Related Manuals for GSi Grain PNEG-1509
Summary of Contents for GSi Grain PNEG-1509
- Page 1 Portable Dryer Touch Screen Controls Troubleshooting and Reference Manual 2006 Edition PNEG-1509 PNEG-1509 Date: 3-31-2006...
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Page 2: Table Of Contents
Table of Contents Reference TABLE OF CONTENTS DRYER SAFETY & DRYER INFORMATION...........................4 SPECIAL SETUP SCREENS................................5 DRYER NETWORK LAYOUT................................6 PROGRAMMING INSTRUCTIONS..............................7 PROGRAMMING INSTRUCTIONS (cont’)............................8 PROGRAMMING INSTRUCTIONS (cont’)............................9 PROGRAMMING INSTRUCTIONS (cont’).............................10 PROGRAMMING INSTRUCTIONS (cont’).............................11 PROGRAMMING INSTRUCTIONS (cont’).............................12 PROGRAMMING INSTRUCTIONS (cont’).............................13 PROGRAMMING INSTRUCTIONS (cont’).............................14 FRONT TOUCH SCREEN DISPLAY..............................15 FRONT TOUCH SCREEN DISPLAY..............................16 SETUP PARAMETERS..................................17... - Page 3 Table of Contents Reference TABLE OF CONTENTS HOW TO ADJUST AIR SWITCH..............................37 POSSIBLE FAN & HEATER BOARD ERRORS (cont’).........................38 POSSIBLE FAN & HEATER BOARD ERRORS (cont’).........................39 POSSIBLE FAN & HEATER BOARD ERRORS (cont’).........................40 POSSIBLE FAN & HEATER BOARD ERRORS (cont’).........................41 POSSIBLE FAN &...
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Page 4: Dryer Safety & Dryer Information
The principal concern of the GSI Group, Inc. is your safety and the safety of others associated with grain drying equipment. This manual is written to help you recognize safe operating, troubleshooting procedures and some of the problems that maybe encountered by the operator or other personnel. -
Page 5: Special Setup Screens
Wiring Reference Troubleshooting SPECIAL TOUCH SCREEN SETUP SCREENS Accessing various screens will enable you to make changes on how the dryer operates. Some of the features rarely need to be changed once the dryer has been setup. Most of the special screens are under the setup button on the main touch screen. -
Page 6: Dryer Network Layout
Wiring Reference Troubleshooting DRYER NETWORK LAYOUT The bootloader master node (Display I/O) connects to a CPU host (ICOP) via an RS232 serial connection to receive instructions and flash program data. The master node (Display I/O) then consumes these commands and data itself, or passes them on to the pertinent slave nodes. -
Page 7: Programming Instructions
Wiring Reference Troubleshooting PROGRAMMING INSTRUCTIONS Figure 1: Control Panel CONTROL POWER SWITCH 1.) Turn off the control power. (see figure 1). Figure 2: USB Port Location DRYER CONTROL COMPUTER PORT 2.) Locate the USB port on the bottom of the Dryer Control Computer (see figure 2). The Dryer Control Computer is on the back side of the dryer control panel. -
Page 8: Programming Instructions (Cont')
Wiring Reference Troubleshooting PROGRAMMING INSTRUCTIONS Figure 3: USB Flash Drive inserted in USB port USB FLASH DRIVE INSTALLED 3.) Insert USB flash drive into USB (see figure 3). 4.) Turn on the dryer control power. (see figure 1). The dryer control computer will start. Figure 4: Boot Screen 5.) When the boot screen appears touch the Look For New Program on Flash Card button. -
Page 9: Programming Instructions (Cont')
Wiring Reference Troubleshooting PROGRAMMING INSTRUCTIONS Figure 5: Copying files from USB flash drive to dryer control computer 6.) The display will now confirm that proram files were found on USB flash drive and that they are being copied to the dryer control computer hard drive. Fig. -
Page 10: Programming Instructions (Cont')
Wiring Reference Troubleshooting PROGRAMMING INSTRUCTIONS Figure. 7: Network Scan Complete EXIT BUTTON 8.) After the scan is complete the Display I/O, Main I/O, Moisture Control, and the Fan/Heater(s) should be shown as Nothing To Report (see figure 7). Touch the Exit button. Figure. -
Page 11: Programming Instructions (Cont')
Wiring Reference Troubleshooting PROGRAMMING INSTRUCTIONS Figure. 9: Select Dryer Program. MOVE UP & MOVE DOWN BUTTONS ACCEPT/EXIT BUTTON 10.) Select the program file you want to upload by touching the Move Up and Move Down buttons until the desired program file is highlighted. Touch the Accept / Exit button. Figure. -
Page 12: Programming Instructions (Cont')
Wiring Reference Troubleshooting PROGRAMMING INSTRUCTIONS Figure. 11: Start Upload 12.) When the Upload Progress screen appears touch the Start Upload button. Figure. 12: Upload Progress 13.) The computer will now begin programming each of the network circuit boards on the dryer. The box on the right of the screens lists the network circuit boards detected in the scan. -
Page 13: Programming Instructions (Cont')
Wiring Reference Troubleshooting PROGRAMMING INSTRUCTIONS Figure. 13: Exit to Dryer EXIT TO DRYER BUTTON 14.) The program upload procedure was successful. Touch the Exit To Dryer button to exit bootloader and start the dryer. Figure. 13: Starting Dryer 15.) The dryer will begin running the program that was just installed. Pneg 1509 - Troubleshooting... -
Page 14: Programming Instructions (Cont')
Wiring Reference Troubleshooting PROGRAMMING INSTRUCTIONS Figure. 14: Program Upload Complete 16.) The dryer control is now ready to operate the dryer. Pneg 1509 - Troubleshooting... -
Page 15: Front Touch Screen Display
Wiring Reference Troubleshooting FRONT TOUCH SCREEN DISPLAY • SHOWING DATA COLUMN MODE • CHOOSE FREQUENCY OF SAMPLING TIME • VIEW THE FOLLOWING: √ SAMPLE TIME & DATE √ GRAIN TEMP IN & OUT √ GRAIN MOISTURE IN & OUT √ METER ROLL OUTPUT % √... -
Page 16: Front Touch Screen Display
Wiring Reference Troubleshooting FRONT TOUCH SCREEN DISPLAY • SHOWING DATA GRAPH MODE • CHOOSE FREQUENCY OF SAMPLING TIME • CHOICE OF WHICH TO VIEW: √ SAMPLING TIME & DATE √ GRAIN TEMP IN & OUT √ GRAIN MOISTURE IN & OUT √... -
Page 17: Setup Parameters
Wiring Reference Troubleshooting SETUP PARAMETERS • THIS SCREEN COMES AFTER SELECTING SETUP ON TOUCH SCREEN • SELECT WHICH YOU WANT TO MODIFY Pneg 1509 - Troubleshooting... -
Page 18: Select Timer Screen
Wiring Reference Troubleshooting SELECT TIMER SCREEN • TOUCH TIMERS BUTTON ON THE MAIN TOUCH SCREEN • SELECT WHICH TIMER TO MODIFY • MODIFY TIMER SCREEN COMES UP ( NEXT PAGE) Pneg 1509 - Troubleshooting... -
Page 19: Modify Timer Screen
Wiring Reference Troubleshooting MODIFY TIMER SCREEN • AFTER SELECTING WHICH TIMER TO MODIFY • SELECT DESIRED TIME • TOUCH ACCEPT Pneg 1509 - Troubleshooting... -
Page 20: Modify Temp Screen
Wiring Reference Troubleshooting MODIFY TEMP SCREEN • SELECT WHICH TEMP TO MODIFY • MODIFY TEMP SCREEN COMES UP (NEXT PAGE) Pneg 1509 - Troubleshooting... -
Page 21: Modifying Plenum Or Grain Setpoint
Wiring Reference Troubleshooting MODIFYING PLENUM OR GRAIN SETPOINT • SELECT DISIRED SETPOINT • TOUCH ACCEPT Pneg 1509 - Troubleshooting... -
Page 22: Select Dryer Model
Wiring Reference Troubleshooting SELECT DRYER MODEL • THIS SHOULD BE ALREADY SET AT FACTORY • DRYER SETUP MUST BE DONE CORRECTLY FOR DRYER TO RUN PROPERLY • TOUCH SETUP BUTTON MAIN TOUCH SCREEN • SELECT DRYER MODEL BUTTON • DRYER HARDWARE SCREEN COMES UP •... -
Page 23: Select Burner Mode
Wiring Reference Troubleshooting SELECT BURNER MODE • TOUCH SETUP BUTTON MAIN TOUCH SCREEN • TOUCH BURNER MODE BUTTON • SELECT HI/LOW OR ON/OFF MODE • TOUCH ACCEPT Pneg 1509 - Troubleshooting... -
Page 24: Modify Burner Differential
Wiring Reference Troubleshooting MODIFY BURNER DIFFERENTIAL • TOUCH SETUP BUTTON MAIN TOUCH SCREEN • TOUCH ON/OFF DIFFERENTIAL BUTTON • SELECT WHICH BURNER TO MODIFY • SELECT DIFFERENTIAL 1 TO 5 DEGREES • TOUCH ACCEPT Pneg 1509 - Troubleshooting... -
Page 25: Air Switch Testing Screen
Wiring Reference Troubleshooting AIR SWITCH TESTING • TOUCH SETUP BUTTON MAIN TOUCH SCREEN • TOUCH DIAGNOSTIC BUTTON • SELECT WHICH FAN • SELECT ENABLE OR DISABLE • TOUCH EXIT Pneg 1509 - Troubleshooting... -
Page 26: Check Display I/O Switch Lite Outputs
Wiring Reference Troubleshooting CHECK DISPLAY I/O SWITCH LITE OUTPUTS • TOUCH SETUP BUTTON MAIN TOUCH SCREEN • TOUCH DIAGNOSTIC BUTTON • SELECT DISPLAY I/O TESTING BUTTON • CHECK LIGHT OUTPUT BY CHANGING SWITCH POSITION • EXIT AFTER TESTING Pneg 1509 - Troubleshooting... -
Page 27: Check Display I/O Switch Inputs
Wiring Reference Troubleshooting CHECK DISPLAY I/O SWITCH INPUTS • TOUCH SETUP BUTTON MAIN TOUCH SCREEN • TOUCH DIAGNOSTIC BUTTON • SELECT DISPLAY I/O TESTING BUTTON • CHECK SWITCH INPUT BY CHANGING SWITCH POSITION • EXIT AFTER TESTING Pneg 1509 - Troubleshooting... -
Page 28: Modify Meter Roll Speed Setpoint
Wiring Reference Troubleshooting MODIFY METER ROLL SPEED SETPOINT • PRESS THE METER ROLL SPEED KNOB • THIS SCREEN WILL APPEAR • THE ONE HIGHLIGHTED IS THE ONE YOU WILL BE ADJUSTING • PUSH THE KNOB AGAIN WILL CHANGE WHICH ONE IS HIGHLIGHTED •... -
Page 29: Shutdown Error Screen
Wiring Reference Troubleshooting SHUTDOWN ERROR SCREEN • SHOWS WHERE & WHAT ERROR OCCURRED • CHECK ERROR • CORRECT ERROR • PRESS STOP BUTTON TO CLEAR Pneg 1509 - Troubleshooting... -
Page 30: Shutdown History Screen
Wiring Reference Troubleshooting SHUTDOWN HISTORY SCREEN • TOUCH THE VIEW BUTTON ON MAIN TOUCH SCREEN • SELECT SHUTDOWN HISTORY BUTTON • SORT BY WARNING, DATE & TIME OR BY BOARD • FOLLOWING CHOICES: • KEEP A RUNNING HISTORY • COPY HISTORY TO A USB FLASH CARD •... -
Page 31: Set Time & Date
Wiring Reference Troubleshooting SET TIME & DATE • TOUCH SETUP BUTTON MAIN TOUCH SCREEN • TOUCH SET TIME/DATE BUTTON • SET TIME & DATE • EXIT OUT Pneg 1509 - Troubleshooting... -
Page 32: Display I/O Board Errors
Wiring Reference Troubleshooting DISPLAY INPUT OUTPUT BOARD ERRORS (BOARD LOCATED ON THE BACK OF THE LOWER DOOR) Viewing the Shutdown History The shutdown history can store over 256 shutdown warnings, if the dryer exceeds this amount, your oldest shutdown will be replaced with the current shutdown warning. You will be able to access the shutdown history by pressing the view button on the touch screen. -
Page 33: Possible Main I/O Board Errors
Wiring Reference Troubleshooting POSSIBLE MAIN INPUT OUTPUT BOARD ERRORS (BOARD LOCATED IN THE UPPER PANEL) The following is a list of possible errors that are generated with the input/output board. This board is located in the upper main panel. This board has a LED light beside each input and output on the board. -
Page 34: Possible Main I/O Board Errors (Cont')
Wiring Reference Troubleshooting POSSIBLE MAIN INPUT OUTPUT BOARD ERRORS (BOARD LOCATED IN THE UPPER PANEL) Auxiliary Load Motor Overload This error indicates that the auxiliary load motor overload on the dryer has opened. Example: This might be a fill auger wired to the dryer. ( J2-10 ) DC Negative ( J1-01 ) 12 Volt DC output LED should be on. -
Page 35: Possible Main I/O Board Errors (Cont')
Wiring Reference Troubleshooting POSSIBLE MAIN INPUT OUTPUT BOARD ERRORS (BOARD LOCATED IN THE UPPER PANEL) Out of Grain Timer Expired (continued) ( J2-10 ) DC Negative ( J1-01 ) 12 Volt DC output LED should be on. ( J1-06 ) 12 Volt DC when dryer is calling for grain (Grain Level Switch) LED should be on. -
Page 36: Possible Fan & Heater Board Errors (Cont')
Wiring Reference Troubleshooting POSSIBLE FAN HEATER BOARD ERRORS (BOARD LOCATED IN THE FAN HEATER BOX) Fan (#) No Airflow The air pressure switch failed to close do to insufficient air pressure in the plenum. This is usually caused by a pressure switch out of adjustment, if the dryer is full of grain. The message will distinguish between which plenum caused the shutdown. -
Page 37: How To Adjust Air Switch
Wiring Reference Troubleshooting HOW TO ADJUST AIR SWITCH Air Switch locations. Upper Air Switch. Lower Air Switch. 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. With the Load Auger, Fan, Heater, and Unload switches in the off posi- tion turn on the Control power then push the Dryer Power Start switch. -
Page 38: Possible Fan & Heater Board Errors (Cont')
Wiring Reference Troubleshooting POSSIBLE FAN HEATER BOARD ERRORS (BOARD LOCATED IN THE FAN HEATER BOX) Fan (#) Motor Overload This indicates that one of the fan motor thermal overloads has opened. This overload is located in the fan/heater box associated with which fan motor overload has opened. The message will display in which fan the overload occurred. -
Page 39: Possible Fan & Heater Board Errors (Cont')
Wiring Reference Troubleshooting POSSIBLE FAN HEATER BOARD ERRORS (BOARD LOCATED IN THE FAN HEATER BOX) Fan (#) Contactor Did Not Close This occurs when the fan contactor has failed to close on start up or opens after start up. We monitor an auxiliary set of contacts on the fan contactor as an extra safety. The Fan Aux. -
Page 40: Possible Fan & Heater Board Errors (Cont')
Wiring Reference Troubleshooting POSSIBLE FAN HEATER BOARD ERRORS (BOARD LOCATED IN THE FAN HEATER BOX) Burner (#) Lost Flame Detection (continued) Example: Flame Loss #1 on up to Flame Loss #6 depending on the size of the dryer. CAUTION Make sure power is off while making the above adjustment !!!! Assuming you have established airflow. -
Page 41: Possible Fan & Heater Board Errors (Cont')
Wiring Reference Troubleshooting POSSIBLE FAN HEATER BOARD ERRORS (BOARD LOCATED IN THE FAN HEATER BOX) Burner (#) Plenum Overheat (Thermistor Sensor) This occurs when the plenum temperature inside has reached a set overheat limit by the computer. You can activate the emergency cool mode by pressing the start switch. The fan and only the fan will run until the plenum temperature falls below its set hi-limit. -
Page 42: Possible Fan & Heater Board Errors (Cont')
Wiring Reference Troubleshooting POSSIBLE FAN HEATER BOARD ERRORS (BOARD LOCATED IN THE FAN HEATER BOX) Burner (#) Grain Overheat (Thermistor Sensor)(continued) Example: Burner #1 Grain Overheat (Thermistor) on up to Burner #6 Grain Overheat (Thermistor) depending on the size of the dryer. The grain thermistor sensors are located in the conduit running inside the grain column. -
Page 43: Procedure For Defective Plenum Sensor
Wiring Reference Troubleshooting PROCEDURE FOR LOCATING, TESTING & 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. -
Page 44: Temperature / Resistance Chart
Wiring Reference Troubleshooting TEMPERATURE / RESISTANCE CHART °F Ohms °F Ohms °F Ohms °F Ohms °F Ohms °F Ohms °F Ohms 36,601 14,546 6,382 3,047 1,565 855.7 494.3 35,565 14,179 6,238 2,985 1,536 841.4 86.8 34,562 13,822 6,097 2,925 1,508 827.3 479.4 33,591... -
Page 45: Procedure For Defective Grain Sensor
Wiring Reference Troubleshooting PROCEDURE FOR LOCATING, TESTING & 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. Display readings of 255 degrees or -127 degrees. -
Page 46: Procedure For Defective Grain Sensor (Cont')
Wiring Reference Troubleshooting PROCEDURE FOR LOCATING, TESTING & REPLACING A DEFECTIVE GRAIN TEMPERATURE SENSOR 10. Connect the red lead to either of the disconnected 26 ga. wires and make note of the reading. 11. Now move the red lead to the other disconnected 26 ga. wire and make note of this reading. -
Page 47: Procedure For Defective Grain Sensor (Cont')
Wiring Reference Troubleshooting TESTING PROCEDURES AND LOCATION OF GRAIN SENSORS GRAIN T EMPERATURE SENSORS GAIN ACCESS TO THEM BY REMOVING COVER OFF OF 4"x 4" W HITE BOXES) * SEE BELOW FOR TESTING PROCEDURES Load M otor Load M ercury FAN #2 Switch Outside Light... -
Page 48: Upper Control Panel Wiring (230 Volt)
Wiring Reference Troubleshooting UPPER PANEL CONTROL WIRING (230 VOLTS) Pneg 1509 - Troubleshooting... -
Page 49: Upper Control Panel Wiring (380, 440 & 575 Volt)
Wiring Reference Troubleshooting UPPER PANEL CONTROL WIRING (380, 440 & 575 VOLTS) Pneg 1509 - Troubleshooting... -
Page 50: Upper Terminal Strip
Wiring Reference Troubleshooting UPPER TERMINAL STRIP (LOCATED IN THE UPPER PANEL) Pneg 1509 - Troubleshooting... -
Page 51: Ac Input Wiring
Wiring Reference Troubleshooting AC INPUT WIRING Pneg 1509 - Troubleshooting... -
Page 52: Main I/O Board Identification
Wiring Reference Troubleshooting MAIN I/O BOARD IDENTIFICATION (LOCATED IN THE UPPER PANEL) Pneg 1509 - Troubleshooting... -
Page 53: Fan / Heater Box Wiring
Wiring Reference Troubleshooting FAN / HEATER BOX WIRING PART # D03-0730 Pneg 1509 - Troubleshooting... -
Page 54: Fenwal Board Wiring
Wiring Reference Troubleshooting FEWAL BOARD WIRING IGNITOR FLAME ROD Part No. HF-4624-R Fenwal Flame 110VAC SUPPLIED FROM FH BOARD (J2-03) SOLENOID 110VAC NEUTRAL (J2-04) Detection Board 110 VAC NEUTRAL (J2-04) SOLENOID 110VAC FROM FENWAL BOARD TO FH BOARD (V1)-(J1-01) ALARM NOT USED ALSO REFER TO THE FAN &... -
Page 55: Vdc Wiring To Switches (2 Fan)
Wiring Reference Troubleshooting 12 VDC WIRING TO SWITCHES (EXAMPLE 2 FAN) Pneg 1509 - Troubleshooting... -
Page 56: Vdc Wiring To Switches (3 Fan)
Wiring Reference Troubleshooting 12 VDC WIRING TO SWITCHES (EXAMPLE 3 FAN) Pneg 1509 - Troubleshooting... -
Page 57: Vdc Wiring To Switches (4 Fan)
Wiring Reference Troubleshooting 12 VDC WIRING TO SWITCHES (EXAMPLE 4 FAN) Pneg 1509 - Troubleshooting... -
Page 58: Vdc Wiring To Switches (6 Fan)
Wiring Reference Troubleshooting 12 VDC WIRING TO SWITCHES (EXAMPLE 6 FAN) Pneg 1509 - Troubleshooting... -
Page 59: Switch Input Wiring (2 Fan)
Wiring Reference Troubleshooting SWITCH INPUT TO BOARD WIRING (EXAMPLE 2 FAN) Pneg 1509 - Troubleshooting... -
Page 60: Switch Input Wiring (3 Fan)
Wiring Reference Troubleshooting SWITCH INPUT TO BOARD WIRING (EXAMPLE 3 FAN) Pneg 1509 - Troubleshooting... -
Page 61: Switch Input Wiring (4 Fan)
Wiring Reference Troubleshooting SWITCH INPUT TO BOARD WIRING (EXAMPLE 4 FAN) Pneg 1509 - Troubleshooting... -
Page 62: Switch Input Wiring (6 Fan)
Wiring Reference Troubleshooting SWITCH INPUT TO BOARD WIRING (EXAMPLE 6 FAN) Pneg 1509 - Troubleshooting... -
Page 63: Lamp Input Wiring (2 Fan)
Wiring Reference Troubleshooting LAMP INPUT WIRING (EXAMPLE 2 FAN) Pneg 1509 - Troubleshooting... -
Page 64: Lamp Input Wiring (3 Fan)
Wiring Reference Troubleshooting LAMP INPUT WIRING (EXAMPLE 3 FAN) Pneg 1509 - Troubleshooting... -
Page 65: Lamp Input Wiring (4 Fan)
Wiring Reference Troubleshooting LAMP INPUT WIRING (EXAMPLE 4 FAN) Pneg 1509 - Troubleshooting... -
Page 66: Lamp Input Wiring (6 Fan)
Wiring Reference Troubleshooting LAMP INPUT WIRING (EXAMPLE 6 FAN) Pneg 1509 - Troubleshooting... -
Page 67: Moisture Control Hookup
Wiring Reference Troubleshooting MOISTURE CONTROL HOOKUP Pneg 1509 - Troubleshooting... -
Page 68: Moisture Control Board Identification
Wiring Reference Troubleshooting MOISTURE CONTROL BOARD IDENTIFICATION (LOCATED IN THE LOWER PANEL) PART # D03-0725 Pneg 1509 - Troubleshooting... -
Page 69: Switch I/O Board Identification
Wiring Reference Troubleshooting SWITCH I/O BOARD IDENTIFICATION (LOCATED ON BACK OF LOWER PANEL DOOR) Pneg 1509 - Troubleshooting... - Page 70 Authorities having jurisdiction should be consulted before installation occurs. The GSI Group, Inc. 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 217-226-4421 Fax: 217-226-4420 e-mail: gsisales@grainsystems.com internet: http://www.grainsystems.com internet: http://www.fficorp.com Copyright © 2006 by The GSI Group Printed in the USA...
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