GSI Outdoors PNEG-630 Troubleshooting And Reference Manual
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GSI Outdoors PNEG-630 Troubleshooting And Reference Manual

Competitor series 2000 portable dryer
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Troubleshooting and
Reference Manual
2004 Revised Edition
PNEG-630
GSI
Competitor
Portable Dryer
Models
EMCS
&
Competitor Series 2000 Dryer

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Summary of Contents for GSI Outdoors PNEG-630

  • Page 1 Competitor EMCS & Portable Dryer Models Troubleshooting and Reference Manual 2004 Revised Edition PNEG-630 Competitor Series 2000 Dryer...

  • Page 2: Table Of Contents

    Table Of Contents Portable Dryer Troubleshooting Safety ..................................3 Safety Sign Off Sheet ............................8 EMCS Portable Dryer (1993-1998) Safety Voltage Check Points ..........................9 Programming Instructions for EMCS Grain Dryers ....................10 EMCS Display Board ............................11 Input/Output Board Identification .......................... 12 EMCS Switch Replacement.........................13 1100 Series Control Box Wiring ..........................
  • Page 3 Table Of Contents Portable Dryer Troubleshooting 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) ...................

  • Page 4: Safety

    Safety Portable Dryer Troubleshooting 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.
  • Page 5 Safety Portable Dryer Troubleshooting Grain Systems, Inc. recommends A CAREFUL OPERATOR you contact your local power com- IS THE BEST INSURANCE pany and have a representative sur- vey your dryer installation, so your AGAINST AN ACCIDENT wiring will be compatible with their system and you will have adequate power supplied to your unit.
  • Page 6 Safety Portable Dryer Troubleshooting...
  • Page 7 Safety Portable Dryer Troubleshooting...
  • Page 8 Safety Precautions Portable Dryer Troubleshooting READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE Use Caution in the SAVE FOR FUTURE REFERENCE Operation of this 1. Read and understand the operating manual before trying to operate the Equipment dryer. The design and manufacture of this dryer is directed toward operator 2.

  • Page 9: Safety Sign Off Sheet

    Safety Sign-Off Sheet Portable Dryer Troubleshooting Date Employer’s Signature Employee ________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ ___________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________________ ___________________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ ___________________________________________________________________________________________________________________...

  • Page 10: Safety Voltage Check Points

    Wiring Reference Portable Dryer Troubleshooting Safety Voltage Check Points...

  • Page 11: Programming Instructions For Emcs Grain Dryers

    Portable Dryer Troubleshooting Programming 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.

  • Page 12: Emcs Display Board

    Programming Portable Dryer Troubleshooting EMCS Display Board...

  • Page 13: Input/Output Board Identification

    Wiring Reference Portable Dryer Troubleshooting Input/Output Board Identification 12 VOLT DC INPUTS 120 VOLT AC OUTPUTS 120VAC POWER (INPUT) 120VAC POWER (OUTPUT) +12 LIMIT OUTPUT AC NEUTRAL AC NEUTRAL 12 VOLT DC NEUTRAL +12 LIMIT OUTPUT 120VAC POWER (INPUT) 120VAC POWER (OUTPUT) METERING ROLL INPUT 12 VOLT DC NEGATIVE AC NEUTRAL...

  • Page 14: Emcs Switch Replacement

    Switch Replacement Portable Dryer Troubleshooting Switch Replacement for EMCS Dryer Switch N/O Contact Block - Part No. D63-0006 Switch Light Block - D01-0455...

  • Page 15: 1100 Series Control Box Wiring

    Portable Dryer Troubleshooting Wiring Reference 1100 Series Control Box Wiring 1100 FAN TO CONTROL BOX WIRING 42 TOTAL TERMINALS DESCRIPTION WIRING VOLTAGE COLOR J5-8 AIR PRESSURE SWITCH +12VDC NEED JUMPER J5-8 12 VOLTS DC (RED) HOUSING HIGH LIMIT 12 VOLTS DC (RED) J1-7 VAPOR HIGH LIMIT (LP ONLY)

  • Page 16: 1100 Series Control Box Wiring (New)

    Wiring Reference Portable Dryer Troubleshooting 1100 Series Control Box Wiring (New Version)

  • Page 17: 1200 Series Control Box Wiring

    Portable Dryer Troubleshooting Wiring Reference 1200 Series Control Box Wiring 52 TOTAL TERMINALS DESCRIPTION WIRING TERMINAL VOLTAGE COLOR AIR PRESSURE SWITCH +12VDC J5-8 NEED JUMPER J5-8 12 VOLTS DC (RED) FAN #2 HOUSING HIGH LIMIT 12 VOLTS DC (RED) J1-8 FAN #2 VAPOR HIGH LIMIT RELAY CONTACTS LOCATED 12 VOLTS DC...

  • Page 18: 1200 Series Control Box Wiring (New)

    Wiring Reference Portable Dryer Troubleshooting 1200 Series Control Box Wiring (New Version)

  • Page 19: 1100 Fan Lower Control Box Interconnect Strip

    Wiring Reference Portable Dryer Troubleshooting 1100 Fan Lower Control Box Interconnect Strip J9-1 AC-1 EMERGENCY COOLING JUMPERS INSTALL J6-13 TO J1-5 5VB1 J9-3 INSTALL J6-14 TO J1-19 J9-3 INSTALL J6-16 TO J5-5 EMI FILTER D03-0181 INSTALL J6-17 TO J4-19 BLACK - 120 VAC - OUTSIDE LIGHT BROWN - 120 VAC - BURNER #1 LIGHT ORANGE - TEMPERATURE SENSOR ORANGE - TEMPERATURE SENSOR...

  • Page 20: 1200 Fan Lower Control Box Interconnect Strip

    Wiring Reference Portable Dryer Troubleshooting 1200 Fan Lower Control Box Interconnect Strip J9-1 AC-1 5VB1 J9-3 J9-3 EMI FILTER D03-0181 BLACK - 120 VAC - OUTSIDE LIGHT BROWN - 120 VAC - BURNER #1 LIGHT BROWN - 120 VAC - BURNER #2 LIGHT ORANGE - TEMPERATURE SENSOR ORANGE - TEMPERATURE SENSOR SCR2...

  • Page 21: Upper Control Box External Wiring

    Portable Dryer Troubleshooting Wiring Reference 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...

  • Page 22: Fan Housing And Vapor Hi-Limit Circuit

    Wiring Reference Portable Dryer Troubleshooting Fan Housing and Vapor Hi-Limit Circuit...

  • Page 23: Plenum Hi-Temperature Switch

    Portable Dryer Troubleshooting Wiring Reference Plenum Hi-Temperature Switch...

  • Page 24: Fixed Grain Hi-Limit

    Wiring Reference Portable Dryer Troubleshooting Fixed Grain Hi-Limit...

  • Page 25: Grain & Plenum Hi-Limit Circuit

    Portable Dryer Troubleshooting Wiring Reference Grain & Plenum Hi-Limit Locations RED J1-11 ORANGE J1-19 RED J5-05 BLUE J1-11 YELLOW J1-05 ORANGE J4-19...

  • Page 26: Two Fan Plenum And Grain Limit Switch Wiring

    Wiring Reference Portable Dryer Troubleshooting 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...

  • Page 27: Rear Discharge & Emergency Cooling Circuit

    Portable Dryer Troubleshooting Wiring Reference Rear Discharge & Emergency Cooling Circuit...

  • Page 28: Rear Discharge Mercury Switch

    Wiring Reference Portable Dryer Troubleshooting Rear Discharge Mercury Switch...

  • Page 29: Adjustable Hi-Limit & Emergency Cooling Circuit

    Portable Dryer Troubleshooting Wiring Reference Adjustable Hi-Limit & Emergency Cooling Circuit...

  • Page 30: Motor Overloads

    Wiring Reference Portable Dryer Troubleshooting Motor Overloads...

  • Page 31: Air Pressure Switch

    Portable Dryer Troubleshooting Wiring Reference Air Pressure Switch 12 VOLT DC NEGATIVE 12 VOLT SOURCE DC POSITIVE J5-8 J1-8 J1-6 J1-10 J1-7 INPUT/OUTPUT BOARD J1-5 TERMINAL LOCATIONS J1-9 J1-12 J1-11 J1-19 J6-14 12V DC SOURCE FROM MOTOR OVERLOADS J5-5 J4-19 J6-17 BLUE J4-12...

  • Page 32: Air Pressure Switch Drawing

    Wiring Reference Portable Dryer Troubleshooting Air Pressure Switch Drawing...

  • Page 33: Out Of Grain Safety Circuit

    Portable Dryer Troubleshooting Wiring Reference Out of Grain Safety Circuit...

  • Page 34: Out Of Grain Safety Circuit Drawing

    Wiring Reference Portable Dryer Troubleshooting Out of Grain Safety Circuit Location...

  • Page 35: Upper Junction Box Wiring

    Portable Dryer Troubleshooting Wiring Reference Upper Junction Box Drawing BLACK TO 12VDC J5-09 J5-04 BLACK J9-03 BLACK WHITE...

  • Page 36: Meter Roll Sensor

    Wiring Reference Portable Dryer Troubleshooting Meter Roll Sensor...

  • Page 37: Meter Roll Sensor Wiring

    Portable Dryer Troubleshooting Wiring Reference Meter Roll Sensor Wiring Board Board Roll Meter Roll Meter...

  • Page 38: Meter Roll Reversing

    Wiring Reference Portable Dryer Troubleshooting Meter Roll Reversing YOU MUST ENTER INTO THE DRYER PARMETER MODE BY PRESSING THE SCR DRIVE INCREASE AND DECREASE BUTTONS SIMULTANIOUSLY. YOU WILL HAVE BOARD THE FOLLOWING OPTIONS LISTED: SHUTDOWN HISTORY (PRESS ENTER) DRYER MODEL # (IE. 1112) FAN DELAY (DEFAULT = 5) FILL AUGER (DEFAULT = END)

  • Page 39: Lower Junction Box Wiring

    Portable Dryer Troubleshooting Wiring Reference 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.

  • Page 40: New Fenwal Board Wiring

    Portable Dryer Troubleshooting Wiring Reference New Fenwal Board Wiring 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.

  • Page 41: New Fenwal Board Troubleshooting

    Portable Dryer Troubleshooting Wiring Reference Fenwal Board Troubleshooting 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.

  • Page 42: Flame Control Circuit

    Wiring Reference Portable Dryer Troubleshooting Flame Control Circuit COMMON COMMON...

  • Page 43: Fan Burner Circuit For Canadian Models

    Portable Dryer Troubleshooting Wiring Reference Fan Burner Circuit for Canadian Models Only...

  • Page 44: Conversion Diagram For C Series Dryers To A Switchable Hi/Low Or On/Off Burner

    Wiring Reference Portable Dryer Troubleshooting Conversion Diagram For C Series Dryers To A Switchable Hi/Low Burner Or A On/Off Burner...

  • Page 45: Fan 28 Lp Hi/Low-On/Off

    Portable Dryer Troubleshooting Wiring Reference Fan 28 LP Hi/Low-On/Off...

  • Page 46: Fan 28 Lp On/Off Burner With Mercoid

    Wiring Reference Portable Dryer Troubleshooting Fan 28 LP Hi/Low-On/Off Burner With Mercoid...

  • Page 47: Fan 28 Ng Hi/Low-On/Off

    Portable Dryer Troubleshooting Wiring Reference Fan 28 NG Hi/Low-On/Off...

  • Page 48: Fan 28 Ng On/Off Burner With Mercoid

    Wiring Reference Portable Dryer Troubleshooting Fan 28 NG Hi/Low-On/Off Burner With Mercoid...

  • Page 49: Fan 42 Lp Hi/Low-On/Off

    Portable Dryer Troubleshooting Wiring Reference Fan 42 LP Hi/Low-On/Off...

  • Page 50: Fan 42 Lp On/Off Burner With Mercoid

    Wiring Reference Portable Dryer Troubleshooting Fan 42 LP Hi/Low-On/Off Burner With Mercoid...

  • Page 51: Fan 42 Ng Hi/Low-On/Off

    Portable Dryer Troubleshooting Wiring Reference Fan 42 NG Hi/Low-On/Off...

  • Page 52: Fan 42 Ng On/Off Burner With Mercoid

    Wiring Reference Portable Dryer Troubleshooting Fan 42 NG Hi/Low-On/Off Burner With Mercoid...

  • Page 53: Scr Drive Circuit

    Portable Dryer Troubleshooting Wiring Reference SCR Drive Circuit COIL...

  • Page 54: Rtd Temperature Sensor

    Wiring Reference Portable Dryer Troubleshooting RTD Temperature Sensor BLACK S2 BLACK S2 WHITE S1 WHITE S1...

  • Page 55: Test Procedure For Emcs Dryers

    Portable Dryer Troubleshooting Wiring Reference Test Procedure for E.M.C.S. Dryers...

  • Page 56: Temperature Charts

    Portable Dryer Troubleshooting Temperature Charts 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.

  • Page 57: Emcs Troubleshooting Tips

    Troubleshooting Tips Portable Dryer Troubleshooting DC Drive Metering Roll System in the 2 Speed position. If this is present then the SCR contactor and input/output board Symptoms: Metering Roll will not turn, are okay. dryer shutdown-"Metering Roll Drive Failure" • If 220 volts AC is present across input of Metering Roll Operation the SCR drive board (L1 and L2) then...
  • Page 58 Portable Dryer Troubleshooting Troubleshooting Tips Fenwal Ignition System. If no voltage is Fenwal Ignition System present after the 10 second purge delay, Symptoms: Burner will not light, dryer check for voltage going through the auxil- shutdown for "Loss of Flame" iary switch mounted on the side of the fan contactor for that burner.
  • Page 59 Troubleshooting Tips Portable Dryer Troubleshooting Fenwal Ignition System continued... Ignitor Tips Hints • Make sure that the ignitors are mounted correctly through an opening in the burner • Hearing the solenoids snap on after the skirting. Also, make sure that they are not close 10 second purge delay means that power enough to the edges of the opening to cause a is coming to and through the Fenwal...
  • Page 60 Troubleshooting Tips Portable Dryer Troubleshooting Metering Roll Sensors the incoming 12 volts DC (the T1-+12V and T2-GND terminals), and one is a pulsing Symptoms: No BPH, Total Bushels, RPM dis- 12 volts DC back to the input/output board played on LCD or dryer shutdown with metering (the T3 out terminal).
  • Page 61 Troubleshooting Tips Portable Dryer Troubleshooting driver and turn the adjusting screw coun- Air Pressure System terclockwise. Turning it this way makes the switch more sensitive to pressure and • When inspecting the sensor make sure will turn on the light easier. that the wheel going through the sensor is positioned in the center and is not touch- •...
  • Page 62 Troubleshooting Tips Portable Dryer Troubleshooting Vapor High Temperature • 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 Symptoms: Dryer runs for only a short period of having air pressure in the plenum.
  • Page 63 Troubleshooting Tips Portable Dryer Troubleshooting soon as the burner is turned on. The The two wrap has less surface area and it vaporizer must be adjusted to solve this will not heat the LP quite as much. This problem. may also be true in colder climates where a two wrap will not heat up enough.
  • Page 64 Troubleshooting Tips Portable Dryer Troubleshooting Out Of Grain Warning Shutdown Before setting the Out of Grain timer, monitor how long it takes the dryer to Out Of Grain Warning refill for shrink. Then, set the Out of Grain timer accordingly. Example: If a •...
  • Page 65 Troubleshooting Tips Portable Dryer Troubleshooting Motor Overload Helpful Hints Motor Overload Shutdown Each of the Motor Overload is run in a This indicates that one of the Motor Overloads has tripped, shutting down the dryer. Each of the Motor series circuit. This means, if any of the Motor Overloads trip, a shutdown will Overloads is located in the upper main power control occur.

  • Page 66: Competitor Series 2000 Dryer (Picture Of Dryer)(1995 To Present)

    Competitor Series 2000 Portable Portable Dryer Troubleshooting...

  • Page 67: 220 Volt Single (1) Phase Power Drawing

    Portable Dryer Troubleshooting Competitor Wiring Reference 220 Volt Single (1) Phase Power Drawing SCR BOARD ASSEMBLED D03-0104 KBIC BARRIER TERMINAL BOARD LINE FUSE FUSE ACCEL P3 P2 P 1 I1 F+ F- L1 L2 A+ A- OVERLOAD OVERLOAD OVERLOAD OVERLOAD OVERLOAD...

  • Page 68: Volt Single (1) Phase Power Drawing (New Version)

    Competitor Wiring Reference Portable Dryer Troubleshooting 220 Volt Single (1) Phase Power Drawing (New Version)

  • Page 69: 220 Volt Three (3) Phase Power Drawing

    Portable Dryer Troubleshooting Competitor Wiring Reference 220 Volt Three (3) Phase Power Drawing...

  • Page 70: Volt Three (3) Phase Power Drawing (New Version)

    Competitor Wiring Reference Portable Dryer Troubleshooting 220 Volt Three (3) Phase Power Drawing (New Version)

  • Page 71: Volt 1 Phase Power Circuit (Ladder Diagram)

    Competitor Wiring Reference Portable Dryer Troubleshooting COMPETITOR POWER CIRCUIT ( 220 VOLT 1PH )

  • Page 72: Volt 3 Phase Power Circuit (Ladder Diagram)

    Competitor Wiring Reference Portable Dryer Troubleshooting COMPETITOR POWER CIRCUIT ( 220 VOLT 3PH )

  • Page 73: Volt 3 Phase Power Circuit (Ladder Diagram)

    Competitor Wiring Reference Portable Dryer Troubleshooting COMPETITOR POWER CIRCUIT ( 440 VOLT 3PH )

  • Page 74: Upper Control Box Internal Wiring

    Competitor Wiring Reference Portable Dryer Troubleshooting Upper Control Box Internal Wiring J3-01 J3-02 J3-11 J3-12 J6-03 J3-14 USER SAFETY J1-17 +12 VDC J7-08 HOUSE HI LIMIT J7-02 VAPOR HI LIMIT J1-13 +12 VDC LEFT GRAIN HI NONE RIGHT GRAIN HI NONE PLENUM HI LIMIT J7-01...

  • Page 75: Series 2000 Control Box Wiring (New Version)

    Competitor Wiring Reference Portable Dryer Troubleshooting Series 2000 Control Box Wiring (New Version)

  • Page 76: Series 2000 Control Box Wiring

    Competitor Wiring Reference Portable Dryer Troubleshooting Upper Control Box Wiring 220 Volt 1PH...

  • Page 77: Series 2000 Control Box Wiring (380-460-575 3 Phase)

    Competitor Wiring Reference Portable Dryer Troubleshooting Upper Control Box Wiring 380, 460 & 575 3PH...
  • Page 78 Competitor Wiring Reference Portable Dryer Troubleshooting Series 100 Control Box Wiring 1 - END PROTECTOR# D01-0532 REMOVE SCREW TO ACTIVATE 48 - COMPRESSION TERM.# D01-0531 USER SAFETY TERMINAL 2 - ENDSTOP# D01-0533 CONNECT WIRE FROM J7-08 4 - GROUND TERMINAL# D01-0534 THRU USER SAFETY SWITCH 13"...

  • Page 79: Upper Terminal Strip

    Portable Dryer Troubleshooting Competitor Wiring Reference Upper Terminal Strip With Moisture Control Hook Up...

  • Page 80: Upper Terminal Strip (Moisture Control Relay Hook-Up)

    Competitor Wiring Reference Portable Dryer Troubleshooting Upper Terminal Strip With Moisture Control Relay Hook Up...

  • Page 81: Moisture Manager To Dryer Wiring

    Portable Dryer Troubleshooting Competitor Wiring Reference Moisture Manager to Dryer Wiring (Upper Control Box)

  • Page 82: Input/Output Board & Terminal Strip

    Competitor Wiring Reference Portable Dryer Troubleshooting Input/Output Board & Terminal Strip LINE LOAD...

  • Page 83: Control Circuit (Cpu/Display)(Ladder Diagram)

    Portable Dryer Troubleshooting Competitor Wiring Reference Competitor Control Circuit CPU/Display Board...

  • Page 84: Control Circuit (I/O Board)(Ladder Diagram)

    Competitor Wiring Reference Portable Dryer Troubleshooting Competitor Control Circuit I/O Board...

  • Page 85: Control Circuit (Scr Drive Board)(Ladder Diagram)

    Competitor Wiring Reference Portable Dryer Troubleshooting Competitor Control Circuit SCR Drive Board...

  • Page 86: Scr Board (Installing & Calibrating)

    Competitor Wiring Reference Portable Dryer Troubleshooting * The SCR board is located in the upper control box. * Terminals L1 and L2 are the input RESISTOR terminals. When the unload system is turned on there should be 220 Volts AC accross these terminals. * Terminals A+ and A- are the ouput terminals.
  • Page 87 Portable Dryer Troubleshooting Competitor Wiring Reference 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.
  • Page 88 Portable Dryer Troubleshooting Competitor Wiring Reference 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.

  • Page 89: Upper Control Box External Wiring

    Portable Dryer Troubleshooting Competitor Wiring Reference 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...

  • Page 90: Input/Output Board 12 Volt

    Competitor Wiring Reference Portable Dryer Troubleshooting Input/Output Board 12 Volt UNLOAD AUGER NEUTRAL UNLOAD AUGER POWER AC NEUTRAL MAXON VALVE/DRYER RUNNING LIGHT AC NEUTRAL PROOF OF FLAME LIGHT AC NEUTRAL PROOF OF AIRFLOW LIGHT AC NEUTRAL MOISTURE CONTROL HOLDING LIGHT LOAD AUGER NEUTRAL LOAD POWER FAN NEUTRAL...

  • Page 91: Cpu Board Wiring

    Portable Dryer Troubleshooting Competitor Wiring Reference Cpu Board Wiring FUSE...

  • Page 92: Programming Instructions For Competitor Series Grain Dryers

    Competitor Wiring Reference Portable Dryer Troubleshooting 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.

  • Page 93: Programming Hook Up Diagram

    Portable Dryer Troubleshooting Competitor Wiring Reference Programmer Hook Up Diagram FUSE 8 7 6 5 4 3 2 1...
  • Page 94 Portable Dryer Troubleshooting Competitor Wiring Reference 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.
  • Page 95 Portable Dryer Troubleshooting Programming Competitor Programming Competitor Dryer Using Palm Pilot Hot Sync Ca ble D03-0694 Palm Pilot D03-0689 (M100) D03-0688 (IIIC) P al m S i d e DB-9 M-M Ada pter D03-0695 D ryer DB-9 Conne ctor S i d e J2 Connector Connects to the back of CPU/Display board)

  • Page 96: Back Of Switch Panel Layout

    Competitor Wiring Reference Portable Dryer Troubleshooting Back of Switch Panel Layout FUSE...

  • Page 97: Back Of Switch Panel Wiring

    Portable Dryer Troubleshooting Competitor Wiring Reference Back of Switch Panel Wiring FUSE...

  • Page 98: Air Switch Assembly

    Competitor Wiring Reference Portable Dryer Troubleshooting Air Switch Assembly...

  • Page 99: Air Switch Adjusting

    Portable Dryer Troubleshooting Air Switch Adjustment Competitor Air Switch Adjustment 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. 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.

  • Page 100: Fixed Grain Hi-Limit & Temperature Sensor

    Competitor Wiring Reference Portable Dryer Troubleshooting 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.

  • Page 101: Out Of Grain Sensor

    Competitor Wiring Reference Portable Dryer Troubleshooting Out of Grain Sensor...

  • Page 102: Grain Temperature Sensor

    Competitor Wiring Reference Portable Dryer Troubleshooting Grain Temperature Sensor YELLOW J7-12 WHITE/BLACK STRIP J7-13 WHITE/BLACK STRIP J7-13 BLACK J7-14 BLACK J7-14...

  • Page 103: Grain Sensor Testing

    Competitor Wiring Reference Portable Dryer Troubleshooting Grain Sensor Testing FUSE...

  • Page 104: Grain Sensor (Locating,Testing,& Replacing)

    Grain Sensor Portable Dryer Troubleshooting 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. ·...
  • Page 105 Portable Dryer Troubleshooting Grain Sensor Procedure for Locating, Testing and Replacing a Defective Grain Temperature Sensor. (continued) 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.

  • Page 106: Sensor Resistance/Temperature Chart

    Portable Dryer Troubleshooting Sensor Chart Procedure for Locating, Testing and Replacing a Defective Grain Temperature Sensor. (continued) 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. Double check the wire connections then replace the covers on the boxes.

  • Page 107: Plenum Sensor (Locating,Testing & Replacing)

    Plenum Sensor Portable Dryer Troubleshooting 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.
  • Page 108 Plenum Sensor Portable Dryer Troubleshooting 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.

  • Page 109: Stern And Capacitor Diagram

    Portable Dryer Troubleshooting Competitor Wiring Reference Stern and Capacitor Diagram 10-17 HP 1Phase...

  • Page 110: Operation Hints

    Portable Dryer Troubleshooting Operation Hints OPERATION HINTS FOR COMPETITOR DRYERS 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.
  • Page 111 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 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.

  • Page 112: Series 2000 Error Conditions

    Error Codes Portable Dryer Troubleshooting Series 100 Error Conditions...
  • Page 113 Portable Dryer Troubleshooting Competitor Wiring Reference Series 100 Error Conditions...

  • Page 114: Heater Circuit

    Competitor Wiring Reference Portable Dryer Troubleshooting 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...

  • Page 115: Fan Burner Circuit For Canadian Models Only

    Portable Dryer Troubleshooting Competitor Wiring Reference Fan Burner Circuit For Canadian Models Only...

  • Page 116: Series 2000 Lp 26"/28" Fan

    Competitor Wiring Reference Portable Dryer Troubleshooting Series 100 LP 26"/28" Fan WIRES: 2 - PURPLE 2 - YELLOW 3 FEET LONG FROM OUTSIDE OF BOX PURPLE PURPLE BLACK YELLOW YELLOW BLACK J7-19 ORG J7-20 WHT J6-07 WHT J6-06 BLK J6-12 BLK BLACK J6-13 WHT WHITE...

  • Page 117: Series 2000 Natural Gas 26"/28" Fan

    Portable Dryer Troubleshooting Competitor Wiring Reference Series 100 Natural Gas 26"/28" Fan WIRES: 2 - YELLOW 3 FEET LONG FROM OUTSIDE OF BOX BLACK YELLOW YELLOW BLACK J7-19 ORG J7-20 WHT J6-07 WHT J6-06 BLK J6-12 BLK BLACK BLACK J6-13 WHT WHITE J6-14 BRN BROWN...

  • Page 118: Series 2000 Lp 36"/42" Fan

    Competitor Wiring Reference Portable Dryer Troubleshooting Series 100 LP 36"/42" Fan WIRES: 2 - PURPLE 2 - YELLOW 3 FEET LONG FROM OUTSIDE OF BOX BLACK WHITE BROWN PURPLE YELLOW WIRES: 1 - BROWN 1 - WHITE 1 - BLACK PART# HH-1093 IGNITION TRANSFORMER TYPE 312-24A402V...

  • Page 119: Series 2000 Natural Gas 36"/42" Fan

    Portable Dryer Troubleshooting Competitor Wiring Reference 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 IGNITION TRANSFORMER FROM OUTSIDE TYPE 612-6A7...

  • Page 120: Warranty

    Warranty Portable Dryer Troubleshooting 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.
  • Page 121 1004 E. Illinois St. Assumption, IL 62510-0020 Phone 217-226-4421 2004 Edition...

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