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 2 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. 4 Portable Dryer Troubleshooting Safety 5 Safety 6 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. 3. 4. 5. 6. 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 ________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ ___________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________________ ___________________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ ___________________________________________________________________________________________________________________ 8 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 9 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. 10 DISPLAY RIBBON P1 TO START & STOP SWS. U12 1 2 3 P6 P3 TO START SW. BATTERY (TIC) P8 COMMUNICATIONS CABLE TO I/O BOARD P4 P5 S1 SOUND TO STOP SW. P7 KEY PAD RIBBON COMPUTER PROGRAMMING JACK PROGRAMMER JACK (DB9) Portable Dryer Troubleshooting Programming EMCS Display Board 11 Portable Dryer Troubleshooting Wiring Reference Input/Output Board Identification 12 VOLT DC INPUTS +12 LIMIT OUTPUT 20 19 120VAC POWER (INPUT) 1 2 120VAC POWER (OUTPUT) 12 VOLT DC NEUTRAL 18 17 +12 LIMIT OUTPUT AC NEUTRAL 3 4 AC NEUTRAL METERING ROLL INPUT 16 15 12 VOLT DC NEGATIVE 120VAC POWER (INPUT) 5 6 120VAC POWER (OUTPUT) 12 VOLT DC NEGATIVE 14 13 12 VOLT DC NEGATIVE AC NEUTRAL 7 8 AC NEUTRAL 12 VOLT DC NEGATIVE 12 11 12 VOLT DC NEGATIVE AC NEUTRAL 9 10 AC NEUTRAL SAFETY CIRCUIT INPUT 10 9 +12 VOLT LIMIT OUTPUT AC NEUTRAL 11 12 AC NEUTRAL +12 VOLT LIMIT OUTPUT 8 7 +12 VOLT LIMIT OUTPUT AC NEUTRAL 13 14 AC NEUTRAL FLAME SENSOR RETURN 6 5 REAR DISCHARGE AC NEUTRAL 15 16 BURNER #1 POWER OUT OF GRAIN SENSOR 4 3 M.C. THERMOSTAT N.O. TERM #4 FAN #1 POWER 17 18 BURNER #2 POWER MAXON VALVE SENSOR 2 1 M.C. THERMOATAT N.C. TERM #6 FAN #2 POWER 19 20 BURNER #3 POWER MERCOID SFTY FAN#1 (CAN) 20 19 LOWER ADJ. GRAIN HIGH LIMIT MERCOID SFTY FAN#2 (CAN) 18 17 2 SPEED UNLOAD MERCOID SFTY FAN#4 (CAN) 16 15 1 SPEED UNLOAD LOW MERCURY SWITCH (BO) 14 13 UNLOAD BYPASS MOTOR OVERLOADS 12 11 LOAD SWITCH AUTO MOISTURE CONTROL 10 ADJ. GRAIN (MIDDLE) 8 J5 J4 9 LOAD SWITCH ON 7 BATCH MODE J9 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) 6 5 CONTINUOUS FLOW FIXED GRAIN (MIDDLE) 4 3 MERCOID SAFTY FAN#3 (CAN) FIXED GRAIN (UPPER) 2 1 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) 20 19 LO-HEAT THERMOSTAT (BO) FAN #3 POWER 1 2 BURNER #4 POWER BURNER #6 AUTO 18 17 BURNER #5 AUTO FAN #4 POWER 3 4 BURNER #5 POWER BURNER #6 ON 16 15 BURNER #5 ON FAN #5 POWER 5 6 BURNER #6 POWER FAN #6 AIR 14 13 FAN #5 AIR FAN #6 POWER 7 8 LOAD POWER FAN #6 PLENUM 12 11 FAN #5 PLENUM UNLOAD POWER 9 10 SCR POWER FAN #6 FLAME DETECTION 10 9 FAN #5 FLAME DETECTION BUR # 4 NEUTRAL 11 12 FAN #1 NEUTRAL FAN #6 HOUSING HIGH LIMIT 8 7 FAN #5 HOUSING HIGH LIMIT BUR # 3 NEUTRAL 13 14 FAN #2 NEUTRAL FAN #6 VAPOR HIGH LIMIT 6 5 FAN #5 VAPOR HIGH LIMIT FAN # 4 NEUTRAL 15 16 UNLOAD NEUTRAL FAN #6 AUTO 4 3 FAN #5 AUTO FAN # 3 NEUTRAL 17 18 LOAD NEUTRAL FAN #6 ON 2 1 FAN #5 ON LOAD #2 NEUTRAL 19 20 SCR NEUTRAL J3 J8 20 19 LOAD #2 POWER 1 2 PROCESS LIGHT BURNER #4 AUTO 18 17 BURNER #3 AUTO MAXON POWER 3 4 BURNER #1 NEUTRAL BURNER #4 ON 16 15 BURNER #3 ON BUR #6 NEUTRAL 5 6 BURNER #2 NEUTRAL FAN #4 AIR 14 13 FAN #3 AIR BUR #5 NEUTRAL 7 8 MAXON NEUTRAL FAN #4 PLENUM 12 11 FAN #3 PLENUM FAN #6 NEUTRAL 9 10 AC NEUTRAL FAN #4 FLAME DETECTION 10 9 FAN #3 FLAME DETECTION FAN #5 NEUTRAL 11 12 LO-HEAT POWER (BO) FAN #4 HOUSING HIGH LIMIT 8 7 FAN #3 HOUSING HIGH LIMIT 13 14 HI-HEAT POWER (BO) FAN #4 VAPOR HIGH LIMIT 6 5 FAN #3 VAPOR HIGH LIMIT NC 15 16 NC FAN #4 AUTO 4 3 FAN #3 AUTO NC 17 18 FAN #4 ON 2 1 FAN #3 ON 19 20 M.R.H POT 3 USER SUPPLIED SAFETY 20 J2 19 THERMOSTAT 110VAC (BO) J7 LOWER GRAIN HIGH LIMIT SCR P1 & V1 FROM BR#1 (BO) 1 2 M.R.L POT 3 & HIGH SOLENOID BUR#1 (BO) M.R.H POT 2 3 4 SCR P3 & V1 FROM BR#2 (B0 5 6 SENSOR 1 LOWER BURNER #2 AUTO 18 17 BURNER #1 AUTO BURNER #2 ON 16 15 BURNER #1 ON FAN #2 AIR 14 13 FAN #1 AIR THERMOSTAT SENSOR S1 7 8 SENSOR 1 UPPER FAN #2 PLENUM 12 11 FAN #1 PLENUM SENSOR 2 LOWER. 9 10 THERMOSTAT SENSOR S2 FAN #2 FLAME DETECTION 10 9 FAN #1 FLAME DETECTION SENSOR 2 UPPER 11 12 AUX #6 A-N.C. FAN #2 HOUSING HIGH LIMIT 8 7 FAN #1 HOUSING HIGH LIMIT ENERGENCY COOLING 13 14 EMERGENCY COOLING FAN #2 VAPOR HIGH LIMIT 6 5 FAN #1 VAPOR HIGH LIMIT AUX #6 B-COMMON 15 16 EMERGENCY COOLING FAN #2 AUTO 4 3 FAN #1 AUTO EMERGENCY COOLING 17 18 NC FAN #2 ON 2 1 FAN #1 ON 19 20 NC J1 ** IMPORTANT--JUMPERS LISTED ABOVE MUST BE INSTALLED 12 120 VOLT AC OUTPUTS M.R.L POT 2 & HI SOLENOID BUR#2 (BO) NC J6 Switch Replacement Portable Dryer Troubleshooting Switch Replacement for EMCS Dryer Switch N/O Contact Block - Part No. D63-0006 Switch Light Block - D01-0455 13 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) OR J1-19 12 VOLTS DC (RED) OR J5-5 12 VOLTS DC (RED) OR J4-19 OR 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 S1 TEMP SENSOR TEMP SENSORS BLK S2 TEMP SENSOR WORK LIGHT RED L1 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 14 (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) 15 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 OR 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 RED J5-8 J5-8 12 VOLTS DC (RED) YEL J1-8 12 VOLTS DC (RED) PUR J1-6 12 VOLTS DC (RED) OR J1-10 12 VOLTS DC (RED) YEL J1-7 12 VOLTS DC (RED) PUR J1-5 12 VOLTS DC (RED) OR J1-9 12 VOLTS DC (RED) YEL J1-12 12 VOLTS DC (RED) BLU J1-11 12 VOLTS DC (RED) OR J1-19 12 VOLTS DC (RED) OR 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 B2 120 VAC BURNER #1 LIGHT BRN B1 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 BLK METERING ROLL NEGATIVE NEED JUMPER TEMP SENSOR TEMP SENSOR WHT BLK S1 S2 TEMP SENSOR WORK LIGHT RED L1 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 16 (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) 17 Wiring Reference Portable Dryer Troubleshooting 1100 Fan Lower Control Box Interconnect Strip J9-1 18 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 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 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 19 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 20 TO PLENUM AND RIGHT FIXED GRAIN HIGH LIMIT SWITCHES AND TEMPERATURE SENSORS Portable Dryer Troubleshooting Wiring Reference Fan Housing and Vapor Hi-Limit Circuit 21 Wiring Reference Portable Dryer Troubleshooting Plenum Hi-Temperature Switch 22 Portable Dryer Troubleshooting Wiring Reference Fixed Grain Hi-Limit 23 24 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 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 25 Wiring Reference Portable Dryer Troubleshooting Rear Discharge & Emergency Cooling Circuit 26 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 27 Wiring Reference Portable Dryer Troubleshooting Adjustable Hi-Limit & Emergency Cooling Circuit 28 Portable Dryer Troubleshooting Wiring Reference Motor Overloads 29 Portable Dryer Troubleshooting Wiring Reference Air Pressure Switch J5 11 12 VOLT SOURCE 12 VOLT DC NEGATIVE 8 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 J3 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 30 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 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 31 Wiring Reference Portable Dryer Troubleshooting Out of Grain Safety Circuit 32 UP 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 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 33 34 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 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 35 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 Pulse 12 Volt - 12 Volt + METER ROLL SENSOR Meter Roll Board 36 Meter Roll Board S2 S1 J5-12 J1-20 J5-9 J5-19 J5-16 J5-4 J7-8 J7-3 B1 J7-4 J9-16 J1-13 J4-12 J4-19 J5-5 J1-19 J1-11 J1 J2 J3 J4 J5 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 8 5 4 1 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 14 13 12 9 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 38 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 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. E2 E1 NEU. 120 VAC GAS VALVE H.V. S1 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 39 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 S1 + Flame Test Flame Test FC+ - FC- Micro Amp Meter 40 BURNER BURNER BURNER YES NO NO OR OR 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 S1 L1 BLK BRN WHT V2 FENWAL BOARD V1 E2 WHT L2 Neutral TIME DELAY WHT Coil BLK WHT Neutral Coil BRN WHT BRN OR OR Normal Closed BLK Normal Closed COIL WHT WHT 1 3 2 5 4 6 8 7 OR OR TER. 1-5 (12 VOLTS DC) TER. 6-8 (110 VOLTS AC) OR OR COMMON FLAME SENSOR COMMON IGNITOR Portable Dryer Troubleshooting Wiring Reference Flame Control Circuit 41 42 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 V1 E1 S1 BLK L1 BLACK BROWN GREY V2 WHITE L2 FLAME SENSOR FENWAL PART# HF-4624 E2 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 1 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 YELLOW BROWN LIQUID R LOW t o B 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 43 Wiring Reference Portable Dryer Troubleshooting Fan 28 LP Hi/Low-On/Off 44 Portable Dryer Troubleshooting Wiring Reference Fan 28 LP Hi/Low-On/Off Burner With Mercoid 45 Wiring Reference Portable Dryer Troubleshooting Fan 28 NG Hi/Low-On/Off 46 Portable Dryer Troubleshooting Wiring Reference Fan 28 NG Hi/Low-On/Off Burner With Mercoid 47 Wiring Reference Portable Dryer Troubleshooting Fan 42 LP Hi/Low-On/Off 48 Portable Dryer Troubleshooting Wiring Reference Fan 42 LP Hi/Low-On/Off Burner With Mercoid 49 Wiring Reference Portable Dryer Troubleshooting Fan 42 NG Hi/Low-On/Off 50 Portable Dryer Troubleshooting Wiring Reference Fan 42 NG Hi/Low-On/Off Burner With Mercoid 51 52 J6-4 SCR P3 W PUR OR P P P OR 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 2 3 F+ F- L1 L2 A+ A- OR T1 T2 S C R Board BLK BLK To Coil 220 Volt SCR CONTACTOR Fuse L2 L1 Wiring Reference Portable Dryer Troubleshooting SCR Drive Circuit 1 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 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 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 53 54 S2 3.4 ON 20K SCALE AT 70 DEGREES S1 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. 55 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 • 56 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. 57 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. 58 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. • 60 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 4. 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. 5. 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. 2. 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. 3. 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. 62 Troubleshooting Tips Portable Dryer Troubleshooting Out Of Grain Warning Shutdown 2. 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.) 3. 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. 63 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. 64 1. 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. 2. 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. 3. 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. 4. Always check amperages on the motors to be sure that the problem is not in the motor itself. 5. 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 65 5 6 7 8 9 10 TO LOAD MOTOR TO FAN #1 MOTOR AC-1 IR 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 L1 L2 MAX MIN TRANSFORMER 110 VAC OUTPUT 110X0 SCR CONTACTOR ACCEL TO UNLOAD MOTOR 4 1FO 220 VAC INPUT 3F0 220V FUSES LINE FUSE TO AUX UNLOAD MOTOR 3 FAN #1 LOAD LOAD AUX UNLOAD 3FI 1FI DISTRIBUTION BLOCK INPUT KBIC BARRIER TERMINAL BOARD 2 FAN #1 CONTACTOR OVERLOAD MAIN BREAKER SCR BOARD ASSEMBLED D03-0104 1 UNLOAD AUX LOAD CONTACTOR FAN #1 BREAKER OVERLOAD UNLOAD CONTACTOR LOAD BREAKER OVERLOAD UNLOAD BREAKER OVERLOAD 66 OVERLOAD Competitor Wiring Reference Portable Dryer Troubleshooting 220 Volt Single (1) Phase Power Drawing CL A+ AP3 P2P1 I1 F+ F- L1 L2 Portable Dryer Troubleshooting Competitor Wiring Reference 220 Volt Single (1) Phase Power Drawing (New Version) 67 68 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) 69 Competitor Wiring Reference Portable Dryer Troubleshooting COMPETITOR POWER CIRCUIT ( 220 VOLT 1PH ) 70 Portable Dryer Troubleshooting Competitor Wiring Reference COMPETITOR POWER CIRCUIT ( 220 VOLT 3PH ) 71 Competitor Wiring Reference Portable Dryer Troubleshooting COMPETITOR POWER CIRCUIT ( 440 VOLT 3PH ) 72 Competitor Wiring Reference Portable Dryer Troubleshooting Upper Control Box Internal Wiring COM J3-02 COM YEL YEL R LOAD R WHT UNLOAD J3-01 UNLOAD UNLOAD OVERLOAD UNLOAD AUX. R R OR N/O N/C BREAKER R BREAKER ORG ORG R R R YEL N/O N/C J3-11 FAN #1 BREAKER LOAD LOAD OVERLOAD LOAD AUX. WHT J3-12 BLU R J6-03 R 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 49 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 W UNLOAD POWER J3-01 OR LOAD NEUTRAL J3-12 W LOAD POWER J3-11 Y FAN NEUTRAL J3-14 W 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 W SCR CONT POWER J6-09 O SCR P1 J4-02 P 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 1 OR A- 2 SCR DRIVE TERMINAL ON UPPER STRIP A+ 3 F+ F- L1 L2 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 35 RED MOTOR OVERLOAD J6-12 (BLK) +12 VDC DISTRIBUTION BLOCK OUT OF GRAIN 73 Competitor Wiring Reference Portable Dryer Troubleshooting Series 2000 Control Box Wiring (New Version) 74 Portable Dryer Troubleshooting Competitor Wiring Reference Upper Control Box Wiring 220 Volt 1PH 75 Competitor Wiring Reference Portable Dryer Troubleshooting Upper Control Box Wiring 380, 460 & 575 3PH 76 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 78 Portable Dryer Troubleshooting Competitor Wiring Reference Upper Terminal Strip With Moisture Control Relay Hook Up 79 Competitor Wiring Reference Portable Dryer Troubleshooting Moisture Manager to Dryer Wiring (Upper Control Box) 80 2 20 BLK J1 J4 19 YEL 1 RED-2 ORANGE-1 WHITE-5 YELLOW-1 BLACK-1 PURPLE-2 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 20 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 19 J2 J3 1 81 Competitor Wiring Reference Portable Dryer Troubleshooting Competitor Control Circuit CPU/Display Board 82 Portable Dryer Troubleshooting Competitor Wiring Reference Competitor Control Circuit I/O Board 83 Competitor Wiring Reference Portable Dryer Troubleshooting Competitor Control Circuit SCR Drive Board 84 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- 86 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- 87 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 88 TO PLENUM AND RIGHT FIXED GRAIN HIGH LIMIT SWITCHES AND TEMPERATURE SENSORS Competitor Wiring Reference Portable Dryer Troubleshooting 2 J3 16 14 19 20 17 18 15 13 11 12 9 10 7 8 5 6 3 4 1 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 J4 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 J1 12 VDC FAN ON BURNER ON UNLOAD 1 SPEED LOAD ON CONTINUOUS FLOW VAPOR HIGH LIMIT INPUT SPARE USER SAFETY INPUT 12 VDC 1 2 R E L A Y 12 VOLT DC INPUT J5 J2 DATA INTERLINK CABLE CONNECTION RL1-A N.O. HIGH SPEED POT B 89 90 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 J7 - J5 4 1 12 VDC GROUND N J8 J1 RL1 COMMON 3 1 110VAC IN 3 RL1 N.O. 1 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 J2 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 J6 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. 91 19 20 17 - 18 15 16 13 14 11 12 9 - 10 7 8 5 6 3 4 1 2 J7 1 2 3 4 5 6 7 8 4 J2 J5 J4 1 J8 J1 3 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 93 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) 94 OR J3-09 PR J4-04 PR J4-06 PR SCR-2 no com STOP T B M T B M METERING ROLL SPEED OR OR OR J3-01 J1-08 J1-07 THREE POS UNLOAD 2 1 20 19 BK no com START OR J1-14 J7 J3-03 MOISTURE CONTROL BL BR J4-05 PR J4-03 PR J1-04 J1-05 BR J1-10 YL J1-03 BL YL J1-06 J3-11 BL 19 J3-07 3 3 1 1 FAN J8 J6 TRANSFORMER BR BURNER CONNECT J6-05 TO J6-01. 4 1 J5 J3-05 MONITORING DISPLAY 20 FUSE YL J1-09 LOAD J6 1 2 CF GY BATCH GY GY 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 BK AC1 BK 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 95 96 J7-07 YEL J7-06 BLU RED RED J6-02 no com STOP no 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 J7 MONITORING DISPLAY 4 1 J5 J6-2 J7-15 FAN J8 3 3 1 1 J1 19 J6 1 2 20 FUSE J7-15 J6-02 LOAD AUGER TRANSFORMER CF 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 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 97 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. 2. 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. 4. 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. 98 FAN OFF AUTO ON 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 99 UP 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 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 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 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 - J5 4 1 12 VDC GROUND J8 110VAC IN 3 RL1 N.O. RL1 COMMON 3 1 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 J6 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 J2 J1 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. N 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 J7 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) 2. Open each box by removing the lid. They are held in place by 4 phillips head bolts and nuts. 3. 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 4. 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. 5. 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. 6. Disconnect the white and black 18 ga. wires from the smaller white grain sensor wires. 7. Strip back about 1/4 inch from the end of each 26 ga. sensor wire. 8. With a ohm meter, set your scale to 20k (if its not a autorange model). 9. 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. 2. 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) 3. 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. 4. 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 1 108 2 3 180 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 ERROR ERROR ERROR ERROR ERROR ERROR ERROR ERROR ERROR ERROR 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 1 2 3 BROWN PINK PURPLE PURPLE 5 4 WHITE 7 6 YELLOW YELLOW BROWN LIQUID FLAME PROBE NEUTRAL ---- WHITE BLACK 12 11 8 FLAME PROBE (SILICONE WIRE) 13 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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