GSI Outdoors PNEG-630 manual

2004 Revised Edition

PNEG-630

Troubleshooting and

Reference Manual

GSI

Competitor & EMCS

Portable Dryer

Models

Competitor Series 2000 Dryer

Contents

Main Page Table Of Contents Safety WARNING! BE ALERT! Safety Alert Symbol Dryer Safety Instructions and Information Safety Page Page Use Caution in the Operation of this Equipment Safety Precautions READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE SAVE FOR FUTURE REFERENCE Date Employers Signature Employee Safety Sign-Off Sheet Safety Voltage Check Points FAN # 123456 Programming Instructions for EMCS Grain Dryers EMCS Display Board Programming Input/Output Board Identification 120 VOLT AC OUTPUTS12 VOLT DC INPUTS Page 1100 Series Control Box Wiring COLORVOLTAGE 1100EW98.PRT REV. DATE 4/10/98 J8-16 J8-9 Page 1200 Series Control Box Wiring 52 TOTAL TERMINALS J8-16 J8-9 J8-18 Page 1100 Fan Lower Control Box Interconnect Strip 1200 Fan Lower Control Box Interconnect Strip J9-3 I/O BOARD JUMPERS 45 - D01-0531 ENTRELEC TERMINALS 2 - D01-0533 END STOPS 1 - D01-0532 BLANK PROTECTOR ENDS INSTALL J1-9 TO J5-6 INSTALL J5-2 TO J5-20 INSTALL J4-12 TO J5-10 INSTALL J9-1 TO J9-5 Upper Control Box External Wiring Page Page Page Grain & Plenum Hi-Limit Locations FAN 11XX 2FNLMTSW98.PRT REV. DATE 4/5/98 Two Fan Plenum and Grain Limit Switch Wiring FAN #1 FAN #2 12XX Page Rear Discharge Mercury Switch Page Page Air Pressure Switch INPUT/OUTPUT BOAR D TERMINAL LOCATION PRESSURE SWITCH SAFETY CIRCUIT HIGH BLUE J1-13 AIRFLOW (N.O.) BACKVIEW OF AIR SWITCH ASSEMBLY Air Pressure Switch Drawing BLUE J5-08 12VDC POSITIVE Page Out of Grain Safety Circuit Location FAN 11XX FRONT VIEW OF OPEN BOX UP Upper Junction Box Drawing BLACK BLACK J5-04 BLACK WHITE TO LOAD MERCURY SWITCH LEFT METER RIGHT METER ROLL SENSOR Meter Roll Sensor Wiring METER ROLL SENSOR 2 T-3 wires together. Remove one meter roll board and tie the 1997 Dryers have only 1 meter roll board. Board Meter Roll IMPORTANT Lower Junction Box Wiring FAN AND TEMPERATURE TO REAR DRIVE MOTOR New Fenwal Board Wiring Wiring Reference IGNITOR FLAME ROD Fenwal Board Troubleshooting Wiring Reference Measure Flame Current Flame Control Circuit Fan Burner Circuit for Canadian Models Only Page Page Page Page Page Page Page Page Page SCR Drive Circuit TO TERMINAL ON CONTACTOR UPPER POWER STRIP WITH POWER WIRES SCR 11XX REAR FRONT E.M.C.S. PORTABLE DRYERS Page DC Drive Metering Roll System Metering Roll Operation Check the Motor Check the SCR Drive Board Fenwal Ignition System Fenwal Ignition Operation Fenwal Troubleshooting Hints Ignitor Tips Hints Metering Roll Sensors Metering Roll Sensor Operation Air Pressure System Airflow Operation Troubleshooting: "Loss of Airflow" Hints Vapor High Temperature Troubleshooting: Vapor High Temperature Vapor High Limit Hints Out Of Grain Warning Possible Solution Out of Grain Hints Out Of Grain Warning Shutdown Motor Overload Helpful Hints Motor Overload Shutdown Page 220 Volt Single (1) Phase Power Drawing Page Page Page Page Page Page Upper Control Box Internal Wiring AC1 TERMINAL ON UPPER STRIP J6-15 Page Page Page Series 100 Control Box Wiring 16 GA WIRES 100STRIP98.PRT REV. DATE 3/12/98 Page Page Page Input/Output Board & Terminal Strip Page Page Page Page Page Page Upper Control Box External Wiring Input/Output Board 12 Volt 120 VOLT AC OUTPUT 12 VOLT DC INPUT J1 3 AMP FUSE J2 J5 Cpu Board Wiring J7 J6 DISPLAY MONITORING Programing Instructions for Competitor Series Grain Dryers Programmer Hook Up Diagram THE PROGRAMMER J7 J1 1 J8 Programming Instructions Using Palm Pilot Programming Competitor Prog rammin g Com petito r Drye r Usin g Palm Pilot Back of Switch Panel Layout YELLOW-3 BLACK J6-05 TO J6-11 WHITE J3-04 TO J6-17 RED J3-19 TO J6-16 Back of Switch Panel Wiring J7-07 WHITE RED BLU 1XX Air Switch Assembly HIGH WHITE/BLACK STRIP J7-10 AIRFLOW GROUND BLUE J7-09 AIRFLOW (N.O.) BACKVIEW OF AIR SWITCH ASSEMBLY IMPORTANT: Air Switch Adjustment Competitor Air Switch Adjustment need to be full of grain so that the plenum can build up air pressure and close the air switch. Air Switch assembly. 1XX TO REAR DRIVE MOTOR TO SCR AND TEMPERATURE 1XX FRONT VIEW OF OPEN BOX UP Grain Temperature Sensor 1XX Grain Sensor Testing SENSORS COMP98.PRT Temperature chart See page 47 for resistance vs. FIG.1 Grain Sensor a Defective Grain Temperature Sensor Grain Sensor Procedure for Locating, Testing and Replacing a Defective Grain Temperature Sensor. (continued) Sensor Chart Resistance / Temperature Chart Page Page Stern and Capacitor Diagram 10-17 HP 1Phase OPERATION HINTS FOR COMPETITOR DRYERS Operation Hints OPERATION HINTS FOR COMPETITOR DRYERS Operation Hints Series 100 Error Conditions Error Codes Page Heater Circuit Webster PART# HH-1093 SILICONE HIGH VOLTAGE IGNITION WIRES GRN Fan Burner Circuit For Canadian Models Only INSIDE VIEW OF MERCOID RELAY MERCOID SAFETY PRESSURE SWITCH Series 100 LP 26"/28" Fan PART# HH-1093 Webster Series 100 Natural Gas 26"/28" Fan PART# HH-1093 Webster Series 100 LP 36"/42" Fan PART# HH-1093 Webster Series 100 Natural Gas 36"/42" Fan PART# HH-1093 Webster Warranty