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Dryer Master DM510 Commissioning Manual

Computerized grain drying control system
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COMMISSIONING GUIDE

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Summary of Contents for Dryer Master DM510

  • Page 1 COMMISSIONING GUIDE...
  • Page 2 USA & Canada – Toll Free – 1-800-265-2757 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. February 28, 2015 January 15, 2016...
  • Page 3 When you need help there is the Dryer Master Customer Support Centre One of the unique benefits you receive with the DM510 is access to support from the Dryer Master Support Center where we have experts in the theory (application to drying), installation and operation of the DM510.

  • Page 4: Table Of Contents

    Safety Notice: ............................23 Calibration of DM510 displayed rate to the dryer’s speed display ..........23 Calibration of DM510 rate setpoint – to set rate for the dryer ............27 Moisture Calibration: ..........................31 Dryer Volumes & Throughput: ......................32 Dryer Volumes and Throughput –...

  • Page 5: Table Of Figures

    FIGURE 5 - DISCHARGE SYSTEM SIGNAL CONNECTIONS AT DRYER MASTER ........12 FIGURE 6 - CALIBRATION BUTTON SIGNAL CONNECTION ................13 FIGURE 7 - LOCAL REMOTE STATUS AND CONTROL SIGNAL CONNECTION IN THE DRYER MASTER ..................................... 14 FIGURE 8 - FAN STATUS SIGNAL CONNECTIONS IN THE DRYER MASTER ..........15 FIGURE 9 - SETTINGS TYPE MENU ........................

  • Page 6: System Components

    An optional printer for continuous reporting of dryer operation and results is also available. DM510 Control Panel: 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 7: Equipment Schematic

    Control Panel Discharge or unload rate, Drying R ate set Rate, Rate Notes: DM510 systems come with either a drying point, and setpoint & L/R control L/ R control air temp sensor (shown in diagram), or a signal switching switching converter which uses the dryer’s temperature...

  • Page 8: System Checkout (General)

    Before you turn the DM510 on If you have the optional printer, plug the printer into the power outlet and connect the printer cable to the bottom of the DM510. Put the ribbon and paper in the printer if this has not already been done.

  • Page 9: Perform A Printer Test (For Systems With A Printer)

    Setting Alarm Limits The DM510 comes with an alarm feature that can help you to monitor the drying process. High and low alarm limits can be set for inlet moisture, outlet moisture, drying air temperature, discharge rate and inlet and outlet product temperatures.

  • Page 10: System Checkout (Specific)

    Dryer Master DM510 Commissioning Guide System Checkout (Specific): Use this section to check that the installation has been completed correctly and to troubleshoot any components that may not be displaying as they should be. Checking the Moisture Sensors Use a Digital Voltmeter set to DC Volts to measure the DC voltage between GND (Black) and the three other wires (Green, Red and White) at the connectors plugged into the isolation card in the DM510 Dryer Master.

  • Page 11: Checking Drying Air Temperature Sensor (For Systems With Temp Sensor)

    Checking Drying Air Temperature Sensor (for systems with temp sensor) Use a Digital Voltmeter set to DC Volts to measure the DC voltage between GND (Black) and the two other wires (Red and White) at the connector plugged into the isolation card in the DM510 Dryer Master I/O.

  • Page 12: Checking Drying Air Temperature (For Systems With Signal Converter)

    The signal converter should be wired as in Figure 4 - Temperature signal converter wiring . The DM510 drying air temperature should read approximately the same value as on the dryer temperature controller. The converter is programmed for use with a J-type thermocouple. If you are using another type of thermocouple contact the Dryer Master Support Center.

  • Page 13: Checking The Discharge Rate Input & Output Signals

    Table 3 - Discharge System Signal Voltages These tests are performed with the DM510 in ‘Local’ mode. In ‘Local’ mode the DM510 sets the ‘Rate Out’ signal proportionately to the ‘Rate In’ signal. The default setup is such that 100% rate approximately equals 10 volts.

  • Page 14: Checking The Calibration Button Signals

    Dryer Master DM510 Commissioning Guide Checking the Calibration Button signals Press the Calibration button and hold for a few seconds to start the lamp flashing. The flashing lamp followed by a solid light 30 seconds later indicates the button and lamp are wired correctly. If this is not the case use a Digital Voltmeter, set to DC Volts to measure the DC voltages as described in Table 4 - Calibration Button Signal Voltages‘...

  • Page 15: Checking Local Remote Function & Control Signals

    In ‘Local’ mode the DM510 serves to monitor the operation and provides information for the operator to control the Dryer. In ‘Manual’ and ‘Automatic’ modes the rate is set from the DM510 panel. The figures below show the required wiring. The operation will be tested as part of the rate output calibration in the section Calibration of DM510 rate setpoint –...

  • Page 16: Checking Fan Status Signals

    Commissioning Guide Checking Fan Status signals The Fan Status signal provides the DM510 Dryer Master a direct indication of the dryer’s state of operation. In systems where this signal is not available the Dryer temperatures falling below the ‘OFF’ temperature parameter setting and the rate falling below the ‘OFF’ rate parameter setting indicate to the DM510 that the dryer has been shut down.

  • Page 17: System Setup & Calibration

    Commissioning Guide System Setup & Calibration System setup and calibration involves setting a number of parameters to tune the DM510 Dryer Master to the dryer. This section will describe in detail the steps and procedures for completing this task. There will be checks to verify the steps have been performed correctly. The system setup can be performed completely from the Dryer Master DM510 keypad and console.

  • Page 18: Supervisor Setup, Control Limits

    Set this value to slightly less than the ‘Minimum Discharge rate in Auto’. Automatic control will be severely compromised if this value is set so that the DM510 does not obtain an OFF indication. Do not set = 0.

  • Page 19: Supervisor Setup, Alarm Actions

    ‘Control Limits’ menu ‘Min Discharge rate in Auto’ value. This feature only functions if the Dryer Fan run signal is wired to the DM510 Dryer Master. The DM510 will not properly control the discharge if enabled without the Dryer Fan signal.

  • Page 20: Supervisor Setup, Calibration

    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 21 Dryer Master DM510 Commissioning Guide Rate to Bushels/Hr This is the conversion of the discharge or unload rate to bushels Conversion per hour. It is used to calculate the production numbers for Summary Reports. To calculate this value requires 3 items.

  • Page 22: Supervisor Setup, Deg F Deg C Conversion

    System shutdown is a controlled shutdown of all the system software much like the shutdown of a PC. The system will display the Dryer Master Logo and exit all software. It is safe to turn OFF the power once the Dryer Master Logo is displayed.

  • Page 23: Setup And Calibration - Installer Setup

    The settings in this section are typically not adjusted once you start drying, unless you make changes to your dryer or discharge system. In this section you will tell the DM510 more about your dryer and you will calibrate the discharge rate settings so that the DM510 and the dryer are reading the same values.

  • Page 24: Discharge Rate Setup

    Discharge Rate setup involves calibrating the DM510 displayed rate to the dryers unload rate display and calibrating the DM510 control output to run the dryer at the requested rate. Dryers with no discharge or unload rate display will be calibrated for 0 to 100% to coincide with 0 to 100% speed of the dryers unload system.

  • Page 25: Figure 20 - Discharge Settings

    PID Control Loop: OFF, ON Loop MUST be turned off for calibration. This item in conjunction with the ‘PID Gain (Kp)’ value permits the DM510 system to recover from small calibration errors or drift in the dryer’s discharge systems speed control. It is recommended that this be turned on for systems with DC motor speed controls as these are not as capable as Variable Frequency drives of locking in a speed.
  • Page 26 The channel resolution is 10 bits. This equates to 10 volts being divided into 1023 steps. Most times the input relationship To calculate the new slope: is linear. This means the offset Example values: remains at 0. Actual rate of discharge system DM510 displayed Rate (Rate Input) Rate Input Slope 0.09766 Page | 25...

  • Page 27: Figure 21 - Rate Input Example Calculation 1

    The system should be checked at one or two different rate settings on the dryer motor speed control to ensure that the Rate Input reading displayed on the DM510 is very close to the motor speed control setting. You may need to make some additional adjustments to the Rate input slope and Rate input offset settings to do this.

  • Page 28: Calibration Of Dm510 Rate Setpoint - To Set Rate For The Dryer

    Rate Input value at different typical rate setpoints, while in Remote mode. This is to ensure that the dryer discharge will run at the speed requested by the DM510. This part of the calibration is done by adjusting the Rate Output Slope and Rate Output Offset on the Discharge Settings screen, and should only be done AFTER the Rate Input has been calibrated (see previous section).
  • Page 29 1. If the ‘Remote’ light does not illuminate when selecting ‘Remote’ and requesting a speed the safety run timer in the DM510 may have expired. To reset this timer, restart the DM510. This Safety Run timer takes 25 minutes to expire and is usually the result of running the system in ‘Manual’...

  • Page 30: Figure 23 - Rate Output Example Calculation 1

    Example values: • Rate SP value DM510 displayed Rate (Rate Input) Rate Output Slope 10.23 Rate SP / DM510 displayed rate * ‘Rate Output’ = new ‘Rate • output Slope’. Therefore: • 50 / 80 * 10.23 = 6.39375 The ‘Rate Output Slope’ would change from 10.23 to 6.39375 Figure 23 –...

  • Page 31: Figure 24 - Rate Output Example Calculation 2

    The channel resolution is 10 bits. This equates to 10 volts being divided into 1024 steps. This situation is for systems To calculate the new slope: where the DM510 displayed 1. To calculate the setpoint range 0 – 100% to provide a value is not a linear control output of 2 to 10 VDC.

  • Page 32: Moisture Calibration

    Changes to the other parameters should only be made after consultation with the Dryer Master Support Center. Select ‘Moisture Calibration’ to display the ‘Moisture Calibration’ screen.

  • Page 33: Dryer Volumes & Throughput

    Commissioning Guide Dryer Volumes & Throughput: The dryer’s dimensions are critical to the operation of the DM510 Dryer Master control system. The DM510 Dryer Master requires accurate information with regard to the dryer holding volumes and throughput. Inaccurate values will reduce the effectiveness of your DM510 Dryer Master and may cause an out of control situation.

  • Page 34: Figure 27 - Dryer Zones

    Dryer Master DM510 Commissioning Guide Garner Bin Volume: Measure the Inlet Moisture & Product volume of the garner bin from the top of Temperature Sensor inlet sensor to the top of the hot zone. DO NOT include the volume above the inlet sensor.
  • Page 35 This is a good temporary value to begin with. It might also be possible for the Dryer Master Support Center to track inlet moisture changes through to the outlet and assist in determining a throughput. A few days of continuous operation with some inlet moisture variation is required for this to take place.

  • Page 36: Dryer Volumes And Throughput - Grain Handler Dryers

    Dryer Master DM510 Commissioning Guide Dryer Volumes and Throughput – Grain Handler dryers There is a simple way to determine the dryer volumes and throughput for Grain Handler dryers, using the rule of thumb that each layer/tier has 52 bushels per tier, per 8 feet of dryer length. (Note: To simplify things there is also a chart of GrainHandler dryer volumes and throughputs for various models in Appendix 1.)

  • Page 37: Moisture Sensor Setup

    Inlet Empty Voltage Signal level, at which the moisture sensor readings are considered too low to be valid as a moisture reading. The DM510 displays ‘Empty’ Outlet 1 Empty Voltage when the signal level drops below this value. The sensors minimum Outlet 2 Empty Voltage reading is between 0.5 and 0.75 volts.

  • Page 38: System Setup

    Note: The command (6) Save Good ‘piv’ files to archive’ should not be attempted without explicit instructions from the Dryer Master support center. In the event that this command is executed with damaged setup files, the system will NOT be repairable without returning the system to Dryer Moisture Systems Inc.

  • Page 39: Drying Temperature Setup

    Dryer Master DM510 Commissioning Guide Drying Temperature Setup: Press ‘Drying Temperature Setup’ to display the ‘Drying Temperature Setup’ screen Drying Temperature Press the ‘arrow’ keys to highlight the • Setup selection. Type in a new ‘Value’ followed by the ‘Enter’ key Drying Temperature gain (slope) 0.873910...

  • Page 40: Equipment Setup Check

    It is also a good idea to record some of the key parameters in case you ever need to re-enter them. There is a sheet to record parameters inside the door of the DM510. You can record the parameters there for safe storage, or on the rest of the page below.
  • Page 41 Dryer Master DM510 Commissioning Guide Rate Output Slope ______________ Rate Output Offset ______________ PID Control Loop Installer Setup – Dryer Volumes & Throughput: Setup Completed for product Corn Bean Wheat Garner Size _________ _________ _________ Hot Zone Size _________ _________...

  • Page 42: Appendix 1: Dryer Volumes And Throughput For Grain Handler Dryers

    Dryer Master DM510 Commissioning Guide Appendix 1: Dryer Volumes and Throughput for Grain Handler dryers GrainHandler Volumes and Throughputs For Dryer Master DM510 (Assumes inlet sensor is at the bottom of the garner/top of the hot zone) Dryer Zones Hot Zone Cold Zone...

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