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GSI
Competitor & EMCS
Portable Dryer
Models
Troubleshooting and
Reference Manual
2004 Revised Edition
PNEG-630
Competitor Series 2000 Dryer
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Table Of Contents Portable Dryer Troubleshooting Safety ..................................................................................................................................................................... 3 Safety Sign Off Sheet ............................................................................................................................................ 8 EMCS Portable Dryer (1993-1998) Safety Voltage Check Points ...................................................
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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 Drawin
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Safety Portable Dryer Troubleshooting Dryer Safety Instructions and Information Thank you for choosing an GSI Grain Dryer. It is designed to pro- vide excellent performance and ser- vice for many years. This manual refers to the trouble- shooting of the E.M.C.S.and Series 2000 Competitor models. Different models are available for liquid pro- pane or natural gas fuel supply, with either single phase 230 volt, or three phase 230, 460, 575 volt electrical power. (Also 380 volt 50Hz). Th
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Safety Portable Dryer Troubleshooting Grain Systems, Inc. recommends A CAREFUL OPERATOR you contact your local power com- IS THE BEST INSURANCE pany and have a representative sur- vey your dryer installation, so your AGAINST AN ACCIDENT wiring will be compatible with their system and you will have adequate power supplied to your unit. Safety decals should be read and understood by all people in and around the dryer area. If the follow- ing safety decals are not displayed on your dryer, or if t
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Safety Portable Dryer Troubleshooting 5
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Safety Portable Dryer Troubleshooting 6
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Safety Precautions Portable Dryer Troubleshooting READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE Use Caution in the SAVE FOR FUTURE REFERENCE Operation of this 1. Read and understand the operating manual before trying to operate the Equipment dryer. The design and manufacture of this dryer is directed toward operator 2. Power supply should be OFF for service of electrical components. Use safety. However, the very nature of CAUTION in checking voltage or other procedures requiring power to
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Safety Sign-Off Sheet Portable Dryer Troubleshooting Date Employer’s Signature Employee ________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ ____________________________
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Wiring Reference Portable Dryer Troubleshooting Safety Voltage Check Points 9 FAN # 123 4 5 6 Error Message - + - + - + - + - + - + RESULT Fan # Housing High Temperature J5-12 J1-7 J5-12 J1-8 J5-12 J2-7 J5-12 J2-8 J5-12 J3-7 J5-12 J3-8 12VDC Burner # Vapor High Temperature J5-12 J1-5 J5-12 J1-6 J5-12 J2-5 J5-12 J2-6 J5-12 J3-5 J5-12 J3-6 12VDC Burner # Flame not Detected J5-12 J1-9 J5-12 J1-10 J5-12 J2-9 J5-12 J2-10 J5-12 J3-9 J5-12 J3-10 12VDC Plenum # High Temperature J5-12 J1-11 J5-12 J1-12 J
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Portable Dryer Troubleshooting Programming 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
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Programming Portable Dryer Troubleshooting EMCS Display Board 11 PROGRAMMER JACK (DB9) COMPUTER COMMUNICATIONS CABLE PROGRAMMING TO I/O BOARD JACK P8 P7 SOUND DISPLAY S1 RIBBON P1 P5 P6 P4 KEY PAD RIBBON BATTERY (TIC) U12 1 2 3 P3 TO STOP SW. TO START & STOP SWS. TO START SW.
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Wiring Reference Portable Dryer Troubleshooting Input/Output Board Identification 12 VOLT DC INPUTS 120 VOLT AC OUTPUTS 120VAC POWER (INPUT) 120VAC POWER (OUTPUT) 1 +12 LIMIT OUTPUT 2 20 19 AC NEUTRAL AC NEUTRAL 3 4 12 VOLT DC NEUTRAL +12 LIMIT OUTPUT 18 17 120VAC POWER (INPUT) 5 6 120VAC POWER (OUTPUT) METERING ROLL INPUT 12 VOLT DC NEGATIVE 15 16 AC NEUTRAL AC NEUTRAL 7 8 12 VOLT DC NEGATIVE 12 VOLT DC NEGATIVE 14 13 AC NEUTRAL AC NEUTRAL 9 10 12 V
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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
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Portable Dryer Troubleshooting Wiring Reference 1100 Series Control Box Wiring 1100 FAN TO CONTROL BOX WIRING 42 TOTAL TERMINALS DESCRIPTION WIRING VOLTAGE COLOR J5-8 AIR PRESSURE SWITCH +12VDC RED NEED JUMPER RED J5-8 12 VOLTS DC (RED) HOUSING HIGH LIMIT OR YEL 12 VOLTS DC (RED) J1-7 VAPOR HIGH LIMIT (LP ONLY) RELAY CONTACTS LOCATED 12 VOLTS DC (RED) PUR J1-5 IN DRYER FAN CAN BOX YEL FLAME DETECTION OR 12 VOLTS DC (RED) J1-9 PLENUM BLU 12 VOLTS DC (RED) J1-11 RED LEFT
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Wiring Reference Portable Dryer Troubleshooting 1100 Series Control Box Wiring (New Version) 15
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Portable Dryer Troubleshooting Wiring Reference 1200 Series Control Box Wiring 52 TOTAL TERMINALS DESCRIPTION WIRING TERMINAL VOLTAGE COLOR AIR PRESSURE SWITCH +12VDC RED J5-8 NEED JUMPER RED J5-8 12 VOLTS DC (RED) OR FAN #2 HOUSING HIGH LIMIT 12 VOLTS DC (RED) YEL J1-8 FAN #2 VAPOR HIGH LIMIT RELAY CONTACTS LOCATED 12 VOLTS DC (RED) PUR J1-6 IN FAN CAN CONTROL BOX RED FAN #2 FLAME DETECTION OR 12 VOLTS DC (RED) J1-10 OR FAN #1 HOUSING HIGH LIMIT YEL 12 VOLTS DC (RED) J
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Wiring Reference Portable Dryer Troubleshooting 1200 Series Control Box Wiring (New Version) 17
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LINE LOAD Wiring Reference Portable Dryer Troubleshooting 1100 Fan Lower Control Box Interconnect Strip J9-1 AC-1 EMERGENCY COOLING JUMPERS INSTALL J6-13 TO J1-5 J9-3 J9-3 INSTALL J6-14 TO J1-19 EMI FILTER INSTALL J6-16 TO J5-5 D03-0181 INSTALL J6-17 TO J4-19 L1 BLACK - 120 VAC - OUTSIDE LIGHT B1 BROWN - 120 VAC - BURNER #1 LIGHT S1 ORANGE - TEMPERATURE SENSOR S2 ORANGE - TEMPERATURE SENSOR SCR2 PURPLE - CONTROL POT P2 J1-5 RED - 12 VDC - FAN #1 VAPOR HIGH LIMIT J1-7 RED - 12
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LINE LOAD Wiring Reference Portable Dryer Troubleshooting 1200 Fan Lower Control Box Interconnect Strip J9-1 AC-1 J9-3 J9-3 EMI FILTER D03-0181 L1 BLACK - 120 VAC - OUTSIDE LIGHT B1 BROWN - 120 VAC - BURNER #1 LIGHT B2 BROWN - 120 VAC - BURNER #2 LIGHT S1 ORANGE - TEMPERATURE SENSOR S2 ORANGE - TEMPERATURE SENSOR SCR2 PURPLE - CONTROL POT P2 J1-5 RED - 12 VDC - FAN #1 VAPOR HIGH LIMIT J1-6 RED - 12 VDC - FAN #2 VAPOR HIGH LIMIT J1-7 RED - 12 VDC - FAN #1 HOUSING
