Gsi Outdoors Pneg 630 Users Manual New 630a

PNEG-630 to the manual 3088b64c-8c8b-409d-9571-08cc4705fb55

2015-02-09

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GSI
Competitor & EMCS
Portable Dryer
Models

Troubleshooting and
Reference Manual
2004 Revised Edition
PNEG-630

Competitor Series 2000 Dryer

Portable Dryer Troubleshooting

Table Of Contents

Safety ..................................................................................................................................................................... 3
Safety Sign Off Sheet ............................................................................................................................................ 8
EMCS Portable Dryer (1993-1998)
Safety Voltage Check Points ................................................................................................................................. 9
Programming Instructions for EMCS Grain Dryers .............................................................................................. 10
EMCS Display Board ............................................................................................................................................ 11
Input/Output Board Identification .......................................................................................................................... 12
EMCS Switch Replacement.........................................................................................................................13
1100 Series Control Box Wiring ............................................................................................................................. 14
1100 Series Control Box Wiring (New) ................................................................................................................. 15
1200 Series Control Box Wiring ............................................................................................................................. 16
1200 Series Control Box Wiring (New) ................................................................................................................. 17
1100 Fan Lower Control Box Interconnect Strip ................................................................................................... 18
1200 Fan Lower Control Box Interconnect Strip .................................................................................................. 19
Upper Control Box External Wiring ....................................................................................................................... 20
Fan Housing and Vapor Hi-Limit Circuit ............................................................................................................... 21
Plenum Hi-Temperature Switch ............................................................................................................................ 22
Fixed Grain Hi-Limit .............................................................................................................................................. 23
Grain & Plenum Hi-Limit Circuit ........................................................................................................................... 24
Two Fan Plenum and Grain Limit Switch Wiring .................................................................................................. 25
Rear Discharge & Emergency Cooling Circuit ..................................................................................................... 26
Rear Discharge Mercury Switch ........................................................................................................................... 27
Adjustable Hi-Limit & Emergency Cooling Circuit ............................................................................................... 28
Motor Overloads .................................................................................................................................................... 29
Air Pressure Switch ............................................................................................................................................... 30
Air Pressure Switch Drawing ................................................................................................................................ 31
Out of Grain Safety Circuit .................................................................................................................................... 32
Out of Grain Safety Circuit Drawing ..................................................................................................................... 33
Upper Junction Box Wiring .................................................................................................................................... 34
Meter Roll Sensor .................................................................................................................................................. 35
Meter Roll Sensor Wiring ...................................................................................................................................... 36
Meter Roll Reversing ............................................................................................................................................. 37
Lower Junction Box Wiring ................................................................................................................................... 38
New Fenwal Board Wiring.......................................................................................................................... 39
New Fenwal Board Troubleshooting.............................................................................................................40
Flame Control Circuit ............................................................................................................................................. 41
Fan Burner Circuit for Canadian Models .............................................................................................................. 42
Conversion Diagram for C Series Dryers to a Switchable Hi/Low or On/Off Burner ......................................... 43
Fan 28 LP Hi/Low-On/Off .................................................................................................................................... 44
Fan 28 LP On/Off Burner with Mercoid ............................................................................................................... 45
Fan 28 NG Hi/Low-On/Off ................................................................................................................................... 46
Fan 28 NG On/Off Burner with Mercoid .............................................................................................................. 47
Fan 42 LP Hi/Low-On/Off .................................................................................................................................... 48
Fan 42 LP On/Off Burner with Mercoid ............................................................................................................... 49
Fan 42 NG Hi/Low-On/Off ................................................................................................................................... 50
Fan 42 NG On/Off Burner with Mercoid .............................................................................................................. 51
SCR Drive Circuit .................................................................................................................................................. 52
RTD Temperature Sensor ...................................................................................................................................... 53
Test Procedure for EMCS Dryers ......................................................................................................................... 54
Temperature Charts ............................................................................................................................................... 55
EMCS Troubleshooting Tips........................................................................................................................ 56
1

Table Of Contents

Portable Dryer Troubleshooting

Competitor Series 2000 Dryer (Picture of Dryer)(1995 to Present)......................................................65
220 Volt Single (1) Phase Power Drawing ............................................................................................................ 66
220 Volt Single (1) Phase Power Drawing (New Version) .................................................................................. 67
220 Volt Three (3) Phase Power Drawing ............................................................................................................ 68
220 Volt Three (3) Phase Power Drawing (New Version) ................................................................................... 69
220 Volt 1 Phase Power Circuit (Ladder Diagram)........................................................................................70
220 Volt 3 Phase Power Circuit (Ladder Diagram)........................................................................................71
440 Volt 3 Phase Power Circuit (Ladder Diagram)........................................................................................72
Upper Control Box Internal Wiring ........................................................................................................................ 73
Series 2000 Control Box Wiring (New Version) .................................................................................................... 74
Series 2000 Control Box Wiring ............................................................................................................................. 75
Series 2000 Control Box Wiring (380-460-575 3 Phase).................................................................................76
Upper Terminal Strip...................................................................................................................................77
Upper Terminal Strip (Moisture Control Hook-Up)........................................................................................78
Upper Terminal Strip (Moisture Control Relay Hook-Up)...............................................................................79
Moisture Manager to Dryer Wiring...............................................................................................................80
Input/Output Board & Terminal Strip .................................................................................................................... 81
Control Circuit (CPU/Display)(Ladder Diagram)......................................................................................... 82
Control Circuit (I/O Board)(Ladder Diagram)...............................................................................................83
Control Circuit (SCR Drive Board)(Ladder Diagram)....................................................................................84
SCR Board (Installing & Calibrating)............................................................................................................85
Upper Control Box External Wiring ....................................................................................................................... 88
Input/Output Board 12 Volt .................................................................................................................................... 89
CPU Board Wiring ................................................................................................................................................. 90
Programming Instructions for Competitor Series Grain Dryers ............................................................................ 91
Programming Hook Up Diagram ........................................................................................................................... 92
Back of Switch Panel Layout ................................................................................................................................ 95
Back of Switch Panel Wiring ................................................................................................................................. 96
Air Switch Assembly ............................................................................................................................................. 97
Air Switch Adjusting...................................................................................................................................98
Fixed Grain Hi-Limit & Temperature Sensor ........................................................................................................ 99
Out of Grain Sensor...................................................................................................................................100
Grain Temperature Sensor..........................................................................................................................101
Grain Sensor Testing..................................................................................................................................102
Grain Sensor (Locating,Testing,& Replacing)...............................................................................................103
Sensor Resistance/Temperature Chart.........................................................................................................105
Plenum Sensor (Locating,Testing & Replacing)............................................................................................106
Stern and Capacitor Diagram......................................................................................................................108
Operation Hints..........................................................................................................................................109
Series 2000 Error Conditions.......................................................................................................................111
Heater Circuit............................................................................................................................................113
Fan Burner Circuit for Canadian Models Only..............................................................................................114
Series 2000 LP 26"/28" Fan ........................................................................................................................115
Series 2000 Natural Gas 26"/28" Fan............................................................................................................116
Series 2000 LP 36"/42" Fan.........................................................................................................................117
Series 2000 Natural Gas 36"/42" Fan............................................................................................................118
Warranty....................................................................................................................................................119

Portable Dryer Troubleshooting

Safety

Dryer Safety
Instructions and
Information
Thank you for choosing an GSI
Grain Dryer. It is designed to provide excellent performance and service for many years.
This manual refers to the troubleshooting of the E.M.C.S.and Series
2000 Competitor models. Different
models are available for liquid propane or natural gas fuel supply, with
either single phase 230 volt, or three
phase 230, 460, 575 volt electrical
power. (Also 380 volt 50Hz).
The GSI Group Inc. recommends
contacting your local power company, and having a representative
survey your installation so the wiring is compatible with your system
and adequate power is supplied.
The principal concern of the GSI
Group, Inc. ("GSI") is your safety
and the safety of others associated
with grain handling equipment. This
manual is written to help you understand safe operating procedures, and some of the problems
that may be encountered by the operator or 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 who are in the dryer area. Avoid any alterations to
the equipment. Such alterations may produce a very dangerous situation, where serious injury or death may
occur.

Safety Alert Symbol
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.

The symbol shown is used to call your
attention to instructions concerning your
personal safety. Watch for this symbol;
it points out important safety precautions. It means "ATTENTION",
"WARNING", "CAUTION", and "DANGER". Read the message and be cautious to the possibility of personal injury or death.
3

Safety

Portable Dryer Troubleshooting

Grain Systems, Inc. recommends
you contact your local power company and have a representative survey your dryer installation, so your
wiring will be compatible with their
system and you will have adequate
power supplied to your unit.

A CAREFUL OPERATOR
IS THE BEST INSURANCE
AGAINST AN ACCIDENT

Safety decals should be read and
understood by all people in and
around the dryer area. If the following safety decals are not displayed
on your dryer, or if they are damaged, contact Grain Systems, Inc. for
replacement.

Portable Dryer Troubleshooting

Safety

Portable Dryer Troubleshooting

Portable Dryer Troubleshooting
READ THESE INSTRUCTIONS
BEFORE OPERATION AND SERVICE
SAVE FOR FUTURE REFERENCE
1. Read and understand the operating manual before trying to operate the
dryer.
2.

Safety Precautions

Use Caution in the
Operation of this
Equipment

The design and manufacture of this
Power supply should be OFF for service of electrical components. Use dryer is directed toward operator
CAUTION in checking voltage or other procedures requiring power to safety. However, the very nature of
a grain dryer having a gas burner,
be ON.
high voltage electrical equipment
Check for gas leaks at all gas pipe connections. If any leaks are deand high speed rotating parts, does
tected, do not operate the dryer. Shut down and repair before further
present a hazard to personnel, which
operation.
can not be completely safeguarded
against, without interfering with efNever attempt to operate the dryer by jumping or otherwise bypassing ficient operation and reasonable acany safety devices on the unit.
cess to components.
Use extreme caution in working
Set pressure regulator to avoid excessive gas pressure applied to burner
around high speed fans, gas-fired
during ignition and when burner is in operation. Do not exceed maxiheaters, augers and auxiliary conmum recommended drying temperature.
veyors, which may start without
Keep the dryer clean. Do not allow fine material to accumulate in the warning when the dryer is operating on automatic control.
plenum or drying chamber.

7. Use CAUTION in working around high speed fans, gas burners, augers
and auxiliary conveyors which START AUTOMATICALLY.
8. Do not operate in any area where combustible material will be drawn into
the fan.

KEEP THE DRYER CLEAN
DO NOT ALLOW FINE
MATERIAL TO ACCUMULATE
IN THE PLENUM CHAMBER
OR SURROUNDING THE
OUTSIDE OF THE DRYER

9. Before attempting to remove and reinstall any propeller, make certain to
read the recommended procedure listed within the servicing section of
Continued safe, dependable operathe manual.
tion of automatic equipment de10. Clean grain is easier to dry. Fine material increases resistance to airflow pends, to a great degree, upon the
and requires removal of extra moisture.
owner. For a safe and dependable
This product is intended for the use of grain handling only. Any other
use is considered a misuse of the product.
Some edges of the product components can be sharp. It is recommended
that each component of this product be examined to determine if there
are any safety considerations to be taken. Any and all necessary personal
protective equipment should be worn at all tines when handling, assembling, installing and operation of the product and/or components.
Guards are removed for illustration purpose only. All guards must be
in place before/during operation.

drying system, follow the recommendations within this manual, and
make it a practice to regularly inspect the operation of the unit for
any developing problems or unsafe
conditions.
Take special note of the safety precautions listed at left before attempting to operate the dryer.
7

Safety Sign-Off Sheet

Date

Portable Dryer Troubleshooting

Employer’s Signature

Employee

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Misc Errors
Auxilliary Safety Shutdown
Motor Overload
Grain Discharge Warning
Maxon Valve Shut Warning
Unknown Safety Error
20 Second Safety Circuit Failure

Lower or Left Fixed Grain
Lower Adjustable or Right Fixed Grain
Middle Fixed Grain
Middle Adjustable Grain
Upper Fixed Grain
Upper Adjustable Grain

+
J1-7
J1-5
J1-9
J1-11
J1-13
J1-13
J1-13

J5-12
J5-12
J5-12
J5-12
J5-12
J5-12

J1-20
J4-12
J5-5
J5-2
J5-10
J5-6

1100/1200/1300
J5-12 J1-19
J5-12 J4-19
J5-12 N/A
J5-12 N/A
J5-12 N/A
J5-12 N/A

1
J5-12
J5-12
J5-12
J5-12
J5-12
J5-12
J5-12

FAN #

Error Message
Fan # Housing High Temperature
Burner # Vapor High Temperature
Burner # Flame not Detected
Plenum # High Temperature
Burner # Shutdown Loss of Airflow
Fan # Failure No Airflow
Fan # cannot Start Check Air Switch

2
J5-12
J5-12
J5-12
J5-12
J5-12
J5-12
J5-12

Note:

+
J1-8
J1-6
J1-10
J1-12
J1-14
J1-14
J1-14

3
+
J2-7
J2-5
J2-9
J2-11
J2-13
J2-13
J2-13

4
J5-12
J5-12
J5-12
J5-12
J5-12
J5-12
J5-12

+
J2-8
J2-6
J2-10
J2-12
J2-14
J2-14
J2-14

5
+
J3-7
J3-5
J3-9
J3-11
J3-13
J3-13
J3-13

3300/3400/3600
J5-12 J1-19
J5-12 J4-19
J5-12 J4-4
J5-12 J4-8
J5-12 J4-2
J5-12 J4-6

J5-12
J5-12
J5-12
J5-12
J5-12
J5-12
J5-12

6
J5-12
J5-12
J5-12
J5-12
J5-12
J5-12
J5-12

+
RESULT
J3-8
12VDC
J3-6
12VDC
J3-10 12VDC
J3-12 12VDC
J3-14 Note 1
J3-14 Note 2
J3-14 Note 3

1 This error will occur if the fan and burner were both operating and
the air switch opens which indicates loss of static pressure.
12 volts should be present if the fan is on.
2 This error will occur if after the fan has started the air switch does
not detect any static pressure. 12 volts should be present if
the fan is on.
3 The condition for this error will occur if the air switch is stuck
in the closed postition. No voltage should be present if the
dryer is stopped.

2200/2300/2400
J5-12 J1-19
J5-12 J4-19
J5-12 N/A
J5-12 N/A
J5-12 J4-4
J5-12 J4-8

J5-12
J5-12
J5-12
J5-12
J5-12
J5-12
J5-12

Portable Dryer Troubleshooting
Wiring Reference

Safety Voltage Check Points

Programming

Portable Dryer Troubleshooting

Programming Instructions for EMCS Grain Dryers
1. Turn Control Power on dryer to off.
2. Locate programming jack (P7) on back of computer. (See page 13).
3. Plug the DB-9 jack of the programmer into the computer's jack.
4. Be sure that the rotary switch on the programmer is set to position 8.
5. Turn on Control Power to the dryer.
6. The four (4) lights on the programmer will come on, then three (3) will go out leaving the power light still on.
7. Push the start button on the programmer to start the transfer of Software.
8. The busy light will flash until the transfer process is complete.
9. When completed the pass light will flash indicating a successful transfer.
10. If the fail light flashes then check your connections and repeat the above process.
11. Turn Control Power on dryer to off and remove the cable.
12. Turn on the dryer and the opening screens should indicate the newer version of software.

DISPLAY
RIBBON

TO START &
STOP SWS.

U12

1 2 3

TO START SW.

BATTERY (TIC)

COMMUNICATIONS CABLE
TO I/O BOARD

SOUND

TO STOP SW.

KEY PAD RIBBON

COMPUTER
PROGRAMMING
JACK

PROGRAMMER
JACK (DB9)

Portable Dryer Troubleshooting
Programming

EMCS Display Board

Portable Dryer Troubleshooting

Wiring Reference

Input/Output Board Identification

12 VOLT DC INPUTS
+12 LIMIT OUTPUT

120VAC POWER (INPUT)

120VAC POWER (OUTPUT)

12 VOLT DC NEUTRAL

+12 LIMIT OUTPUT

AC NEUTRAL

METERING ROLL INPUT

12 VOLT DC NEGATIVE

120VAC POWER (INPUT)

120VAC POWER (OUTPUT)

12 VOLT DC NEGATIVE

AC NEUTRAL

12 VOLT DC NEGATIVE

AC NEUTRAL

SAFETY CIRCUIT INPUT

+12 VOLT LIMIT OUTPUT

AC NEUTRAL

+12 VOLT LIMIT OUTPUT

AC NEUTRAL

FLAME SENSOR RETURN

REAR DISCHARGE

AC NEUTRAL

BURNER #1 POWER

OUT OF GRAIN SENSOR

M.C. THERMOSTAT N.O. TERM #4

FAN #1 POWER

BURNER #2 POWER

MAXON VALVE SENSOR

M.C. THERMOATAT N.C. TERM #6

FAN #2 POWER

BURNER #3 POWER

MERCOID SFTY FAN#1 (CAN)

LOWER ADJ. GRAIN HIGH LIMIT

MERCOID SFTY FAN#2 (CAN)

2 SPEED UNLOAD

MERCOID SFTY FAN#4 (CAN)

1 SPEED UNLOAD

LOW MERCURY SWITCH (BO)

UNLOAD BYPASS

MOTOR OVERLOADS

LOAD SWITCH AUTO

MOISTURE CONTROL

ADJ. GRAIN (MIDDLE)

LOAD SWITCH ON

BATCH MODE

JUMPER J1-9 TO J5-6 IS A HARDWARE TIMER FOR THE FLAME SENSOR SHUTDOWN
JUMPER J5-2 TO J5-20 IS A CONNECTION FOR THE MAXON VALVE SENS0R
JUMPER J4-12 TO J5-10 IS A HARDWARE TIMER FOR THE SAFETY SHUTDOWNS
JUMPER J1-20 TO J5-8 IS A CONNECTION FOR THE USER SUPPLLIED SAFETY
JUMPERS MUST BE INSTALLED FOR THE INPUT/OUTPUT BOARD TO OPERATE!!

ADJ. GRAIN (UPPER)

CONTINUOUS FLOW

FIXED GRAIN (MIDDLE)

MERCOID SAFTY FAN#3 (CAN)

FIXED GRAIN (UPPER)

OUT OF GRAIN FOR LOAD #2

JUMPERS TO BE INSTALLED FOR E-COOL
INSTALL JUMPER FROM J6-13 TO J1-5
INSTALL JUMPER FROM J6-14 TO J1-19
INSTALL JUMPER FROM J6-16 TO J5-5
INSTALL JUMPER FROM J6-17 TO J4-19

HI-HEAT THERMOSTAT (BO)

LO-HEAT THERMOSTAT (BO)

FAN #3 POWER

BURNER #4 POWER

BURNER #6 AUTO

BURNER #5 AUTO

FAN #4 POWER

BURNER #5 POWER

BURNER #6 ON

BURNER #5 ON

FAN #5 POWER

BURNER #6 POWER

FAN #6 AIR

FAN #5 AIR

FAN #6 POWER

LOAD POWER

FAN #6 PLENUM

FAN #5 PLENUM

UNLOAD POWER

SCR POWER

FAN #6 FLAME DETECTION

FAN #5 FLAME DETECTION

BUR # 4 NEUTRAL

FAN #1 NEUTRAL

FAN #6 HOUSING HIGH LIMIT

FAN #5 HOUSING HIGH LIMIT

BUR # 3 NEUTRAL

FAN #2 NEUTRAL

FAN #6 VAPOR HIGH LIMIT

FAN #5 VAPOR HIGH LIMIT

FAN # 4 NEUTRAL

UNLOAD NEUTRAL

FAN #6 AUTO

FAN #5 AUTO

FAN # 3 NEUTRAL

LOAD NEUTRAL

FAN #6 ON

FAN #5 ON

LOAD #2 NEUTRAL

SCR NEUTRAL

LOAD #2 POWER

PROCESS LIGHT

BURNER #4 AUTO

BURNER #3 AUTO

MAXON POWER

BURNER #1 NEUTRAL

BURNER #4 ON

BURNER #3 ON

BUR #6 NEUTRAL

BURNER #2 NEUTRAL

FAN #4 AIR

FAN #3 AIR

BUR #5 NEUTRAL

MAXON NEUTRAL

FAN #4 PLENUM

FAN #3 PLENUM

FAN #6 NEUTRAL

AC NEUTRAL

FAN #4 FLAME DETECTION

FAN #3 FLAME DETECTION

FAN #5 NEUTRAL

LO-HEAT POWER (BO)

FAN #4 HOUSING HIGH LIMIT

FAN #3 HOUSING HIGH LIMIT

HI-HEAT POWER (BO)

FAN #4 VAPOR HIGH LIMIT

FAN #3 VAPOR HIGH LIMIT

FAN #4 AUTO

FAN #3 AUTO

FAN #4 ON

FAN #3 ON

M.R.H POT 3

USER SUPPLIED SAFETY

THERMOSTAT 110VAC (BO)

LOWER GRAIN HIGH LIMIT

SCR P1 &
V1 FROM BR#1 (BO)

M.R.L POT 3 &
HIGH SOLENOID BUR#1 (BO)

M.R.H POT 2

SCR P3 & V1 FROM BR#2 (B0

SENSOR 1 LOWER

BURNER #2 AUTO

BURNER #1 AUTO

BURNER #2 ON

BURNER #1 ON

FAN #2 AIR

FAN #1 AIR

THERMOSTAT SENSOR S1

SENSOR 1 UPPER

FAN #2 PLENUM

FAN #1 PLENUM

SENSOR 2 LOWER.

THERMOSTAT SENSOR S2

FAN #2 FLAME DETECTION

FAN #1 FLAME DETECTION

SENSOR 2 UPPER

AUX #6 A-N.C.

FAN #2 HOUSING HIGH LIMIT

FAN #1 HOUSING HIGH LIMIT

ENERGENCY COOLING

EMERGENCY COOLING

FAN #2 VAPOR HIGH LIMIT

FAN #1 VAPOR HIGH LIMIT

AUX #6 B-COMMON

EMERGENCY COOLING

FAN #2 AUTO

FAN #1 AUTO

EMERGENCY COOLING

FAN #2 ON

FAN #1 ON

** IMPORTANT--JUMPERS LISTED ABOVE MUST BE INSTALLED

120 VOLT AC OUTPUTS

M.R.L POT 2 & HI SOLENOID BUR#2 (BO)

Switch Replacement

Portable Dryer Troubleshooting
Switch Replacement for EMCS Dryer

Switch N/O Contact Block - Part No. D63-0006
Switch Light Block - D01-0455

Portable Dryer Troubleshooting

Wiring Reference

1100 Series Control Box Wiring
1100 FAN TO CONTROL BOX WIRING
DESCRIPTION
AIR PRESSURE SWITCH +12VDC

VAPOR HIGH LIMIT (LP ONLY)
RELAY CONTACTS LOCATED
IN DRYER FAN CAN BOX

RED

J5-8

12 VOLTS DC

(RED)

YEL

J1-7

12 VOLTS DC

(RED)

PUR

J1-5

12 VOLTS DC

(RED)
(RED)

YEL

FLAME DETECTION
PLENUM

J1-9

12 VOLTS DC

BLU

J1-11

12 VOLTS DC

(RED)

J1-19

12 VOLTS DC

(RED)

J5-5

12 VOLTS DC

(RED)

J4-19

RED

LEFT FIXED GRAIN HI LIMIT

BRN

*REAR DISCHARGE

RED

RIGHT FIXED GRAIN HI LIMIT

BLU

J1-13

12 VOLTS DC (RED)
12 VOLTS DC (RED)
MOTOR OVERLOADS
12 VOLTS DC (BLUE)

BURNER POWER

BLK

J9-16

120 VAC

BURNER NEUTRAL

WHT

120 VAC NEUT

BURNER LIGHT

BRN

J7-4
B1

120 VAC

(BLUE)

MAXON POWER

PUR

J7-3

120 VAC

(BLACK)

MAXON NEUTRAL

WHT

(WHITE)
(YELLOW)

J4-12
AIR PRESSURE SWITCH

USED ON SINGLE FAN
NAT GAS ONLY

* LEFT METERING ROLL SENSOR
* RIGHT METERING ROLL SENSOR
METERING ROLL 12 VOLTS

(WHITE)

J7-8

BLK

J5-4

12 VOLTS DC

YEL

J5-16

METER ROLL PULSE (PUR)

BLU

J5-19

NO LONGER USED

RED

J5-9

12 VOLTS DC

(RED)

J1-20
J5-12

12 VOLTS DC

(RED)

BLK

BLK
BLK

CUSTOMER SUPPLIED SAFETY
METERING ROLL NEUTRAL
NEED JUMPER

12 VOLTS DC NEG (WHITE)

-12VDC

TEMP SENSORS

WHT

TEMP SENSOR

TEMP SENSORS

BLK

TEMP SENSOR

WORK LIGHT

RED

120 VAC

J9-3

120 VAC NEUT

AC 1

120 VAC

J8-16

120 VAC NEUT (WHITE)

J8-9

120 VAC

J8-18

120 VAC NEUT (WHITE)

120VAC FOR AUX UNLOAD CONTACTOR COIL

120VAC FOR AUX LOAD CONTACTOR COIL
DRYER SAFETY CIRCUIT ALWAYS STARTS ON J5-8 AND ENDS
ON J4-12.USING THE J5-12 TERMINAL FOR NEGATIVE,
THERE SHOULD BE 12 VOLTS DC ON EACH TERMINAL FROM
J5-8 TO J4-12.
WHEN CHECKING FOR 12 VOLTS DC ALWAYS PUT THE
NEGATIVE PROBE OF VOLT METER TO TERMINAL J5-12
SAFETY CIRCUIT IN BOLD IS FOR FLAME DETECTION ONLY.
EACH OF THE TERMINALS CONNECTED TO IT CAN LOOSE
12 VDC FOR 20 SECONDS BEFORE A SHUTDOWN OCCURS.
THIS GIVES THE BURNER CIRCUIT TIME TO SENSE FLAME.
ALL OTHER SAFETY CONNECTIONS MUST HAVE 12 VDC
PRESENT AT ALL TIMES TO OPERATE PROPERLY.
AUX CONTACT POINTS FOR LOAD AND UNLOAD SYSTEMS
ALL VOLTAGE SUPPLIED BY USER

*LOCATED AT REAR OF DRYER
1100EW98.PRT REV. DATE 4/10/98

(BLACK)

120 VAC NEUT

MERCURY SWITCH LOCATED
ON TOP OF DRYER

OUT OF GRAIN SENSOR
OK OTHER SIDE
(N/C) SAFETY
J5-8 OR J5-9 --

COLOR

J5-8

RED

NEED JUMPER
OR

HOUSING HIGH LIMIT
SAFETY CIRCUIT

42 TOTAL TERMINALS
VOLTAGE

WIRING

(ORANGE)
(ORANGE)
(BLACK)
(WHITE)

(BLACK)

(ORANGE)

J8-8

120 VAC

J8-12

120 VAC NEUT (WHITE)

J9-17

120 VAC

J8-20

120 VAC NEUT (WHITE)

J8-10

120 VAC

J6-1

CONTROL POT P1 (PUR)

SCR 2

CONTROL POT P2 (PUR)

J6-4

CONTROL POT P3 (PUR)

U-COM

UNLOAD AUX COM(ORANGE)

U-N/O

UNLOAD AUX N/O(ORANGE)

(YELLOW)
(BLUE)

(ORANGE)

L-COM

LOAD AUX COM (YELLOW)

L-N/O

LOAD AUX N/O (YELLOW)

ALL SAFETIES MUST BE CLOSED FOR DRYER TO OPERATE

Portable Dryer Troubleshooting

Wiring Reference

1100 Series Control Box Wiring (New Version)

Portable Dryer Troubleshooting

Wiring Reference

1200 Series Control Box Wiring
52 TOTAL TERMINALS

DESCRIPTION

WIRING

AIR PRESSURE SWITCH +12VDC

NEED JUMPER
OR

FAN #2 HOUSING HIGH LIMIT
FAN #2 VAPOR HIGH LIMIT

SAFETY CIRCUIT

RELAY CONTACTS LOCATED
IN FAN CAN CONTROL BOX

RED

FAN #2 FLAME DETECTION
FAN #1 HOUSING HIGH LIMIT

TERMINAL

RED

FAN #1 FLAME DETECTION
FAN #2 PLENUM
FAN #1 PLENUM
FIXED GRAIN HIGH LIMIT

RED

*REAR DISCHARGE

BRN

ADJ. GRAIN HIGH LIMIT

RED

J5-8
J5-8

12 VOLTS DC

(RED)

YEL

J1-8

12 VOLTS DC

(RED)

PUR

J1-6

12 VOLTS DC

(RED)

J1-10

12 VOLTS DC

(RED)

YEL

J1-7

12 VOLTS DC

(RED)

PUR

J1-5

12 VOLTS DC

(RED)

J1-9

12 VOLTS DC

(RED)

YEL

J1-12

12 VOLTS DC

(RED)

BLU

J1-11

12 VOLTS DC

(RED)

J1-19

12 VOLTS DC

(RED)

J5-5

12 VOLTS DC

(RED)

RED

J4-19

12 VOLTS DC

(RED)

J4-12

12 VOLTS DC

(RED)

FAN #2 PRESSURE SWITCH

BLU

J1-14

12 VOLTS DC

(BLUE)

FAN #1 PRESSURE SWITCH

BLU

J1-13

12 VOLTS DC

BURNER #2 POWER

BLK

J9-18

120 VAC

BURNER #2 NEUTRAL

WHT

J7-6

120 VAC NEUT

BURNER #1 POWER

BLK

J9-16

120 VAC

BURNER #1 NEUTRAL

WHT

J7-4

120 VAC NEUT

BURNER #2 LIGHT

BRN

120 VAC

BURNER #1 LIGHT

BRN

120 VAC

(BROWN)

MAXON POWER

PUR

J7-3

120 VAC

(BLACK)

WHT

MOTOR OVERLOADS

MAXON NEUTRAL

(WHITE)

(BLACK)
(WHITE)

(BROWN)

J7-8

120 VAC NEUT

(WHITE)

J5-4

12 VOLTS DC

(YELLOW)

*LEFT METERING ROLL SENSOR

YEL

J5-16

METER ROLL PULSE (PUR)

*RIGHT METERING ROLL SENSOR

BLU

J5-19

NO LONGER USED

RED
RED

J5-9
J1-20

12 VOLTS DC
12 VOLTS DC

J5-12

12 VOLTS DC NEG (WHITE)

METERING ROLL 12 VOLTS
CUSTOMER SUPPLIED SAFETY

BLK

METERING ROLL NEGATIVE

NEED JUMPER
TEMP SENSOR
TEMP SENSOR

WHT
BLK

S1
S2

TEMP SENSOR

WORK LIGHT

RED

120 VAC

120VAC FOR AUX LOAD CONTACTOR COIL

53 TOTAL TERMINALS
15 - RED
4 - BLUE
1 - WHITE/BLACK
3 - BLACK (1-16GA)
9 - WHITE (1-16GA
2 - BROWN
4 - PURPLE
4 - ORANGE)

AUX CONTACT POINTS FOR LOAD AND UNLOAD SYSTEMS
ALL VOLTAGE SUPPLIED BY USER

*LOCATED AT REAR OF DRYER

1200EW98.PRT REV. DATE 3/5/98

(RED)
(RED)

-12VDC

120VAC FOR AUX UNLOAD CONTACTOR COIL

(BLUE)
(BLACK)

BLK

MERCURY SWITCH LOCATED
ON TOP OF DRYER

OUT OF GRAIN SENSOR

HOOK OTHER SIDE
OF (N/C) SAFETY
TO J5-8 OR J5-9 --

COLOR

RED

FAN #1 VAPOR HIGH LIMIT
RELAY CONTACTS LOCATED
IN FAN CAN CONTROL BOX

VOLTAGE

(ORANGE)

TEMP SENSOR

(ORANGE)
(BLACK)

J9-3

120 VAC NEUT

AC 1

120 VAC

(WHITE)

(BLACK)

J8-16

120 VAC NEUT (WHITE)

J8-9

120 VAC

J8-18

120 VAC NEUT (WHITE)

J8-8

120 VAC

J8-14

120 VAC NEUT (WHITE)

(ORANGE)

(YELLOW)

J9-19

120 VAC

J8-12

120 VAC NEUT (WHITE)

(BLUE)

J9-17

120 VAC

J8-20

120 VAC NEUT (WHITE)

J8-10

120 VAC

J6-1

CONTROL POT P1 (PUR)

SCR 2

CONTROL POT P2 (PUR)

(BLUE)

(ORANGE)

J6-4

CONTROL POT P3 (PUR)

U-COM

UNLOAD AUX COM(ORANGE)

U-N/O

UNLOAD AUX N/O(ORANGE)

L-COM

LOAD AUX COM (YELLOW)

L-N/O

LOAD AUX N/O (YELLOW)

ALL SAFETIES MUST BE CLOSED FOR DRYER TO OPERATE

Portable Dryer Troubleshooting

Wiring Reference

1200 Series Control Box Wiring (New Version)

Wiring Reference

Portable Dryer Troubleshooting

1100 Fan Lower Control Box Interconnect Strip
J9-1

5VB1

35 - D01-0531 ENTRELEC TERMINALS
2 - D01-0533 END STOPS
1 - D01-0532 BLANK PROTECTOR END

LINE

L1
B1
S1
S2
SCR2
J1-5
J1-7
J1-9
J1-11
J1-13
J1-19
J1-20
J4-12
J4-19
J5-4
J5-5
J5-8
J5-9
J5-12
J5-16
J5-19
J6-1
J6-4
J7-3
J7-4
J7-8
J8-8
J8-9
J8-10
J8-12
J8-16
J8-18
J8-20
J9-16
J9-17

LOAD

EMERGENCY COOLING JUMPERS
INSTALL J6-13 TO J1-5
INSTALL J6-14 TO J1-19
INSTALL J6-16 TO J5-5
INSTALL J6-17 TO J4-19

AC-1

J9-3

EMI FILTER
D03-0181

BLACK - 120 VAC - OUTSIDE LIGHT
BROWN - 120 VAC - BURNER #1 LIGHT
ORANGE - TEMPERATURE SENSOR
ORANGE - TEMPERATURE SENSOR
PURPLE - CONTROL POT P2
RED - 12 VDC - FAN #1 VAPOR HIGH LIMIT
RED - 12 VDC - FAN #1 HOUSING HIGH LIMIT
RED - 12 VDC - FAN #1 FLAME DETECTION
RED - 12 VDC - FAN #1 PLENUM HIGHT LIMIT
BLUE - 12 VDC - FAN #1 AIR SWITCH
RED - 12 VDC - LOWER FIXED GRAIN LIMIT
RED - 12 VDC - USER SUPPLIED SAFETY
RED - 12 VDC - MOTOR OVERLOADS
RED - 12 VDC - LOWER ADJUSTABLE GRAIN HIGH LIMIT
YELLOW - 12 VDC - OUT OF GRAIN SENSOR
RED - 12 VDC - REAR DISCHARGE SWITCH
RED - 12 VDC - 12 VOLT SUPPLY
RED - 12 VDC - 12 VOLT SUPPLY
WHITE - 12 VDC NEG - 12 VOLT SUPPLY NEGATIVE
PURPLE -TIMING PULSE- LEFT METERING ROLL PULSE
PURPLE -TIMING PULSE- RIGHT METERING ROLL PULSE
PURPLE - CONTROL POT P1
PURPLE - CONTROL POT P3
BLACK - 120 VAC - MAXON POWER
WHITE - AC NEUTRAL - BURNER NEUTRAL
WHITE - AC NEUTRAL - MAXON NEUTRAL
YELLOW - 120 VAC - LOAD POWER
ORANGE - 120 VAC - UNLOAD POWER
ORANGE - 120 VAC - SCR POWER
WHITE - AC NEUTRAL - FAN #1 NEUTRAL
WHITE - AC NEUTRAL - UNLOAD NEUTRAL
WHITE - AC NEUTRAL - LOAD NEUTRAL
WHITE - AC NEUTRAL - SCR NEUTRAL
BLACK - 120 VAC - BURNER #1 POWER
BLUE - 120 VAC - FAN #1 POWER

I/O BOARD JUMPERS
INSTALL J1-9 TO J5-6
INSTALL J5-2 TO J5-20
INSTALL J4-12 TO J5-10
INSTALL J1-20 TO J5-8

Wiring Reference

Portable Dryer Troubleshooting

1200 Fan Lower Control Box Interconnect Strip

J9-1

AC-1

LINE

LOAD

5VB1

J9-3

EMI FILTER
D03-0181

BLACK - 120 VAC - OUTSIDE LIGHT
BROWN - 120 VAC - BURNER #1 LIGHT
BROWN - 120 VAC - BURNER #2 LIGHT
ORANGE - TEMPERATURE SENSOR
ORANGE - TEMPERATURE SENSOR
PURPLE - CONTROL POT P2
RED - 12 VDC - FAN #1 VAPOR HIGH LIMIT
RED - 12 VDC - FAN #2 VAPOR HIGH LIMIT
RED - 12 VDC - FAN #1 HOUSING HIGH LIMIT
RED - 12 VDC - FAN #2 HOUSING HIGH LIMIT
RED - 12 VDC - FAN #1 FLAME DETECTION
RED - 12 VDC - FAN #2 FLAME DETECTION
RED - 12 VDC - FAN #1 PLENUM HIGHT LIMIT
RED - 12 VDC - FAN #2 PLENUM HIGHT LIMIT
BLUE - 12 VDC - FAN #1 AIR SWITCH
BLUE - 12 VDC - FAN #2 AIR SWITCH
RED - 12 VDC - LOWER FIXED GRAIN LIMIT
RED - 12 VDC - USER SUPPLIED SAFETY
RED - 12 VDC - MOTOR OVERLOADS
RED - 12 VDC - LOWER ADJUSTABLE GRAIN HIGH LIMIT
YELLOW - 12 VDC - OUT OF GRAIN SENSOR
RED - 12 VDC - REAR DISCHARGE SWITCH
RED - 12 VDC - 12 VOLT SUPPLY
RED - 12 VDC - 12 VOLT SUPPLY
WHITE - 12 VDC NEG - 12 VOLT SUPPLY NEGATIVE
PURPLE -TIMING PULSE- LEFT METERING ROLL PULSE
PURPLE -TIMING PULSE- RIGHT METERING ROLL PULSE
PURPLE - CONTROL POT P1
PURPLE - CONTROL POT P3
BLACK - 120 VAC - MAXON POWER
WHITE - AC NEUTRAL - BURNER #1 NEUTRAL
WHITE - AC NEUTRAL - BURNER #2 NEUTRAL
WHITE - AC NEUTRAL - MAXON NEUTRAL
YELLOW - 120 VAC - LOAD POWER
ORANGE - 120 VAC - UNLOAD POWER
ORANGE - 120 VAC - SCR POWER
WHITE - AC NEUTRAL - FAN #1 NEUTRAL
WHITE - AC NEUTRAL - FAN #2 NEUTRAL
WHITE - AC NEUTRAL - UNLOAD NEUTRAL
WHITE - AC NEUTRAL - LOAD NEUTRAL
WHITE - AC NEUTRAL - SCR NEUTRAL
BLACK - 120 VAC - BURNER #1 POWER
BLUE - 120 VAC - FAN #1 POWER
BLACK - 120 VAC - BURNER #2 POWER
BLUE - 120 VAC - FAN #2 POWER

L1
B1
B2
S1
S2
SCR2
J1-5
J1-6
J1-7
J1-8
J1-9
J1-10
J1-11
J1-12
J1-13
J1-14
J1-19
J1-20
J4-12
J4-19
J5-4
J5-5
J5-8
J5-9
J5-12
J5-16
J5-19
J6-1
J6-4
J7-3
J7-4
J7-6
J7-8
J8-8
J8-9
J8-10
J8-12
J8-14
J8-16
J8-18
J8-20
J9-16
J9-17
J9-18
J9-19

EMERGENCY COOLING JUMPERS
INSTALL J6-13 TO J1-5
INSTALL J6-14 TO J1-19
INSTALL J6-16 TO J5-5
INSTALL J6-17 TO J4-19

I/O BOARD JUMPERS
INSTALL J1-9 TO J5-6
INSTALL J5-2 TO J5-20
INSTALL J4-12 TO J5-10
INSTALL J9-1 TO J9-5

45 - D01-0531 ENTRELEC TERMINALS
2 - D01-0533 END STOPS
1 - D01-0532 BLANK PROTECTOR ENDS

Portable Dryer Troubleshooting

Wiring Reference

Upper Control Box External Wiring

BLACK FROM J9-16 TO L1 ON FENWAL BOARD 120VAC POWER
WHITE FROM J7-04 TO L2 ON FENWAL BOARD 120VAC NEUTRAL
BROWN TO B1 FROM V1 ON FENWAL BOARD 120VAC
ORANGE FROM J1-09 TO FLAME DETECTION RELAYS
ORANGE FROM J5-08 TO FLAME DETECTION RELAYS

TO FAN CONTROL BOX

WHITE/BLACK STRIP J5-12 12VDC NEGATIVE
YELLOW TO J1-07 FROM HOUSING HIGH LIMIT SWITCH
RED FROM J5-08 TO HOUSING & VAPOR HIGH LIMIT SWITCHES
PURPLE TO J1-05 FROM VAPOR HIGH LIMIT SWITCH

BLUE FROM J5-08 TO AIRSWITCH COMMON TERMINAL
TO AIRSWITCH ASSEMBLY
BLUE TO J1-13 FROM AIRSWITCH N.O. TERMINAL

WHITE TO S1 FROM RIGHT GRAIN TEMPERATURE SENSOR
BLACK TO S2 FROM RIGHT GRAIN TEMPERATURE SENSOR
RED FROM J1-11 TO LEFT GRAIN HIGH LIMIT SWITCH
ORANGE TO J1-19 FROM LEFT GRAIN HIGH LIMIT SWITCH
PURPLE J7-03 MAXON POWER 120VAC (NATURAL GAS ONLY)
WHITE J7-08 MAXON 120VAC NEUTRAL (NATURAL GAS ONLY)

TO LOWER JUNCTION BOX

BROWN FROM J1-19 TO REAR DISCHARGE SWITCH
ORANGE TO J5-05 FROM REAR DISCHARGE SWITCH
RED 16 GA. A+ SCR DRIVE MOTOR
BLACK 16 GA. A- SCR DRIVE MOTOR
GREEN 16 GA. SCR DRIVE MOTOR GROUND
BLACK FROM J5-09 TO LOAD MERCURY SWITCH
BLACK TO J5-04 FROM LOAD MERCURY SWITCH

TO UPPER JUNCTION BOX

WHITE FROM J9-03 TO OUTSIDE LIGHT AC NEUTRAL
RED FROM L1 120VAC TO OUTSIDE LIGHT POWER

YELLOW FROM J1-05 TO PLENUM HIGH LIMIT SWITCH
WHITE TO S1 FROM GRAIN TEMPERATURE SENSOR
BLACK TO S2 FROM GRAIN TEMPERATURE SENSOR
BLUE TO J1-11 FROM PLENUM HIGH LIMIT SWITCH
YELLOW FROM J1-05 TO PLENUM HIGH LIMIT SWITCH
RED FROM J5-05 TO RIGHT GRAIN HIGH LIMIT SWITCH
ORANGE TO J4-19 FROM RIGHT GRAIN HIGH LIMIT SWITCH

TO PLENUM AND RIGHT
FIXED GRAIN HIGH LIMIT
SWITCHES AND TEMPERATURE
SENSORS

Portable Dryer Troubleshooting

Wiring Reference

Fan Housing and Vapor Hi-Limit Circuit

Wiring Reference

Portable Dryer Troubleshooting

Plenum Hi-Temperature Switch

Portable Dryer Troubleshooting

Wiring Reference

Fixed Grain Hi-Limit

BLUE J1-11

RED J5-05

ORANGE J4-19

YELLOW J1-05

TO UPPER CONTROL BOX

BLUE J1-11

LEFT GRAIN HIGH LIMIT SWITCH
D03-0005 210 DEGREE

YELLOW J1-05

RIGHT GRAIN HIGH LIMIT SWITCH
D03-0005 210 DEGREE

RED J1-11

ORANGE J1-19

TO LOWER JUNCTION BOX

PLENUM HIGH LIMIT SWITCH
D03-0004 300 DEGREE

AIR SWITCH

UNLOAD
MOTOR

LOWER
JUNCTION
BOX

SCR

GAS PIPE TRAIN

TEMP. SENSORS

FAN

BURNER
HI-LOW
THERMO

SOLENOID

LEFT FIXED
GRAIN HIGH
LIMIT
PLENUM

11XX

RIGHT FIXED
GRAIN HIGH
LIMIT

OUTSIDE LIGHT

LOAD MERCURY SWITCH

UPPER
JUNCTION
BOX

LOAD
MOTOR

Wiring Reference
Portable Dryer Troubleshooting

Grain & Plenum Hi-Limit Locations

FAN #1
PLENUM HIGH LIMIT SWITCH
D03-0004 300 DEGREE

FIXED GRAIN HIGH LIMIT SWITCH
D03-0005 210 DEGREE

FAN #2
PLENUM HIGH LIMIT SWITCH
D03-0004 300 DEGREE

RED TO J1-11

ORANGE TO J1-19

TO LOWER JUNCTION BOX

ADJUSTABLE
GRAIN HIGH
LIMIT
TEMP. SENSORS

OUTSIDE LIGHT

LOAD MERCURY SWITCH

FAN #1

FAN #2

12XX

SOLENOID

AIR
SWITCHES

SOLENOID

SCR

BURNER #1
HI-LOW
THERMO

BURNER #2
HI-LOW
THERMO

MAXON

2FNLMTSW98.PRT REV. DATE 4/5/98

UNLOAD
MOTOR

PLENUM #1

PLENUM #2

UPPER
JUNCTION
BOX

FIXED GRAIN
HI-LIMIT AND
THERMO SENSORS

LOAD
MOTOR

Portable Dryer Troubleshooting
Wiring Reference

Two Fan Plenum and Grain Limit Switch Wiring

YELLOW TO J1-12
BLUE TO J1-11
RED TO J1-05

Wiring Reference

Portable Dryer Troubleshooting

Rear Discharge & Emergency Cooling Circuit

LOOSEN SCREWS ON BRACKET
TO CHANGE SENSITIVITY
OF REAR DISCHARGE SWITCH

CONNECT TO SJOW CORD
INSIDE LRL BOX

POSITIONED WITH LID CLOSED AND
SJOW 18/2 CORD POINTED TOWARDS
THE FRONT OF THE DRYER CONNECT
INSIDE METER ROLL BOX TO BROWN
AND ORANGE WIRES.

Portable Dryer Troubleshooting
Wiring Reference

Rear Discharge Mercury Switch

Wiring Reference

Portable Dryer Troubleshooting

Adjustable Hi-Limit & Emergency Cooling Circuit

Portable Dryer Troubleshooting

Wiring Reference

Motor Overloads

Portable Dryer Troubleshooting

Wiring Reference

Air Pressure Switch

J5
11
12 VOLT SOURCE

12 VOLT
DC NEGATIVE

DC POSITIVE

J5-8
J1-8
J1-6
J1-10
12
J1-7
J4
J1-5
J1-9
J1-12
J1-11
J1-19

12V DC SOURCE FROM
MOTOR OVERLOADS

J6-14
J5-5
J4-19
J6-17

BLUE
J4-12

FAN #2 PRESSURE SWITCH

BLUE
J1-14

FAN #1 PRESSURE SWITCH

J1-13

BLUE
J2

BLUE

PRESSURE SWITCH SAFETY
CIRCUIT

1413
J1

INPUT/OUTPUT BOARD
TERMINAL LOCATIONS

HIGH

C N.C. N.O.

CALIBRATED WITH
DIAPHRAGM VERTICAL

TO UPPER CONTROL BOX

BLUE J1-13 AIRFLOW (N.O.)

BLUE J5-08 12VDC POSITIVE

BACKVIEW OF AIR SWITCH ASSEMBLY

AIR SWITCH

UNLOAD
MOTOR

LOWER
JUNCTION
BOX

SCR

GAS PIPE TRAIN

TEMP. SENSORS

FAN

SOLENOID

LEFT FIXED
GRAIN HIGH
LIMIT
PLENUM

11XX

RIGHT FIXED
GRAIN HIGH
LIMIT

OUTSIDE LIGHT

LOAD MERCURY SWITCH

UPPER
JUNCTION
BOX

LOAD
MOTOR

Portable Dryer Troubleshooting
Wiring Reference

Air Pressure Switch Drawing

Wiring Reference

Portable Dryer Troubleshooting

Out of Grain Safety Circuit

REMOVE THESE EARS

SJOW 18/2 WIRE
EXITS THROUGH
BOX COVER

WHITE
BLACK

FRONT VIEW OF OPEN BOX

LEADS MUST BE IN THIS POSITION
FOR PROPER OPERATION

FAN
AIR SWITCH

UNLOAD
MOTOR

LOWER
JUNCTION
BOX

SCR

GAS PIPE TRAIN

TEMP. SENSORS

BURNER
HI-LOW
THERMO

SOLENOID

LEFT FIXED
GRAIN HIGH
LIMIT
PLENUM

11XX

RIGHT FIXED
GRAIN HIGH
LIMIT

OUTSIDE LIGHT

LOAD MERCURY SWITCH

UPPER
JUNCTION
BOX

LOAD
MOTOR

Portable Dryer Troubleshooting
Wiring Reference

Out of Grain Safety Circuit Location

BLACK

WHITE

BLACK
WHITE

J9-03
BLACK
BLACK

L1
TO 12VDC J5-09
J5-04

TO UPPER CONTROL BOX

TO OUTSIDE LIGHT FIXTURE

RED

WHITE

TO LOAD MERCURY SWITCH

AIR SWITCH

UNLOAD
MOTOR

LOWER
JUNCTION
BOX

SCR

GAS PIPE TRAIN

TEMP. SENSORS

FAN

BURNER
HI-LOW
THERMO

SOLENOID

LEFT FIXED
GRAIN HIGH
LIMIT
PLENUM

11XX

RIGHT FIXED
GRAIN HIGH
LIMIT

OUTSIDE LIGHT

LOAD MERCURY SWITCH

UPPER
JUNCTION
BOX

LOAD
MOTOR

Wiring Reference
Portable Dryer Troubleshooting

Upper Junction Box Drawing

TO REAR
JUNCTION BOX

LEFT METER
ROLL SENSOR

16
J519
05 J1J5-

Y
B ELL
RE LACK OW
D

RED 12VDC POS
BLACK OR WHITE/BLACK STRIP 12VDC NEG
YELLOW LEFT METER PULSE RETURN
BLUE RIGHT METER PULSE RETURN
ORANGE REAR DISCHARGE RETURN
BROWN 12VDC TO DISCHARGE SWITCH

OR
BR ANGE
OW
N

2
5-1
9 J
5J -0
19
J5-

D
RE
K
LB AC
E
U
BL

RIGHT METER
ROLL SENSOR

TO REAR DISCHARGE SWITCH

J509
J512
J519

NOTE:
RIGHT SENSOR IS
NO LONGER USED ON
DRYERS MANUFACTURED
AFTER MARCH 1, 1997

Portable Dryer Troubleshooting
Wiring Reference

Meter Roll Sensor

T-3

T-2

T-1

12 Volt -

T-3

T-2

T-1

1997 Dryers have only 1 meter roll board.
Remove one meter roll board and tie the
2 T-3 wires together.

12 Volt +

Pulse

12 Volt -

12 Volt +

METER ROLL SENSOR

Meter Roll
Board

36
Meter Roll
Board

J5-12

J1-20

J5-9

J5-19

J5-16

J5-4

J7-8

J7-3

J7-4

J9-16

J1-13

J4-12

J4-19

J5-5

J1-19

J1-11

J1-5
J1-9

12
9

J1-7

J5-8

19
16

Wiring Reference
Portable Dryer Troubleshooting

Meter Roll Sensor Wiring

Wiring Reference

Portable Dryer Troubleshooting

Meter Roll Reversing
YOU MUST ENTER INTO THE DRYER
PARMETER MODE BY PRESSING THE
INCREASE AND DECREASE BUTTONS
SIMULTANIOUSLY. YOU WILL HAVE
THE FOLLOWING OPTIONS LISTED:
SHUTDOWN HISTORY (PRESS ENTER)
DRYER MODEL # (IE. 1112)
FAN DELAY (DEFAULT = 5)
FILL AUGER (DEFAULT = END)
BPH FACTOR (DEFAULT = 1.0)
TEST METER ROLL (DEFAULT = YES)
TEST AIR SWITCH (DEFAULT = YES)
M.R. REVERSE (DEFAULT = NO) <- CHANGE TO YES
* REVERSE DELAY (DEFAULT = 60)
* REVERSE TIME (DEFAULT = 1)

TO
SCR DRIVE
BOARD
A+
AORANGE

* DISPLAYED ONLY IF M.R. REVERSE
IS CHANGED TO YES
REVERSE DELAY = METER ROLLS NORMAL ROTATION TIME
(AMOUNT OF TIME METER ROLLS WILL OPERATE BEFORE
THEY WILL BEGIN REVERSE ROTATION)
REVERSE TIME = METER ROLLS REVERSE ROTATION TIME
(AMOUNT OF TIME METER ROLLS WILL OPERATE IN THE
REVERSED ROTATION MODE)

PURPLE

JUMPER WIRES SHOULD
GO BETWEEN:
TERMINALS 4 AND 5
TERMINALS 1 AND 8

EXAMPLE: REVERSE DELAY = 10 MINUTES
REVERSE TIME = 1 MINUTE

LOCATE THE ORANGE AND
PURPLE WIRES COMING FROM
THE SCR DRIVE BOARD GOING
TO THE TERMINAL STRIP AND
INSERT THE RELAY AS SHOWN

NOTE:
WHEN INSTALLING RELAY
BASE NOTE POSITION OF
SLOTS FOR RELAY!!

BLACK

J7-17
(110 VAC CONTROL)

WHITE

J8-20
(110 VAC NEUTRAL)

PURPLE

ORANGE

IMPORTANT
YOU MUST ADD A JUMPER WIRE
FROM J9-09 TO J7-16 IN THE
LOWER CONTROL BOX.

A- TO
A+
DC DRIVE
MOTOR
37

WIRES GO TO UPPER
CONTROL BOX

WHITE J7-08

RED 16 GA. A+ TO SCR DRIVE MOTOR
BLACK 16 GA. A- TO SCR DRIVE MOTOR
GREEN 16 GA. TO SCR DRIVE GROUND

TO SCR
DRIVE MOTOR

SJOW 18/2 WIRE

BLACK TO MAXON

PURPLE J7-03

WHITE TO MAXON

NATURAL GAS DRYERS ONLY

RED FROM J5-09 TO 12VDC POSITIVE TERMINAL ON METER ROLL SENSOR
BLACK FROM J5-12 TO 12V NEGATIVE TERMINAL ON METER ROLL SENSOR
YELLOW FROM J5-16 TO LEFT METER ROLL SENSOR
BLUE FROM J5-19 TO RIGHT METER ROLL SENSOR
BROWN FROM J1-19 TO DISCHARGE SWITCH
ORANGE FROM J5-05 TO DISCHARGE SWITCH

TO REAR
OF DRYER

BLACK S2
ORANGE J1-19

WHITE S1
RED J1-11

TO LEFT FIXED
GRAIN HIGH LIMIT
AND TEMPERATURE
SENSORS

FAN
AIR SWITCH

UNLOAD
MOTOR

LOWER
JUNCTION
BOX

SCR

GAS PIPE TRAIN

TEMP. SENSORS

BURNER
HI-LOW
THERMO

SOLENOID

LEFT FIXED
GRAIN HIGH
LIMIT
PLENUM

11XX

RIGHT FIXED
GRAIN HIGH
LIMIT

OUTSIDE LIGHT

LOAD MERCURY SWITCH

UPPER
JUNCTION
BOX

LOAD
MOTOR

Wiring Reference
Portable Dryer Troubleshooting

Lower Junction Box Wiring

Portable Dryer Troubleshooting

Wiring Reference

New Fenwal Board Wiring
The B. GND terminal is used to ground the burner and to complete the flame current signal circuit. This terminal is
new for systems that used the older version of the Fenwal board. This terminal must be connected to the burner
(chassis) ground not only to ensure the best, long term, stable flame signal, but also to ground the burner for
proper sparking.
The use of a burner ground terminal eliminates the problem of loss of flame sense signal due to a missing or loose
neutral or ground (green) wire at the 120 VAC power source. The new board has been designed such that reversing
the polarity of the 120 VAC line does not cause a loss of flame signal. Thus providing a more reliable flame signal
along with a reduction of nuisance lockouts, due to its design and the use of the B. GND terminal.
L2
V2
(A) L1

(B) V1
S1

H.V.

NEU.

120
VAC
GAS
VALVE

H.V.

BURNER

HOT

B. GND
L1
V2
L2

BURNER

HOT
NEU.

120
VAC

GAS
VALVE

V1
NC

Old version with Remote Flame Sense.

New version with Remote Sense using existing
spark and remote sense electrodes.

Note that terminal E2 on the old version has been replaced by terminal B.GND on the new board.

IGNITOR

BURNER
GROUND
(B. GND)

FLAME ROD
Part No. HF-4624
Flame Safety Board

Portable Dryer Troubleshooting

Wiring Reference

Fenwal Board Troubleshooting
On-Board Diagnostics
The LED will flash on for 0.2 seconds then off for 0.2 seconds to indicate an error condition.
The pause time between error codes will be 2.5 to 3.0 seconds. During power-up, the LED will light
for one second and then turn off to indicate normal operation.
LED Indication
Steady on
2 Flashes
3 Flashes

Fault Mode
Internal Control Failure
Flame Fault**
Ignition Lockout Fault

** May indicate either that a flame was detected during
pre- or post-purge, or that there is a flame sensing error.
If a lockout occurs, the board will have to be reset
by shutting off the power to the board.

Measure Flame Current

S1
+

Flame
Test

Flame
Test
FC+

FC-

Micro Amp Meter

BURNER

YES

ALL WIRES COME FROM
MAIN CONTROL BOX

20 SEC SAFETY
20 SEC INPUT

12 VOLTS DC

WHT
BLK
BRN

120 VOLTS AC

NEUTRAL
120 VOLTS AC
BURNER LIGHT

L1
BLK

BRN

WHT

FENWAL BOARD

WHT

L2
Neutral

TIME
DELAY

WHT

Coil BLK

WHT

Neutral

Coil

BRN

WHT

BRN

OR
OR

Normal Closed

BLK
Normal Closed

COIL

WHT

3
2

5
4

8
7

TER. 1-5 (12 VOLTS DC)

TER. 6-8 (110 VOLTS AC)

COMMON

FLAME
SENSOR

COMMON

IGNITOR

Portable Dryer Troubleshooting
Wiring Reference

Flame Control Circuit

COM

SWITCH CLOSES WHEN
PRESSURE IS SENSED

BROWN

MERCOID
PRESSURE SWITCH

NEUTRAL- - - - WHT
BURNER LIGHT - BRN

110 VOLTS AC

110 VOLTS AC
TO BURNER CIRCUIT

N/C

N/O

BRN

BLK

BLACK

BROWN

GREY

WHITE

FLAME
SENSOR

FENWAL PART# HF-4624

IGNITOR

WHITE

PUR
RED
YEL
ORG
ORG
PNK

VAPOR LIMIT
HOUSING LIMIT
12 VOLTS DC
20 SEC SAFETY
20 SEC INPUT
MERCOID SAFETY

WHITE

BLK

L1 BURNER

TIME
DELAY

GREY

3
2

5
4

BLACK

7
6

ORG

BLK

WHITE

ORG

PURPLE
PURPLE

BROWN
WHITE

9
8

MERCOID SAFETY
RELAY

BLK
WHT
BRN
PUR
RED
YEL
ORG
ORG
PNK

TER. 1-7 (12 VOLTS DC)
TER. 8-10 (110 VOLTS AC)

BLACK

MERCOID
SWITCH
WIRING

BROWN

ORG
ORG

YELLOW

BROWN

LIQUID

LOW
t

SOLENOIDS
VAPOR
HOUSING

BROWN

HIGH

HONEYWELL THERMOSTAT
PART# D03-0047

* MERCOID TERMINALS
J4-20 FOR 1 FAN DRYERS
J4-18 FOR 2 FAN DRYERS

Wiring Reference
Portable Dryer Troubleshooting

Fan Burner Circuit for Canadian Models Only

Portable Dryer Troubleshooting

Wiring Reference

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

Wiring Reference

Portable Dryer Troubleshooting

Fan 28 LP Hi/Low-On/Off

Portable Dryer Troubleshooting

Wiring Reference

Fan 28 LP Hi/Low-On/Off Burner With Mercoid

Wiring Reference

Portable Dryer Troubleshooting

Fan 28 NG Hi/Low-On/Off

Portable Dryer Troubleshooting

Wiring Reference

Fan 28 NG Hi/Low-On/Off Burner With Mercoid

Wiring Reference

Portable Dryer Troubleshooting

Fan 42 LP Hi/Low-On/Off

Portable Dryer Troubleshooting

Wiring Reference

Fan 42 LP Hi/Low-On/Off Burner With Mercoid

Wiring Reference

Portable Dryer Troubleshooting

Fan 42 NG Hi/Low-On/Off

Portable Dryer Troubleshooting

Wiring Reference

Fan 42 NG Hi/Low-On/Off Burner With Mercoid

J6-4

SCR P3

PUR

TO TERMINAL ON
UPPER POWER STRIP
WITH POWER WIRES

A-

A+

J6-1

SCR 2

SCR P2

J8-10

SCR POWER

SCR P1

J8-20

SCR NEUTRAL

To SCR Drive Motor

L1
L2

6
8
A2
5
7
A1

COIL

F+

F-

A+

A-

T1
T2

S C R Board

BLK

To Coil

220 Volt

SCR
CONTACTOR

Fuse
L2

Wiring Reference
Portable Dryer Troubleshooting

SCR Drive Circuit

INSIDE GRAIN COLUMN CONDUIT

FRONT
WHITE 20 GA.

BLACK 20 GA.

WHITE 20 GA.

BLACK 20 GA.

TO UPPER CONTROL BOX

WHITE S1

SOLDERED AND INSULATED INSIDE CONDUIT

INSIDE GRAIN COLUMN CONDUIT

FRONT

BLACK S2

REAR

SOLDERED AND INSULATED INSIDE CONDUIT

BLACK S2
WHITE S1

TO LOWER JUNCTIONL BOX

AIR SWITCH

UNLOAD
MOTOR

LOWER
JUNCTION
BOX

SCR

GAS PIPE TRAIN

TEMP. SENSORS

FAN

BURNER
HI-LOW
THERMO

SOLENOID

LEFT FIXED
GRAIN HIGH
LIMIT
PLENUM

11XX

RIGHT FIXED
GRAIN HIGH
LIMIT

OUTSIDE LIGHT

LOAD MERCURY SWITCH

UPPER
JUNCTION
BOX

LOAD
MOTOR

Portable Dryer Troubleshooting
Wiring Reference

RTD Temperature Sensor

54
S2

3.4 ON 20K
SCALE AT
70 DEGREES

1 2 3
7 8 9

MOISTURE
CONTROL
THERMOSTAT

6 5 4

J5-3

FIG.1

IF NONE OF THE MEASUREMENTS = 3.4 K,
THEN CHECK EACH INDIVIDUAL SENSOR.

IF MEASUREMENTS DO NOT = 3.4 K
CHECK CONNECTIONS IN WHITE
JUNCTION BOX ON FAR LEFT AND
RIGHT SIDES FACING THE FAN END.

IF OHMS DOES NOT = 3.4 K
CHECK LOWER AND UPPER TERMINAL
STRIP (ON SINGLE MODULES CHECK S1 & S2)
(ON DOUBLE OR TRIPLE MODULES
CHECK J6-9 TO J6-6 = 3.4 AND
CHECK J6-11 TO J6-8 = 3.4)

USING OHM METER BEGIN CHECKING
THE SENSORS FOLLOWING FIG. 1

E.M.C.S. PORTABLE DRYERS

Wiring Reference
Portable Dryer Troubleshooting

Test Procedure for E.M.C.S. Dryers

Portable Dryer Troubleshooting

Temperature Charts

We use two (2) different types of sensors (NTC thermistor on the Competitor Series 2000, and an
encapsulated sensor on the E.M.C.S dryer) in our dryers. The resistance of the sensors varies according to the
outside temperature. For example, on the E.M.C.S. dryers, for every one (1) degree rise in temperature the
resistance increases 4.8 ohms. However, on the Competitor Series 2000 dryer, the sensor reacts just the opposite,
the resistance rises with colder temperatures. The charts displayed above will help when troubleshooting any
sensor problems.

Troubleshooting Tips

Portable Dryer Troubleshooting

DC Drive Metering Roll System

in the 2 Speed position. If this is present
then the SCR contactor and input/output board
are okay.

Symptoms: Metering Roll will not turn,
dryer shutdown-"Metering Roll Drive Failure"

Metering Roll Operation
•

The DC drive system on the portable
dryer is used to control the output of grain
from the dryer. It is adjusted from the
front of the control box using the high and
low metering roll potentiometers. Components used in this circuit are the SCR
contactor, SCR drive board, DC motor/
gear box, and the input/output board from
the Electronic Monitoring Control System.

•

All voltage for the drive system comes
from terminals 1-(L1) and 3-(L2) of the
SCR contactor. There should be 220 volts
AC across these two points even if the
unload system is turned off. If this voltage
is zero, check your incoming main power.

•

When the unload system is turned on you
should be able to observe the SCR
contactor energizing. The power to the
contactor should turn on and off with the
unload switch. You can check for power by
putting an AC voltmeter across terminals
A1 and A2. Across these points you
should read 120 Volts AC. Also on the top
of the contactor you can see a plunger pulling
in whenever the contactor coil gets power. When
the contactor is energized, power is transferred
from terminals L1 and L2 to terminals T1 and
T2. Understand that L1 and L2 are the Input
of the SCR contactor and T1 and T2 are the
Output of the contactor.

Check the SCR Drive Board
•

Next if all the above checks out okay, put
your voltmeter across terminal L1and L2 of the
SCR drive board. You should get 220 Volts AC
across these points when the Unload Switch Is

•

If 220 volts AC is present across input of
the SCR drive board (L1 and L2) then
check for voltage across the output of the
board. Change your voltmeter to check for
DC voltage at a range above the 200 volt
scale. Put the leads across A+ and A-. The
voltage across these two points will vary
depending on where the speed control potentiometer is turned. Also try turning the potentiometer up and down. The voltage should go
from zero to approximately 180 Volts DC. If
zero voltage is present across the A+ and Aterminal, first try to disconnect the wires from
these two points and then check for DC volts
again. If the voltage returns, suspect a bad
motor or a problem in the wiring to the motor.
If the voltage does not return, suspect a bad
DC drive board.

Check the Motor
•

The wires attached to A+ and A- go directly to
the DC drive motor on the dryer. You may
remove the top cover of the motor and check
for the same DC voltages mentioned above at
the motor. If the voltage is not present try to
disconnect the wires, then check for DC volts
again. If you do not get any voltage then look
for a broken or loose wire between the motor
and the drive board terminals.

•

If the voltage is present suspect the motor
or the gear box. Removing the motor from
the gear box and trying to run the motor only
is one way of narrowing down the problem, or
you may want to remove the chain and see if
the metering rolls are froze up. Using a pipe
wrench is an easy way to try and rotate the
metering rolls.

Portable Dryer Troubleshooting

Troubleshooting Tips

Fenwal Ignition System. If no voltage is
present after the 10 second purge delay,
check for voltage going through the auxiliary switch mounted on the side of the fan
contactor for that burner. This switch has
to close before the Fenwal gets power. If
this is OK, check the appropriate output
on the input/output board for that burner.

Fenwal Ignition System
Symptoms: Burner will not light, dryer
shutdown for "Loss of Flame"

Fenwal Ignition Operation
•

The Fenwal Ignition System ignites the
Fenwal
Operation
burnerIgnition
and monitors
the flame. Once 120

VAC is applied to the Fenwal, the solenoids
are powered up and the transformer begins
ignition through the ignitor. If flame is
sensed during the ignition period (about
4 seconds), the transformer is turned off,
but the solenoids stay on. If no flame is detected after the ignition period, both the solenoids
and transformer lose power and the dryer
begins a shutdown sequence.
•

All voltage for the Fenwal Ignition
System is derived from the input/output
board of the Electronic Monitoring
Control System. For ignition to occur:
1. The fan must be turned on.
2. The pressure switch in the plenum
must indicate the fan is operating.
3. The burner switch must be in the
auto or manual position.
4. The dryer must go through a 10
second purge delay, which is indicated
on the LCD screen.
ing
These steps must take place before troubleshooting
of the Fenwal System can occur. The following
assumes the above steps have been taken.

Fenwal Troubleshooting
•

The Fenwal Board located in the fan can
control box on the dryer has seven(7)
terminals. They are L1, L2, V1, V2, S1, S2
and E2. L1 and L2 are considered the input
to the board. After the 10 second purge delay,
an AC voltmeter connected Across L1 and
L2 should read 120 Volts AC. If this is true,
you can assume the input/output board is
operating properly and the problem is in the

•

If voltage is present across L1 and L2,
check for voltage across the Output of
the Fenwal board. The output terminals
are V1 and V2, and they will also have
120 VAC across them for approximately four(4) seconds. The four(4)
seconds is the amount of time the Fenwal
has to ignite and sense flame or it concludes
no flame is detected and begins a "Loss of
Flame" shutdown. If you have power on the in
put terminals and no voltage on the output terminals, unload the secondary (take the wires off
of V1 and V2) and recheck for voltage. If no
voltage is present then suspect a bad Fenwal
board. If power returns, look for a bad solenoid valve or a problem in the wiring.
Note: All of the above voltage checks can be
bypassed if you can hear one or more of the
solenoids on the gas train snap on after the 10
second purge delay. This is true because the solenoids are connected across V1 and V2, and
for the solenoids to come on, power must be
going through the Fenwal board. Also during
the four(4) second ignition period the transformer is energized and you should be able to
observe sparking across the ignitor. If the solenoids snap, but no ignition takes place, check
for loose ignitor wires or check the ignitor condition/ignition gap (1/8 " to 3/16"). Remember
even if flame is sensed the sparking will discontinue after the ignition period (4 seconds).

Continued on page 55.

Troubleshooting Tips

Portable Dryer Troubleshooting

Fenwal Ignition System continued...

Hints
•

Hearing the solenoids snap on after the
10 second purge delay means that power
is coming to and through the Fenwal
board. The Fenwal board is probably okay.

•

If flame is sensed, the power to the solenoids stays on but the power to the ignitor
always goes off after about four(4) seconds.

•

Power to the low pressure solenoid is always on anytime flame is sensed. This is
because the power to the low solenoid is
hooked directly across terminals V1 and
V2 of the Fenwal board.

•

Power to the high pressure solenoids is
controlled by the Plenum thermostat. One
side of the solenoid is hooked to V2(neutral)
and the other side is run through the normally closed switch of the thermostat and
then back to V1. This is how the burner is
made to cycle. When the plenum is below
tem perature, power is run through the ther
mostat to the high pressure solenoid. When
temperature is reached, the thermostat opens
and the high solenoid loses power.

•

L2 and V2 are connected internally in the
Fenwal, and they must be nuetral.

Ignitor Tips
•

Make sure that the ignitors are mounted
correctly through an opening in the burner
skirting. Also, make sure that they are not close
enough to the edges of the opening to cause a
spark to jump the skirting, instead of between
the ignitors.

•

Be sure that the ignitor tips are no more than
1/8" apart from each other.

•

Make sure that the wire connections on the
ignitors are good and tight.

•

On stubborn lighting burners reverse the
direction the ignitor tips are facing. Instead of
having the tips pointing toward the fan or burner,
change the direction so the tips are facing the exhaust end of the dryer. (This is especially true on
burners with no burner cone installed (i.e. Natural Gas).

Troubleshooting Tips

Portable Dryer Troubleshooting

the incoming 12 volts DC (the T1-+12V and
T2-GND terminals), and one is a pulsing
12 volts DC back to the input/output board
(the T3 out terminal). Checking across T1
and T2 will verify that 12 volts DC is getting
to the sensor.

Metering Roll Sensors
Symptoms: No BPH, Total Bushels, RPM displayed on LCD or dryer shutdown with metering
roll problems

Metering Roll Sensor Operation
•

Each metering roll on the portable dryer
has a sensor mounted to read pulses as
the metering roll is turning. These
pulses are transmitted to the input/output board of the Electronic Monitoring
Control System. The computer interprets this information and then displays
the data on the LCD screen.
• All voltage for the metering roll sensors
is derived from the input/output board
of the Electronic Monitoring Control
System. The sensors are operated with
12 Volts DC from terminals J5-9 and J512 on the board. When checking for voltage the negative or black probe (-)of a
voltmeter should always go to terminal
J5-12.
Always use j5-12 for the negaitve anytime you
check for any DC voltage on the dryer.
Then put the red probe (+) of the voltmeter on terminal J5-9. Across these
two points there should be 12 volts DC.
This voltage needs to be checked, but
you can be reasonably assured the 12
volts DC is present if the rest of the dryer
is operating. Check for this voltage on
the terminal strip in the upper control
box.
•

•

12 volts DC is transmitted from J5-8
and J5-12 directly to the metering
roll sensors located on the back of the
dryer. Each of the metering rolls is enclosed in a white plastic box mounted to the
back of the metering rolls. Inside each box
is the metering roll sensor and the metering
roll wheel.
Each sensor has three(3) wires connected to it. Two(2) of these wires are

•

The T3 (out) terminal is what delivers
the metering roll information back to
the input/output board in the main control box. The information for the metering roll on the left side of the dryer is
sent on a yellow wire and goes to terminal J5-16. The information for the metering roll on the right side is sent on a
blue wire and goes to terminal J5-19.

•

You can use a DC voltmeter to observe
this pulsing voltage. The best place to
check for this voltage is directly on the
input/output board located in the very
back of the lower control box on the
dryer. Check for a pulsing voltage from
J5-16 to J5-12 (negative) and J5-19 to
J5-12 (negative). Across each of these
test points you should be able to observe a pulsing DC voltage when the
metering rolls are turning. You should
be able to speed up or slow down the
pulses by turning the speed of the metering rolls up or down.
Note: Because a digital voltmeter cannot
react fast enough you may not see a full
12 volts DC, instead you may see a pulsing
from zero to about eight(8) volts.

Hints
•

When checking for a pulsing voltage on
J5-16 or J5-19 you should always leave
the voltmeter across the terminals for
about 30 seconds. Watch the meter
closely. Each pulse should be about the
same length and about the same time
apart. If this is not true, suspect a problem with the sensor on the back of the dryer.
59

Troubleshooting Tips

Portable Dryer Troubleshooting

driver and turn the adjusting screw counterclockwise. Turning it this way makes
the switch more sensitive to pressure and
will turn on the light easier.

Air Pressure System
•

When inspecting the sensor make sure
that the wheel going through the sensor is
positioned in the center and is not touching either side. If the sensor is scratched
it is either bad or will probably go bad.

•

If adjusting the screw does not solve your
problem consult the layout diagram of the
input/output board. Look for the input for
the problem switch. Example: Fan #1
switch's input is J1-13. This is a 12 volt
DC input and it can be checked with a DC
voltmeter. One of the following conditions
will exist when checking this input.
NO AIR PRESSURE---ZERO VOLTS
HAS AIR PRESSURE---12 VOLTS DC
Remember when checking for 12 volts DC
you should always use one of the DC
negatives for the black probe(-) of your
voltmeter. Some of the terminals that
may be used for the negative(-) are J5-11,
J5-12 or J5-13.

•

To check fan #1 for air pressure with a
voltmeter:
1. Turn on the dryer.
2. Place the black probe(negative) of
your voltmeter on J5-11 or J5-12.
3. Place the red probe(positive) of your
voltmeter on J1-13. At this point
there should be zero volts here because the fan is not running.
4. Turn on the fan and watch your voltmeter.

•

If the air switch is adjusted properly you
should have zero volts across these test
points when you first turn on the fan. After the fan has run up to about one half of
its normal operating speed you should see
the voltmeter change from zero volts to 12
volts DC. This also works in reverse when
turning off the fan. After the fan is first
turned off, the voltmeter should still show
12 volts DC until the fan has slowed down
to about one half of its operating speed.
This is because even though the fan is
turned off it is still turning and developing some
pressure in the plenum.

Airflow Operation
Symptoms: Dryer will indicate a "Loss of Airflow"
•

After turning on a fan the computer must
get a signal from the air pressure switch
telling it that the fan is actually running
and the plenum has been pressurized. If
the switch does not show the air pressure
within 20 seconds a "Loss of Airflow"
shutdown occurs.

Troubleshooting: "Loss of Airflow"
•

This error message indicates that the fan
is running and the air pressure in the plenum did not pressurize. First, verify that
the fan is running, and the dryer is full of
grain. There must be grain in the dryer or
no pressure will develop. If the fan does
come on and the dryer is full of grain, but
a "Loss of Airflow" shutdown still occurs,
check the air pressure switch circuit.

•

Watching the blue light in the fan switch
is the easiest way to tell if the air pressure switch is sensing air pressure. Each
air pressure switch has a light in the fan
switch that will only come on if air pressure has developed. Turn on the fan and
after it has run up to about one half of its
operating speed the light should go on. If
the fan light is not coming on then the air
pressure circuit is not sensing pressure.

•

Try adjusting the air switch on the front
of the plenum to see if it is just out of adjustment. Use a straight blade screw-

Troubleshooting Tips

Portable Dryer Troubleshooting

•

If all the above fails to work then remove
the two wires while blowing into the air
tube. Blowing into the switch is the same as
having air pressure in the plenum. You
should have an open circuit until you blow
into the switch, then it should close. If the
switch does not close try adjusting it, or
replace it with a known good one.

Vapor High Temperature
Symptoms: Dryer runs for only a short period of
time, then a shutdown occurs.erature Operation

•

This message indicates that the vaporizer on
an LP Dryer is not properly adjusted. LP
(liquified petroleum) must be vaporized
before the burner can operate properly. If
LP is being fed to the dryer it must run
through a vaporizer before it can be burned.
If the vaporizer is getting the fuel too hot it
will cause a Vapor High Limit shutdown.

•

The vaporizer is located in the fan/heater
unit. It is wrap of pipe mounted inside the
fan can directly in front of the burner. It
can be seen by looking through the inspection door on the side of the burner.

•

To properly adjust the vaporizer a 1/2"
wrench is needed. Knowing that the gas
can get too hot, you must feel the pipe train
before the regulator to check this temperature. This point may be very hot so be
careful while checking the temperature.
The temperature before the regulator must
be warm to the touch. This point cannot be
hot, nor can it be cold...only warm. Use the
1/2" wrench to loosen the hold down
bracket on the vaporizer. Move the vapor
izer away from the flame to cool down the
pipe train or move it closer to the flame to
make the pipe train warmer.

Hints
1. Dryer must be full of grain.
2. Light in the fan switch can be used exactly
like a voltmeter to test.
3. Make adjustments of the pressure in one
quarter turns.
4. Make sure the air tube in the plenum is
not plugged after sitting over the summer.
5. Check the bulb in the fan light. It is a 12
volt bulb.

Troubleshooting: Vapor High
Temperature
•

The dryer will shutdown but will probably
restart as soon as the computer is reset.
This is because the high limit is an automatic reset and after the dryer shuts down it
allows the pipe train to cool down.

•

After the dryer is reset, it will run from a
few seconds to a few minutes and then
shutdown again. This is because the
Vapor High Limit is heating up again as
61

Troubleshooting Tips

Portable Dryer Troubleshooting

soon as the burner is turned on. The
vaporizer must be adjusted to solve this
problem.

The two wrap has less surface area and it
will not heat the LP quite as much. This
may also be true in colder climates where a
two wrap will not heat up enough. In this
case, the pipe train may develop frost or
even freeze the solenoids open.

Using J5-11 as the negative test point for all voltage
tests, check for 12 volts DC using the following terminals to help diagnose the problem:
Fan #1-J1-5
Fan #3-J2-5
Fan #5-J3-5

The Vapor High Limit is an automatic reset
safety device. It will reset itself as soon as
its temperature drops below 190° F. Because the pipe train of the burner cools
down rapidly when there is a dryer shut
down, the Vapor High Limit will generally
be cool before the operator gets back to the
dryer. As soon as he hits the stop button to
reset the computer, it comes back up to
normal operation. It appears that the dryer
is shutting down for no apparent reason.
Usually if this happens the dryer will shut
down again a short while after restarting the
dryer.

If the LP tank feeding the dryer is getting
very low on fuel, it can also cause the
dryer to shutdown on a Vapor High Limit.
Before adjusting the vaporizer always
check the fuel level in the customers tank.
If the fuel pressure is very low, try suggest
ing that the tank be refilled. Usually this
will solve the problem.

Fan #2-J1-6
Fan #4-J2-6
Fan #6-J3-6

Remember that each of these input terminals is part of
the main safety circuit of the dryer, and each must
have 12 volts DC on it before the dryer will operate.

Vapor High Limit Hints
1.

Anytime you adjust the Vapor High you
should wait and be sure that the pipe train
temperature stays constant. It may slowly
allow the pipe train to get hotter or colder
the longer the dryer runs.

If a dryer is shutting down constantly from
a Vapor High Limit, it may also be caused
from a gas line that is exposed to direct
sunlight. If the fuel line to the dryer is
exposed to direct sunlight, the liquid in
the line will start to vaporize before it
even gets to the dryer. Then, when it runs
through the vaporizer it gets too hot and
causes a shutdown (no matter where you
try and adjust the vaporizer). This problem can be helped by insulating the gas
line from outside heat.

In extreme cases the vaporizer may have
to be changed before it will run the proper
temperature. Example: If a dryer has a
burner with a three wrap vaporizer and the
dryer is located in the southern United
States, you may have problems adjusting
thevaporizer far enough from the flame.
In this case, you may have to install a two
wrap vaporizer.

Troubleshooting Tips

Portable Dryer Troubleshooting

Out Of Grain Warning Shutdown

Before setting the Out of Grain timer,
monitor how long it takes the dryer to
refill for shrink. Then, set the Out of
Grain timer accordingly. Example: If a
dryer takes six minutes to refill for
shrink, add an additional five minutes to
this, and use this as the amount of time to
program into the Out of Grain timer. The
additional five minutes is to avoid any
nuisance shutdowns. A lot of customers
don't want their fill augers to run empty if
the source of grain runs out. They may
want to set the Out of Grain timer closer
than the additional five minutes. (this is
fine, but caution the customer that it may
cause some nuisance shutdowns.)

For the Out of Grain warning to work
properly, the fill equipment must be large
enough to handle the capacity of the
dryer. You do not want the side columns
to get low on grain. This will allow the
airflow to escape from the dryer through
the side screens. If this happens you lose
efficiency and may start having a loss of
airflow shutdown.

Out Of Grain Warning
•

This message indicated that the dryer has
run low on grain. The shutdown occurs
when the loading equipment has run
longer than the time the operator has set on
the Out of Grain timer. The mercury
switch located on top of the dryer tells the
computer when the dryer is full or calling
for grain. The shutdown usually occurs
when the loading equipment is having
trouble keeping up with the output of the
dryer.

Possible Solution
•

Look at the loading equipment to see if this
is the problem. Remember, the top hopper
of the dryer should always have grain in it.
If any of the side screens are opening up at
anytime, then you are losing heat along
with efficiency. This indicates that you are
not filling fast enough. Speed up the
loading equipment to the dryer.

•

Using J5-11 for the test point ground, test
for 12 volts on J5-4 to test the load mercury
switch. This switch should have 12 volts DC
on it when the dryer is calling for grain and has
zero volts on it when thedryer is full.

Out of Grain Hints
1.

The out of grain timer is only in use when
the fill switch is in the auto position. In
the manual position the top mercury
switch will still shut off the fill auger, but
the dryer will not shutdown if the source
of grain to the fill auger is depleted.

Troubleshooting Tips

Portable Dryer Troubleshooting

Motor Overload Helpful Hints

Motor Overload Shutdown
This indicates that one of the Motor Overloads
has tripped, shutting down the dryer. Each of the Motor
Overloads is located in the upper main power control
box. They are all wired into a single series circuit that
goes to the input/output board on terminal J4-12. Before the dryer will start terminal J4-12 must have 12
volts DC present, or the Motor Overload shutdown will
occur.
Visually inspect each of the overloads. You can
tell by looking at them if a trip has occurred. Simply
press the reset handle on the overload to reset it. After
resetting the overloads press the stop button to clear the
error.
If no overloads are tripped try the following voltage tests: Using terminal J5-11 as the negative terminal
for all DC voltage checks. Look for 12 volts DC on
terminal J-419. This is the terminal that feeds power to
the Motor Overloads. If the 12 volts DC is present then
check for voltage on J4-12. During a Motor Overload
shutdown J4-12 should have zero volts. If you have
power going to and not returning to J4-12 inspect the
siring from J4-19 to the overloads and then back to J412. If the wiring is okay, turn off all power to the dryer
and do a continuity check from J4-19 to J4-12. This
must be closed circuit to operate properly.

Each of the Motor Overload is run in a
series circuit. This means, if any of the
Motor Overloads trip, a shutdown will
occur. Visually inspect the overload to tell
which has caused the shutdown.

Even though GSI uses ambient compensated overloads, hot weather or positioning
the dryer control box in the sunlight may
cause a Motor Overload shutdown to
occur. This can usually be tested by trying
to run the dryer with the control box door
open a little bit.

Each of the overloads has an adjustable
trip setting that can set up to 115 %. At
115% the overload will hold in longer
before it trips.

Always check amperages on the motors to
be sure that the problem is not in the
motor itself.

Remember that each motor has a built-in
service factor. This allow the motor to
actually run over the rated full load amps.
The motor manufacturers have allowed
GSI, on a number of applications, to run
motors over the full load amp rating. this
is possible because they are being used in
an air over application.

Portable Dryer Troubleshooting

Competitor Series 2000 Portable

6
7

TO LOAD
MOTOR

TO FAN #1
MOTOR

AC-1

SCR BOARD
RESISTOR

25 AMP
8 AMP

1F0

3FO

SCR BOARD RESISTOR VALUES
1108-1112 (1/3H.P. 240V) #D03-0039
1114-1126 (3/4H.P. 240V) #D33-0001

ARM
FUSE

TO AUX LOAD
MOTOR

J6-02

16GA BLACK

MAX MIN

TRANSFORMER

110 VAC OUTPUT

110X0

SCR
CONTACTOR

ACCEL

TO UNLOAD
MOTOR

1FO

220 VAC INPUT

3F0

220V FUSES

LINE
FUSE

TO AUX UNLOAD
MOTOR

FAN #1

LOAD

LOAD AUX

UNLOAD

3FI

1FI

DISTRIBUTION
BLOCK

INPUT

KBIC BARRIER TERMINAL BOARD

FAN #1
CONTACTOR

OVERLOAD

MAIN
BREAKER

SCR BOARD ASSEMBLED
D03-0104

UNLOAD AUX

LOAD
CONTACTOR

FAN #1
BREAKER

OVERLOAD

UNLOAD
CONTACTOR

LOAD
BREAKER

OVERLOAD

UNLOAD
BREAKER

OVERLOAD

Competitor Wiring Reference
Portable Dryer Troubleshooting

220 Volt Single (1) Phase Power Drawing

A+ AP3 P2P1 I1 F+
F- L1 L2

Portable Dryer Troubleshooting

Competitor Wiring Reference

220 Volt Single (1) Phase Power Drawing (New Version)

UNLOAD
OVERLOAD

4 5 6

TO UNLOAD
MOTOR

1 2 3

TO AUX UNLOAD
MOTOR

10 11 12
TO LOAD
MOTOR

7 8 9
TO AUX LOAD
MOTOR

LOAD AUX
OVERLOAD

LOAD
CONTACTOR

UNLOAD
CONTACTOR

UNLOAD AUX
OVERLOAD

LOAD BREAKER

BREAKER

UNLOAD

LOAD
OVERLOAD

TO FAN #1
MOTOR

13 14 15

FAN #1
OVERLOAD

FAN #1
CONTACTOR

FAN 1 BREAKER

AC NEUTRAL

TRANSFORMER

110 VAC OUTPUT

220 VAC INPUT

DISTRIBUTION
BLOCK

AC1

AC-1

3FO

110X0

1FO

SCR
CONTACTOR

120V FUSES

220V FUSES

MAIN
BREAKER

Competitor Wiring Reference
Portable Dryer Troubleshooting

220 Volt Three (3) Phase Power Drawing

Portable Dryer Troubleshooting

Competitor Wiring Reference

220 Volt Three (3) Phase Power Drawing (New Version)

Competitor Wiring Reference

Portable Dryer Troubleshooting

COMPETITOR POWER CIRCUIT
( 220 VOLT 1PH )

Portable Dryer Troubleshooting

Competitor Wiring Reference

COMPETITOR POWER CIRCUIT
( 220 VOLT 3PH )

Competitor Wiring Reference

Portable Dryer Troubleshooting

COMPETITOR POWER CIRCUIT
( 440 VOLT 3PH )

Competitor Wiring Reference

Portable Dryer Troubleshooting

Upper Control Box Internal Wiring

COM

J3-02

COM

YEL
YEL

LOAD

WHT

UNLOAD

J3-01

UNLOAD

UNLOAD
OVERLOAD

UNLOAD AUX.
R
R

N/O
N/C

BREAKER

ORG
ORG

R
R

YEL

N/O
N/C

J3-11

FAN #1

BREAKER

LOAD

LOAD
OVERLOAD

LOAD AUX.

WHT
J3-12

BLU
R

J6-03

J1-17

RED

+12 VDC

J7-08

RED

HOUSE HI LIMIT

J7-02

RED

VAPOR HI LIMIT

J1-13

RED

FAN #1

USER SAFETY

FAN #1
OVERLOAD

WHT
J3-14

+12 VDC
LEFT GRAIN HI

NONE

RIGHT GRAIN HI

NONE

PLENUM HI LIMIT

J7-01

RED

J7-03

RED

J7-05

RED

+12 VDC
REAR DISCHARGE
+12 VDC

AIRSWITCH COM.

J7-10

WHT

AIRSWITCH N.C.

J7-11

BLU

FLAME DETECT

J7-19

GRY

FLAME DETECT

J7-20

GRY

PLENUM TEMP

J7-12

YEL

GRAIN/PLENUM

J7-13

WHT

GRAIN TEMP

J7-14

ORG

120 AC NEUTRAL

J6-02

WHT

120 AC POWER

AC 1

BLK

MAIN SOL NEUT

J6-13

WHT

BLK

UNLOAD NEUTRAL

J3-02

UNLOAD POWER

J3-01

LOAD NEUTRAL

J3-12

LOAD POWER

J3-11

FAN NEUTRAL

J3-14

FAN POWER

J6-03

IGNITION NEUTRAL

J6-07

WHT

IGNITION POWER

J6-06

BLK

MAXON NEUTRAL

J3-03

WHT

MAXON POWER

J3-04

BLK

SCR CONT NEUTRAL

J3-18

SCR CONT POWER

J6-09

SCR P1

J4-02

BLU

SCR2

SCR P3

J4-01

WORK LIGHT NEUT

J6-18

WHT

LITE

BLK

P
P

J1-16
(CANADA ONLY)
UNLD COM ORG

USER INSTALLED

UNLD N/O

USER INSTALLED

LOAD COM YEL

USER INSTALLED

LOAD N/O

L2
L1

ORG

1FO

3FO

PUR

A-

SCR
DRIVE

TERMINAL ON
UPPER STRIP

A+

F+

F-

A+

A-

YEL

SCR
CONTACTOR

USER INSTALLED

1FI

MERCOID SWITCH

3FI

SCR P2

MAIN
BREAKER

WHT

J6-14

AC1

J6-15

CYCLE SOL PWR

110XO

BLK

M-SOL

CYCLE SOL NEUT

WORK LIGHT PWR

TRANSFORMER

BLU

J6-02

RED

J7-09

AC1

J7-04

AIRSWITCH N.O.

MAIN SOL PWR

RED

MOTOR OVERLOAD

J6-12 (BLK)

+12 VDC

DISTRIBUTION
BLOCK

OUT OF GRAIN

Competitor Wiring Reference

Portable Dryer Troubleshooting

Series 2000 Control Box Wiring (New Version)

Portable Dryer Troubleshooting

Competitor Wiring Reference

Upper Control Box Wiring
220 Volt 1PH

Competitor Wiring Reference

Portable Dryer Troubleshooting
Upper Control Box Wiring
380, 460 & 575 3PH

Portable Dryer Troubleshooting

Competitor Wiring Reference

Series 100 Control Box Wiring
1 - END PROTECTOR# D01-0532
48 - COMPRESSION TERM.# D01-0531
2 - ENDSTOP# D01-0533
4 - GROUND TERMINAL# D01-0534
13" DIN RAIL# D03-0013

2 WIRES 2 WIRES -

16 GA WIRES

NO CONNECTION (12VDC CNTR TAP)
+12 VOLTS
RED
HOUSING HIGH LIMIT
YEL
VAPOR HIGH LIMIT - - PURP
RED
+12 VOLTS
LEFT GRAIN HI- 2 WIRES ORG
RIGHT GRAIN HI 2 WIRES RED
PLENUM HIGH LIMIT - -BLUE
BRN
+12 VOLTS
ORG
REAR DISCHARGE
BLK
+12 VOLTS
BLK
OUT OF GRAIN
NO CONNECTION (12 VDC CNTR TAP)
NO CONNECTION
BLUE
AIRFLOW
2 WIRES WHT/BLK
AIR GND
GRY
NO AIRFLOW
ORG
FLAME DETECT
WHT
FLAME DETECT
PLENUM TEMPERATURE YEL
GRAIN/PLENUM GND WHT/BLK
BLK
GRAIN TEMPERATURE
NO CONNECTION
NO CONNECTION
MAIN SOLENOID NEUTRAL -WHT
MAIN SOLENOID POWER BLK
CYCLE SOLENOID POWER BRN
UNLOAD AUGER NEUTRAL WHT
UNLOAD AUGER POWER BLK
WHT
LOAD AUGER NEUTRAL
BLK
LOAD AUGER POWER
WHT
FAN NEUTRAL
FAN POWER
BLK
WHT
IGNITION NEUTRAL-----IGNITION POWER
BLK
MAXON POWER ---------- PUR
MAXON NEUTRAL -------- WHT
SCR CONTACTOR NEUTRAL WHT
SCR CONTACTOR POWER - ORG
METERING ROLL POT
BLK
METERING ROLL POT
BLK
METERING ROLL POT
BLK
WHT
WORK LIGHT NEUTRAL
RED
WORK LIGHT POWER
MERCOID SWITCH (CANADA ONLY)
USER INSTALLED
USER INSTALLED
USER INSTALLED
USER INSTALLED

REMOVE SCREW TO ACTIVATE
USER SAFETY TERMINAL
CONNECT WIRE FROM J7-08
THRU USER SAFETY SWITCH
BACK TO USER SAFETY TERM.

RED - - - -J1-17 USER SAFETY
RED - - - -J7-08
RED - - - -J7-02
RED - - - -J1-13
NO CONNECTION (12 VDC CENTER TAP)
NO CONNECTION
NO CONNECTION
RED - - - -J7-01
NO CONNECTION (12 VDC CENTER TAP)
RED - - - -J7-03
NO CONNECTION (12 VDC CENTER TAP)
RED - - - -J7-05
(MOTOR OVERLOAD-49)
RED - - - -J7-04 (MOTOR OVERLOAD-35)
BLUE- - - -J7-09
WHT - - - -J7-10
BLUE- - - -J7-11
GREY- - - -J7-19
WHT - - - -J7-20
YEL - - - -J7-12
WHT - - - -J7-13
ORG - - - -J7-14
WHT - - - -J6-02
BLK - - - -AC-01
WHT - - - -J6-13
BLK - - - -M-SOL
BLK - - - -J6-14
WHT - - - -J3-02
ORG - - - -J3-01
WHT - - - -J3-12
YEL - - - -J3-11
WHT - - - -J3-14
BLUE- - - -J6-03
WHT - - - -J6-07
BLK - - - -J6-06
BLK - - - -J3-03
WHT - - - -J3-04
WHT - - - -J3-18
ORG - - - -J6-09
PUR - - - -J4-02
PUR - - - - SCR2
PUR - - - -J4-01
WHT - - - -J6-18
BLK - - - - LITE
PINK------------ J1-16
ORG - UNLOAD AUX COM
ORG - UNLOAD AUX N/O
YEL - LOAD AUX COM
YEL - LOAD AUX N/O

100STRIP98.PRT REV. DATE 3/12/98
77

Competitor Wiring Reference

Portable Dryer Troubleshooting

Upper Terminal Strip
With Moisture Control Hook Up

Portable Dryer Troubleshooting

Competitor Wiring Reference

Upper Terminal Strip
With Moisture Control Relay Hook Up

Competitor Wiring Reference

Portable Dryer Troubleshooting

Moisture Manager to Dryer Wiring
(Upper Control Box)

20
BLK

19
YEL

RED-2
ORANGE-1
WHITE-5
YELLOW-1
BLACK-1
PURPLE-2

WIRES
TO DOOR:
BLUE-3
BLACK-4
WHITE-6
RED-6
YELLOW-1
ORANGE-2
GREY-1
WHT/BLK-2

ORG

PUR
PUR

RED

3 AMP FUSE

RED
PNK
RED

J6-02
EMI FILTER
D03-0181

LOAD

TO I/O BOARD:

WHT
WHT
WHT
WHT
WHT

LINE
5VB1

CORCOM

AC1

RED --- J1-13
PNK --- J1-16 - - CANADIAN MODELS ONLY
RED --- J1-17
ORG --- J3-01
WHT --- J3-02
BLK --- J3-03
WHT --- J3-04
YEL --- J3-11
WHT --- J3-12
WHT --- J3-14
WHT --- J3-18
PUR --- J4-01
PUR --- J4-02
BLU --- J6-03
BLK --- J6-06
WHT --- J6-07
ORG --- J6-09
BLK --- J6-12
WHT --- J6-13
BLK --- J6-14
WHT --- J6-15
WHT --- J6-18
RED --- J7-01
RED --- J7-02
RED --- J7-03
RED --- J7-04
RED --- J7-05
RED --- J7-08
BLU --- J7-09
WHT/BLK J7-10
BLU --- J7-11
YEL --- J7-12
WHT/BLK J7-13
ORG --- J7-14
GRY --- J7-19
WHT --- J7-20
BLK --- LITE
PUR --- SCR2

J6-02

J6-1

Portable Dryer Troubleshooting
Competitor Wiring Reference

Input/Output Board & Terminal Strip

Competitor Wiring Reference

Portable Dryer Troubleshooting

Competitor Control Circuit
CPU/Display Board

Portable Dryer Troubleshooting

Competitor Wiring Reference

Competitor Control Circuit
I/O Board

Competitor Wiring Reference

Portable Dryer Troubleshooting

Competitor Control Circuit
SCR Drive Board

Portable Dryer Troubleshooting

Competitor Wiring Reference
* The SCR board is located in the
upper control box.
* Terminals L1 and L2 are the input
terminals. When the unload system
is turned on there should be 220
Volts AC accross these terminals.

RESISTOR

* Terminals A+ and A- are the ouput
terminals. The voltage across these
terminals is DC and will vary depending on where the speed control potentiometer is set.

MIN

* The item circled at the bottom right
of the SCR board in the photograph
is the minimum set potentiometer.
This will be used in the SCR board
set up to set minimum DC voltage.

MAX

* The item circled at the bottom left
of the SCR board in the photograph
is the maximum set potentiometer.
This will be used in the SCR board
set up to set maximum DC voltage.

P3
P2 P1
L1
L2 A+
AIMPORTANT: After the new board has been installed be sure to remove the resistor
(shown in the photograph above) from the old board and install it in the new board. Just
pull the resistor from the two pin socket and install in the same socket on the new board.
Resistor for 1/3 Hp
Meter Roll motors
used on 12 ft dryers
and shorter. (part
no. D03-0039)

Resistor for 3/4 Hp
Meter Roll motors
used on 14 ft dryers
and longer. (part
no. D33-0001)
Control panel switch locations.
Moisture
Control
Switch
Unload
Switch

Metering Roll
Speed (High)
Drying Mode
Switch

Metering Roll
Speed (Low)
85

Competitor Wiring Reference

Portable Dryer Troubleshooting

Setting SCR Board Maximum Voltage

Before starting the procedure set the dryer up as follows:
1. All fan and heater switches to off position and load switch to off position.
2. Control power to on position.
3. Push the dryer power switch.
4. Dryer mode switch to cont. flow position.
5. Moisture control switch to on position.
6. Unload switch to 2 speed position.

1. Set the low metering roll speed to 050 on the dial
indicator shown in the photograph on the left. Set the
high metering roll speed to 999.
Unload
Switch to 2
speed
position

Metering Roll
Speed (High) set to
999

Metering Roll
Speed (Low) set to
050

2. Switch the Unload switch to the 2 speed position.
3. Switch the Moisture Control switch to the off position.
This will put the meter roll rotation speed to the high
setting.
4. Use a voltmeter set at the 200 volt DC range and
probe terminal A+ with the red voltmeter probe and Awith the black voltmeter probe. If the display on your
voltmeter reads 180 volts DC no maximum adjustment
is needed. If your voltmeter does not read 180 VDC,
then use a small screw driver and adjust the max set
petentiometer until the voltage is 180 VDC.

A+
MAX

A-

Portable Dryer Troubleshooting

Competitor Wiring Reference

Setting SCR Board Minimum Voltage

1. Switch the Moisture Control Switch back to the on position. This will put the meter roll rotation
speed at the low setting.
2. Use a voltmeter set at the 20 volt DC range and probe terminal A+ with the red voltmeter probe
and A- with the black voltmeter probe. Use a small screw driver and adjust the min set potentiometer until the voltage is 9 VDC.
The SCR board is now set and dryer is ready for normal operation at desired settings.

SCR Drive Board (Part No. D03-0104)

MIN

A+

A-

Portable Dryer Troubleshooting

Competitor Wiring Reference

Upper Control Box External Wiring

ORANGE J7-19 FLAME DETECTION TO FLAME PROBE
WHITE J7-20 FLAME DETECTION TO FLAME PROBE BASE
WHITE J6-07 IGNITION TRANSFORMER 120VAC NEUTRAL 16 GA. WIRE
BLACK J6-06 IGNITION TRANSFORMER 120VAC POWER 16 GA. WIRE
BLACK J6-12 MAIN SOLENOID 120VAC POWER
WHITE/BLACK STRIP J7-10 12VDC NEGATIVE

TO FAN CONTROL BOX

WHITE J6-13 MAIN/CYCLE SOLENOID 120VAC NEUTRAL
BROWN J6-14 CYCLE SOLENOID 120VAC POWER
YELLOW J7-02 FROM HOUSING HIGH LIMIT SWITCH
RED J7-08 12VDC INPUT POWER TO HOUSING & VAPOR HIGH LIMIT SWITCHES
PURPLE J7-13 FROM VAPOR HIGH LIMIT SWITCH

BLUE J7-09 CONNECTS TO AIRSWITCH N.O. TERMINAL
WHITE/BLACK STRIP J7-10 CONNECTS TO AIRSWITCH COMMON TERMINAL
GREY J7-11 CONNECTS TO AIRSWITCH N.C. TERMINAL

TO AIRSWITCH ASSEMBLY

WHITE J7-13 PLENUM/GRAIN TEMPERATURE SENSOR COMMON
BLACK J7-14 RIGHT GRAIN TEMPERATURE SENSOR
RED 12VDC TO LEFT GRAIN HIGH LIMIT SWITCH
ORANGE 12VDC FROM LEFT GRAIN HIGH LIMIT SWITCH
PURPLE J3-03 MAXON POWER 120VAC (NATURAL GAS ONLY)
WHITE J3-04 MAXON 120VAC NEUTRAL (NATURAL GAS ONLY)

TO LOWER JUNCTION BOX

BROWN 12VDC TO REAR DISCHARGE SWITCH
ORANGE J7-03 FROM REAR DISCHARGE SWITCH
RED 16 GA. A+ SCR DRIVE MOTOR
BLACK 16 GA. A- SCR DRIVE MOTOR
GREEN 16 GA. SCR DRIVE MOTOR GROUND
BLACK 12VDC TO LOAD MERCURY SWITCH
BLACK J7-05 FROM LOAD MERCURY SWITCH

TO UPPER JUNCTION BOX

WHITE J6-18 OUTSIDE LIGHT AC NEUTRAL
RED LITE 120VAC OUTSIDE LIGHT POWER

YELLOW J7-12 PLENUM TEMPERATURE SENSOR
WHITE J7-13 PLENUM/GRAIN TEMPERATURE SENSOR COMMON
BLACK J7-14 GRAIN TEMPERATURE SENSOR
BLUE FROM PLENUM HIGH LIMIT SWITCH TO J7-01
RED TO PLENUM HIGH LIMIT SWITCH
ORANGE TO RIGHT GRAIN HIGH LIMIT SWITCH
RED FROM RIGHT GRAIN HIGH LIMIT SWITCH

TO PLENUM AND RIGHT
FIXED GRAIN HIGH LIMIT
SWITCHES AND TEMPERATURE
SENSORS

Competitor Wiring Reference

Portable Dryer Troubleshooting

J3
16 14

13 11

UNLOAD AUGER POWER
MAXON VALVE/DRYER RUNNING LIGHT
PROOF OF FLAME LIGHT
PROOF OF AIRFLOW LIGHT
MOISTURE CONTROL HOLDING LIGHT
LOAD POWER
TRIAC SPARE
N.C. (TIED TO J3-19)
N.C. (TIED TO J3-19)
120V INPUT FROM CPU

UNLOAD AUGER NEUTRAL
AC NEUTRAL
AC NEUTRAL
AC NEUTRAL
AC NEUTRAL
LOAD AUGER NEUTRAL
FAN NEUTRAL
AC NEUTRAL
AC NEUTRAL
AC NEUTRAL

RL1-A COMMON TO POT INPUT ON SCR BOARD
RL1-B COMMON TO POT INPUT ON SCR BOARD

3 AMP FUSE

120 VOLT AC OUTPUT

Input/Output Board 12 Volt

RL1-B N.C. LOW SPEED POT A
RL1-B N.O. HIGH SPEED POT A
RL1-A N.C. LOW SPEED POT B

8
10
12
14
18 16
20

12 VDC
FAN AUTO
BURNER AUTO
UNLOAD 2 SPEED
LOAD AUTO
DRYER EMPTY (BATCH ONLY)
MOISTURE CONTROL ON
MERCOID SAFETY INPUT
SPARE
12 VDC
THESE JUMPERS MUST BE INSTALLED
J1-1 TO J1-17 - USER SAFETY
J1-1 TO J1-16 - MERCOID SAFETY

4
6

3
5
7
9
13 11
15
17
19

12 VDC
FAN ON
BURNER ON
UNLOAD 1 SPEED
LOAD ON
CONTINUOUS FLOW
VAPOR HIGH LIMIT INPUT
SPARE
USER SAFETY INPUT
12 VDC

R
E
L
A
Y

12 VOLT DC INPUT

J5
J2

DATA INTERLINK CABLE CONNECTION

RL1-A N.O. HIGH SPEED POT B

PLENUM TEMP SENSOR
AIRSWITCH COM (DC NEG)
+12VDC OUTPUT
START SWITCH
MOTOR OVERLOAD
HOUSING HI-LIM

FLAME PROBE B
12VDC NEGATIVE
+ 12VDC OUTPUT
GRAIN TEMP SENSOR

19
20
17
- 18
15
16
13 14
11
12
9
- 10
7
8
5
6
3
4
1
2

12 VDC GROUND
N

RL1 COMMON

3
1 110VAC IN
3 RL1 N.O.

RS485 COM PORTS

MAIN SOL NEUTRAL
CYCLE SOL NEUTRAL
AC NEUTRAL
LOAD COIL NEUTRAL

IGN TRAN NEUTRAL
RL3 N.O. SCR DRIVE OUT
RL3 COM SCR IN

110V NEUTRAL

REAR DISCHARGE SWITCH
GRAIN/PLENUM HIGH LIMIT SWITCH

N/C AIRSWITCH (5 VDC)
N/O AIRSWITCH (5 VDC)
STOP SWITCH
OUT OF GRAIN SWITCH

+ 12VDC OUTPUT
TEMP SENSOR (GROUND)

FLAME PROBE A
+ 12VDC OUTPUT

MONITORING
DISPLAY

TRANSFORMER

FUSE
2N
1
4
3
6
5
8
N7
10
9
12
11
14
N13
16
N15
18 N
N17
20
N19

120VAC TO I/O BOARD
LIGHT AC NEUTRAL
SPARE AC OUTPUT

NO CONNECTION
RL3 N.C.
MAIN SOL PWR 120VAC
CYCLE SOL PWR 120VAC

IGN TRANS PWR 120VAC

AC NEUTRAL INPUT
RL1 N.C.

Competitor Wiring Reference
Portable Dryer Troubleshooting

Cpu Board Wiring

Portable Dryer Troubleshooting

Competitor Wiring Reference

Programing Instructions for Competitor Series Grain Dryers
1. Turn Control Power on dryer to the off position.
2. Locate programming jack (J2) on back of computer. (See next page). There will be a cable plugged into
this jack that comes from the other computer board. Unplug this cable to plug the programmer into the jack.
3. Plug the series 2000 cable into programming jack and into programmers DB-9 jack.
4. Be sure that the rotary switch on the programmer is set to position 8.
5. Turn on Control Power to the dryer.
6. The four (4) lights on the programmer will come on, then three (3) will go out leaving the power light still on.
7. Push the start button on the programmer to start the transfer of Software.
8. The busy light will flash until the transfer process is complete.
9. When completed, the pass light will flash indicating a successful transfer.
10. If the fail light flashes then check your connections and repeat the above process.
11. Turn Control Power on dryer to off and remove the cable.
12. Turn on the dryer and the opening screens should indicate the newer version of software.

19
20
17
- 18
15
16
13 14
11
12
9
- 10
7
8
5
6
3
4
1
2

1 2 3 4 5 6 7 8

J5 J4

3
1

1
RS485
COM
PORTS

J6
2 N
1
4
3
6
5
8
N7
10
9
12
11
14
N13
16
N15
18 N
N17
20
N19

TRANSFORMER

DIP SWITCH #6 = BURNER CYCLE HI-LO (OFF) OR ON-OFF (ON)
DIP SWITCH #5 = NO LOAD DURING LOW FIRE CYCLE (BATCH ONLY)

DIP SWITCH #7 = EMERGENCY COOLING MODE

DIP SWITCH #8 = AIR SWITCH TEST ON OR OFF

DIP SWITCHS

MONITORING
DISPLAY

PROGRAMMING JACK TO UPDATE
SOFTWARE ON EPROM PLUG
PROGRAMMER INTO THIS JACK

SERIES 2000 CABLE

FUSE

92
ON

DB9 JACK
PLUG THIS INTO
THE PROGRAMMER

J2 CONNECTOR

Competitor Wiring Reference
Portable Dryer Troubleshooting

Programmer Hook Up Diagram

Portable Dryer Troubleshooting

Competitor Wiring Reference

Programming Instructions Using Palm Pilot

On the Competitor Dryer there is only one board to program. This board is called the CPU
Display board. It is mounted to the door of the lower box. To access, open the door and the programming jack is located on the back of this board. To program, follow the instructions below.
1. Turn the control power on the dryer to the off position.
2. Locate the programming jack (J2 connector) on back of board.
3. Unplug the communications cable that is connected to that connector. This is the cable that
runs from the CPU/Display board and IO Board.
4. Connect the DB-9 connector from the Palm Pilot to the series 2000 cable.
5. On the Palm Pilot select the program for that particular board and tap on it.
6. Turn the dryer control power back on.
7. The programming process should begin, it will erase the present program and start the new
program.
8. A screen will come up telling you when the transfer of software is complete.
9. When the process is complete turn dryer control power off, remove the connector from the
board and plug the communications cable back on to the CPU/Display board.
10. Turn on the dryer and the opening screens should indicate the latest version of software.
Refer to next page for more information on programming the Series 2000 board.
If ordering Palm Pilot from GSI there are two kits available:
D03-0692 ( Palm Flash Program Kit Deluxe )
D01-1771 Series 2000 Programming Cable
D03-0688 Palm Pilot IIIC (color)
D03-0694 Palm Pilot Hot Sync Cable
D03-0695 Palm Flash 9 Pin M-M Adapter
D03-0709 Disk, CD-Rom Palm Flash Software
D03-0693 ( Palm Flash Program Kit Economy )
D01-1771 Series 2000 Programming Cable
D03-0689 Palm Pilot M100 (black & white)
D03-0695 Palm Flash 9 Pin M-M Adapter
D03-0709 Disk, CD-Rom Palm Flash Software

Portable Dryer Troubleshooting

Programming Competitor

Programming Competitor Dryer Using Palm Pilot

Hot Sync Ca ble
D03-0694

Palm Pilot
D03-0689 (M100)
D03-0688 (IIIC)

P alm
S id e

DB-9 M-M Ada pter
D03-0695
D ryer
S id e

DB-9 Conne ctor

J2 Connector
(Connects to the back
of CPU/Display board)

DB-9 Conne ctor
(Connects to the
DB-9 M-M adapter)

Serie s 2000 Progra mming Ca ble
D01-1771
(Use on CPU/Board)

J3-09

PR J4-04
PR J4-06
PR SCR-2

com

STOP

T
B M
T
B M

METERING ROLL SPEED

J3-01

J1-08

J1-07

THREE POS

UNLOAD

2 1

20 19

com

START

J1-14

J3-03

MOISTURE CONTROL

J4-05 PR
J4-03 PR

J1-04

J1-05

J1-10
YL

J1-03
BL

J1-06

J3-11

J3-07

3
1

FAN

TRANSFORMER

BURNER

CONNECT J6-05
TO J6-01.

J3-05

MONITORING
DISPLAY

FUSE

J1-09

LOAD

1 2

BATCH

J1-11

TWO POS

DRYING MODE

TO DISPLAY:
BLACK-1
RED-1
WHITE-1
BLUE-1
YELLOW-1

J3-03
BLK

OUTSIDE LIGHT

CONTROL POWER

CONNECTS TO
TERMINAL STRIP
ON BACK PANEL

LITE

AC1

RED J1-16 TO J1-20
RED J3-19 TO J6-16
WHITE J3-04 TO J6-17
BLACK J6-05 TO J6-11
BLACK J6-01 TO J6-05

JUMPERS:

FROM I/O BOARD:
ORANGE-5
BLACK-1
PURPLE-4
BROWN-3
BLUE-3
YELLOW-3
GREY-1

Portable Dryer Troubleshooting
Competitor Wiring Reference

Back of Switch Panel Layout

J7-07
YEL

J7-06
BLU

RED

J6-02

com

STOP

com

START

METERING ROLL SPEED

J7-15

THREE POS

UNLOAD

J6-02

WHITE

MOISTURE CONTROL

RED J3-19 TO J6-16
WHT J3-04 TO J6-17
BLK J6-01 TO J6-05

REQUIRED JUMPERS:

RED

J7-15

J6-02

HEATER

2 1

20 19

MONITORING
DISPLAY

J6-2

J7-15

FAN

3
1

1 2

FUSE

J7-15

J6-02

LOAD AUGER

TRANSFORMER

J6-02

BATCH

J7-15

GREY

DRYING MODE

J6-02 (AC NEUTRAL)
WHITE

J6-01
OUTSIDE LIGHT

J6-02

CONTROL POWER

J6-01 (AC POWER) BLACK

BLACK

Competitor Wiring Reference
Portable Dryer Troubleshooting

Back of Switch Panel Wiring

HIGH

C N.C. N.O.

CALIBRATED WITH
DIAPHRAGM VERTICAL

TO UPPER CONTROL BOX

BLUE J7-09 AIRFLOW (N.O.)

WHITE/BLACK STRIP J7-10 AIRFLOW GROUND

GREY J7-11 NO AIRFLOW (N.C.)

BACKVIEW OF AIR SWITCH ASSEMBLY

AIR SWITCH

UNLOAD
MOTOR

LOWER
JUNCTION
BOX

SCR

GAS PIPE TRAIN

TEMP. SENSORS

FAN

SOLENOID

LEFT FIXED
GRAIN HIGH
LIMIT
PLENUM

1XX

RIGHT FIXED
GRAIN HIGH
LIMIT

OUTSIDE LIGHT

LOAD MERCURY SWITCH

UPPER
JUNCTION
BOX

LOAD
MOTOR

Portable Dryer Troubleshooting
Competitor Wiring Reference

Air Switch Assembly

Air Switch Adjustment

Portable Dryer Troubleshooting
Competitor Air Switch Adjustment

Air Switch location.
Air Switch assembly.

IMPORTANT: To adjust the air switch the grain columns
need to be full of grain so that the plenum can build up air
pressure and close the air switch.
1.

With the Load Auger, Fan, Heater, and Unload switches in the off position turn
on the Control power then push the Dryer Power Start switch.

With power now applied to the dryer flip the fan switch to the on position and
watch the light right above that switch. If the light illuminates when the fan
reaches half its full speed, then no adjustment is required. However, if the light
does not illuminate until the fan is running at full speed or the light does not
illuminate at all and the dryer shuts down the air switch is adjusted too high
(skip to step 3a). If the light illuminates before the fan reaches half its full
speed the air switch is adjusted too low (skip to step 3b).

3a.

If the light above the fan switch illuminates after the fan reaches full speed or did not
illuminate at all and the dryer shut down then the air switch needs to be made more
sensitive. Turn adjustment screw in the more sensitive direction (counter clockwise). Make this adjustment on the air switch 1/4 turn at a time and each time restart
the fan and watch to see when the light illuminates.

3b.

If the light above the fan switch illuminates before the fan reaches half its full speed
then the air switch needs to be less sensitive. Turn adjustment screw in the less
sensitive direction (clockwise). Make this adjustment on the air switch 1/4 turn at a
time and each time restart the fan and watch to see when the light illuminates.

Flip the fan switch to the off position and watch the light. Now it should go out when
the fan is about half its full speed. Adjust the air switch if necessary. Remember that
less sensitive (clockwise adjustment) will require a higher fan speed to close the air
switch, and more sensitive (counter clockwise adjustment), the switch can close at
a slower fan speed.

FAN

OFF
AUTO

WIRES GO TO UPPER
CONTROL BOX

WHITE J3-04

PURPLE J3-03

WHITE TO MAXON

NATURAL GAS DRYERS ONLY

RED 16 GA. A+ TO SCR DRIVE MOTOR
BLACK 16 GA. A- TO SCR DRIVE MOTOR
GREEN 16 GA. TO SCR DRIVE GROUND

BROWN FROM 12VDC TO DISCHARGE SWITCH

ORANGE FROM J7-03 TO DISCHARGE SWITCH

TO REAR
OF DRYER

TO SCR
DRIVE MOTOR

BLACK TO MAXON

SJOW 18/2 WIRE

BLACK J7-14
ORANGE

WHITE J7-13
RED

TO LEFT FIXED
GRAIN HIGH LIMIT
AND TEMPERATURE
SENSORS

TEMP.
SENSORS

RIGHT FIXED
GRAIN HIGH
LIMIT

PLENUM

UNLOAD
MOTOR

OUTSIDE LIGHT

LOAD MERCURY
SWITCH

UPPER
JUNCTION
BOX

FAN

LOWER
JUNCTION
BOX

AIR SWITCH

1XX

SCR

LEFT FIXED
GRAIN HIGH
LIMIT
TEMP. SENSORS

MAXON

SOLENOID

LOAD
MOTOR

GAS PIPE
TRAIN

Portable Dryer Troubleshooting
Competitor Wiring Reference

Fixed Grain Hi-Limit & Temperature Sensor

100

REMOVE THESE EARS

SJOW 18/2 WIRE
EXITS THROUGH
BOX COVER

WHITE
BLACK

FRONT VIEW OF OPEN BOX

LEADS MUST BE IN THIS POSITION
FOR PROPER OPERATION

AIR SWITCH

UNLOAD
MOTOR

LOWER
JUNCTION
BOX

SCR

GAS PIPE TRAIN

TEMP. SENSORS

FAN

SOLENOID

LEFT FIXED
GRAIN HIGH
LIMIT
PLENUM

1XX

RIGHT FIXED
GRAIN HIGH
LIMIT

OUTSIDE LIGHT

LOAD MERCURY SWITCH

UPPER
JUNCTION
BOX

LOAD
MOTOR

Competitor Wiring Reference
Portable Dryer Troubleshooting

Out of Grain Sensor

FRONT

INSIDE GRAIN COLUMN CONDUIT

CONNECT TO SHIELD OF WIRE

CENTER WIRE

INSIDE GRAIN COLUMN CONDUIT

CONNECT TO SHIELD OF WIRE

CENTER WIRE

WHITE/BLACK STRIP 20 GA.

BLACK 20 GA.

WHITE/BLACK STRIP 20 GA.

BLACK 20 GA.

TO UPPER CONTROL BOX

YELLOW J7-12
WHITE/BLACK STRIP J7-13
BLACK J7-14

REAR

WHITE/BLACK STRIP J7-13
BLACK J7-14

TO LOWER JUNCTION BOX

LOAD MERCURY
SWITCH

YELLOW J7-12

WHITE/BLACK STRIP J7-13

UNLOAD
MOTOR

PLENUM TEMP SENSOR

FAN

1XX

SCR

SOLENOID

Portable Dryer Troubleshooting
Competitor Wiring Reference

Grain Temperature Sensor

101

102

USING OHM METER BEGIN CHECKING
THE SENSORS FOLLOWING FIG.1

12 VDC GROUND

110VAC IN
3 RL1 N.O.
RL1 COMMON

3
1

110V NEUTRAL

2 N
4
6
8
10
12
11
14
N13
16
N15
18 N
N17
20
N19
1
3
5
N7
9

FUSE

FIG.1

120VAC TO I/O BOARD
LIGHT AC NEUTRAL
SPARE AC OUTPUT

NO CONNECTION
RL3 N.C.
MAIN SOL PWR 120VAC
CYCLE SOL PWR 120VAC

AC NEUTRAL INPUT
RL1 N.C.
IGN TRANS PWR 120VAC

SENSORS COMP98.PRT

IF NONE OF THE MEASUREMENTS = 11.0 K,
THEN CHECK EACH INDIVIDUAL SENSOR.

See page 47 for resistance vs.
Temperature chart

+12V DC

MAIN SOL NEUTRAL
CYCLE SOL NEUTRAL
AC NEUTRAL
LOAD COIL NEUTRAL

IGN TRAN NEUTRAL
RL3 N.O. SCR DRIVE OUT
RL3 COM SCR IN

RS485 COM PORTS

TRANSFORMER

IF MEASUREMENTS DO NOT = 11.0 K
CHECK CONNECTIONS IN WHITE
JUNCTION BOX ON FAR LEFT AND
RIGHT SIDES FACING THE FAN END.

REAR DISCHARGE SWITCH
GRAIN/PLENUM HIGH LIMIT SWITCH

N/C AIRSWITCH (5 VDC)
N/O AIRSWITCH (5 VDC)
STOP SWITCH
OUT OF GRAIN SWITCH

FLAME PROBE A
+ 12VDC OUTPUT
+ 12VDC OUTPUT
TEMP SENSOR (GROUND)

11.0 ON A
20K SCALE
AT 70 DEGREES

19
20
17
- 18
15
16
13 14
11
12
9
- 10
7
8
5
6
3
4
1
2

IF OHMS DOES NOT = 11.0 K
CHECK LOWER AND UPPER TERMINAL
STRIP (J7-13 GND & J7-14)

+12VDC OUTPUT
START SWITCH
MOTOR OVERLOAD
HOUSING HI-LIM

PLENUM TEMP SENSOR
AIRSWITCH COM (DC NEG)

FLAME PROBE B
12VDC NEGATIVE
+ 12VDC OUTPUT
GRAIN TEMP SENSOR

MONITORING
DISPLAY

Competitor Wiring Reference
Portable Dryer Troubleshooting

Grain Sensor Testing

Grain Sensor

Portable Dryer Troubleshooting

Procedure for Locating, Testing and Replacing
a Defective Grain Temperature Sensor

Symptoms of a bad sensor may include:
·

Temperature readings that are not consistent with the ambient outside temperature or with any
known verified grain temperatures entering the dryer.

Grain temp open or grain temp short on Network dryers

Display readings of 255° or –127°.

Grain Thermistor Sensor

Troubleshooting:
1.

Locate the left and right grain sensor electrical boxes on the dryer (see drawing below)

Open each box by removing the lid. They are held in place by 4 phillips head bolts and nuts.

Once inside the box, determine which wires you need to test by identifying the wire routing.
Mounting Screws

Grain Thermal
Overheat wires

Sensor wires
(Small white
26 ga.)

Sensor Wires
(Small white
26 ga.)

Grain Thermal
Overheat wires

The grain sensor wires are small white (26 ga.) and are connected to a 18 ga. white and a 18 ga.
black wire with 2 of the smaller (26 ga.) grain sensor wires butt connected together.

The grain thermal overheat switch is a black disk mounted on a silver bracket with 2 black 18 ga.
wires connected to 2 colored wires.

Disconnect the white and black 18 ga. wires from the smaller white grain sensor wires.

Strip back about 1/4 inch from the end of each 26 ga. sensor wire.

With a ohm meter, set your scale to 20k (if its not a autorange model).

Place the black lead into the still butt connected wire connection with the 2 – 26 ga. wires.

10.

Connect the red lead to either of the disconnected 26 ga. wires and make note of the reading.
103

Portable Dryer Troubleshooting

Grain Sensor

Procedure for Locating, Testing and Replacing
a Defective Grain Temperature Sensor. (continued)
11.

Now move the red lead to the other disconnected 26 ga. wire and make note of this reading.

12.

Go to the other side of the dryer and repeat steps 6 through 11.

13.

You will notice that 3 readings will be very close to the same, but one reading will be different. This
is your defective sensor. (Compare readings to Resistance/Temperature chart page 62.)

14.

If you don’t have a replacement sensor, jump to How to Bypass the Grain Temperature Sensor

Sensor Replacement:

15.

The grain sensors are mounted to the grain overheat capillary and need to be removed together.

16.

To remove the overheat switch disconnect the grain thermal overheat wires.

17.

Then remove the 2 self tapping screws and slide the bracket, overheat switch and sensors out of
conduit.

18.

Remove the tape surrounding the defective grain sensor then remove it.

19.

Place your new sensor upon the capillary then apply tape to secure the sensor.

20.

Slide the overheat switch and sensors back into the conduit until the bracket for the overheat switch
is in the same mounting position as before.

21.

Replace both mounting screws back into the overheat switch mounting bracket.

22.

Butt connect together one wire from each of the grain sensors.

23.

Connect one of the remaining grain sensor wires to the Black 18 ga. wire.

24.

Connect the other remaining grain sensor to the White 18 ga. wire.

25.

Connect one of the grain overheat switch wire to each one of the colored wires.

26.

Reconnect the other side of the dryer following steps 22 through 24.

27.

Double check the wire connections then replace the covers on the boxes.

How to Bypass the Grain Temperature Sensor:
The following instructions are for situations where you don’t have an extra grain sensor to replace the
defective one. So now, we are going to rewire the sensors so that instead of using 4 sensors to monitor the
grain temperature with, we are only going to use one. The dryer will operate fine with only one sensor with
the exception of only being able to monitor one small section of the grain columns.
1.

On the side of the dryer in which sensor is defective, leave this sensor and the joining sensor
disconnected from the white and black 18 ga. wires. Be sure to cap these 18 ga. wires off.

On the other side of the dryer, take one of the small white grain sensor wires and connect it to the
white 18 ga. wire.

104

Portable Dryer Troubleshooting

Sensor Chart

Procedure for Locating, Testing and Replacing
a Defective Grain Temperature Sensor. (continued)

From the same sensor that you connected to the white 18 ga. wire, connect the other small white
grain sensor wire to the black 18 ga. wire.

Double check the wire connections then replace the covers on the boxes.

Resistance / Temperature Chart

°F

Ohms

°F

Ohms

°F

Ohms

°F

Ohms

°F

Ohms

°F

Ohms

°F

Ohms

28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61

36,601
35,565
34,562
33,591
32,650
31,739
30,856
30,000
29,171
28,368
27,590
26,835
26,104
25,394
24,707
24,040
23,394
22,767
22,159
21,569
20,997
20,442
19,903
19,380
18,873
18,380
17,902
17,438
16,988
16,551
16,126
15,714
15,313
14,924

62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95

14,546
14,179
13,822
13,475
13,139
12,811
12,493
12,184
11,884
11,591
11,307
11,031
10,762
10,501
10,247
10,000
9,760
9,526
9,298
9,077
8,862
8,652
8,448
8,249
8,056
7,868
7,685
7,506
7,333
7,164
6,999
6,839
6,682
6,530

96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129

6,382
6,238
6,097
5,960
5,826
5,696
5,569
5,446
5,325
5,208
5,093
4,981
4,872
4,766
4,663
4,562
4,463
4,367
4,273
4,182
4,093
4,006
3,921
3,838
3,757
3,678
3,601
3,526
3,453
3,381
3,311
3,243
3,176
3,111

130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163

3,047
2,985
2,925
2,865
2,807
2,751
2,696
2,642
2,589
2,537
2,487
2,438
2,390
2,343
2,297
2,252
2,208
2,165
2,123
2,082
2,042
2,003
1,965
1,927
1,890
1,855
1,820
1,785
1,752
1,719
1,687
1,655
1,624
1,594

164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197

1,565
1,536
1,508
1,480
1,453
1,427
1,401
1,375
1,350
1,326
1,302
1,279
1,256
1,234
1,212
1,190
1,169
1,149
1,129
1,109
1,089
1,070
1,052
1,034
1,016
998.3
981.2
964.4
947.9
931.8
915.9
900.4
885.2
870.3

198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231

855.7
841.4
827.3
813.6
800.1
786.8
773.8
761.1
748.6
736.3
724.3
712.5
700.9
689.6
678.4
667.5
656.8
646.2
635.9
625.8
615.8
606.1
596.5
587.1
577.9
568.8
559.9
551.2
542.6
534.2
525.9
517.8
509.8
502

232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250

494.3
86.8
479.4
472.1
464.9
457.9
451
444.2
437.6
431
424.6
418.3
412.1
406
400
394.1
388.3
382.7
377.1

105

Portable Dryer Troubleshooting

Plenum Sensor

Procedure for Locating, Testing and Replacing
a Defective Plenum Temperature Sensor
Symptoms of a bad sensor may include:
Temperature readings that are not consistent with the ambient outside temperature or
with a verified plenum temperature that has been taken with a thermometer.
Erratic plenum display readings.
Plenum temp open or plenum temp short.
Troubleshooting:
1. The process of checking the sensor is similar to that of the grain sensors, but you
only have one sensor to check.
2. The actual plenum sensor is located in the plenum just inside the rear access door
to the right. (Facing the rear of the dryer)(See picture on next page)
3. Start at the CPU/Display board, it is located on the door of the lower box.(See below)
4. The wires from the sensor (which are butt connected at the sensor) go through a
conduit in the plenum section of the dryer.(See next page) That conduit terminates at
a white plastic 4"x4" junction box. This box is located on the front of the dryer to the left
of the fan/heater. (Facing the front of the dryer.) From that point to the CPU/Display board.
5. The wires are connected to terminals J7-12 (white wire) and J7-13 (black wire) on the
back of the Cpu/Display board.(see picture below)
6. Unhook those wires
7. What you will be checking is resistance in relationship to a known temperature.
(See resistance/temperature chart on previous page.)
8. With a ohm meter, set your scale to 20k (if it’s not a autorange model).
9. Place one probe of your meter on one wire going out to the sensor and the other
probe to the other wire.
10. The meter should read close to the resistance/temperature chart on previous page.
11. Assuming you have checked the wiring from the CPU/Display board to the sensor and
it is OK. But the resistance is not close to what is on the chart. You probably have a bad
plenum bolt sensor.

Plenum Sensor
Connected to
J7-12 & J7-13

Plenum Bolt
Sensor
(Part No. HF-7236)

Back of Door on Lower Box
CPU/Display Board

106

Portable Dryer Troubleshooting

Plenum Sensor

Procedure for Locating, Testing and Replacing
a Defective Plenum Temperature Sensor

The picture below is of the plenum bolt sensor in the plenum of the dryer. See previous
page for more information.
Plenum Bolt Sensor (Part No. HF-7236)

View of back side of the plenum bolt sensor, as it is mounted in the conduit fitting.
(Located inside the dryer plenum, to the right, just inside the rear access door.)

View of the 4"x4" plastic junction box. This is located to the left of the fan/heater
facing the front of the dryer. It contains the plenum overheat and a juction point
where the wires from the plenum bolt sensor are butt connected together.
Plenum 300 Degree Overheat (10' Length)(Part No.D03-0004)
Plenum 300 Degree Overheat (24' Length)(Part No. D03-0377)

107

WIRE #8 FROM MOTOR

108
2

180 OHM 11 WATT

4
STEARNS SWITCH
PART# TF-1430 = 70 AMP
PART# TF-1709 = 90 AMP

216-259uF, 250VAC CAPACITOR
(ELECTROLYTIC)
PART# TFH-2104
180 OHM 11 WATT

WIRE #1 FROM MOTOR

WIRE #5 FROM MOTOR

60uF, 370VAC CAPACITOR
(OIL FILLED)
FH-6448

USE 12 GA. WIRE BETWEEN
ALL CAP AND SWITCH CONNECTORS

216-259uF, 250VAC CAPACITOR
(ELECTROLYTIC)
PART# TFH-2104

Competitor Wiring Reference
Portable Dryer Troubleshooting

Stern and Capacitor Diagram 10-17 HP 1Phase

Portable Dryer Troubleshooting

Operation Hints

OPERATION HINTS FOR COMPETITOR DRYERS
Present Software version is 2.19
1. BURNER CYCLING
Keep Low pressure setting as low as possible without shutting down dryer or popping. Approx. 1 to 2 lb.
Cycle on average 4 times per minute. 3 -5 times per minute is acceptable.
2. ERRORS
01 User switched from continuous flow to batch while dryer was running.
02 Grain Temperature Sensor Open. One or both leads are off (Open Circuit.).
03 Grain Temperature Sensor Leads are shorted together.
04 Plenum Temperature Sensor Open. One or both leads are off (Open Circuit).
05 Plenum Temperature Sensor Leads are shorted together.
06 Flame Probe Shorted to ground.
07 Illegal Flame Sense. Most likely caused by stuck open gas solenoid.
Error 7 will not shut down fan until loss of flame is detected by control. May occur if 1 of the 12 volt DC limits is
shorted to AC ground, or to the communication port for the air switch or either temperature sensor is shorted to
AC ground.
08 No safety circuit voltage.
09 I/O board communication failure. I/O board and Master board have lost communication.
10 User supplied safety. A safety connected to J7 -8 and J1-17.
11 Canadian Mercoid sensor. In USA jump J7-8 to J1-16.
BATCH ERRORS
BRN on the screen means the Burner Switch is turned off or there is a loose wire in its circuit.
FAN on the screen means the Fan Switch is turned off or there is a loose wire in its circuit.
Presently the Load Switch and the Unload Switch are not monitored by the Dryer Controls.
999 on the screen is not a n Error. It means the board has never had software loaded. This will come up when you
turn on the power just after GSI appears. This means the latest software must be down loaded.
3. DIP SWITCHES
1. Dip Switch 8 = Air Switch Test Bypass. WARNING! Bypassing this test will allow burner to come on
without the Fan running.
2. Dip Switch 7 = Emergency Cooling Mode. Fan will run alone for 5 minutes when the Start button is pushed with
switch on.
3. Dip Switch 6 = Allows Off/On Burner operation instead of High/Low as is standard.
4. Dip Switch 5 = (In Software Ver. 2.11 and up) Adds Low Temp Timer to a nd low Temp finish dry like dual temp.
Batch Dryer.
5. Dip Switch 4 = (In Software Ver. 2.14 and up) Adds Low Temp finish tripped by Grain Temperature to Batch
Mode.
4. SHUTDOWNS
If both the GRAIN and PLENUM HIGH TEMPERATURE warnings appear on the screen at the same time one of
the two mechanical temperature sensors are kicked out. NOTE Emergency Cooling will NOT work if these are
kicked out. These temperature limits are in addition to the electronics high limits and are located in the same
electrical conduits as the electronic thermister sensors. Note that J7-01 is the terminal the computer checks for
12 volts.
5. SPECIAL KEY USAGE
1. Pushing the UP arrow key will gives the Dryers Hour Meter reading. Two successive screens Hours x 100 |
Balance of hours.
In software vers. 2.14 and above it reads in 5 successive screens Total Hours x 100 | Balance of hours | Balance of
minutes | Batch Count | Minutes since last shutdown. So 5 | 23 | 12 | 144 | 188 would be Timer = 523 hours 12
minutes, 144 Batches dumped and 3 hours and 8 minutes since the last shutdown.
2. Pushing the DOWN arrow key while an error is on the screen will tell how long ago the shutdown occurred.
3. Pushing the MODE SELECT key exits any mode back to the main screen.
4. Holding the STOP button for 4 seconds or longer causes the Dry, Cool, and Unload timers to be reset to the
values programmed by the user. This also forces new times.
5. Holding down the HOURS key and turning on the power resets the NOVRAM or does what is called a HARD
BOOT.
6. Holding down the DOWN key while turning on the power restores the factory default settings.
7. In software vers. 2.19 and above Holding down the Up Arrow Key while powering up resets the Total Batch
Counter .
109

Operation Hints

Portable Dryer Troubleshooting
OPERATION HINTS FOR COMPETITOR DRYERS

6. OPERATION HINTS
1. If you set a new timer setting which is lower then the present setting it becomes effective immediately. If it is
7. OPTIONAL WIRING POINTS
1. J7-10, J7-13 and J7-18 are 12 volt ground points for use with a tester.
There are no 12 volt ground connections on the IO board.
2. J1-17 - User Supplied Safety. If 12 volts is interrupted from J7-18 the User Supplied Safety Warning, ERROR 10
results.
3. J1-16 - Canadian Mercoid Sensor. If 12 volts in interrupted from J7-18 the Canadian Mercoid Warning, ERROR
11 results.
4. J1-15 - Discharge Hold Function – First available in Version 2.19 - operates in Batch Mode only.
If 12 volts is applied to J1-15 before the unload cycle is reached, when it does reach the unload cycle the dryer will
turn off the Fan and or the Heater (Only if the switches are in the AUTO position) and not allow the Dryer to unload
until the 12 volts is removed from J1-15. When 12 volts is not detected the dryer will resume normal operation and
immediately unload the Dryer and continue drying. This function cannot be activated if the unload cycle has
already begun. If you are running Dry and Cool and want the Dryer to continue cooling while in Discharge Hold put
the Fan switch in the Manual position. Otherwise both the Fan and Heater Switches should be in the AUTO
position.
5. J7-15, J7-16 and J7-17 are 12 volt Positive source points.
8. Temperature Sensor Testing
1. You can find charts with the Resistance readings at various Temperatures in the following manuals
The Competitors use the Thermister type sensors, the bolt style for the Plenum and the round style for the Grain
Temperature.
Located in Resource 2003 CD in the “Resources – Manuals” Folder
PNEG-630 Portable Dryer – Trouble Shooting
PNEG-377 Fan & Heater – Service Manual Feb 2000.pdf Page 50 (Fans and Heaters | Trouble Shooting Guide)
9. TROUBLESHOOTING TIPS
1. If some 110 volt contactor control devices work and some do not check the fuse on the IO board to see if it has
failed.
Likely devices that will not work are the Load Auger, Unload Auger and SCR drive.

110

Flame probe shorted to AC ground.

Plenum temperature senosr leads are
shorted together OR sensor is shorted.
(See figure 4)

Plenum temperature sensor is open.
One or both leads are off (open circuit)
(See figure 4)

Grain temperature sensor leads are
shorted together OR sensor is shorted.
(See Figure 4)

Grain temperature sensor open. One
or both leads are off (open circuit)
(SEE FIGURE 4)

User switched from continuous flow to
batch while dryer is running.

ERROR

This indicates that one of the other on
screen errors (vapor, plenum, housing
temp hi-limit, flame out, no airflow, motor
overload or rear discharge) has occured.

Mercoid gas pressure safety.

User supplied safety.

I/O board communication failure
I/O board and master have lost
communication.

No safety circuit voltage.

Illegal flame sense. Error 7 is most likely
caused by stuck open solenoid. Error 7 will
not shut down fan until loss of flame is
detected by control. Error 7 may also be
caused by a bad ballast resistor (ballast
resistor not open between poles). It may also
occur if 1 of the 12 volt DC limits is shorted to
AC ground, or either temperature senosr is
shorted to AC ground.

Portable Dryer Troubleshooting
Error Codes

Series 100 Error Conditions

111

112

THIS DISPLAY INDICATES A LOSS OF AIR
PRESSURE 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.
(SEE FIGURE 1)

THIS DISPLAY INDICATES THAT A MOTOR OVERLOAD
RELAY HAS TRIPPED. THIS RELAY MUST BE RESET
MANUALLY. OPEN THE UPPER CONTROL BOX DOOR
MAKE SURE THE POWER IS DISCONNECTED AND PUSH
IN THE RED LEVERS ON ALL OF THE OVERLOAD
RELAYS. NOTICE IF ONE OF THE LEVERS CLICKS
AS IT IS PUSHED IN. THEN INSPECT THE MOTOR
THAT TRIPPED THE RELAY. DETERMINE IF THE
MOTOR IS BEING OVERWORKED.

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
WAS NOT TAKEN AWAY FAST ENOUGH OR
SOMEONE HAS OPENED THE DISCHARGE LID.
(SEE FIGURE 13)

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.

LOAD DELAY

DRY TIME

OUT OF GRAIN TIME
UNLOAD TIME

DRY TIME
COOL TIME

COOL TIME

DRY TIME

PLENUM TEMPERATURE SET POINT

NO AIRFLOW

LOAD DELAY
UNLOAD DELAY

MOISTURE CONTROL SET POINT

LOAD DELAY
UNLOAD DELAY

COOL TIME

DRY TIME

UNLOAD DELAY

LOAD DELAY

COOL TIME

UNLOAD TIME

ERROR

LOAD DELAY
UNLOAD DELAY

OUT OF GRAIN TIME

000

DRY TIME
COOL TIME

DRY TIME

ERROR

LOAD DELAY
UNLOAD DELAY

COOL TIME

MOTOR
OVERLOAD

000

MOISTURE CONTROL SET POINT

LOAD DELAY
PLENUM TEMPERATURE SET POINT

UNLOAD TIME

UNLOAD DELAY

OUT OF GRAIN TIME

DRY TIME

ERROR

COOL TIME

DISCHARGE

000

MOISTURE CONTROL SET POINT

LOAD DELAY
PLENUM TEMPERATURE SET POINT

UNLOAD TIME

UNLOAD DELAY

OUT OF GRAIN TIME

FLAME OUT

DRY TIME

ERROR

000

PLENUM TEMPERATURE SET POINT

MOISTURE CONTROL SET POINT

COOL TIME

UNLOAD DELAY

ERROR

000

ERROR

000

ERROR

000

ERROR

000

THIS DISPLAY INDICATES THAT THE OUT OF
GRAIN TIMER HAS EXPIRED. TRY INCREASI
YOUR TIME ON THE OUT OF GRAIN TIMER.

THIS DISPLAY INDICATES THAT THE HOUSI
HIGH LIMIT SWITCH HAS TRIPPED. TO RESE
THIS SWITCH, REMOVE 2 SCREWS TO THE
OF THE LRL BOX ON TOP OF THE FAN/BUR
ASSEMBLY AND PUSH THE RED BUTTON IN

UNLOAD TIME

OUT OF GRAIN TIME

TEMP HI-LIMIT

GRAIN
PLENUM

THIS DISPLAY INDICATES THAT THE PLENU
ONE OF THE FIXED GRAIN HIGH LIMIT SWIT
HAS TRIPPED. THESE SWITCHES RESET AU
ICALLY WHEN COOLED DOWN. YOU MAY H
START THE DRYER IN EMERGENCY COOLIN
(SEE FIGURE 5 AND FIGURE 14)

PLENUM TEMPERATURE SET POINT

MOISTURE CONTROL SET POINT

UNLOAD TIME

OUT OF GRAIN TIME

TEMP HI-LIMIT

HOUSING

PLENUM TEMPERATURE SET POINT

MOISTURE CONTROL SET POINT

UNLOAD TIME

OUT OF GRAIN TIME

VAPOR
TEMP HI-LIMIT

THIS DISPLAY INDICATES THAT THE
VAPORIZER COIL NEEDS TO BE
ADJUSTED SO THAT IT RUNS COLDER.
(POSITION COIL AWAY FROM FLAME)

PLENUM TEMPERATURE SET POINT

MOISTURE CONTROL SET POINT

UNLOAD TIME

OUT OF GRAIN TIME

OUT

GRAIN

PLENUM TEMPERATURE SET POINT

MOISTURE CONTROL SET POINT

Competitor Wiring Reference
Portable Dryer Troubleshooting

Series 100 Error Conditions

J7-20---WHITE TO FLAME PROBE BASE
J6-07-IGNITION NEUTRAL---WHITE
J6-06-IGNITION POWER---BLACK
J6-12-MAIN SOL.-BLACK
J6-13-MAIN&CYCLE SOL. NEUTRAL-WHITE
J6-14-CYCLE SOL-BROWN
J7-10-DC NEGATIVE - WHITE/BLACK STRIPE
J7-02-HOUSING-YELLOW
J7-08-12V-RED
J7-13-VAPOR-PURPLE

J7-19 FLAME DETECTION ORANGE -

YELLOW
YELLOW/PURPLE
PURPLE

FLAME PROBE NEUTRAL---WHITE
BLACK
BLACK
BLACK
WHITE
BROWN

FLAME PROBE (SILICONE WIRE)

VAPOR

HOUSING

SILICONE HIGH VOLTAGE IGNITION WIRES

HIGH

GRN

LOW

GRN

LIQUID

Portable Dryer Troubleshooting
Competitor Wiring Reference

Heater Circuit

PART# HH-1093

IGNITION TRANSFORMER
TYPE 312-24A402V
CODE D97T
PRI V SEC V HZ PRI A SEC A
120 10,000 60 2.2 .023
SECONDARY MIDPOINT GROUNDED

Webster

113

114

BLK

GREY

INSIDE VIEW OF MERCOID
TERMINAL HOOKUPS

BLACK

MERCOID
SWITCH
WIRING

MERCOID
PRESSURE SWITCH

BROWN

GREY

J6-13 MAIN/CYCLE SOLENOID NETURAL
J6-14 CYCLE SOLENOID POWER
J7-13 VAPOR HIGH LIMIT
J7-08 12 VDC
J7-02 HOUSING HIGH LIMIT
J1-16 MERCOID SAFETY
J7-10 12VDC NEGATIVE WHITE/BLACK STRIP

J6-12 MAIN SOLENOID POWER

J7-19 FLAME DETECTION
J7-20 FLAME PROBE NEUTRAL
J6-07 IGNITION TRANSFORMER NEUTRAL
J6-06 IGNITION TRANSFORMER POWER

WHITE

MERCOID SAFETY
RELAY

ORG
WHT
WHT
BLK
BLK
BLK
WHT
BRN
PUR
RED
YEL
PNK
BLACK
BROWN
BLACK

10
9

BROWN

PINK

PURPLE
PURPLE

5
4

WHITE

7
6

YELLOW

BROWN

LIQUID

FLAME PROBE NEUTRAL ---- WHITE
BLACK

12
11

FLAME PROBE (SILICONE WIRE)

LOW

VAPOR
HOUSING

HIGH

SOLENOIDS

Competitor Wiring Reference
Portable Dryer Troubleshooting

Fan Burner Circuit For Canadian Models Only

Competitor Wiring Reference

Portable Dryer Troubleshooting

Series 100 LP 26"/28" Fan

PART# HH-1093

IGNITION TRANSFORMER
TYPE 612-6A7
CODE J94E
PRI V SEC V HZ PRI A SEC A
120 10,000 60 2.2 .023
SECONDARY ENDPOINT GROUNDED

Webster

WIRES:
2 - PURPLE
2 - YELLOW
3 FEET LONG
FROM OUTSIDE
OF BOX
PURPLE
PURPLE

BLACK

YELLOW
YELLOW

BLACK

J7-19 ORG
J7-20 WHT
J6-07 WHT
J6-06 BLK
J6-12 BLK
J6-13 WHT
J6-14 BRN
J7-13 PUR
J7-08 RED
J7-02 YEL
J7-10 WHT/BLK

BLACK
WHITE
BROWN
PURPLE
PURPLE
YELLOW
YELLOW

BROWN
WHITE
BLACK

WIRES:
1 - WHITE
1 - BLACK
1 - BROWN
1 FOOT LONG
FROM OUTSIDE
OF BOX
S228LP.PRT

115

Portable Dryer Troubleshooting

Competitor Wiring Reference

Series 100 Natural Gas 26"/28" Fan

PART# HH-1093

IGNITION TRANSFORMER
TYPE 612-6A7
CODE J94E
PRI V SEC V HZ PRI A SEC A
120 10,000 60 2.2 .023
SECONDARY ENDPOINT GROUNDED

Webster

WIRES:
2 - YELLOW
3 FEET LONG
FROM OUTSIDE
OF BOX

BLACK

YELLOW
YELLOW

BLACK

J7-19 ORG
J7-20 WHT
J6-07 WHT
J6-06 BLK
J6-12 BLK
J6-13 WHT
J6-14 BRN
J7-08 RED
J7-02 YEL
J7-10 WHT/BLK

BLACK

BLACK
WHITE

BROWN
YELLOW
YELLOW

BROWN
WHITE
BLACK

WIRES:
1 - WHITE
1 - BLACK
1 - BROWN
1 FOOT LONG
FROM OUTSIDE
OF BOX
S228NG.PRT

116

Competitor Wiring Reference

Portable Dryer Troubleshooting

Series 100 LP 36"/42" Fan

WHT
WHT
BLK
BLK
WHT
BRN
PUR
RED
YEL
WHT/BLK

J7-19 ORG

J7-20
J6-07
J6-06
J6-12
J6-13
J6-14
J7-13
J7-08
J7-02
J7-10

WIRES:
2 - PURPLE
2 - YELLOW

3 FEET LONG
FROM OUTSIDE
OF BOX
BLK
BLK

BLK
BLK
WHT
WHT

PUR
YEL

BRN
PUR

YEL

BLACK
WHITE
BROWN
PURPLE
YELLOW

PART# HH-1093
IGNITION TRANSFORMER
TYPE 312-24A402V CODE D97T
PRI V SEC V HZ PRI A SEC A
120 10,000 60 2.2 .023
SECONDARY MIDPOINT GROUNDED

Webster

S242LP.PRT

WIRES:
1 - BROWN
1 - WHITE
1 - BLACK

1 FEET LONG
FROM OUTSIDE
OF BOX

WIRES:
1 - WHITE
1 - BLACK

12 FEET LONG
FROM OUTSIDE
OF BOX

117

Portable Dryer Troubleshooting

Competitor Wiring Reference

Series 100 Natural Gas 36"/42" Fan

J7-19 ORG

J7-20 WHT
J6-07 WHT
J6-06 BLK
J6-12 BLK
J6-13 WHT
J6-14 BRN
J7-08 RED
J7-02 YEL
J7-10 BLK/WHT

WIRES:
2 - YELLOW
3 FEET LONG
FROM OUTSIDE
OF BOX
BLK
BLK

BLK
BLK
WHT
WHT

YEL

BRN

YEL

BLACK
WHITE
BROWN
YELLOW
WIRES:
1 - BROWN
1 - WHITE
1 - BLACK

PART# HH-1093
IGNITION TRANSFORMER
TYPE 612-6A7
CODE J94E
PRI V SEC V HZ PRI A SEC A
120 10,000 60 2.2 .023
MIDPOINT GROUNDED

Webster

S242NG.PRT

118

1 FEET LONG
FROM OUTSIDE
OF BOX

Portable Dryer Troubleshooting

Warranty

THE GSI GROUP, INC. ("GSI") WARRANTS ALL PRODUCTS MANUFACTURED BY GSI TO BE
FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDITIONS FOR A PERIOD OF TWENTY-FOUR MONTHS AFTER RETAIL SALE TO THE ORIGINAL END
USER OF SUCH PRODUCTS. GSI'S ONLY OBLIGATION IS, AND PURCHASER'S SOLE REMEDY
SHALL BE FOR GSI, 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 ABOVE STATED EXPRESS LIMITED WARRANTIES, GSI MAKES NO WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN CONNECTION WITH (i) PRODUCT MANUFACTURED OR SOLD BY GSI OR (ii) 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 PRODUCT OR PRODUCTS.
IN NO EVENT SHALL GSI 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 SHALL BE LIMITED TO THAT
STATED 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 REPRESENTATIVE OR WARRANTIES MADE BY OR ON BEHALF OF ANY DEALER, AGENT OR DISTRIBUTOR OF GSI.
GSI ASSUMES NO RESPONSIBILITY FOR FIELD MODIFICATIONS OR ERECTION DEFECTS
WHICH CREATE STRUCTURAL OR STORAGE QUALITY PROBLEMS. MODIFICATIONS TO THE
PRODUCT NOT SPECIFICALLY COVERED BY THE CONTENTS OF THIS MANUAL WILL NULLIFY ANY PRODUCT WARRANTY THAT MIGHT HAVE BEEN OTHERWISE AVAILABLE.
THE FOREGOING WARRANTY SHALL NOT COVER PRODUCTS OR PARTS WHICH HAVE
BEEN DAMAGED BY NEGLIGENT USE, MISUSE, ALTERATION OR ACCIDENT. THIS WARRANTY
COVERS ONLY PRODUCTS MANUFACTURED BY GSI. THIS WARRANTY IS EXCLUSIVE AND IN
LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED. GSI RESERVES THE RIGHT TO MAKE
DESIGN OR SPECIFICATION CHANGES AT ANY TIME.
PRIOR TO INSTALLATION, PURCHASER HAS THE RESPONSIBILITY TO RESEARCH AND
COMPLY WITH ALL FEDERAL, STATE AND LOCAL CODES WHICH MAY APPLY TO THE LOCATION AND INSTALLATION.
119

1004 E. Illinois St.
Assumption, IL 62510-0020
Phone 217-226-4421
2004 Edition

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Metadata Date                   : 2004:06:01 09:36:42-05:00
Creator Tool                    : Adobe PageMaker 6.52
Document ID                     : uuid:e29cf067-51ce-450e-a60c-3e217fcf05c2
Format                          : application/pdf
Creator                         : milesl
Title                           : New pneg-630a
Description                     : New pneg-630a
Author                          : milesl
Subject                         : New pneg-630a

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Gsi Outdoors Pneg 630 Users Manual New 630a

PNEG-630 to the manual 3088b64c-8c8b-409d-9571-08cc4705fb55

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