Grain-systems PNEG-630 Uživatelský manuál

2004 Revised EditionPNEG-630Troubleshooting andReference ManualGSICompetitor & EMCSPortable DryerModelsCompetitor Series 2000 Dryer

Portable Dryer Troubleshooting9FAN #12345 6Error Message - + - + - + - + - + - + RESULTFan # Housing High Temperature J5-12 J1-7 J5-12 J1-8 J5-12 J2-7

Portable Dryer Troubleshooting99Fixed Grain Hi-Limit & Temperature SensorPLENUMSCRUNLOADMOTOR1XXRIGHT FIXEDGRAIN HIGHLIMITOUTSIDE LIGHTTEMP.SENSOR

Portable Dryer Troubleshooting100Out of Grain SensorJUNCTIONBOXLOWERGAS PIPE TRAINTEMP. SENSORSLIMITGRAIN HIGHLEFT FIXEDAIR SWITCHSOLENOIDFANJUNCTIONB

Portable Dryer Troubleshooting101Grain Temperature SensorBLACK 20 GA.WHITE/BLACK STRIP 20 GA.REARFRONTWHITE/BLACK STRIP J7-13PLENUM TEMP SENSORINSIDE

Portable Dryer Troubleshooting102Grain Sensor TestingSENSORS COMP98.PRTIF OHMS DOES NOT = 11.0 K CHECK LOWER AND UPPER TERMINAL STRIP (J7-13 GND &

Portable Dryer Troubleshooting103Grain SensorProcedure for Locating, Testing and Replacinga Defective Grain Temperature Sensor Symptoms

Portable Dryer Troubleshooting104 Procedure for Locating, Testing and Replacinga Defective Grain Temperature Sensor. (continued) 11. Now

Portable Dryer Troubleshooting105 Procedure for Locating, Testing and Replacinga Defective Grain Temperature Sensor. (continued) 3.

Portable Dryer Troubleshooting106Plenum Sensor Procedure for Locating, Testing and Replacing a Defective Ple

Portable Dryer Troubleshooting107 Procedure for Locating, Testing and Replacing

Portable Dryer Troubleshooting108Stern and Capacitor Diagram 10-17 HP 1PhaseWIRE #8 FROM MOTORWIRE #5 FROM MOTORWIRE #1 FROM MOTOR216-259uF, 250VAC CA

Portable Dryer Troubleshooting10Programming Instructions for EMCS Grain DryersProgramming1. Turn Control Power on dryer to off.2. Locate programming

Portable Dryer Troubleshooting109OPERATION HINTS FOR COMPETITOR DRYERS Present Software version

Portable Dryer Troubleshooting110 6. OPERATION HINTS 1. If you set a new timer setting which is lower then the present setting it becomes effective im

Portable Dryer Troubleshooting111Series 100 Error ConditionsThis indicates that one of the other onscreen errors (vapor, plenum, housingtemp hi-limit,

Portable Dryer Troubleshooting112Series 100 Error Conditions PLENUMERRORTHIS DISPLAY INDICATES A LOSS OF AIRPRESSURE INSIDE THE DRYER. THIS ISUSUALLY

Portable Dryer Troubleshooting113Heater CircuitJ7-19 FLAME DETECTION ORANGE -J6-07-IGNITION NEUTRAL---WHITEJ6-06-IGNITION POWER---BLACKJ7-13-VAPOR-PUR

Portable Dryer Troubleshooting114J7-10 12VDC NEGATIVE WHITE/BLACK STRIP1PINKWHITEBROWNGREYJ7-02 HOUSING HIGH LIMITJ6-14 CYCLE SOLENOID POWERJ6-13 MAIN

Portable Dryer Troubleshooting115S228LP.PRTJ7-10 WHT/BLKJ7-02 YELJ7-08 REDJ7-13 PURJ6-14 BRNJ6-13 WHTJ6-12 BLKJ6-06 BLKJ6-07 WHTJ7-20 WHTJ7-

Portable Dryer Troubleshooting116Series 100 Natural Gas 26"/28" FanS228NG.PRTJ7-10 WHT/BLKJ7-02 YELJ7-08 REDJ6-14 BRNJ6-13 WHTJ6-12 BL

Portable Dryer Troubleshooting117Series 100 LP 36"/42" FanYELPURBLKWHTYELPURWHTBRNBLKBLKBLKJ7-10 WHT/BLKJ7-02 YELJ7-08 REDJ7-13 PURJ6-14

Portable Dryer Troubleshooting118Series 100 Natural Gas 36"/42" FanYELBLKWHTYELWHTBRNBLKBLKBLKJ7-10 BLK/WHTJ7-02 YELJ7-08 REDJ6-14 BRNJ6-

Portable Dryer Troubleshooting11TO STOP SW.TO START SW.TO START & STOP SWS.321DISPLAYRIBBONS1U12P3COMMUNICATIONS CABLE TO I/O BOARDP5P4KEY P

Portable Dryer Troubleshooting119WarrantyEXCEPT FOR THE ABOVE STATED EXPRESS LIMITED WARRANTIES, GSI MAKES NO WAR-RANTY OF ANY KIND, EXPRESSED OR IMPL

1004 E. Illinois St.Assumption, IL 62510-0020Phone 217-226-44212004 Edition

Portable Dryer Troubleshooting12 Wiring ReferenceInput/Output Board Identification1357924681012141618201113151719J11357924681012141618201113151719J213

Portable Dryer Troubleshooting13Switch Replacement for EMCS DryerSwitch N/O Contact Block - Part No. D63-0006Switch Light Block - D01-0455Switch Repla

Portable Dryer Troubleshooting14 Wiring Reference1100 Series Control Box WiringNEED JUMPERNEED JUMPERREDJ5-8120 VAC (BLACK)AC 1120 VAC NEUT

Portable Dryer Troubleshooting15 Wiring Reference1100 Series Control Box Wiring (New Version)

Portable Dryer Troubleshooting16 Wiring Reference1200 Series Control Box Wiring52 TOTAL TERMINALSSAFETY CIRCUITNEED JUMPERNEED JUMPERRED53 TOTAL TERMI

Portable Dryer Troubleshooting17 Wiring Reference1200 Series Control Box Wiring (New Version)

Portable Dryer Troubleshooting18J8-16 WHITE - AC NEUTRAL - UNLOAD NEUTRAL35 - D01-0531 ENTRELEC TERMINALS2 - D01-0533 END STOPS1 - D01-0532 BLANK P

Portable Dryer Troubleshooting1Table Of ContentsSafety...

Portable Dryer Troubleshooting191200 Fan Lower Control Box Interconnect StripS2 ORANGE - TEMPERATURE SENSORS1 ORANGE - TEMPERATURE SENSORB2WHITE - AC

Portable Dryer Troubleshooting20YELLOW FROM J1-05 TO PLENUM HIGH LIMIT SWITCHWHITE TO S1 FROM GRAIN TEMPERATURE SENSORBLACK TO S2 FROM GRAIN TEMPERATU

Portable Dryer Troubleshooting21Fan Housing and Vapor Hi-Limit Circuit Wiring Reference

Portable Dryer Troubleshooting22Plenum Hi-Temperature Switch Wiring Reference

Portable Dryer Troubleshooting23Fixed Grain Hi-Limit Wiring Reference

Portable Dryer Troubleshooting24 Grain & Plenum Hi-Limit LocationsPLENUMSCRUNLOADMOTOR11XXRIGHT FIXEDGRAIN HIGHLIMITOUTSIDE LIGHTTEMP. SENSORSLOAD

Portable Dryer Troubleshooting252FNLMTSW98.PRT REV. DATE 4/5/98RED TO J1-05BLUE TO J1-11YELLOW TO J1-12 FAN #1PLENUM HIGH LIMIT SWITCHD03-0

Portable Dryer Troubleshooting26Rear Discharge & Emergency Cooling Circuit Wiring Reference

Portable Dryer Troubleshooting27Rear Discharge Mercury SwitchPOSITIONED WITH LID CLOSED ANDSJOW 18/2 CORD POINTED TOWARDSTHE FRONT OF THE DRYER CONNEC

Portable Dryer Troubleshooting28Adjustable Hi-Limit & Emergency Cooling Circuit Wiring Reference

Portable Dryer Troubleshooting2Table Of ContentsCompetitor Series 2000 Dryer (Picture of Dryer)(1995 to Present)...

Portable Dryer Troubleshooting29Motor Overloads Wiring Reference

Portable Dryer Troubleshooting30Air Pressure SwitchJ5-8J1-8J1-6J1-7J1-58J51 112 VOLTDC NEGATIVE12 VOLT SOURCEDC POSITIVEJ2J3INPUT/OUTPUT BOARDTERMINAL

Portable Dryer Troubleshooting31HIGHBACKVIEW OF AIR SWITCH ASSEMBLYTO UPPER CONTROL BOXBLUE J1-13 AIRFLOW (N.O.)BLUE J5-08 12VDC POSITIVE CALIBRATED W

Portable Dryer Troubleshooting32Out of Grain Safety Circuit Wiring Reference

Portable Dryer Troubleshooting33Out of Grain Safety Circuit LocationJUNCTIONBOXLOWERGAS PIPE TRAINTEMP. SENSORSLIMITGRAIN HIGHLEFT FIXEDAIR SWITCHTHER

Portable Dryer Troubleshooting34Upper Junction Box DrawingREDWHITETO OUTSIDE LIGHT FIXTUREBLACKBLACKJ5-04TO 12VDC J5-09J9-03L1TO LOAD MERCURY SWITCHWH

Portable Dryer Troubleshooting35Meter Roll SensorJ5-09J5-12J5-19J5-16J5-05J1-19TO REAR DISCHARGE SWITCH TO REARJUNCTION BOXLEFT METERROLL SENSORRIGHT

Portable Dryer Troubleshooting36Meter Roll Sensor Wiring1997 Dryers have only 1 meter roll board.Remove one meter roll board and tie the 2 T-3 wires

Portable Dryer Troubleshooting37Meter Roll Reversing14913121485 TODC DRIVE MOTORORANGE PURPLE J7-17 NOTE: WHEN INSTALLING RELAY

Portable Dryer Troubleshooting38Lower Junction Box WiringWHITE S1BLACK S2RED J1-11ORANGE J1-19BROWN FROM J1-19 TO DISCHARGE SWITCHORANGE FROM J5-05 TO

Portable Dryer Troubleshooting3SafetyWARNING! BE ALERT!Personnel operating or workingaround electric fans should read thismanual. This manual must b

Portable Dryer Troubleshooting39 The B. GND terminal is used to ground the burner and to complete the flame current signal circuit. This terminal is

Portable Dryer Troubleshooting40Fenwal Board TroubleshootingOn-Board Diagnostics The LED will flash on for 0.2 seconds then off for

Portable Dryer Troubleshooting41CoilV120 SEC SAFETY12 VOLTS DC120 VOLTS ACWHTWHTFENWAL BOARDWHTWHTORCOMMONCOMMONNeutralCOILNormal ClosedNormal ClosedW

Portable Dryer Troubleshooting42IGNITORSENSORFLAMEDELAYTIMEE2 S1L2V2L1V1FENWAL PART# HF-462412 VOLTS DC20 SEC SAFETYVAPOR LIMITHOUSING LIMITVAPORHOUS

Portable Dryer Troubleshooting43Conversion Diagram For C Series Dryers To A SwitchableHi/Low Burner Or A On/Off Burner Wiring Reference

Portable Dryer Troubleshooting44Fan 28 LP Hi/Low-On/Off Wiring Reference

Portable Dryer Troubleshooting45Fan 28 LP Hi/Low-On/Off Burner With Mercoid Wiring Reference

Portable Dryer Troubleshooting46Fan 28 NG Hi/Low-On/Off Wiring Reference

Portable Dryer Troubleshooting47Fan 28 NG Hi/Low-On/Off Burner With Mercoid Wiring Reference

Portable Dryer Troubleshooting48Fan 42 LP Hi/Low-On/Off Wiring Reference

Portable Dryer Troubleshooting4SafetySafety decals should be read andunderstood by all people in andaround the dryer area. If the follow-ing safety d

Portable Dryer Troubleshooting49Fan 42 LP Hi/Low-On/Off Burner With Mercoid Wiring Reference

Portable Dryer Troubleshooting50Fan 42 NG Hi/Low-On/Off Wiring Reference

Portable Dryer Troubleshooting51Fan 42 NG Hi/Low-On/Off Burner With Mercoid Wiring Reference

Portable Dryer Troubleshooting52SCR Drive CircuitTo CoilWITH POWER WIRESUPPER POWER STRIP TO TERMINAL ONCONTACTORSCRS C R BoardTo SCR Drive MotorF +F

Portable Dryer Troubleshooting53RTD Temperature SensorBLACK 20 GA.WHITE 20 GA.REARFRONTINSIDE GRAIN COLUMN CONDUITTO UPPER CONTROL BOXWHITE S1BLACK S2

Portable Dryer Troubleshooting54Test Procedure for E.M.C.S. DryersIF NONE OF THE MEASUREMENTS = 3.4 K,THEN CHECK EACH INDIVIDUAL SENSOR.IF MEASUREMENT

Portable Dryer Troubleshooting55Temperature ChartsWe use two (2) different types of sensors (NTC thermistor on the Competitor Series 2000, and anenca

Portable Dryer Troubleshooting56• If 220 volts AC is present across input ofthe SCR drive board (L1 and L2) thencheck for voltage across the output of

Portable Dryer Troubleshooting57Fenwal Ignition SystemSymptoms: Burner will not light, dryershutdown for "Loss of Flame"Fenwal Ignition Oper

Portable Dryer Troubleshooting58• Hearing the solenoids snap on after the10 second purge delay means that poweris coming to and through the Fenwalboar

Portable Dryer Troubleshooting5Safety

Portable Dryer Troubleshooting59HintsMetering Roll SensorsMetering Roll Sensor Operation• The T3 (out) terminal is what deliversthe metering roll info

Portable Dryer Troubleshooting60Air Pressure SystemSymptoms: Dryer will indicate a "Loss of Airflow"negatives for the black probe(-) of your

Portable Dryer Troubleshooting61Symptoms: Dryer runs for only a short period oftime, then a shutdown occurs.erature Operation• This message indicates

Portable Dryer Troubleshooting62soon as the burner is turned on. Thevaporizer must be adjusted to solve thisproblem.Using J5-11 as the negative test

Portable Dryer Troubleshooting63Out Of Grain Warning• This message indicated that the dryer hasrun low on grain. The shutdown occurswhen the loading

Portable Dryer Troubleshooting64Troubleshooting TipsThis indicates that one of the Motor Overloadshas tripped, shutting down the dryer. Each of the M

Portable Dryer Troubleshooting65 Competitor Series 2000 Portable

Portable Dryer Troubleshooting66220 Volt Single (1) Phase Power Drawing Competitor Wiring ReferenceOVERLOAD110 VAC OUTPUT220 VAC INPUTJ6-02AC-1220V FU

Portable Dryer Troubleshooting67220 Volt Single (1) Phase Power Drawing (New Version) Competitor Wiring Reference

Portable Dryer Troubleshooting68110X0AC13FO1FO120V FUSES110 VAC OUTPUT220 VAC INPUTAC NEUTRALAC-1220V FUSESCONTACTORSCRTRANSFORMERMOTORTO FAN #1MOTORT

Portable Dryer Troubleshooting6Safety

Portable Dryer Troubleshooting69220 Volt Three (3) Phase Power Drawing (New Version) Competitor Wiring Reference

Portable Dryer Troubleshooting70 COMPETITOR POWER CIRCUIT

Portable Dryer Troubleshooting71 COMPETITOR POWER CIRCUIT

Portable Dryer Troubleshooting72 COMPETITOR POWER CIRCUIT

Portable Dryer Troubleshooting73Upper Control Box Internal WiringAC1L1L2J6-023FO1FO110XOAC13FI1FI3549YELYELORGORGCOMN/ON/CN/CCOMN/OYELLOAD N/OUSER INS

Portable Dryer Troubleshooting74Series 2000 Control Box Wiring (New Version) Competitor Wiring Reference

Portable Dryer Troubleshooting75Upper Control Box Wiring220 Volt 1PH Competitor Wiring Reference

Portable Dryer Troubleshooting76Upper Control Box Wiring380, 460 & 575 3PHCompetitor Wiring Reference

Portable Dryer Troubleshooting77 Competitor Wiring ReferenceSeries 100 Control Box Wiring100STRIP98.PRT REV. DATE 3/12/981 - END PROTECTOR# D01-05

Portable Dryer Troubleshooting78Upper Terminal StripWith Moisture Control Hook UpCompetitor Wiring Reference

Portable Dryer Troubleshooting71. Read and understand the operating manual before trying to operate thedryer.2. Power supply should be OFF for service

Portable Dryer Troubleshooting79Upper Terminal StripWith Moisture Control Relay Hook UpCompetitor Wiring Reference

Portable Dryer Troubleshooting80Moisture Manager to Dryer Wiring(Upper Control Box)Competitor Wiring Reference

Portable Dryer Troubleshooting81Input/Output Board & Terminal StripPURPURREDRED --- J1-17PUR --- SCR2BLK --- LITEPUR --- J4-01PUR --- J4-02PNKREDR

Portable Dryer Troubleshooting82Competitor Control CircuitCPU/Display BoardCompetitor Wiring Reference

Portable Dryer Troubleshooting83Competitor Control CircuitI/O BoardCompetitor Wiring Reference

Portable Dryer Troubleshooting84Competitor Control CircuitSCR Drive BoardCompetitor Wiring Reference

Portable Dryer Troubleshooting85P3 P2 P1 L1 L2 A-A+MINMAX* The SCR board is located in theupper control box.* Terminals L1 and L2 are the inputtermina

Portable Dryer Troubleshooting86A-A+MAXBefore starting the procedure set the dryer up as follows:1. All fan and heater switches to off position and l

Portable Dryer Troubleshooting87A-A+MINSetting SCR Board Minimum Voltage1. Switch the Moisture Control Switch back to the on position. This will put

Portable Dryer Troubleshooting88Upper Control Box External WiringTO FAN CONTROL BOXTO AIRSWITCH ASSEMBLYTO LOWER JUNCTION BOXTO UPPER JUNCTION BOXTO P

Portable Dryer Troubleshooting8 Date Employer’s Signature Employee_______________________________________________________

Portable Dryer Troubleshooting89Input/Output Board 12 VoltTHESE JUMPERS MUST BE INSTALLEDJ1-1 TO J1-17 - USER SAFETYJ1-1 TO J1-16 - MERCOID SAFETYAC N

Portable Dryer Troubleshooting9012 VDC GROUND----MOTOR OVERLOADPLENUM TEMP SENSOROUT OF GRAIN SWITCHSTOP SWITCHSTART SWITCH12VDC NEGATIVEFLAME PROBE B

Portable Dryer Troubleshooting91Programing Instructions for Competitor Series Grain Dryers Competitor Wiring Reference1. Turn Control Power on dryer

Portable Dryer Troubleshooting92Programmer Hook Up Diagram DB9 JACKPLUG THIS INTO THE PROGRAMMERJ2 CONNECTORSERIES 2000 CABLEPROGRAMMING JACK TO UP

Portable Dryer Troubleshooting93Competitor Wiring Reference Programming Instructions Using Palm PilotOn th

Portable Dryer Troubleshooting94Programming Competitor Dryer Using Palm PilotPalm PilotD03-0689 (M100)D03-0688 (IIIC)Hot Sync Cable D03-0694DB-9

Portable Dryer Troubleshooting95Back of Switch Panel LayoutMONITORINGDISPLAYTRANSFORMERFUSEJ619 2012J8J61133J514121920J7STARTSTOP METERING ROLL SPEEDC

Portable Dryer Troubleshooting96MONITORINGDISPLAYTRANSFORMERFUSEJ619 2012J8J11133J514121920J7STARTSTOPUNLOADMETERING ROLL SPEEDHEATERCONTROL POWEROUTS

Portable Dryer Troubleshooting97GREY J7-11 NO AIRFLOW (N.C.)PLENUMSCRUNLOADMOTOR1XXRIGHT FIXEDGRAIN HIGHLIMITOUTSIDE LIGHTTEMP. SENSORSLOADMOTORLOAD M

Portable Dryer Troubleshooting98IMPORTANT: To adjust the air switch the grain columnsneed to be full of grain so that the plenum can build up airpres