screen’. The incorrect entry will effectively be the same as canceling the calibration.

  • Page 43: Alarms' Key

    Dryer Master DM510 Operations Manual ‘Alarms’ key Figure 33 - Alarm key Hierarchy Page | 42...

  • Page 44: Setting & Changing Alarms Limits

    ‘Main Operations Screen’, and for some conditions the alarm light will illuminate. To clear the alarms press any key. Both the DM510 alarm beeper and the message will clear. The alarm light will remain illuminated until conditions return to normal. In the event the DM510 is not on ‘Main Operations Display’...
  • Page 45 Dryer Master DM510 Operations Manual The ‘Alarm Limits’ selection menu will display Only the Inlet Moisture alarms entry will be described in detail. The other menus are similar in form and should be reviewed and set as required. Press ‘1’ to select ‘Inlet Moisture’...

  • Page 46: Viewing Alarm Summary

    Dryer Master DM510 Operations Manual Viewing Alarm Summary The alarm summary is an information screen. Its function is to provide view only access to previous alarm events. Press the ‘Alarms’ key to display the • ‘Alarms’ menu. Press ‘2’ to select ‘View Alarm Summary’...

  • Page 47: Bin' Key (Reports Require Optional Printer)

    ‘Bin’ key (Reports require optional printer) Figure 39- Bin key Hierarchy The Bin number tracking system is a feature for tracking the product exiting the dryer. The DM510 can track the average moisture and approximate quantity of product placed into the bins. The information can be printed to provide a hard copy record approximating the average moisture and quantity of product in the bin.

  • Page 48: Switching Bins, Printing Final Bin Report (The Bin Is Full)

    • Press the ‘Enter’ key to return to the ‘Main • Operations Screen’ and print a report. The DM510 will take a few minutes to compile the information and print the report. Press the ‘Cancel’ key to clear the •...

  • Page 49: Printing A Bin Report

    Dryer Master DM510 Operations Manual Enter a new bin number and press the • ‘Enter’ key to accept the new Bin and return to the ‘Main Operations Display’. Press the ‘Cancel’ key to return to the • ‘Main Operations Display’ without changing the Bin.

  • Page 50: Bin Summary Report

    Dryer Master DM510 Operations Manual Bin Summary Report. The bin report is the DM510’s accumulated drying statistics for the selected bin. Figure 46- Bin Summary report (report items description) Page | 49...

  • Page 51: Print' Key (Requires Optional Printer)

    Operations Manual ‘Print’ key (requires optional printer) The DM510 has the capability to print a variety of reports. Before setting up printing ensure that the printer is plugged into the printer port of the DM510 and is ON. The printer data connector is labeled Printer and is located on the lower panel of the DM510. Use only the supplied data cable to connect the DM510 to the printer.

  • Page 52: Print Options

    Dryer Master DM510 Operations Manual Print Options Press the ‘Print’ key to display the ‘Print Options’ menu: Press ‘1’ to select the ‘Print History’ options • Print Options menu. (1) Print History (2) Configure Print Reports Press ‘2’ to select the ‘Configure Print •...

  • Page 53: Averages Report

    Dryer Master DM510 Operations Manual Averages Report The Averages report is a compilation of operation over the selected interval. The information is printed continuously at the selected interval. Press the ‘arrow’ keys to highlight the • Select Value selection (Status or Interval) .

  • Page 54: The Averages Report Format

    DM510 Operation modes: Local = Operation from Dryer panel Manual = Manual control, Operator sets discharge rate at DM510 Auto = Automatic control, DM510 sets discharge rate. In the printout, a value immediately followed by the letter ‘W’ indicates a warning alarm occurred during the reporting period.

  • Page 55: Hourly Summary

    Dryer Master DM510 Operations Manual Hourly Summary The Hourly Summary report is a compilation of operation for the previous hour. The information is printed continuously at the selected time. Press the ‘arrow’ keys to highlight the • Hourly Summary selection (Status or Interval) Press the Status: ‘Enter’...

  • Page 56: The Hourly Summary Report Format

    Dryer Master DM510 Operations Manual The Hourly Summary report format: The report values are the calculated averages for the Hour ending at the report print time. Figure 56 - Hourly Summary Report (example printout) Time Report print time Inlet Moisture...

  • Page 57: Daily Summary

    Dryer Master DM510 Operations Manual Daily Summary The Daily Summary report is a compilation of dryer operation for the 24-hour period ending at the selected time. The information is printed daily at the selected time. Press the ‘arrow’ keys to highlight the •...

  • Page 58: View' Key

    Dryer Master DM510 Operations Manual ‘View’ key The DM510 provides an online operations history display screen. The View key Hierarchy: VIEW NEXT PAGE PREVIOUS PAGE CANCEL Figure 59 –View Key Hierarch View History screen Time Out% Rate Mode 13:10 10.8 15.4...

  • Page 59: Product' Key

    BEANS WHEAT Figure 61 - Product Selection Key Hierarchy Select Product The DM510 can track up to 8 different products with unique and different dryer parameters and sensor calibration values. Press the ‘Product’ key to display the ‘Select Select Product...

  • Page 60: Support' Key

    Dryer Master DM510 Operations Manual ‘Support’ Key The Support key Hierarchy: The ‘Support’ key menus provide access to system diagnostics to help with troubleshooting. System SUPPORT Diagnostics Help ENTER Control Support Overview ENTER Figure 64- Support key hierarchy Support (System Help): Press the ‘Support’...

  • Page 61: Diagnostics Screen 1

    Discharge Rate Input Calibrated rate. Same as on main screen Discharge Rate Output Signal Dryer Master sends to dryer to run at the requested speed. Should be equal to Discharge Rate Input. Calculated Residence Calculation is based on dryer volumes and throughput and the Time, in seconds current running speed.

  • Page 62: Diagnostics Screen 3

    Dryer Fan Status Toggles to 1 if installed. Normally not used Dryer Discharge Toggles to 1 if control, Manual or Automatic, is at Dryer Master. Dryer Burner Status Virtual state. Dryer temperature is above burner off temperature setting in Supervisor setup, control limits.

  • Page 63: Control Update

    Dryer Master DM510 Operations Manual Model Beta 1 Control Model Beta 1 Model Beta 2 Control Model Beta 2 Model Actual Setpoint Rate Control Model Actual rate as displayed The requested rate in suggested or predicted on the main screen Manual or Automatic.

  • Page 64: Settings' Key

    The ‘Settings’ key menus gain access to the system setup information. The critical items are password protected and are not intended for the casual user. DMSI or the Dryer Master Support Center will provide the passwords to gain entry to either the Supervisor setup or the Installer Setup menus.

  • Page 65: Supervisor Setup

    Dryer Master DM510 Operations Manual Supervisor Setup: Supervisor Type the ‘password’ followed by the ‘Enter’ • key to gain access. Password Press ‘Cancel’ to return to the ‘Main • Operations Screen’. Enter the password, then press ENTER. Press CANCEL to exit.

  • Page 66: Control Limits

    Set this value to slightly less than the ‘Minimum Discharge rate in Auto’ value. Control will be severely compromised if this value is set so that the DM510 does not obtain an OFF indication. Burner Off Temperature The DM510 Dryer Master uses this value along with discharge or unload rate to determine the dryer state.

  • Page 67: Alarm Actions

    Actions menu Note: The Alarm Actions are CRITICAL for proper system operation. Review and adjust as required. The Dryer Master is not a substitute for improperly functioning Dryer safety equipment. If in doubt do not enable these items. Remote Alarm Activation The DM510 Dryer Master provides a contact for an external remote alarm.

  • Page 68: Calibration

    IMPORTANT: Adjusting the calibration values impacts the displayed moisture readings. A change in the moisture readings will have an impact on control. It is best to return the DM510 to manual control before making adjustments to the sensor calibrations. Inlet calibration bias (offset)
  • Page 69 Dryer Master DM510 Operations Manual This is the conversion of the discharge or unload rate to bushels RATE TO BUSHELS/HR per hour. CONVERSION To calculate this value requires 3 items. 1) Product volume = bushels 2) Time = minutes 3) Discharge rate...

  • Page 70: Hang-Up Modem (Only For Systems With An Optional Modem)

    System shutdown is a controlled shutdown of all the system software much like the shutdown of a personal computer. The system will display the Dryer Master Logo and exit all software. It is safe to turn off the power when the Dryer Master Logo is displayed.

  • Page 71: Changing System Date & Time

    Figure 78 –Settings Set Date & Time screen Product Information Dryer Master Inlet Sensor Signal Dryer Master Inc. Kitchener, Ontario, Canada Telephone 519 725-4700 519 885-4300 www.dryermaster.com System Type Dryer Master Model DM510 Version yyyyddd Press CANCEL to exit Figure 79 Page | 70...
  • Page 72 Dryer Master DM510 Operations Manual Figure 80 - Product Information screen Page | 71...

  • Page 73: Dm Mobile - Remote Access

    Operations Manual DM Mobile – Remote Access DM Mobile gives you access to much of the functionality of the DM510 without having to be physically present at the DM510 panel. To use DM Mobile the DM510 should be on and should be...

  • Page 74: Appendix 1: Hints For Better Drying

    Large dryers cannot respond quickly to large, abrupt changes in the moisture content of the incoming grain. Although the DM510 will significantly reduce these kinds of effects, the response limitation of the dryer will still result in undesirable variations in output moisture levels.

  • Page 75: Cleaning

    Bench Top Moisture Meter Calibration The bench top moisture meter is the standard that the DM510 sensors are calibrated against. If the manual reading from your bench top moisture meter is not accurate, then the DM510 moisture reading will not be accurate. Accuracy of the manual reading depends on maintenance and measuring procedures.

  • Page 76: Discharge System

    This can result in a situation where columns in a dryer have over dried product while others are wet. The DM510 can only attempt to average the product exiting the dryer. This behavior can result in poor DM510 moisture sensor to bench top meter calibration agreement and generally poor moisture control.

  • Page 77: Appendix 2: Troubleshooting - Control

    If you have been running for more than two dryer loads and the Ready light has still not come on call the Dryer Master Support Center. Trying to go into Automatic when the system is not READY will provide the operator with a message to indicate the reason why the system will not go into Automatic Why won’t the DM go Ready?

  • Page 78: The Discharge Rate Won't Go Above "X ", Or Below "Y

    Dryer Master DM510 Operations Manual The discharge rate won't go above “X “, or below “Y”. Check whether the maximum and minimum discharge rate settings are correct. a) Press Settings b) Press “1” for Supervisor Setup c) Enter the Password “123”...

  • Page 79: In Local Mode The Dryer Speed Control And The Dm Speed Control Do Not Read The Same

    Dryer Master DM510 Operations Manual In Local mode the dryer speed control and the DM speed control do not read the same. Call the DM support Center and we will help you retune the calibration of the dryer motor speed...

  • Page 80: When I Start Up For The Day The Calibration Is Off

    The moisture sensor is reading frozen This typically happens when the temperature sensor on the moisture sensor fails (although it can also happen if the outside temperature is below -30). Contact the Dryer Master Support Center. The inlet sensor is reading 45% This can be due to surface moisture on the sensor and this can happen when you first start up in the morning and there has been condensation on the sensor.

  • Page 81: Appendix 4: Troubleshooting Dm Mobile

    If the lights are not flashing, and you have not connected in the past, try the following: 1. Make sure that the Ethernet cord is plugged in at both ends (at the DM510 panel and at your router or wireless access point).

  • Page 82: What Is My Login Information

    A sheet with your Login id and Password should have been in with the package with this User Guide. If you cannot find it, give the Dryer Master Support Center a call. I can’t find the DM mobile web page.

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