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PNEG-552 100 Series Dryer Operation and Service Manual PNEG-552 Date: 11-02-07.
2 PNEG-552 100 Series Dryer.
PNEG-552 100 Series Dryer 3 T able of Content s Contents Chapter 1 Safety .............. ................ ................. ................ ................ ................ .............. ............ ................ ......... 5 Safety Guidelines .
4 PNEG-552 100 Series Dryer T able of Content s Chapter 8 Wiring Diagrams ................. ................ ................ ................ ................ ................... ....... ................ ... 44 100 Series Single Fan Wiring to Control Box .
PNEG-552 100 Series Dryer 5 1. Safety Safety Guidelines This manual contains information that is important for you, the owner/opera tor, to know and understand. This information relates to protectin g personal safety and preventing equipment problems .
6 PNEG-552 100 Series Dryer 1. Safety Dryer Operation Thank you for choo sing a GSI prod uct. It is desig ned to give exce llent perform ance and serv ice for many years. This manual describes the operatio n and service for all standard 100 Series single fan grain dryers.
1. Safety PNEG-552 100 Series Dryer 7 Safety Precautions READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVIC E SAVE FOR FUTURE REFERENCE 1. Read and understand the op erating manual before attempting to operate th e dryer. 2. NEVER operate the dryer while the guards are removed.
8 PNEG-552 100 Series Dryer 2. Safety Alert Decals GSI Group recommends contacting the local power co mpany and, having a repre sentative survey the installation so that wiring is compatible with t heir system, and adequate power is supplied to your unit.
2. Safety Alert Decals PNEG-552 100 Series Dryer 9 DC-974 Rotating auger will crush and cut. Auto equipment can start at anytime. Do not enter until electric power is locked in off position. Failure to do so will result in serious injury or death. W ARNING! Automatically controlled belt drive can start at anytime.
10 PNEG-552 100 Series Dryer 2. Safety Alert Decals DC-1229 W ARNING Rotating metering roll. Equipment can start automatically . Keep hands clear . Can cause serious injury . Disconnect power before servicing. DC-1227 Stay clear of rotating blade. Blade could start automatically.
2. Safety Alert Decals PNEG-552 100 Series Dryer 11 16-17" 3/4" MINIMUM BOL T DIAMETER DC-388 Hitch pin must be securely fastened and no less than 3/4" in diameter . Failure to follow installation instructions may result in property damage.
12 PNEG-552 100 Series Drye r 3. Dryer Control Panel Figure 3A Grain Dryer Control Panel.
3. Dryer Control Panel PNEG-552 100 Series Dryer 13 Dryer Control Panel Featuring the 100 Series Control System The control panel provides ea sy access to gauges and controls. The Competitor Series 2000 Control System is a computerized control system that gives instant informatio n regarding dryer operation.
14 PNEG-552 100 Series Dryer 3. Dryer Control Panel Unload Switch The UNLOAD switch turns the metering rolls and discharge auger ON or OFF, a nd selects the operation of the metering rolls.
3. Dryer Control Panel PNEG-552 100 Series Dryer 15 Dryer Power S top Switch This switch stops all dryer functions. If an automatic dryer shut down occurs, first dete rmine and correct the cause of the shut down. Press the dryer power stop button to reset the dryer before restarting.
16 PNEG-552 100 Series Dryer 3. Dryer Control Panel Setting the Dry , Cool, Unload and Out of Grain Timers These switches are used to set the drying cycle times in the staged batch drying mode only. The drying mode switch must be in the staged batch po sition.
3. Dryer Control Panel PNEG-552 100 Series Dryer 17 Setting the Moisture Cont rol and Plenum Setpoint 1. Press the PROGRAM (TEMPERATURES) button unt il the carrot is under the temperature setting to be changed. 2. Use the UP and DOWN arrow keys to change from the present temperature to th e new one.
18 PNEG-552 100 Series Dryer 3. Dryer Control Panel S pecial Features Dual Batch Drying T emperature Mode Emergency Cooling Mode Burner ON/OFF Operation Due to changing fuel conditions a nd to aid in drying wheat and other low temperature grains in hot weather, an ON/OFF burner has been developed in recent years.
3. Dryer Control Panel PNEG-552 100 Series Dryer 19 Loss of Flame The flame sensor failed to detect a burner flame, indi cating that the burner has failed to light. There is a problem with the flame sens ing circuitry or the dryer is no t getti ng burner fuel.
20 PNEG-552 100 Series Dryer 4. Error Conditions Figure 4A.
4. Error Conditions PNEG-552 100 Series Dryer 21 Figure 4B.
22 PNEG-552 100 Series Dryer 5. Dryer Pre-St art Checks Before the dryer is filled, thoroughly in spect the unit and check the operation of the dryer as follows.
5. Dryer Pre-St art Checks PNEG-552 100 Series Dryer 23 Electrical Power Turn ON the electrical power supply t o the dryer. Set all circuit breakers to ON, including the safet y disconnect handle mounted on fron t of the dryer’s power panel. Control Power Switch Turn the CONTROL POWER switch to ON.
24 PNEG-552 100 Series Dryer 5. Dryer Pre-St art Checks Metering Roll Operation To check the metering roll operation, turn high speed knob clockwise. The metering roll speed should increase. Turning the knob counterclockwise will decrease the speed. Turn ON the MOISTU RE CONTROL switch .
5. Dryer Pre-St art Checks PNEG-552 100 Series Dryer 25 Burner Safety To check the burner safety function, make sure the main gas valve is OFF. Turn the FAN switch ON an d allow the fan to start. Then, turn th e HEATER switch ON. The dryer will shut down after 20 seconds.
26 PNEG-552 100 Series Dryer 5. Dryer Pre-St art Checks Dryer Shut Down To shut down the dryer, first close t he fuel supply valve at the tank or valve along the fuel line. If the burner is operating, let the dryer run ou t of fuel, and it will shut do wn automatically due to loss of fla me.
PNEG-552 100 Series Dryer 27 6. Dryer St art-Up Continuous Flow Operation Standard electrical safety p ractices and codes shoul d be used when working with a dryer. Refer to the National Electric Code standard handbook by the Nati onal Fire Protection Associa tion.
28 PNEG-552 100 Series Drye r 6. Dryer St art-Up S t aged Batch Operation 1. Turn the CONTROL POWER switch to ON. 2. With load, unload, fan and burner turned OFF, turn the drying mode switch to continuous then push the dryer power start switch to arm the safety circuit.
6. Dryer St art-Up PNEG-552 100 Series Dryer 29 10. After purging for approximately 10 seconds the hea ter will fire . For informa tion concerning hea ter adjustment, see Dryer Pre-Start Checks on Page 22 . 11. If the dryer is being operated in all heat, move the FAN switch to the ON position.
30 PNEG-552 100 Series Drye r 6. Dryer St art-Up 100 Series Batch T imer Settings *Set unload meter roll high speed setting to 999. If unload equipment cannot a dequately keep up, lower the speed setting and a dd time to the unload timer sett ing to completely unload the batch.
6. Dryer St art-Up PNEG-552 100 Series Dryer 31 Adjusting the T emperature 1. Press the PROGRAM(TEMPERATURES) button until the “carrot” is above the timer to be modifi ed. 2. Use the UP and DOWN arrow keys to change the present temperature to th e desired setting.
32 PNEG-552 100 Series Drye r 6. Dryer St art-Up Full Heat Continuous Flow Operation 1. Refer to the DRYER START-UP section of the Ope rator’s Manual. (CONTINUOUS FLOW METER ROLL SETTINGS - FULL HEAT on Page 3 3.) There are settings for Initial Moisture , Moi sture Removed , Approximate Dry Time , 1 Speed , 2 Speed Low and 2 Speed High .
6. Dryer St art-Up PNEG-552 100 Series Dryer 33 100 Series Continuous Flow Metering Roll Settings Adjusting the Moisture Control 1. 5° on the moisture control will change the output moisture by about 1%. Example: With 100° set, the result is 16% corn but 17% corn is d esired.
34 PNEG-552 100 Series Dryer 7. Service Seasonal Inspection and Service The dryer is made of weather resista nt material, and is designed to require a minimum of service. However, each season we recommend the following items be checked b efore the unit is used and any damaged or questionab le parts replaced.
7. Service PNEG-552 100 Series Dryer 35 Suggested Lubricant s NOTE: All of the auger and metering roll bearings are lifet ime lubricated and do not require service relubrication. Lubrication Procedures If the motor is equ ipped with an alem ite fitting, clean th e tip of the fitting an d apply grease with a gre ase gun.
36 PNEG-552 100 Series Dryer 7. Service 6. Operate dryer clean-out levers, an d check clean-out hatch mechanism for proper operatio n. With hatch open, inspect and remove a ny accumulation of dirt, fines and foreign material from the bottom auger through ar ea.
7. Service PNEG-552 100 Series Dryer 37 Fan Propeller Removal and Inst allation The fan propeller is secured to th e mot or sha ft by the use of a taper-lock bushing, motor shaft key a nd three cap screws. Threaded Bushing Holes The threaded holes within th e bushing are provided for disasse mbly purposes only.
38 PNEG-552 100 Series Dryer 7. Service Figure 7C Fan Blade Remova l 3. Install two grade 5 cap screws into the threa ded holes in bushing and turn them by hand until they bottom against the front surface of the prope ller.
7. Service PNEG-552 100 Series Dryer 39 Figure 7D Posit ion of Fan Mo tor 3. Remove motor mount bolts. If there are shims between the motor and its base, note their location so they can be properly installe d during reassembly.
40 PNEG-552 100 Series Dryer 7. Service Heater Part s Removal and Inst allation Most of the heater parts can be remo ved by identifying attached wiring and d isconnecting the obvious mounting parts. 1. Flame sensor : Disconnect the wire co nnecto r and unscrew the flame sensor out of its moun ting bracket.
7. Service PNEG-552 100 Series Dryer 41 5. Reassemble : To reassemble parts (See Figure 7E) , reverse the disassembly procedure and check the following: a. Make sure all parts are thoroughly cleaned and open. b. Use a dependable brand o f high temperature pipe caulking compound when assembling gas connections.
42 PNEG-552 100 Series Dryer 7. Service 2. DC elec tric motor : The direct cu rre nt (DC) motor pr ovides the drive fo r the metering roll and is located on the fro nt left hand side of stan dard model dryers. The outpu t shaft of the motor is connected directly to the gear box asse mbly.
7. Service PNEG-552 100 Series Dryer 43 How to Clear a Jammed Metering Roll Shut down the fan/heater and e liminate any other noi se when making this check.
44 PNEG-552 100 Series Dryer 8. Wiring Diagrams 100 Series Single Fan Wiring to Control Box.
8. Wiring Diag rams PNEG-552 100 Series Dryer 45 100 Series Front Panel External Wiring.
46 PNEG-552 100 Series Dryer 8. Wiring Diagrams 100 Series Front Panel Internal Wiring.
8. Wiring Diag rams PNEG-552 100 Series Dryer 47 100 Series Lower Back Panel Wiring.
48 PNEG-552 100 Series Dryer 8. Wiring Diagrams 100 Series External Wiring to Dryer.
8. Wiring Diag rams PNEG-552 100 Series Dryer 49 100 Series Upper Control Box Wiring.
50 PNEG-552 100 Series Dryer 8. Wiring Diagrams 100 Series Main Power Wiring.
PNEG-552 100 Series Dryer 51 9. Schematic Diagram 100 Series Control Schematic.
52 PNEG-552 100 Series Dryer 9. Schematic Diagram 100 Series Control Schematic (Continued).
9. Schematic Diagram PNEG-552 100 Series Dryer 53 100 Series Control Schematic (Continued).
54 PNEG-552 100 Series Dryer 9. Schematic Diagram 100 Series 220 V olt 1 Phase Power Schematic.
9. Schematic Diagram PNEG-552 100 Series Dryer 55 100 Series 220V AC 3 Phase Power Schematic.
56 PNEG-552 100 Series Dryer 9. Schematic Diagram 100 Series 440V AC 3 Phase Power Schematic.
PNEG-552 100 Series Dryer 57 10. T roubleshooting A multimeter is required for some of the followi ng checkou t procedures. Before performing any tests, determine if the dryer power sup ply is 1 phas e, 230 volt, or 3 phase, 230 or 460 volt. • The burner circuit is 120 volts AC o n all standard U.
58 PNEG-552 100 Series Dryer 10. T r oubleshooting Display shows “ HOUSING HIGH TEMPERA TURE ” message. The temperature high-li mit locate d on th e fan/burner housing has opened, indicating an over temp erature condition has occurred towards the rear o f the fan/heater housing.
10. T roubleshooting PNEG-552 100 Series Dryer 59 Bottom auger does not start. 1. Check that the bottom auger circuit breaker is ON. 2. If the ligh ted switch does not light, th e out put power to the contactor is missing. Check c onnections, and whethe r the bulb is burned out.
60 PNEG-552 100 Series Dryer 10. T r oubleshooting Burner operates but do es not cycle from high-fire to low-fire. 1. Check the gas pressure reading on the gauge.
PNEG-552 100 Series Dryer 61 11 . FA Q s How much gas pressure is needed? See Step 4 on Page 31 in the Adjusting the Temperature section. How often should the burner cycle? See Step 5 on Page 31 in the Adjusting the Temperature section. How often do I make speed adjustments? See Step 4 on Page 33 in the Adjusting the Moisture Control section.
62 PNEG-552 100 Series Dryer NOTES.
PNEG-552 100 Series Dryer 63 12. W arranty The GSI Group Warranty THE GSI GROUP (GSI) WARRANTS ALL PRODUCT S WHICH IT MANUFACTURES TO BE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDITIONS FOR A PERIOD OF 12 MONTHS AFTER RETAIL SALE TO THE ORIGIN AL END USER.
T his equipment shall be in stalled in a ccor dance with the cur r ent installation codes and applica ble re gulations which should be ca r efully follow ed in all cases. Authorities ha ving jurisdiction should be consulted before inst allations are made.
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