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GSI Outdoors PNEG-552 Clothes Dryer User Manual

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2. H2 VOLTS RED o Tol o RED JT 0B HOUSING HIGH LIMIT YEL e e RED J7 02 412 WES CONNEC mu L T GRAIN HI 2 VIRES R o o ND CONNEC Fina RIGHT GRAIN HI2 VIRES RY o CONNECTION ii UN HIGH LIMIT ME T2 l 01 gH Eege N r 10 2 u CONNECTION 12VDC REAR Org m t lo g m 7 03 32 IL S ak 2 e e NO CONNECTION Dt 2 UT IF ceain BLK o lol O RED 1 6 MH MALL TT m UD ue wg 2 5 o W JM AIR GND HT J NI AIPRN BLU J7 11 FLAME DETECT Ro o e GREY J7 19 FLAME DETECT W to l J1 20 ES PLENUM TEMPERATURE YE l l YEL 7 12 2 mes GNLENN GO wk 12 WHI 13 r WE eee cee S CONNECTION NAIN SOLENDID NELITRAL WHT o O WHT J6 13 S AIN SOLENOID PONER BLK o f e BLK M L x CYCLE SOLENOID PUMER BRN o BLK J6 14 UNLOAD AUGER NEUTRAL WHT o 2 WHT 3 02 S UNLOAD AUGER PONER BL o Tol RG 3 01 HD AGE POI BK Bo el ott m Rn L u Du L J3 FAN NEUTRAL H E l amp l iiii DM 2 d s F o
3. JH BIE ums Kl AAK USE 16 GA 11 HU r JH WIE YRS E ORANGE RH WHITE 5 r ei erm E f iyi 21 S INC og qod hos bh O O m mere EN AN o A E Ela O 24 COLL IP ell Eua aa USE 16 GA olooolololo l r olojalololo GE ololoielolo Em NEUTRAL PE WIRES q D RUND aT ooo E ofofo Hia ololo in gt H 6000 H 6600 I H mn Ho m o IE S E felele ori m Hi E P H ste H H ESCH m elele elele elele L y y LAN n LAR 4 HE o c a a ee K E 111215 i 15 ETA o LO UL WI UNLOAD AX jell EE RUE t ges X 1417 o Qe 0204 OZ O cx T PTIT O gt menet T nnnm pek D m x A Q Moo BAK WITE STRIFE il 7 o LI ALLE e S S S S S S S S S S S S Ss S S S SS SS S S S S SSS SS S SS S SSS SSS S avto S S S o a RED PANE S o o S c o oS o S c S c e o o o o o o o o o o e o o o o o o o o o o o o o o o o o _ o o o o ololololalalolo BU WHITE S S S S S S S S S S S S S S S S S S S S S SS S S S S S S S S S S S S S SS SS SS ARAS S S S S S S S S 5 pr W I WE o GC eS UK CODES PNEG 552 100 Series Dryer 8 Wiring Diagrams 100 Seri
4. 44 100 Series Front Panel External Wiring n n 45 100 Series Front Panel Internal Wiring auaaaaaaaaaaaaasnaaasanannnnnsaanssnnnsananannnnnnanannasnanannanaunnnnnnaania 46 100 Series Lower Back Panel Wiring n nsn 47 100 Series External Wiring to Dryer n 48 100 Series Upper Control Box Wiring nn 49 100 Series Main Power Wiring n 50 Chapter 9 Schematic Diagrami LLULLU III SI W ARAR aa AE Eea EE EESE EE Eaa Era EEEa 51 100 Series Control Schematic sss essen nennen ener nnne nennen nnn enne 51 100 Series 220 Volt 1 Phase Power Schematic 54 100 Series 220VAC 3 Phase Power Schematic aaiaaaaiaaaasaassanassannsanassanassaasananasnnannanannnnnnaannna 55 100 Series 440VAC 3 Phase Power Schematic sss 56 Chapter 10 Troubleshooting U uuu uu uuu uu u u u u u u 57 Chapter 11 FAQS E 61 Chapter 12 Warranty uuu Ynni ALL A din 63 PNEG 552 100 Series Dryer 1 Safety Safety Guidelines This manual contains information that is important for you the owner operator to know and understand This information relates to protecting personal safety and preventing equipment problems It is the responsi
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6. 11 L2 13 GND my Y WA a 1 MAIN i 772777777 DISCONNECT 1 o o o 1 1 1 101 gt ES i 1 1 D E iced 220VAC 3 PHASE DIST 102 BLOCK TOP FAN BREAKER TOP FAN TOP FAN r j a CONTACTOR OVERLOAD 103 GL 1MDL lo y H 1M Q il r i D O 0 1 FAN j alle ER MTR MOTOR 104 5 Zeile 1M x Ho r i 4 1CB e B SCR 52 55 MM F CONTACTOR IF 160 o o B AMP o YH ni 1 260 O o 244 1 1 UN DAD AUGER E 4 r BREAKER _ _ ei UNLOAD AUGER pu OVERLOAD 2MOL 2M 107 olo eler O I 1 Lem 3M 2MDL UNLOAD AUGER 4 o o MOTOR G ui Y 108 o o ole A 4 208 CIRLUIT HREAKER CONTROL 109 L TRANSFORMER XL T x2 S LLO VAC 110 x3 MN 1 I 1X Kl 201 4 m o 9 Las 4 6 ANP 111 cn CIRIT BREAKER S Sok LOAD AUGER LOAD AUGER p CONTACTOR OVERLOAD h FO eler aM S 112 Q um ae Ss 3ML H LOAD AUGER 4 B 1 OTOR Gg Up bun m 3M 20 HO o ele 1 JO 113 Q 8 d oap ee Seen ae J 308 We LOAD AUX AUGER BREAKER LOAD AUX AUGER LOAD AUX AUGER CONTACTOR OVERLOAD bz AM AML us E la b di AM AMOL LOAD AUX AUGER 4 Toro L T T e be MTR MOTOR i l o K O o 115 d B ia mae ee AA SE sl ACB Hr UNLOAD AUX AUGER BREAKER 7 UNLOAD AUX AUGER UNLOAD AUX AUGER CONTACTOR OVERLOAD G Mo SM a oo 118 A ole Wen SM SMOL UNLOAD AUX AUGER Lo 1 20 Q2 1 1
7. x 1 100 Series Dryer Operation and Service Manual PNEG 552 Date 11 02 07 GSI GROUP 5 u PNEG 552 PNEG 552 100 Series Dryer Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Table of Contents Contents LL E 5 Safety EI e ET 5 Ris Ee IT 6 Emergency OP ii A 6 Safety PrecaUutions uu uuu tad FFF FFF YF dd ia eb 7 Safety Alert Decals iii ia 8 Dryer Control Panel uu SS ici 12 Dryer Control Panel Featuring the 100 Series Control System a 13 Special Features viii ada 18 Safety Circuit Shut Down Messages ee Rae n 18 Error ConditioliS s d 20 Dryer Pre Start Checks qa unu Da ay RG 22 Inspect the Metering Rolls E 22 Set Control SWIISGHeS uuu 22 Electrical uo eI 23 Control Power SWitc EE 23 Power Start BUON rumu u RR PWY HAN WW FFO FNAN RY NN FFF FFF FYN FYNN YF NYTH 23 Fuel Check EE 23 Load AUJOT EE 23 1 Speed Bee et uuruuu ua 7 7 23 Metering Roll Operation servirse er nte te Eeer d dote 24 REI EE 24 sme 25 Heater Test FIIO cies a tero bte open aero redet unit I xs uu tent eure 25 Staged Batch Check E 25 Dryer Sh t DOWN Ea aAa 26 Stopping Dryer O
8. 16 GA VIRES MTN PLVER LK 2 O BK 6 05 MAXON POWER PIR Q o BLK J303 AXIN NEUTRAL WI Tol WHT 3 04 4 SCR CONTACTOR NEUTRAL WHT o e WHT DI SR CINTACTIR POR OR pro IRG 0 SS WORK LIGHT NELITRAL WIER J WRK LIGHT Hi RENH l l n LIE MERCOID SWITCH CANADA INLY FQ IK Jl EE onunu B EI qud RAVE SULD USER SAFETY FEATURE _ UNUT TO N C SAFETY SWITCH o r ED 7 08 CONNECT T NC SAFETY SWITTH EE li RED JI 17 IER SAFETY WIB Hi of SR wh USER INSTALLED o 16 GA WIRES DC VOLTMETER POSITIVE o 2 A ORANGE OMC MOISTURE DE VOL ETER NEGATIVE SCH BLACK d WHITE STRIPE 2 ALL METERING ROLL PIT to METERING ROLL PUT 110 VAC TO MOISTURE CONTROL BLK MDIST PONER J6 11 110 VAC FROM MOISTURE CONTROL BRN MCR PINEP LLOVAC NEUTRAL TO M CONTROL WHT MOIST NEUTRAL 56 02 UR J4 01 UR SCR2 PUR J4 02 SCR 1 TU P1 ON SCR BOARD PURPLE o SCR 2 TU P2 ON SCR BOARD PURPLE WO SCR 3 T P3 ON SCR BOARD PURPLE M 0 PNEG 552 100 Series Dryer 8 Wiring Diagrams li K I
9. 1 Press the PROGRAM TEMPERATURES button until the carrot is above the timer to be modified 2 Use the UP and DOWN arrow keys to change the present temperature to the desired setting The new temperature is automatically accepted 3 Keep pressingthe PROGRAM TEMPERATURES button until the carrot disappears or press the MODE SELECT button once to exit 4 On LP gas models adjustthe PRESSURE REGULATOR high fire on the burner fuel line so that burner will reach the thermostat setting and switch to low fire Pressure up to 25 Ibs may be required Natural gas does not have a regulator but uses a LARGE BALL VALVE close to the vertical supply line for adjustment Pressure up to 18 lbs may be required The Approximate Settings should be LP Gas Natural Gas High Fire 6 15 Ibs High Fire 6 10 Ibs Low Fire 2 6 lbs Low Fire 1 3 Ibs Do not set the low fire pressure so low that a popping or fluttering sound is heard in the heater If popping or fluttering sound are heard increase the pressure until the sound goes away On LP and NG gas models adjust the needle valve on the cycle solenoid low fire valve so that the burner maintains flame then switches back to high fire 5 Adjust the burner pressure so that the burner CYCLES 2 to 3 times per minute approximately 15 to 20 seconds on HIGH and approximately 5 8 seconds on LOW Increasing the gas pressure with the LP gas regulator or the Natural Gas hand valve i
10. CONNECTION WITH I PRODUCT MANUFACTURED OR SOLD BY GSI OR 1 ANY ADVICE INSTRUCTION RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION INSTALLATION LAYOUT SUITABILITY FOR A PARTICULAR PURPOSE OR DESIGN OF SUCH PRODUCTS GSI SHALL NOT BE LIABLE FOR ANY DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION LOSS OF ANTICIPATED PROFITS OR BENEFITS PURCHASER S SOLE AND EXCLUSIVE REMEDY IS AS SET FORTH IN THE LIMITED WARRANTY EXPRESSED ABOVE WHICH SHALL NOT EXCEED THE AMOUNT PAID FOR THE PRODUCT PURCHASED THIS WARRANTY IS NOT TRANSFERABLE AND APPLIES ONLY TO THE ORIGINAL PURCHASER GSI SHALL HAVE NO OBLIGATION OR RESPONSIBILITY FOR ANY REPRESENTATIONS OR WARRANTIES MADE BY OR ON BEHALF OF ANY DEALER AGENT OR DISTRIBUTOR OF GSI GSI ASSUMES NO RESPONSIBILITY FOR CLAIMS RESULTING FROM ERECTION DEFECTS OR UNAUTHORIZED MODIFICATIONS TO PRODUCTS WHICH IT MANUFACTURED MODIFICATIONS TO PRODUCTS NOT SPECIFICALLY DELINEATED IN THE MANUAL ACCOMPANYING THE EOUIPMENT AT INITIAL SALE WILL NULLIFY THE PRODUCT WARRANTY THAT MIGHT HAVE BEEN OTHERWISE AVAILABLE THE FOREGOING WARRANTY SHALL NOT EXTEND TO PRODUCTS OR PARTS WHICH HAVE BEEN DAMAGED BY NEGLIGENT USE MISUSE ALTERATION OR ACCIDENT THIS WARRANTY EXTENDS SOLELY TO ONLY PRODUCTS MANUFACTURED BY GSI THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED GSI RESE
11. M tra no ur l IEB G pr al SCR ie ee r SR a CONTACTOR iE 1 A Im bl y i a lo 244 6 AMP 106 I Su Lim 244 UN DAD AUGER CS 3 T pu t UNLDAD AUGER Ve a o o 1 2M OVERLOAD e T T F o Q M UNLOAD AUGER MOTOR 17 MTR 108 y Q 2MOL Ho o ele i i oa 4 208 109 F FL L BREAKER CONTROL A 1 TRANSFURNER i 1 HI xl 35i mr Ven i 110 orsae Iw ac 110 VAC B 3 il ZU 2201 1221 110x0 201 r ofo Xt 111 xs 7 Ban ae CIRCUIT BREAKER pa BREAKER LOAD AUGER LOAD AUGER p 1 CONTACTOR OVERLOAD 112 K R ole 1 3M T T T M Q O m 3MOL LOAD AUGER 1 i m MOTOR T G e ub 115 M 3MOL T 1 1 i Gl A d 3EH 114 LOAD AUX AUGER r BREAKER___ LOAD AUX AUGER LOAD AUX AUGER yN 1 CONTACTOR OVERLOAD 115 241 0 o yo T TO T 1 1 O O og AM AMOL 2 LOAD AUX AUGER 3 MTR GE Q e 116 Kr o o f 4M AMIL V il il 1 Q El Did ia Nes 4 ACB 117 UNLOAD AUX AUGER p BREAKER L iw pan AUX AUGER UNLOAD AUX ALGER AK CONTACTOR OVERLOAD 118 1 1 SM O O ele 1 A i Ol l d e SMOL 5 UNLOAD AUX AUGER Ie eni Mig MOTOR i ale e i i SMOL Lo o i t 1 Ol KE 1 1 La ae 4 DCH PNEG 552 100 Series Dryer 9 Schematic Diagram 100 Series 220VAC 3 Phase Power Schematic
12. The dryer fan heater controls featuring Ref Description 1 Pressure Regulator Low Fire Solenoid Adjustment High Pressure Solenoid Low Pressure Solenoid Supply Line Solenoid Cc1 GO N PNEG 552 100 Series Dryer 6 Dryer Start Up Continuous Flow Operation Standard electrical safety practices and codes should be used when working with a dryer Refer to the National Electric Code standard handbook by the National Fire Protection Association A qualified electrician should make all wiring installations A Always disconnect and lock out power before working on or around dryer WARNING Full Start Up Check This start up procedure assumes the following 1 You have read and understand the DRYER OPERATION AND SERVICE MANUAL You have taken special note of all SAFETY PRECAUTIONS All safety shields are in place All meter roll access doors have been opened and all foreign objects have been removed Apre start up check has been performed 2 3 4 5 6 All motors have been checked for proper rotation 7 All heaters have been test fired 8 The fuel has been turned ON at the tank 9 The electric power has been turned ON 0 10 The main disconnect switch on the dryer is ON 11 There is wet grain in the wet holding bin 12 The incoming grain moisture is known 13 Dry grain take away equipment is in place 14 Grain is going to the proper bin 15 All switches have be
13. 140 213 27 12 62 161 132 196 28 13 66 5 150 123 185 29 14 71 5 140 116 172 30 15 76 132 110 161 31 16 81 123 104 150 32 17 86 116 100 140 33 18 91 110 096 132 34 19 96 104 087 123 35 20 100 100 082 116 These are approximate starting points Adjusting the Moisture Control 1 5 on the moisture control will change the output moisture by about 1 Example With 100 set the result is 16 corn but 17 corn is desired Reduce the moisture control setpoint temperature by 5 to 95 This should change the moisture out to about 17 If you want the corn to come out dryer raise the temperature on the moisture control setpoint Four 4 sensors are averaged together for sensing moisture control temperature one 1 on each side of the dryer in the front and one 1 on each side of the dryer in the back They are located about 1 3 of the way up the grain column from the bottom and in from the side about 4 3 Grain temperatures can be monitored by pressing the mode select button 4 The moisture control should stay on HIGH about 50 to 90 of the time There is a broad range that will work It should switch from low to high and back again to maintain the desired moisture A control that does not switch will not maintain an evenly dried grain moisture when the incoming wet grain moisture varies If the metering roll switches to LOW and stays there for long periods of time both the High and Low Speed Potentiome
14. HZ 1D 000 60 22 SEC Y PART HH SECONDARY MIDPOINT GROLINDED IGNETION TRANSFORMER TYPE B12 B47 PRI V ER VR NW PNEG 552 100 Series Dryer 8 Wiring Diagrams 85 91 41Y 144 JEMI 1001 nu DIE NII TILS WNIRELLI I IL UND i 1 1 i I I 1 I 1 1 1 I I I I I Hl I l 8 Eu NE 38 D ismi 1 WEIT m DI WI HIT 00 836 TIN Als l 40 28 EI M4 O y WN LD 0 HOVE i UT wo vg i Bel DID Fm M amp Qe Cir par B pi 1 1 AH A I I S S aer mu mm mn mm Nd mp mm DMS DU 16 5 5 T 000000000 Sj 5600000000 9000000000 T 0 o o o D D D D cC c 00 92 OL 10 9f rg l II 9f OL 60 9f XOVTH Se x OL rO f ALHA de ir I 3 CRT 91 97 OL 61 67 QAN G OI l 91 11 ZN LL H A SSNEGNAP _ _ _ 1 A s a 5 CEN E E MOTIEA L m HDTH T MOTTEA a um TAE po Tddld 1 T ALIHA ENVd 1404 OL SNOTLISNNOI a Leg T EN E HONYNO s mm l o 201708 0 1 NOW Gett OL PNEG 552 100 Series Dryer 8 Wiring Diagrams 80 91 3140 8 184 BENT OT nz imana r xm a a ai a lu xn im ss l I Y 3 EN OD OKU Wu SC T S TI NIE 1 Hu EI SS
15. Out of grain time Unload time No voltage on the orange or grey wires Di and 6 connection points below the ground lugs on the left side of the Upper Terminal Strip will cause this error condition Grain plenum 000 ERROR Temperature high limit Dry time Cool time Load delay Moisture control set point Unload delay N N Plenum temperature set point This Display indicates that the Electronic Plenum Plenum Temperature High Limit has 000 tripped in the software This will reset ERROR automatically when cooled down T t There is no place to check this for voltage 20 as it is software based The Emergency TORT Cooling Mode can be used to cool down the plenum if necessary PNEG 552 100 Series Dryer Dry time Out of grain time Dry time _ m Out of grain time Cool time Unload time Cool time Unload time Figure 4B 5 Dryer Pre Start Checks Before the dryer is filled thoroughly inspect the unit and check the operation of the dryer as follows Inspect the Metering Rolls Figure 5A Asco Safety Shut Off Valve Open all metering roll access doors and inspect each compartment for any bolts nuts or other foreign material that may cause possible jamming of the metering rolls Before attempting to operate the dryer make sure all safety shields are in place CX all bottom clean out and rear access doors are closed and all personnel are CAUTION clear of the dryer Set Control Sw
16. in seguence When the unload cycle is complete the timers will automatically reset to their original settings and start the dryer timer again NOTE f the dryer is empty the burner does not operate The fans cannot create enough static pressure to engage the air switch You will receive a no airflow message To start the dryer when it is low on grain the airflow switches must be turned OFF Switching Dip Switch number eight 8 on the back of the computer control board to ON turns the Air Switch OFF A Dip switch number eight 8 must be turned back to the OFF position after this WARNING fest is complete or no air testing will occur PNEG 552 100 Series Dryer 26 5 Dryer Pre Start Checks Dryer Shut Down To shut down the dryer first close the fuel supply valve at the tank or valve along the fuel line If the burner is operating let the dryer run out of fuel and it will shut down automatically due to loss of flame Close the fuel valve at the dryer and press the dryer power stop button Turn OFF the safety disconnect handle on the front of the power box and turn OFF the main power to the dryer Stopping Dryer Operation To stop operation of the dryer push the dryer power stop button The fan burner and all augers will stop immediately Emergency Stop In case of emergency push the emergency stop button located at the bottom of the Upper Control Box See Page 6 Figure 5C
17. mechanical high limits located in each of the two grain columns has been tripped due to heat exceeding their 200 setpoint or one or both have failed They will automatically reset when the temperature returns below 200 NOTE 7he emergency cooling feature will not function if either or both of these mechanical sensors are tripped PNEG 552 100 Series Dryer 4 Error Conditions peunooo sey aDleydsip JeaJ Jo PEOH AO JOJOW wojure ou no uujJ luui uBiu 6uisnou unuejd oden 5 ueeJos UO ou Jo euo jeu sepeoipul siU Uonipuoo 1011 siU esneo M pieoq yndino ndu ayy uo 9 Lf uo aBeyon ON A yes einsseud seb priooJe N UONIPUOI SI esneo WA pueog indjnojNndu eu uo 7 p Uo eBeyoA oN A yes 40 5 Joen Uoneoiunuuoo so ABU 49jseu pue pueoq ndino ndul eJnjiej uonpeoiunuiuioo pJeoq 3ndino indu punoJ6 o peuous si Ajddns 110A ZL BENOA INJ jojes ON dy o peuous SI Josues 4eupie JO punoJ6 OY o p Hous s Su OG HOA L eu JO J nooo OSIE Aew y S lod uaamjeq uedo jou JO SIS J jse eqd JojsiseJ jsejjeg peq e Aq pesneo og osje Aew 10413 ojuoo Aq SI Jo SSO JUN UEL umop jnus jou JIM Z 40412 piou jos uedo y n s Aq pesneo YI JSOW si 10414 su s 2 punol Ov 0 peuous qoid aw
18. metering roll potentiometer NOTE f the unload auxiliary motor overload relay is being utilized in the dryer control panel the same switch will also control the operation of the auxiliary equipment Low Speed Metering Roll Potentiometer Use this to adjust the low speed of the metering roll when the 2 Speed automatic moisture control feature of the dryer is in use High Speed Metering Roll Potentiometer Use this to Set the high speed of the metering roll when the 2 Speed automatic moisture control feature of the dryer is utilized Set the speed of the metering rolls when the 1 Speed automatic moisture control feature of the dryer is utilized Set the speed of the metering rolls during continuous flow operation when the moisture control is not used Set the rate of grain discharge from the dryer during the unload cycle of staged batch dryer operation Dryer Power Start Switch This switch starts and operates the dryer based on switch settings If other switch settings are in the OFF position individual dryer components can be operated by turning the drying mode switch to continuous flow pressing the dryer power start button and then turning on the desired dryer component PNEG 552 100 Series Dryer 3 Dryer Control Panel Dryer Power Stop Switch This switch stops all dryer functions If an automatic dryer shut down occurs first determine and correct the cause of the shut down Press the dryer power stop button to
19. o Ajeoneuojne IM 3 AeAIp eut uo sinou ejoi ey oi fejdsip eui se6ueuo uoyng eseaioul eu Buisseiq aaau unoy eui einpeieduieg uinuejd pue urei6 senje Jeu uoe yeg Aejdsip eu 2 660 Wan uopng ees y uisseud 109jes epoui eu Buisn enjeA meu y sideooe Ajeomeuiopne Jejnduoo eu pebueuo u q seu eJnpeiedue Jo aun eu Joy anyes d l Jo au juoseud ey o ueuo ol suonnq eseeJoep pue eseeuoul eu esp ul Jo eu ey e ueuo Ol ysim no yeu unieiDodd y 10 uogng eui ssalg L seinieioduio pue s ejop oui siouin Bum s suoyon1su uiuiurei Dog Figure 3A Grain Dryer Control Panel PNEG 552 100 Series Dryer 3 Dryer Control Panel Dryer Control Panel Featuring the 100 Series Control System The control panel provides easy access to gauges and controls The Competitor Series 2000 Control System is a computerized control system that gives instant information regarding dryer operation Moisture Control The Series 2000 Dryer has a built in moisture control It controls the moisture level of discharged grain by sensing grain column temperature Moisture Control Switch This switch turns the power ON or OFF to the moisture control The light beside the switch is illuminated when the grain column temperature is below the moisture control setpoint Control Power Switch The power to the Competit
20. previous instructions PNEG 552 100 Series Dryer 7 Service Heater Parts Removal and Installation Most of the heater parts can be removed by identifying attached wiring and disconnecting the obvious mounting parts 1 Flame sensor Disconnect the wire connector and unscrew the flame sensor out of its mounting bracket See Figure 7E IMPORTANT Flame sensor has voltage present Turn OFF main disconnect before removing or adjusting 2 Gas solenoid valve coil Unsnap either the plastic cap or the metal clip on the gas valve and slide the housing and coil off the valve stem and body Do not energize the coil when it is removed as the coil may become damaged due to excessive current flow See Figure 7E 3 Regulator and gas solenoid valve s The gas regulator and solenoid valve s are directional and must be connected as indicated by the markings near the port openings Make sure gas is shut OFF and purged from the system before removing parts See Figure 7E NOTE When installing a liquid gas solenoid valve on LP models do not overtighten the connection into the inlet side as the inlet orifice may become partially blocked Figure 7E 4 Main Gas Orifice With fuel shut OFF and gas purged from system See Figure 7E proceed as follows a Disconnect the plumbing support brackets from the pipetrain b Disconnect gas solenoid valve coils Be sure to mark which one goes where c Lift pipe with orifice sol
21. reset the dryer before restarting 100 Series Control System The 100 Series System controls all timing functions and safety circuit checks It is designed to simplify dryer operation by providing messages and warnings on its Liquid Crystal Display LCD Turning ON the 100 Series Control System Turn the CONTROL POWER switch to ON The monitor will display GSI and the current software version number Programming Instructions Setting timers time delays and temperatures Press the button for Ihe nat Using the mode select Pressing the mode select button will toggle the MOISTURE CONTROL LIGHT ON peto oe o kaptay between Emer values grain temperature and plenum temperature Checking the hour meter Prossng tha increase button changes the dpi to the total hours on the dryer t will automatically return to the main screen after the bution is released CONTROL POWER DRYING MODE LOAD AUGER HEATER DRYER POWER 1 SPEED 2 SPEED STAGED CONT BATCH FLOW METERING ROLL SPEED OUTSIDE LIGHT OFF AUTO O Figure 3B 100 Series Dryer Control Panel PNEG 552 100 Series Dryer 3 Dryer Control Panel Setting the Dry Cool Unload and Out of Grain Timers These switches are used to set the drying cycle times in the staged batch drying mode only The drying mode switch must be in the staged batch position Out of grain sets the length of time the dryer will run befor
22. 0 35 0 20 0 100 0 90 0 0 10 0 110 0 110 0 18 0 10 0 These are approximate starting points Set unload meter roll high speed setting to 999 If unload equipment cannot adequately keep up lower the speed setting and add time to the unload timer setting to completely unload the batch In full heat mode the time added to the unload timer will need to be subtracted from the dry timer If fan is on AUTO and does not run during unload set cool timer to 25 minutes New unload time calculation present unload time new dial setting 1000 Example 13 75 11 800 1000 Starting the Dryer This start up procedure is for a cold start on wet grain for continuous flow operation 1 Turn on the LP gas tank and any other manual gas valve at this time Set the MAXON or FAST ACTION HAND VALVE if so equipped on the incoming fuel line to the ON position Make sure the MOISTURE CONTROL switch is in the OFF position Turn the FAN switch to the ON position Adjust the AIR PRESSURE SWITCH if necessary a O N Turn the HEATER switch to the ON position The heater will purge for about 10 seconds then ignite If flame is detected the dryer will run if not a loss of flame error will occur If this happens check gas supply and all valves in the fuel line to make sure they are ON and attempt again PNEG 552 100 Series Dryer 6 Dryer Start Up Adjusting the Temperature
23. APOR HIGH TEMPERATURE message Display shows LOSS OF FLAME message The LP gas vapor temperature sensor located in the gas train downstream from the vaporizer has opened indicating that the vaporizer is running too hot and must be readjusted This control is a 200 F limit which automatically resets when it cools The flame sensor has failed to detect a burner flame indicating that the burner has failed to light There is a problem with the flame sensing circuitry or the dryer is not getting burner fuel PNEG 552 100 Series Dryer 10 Troubleshooting Problem Possible Cause Display shows HOUSING HIGH TEMPERATURE message The temperature high limit located on the fan burner housing has opened indicating an over temperature condition has occurred towards the rear of the fan heater housing This control is a 200 F limit control that must be manually reset Display shows REAR DISCHARGE WARNING message The cover on the grain discharge box has opened indicating that grain is backing up into the discharge box Display shows OUT OF GRAIN message The dryer has run low on grain and the out of grain timer has timed out shutting the dryer down The unload auger will then clean out the dryer if the unload switch is ON during continuous flow operation Check the out of grain timer setting and if necessary adjust Also before restarting inspect load equipment for possib
24. L O fe a Mr Dy n y 5 f i me DD I YW IND NI Tor sr A SS es E Ss c J ILIM Ce CAN 20 9 3E dE Au SE 12 LD H 212 H JE TAINO SYN SION tedi H T ya GEM M T0 3Y m l i i Lo T yun O n n 50 97 OL 10 97 YB LI O OL vO ET LHM 91 07 DI 61 EP 38 ALO NU SNOLLISNNOD UT mv SHAT BIND D E i o m o c a o c o Been LL 0 o i o o e o YT PNEG 552 100 Series Dryer 8 Wiring Diagrams 100 Series Lower Back Panel Wiring 80 91 1140 AY L d WO 001 ANI SOON WI Sr
25. ME OUT DRY TIME 2 COOL TIME OUT OF GRAIN TIME UNLOAD TIME PROGRAM HOURS HOURS TIMERS X 1000 PROGRAM PROGRAM MODE SELECT TEMPERATURES DELAYS TIMERS PLENUM TEMP GRAIN TEMP Figure 3D 100 Series Control System Monitoring Grain Temperatures Plenum Temperature or Timers Use the mode select to decide which of the modes you want to view Checking the Hour Meter Press the UP arrow key and the total hours on the machine are displayed along with the batch count and minutes since the last shut down in five 5 successive screens The screens appear in the following order Hours X 100 balance of hours balance of minutes batch count and minutes since last shut down For example five 5 screens displaying 5 23 12 144 188 would be 523 Hours 12 minutes on the Hour Meter Batch Count at 144 and 188 minutes since the last shut down PNEG 552 100 Series Dryer 3 Dryer Control Panel Special Features Dual Batch Drying Temperature Mode To greatly improve quality in batch mode reduce the plenum temperature at the end of the drying cycle This will reduce peak temperature that the grain on the inside of the column attains and thereby reduce over drying Enter dual batch drying temperature mode by switching ON dip switch number four 4 the fourth switch from the bottom on the dip switches located inside the control box on the back of the computer control board This enables two plenum and t
26. MTR MOTOR 119 i o l PNEG 552 100 Series Dryer 9 Schematic Diagram 100 Series 440VAC 3 Phase Power Schematic ES Lz ES GND Sak eessieress eat 1 MAIN 1 DISCONNECT 1 o D D 1 1 1 101 y m 102 TOP FAN BREAKER FAN FAN r 3 a CONTACTOR OVERLOAD 103 1 A 1N 7 sd ba 1 il Pans 9 MU FAN 1510 elei ab os MOTOR LN m 1MDL 104 tio o o yoz MU n H ICB ala ener de 4 SCR 105 CIRCUIT BREAKER m P 1 CONTACTOR SCR AS Ee TRANSFORMER o 0 o 4 l I ios i 6 AMP O e H m ul mt TN 1 200 UNLOAD ALGER J o 20 00 UNLOAD AUGER 107 y OVERLOAD 1 sg UNLOAD AUGER MOTOR sei 2 308 109 LIRCULT BREAKER CONTROL r 1 TRANSFORMER 110 Ba LLO VAE l 1 I 110x0 S 8 o o ACI En 111 sua 4 AMP Log ALGER CIRCUIT BREAKER 25 LOAD AUGER LOAD ALIGER k CONTACTOR OVERLOAD 112 AM 4MOL KS ole a ls IN i AM LOAD AUGER Qo AY MOTOR ale 113 AM 4MDL Y ola J ACB 114 LOAD AUX AUGER r BREAREB LOAD ALIX AUGER LOAD AUX AUGER CONTACTOR OVERLOAD ns Ge y ai k i alo ST Soo E LOAD AUX AUGER MOTOR 116 ZN i SM SM Go TERAS 7 sce 117 UNLOAD AUX AUGER BREAKER A UNLOAD AUX AUGER UNLOAD ALX AUGER a CONTACTOR OVERLOAD 118
27. ONER 3716 5 15 217 37217 36 17 ERAIN NEUTRA BF SENSR e e 37 18 J6 18 218 FLAVE D a e 1719 J6 19 RAE PRIF GU e 213 37 20 J6 20 220 PNEG 552 100 Series Dryer 9 Schematic Diagram 100 Series Control Schematic Continued 221 UNLOAD COMPETITOR 7 222 1 0 BOARD KE UNLOAD AUX MOTOR 223 MAXON GAS 224 FAN VALVE SWITCHS N Z FLAME 225 HIF F RAE eso DETECT LIGHT BURNER 226 PRIF F AIR SY lean AIRFLUM UNLOAD z EIGHT SWITCH f 227 MISIE CINRIL morsture Qu LOAD LOAD MOTOR 229 MODE P SVITCH Loan Aux P MOTOR AC NEUTRAL ren LOAD 230 AA uem HI d LIMIT MOISTURE 231 CONTROL SWITCH 232 MERCDID SAFETY USER 233 _ SAFETY 234 12VDC 235 236 237 238 SCR2 7225 239 240 PNEG 552 100 Series Dryer 9 Schematic Diagram 100 Series Control Schematic Continued SCR BOARD PNEG 552 100 Series Dryer 9 Schematic Diagram 100 Series 220 Volt 1 Phase Power Schematic EX L2 GNO a 1 MAIN DISCONNECT I 1 I D E 22OVAC 1 PHASE DIST 102 BLOCK TOP FAN BREAKER FAN FAN Sj 1 CONTACTOR OVERLOAD 103 d 1 1M rT o I il 3 a a 1 FAN JO 1 1 a la HIR Y MOTOR l 1M L 104 1 J
28. OO O LS 141 S38NW4 A0ZZ N3V3Md NIVIA 49018 NOILNGINLSIC INdNI OVNI 3 Szld45 d llL4diNOO ASVHd F19NIS A0cc 0002 SalM4S PNEG 552 100 Series Dryer 9 Schematic Diagram 100 Series Control Schematic 207 230 Hot WEE fib Neutral 201 E CONTROL EMERGENCY POWER POWER ON ren S o DFF 7 202 O Q P o ony 9 POWER ON e Z DUTSIDE SHETCH N 7 293 ON DUTSIDE o 0 LIGHT MONITOR 204 224 Fen START LIGHT 205 PA N COMPETITOR Reo CF MODE DRYER LIGHT 206 CONTROL BOARD DRE LE AA GRAINY SVITCH4 o o 22 PLENUM i Bak mman e ju BATCH RED BATCH MODE SWITCH n 621 25 Pg LIGHT HOUSING 207 HOUSING MUSING HI LINT e AL NEUTRAL SWITCH J7 02 J6 02 AR FER SORE a FAN STARTER FAN DTSCH S MOTOR 208 J7 03 J6 03 L 20 am oW MOTOR M NE SR e 2 Fo 85 04 209 FILL FIL VIT 4 o e e SVITC OF Fs dns START TIT mmm IGNITION o TRANSFORMER 47 08 J6 06 210 STOP e AC emm o 37 07 J6 07 ET 12V0C e J7 08 5 08 e mma m j SCR p Nm CONTACTOR 212 m SWITCH NR WHO CM s 37 10 J8 10 as HR TOC J7211 JB 11 les e GO SOLENOID J7 12 J6 12 214 ee e e el J7 13 J6 13 e e ME j CYCLE 215 x ez at SOLENDID 1avoc AC NEUTRAL J7 15 8 15 218 TA0 BOARD P
29. RVES THE RIGHT TO MAKE DESIGN OR SPECIFICATION CHANGES AT ANY TIME PRIOR TO INSTALLATION PURCHASER HAS THE RESPONSIBILITY TO COMPLY WITH ALL FEDERAL STATE AND LOCAL CODES WHICH MAY APPLY TO THE LOCATION AND INSTALLATION OF PRODUCTS MANUFACTURED OR SOLD BY GSI PHLEGAL 1832020 v1 139LG01 DOC revised December 2005 PNEG 552 100 Series Dryer This equipment shall be installed in accordance with the current installation codes and applicable regulations which should be carefully followedin all cases Authorities having jurisdiction should be consulted before installations are made GSI GROUP GSI Group 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4421 Fax 1 217 226 4420 www gsiag com Copyright 2007 by GSI Group Printed in the USA
30. T BE MANUALLY RESET Rear Discharge Warning The lid on the grain discharge box has opened indicating that grain is not being taken away fast enough at the discharge box Motor Overload One of the thermal overloads on either the fan load unload or auxiliary motors has opened indicating an over current condition The overloads MUST BE MANUALLY RESET Grain High Temperature An over temperature condition has occurred in one of the grain columns causing the control to shut down the dryer This control is set at 2109F and automatically resets itself when cool Out of Grain The dryer has run low on grain and the out of grain timer has timed out shutting the dryer down The unload auger will clean out the dryer if in continuous flow operation Plenum High Temperature An over temperature condition has occurred inside the dryer plenum This control is a 300 F limit and automatically resets itself when cool See Emergency Cooling Mode on Page 18 No Airflow The contacts in the air switch have opened due to insufficient airflow for the burner to operate The contacts in the air switch have opened due to the fan not turning or the air switch may need adjusting Air The air switch contacts have closed prior to the fan starting indicating a free wheeling blade or improper setting of the air switch Grain and Plenum High Temperature Both at Same Time If both of these warnings appear on the screen at the same time one of the two
31. VE A PRESSURE REGULATOR MOUNTED TO IT If using natural gas make sure an adeguate supply is available If using LP gas slowly open the main fuel supply valve at the tank If using natural gas turn ON the valve along the supply line Then open the electronic shut off valve Asco valve if so eguipped or open the manual shut off valve on the dryer to allow fuel flow to the dryer Inspect all gas lines and connections for possible leaks ANY GAS LEAKS NEED TO BE FIXED IMMEDIATELY Load Auger With the grain supply shut off guickly bump the load auger switch to MANUAL and see if the load auger rotates clockwise as viewed from the drive end or counterclockwise if the dryer is a front load model If the wet grain supply auxiliary is wired to the dryer it should also rotate in the correct direction at this time Turn the load auger switch to the AUTO position The top auger and wet grain supply auxiliary should run for one minute and then the dryer will shut down leaving the safety shut down message out of grain displayed Press the dryer power stop button to reset the panel then press the start button to resume operation 1 Speed Operation To check 1 Speed operation place the unload switch in the 1 Speed setting Turn the high speed metering roll dial up until the metering rolls start rotating The bottom auger should rotate counterclockwise as viewed from the drive end The metering roll drive motor should rotate clockwise as viewed from t
32. ams for test locations o o o m Control power is ON Drying mode light OFF This indicates control power is present at input output board but no power is being transferred through the UO board 1 Power interruption Incoming power to the dryer has been interrupted The display screen will show the date and time if this has occurred once power has returned 2 Display not finished initial setup The monitor will display a copyright message and model number total running time in hours and minutes and then the current date and time To activate the controller press the reset button 3 Input output board The input output board has developed a problem that reguires its replacement No display on LCD screen Check for a defective power switch Check wiring between fuses and input output board Check for 120 volts AC between points J6 02 and AC 1 The display may have a malfunction reguiring its replacement Control power light is ON drying mode light is ON load auger fan heater unload auger does not operate Press the dryer power start button Refer to the problem listed for load auger fan heater and unload auger in the following sections N Alb om Display shows MOTOR OVERLOAD message The thermal overload on the fan motor load motor unload motor or an auxiliary motor has opened indicating an overloaded motor The overloads must be manually reset Display shows V
33. any of the selected switches are improperly positioned for staged batch drying the display will indicate the proper switch position and will not allow the dryer to operate until the position of the switch is corrected 9 The fan will start and airflow is checked PNEG 552 100 Series Dryer 6 Dryer Start Up After purging for approximately 10 seconds the heater will fire For information concerning heater adjustment see Dryer Pre Start Checks on Page 22 11 If the dryer is being operated in all heat move the FAN switch to the ON position In this position the fan will run continuously during the dry cool and unload stages of the staged batch operation If the dryer is being operated in the dry and cool mode the preferred position for the FAN switch is the ON position so the fan will run continuously and continue to cool the grain during the unload operation If desired the fan can be turned OFF during the unload cycle of the dry cool unload seguence by turning the FAN switch to AUTO 12 If the dryer is being operated in all heat move the HEATER switch to ON The burner will operate whenever the fan is operating If the dryer is being used in dry and cool turn the HEATER switch to AUTO and the burner will automatically shut down during the cooling and unloading cycles 13 The bottom auger and metering rolls will start automatically during the unload cycle of the dry cool unload mode along with any grain ha
34. ath Threaded Bushing Holes The threaded holes within the bushing are provided for disassembly purposes only Do not attempt to use these holes for reassembly They do not allow the parts to lock onto the shaft and thereby create a very hazardous operating condition Clearance Holes When reassembling parts the cap screws must be installed through the untapped clearance holes as shown This will cause the propeller to be pulled forward onto the tapered bushing thus locking the parts securely onto the motor shaft See Figure 7B When fan servicing reguires removal and installation of the propeller make sure the propeller is removed and reinstalled properly 1 Lock out the fan power supply remove the fan guard and the venturi as reguired on some models 2 Remove the three cap screws from the clearance holes in the taper lock bushing Capscrews installed through threaded holes of bushing Key Fan hub Split taper bushing Figure 7B Fan Blade Installation PNEG 552 100 Series Dryer 7 Service Capscrews installed through threaded holes of bushing Fan hub Split taper bushing Figure 7C Fan Blade Removal 3 Install two grade 5 cap screws into the threaded holes in bushing and turn them by hand until they bottom against the front surface of the propeller 4 Block propeller to prevent it from turning and gradually turn the cap screws up to 1 4 turn at a time until the prope
35. atures 3 If the burner continues to operate on high fire check the high fire gas solenoid valve for a stuck or blocked open condition or for reversed gas pipe connections The solenoid valve must not allow gas flow when its coil is not energized Burner operates but does not cycle from low fire to high fire 1 Check for an excessive low fire gas pressure setting Observe pressure setting shown on gauge and compare reading with recommended low pressure settings listed in this manual Readjust low fire setting on flow control valve if necessary 2 Check for improperly adjusted or defective High Low Fire thermostat control Temporarily increase the temperature setting If the heater will still not cycle check for problem in the control wire connections The control wires should be connected to terminals R and B of the thermostat so the switch will open upon temperature rise If the burner will cycle with these two wires connected together the thermostat is faulty 3 Check for improperly connected or faulty high fire gas vapor solenoid valve Correct any poor connections or defective wiring If wiring appears proper problem may be caused by a burned out valve coil or defective valve Replace high fire solenoid valve or its coil if defective If the Load and Unload Auger does not start but everything else seems to work Check the fuse on the 1 O Board in the back of the lower control Box PNEG 552 100 Seri
36. bility of the owner operator to inform anyone operating or working in the area of this equipment of these safety guidelines To help you recognize this information we use the symbols that are defined below Please read the manual and pay attention to these sections Failure to read this manual and its safety instructions is a misuse of the equipment and may lead to serious injury or death This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently hazardous situation which DAN if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which WARN N G if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which CAU T O N if not avoided may result in minor or moderate injury CAUTION used without the safety alert symbol indicates a CAU TIO N potentially hazardous situation which if not avoided may result in property damage N OTE NOTE indicates information about the equipment that you should pay special attention WARNING BE ALERT Personnel operating or working around electric fans should read this manual This manual must be delivered with the equipment to its owner Failure to read this manual and its safety instructions is a misuse of the equipment PNEG 552 100 S
37. d no less than 3 4 in diameter Failure to follow installation instructions may result in property damage DC 388 Dryer must be towed empty and in accordance with state and provincial regulations Decal DC 338 Decal DC 388 is located on the hitch tongue Decal DC 1249 Decal DC 1249 is located on the hitch tongue 2 Safety Alert Decals 3 Dryer Control Panel 03398 03345 MOT Olle 03345 TOY 9NIH2 L3W O HOLWa SnOnNLINOO daevis 03348 2 o qaads L 340 1 15 H3MOd H3AHG avo INN O olny Onun 1NI0d13S 3A08V JYNLSIOW S HYHOS Q N3HM NO LHO IOHLNOO 4HnLS1OH Ule p Jo A nlul snoH s asnes Aew BeHoA snopiezey VM S Jo uol 199dsul TE J1amod nox90 pue Ho WNL iHdO NVO V ANO 11242 AHA HOLvVe NY4 N3HM ONINA K STOTNL NOO NO HELVAH NO H3LV3H SNAH NY NO olny NO O O H3LV3H dial niya DP SAVT30 S3univu3dAB D 193138 300 WYHOOHd WYH9OHd O 0001 X SHAWL SYNOH SYNDH Wed IL GVOINN IAIL 1009 JWL Mun 304007 N SIL AMO Tnaryan uouus uo1on Ween pi FC m E Hl avus 0 H HE ool xsun GD8YNOGG mowHvon v pom ANIOd 145 1 mau V Av 130 avo wn 1M k 145 TOHINOO JHALSIOAL Av 130 qvo1 NO o 440 1H9 1 aqis1no NL mo H LVE NO OLNV INOO daovis 340 HOLWA O O O H39nv avol 30M 5NIAHG peseojeJ si Uojjng el Jeye ueeuos urew y
38. e peuous si Josuas YO JeujeBo peuoys ase speo Josues unuejd nou uedo 440 spee uloq Jo sup uado si Josues aunjeJadua unuejd D HOUS si Josues YO peuous ale speo Josues uieJc uedo 440 ae spe yog Jo euo uedo Josues Buluuni si JS Jp e luw uojeq O MOY Snonunuoo WO PSYIIMS Joen Figure 4A PNEG 552 100 Series Dryer 4 Error Conditions This display indicates the computer has stopped sensing flame This can be caused from running out of fuel flame probe out of adjustment or the burner failed to ignite during ignition sequence This display indicates that the grain discharge switch located in the rear of the dryer was activated This is caused by the grain exiting the dryer not being taken away fast enough or someone has opened the discharge lid No voltage on J7 03 will also cause this error condition This display indicates that a motor overload relay has tripped This relay must be reset manually Before resetting turn OFF all power sources Open the upper control box door push in the red levers on all of the overload relays Notice if one of the levers clicks Load delay Unload delay Dry time Cool time Load delay Unload delay Dry time Cool time Load delay Unload delay Plenum temperature set point 000 ERROR Flame out Out of grai
39. e UNLOAD switch turns the metering rolls and discharge auger ON or OFF and selects the operation of the metering rolls Inthe 2 Speed position if the MOISTURE CONTROL switch is ON and the drying mode switch is turned to continuous flow the metering roll speed will alternate between the high speed metering roll potentiometer setting and the low speed metering roll potentiometer setting depending on the control signal from the moisture control thermostat The discharge auger will operate continuously Inthe 1 Speed position if the MOISTURE CONTROL switch is ON and the drying mode switch is turned to continuous flow the metering roll speed will operate at the high speed metering roll potentiometer setting or turn off depending on the control signal from the moisture control thermostat The discharge auger will operate whenever the metering rolls are operating In both the 1 Speed and the 2 Speed position if the MOISTURE CONTROL switch is OFF and the drying mode switch is turned to continuous flow the metering roll speed can be manually controlled by adjusting the high speed metering roll potentiometer The discharge auger will operate continuously If the drying mode switch is turned to staged batch the UNLOAD switch should be set to the 1 Speed position The discharge auger and metering rolls will only operate during the unload cycle of the staged batch operation and the speed of the metering rolls is adjusted using the high speed
40. e jam by sound Once the location is determined the roll can be reached from the inside of the dryer by opening the hinged auger cover panel in that specific section Loosen the two 2 nuts on the bolts holding the meter roll shield also called meter roll strike off Plate in the past and lift the shield to access the area above and behind the meter roll If removing all the grain from this column is necessary lift the shield to its highest position and tighten the nuts FROM OUTSIDE THE DRYER manually run the Unload Auger with the MOISTURE CONTROL switch turned OFF and the high speed potentiometer set to 000 This will allow the grain from that column alone to pass over the metering roll and into the auger emptying that column for complete access to the meter roll Never run the unload auger or the metering rolls with anyone inside the dryer DANGER PNEG 552 100 Series Dryer 8 Wiring Diagrams 100 Series Single Fan Wiring to Control Box ET BALE IHd c FAA Nd Til NAH DL JIVD UN dd BOOKS DCH Ski Je gt 38 A21 80 L1 NI AU UH JLTHN WALAN 106 3 IRCH 20v E LIS NIWECL D DII ym LHA NaLTEN 380 2171 HI NDTIS 38080 JAV B NILLINJTIT 3 3 14 WI MIT ENEE WH Al DNI NIT OI WH 61 L7 023 FAM NILIINI 3yLA HII NOTITS CODE DAE PRE A SEC 93
41. e shutting down when the load switch is in the AUTO position To change the setting of these timers follow these instructions 1 Press the PROGRAM TIMERS button until the carrot See Figure 3C is above the timer you want to modify 2 Use the UP and DOWN arrow keys to change from the present time to the desired setting The new time is automatically accepted 3 Keep pressing the PROGRAM TIMERS button until the carrot disappears or press the mode select button once to exit During the operation the remaining time on each timer is displayed on the screen If the power goes out or if the dryer is stopped these times are saved by the controller When the dryer is restarted the timers will continue timing down The timers will return to their initial settings by pressing and holding the stop button for 5 seconds ys CARROT HILOSPEED A A A A NO AIRFLOW DISCHARGE HRS X 100 GRAIN LO FLAME 1 CH r F PLENUM HI FLAME j r1 C HOUSING zem em VAPOR PURGE MOTOR ERROR TEMP HI LIMIT OVERLOAD Y Y Y Y FLAME OUT Figure 3C Dryer LCD Display Setting the Load and Unload Delays The load delay is used to delay the starting of the load auger when the dryer is unloading to prevent the load auger from starting and stopping too often The unload delay is used to control the amount of time the unload auger runs after the metering rolls stop to allow for auger clean out 1 Press the PROGRAM DELAYS button unti
42. en set to the OFF position 16 The load tilt switch box is installed with the side stamped up in the UP position Filling the Dryer 1 Turn the CONTROL POWER switch to ON 2 Turn the drying mode switch to CONTINUOUS FLOW 3 Make sure the FAN BURNER and UNLOAD switches are in the OFF position 4 Push the DRYER POWER START switch 5 Turn the LOAD AUGER switch to the MANUAL position to fill the dryer The load auger should start and run until the dryer is full then shut off automatically If the switch is set to the AUTO position the dryer will shut down each time the out of grain timer times out and will have to be restarted 6 When the dryer has filled turn the LOAD AUGER switch to the AUTO position PNEG 552 100 Series Dryer 6 Dryer Start Up Staged Batch Operation 1 Turn the CONTROL POWER switch to ON 2 With load unload fan and burner turned OFF turn the drying mode switch to continuous then push the dryer power start switch to arm the safety circuit Turn the LOAD switch to ON and Fill the dryer with grain The load auger will stop when full if the LOAD TILT Switch is installed and set properly 3 Turn the drying mode switch to staged batch 4 Open the main fuel supply valve on the tank if using LP gas or the valve in the fuel supply line if using natural gas Turn ON the electric shut off Maxon valve if so equipped or open the manual shut off valve to allow fuel flow to the dryer 5 Set switches to t
43. enoid valve and other parts attached straight up and remove from fan heater housing Orifice and other parts can now be removed from pipe train if desired PNEG 552 100 Series Dryer 7 Service 5 Reassemble To reassemble parts See Figure 7E reverse the disassembly procedure and check the following a Make sure all parts are thoroughly cleaned and open b Use a dependable brand of high temperature pipe caulking compound when assembling gas connections Apply only a light coating onto male threaded end of fittings c Solenoid valves and gas regulators are directional and must be properly installed Do not attempt to connect gas solenoid valve by applying force to the valve core stem as it may ruin the unit d Make sure all electrical wires are properly connected Refer to Wiring Diagrams Figure 7E shows 1 Gas Solenoid Valve Coils 2 Gas Regulator 3 Gas Solenoid Valves Metering Roll Servicing Figure 7F Meter Roll Motor and Speed Reducer Gear Box for the Metering Rolls This dryer is equipped with SCR silicon controlled rectifier metering roll drive assembly The metering rolls are driven by a separate DC type electric motor The speed of the motor is variable and is controlled by an electric SCR control within the main control box See Figure 7F Main Controls 1 SCR speed control The control unit dial on the front of the control box regulates the speed of the DC motor which drives the meterin
44. er located on the front of the power panel Turn OFF the main power supply to the dryer 17 In case of an emergency press the dryer power stop button The burner fan and all augers will stop immediately PNEG 552 100 Series Dryer 6 Dryer Start Up 100 Series Batch Timer Settings Full Heat Dry and Cool Fan and Burner Switches on MANUAL Fans on MANUAL Burners on AUTO Initial Moisture Approx Dry Cool Unload Approx Dry Cool Unload Moisture 96 Removed pts Dry Time min min min min Dry Time min min min min 17 0 2 0 16 0 6 0 0 10 0 18 0 18 0 18 0 10 0 18 0 3 0 21 0 11 0 0 10 0 24 0 24 0 18 0 10 0 19 0 4 0 26 0 16 0 0 10 0 30 0 30 0 18 0 10 0 20 0 5 0 31 5 21 5 0 10 0 35 0 35 0 18 0 10 0 21 0 6 0 37 0 27 0 0 10 0 40 0 40 0 18 0 10 0 22 0 7 0 41 5 31 5 0 10 0 45 0 45 0 18 0 10 0 23 0 8 0 47 0 37 0 0 10 0 50 0 50 0 18 0 10 0 24 0 9 0 51 0 47 0 0 10 0 55 0 55 0 18 0 10 0 25 0 10 0 54 0 44 0 0 10 0 60 0 60 0 18 0 10 0 26 0 11 0 58 0 48 0 0 10 0 65 0 65 0 18 0 10 0 27 0 12 0 62 0 52 0 0 10 0 70 0 70 0 18 0 10 0 28 0 13 0 66 5 56 5 0 10 0 75 0 75 0 18 0 10 0 29 0 14 0 71 5 61 5 0 10 0 80 0 80 0 18 0 10 0 30 0 15 0 76 0 66 0 0 10 0 85 0 85 0 18 0 10 0 31 0 16 0 81 0 71 0 0 10 0 90 0 90 0 18 0 10 0 32 0 17 0 86 0 76 0 0 10 0 95 0 95 0 18 0 10 0 33 0 18 0 91 0 81 0 0 10 0 100 0 100 0 18 0 10 0 34 0 19 0 96 0 86 0 0 10 0 105 0 105 0 18 0 10
45. eries Dryer 1 Safety Dryer Operation Thank you for choosing a GSI product It is designed to give excellent performance and service for many years This manual describes the operation and service for all standard 100 Series single fan grain dryers These models are available for liquid propane or natural gas fuel supply with either single phase 230 volt or three phase 220 or 440 volt electrical power Our foremost concern is your safety and the safety of others associated with this equipment We want to keep you as a customer This manual is to help you understand safe operating procedures and some problems which may be encountered by the operator and other personnel As owner and or operator it is your responsibility to know what requirements hazards and precautions exist and to inform all personnel associated with the equipment or in the area Safety precautions may be required from the personnel Avoid any alterations to the equipment Such alterations may produce a very dangerous situation where SERIOUS INJURY or DEATH may occur This equipment shall be installed in accordance with the current installation codes and applicable regulations which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made Emergency Stop The emergency stop switch is located on the upper control box on the door Pushing the emergency stop switch will interrupt the control power a
46. es Dryer 11 FAQs How much gas pressure is needed See Step 4 on Page 31 in the Adjusting the Temperature section How often should the burner cycle See Step 5 on Page 31 in the Adjusting the Temperature section How often do I make speed adjustments See Step 4 on Page 33 in the Adjusting the Moisture Control section How do I set the moisture control See Step 1 on Page 33 in the Adjusting the Moisture Control Section PNEG 552 100 Series Dryer NOTES PNEG 552 100 Series Dryer 12 Warranty The GSI Group Warranty THE GSI GROUP GSI WARRANTS ALL PRODUCTS WHICH IT MANUFACTURES TO BE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDITIONS FOR A PERIOD OF 12 MONTHS AFTER RETAIL SALE TO THE ORIGINAL END USER THE PURCHASER S SOLE REMEDY AND GSI S ONLY OBLIGATION SHALL BE TO REPAIR OR REPLACE AT GSI S OPTION AND EXPENSE PRODUCTS THAT IN GSI S SOLE JUDGMENT CONTAIN A MATERIAL DEFECT DUE TO MATERIALS OR WORKMANSHIP ALL DELIVERY AND SHIPMENT CHARGES TO AND FROM GSI S FACTORY WILL BE PURCHASER S RESPONSIBILITY EXPENSES INCURRED BY OR ON BEHALF OF THE PURCHASER WITHOUT PRIOR WRITTEN AUTHORIZATION FROM AN AUTHORIZED EMPLOYEE OF GSI SHALL BE THE SOLE RESPONSIBILITY OF THE PURCHASER EXCEPT FOR THE LIMITED WARRANTY EXPRESSED ABOVE GSI MAKES NO FURTHER WARRANTY OF ANY KIND EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN
47. es Main Power Wiring LOY GNDOMO co op 0318 1355 8 MOS dl 66 6 2 2 LVd NOISIA3M lu O fla O Oly O Oh n O ZK H3INHOJSNVHLL xnv AVOINN QvONn Xnvavoi avol NV sb INdLNO OVA OLL S E o s H o s H o MOV 19 39vno 9L lololo lololo lololol 17 a Lol Loli keed 501 ojo o O O LO G O Ol e LMANI OVA 022 WE OI o o isi 000 O O 000 000 NOLOVINOO Jos mo som axoli mo Om mo Om DO OI ax WO OW OAL 042 oljo o o llolo oof llolo axe cw C ce 1 Oli O O oli oli o Oo l O O l O l O
48. eyors which can START AUTOMATICALLY 10 Keep area around air inlet to the fan clear of any obstacles and combustible materials 11 BEFORE attempting to remove and reinstall any propeller make sure to read the recommended procedure listed in the Service section of the manual 12 Make sure that capacities of auxiliary conveyors are matched to dryer auger capacities Use Caution in the Operation of this Equipment This dryer is designed and manufactured with operator safety in mind However the very nature of a grain dryer having a gas burner high voltage electrical equipment and high speed rotating parts presents hazards to personnel which can not be completely safeguarded against without interfering with the efficient operation of the dryer and reasonable access to its components Use extreme caution in working around high speed fans gas fired heaters augers and auxiliary conveyors which may start without warning when the dryer is operating on automatic control A Keep the dryer clean Do not allow fine material to accumulate in the plenum CAUTION chamber or surrounding the outside of the dryer Continued safe dependable operation of automatic eguipment depends to a great degree upon the owner For a safe and dependable drying system follow the recommendations within the Owner s Manual and make it a practice to regularly inspect the unit for any developing problems or unsafe conditions Take special note of the Safe
49. g rolls See Figure 7F The markings on the scale from 0 to 999 represent the flow of grain past the metering rolls as a percent of the maximum grain discharge rate for the dryer The maximum setting of 999 provides a maximum 100 discharge of 857 BPH for 190T 1285 BPH for 270 1499 BPH for 320 1714 BPH for 370 1928 BPH for 400 2142 BPH for 460 2356 BPH for 511 and 2785 BPH for 601 model dryers NOTE When the control is set to the maximum discharge rate 999 the metering roll speed should be 17 5 RPM PNEG 552 100 Series Dryer 7 Service 2 DC electric motor The direct current DC motor provides the drive for the metering roll and is located on the front left hand side of standard model dryers The output shaft of the motor is connected directly to the gear box assembly See Figure 7F The DC motor requires no operational adjustment as it is completely controlled from the control box 3 Speed reducer gear box The direct drive gear box provides the required speed reduction and transmits power to the metering rolls through a drive chain arrangement The gear box does not require adjustment The drive chain should also be periodically lubricated and tensioned as necessary See Figure 7F 4 Unload auger time delay The delay controls the bottom auger system and causes the unload auger and any connected auxiliary unloading conveyors to continue operating for the programmed amount of time even after the metering rolls sto
50. he drive end of the gear box If the dry grain take away auxiliary is wired to the dryer it should start and rotate in the proper direction PNEG 552 100 Series Dryer 5 Dryer Pre Start Checks Metering Roll Operation To check the metering roll operation turn high speed knob clockwise The metering roll speed should increase Turning the knob counterclockwise will decrease the speed Turn ON the MOISTURE CONTROL switch If the Grain Temperature Setpoint is set above the outside temperature the system will switch to Low Speed if working correctly Make sure the drive chain tension is properly adjusted and all sections of the metering rolls rotate Turn the unload switch OFF after these checks are complete The bottom auger will continue to run for 30 seconds after the switch is turned OFF to allow for clean out Figure 5B The Metering Roll Access Area Fan Switch Bump the FAN switch and observe the fan rotation The fan should run counterclockwise Sometimes on three phase models all motors on the dryer will run backwards They can easily be reversed by interchanging two of three power supply wires Reverse the two outside wires L1 and L3 and leave the middle one in the same position NOTE fthe dryer is empty the burner does not operate The fans cannot create enough static pressure to engage the air switch You will receive a no airflow message To start the dryer when it is low on grain the airflow switches mus
51. he following settings Load AUTO For timed shut down when out of grain ON will shut off auger when full but will not shut dryer down when out of grain Fan AUTO To Stop during Unloading ON to Continue Cooling during Unloading Heater AUTO For Dry and Cool ON for All Heat Unload 1 Speed Fan Heater Switch Settings Fan Setting Heater Setting Fan Function Heater Function AUTO AUTO Fans stay ON during dry and cool cycle only SCH ONI curing ciry timer AUTO ON Fans stay ON during dry and cool cycle only Burners stay ON during dry and cool ON ON Fans are ON continuously Burners are ON continuously ON AUTO Fans are ON continuously dm At the end of the dry cycle in staged batch the fans and heaters will continue running if the MOISTURE CONTROL is ON until the preset temperature on the moisture control thermostat is reached 6 Make sure the load auger switch is set to AUTO In both the AUTO and MANUAL position the grain level switch will automatically Keep the dryer full of grain In the AUTO position the dryer will shut down after the preset time period on the out of grain timer or if the grain flow to the dryer is interrupted 7 To properly set the correct dry cool and unload time for various moisture content grains see the chart on Page 30 8 To start the drying operation push the dryer power start button The controller will start all the dryer components in their proper order If
52. he third switch number six 6 on the dip switch located inside the control box on the back of the computer control board to ON the burner can be changed from a high low burner to an ON OFF burner The burner will operate exactly the same as the high low burner however when the setpoint is reached the burner cycles OFF instead of switching to alower pressure The vaporizer cools much more quickly and allows a closer tolerance on the setpoint and to operate at lower temperature rises Safety Circuit Shut Down Messages Vapor High Temperature This shut down message indicates that the LP gas vapor temperature sensor located in the gas pipe train downstream from the vaporizer has opened This indicates that the vaporizer is running too hot and must be readjusted This sensor is set at 200 F and automatically resets itself when cool PNEG 552 100 Series Dryer 3 Dryer Control Panel Loss of Flame The flame sensor failed to detect a burner flame indicating that the burner has failed to light There is a problem with the flame sensing circuitry or the dryer is not getting burner fuel The burner switch light will be lit any time flame has been sensed by the burner controls Housing High Temperature The temperature high limit located on the fan heater housing has opened indicating an over temperature condition has occurred toward the rear of the fan heater housing in an oblong covered electrical box This control is set at 200 F and MUS
53. hen 50 to 150 S Mais shaft end gets hot The bearings have been lubricated at the factory thus no lubrication should be added before start up PNEG 552 100 Series Dryer 7 Service Suggested Lubricants Insulation Class Consistency Type Grease Frame Type A and B Medium Polyurea Shell Dolium R 215T and Smaller A and B Medium Polyurea Shell Dolium R 254 and Larger F and H Medium Polyurea Shell Dolium R All NOTE AU of the auger and metering roll bearings are lifetime lubricated and do not require service relubrication Lubrication Procedures If the motor is equipped with an alemite fitting clean the tip of the fitting and apply grease with a grease gun Use 1 or 2 full strokes on motors in NEMA 215 frame and smaller Use 2 to 3 strokes on NEMA 254 through NEMA 365 frame Use 3 to 4 strokes on NEMA 404 frames and larger On motors having drain plugs remove drain plug and operate motor for 20 minutes before replacing drain plug On motors equipped with slotted head grease screw remove screw and apply grease tube to hole Insert 2 to 3 length of grease string into each hole on motors in NEMA 215 frame and smaller Insert 3 to 5 length on larger motors On motors having grease drain plugs remove plug and operate motor for 20 minutes before replacing drain plug Suggested Lubricants Insulation Class Consistency Type Grease Frame Ty
54. issing Check connections and whether the bulb is burned out Check that the unload switch is ON 1 Speed or 2 Speed Verify closing of bottom auger contactor check voltage on load side of contactor If using the moisture control check for proper setting or defective operation of the control Check for any loose wire connections in unload auger and moisture control thermostat circuits Grain not moving through columns 1 Check the dryer for fine material buildup inside the columns Avoid leaving the dryer columns full for long periods at a time 2 3 days while not operating the dryer or during rainy weather Empty the dryer Keep the dryer clean Do not allow fine material to gather in the plenum chamber It may be necessary to open the strike off plates in the affected columns in half inch intervals Uneven drying Some kernels appear brown while others are under dried Uneven heat exiting from dryer columns Check plenum thermostat temperature setting Some varieties of grain are more sensitive to higher operating temperatures It may be necessary to lower the plenum operating temperature to accommodate this Check for proper burner alignment side to side Vibration during shipment may have caused misalignment Burner does not fire with fan operating Burner switch must be ON Check for power to ignition board Heater light and gas solenoids go ON and OFF erra
55. itches Moisture Control Switch OFF Moisture Control Thermostat 200 Load Switch OFF Unload Switch OFF Fan Switch OFF Burner Switch OFF Out of Grain Timer 1 MINUTE Reset to 8 Minutes after testing Load Delay 30 SECONDS Unload Delay 30 SECONDS Metering Roll Speed LOW AND HIGH SPEED SETTINGS PUT ON ZERO Dry Timer 60 MINUTES Cool Timer 20 MINUTES Unload Timer 10 MINUTES Mode Switch CONTINUOUS FLOW PNEG 552 100 Series Dryer 5 Dryer Pre Start Checks Electrical Power Turn ON the electrical power supply to the dryer Set all circuit breakers to ON including the safety disconnect handle mounted on front of the dryer s power panel Control Power Switch Turn the CONTROL POWER switch to ON The switch light comes on GSI and the software version will appear At this point the controller will lock out all other dryer functions and the dryer will perform its safety circuit check If a fault is found the cause will be displayed on the LCD If all safeties are found safe the controller will supply power to the electronic fuel shut off valve if so equipped Press the start button to initialize the computer Power Start Button Push the dryer start button and all the toggle switches on the control panel will be activated This initializes the load fan burner unload and metering rolls individually Fuel Check If using LP gas make sure the tank has plenty of fuel and that the TANK DOES NOT HA
56. l the carrot is under the time delay to be changed 2 Use the UP and DOWN arrow keys to change from the present time to the new one The new time is automatically entered 3 Keep pressing the PROGRAM DELAYS button until the carrot disappears or press the mode select button once to exit PNEG 552 100 Series Dryer 3 Dryer Control Panel Setting the Moisture Control and Plenum Setpoint 1 Press the PROGRAM TEMPERATURES button until the carrot is under the temperature setting to be changed 2 Use the UP and DOWN arrow keys to change from the present temperature to the new one The new time is automatically entered 3 Keep pressing the PROGRAM TEMPERATURES button until the carrot disappears or press the mode select button once to exit Dryer Safety Circuit The Competitor Series 2000 Control System continuously checks all safety circuits on the dryer and will automatically shut the dryer down should a problem occur The cause of the dryer shut down will be shown on the LCD display To restart the dryer after a safety shut down first correct the reason for the shut down and then press the dryer power stop button to reset the circuit Press the start button LOAD DELAY MOISTURE CONTROL SET POINT UNLOAD DELAY A y 77 TEMPERATURE SET POINT HI LO SPEED A A A A NOAIRFLOW DISCHARGE HRS X 100 GRAIN LO FLAME L N 7 F PLENUM HI FLAME C HOUSING PURGE UO A MOTOR ERROR TEMP HI LIMIT OVERLOAD Y T v Y FLA
57. le damage or adjustment Display shows PLENUM HIGH TEMPERATURE message An over temperature condition has occurred inside the dryer Plenum This control is a 300 F limit which automatically resets when it cools Display shows NO AIRFLOW message The air switch contacts have opened indicating the fan may not be turning The air switch may need adjustment Display shows Grain High Temperature message An over temperature condition has occurred in the Dryer Grain Columns This control is a 200 F limit which automatically resets when it cools It may require the use of the Emergency Cool Feature as described on Page 18 Display shows Grain High Temperature and Plenum High Temperature messages at the same time One of both of the mechanical high limits located one in each grain column have tripped Note that the Emergency Cooling Feature will not work in this case open the back access door to help speed the cooling of the grain Replace the mechanical sensor if faulty Fan motor does not start 1 Check that the fan circuit breaker and the FAN switch are ON Also check for defective switch or bad wiring connections 2 If lighted switch does not light the air switch needs adjustment or the bulb may be burned out 3 Verify closing of fan motor contactor Check voltage on load side of contactor See appropriate power Wiring Diagrams for terminal numbers Inspect contactor fo
58. ller breaks loose from the bushing and motor shaft Carefully remove bushing and propeller With the propeller free from the bushing a gear puller can be used to pull the bushing off of the motor shaft Reattach bushing onto propeller to prevent the loss of parts NOTE During manufacture the propeller and bushing on the 26 and 28 solid aluminum blades are balanced together and are marked with two small dots to identify their original alignmentposition Check the bushing and propeller to make sure they have alignment marks Mark the alignment of the propeller and bushing if necessary On Crowley blades a composite plastic the propeller and bushing have a keyway that prevents any misalignment of the two pieces There are alignment marks on the back of the fan hub assembly If the user were to replace one of the blade fins alignment would be necessary However this is not recommended In most cases the complete propeller should be changed Fan Motor Removal and Installation In the event of motor failure remove the motor as described and take it to the nearest service station An authorized service station is the only place that can provide possible motor warranty Motor service and repair at other places will be at owner s expense If the service station determines motor failure is caused by faulty material or workmanship within the warranty period repair will be covered under the warranty Motor failure caused by external sources will re
59. n time Unload time Moisture control set poini Plenum temperature set point Discharge Out of grain time Unload time Plenum temperature set point 000 Motor ERROR overload as it is pushed in Then inspect the motor that tripped the relay Determine if the motor is being overworked No voltage on J7 04 will also cause this error condition Dry time Cool time Out of grain time Unload time 7 inside the dryer This is usually caused by lack of grain inside the dryer The airswitch may also need to be adjusted so that it becomes more sensitive to air pressure Load delay Unload delay Plenum temperature N set point This display indicates a loss of air pressure No airflow 000 ERROR This Display indicates that the Electronic Grain Temperature High Limit has tripped in the software This will reset automatically when cooled down There is no place to check this for voltage as it is software based The Emergency Cooling Mode can be used to cool the grain Dry time Cool time Load delay Unload delay Out of grain time Unload time Te Moisture control set point Plenum temperature set point 000 ERROR Temperature high limit Moisture control set point Moisture control set point Load delay Unload delay ex F 000 Grain ERROR 7 Moisture control set point Plenum temperature set point This display indicates that the out of grai
60. n timer has expired Try increasing your time on the out of grain timer to a few minutes longer than it takes for Out the dryer to refill Dry time Cool time Out of grain time Unload time t Load delay Unload delay Moisture control set point Plenum temperature set point 2 7 000 This display indicates that the vaporizer coil needs to be adiusted so that it runs colder ERROR Position coil avvay from flame Vapor temperature high limit No voltage on J1 13 will also cause this error condition Dry time _ A Out of grain time Cool time Unload time Load delay Unload delay Moisture control set point Plenum temperature set point AN fr This display indicates that the housing 000 high limit switch has tripped To reset this Housing switch remove two 2 screws to the lid ERROR of the LRL box on top of the fan burner assembly and push the red button in Temperature high limit No voltage on J7 02 will also cause this error condition Out of grain time Unload time Dry time Cool time ZZ Moisture control set point Load delay Unload delay Moisture control set point Plenum temperature set point This Display indicates that one or both of the Mechanical Grain Column Limits has been tripped These Switches reset automatically when cooled down You can not start the Emergency Cooling Mode when this Warning appears Open the Service door to assist cooling down
61. ncreases the cycling rate and lowering it decreases the rate This is the primary way to change the cycling rate Decreasing the low pressure setting with the needle valve will also increase the rate while increasing that pressure will decrease the rate 6 On LP gas models adjust the vaporizer so the fuel pipes going to the burner from the regulator are warm to the touch not hot and cold The vaporizer can be adjusted two ways First by loosening the bolt in the hinging mechanism and swinging it to a hotter or cooler position Second by loosening the two bolts in the hinge pipe and sliding the vaporizer in or out to a cooler or hotter position Either one or both methods may need to be used to get the vaporizer to the proper temperature but the first almost always gives adequate adjustment Natural gas does not use a vaporizer PNEG 552 100 Series Dryer 6 Dryer Start Up Full Heat Continuous Flow Operation 1 2 3 4 5 10 Refer to the DRYER START UP section ofthe Operator s Manual CONTINUOUS FLOW METER ROLL SETTINGS FULL HEAT on Page 33 There are settings for nitial Moisture Moisture Removed Approximate Dry Time 1 Speed 2 Speed Low and 2 Speed High Select the line that indicates the initial moisture These are the settings referred to throughout this start up procedure Make sure the UNLOAD switch is OFF Make sure the MOISTURE CONTROL switch is OFF If the dryer is stopped press the dryer start switch t
62. nd stop all dryer functions Pushing the emergency stop switch does not interrupt the main power to the WARNING Upper control box panel PNEG 552 100 Series Dryer 1 Safety Safety Precautions READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE SAVE FOR FUTURE REFERENCE 1 Read and understand the operating manual before attempting to operate the dryer 2 NEVER operate the dryer while the guards are removed 3 Power supply should be OFF for service of electrical components Use CAUTION in checking voltage or other procedures requiring the power to be ON 4 Check for gas leaks at all gas pipe connections If any leaks are detected DO NOT operate dryer Shut down and repair before further operation 5 NEVER attemptto operate the dryer by jumping or otherwise bypassing any safety devices on the unit 6 Set pressure regulator to avoid excessive gas pressure applied to the burner during ignition and when the burner is in operation See Chart on Page 25 for operating procedures DO NOT exceed maximum recommended drying temperature 7 Keep the dryer clean DO NOT allow fine material to accumulate in the plenum chamber Clean grain is easier to dry Fine material increases resistance to airflow and requires removal of extra moisture 8 Keep auger drive belts tight enough to prevent slippage 9 Use CAUTION in working around high speed fans gas burners augers and auxiliary conv
63. ndling eguipment that is wired to the dryer The speed at which the metering rolls operate during the unload cycle is adjusted by using the high speed metering roll Knob Turning the dial clockwise will increase the grain discharge rate and turning it counterclockwise will decrease the discharge rate 14 When the last batch is done and the dryer is out of grain turn the drying mode switch to continuous Turn the load unload fan heater switches off and push the dryer power start switch to arm the safety circuit Run the fan heater manually for 6 minutes per point of moisture to be removed Turn the burner off to cool the grain for 30 minutes Turn off the fan and manually unload the dryer by turning the unload switch to 1 Speed and setting the meter rolls as fast as the unload eguipment will allow 15 To control the length of the dry cycle using only the dry time setting programmed into the system turn the MOISTURE CONTROL setting to OFF To use the automatic moisture control so that the dry time is determined not only by the dry time setting but also by the moisture content of the drying grain turn the MOISTURE CONTROL switch to ON 16 To shut down the dryer close the fuel supply valve at the fuel tank or fuel source If the burner is operating let the dryer run out of fuel causing an automatic shut down due to a loss of flame Close the fuel valve at the dryer and press the dryer power stop button Turn OFF the dryer s main circuit break
64. ne and inspect Ref Description 1 Inspect the collector plate at the top of the burner casting and the burner cup for any accumulation of foreign material Clean if required Foreign material in the burner cup or casting will not burn out and will impair burner operation 2 Burner Cup 3 Ignitor Plug and Electrodes 4 Flame Sensor on the Heater 8 Inspect entire dryer for loose worn or damaged parts Include check of auger flighting metering rolls and other internal parts Ensure that temperature sensors in air plenum chamber are secured by insulated clamps and do not chafe on other metal parts 9 Make sure all dryer guards and warning decals are securely installed Guards should not interfere with moving parts If guards or warning decals are missing contact your dealer for a free replacement 10 Test fire the dryer several weeks ahead of the drying season Check for possible gas leaks See page 25 for heater test fire PNEG 552 100 Series Dryer 7 Service Fan Propeller Removal and Installation The fan propeller is secured to the motor shaft by the use of a taper lock bushing motor shaft key and three cap screws Although the taper lock method of retaining the propeller onto the motor shaft is simple it is essential that the following points be read carefully and fully DANGER understood Improper installation can cause a loose flying propeller and result in serious injury or de
65. nter until electric power is locked in off position Failure to do so will result in serious injury or death PNEG 552 100 Series Dryer 2 Safety Alert Decals Decal DC 1227 Decal DC 1227 is located on the fan heater access door Flame and pressure beyond door can cause serious injury Do not operate with service door removed Keep head and hands clear DC 1227 Decal DC 1225 Decal DC 1225 is located on the B fan heater access door Stay clear of rotating blade Blade could start automatically Can cause serious injury Disconnect power before servicing DC 1225 Decal DC 1229 Decal DC 1229 is located on each Rotating metering roll of the meter roll access doors Equipment can start automatically Keep hands clear Can cause serious injury Disconnect power before servicing DC 1229 PNEG 552 100 Series Dryer A DANGER Automatic eguipment can start at anytime Do not enter until fuel is shut off and electrical power is locked in off position Failure to do so will result in serious injury or death DC 973 3 4 MINIMUM BOLT DIAMETER HUB TEMPERATURE NO GREATER THAN 150 F TIGHTEN TO 90FT LBS 0 50 100 150 200 250 CHECK AFTER 50 MILES AND EVERY 200 MILES PNEG 552 100 Series Dryer Decal DC 973 Decal DC 973 is located on the rear plenum access door inside and outside Hitch pin must be securely fastened an
66. ny additional weight can seriously affect the balance and result in harmful vibrations and a short bearing life 3 Check propeller for free play Any side play is an indication of defective motor bearings which should be replaced to prevent a complete motor failure Make sure motor mount bolts are tight 4 Motor bearings should be lubricated periodically depending on operating conditions Under normal usage it is desirable to have the motor cleaned checked and bearings repacked by an authorized service station every two to three seasons If the unit is operated continuously through most of the year this service should be performed each year NOTE f on site bearing relubrication is to be performed see lubrication instructions for ball bearing motors To keep motor bearings properly lubricated and dispel any accumulation of moisture vvithin the vvindings the fan and auger motors should be operated for 15 to 30 minutes each month Lubrication Instructions for Ball Bearing Motors Suggested Lubrication Intervals Hours of Service per Year H P Range Suggested Lube Interval 1 8 to 7 1 2 5 years 5000 10 to 40 3 years 50 to 150 1 years 1 8 to 7 1 2 1 year Continuous Normal Applications 10 to 40 3 year 50 to 150 9 months Seasonal Service motor is idle for 6 months or more All 1 year Beginning of season Continuous high ambient 1 8 to 40 6 months temperatures dirty or moist locations high vibrations or w
67. o lock in the control circuit Turn the fan and burner switches to the ON position to run fans and burners Be sure to adjust the plenum temperature to 180 F for all burners Run the fans and burners for about 10 longer than the approximate dry time from chart on Page 33 for the incoming moisture Example 10 pt removal from the chart is 54 minutes plus 5 4 minutes 10 equals 59 4 minutes round up to 60 Increase the drying temperature to a maximum of 210 F corn for single fan dryers For multiple fan dryers adjust the top burner to a maximum of 2309F corn and stage the temperature of the lower burners down 30 per burner Example 3 fan dryer Top burner 230 Middle burner 200 Bottom burner 170 After the initial fan and burner run time set the unload switch to 1 Speed and set the high speed meter roll potentiometer to the setting for 1 Speed see chart on Page 33 Meter rolls should start and grain will begin to flow from discharge of dryer Run time for this step should be the same as from Step 5 above DO NOT TO ADJUST THE DRYER DURING THIS PERIOD The grain discharging towards the end of this period will be over dried but it is necessary so that the corn moisture is staged properly and evenly in the dryer Turn the Moisture control switch to ON Set the moisture control grain temperature to 100 F Turn the Unload switch to 2 Speed Find the 2 Speed High and 2 Speed Lo
68. or 2000 Control System is turned ON or OFF with this switch Outside Light The dryer outside light is turned ON or OFF here Drying Mode Switch This is used to select staged batch or continuous flow drying Load Auger Switch This is used to select the operation of the fill auger In both the AUTO and MANUAL position the load auger will operate if the dryer is low on grain and will automatically shut off when the dryer is full In the AUTO position only the dryer will shut down after a preset period of time set on the out of grain timer NOTE f the load auxiliary motor overload relay is being utilized in the dryer control panel this switch will also control the operation of the auxiliary equipment Fan Switch The fan is turned ON or OFF with this switch The ON position operates the fan continuously during staged batch and continuous flow modes The AUTO position is used in batch mode only and allows the fan to shut down during the unloading operation if desired The light comes ON only when air pressure is sensed Heater Switch This switch is used to turn the burner ON or OFF The ON position will operate the burner continuously but only when the fan is running The AUTO position is used in batch mode only and allows the heater to be turned OFF to cool the grain and during the unloading operation The burner light comes ON only when flame is detected PNEG 552 100 Series Dryer 3 Dryer Control Panel Unload Switch Th
69. p See Figure 7F This feature permits the clean out of grain within the unloading equipment at the end of all discharge cycles How to Determine a Metering Roll Problem Figure 7G Metering Roll Drive To determine if the metering problem is from blockage perform the following test with the power OFF Remove the drive chain by loosening the motor mounting bolts Refer to Figure 7G and place a pipe wrench on the hub of the roller chain sprocket on the left hand metering roll at the drive end of the dryer Apply up to 100 ft lbs of force and try to rotate the roll towards the inside of the dryer If the metering roll turns then repeat for right hand side and it can be assumed that no blockage exists and the problem is from some other cause Check for a break in the power train chain drive key pin etc A Keep hands away from sprocket teeth to avoid injury from chain backlash as a CAUTION result of torsion build up in the system caused by the jam 42 PNEG 552 100 Series Dryer 7 Service How to Clear a Jammed Metering Roll Shut down the fan heater and eliminate any other noise when making this check Place a pipe wrench on the hub of the sprocket of the jammed metering roll and turn the roll Firstbackward and then forward several times in an attempt to dislodge the object and clear it through the roll lf this is not successful have an assistant turn the metering roll and attempt to locate th
70. pe A and B Medium Polyurea Shell Dolium R 215T and Smaller A and B Medium Polyurea Shell Dolium R 254 and Larger F and H Medium Polyurea Shell Dolium R All NOTE AII of the auger and metering roll bearings are lifetime lubricated and do not require service relubrication Additional Checks 1 Remove and clean the gas line strainers Make certain gas valves are closed and that gas is purged from the system before attempting disassembly 2 lf required inspect ignitor plug and clean the electrodes Use an ignition point file to remove carbon and rust between the electrode surfaces Ignitor gap should be about 1 8 3 Inspect flame sensor for possible damage or poor connections Flame sensor wire must be in good condition 4 Inspect and manually rotate the top auger paddle assembly The paddle unit must rotate freely without any indication of sticking or binding 5 Inspect the top auger and bottom auger drive lines for proper adjustment and condition Readjust line tension as reguired PNEG 552 100 Series Dryer 7 Service 6 Operate dryer clean out levers and check clean out hatch mechanism for proper operation With hatch open inspect and remove any accumulation of dirt fines and foreign material from the bottom auger through area NOTE Do not allow high moisture material to collect within the trough area lt may adversely affect metal parts Figure 7A 7 Remove the blue burn optimizer co
71. peration EE 26 Emergency Stop EE 26 Dryer Start Up e ii ii 27 Continuous Flow Operation A AAA ARA eee ey aye ARAYA aa r 27 Full Start Up Check EE 27 Filing the El 27 Staged Batch Operation 28 SA 30 Adjusting the Temperature u id 31 Full Heat Continuous Flow Operation n n 32 Adjusting the Moisture Control l AAA AAA see ea asa cnn 33 A ee 34 Seasonal Inspection and Service n n n n 34 Suggested LUDfiCants cese tete age YY NET tl 35 Lubrication Proced res ien NEES R kr 35 Additional Check sico 0000000000 0000 35 Fan Propeller Removal and Installation U 37 Threaded Bushing Holes uuu ur uu u ettet tret t ud Fede Dex dl o darte 37 Clearance H les luu uu u au qushun EFFRO ga dada za asas qas 37 Fan Motor Removal and Installation uuu uu Ka K aaa u RRR 38 Heater Parts Removal and Installation a aaaaaaaaaaas nnanantnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnnnannnnnnnnnnna 40 Metering Roll Servicind EE 41 How to Determine a Metering Roll Problem A 42 How to Clear a Jammed Metering Roll a aaaaaaaaaaaaasnnansnnnsnnansnnansnanannannannannanannannnnnnnnananananaanana 43 PNEG 552 100 Series Dryer Table of Contents Chapter 8 Wiring AE TT 44 100 Series Single Fan Wiring to Control BOX
72. r defective points or a burned out coil 4 Inspect connections and check voltage applied to the motor leads in the fan heater box to determine if the motor is defective 5 Check capacitors on single phase motors and replace if defective If motor starts slowly check for low voltage during starting due to excessive voltage drop in power supply wiring Top auger does not start 1 Check that the top auger circuit breaker and the load auger switch are turned ON 2 If lighted switch does not light the output power to the contactor is missing Check connections or if the bulb is burned out 3 Check position of the upper auger paddle switch It must be down to start auger 4 Inspect for secure mounting and wiring of mercury switch in the terminal box on the top auger paddle switch shaft Include check for a defective mercury switch 5 Verify closing of the top auger contactor Check voltage on load side of contactor Inspect contactor for defective points or a burned out coil 6 Inspect connections and check voltage applied to motor leads in motor junction box to determine if motor is defective 7 Check that the mercury switch box is in the proper position PNEG 552 100 Series Dryer 10 Troubleshooting Problem Possible Cause Bottom auger does not start 1 Check that the bottom auger circuit breaker is ON If the lighted switch does not light the output power to the contactor is m
73. sult in a charge to the owner for repair 1 Make certain power is shut OFF and locked out Remove fan guard and propeller See Figure 7D 2 Remove cover from fan heater control box and disconnect the motor lead wires within the box NOTE Tag or otherwise identify wires for ease of reassembly PNEG 552 100 Series Dryer 7 Service Figure 7D Position of Fan Motor 3 Remove motor mount bolts If there are shims between the motor and its base note their location so they can be properly installed during reassembly 4 Disconnect the upper end of the motor conduit then carefully pull the wires through the hole in the fan heater housing Remove motor from the fan heater unit with the conduit still attached lf motor requires service take it to an authorized service station 5 To reinstall motor slide onto motor base plate and replace shims if required between motor base and plate Reinstall motor mount bolts and washer but do not fully tighten at this time 6 Reinstall conduit and wires through hole in fan heater housing and carefully connect all electrical wiring 7 Adjust position of motor by temporarily mounting fan blade on motor shaft Rotate fan blade by hand making the necessary adjustments so the tip clearance between blade and housing is uniform If required remove the fan blade and fully tighten all four motor mount bolts NOTE Make sure to install and tighten the propeller in accordance with
74. t BM D I I y 1 dan UNLOAD AUX ALGER Lo o 1 MOTOR l 119 ed H Lo o o o 1 1 1 il f Tar 4 BCB PNEG 552 100 Series Dryer 10 Troubleshooting A multimeter is required for some of the following checkout procedures Before performing any tests determine if the dryer power supply is 1 phase 230 volt or 3 phase 230 or 460 volt The safety circuit is 12 volts DC The burner circuit is 120 volts AC on all standard U S production models The control circuit to the motor starters is 120 volts AC When checking these circuits measure voltage between the circuit test location and to ground DC circuits should be measured between the test location and its respective DC ground Refer to Wiring Diagrams and the parts list for identification of parts and the electrical terminals A When making high voltage tests with live circuits be extremely careful Follow established safety practices Turn power ON for testing only Do not CAUTION attempt to make the dryer operate by using a jumper wire to bypass a defective safety component Problem Possible Cause Control power light OFF 1 Check that main power and circuit breakers are turned ON Check for tripped breaker Check for blown 5 amp fuses Monitor relay is defective Defective transformer or wiring Check for a defective power switch Check wiring between fuses and input output board Refer to Wiring Diagr
75. t be turned OFF Switching Dip Switch number eight 8 on the back of the computer control board to ON turns the Air Switch OFF A Dip switch number eight 8 must be turned back to the OFF position after this WARNING fest is complete or no air testing will occur PNEG 552 100 Series Dryer 5 Dryer Pre Start Checks Burner Safety To check the burner safety function make sure the main gas valve is OFF Turn the FAN switch ON and allow the fan to start Then turn the HEATER switch ON The dryer will shut down after 20 seconds The safety message loss of flame will appear Heater Test Fire The following test should be done with grain in the dryer lf no grain is present set approximate pressure settings and fine tune when grain arrives Test fire the burner by starting the fan and then turn the burner switch to ON with the fuel supply turned on The heater should ignite after a short purge delay of approximately 10 seconds Gas pressure should be shown on the gauge At this time set the high fire and low fire pressure settings Use the pressure regulator See 1 on Page 26 for high fire and the needle valve located in the side of the Cycle Solenoid low fire Valve See 2 on Page 26 for low fire The burner should cycle between high and low fire approximately 2 or 3 times per minute Approximate settings should be LP Gas Natural Gas High Fire 6 15 Ibs High Fire 6 10 Ibs Low Fire 2 6 lbs Lov
76. ters should be slowed down 2 20 points and monitored for further adjustment If the metering roll switches to HIGH and stays on HIGH more then 90 of the time increase the speed on both Potentiometers 2 20 points and monitor for further adjustment When adjusting the METER ROLL SPEEDS it is better not to change the speed more than 20 points 2 at a time Anytime a change is made wait the approximate dry time for that moisture grain from the Chart above before checking the grain moisture level and making another change if necessary PNEG 552 100 Series Dryer 7 Service Seasonal Inspection and Service The dryer is made of weather resistant material and is designed to require a minimum of service However each season we recommend the following items be checked before the unit is used and any damaged or questionable parts replaced These checks will help eliminate possible failures and assure dependable operation of the equipment A Alvvays shut off and lock out povver before servicing DANGER 1 Shut OFF electrical power Open power box and control box and inspect for moisture rodent damage or accumulated foreign material Remove any foreign material present Inspect and tighten any loose terminal connections Replace any damaged or deteriorated wiring 2 Check propeller for freedom of rotation and uniform tip clearance t should also be inspected for dirt and grain dust especially inside the hub A
77. the porcelain and electrodes for damage or cracking Replace or clean if necessary Burner maintains desired drying temperature but cycles from high fire to OFF without going to low fire Make sure the low flow control valve is not completely closed Valve must be adjusted open to provide the proper low fire gas pressure listed in this manual Check low fire solenoid valve for proper operation PNEG 552 100 Series Dryer 10 Troubleshooting Problem Possible Cause Burner operates but does not cycle from high fire to low fire 1 Check the gas pressure reading on the gauge Problem may be due to insufficient gas regulator setting Temporarily decrease the High Low Fire thermostat setting to verify that the thermostat will function and cause the burner to cycle lf burner will cycle at the reduced thermostat setting it indicates that the problem was due to insufficient heat to satisfy the original setting Increase the gas regulator setting for additional heat output Do not exceed the maximum pressure listed in this manual 2 High Low Fire thermostat control may be defective If the burner still does not cycle to low fire after decreasing the thermostat the problem may be due to a broken or kinked thermostat sensor tube Observe reading on the thermometer Replace control assembly if it cannot be set to cause its switch to go to the open circuit position with normally hot air plenum temper
78. tically The light blinks ON and OFF while the solenoids chatter Burner does not fire No gas pressure with fan The blinking light indicates the flame sensor is not detecting flame The chattering solenoids are caused by the loss of flame detection and the thermostat and Fenwal Ignition Board trying to reestablish a flame Check for loose wires on flame sensor replace or repair wires or sensor Check gas supply Also check gas filter and gas line for possible operating at least 15 seconds gas supply or fan heater malfunction obstruction or closed valves Refill tank replace or repair parts as required Inspect gas solenoid valves including liquid valve on LP units for defective coils or improper wiring Replace valve or coil if valve will not open with proper voltage applied 115 volts Check for proper voltage 115 volts across L1 and L2 incoming voltage to the Fenwal Ignition Board and 115 volts outgoing across V1 and V2 to the solenoids Burner does not fire but gauge shows gas pressure Fenwal Ignition Board Check board for spark by removing ignition wire from board and holding an insulated screwdriver against the output terminal and 1 4 away from the control box casing There should be a strong spark Check board wire connections Replace the Fenwal Board if necessary Ignitor Check that the ignitor is properly gapped to 1 8 and that it has a strong spark Inspect
79. ty Precautions before attempting to operate the dryer PNEG 552 100 Series Dryer 2 Safety Alert Decals GSI Group recommends contacting the local power company and having a representative survey the installation so that wiring is compatible with their system and adequate power is supplied to your unit Safety decals should be read and understood by all people in the grain handling area If a decal is damaged or is missing contact GSI Decals 1004 E Illinois St Assumption IL 62510 Phone 217 226 4421 A free replacement will be sent to you Decal DC 1224 A B A N G E R Decal DC 1224 is located in two places on the fan heater control box One is located on the lid and another one is on the front of the fan heater control box An additional location for this decal is inside the upper control box for the dryer HIGH VOLTAGE Will cause serious injury or death Lockout power before servicing DC 1224 1 889 DA N G R Decal DC 889 has two locations One is located insi heater control box and another one HIGH VOLTAGE inside the fan is on the dryer upper control box door next to the main power disconnect Will cause inju or death ee Lockout power before servicing PNEG 552 100 Series Dryer 2 Safety Alert Decals Decal DC 972 Decal DC 972 is located on the bottom auger belt guard and the front bearing plate which is visible when the bottom a
80. uger belt guard is removed An alternate CH location would be at the rear of the dryer for portable dryers equipped with the Front Discharge Option Moving parts can crush and cut Keep hands clear Do not operate vvithout guards in place Failure to do so could result in serious iniury DC 972 Decal DC 971 Decal DC 971 is located on the bottom auger belt guard and the front bearing plate which is visible when the bottom auger belt guard is removed An alternate location would be at the rear of the dryer for portable dryers equipped with the Front Discharge Option An additional location for decal DC 971 is the top auger belt guard one on the belt guard cover and another one is on the inside belt guard body visible when the belt guard cover is removed Automatically controlled belt drive can start at anytime Keep hands clear Failure to do so could result in serious injury E ADANGER Decal DC 974 Decal DC 974 has several different locations Two are located on the front end panel below the fan heater Two are located on the rear end panel below the rear access door Two are located on the auger discharge box one on the outside top and one on the inside of the flapper lid next to the discharge mercury switch One more of these decals is located inside the plenum on the rear plenum closure door just inside the rear access door Rotating auger will crush and cut Auto equipment can start at anytime Do not e
81. v Fire 1 3 lbs If the burner remains on high fire and does not cycle increase the regulator setting on the propane models or the supply valve on the natural gas models in order to reach the thermostat setting If the burner remains in low fire and does not cycle slightly decrease gas pressure with the low fire solenoid needle valve If the gas pressure is decreased too much a popping or fluttering sound will be heard Be sure to adjust the low pressure needle valve anytime the high pressure regulator is adjusted Staged Batch Check The following test must be done with grain in the dryer or with the air switch turned OFF as noted in the FAN switch Section on Page 24 To check the staged batch operation turn the CONTROL POWER switch to the ON position Open the main fuel supply valve at the tank on an LP dryer or open the valve in the fuel supply line on a natural gas dryer Turn the drying mode switch to the staged batch position Turn ON the electric shut off valve to allow fuel flow to the dryer Turn the load switch to AUTO the unload switch to 1 Speed and the fan and burner to ON Push the dryer power start button and the controller will sequentially start all dryer components in their proper order If any switches are notin their correct position for staged batch operation the dryer will indicate improper switch position and will not start until the switches are in the proper position After starting all batch timers will time down
82. w meter roll settings see chart on Page 33 and set meter roll potentiometers accordingly Allow the dryer to run for the time established in Step 5 and then sample the grain If the dryer has been cycling regularly from high to low and the grain is not coming out to moisture desired then adjust the moisture control grain temperature up or down 5 per point of moisture Example Moisture control is set to 1009 desired moisture is 15 sampled moisture is 17 Adjust moisture control to 1102 EVERY TIME AN ADJUSTMENT IS MADE IT IS IMPERATIVE THAT THE DRYER IS ALLOWED TO RUN FOR THE ESTABLISHED TIME IN ORDER FOR CHANGES TO TAKE AFFECT Repeal this process as necessary until desired moisture content is being discharged from dryer After the run time in Step 9 the moisture control and the meter roll speeds can be adjusted if required Each time an adjustment to the moisture control is made it will take approximately the time as shown in the example in Step 5 to see the results of this adjustment PNEG 552 100 Series Dryer 100 Series Continuous Flow Metering Roll Settings 6 Dryer Start Up Initial Moisture 57 i o Approxim 2 2 Moisture 9c Removed pts Dry Time A 1 Speed 7 17 2 16 625 317 875 18 3 21 476 270 775 19 4 26 385 241 675 20 5 31 5 317 213 575 21 6 37 270 196 476 22 7 41 5 241 185 385 23 8 47 213 172 317 24 9 51 196 161 270 25 10 54 185 150 241 26 11 58 172
83. wo grain temperature settings high and low Set these parameters the same way the single plenum and grain temperature settings are made The first of each temperatures being set will be the low setting and will be indicated by the word Low on the screen The second setting will be identified by High on the display screen Typically the plenum settings would be 170 for low and 230 for high and the low grain temperature setting would be 10 to 20 below the normal moisture control temperature setting which becomes the new high setting Both capacity and quality will improve using this feature while operating in batch dry and cool or all heat modes Emergency Cooling Mode To enter an emergency cooling mode switch ON switch number seven 7 which is the second switch from the top on the dip switch inside of the control box on the back of the computer control board This initiates a mode in which only the dryer fan runs in case there is a plenum temperature or grain high limit warning When either of these safeties shuts down the dryer run the fan to help cool the grain and or plenum high limit back down to a safe level After flipping the switch press the Start button and only the fan will run for approximately five minutes Burner ON OFF Operation Due to changing fuel conditions and to aid in drying wheat and other low temperature grains in hot weather an ON OFF burner has been developed in recent years By moving t

GSI Outdoors PNEG-552 Clothes Dryer User Manual

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