Digital Moisture Control Thermostat

Transcription

1 Digital Moisture Control Thermostat Installation and Operation Manual PNEG 1711 Date: 2009 PNEG Page 1 of 22 06/30/2009

2 READ THESE INSTRUCTIONS BEFORE INSTALLATION and OPERATION. SAVE FOR FUTURE REFERENCE. Thank you for choosing a GSI Vision Series grain dryer. These units are among the finest grain dryers ever built; designed to give you excellent operating performance and reliable service for many years. This manual describes the installation and operation for all standard production model dryers. These dryers are available with liquid propane or natural gas fuel supply, single phase 230 volt, three phase 230 or 460 volt (60Hz) electrical power. USE CAUTION IN THE OPERATION OF THIS EQUIPMENT The design and manufacture of this dryer is directed toward operator safety. However, the very nature of a grain dryer having a gas burner, high voltage electrical equipment and high speed rotating parts does present a hazard to personnel which cannot be completely safeguarded against without interfering with efficient operation and reasonable access to components. Use extreme caution in working around high speed fans, gas-fired heaters, augers and auxiliary conveyors which may start without warning when the dryer is operating on automatic control. Continued safe dependable operation of automatic equipment depends, to a great degree, upon the owner. For a safe and dependable drying system, follow the recommendations within the 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 Operating Precautions listed below before attempting to operate the dryer. Keep the dryer clean. Do not allow fine material to accumulate in the plenum chamber. A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENT. OPERATING PRECAUTIONS 1. Read and understand the operation manual before attempting to operate the unit. 2. Keep ALL guards, safety decals, and safety devices in place. Never operate dryer while guards are removed. 3. Keep visitors, children and untrained personnel away from dryer at all times. 4. Never attempt to operate the dryer by jumping or otherwise bypassing any safety devices on the unit. 5. Always set the main power supply disconnect switch to OFF and lock it in the OFF position using a padlock before performing any service or maintenance work on the dryer or the auxiliary conveyor equipment. 6. Before attempting to remove and reinstall the fan blade, make certain to read recommended procedure listed within the SERVICING section of the manual. 7. Keep the dryer and wet holding equipment CLEAN. Do not allow fine material to accumulate. PNEG Page 2 of 22 06/30/2009

3 8. Set pressure regulator to avoid excessive gas pressure applied to a burner during ignition and when burner is in operation. See page 19 for operating gas pressures. Do not exceed maximum recommended drying temperatures. 9. Do not operate the dryer if any gas leak is detected. Shut down and repair before further operation. 10. Clean grain is safer and easier to dry. Fine material can be highly combustible, and it also requires removal of extra moisture. 11. Use CAUTION in working around high-speed fans, gas burners, augers, and auxiliary conveyors which can start automatically. 12. Be certain that capacities of auxiliary conveyors are matched to dryer auger capacities. 13. Do not operate in an area where combustible material will be drawn into the fan. 14. The operating and safety recommendations in this manual pertain to the common cereal grains as indicated. When drying any other grain or products, consult the factory for additional recommendations. 15. Routinely check for any developing gas plumbing leaks. Check LP vaporizer for contact with burner vanes. PNEG Page 3 of 22 06/30/2009

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8 Table of Contents TABLE OF FIGURES CONTENTS INSTALLATION OPERATION EXAMPLE SETUP TROUBLESHOOTING GUIDE DRILL DIMENSIONS TO SCALE WARRANTY...21 PNEG Page 8 of 22 06/30/2009

9 Table of Figures Figure 1 - Drill Pattern...11 Figure 2 - A1 through A3 Connections...12 Figure 3 - B1 through B6 Connections...12 Figure 4 - Assembly Drawing...13 Figure 5 - Default Hi / Lo Screen...15 Figure 6 - Default On / Off Screen...16 Figure 7 - Engaged Mode, notice the temperature to the left...17 Figure 8 - Disengaged Mode, notice the temperature to the right...17 PNEG Page 9 of 22 06/30/2009

10 1. Contents 1.1 Digital Thermostat Contents Qty GSI Part Number Description 1 D Digital Moisture Control Thermostat 4 S #10-24 Machine Screw, Pan Head Phillip Stainless Steel 4 S-2010 Nut, Nylock #10-24 Zinc 2. Installation 2.1 Mounting in Control Panel 1. Turn the Main Power Disconnect to the OFF position. 2. Use the following table to document the wiring of the Honeywell that is being replaced, as this will be referenced later in the manual. # on Honeywell Wire Description (RTD) 1 (RTD) 2 (NO) 4 (SRC) 5 (110 VAC) 8 (NEUTRAL) 9 3. Remove the Honeywell controller from the control panel door. Loosen the flat head screw at the bottom of the face of the dial. Grab the edges of the controller on the front of the control panel door and pull away from the control panel. The controller should slide out, leaving a shell in the 1/4 din cut-out. On the left and the right side of the shell, there is a flat head screw. Loosen these screws until you are able to remove the shell from the control panel door. 4. Holes need to be drilled in the control panel door for mounting new thermostat. This is a two person job, as the door needs to be open at least 90 degrees from closed when the drill breaks through to avoid damaging internal circuitry. Refer to Figure 1 for drilling dimensions. Make sure all wires and human limbs are out of the way when drilling. Section 6 is a drawing to scale that can be removed from this manual to be used as a guide for drilling the holes. PNEG Page 10 of 22 06/30/2009

11 Figure 1 - Drill Pattern 5. Before mounting the GSI moisture control to the panel door, attach the necessary wiring. Be sure to kill power when installing. Table 1 depicts the relation between the Honeywell controller and the GSI moisture control. Refer to Figure 2 and Figure 3 for connections of the GSI moisture control. For example, if a wire is attached to the connection labeled 1 on the Honeywell controller, that wire would need to be attached to A1 on the GSI moisture control. Remove the four Phillip head screws from the corner of the controller to access the connections on the GSI controller. Table 1 - Honeywell to GSI relation Honeywell Connection # GSI Connection # 1 A1 2 A2 4 B3 5 B4 8 B1 9 B2 PNEG Page 11 of 22 06/30/2009

12 Figure 2 - A1 through A3 Connections Figure 3 - B1 through B6 Connections PNEG Page 12 of 22 06/30/2009

13 6. Once the control has been wired, refer to Figure 4 for mounting the new controller to the control panel door. The S-7931 nuts are already installed in the bottom assembly (Figure 3). There are recessions on the bottom of the corners of the box that fit the nuts. Make sure to place the gasket between the two box pieces. Figure 4 - Assembly Drawing 7. The GSI Digital Thermostat is now ready for operation. Refer to Section 3 for operation instructions. 3. Operation 3.1 Setting Temperature Setpoint Press and release the SET button to enter the temperature setpoint menu. Here the user may press and release the UP or DOWN button to adjust the setpoint accordingly, incrementing/decrementing by one. The setpoint can be adjusted rapidly by holding the UP or DOWN button. To accept the setpoint, press and release the SET button. The controller is still running in the background while in this menu and the new setpoint is not accepted until the SET button is pressed. While in the setpoint menu, if the user allows approximately twenty-five seconds to pass without pressing a button, the menu is exited and the new setpoint is not saved. PNEG Page 13 of 22 06/30/2009

14 3.2 Configuration Menu To access the configuration menu, press and hold the SET button until the configuration menu appears, approximately five seconds. Once in the menu structure, us UP and DOWN to browse through the options and SET to enter the sub menu. While in the configuration, if the user allows approximately twenty-five seconds to pass without pressing a button, the configuration menu is exited and no changes will be saved. The following are the menu options Save and Exit No modifications will actually be accepted until the user selects the Save and Exit option. Once selected, the controller returns to the default screen with all of the new parameters being used and stored to a non-volatile EEPROM (will not be erased on power down) Operation Select The Thermostat has four modes of operation. The factory default is No Operation to prevent accidental operation on initial install No Operation Relays are set to an open state Hi / Lo Operation (Plenum Temperature Control) See Section On / Off Operation (Plenum Temperature Control) See Section Dryer / TopDry Operation (Grain Temperature / Moisture Control) See Section Units Select Choose between Standard ( F) and Metric ( C) units for the controller to use Sensor Selection The controller can use one of two sensors, one being a BetaTherm Bolt Thermistor (HF-7236) and the other a Honeywell RTD (D ). See wiring diagram for installation Hi-Limit Differential This is only applicable when the controller is in Hi / Lo mode. See Section for behavior. Range from 10 to 30 degrees Temperature Differential See descriptions of mode operations for behavior. Range from 1 to 10 degrees. PNEG Page 14 of 22 06/30/2009

15 3.3 Operating Modes Hi / Lo Operation (Plenum Temperature Control) There are three states the burner can assume when Hi / Lo operation is selected: High, Low, and Off. Anytime the sensor temperature is below the temperature setpoint minus the differential, the controller will engage the High state. Once the sensor temperature rises above the setpoint plus the temperature differential, the Thermostat will enter Low mode and will remain in this state until one of two things happen: 1. The sensor temperature falls below the setpoint minus the temperature differential. At which point the controller returns to High mode. This should be normal operation. 2. The sensor temperature rises above the temperature setpoint plus the temperature differential plus the hilimit differential. If this occurs the controller will switch the Off position until the sensor temperature drops below the temperature setpoint minus the temperature differential. The relay position in each state is depicted below. Table 2 - Hi / Lo Controller States Controller State Relay 1 Relay 2 High Closed (0 Ω) Closed (0 Ω) Low Closed (0 Ω) Open ( Ω) Off Open ( Ω) Open ( Ω) The default screen displays current state of controller, current sensor temperature, and current setpoint. Figure 5 - Default Hi / Lo Screen On / Off Operation (Plenum Temperature Control) There are two states the controller can assume using On / Off operation: On and Off. Anytime the sensor temperature is below the setpoint minus the temperature differential, the Thermostat will be in the On state. If the sensor temperature rises above the setpoint plus the differential, the Thermostat will be in the Off state. The relay position in each state is depicted below. PNEG Page 15 of 22 06/30/2009

16 Table 3 - On / Off Controller States Controller State Relay 1 Relay 2 On Closed (0 Ω) Closed (0 Ω) Off Open ( Ω) Open ( Ω) The default screen displays current state of controller, current sensor temperature, and current setpoint. Figure 6 - Default On / Off Screen Dryer / TopDry Operation (Grain Temperature / Moisture Control) There are two states the controller can assume using Dryer / TopDry operation: Engaged and Disengaged. Anytime the sensor temperature is below the setpoint minus the temperature differential, the Thermostat will be in the Engaged state. If the sensor temperature rises above the setpoint plus the differential, the Thermostat will be in the Disengaged state. The relay position in each state is depicted below. Table 4 - Dryer / TopDry Relay States Controller State Relay 1 Relay 2 Engaged Closed (0 Ω) Closed (0 Ω) Disengaged Open ( Ω) Open ( Ω) The default screen displays the current setpoint on the top line and the current sensor temperature on the bottom line. If the controller is in the Engaged mode, the current sensor temperature is displayed on the left side of the screen (see Figure 7). If the controller is in the Disengaged mode, the current sensor temperature is displayed on the right side of the screen (see Figure 8). PNEG Page 16 of 22 06/30/2009

17 Figure 7 - Engaged Mode, notice the temperature to the left Figure 8 - Disengaged Mode, notice the temperature to the right PNEG Page 17 of 22 06/30/2009

18 4. Example Setup Once the thermostat has been wired and secured to the control panel door, turn the power on. The display will show GSI Group, LLC for approximately ten seconds while the thermostat is booting. The next screen will display No Operation, provided this is the first time the controller has been used. 1. Press and hold the SET button until the configuration menu appears, approximately five seconds. You can press and release UP or DOWN to navigate through the menus. Since No Operation is selected, the menus are limited to Operation Selection and Save and Exit. Once an operation mode is selected other than No Operation, more menus will be available depending on the mode. 2. Operation Selection is the first menu that is displayed in the configuration menu. While Operation Selection is visible, press and release SET to enter the menu. 3. Press and release UP twice, or until Dryer / TopDry is displayed. Press and release SET to accept the operation mode and return to the list of menus. You can now scroll through the menus to see the options that are available for that mode of operation. Refer to Section 3.2 for an explanation of what each menu controls. Scroll through the menus until Exit and Save is visible and press and release SET to save and exit the configuration menu. 4. The controller should now display the default screen for Dryer / TopDry (Figure 7 and 8). Press and release the SET button to enter the Temperature Setpoint menu. Use the UP and DOWN buttons to adjust the setpoint to the desired temperature. Holding UP or DOWN will change the temperature rapidly. Once the desired setpoint is displayed, press and release SET to accept the new setpoint. 5. The controller is now setup and ready to go. Refer to Section for the behavior of the controller in this mode. 5. Troubleshooting Guide # Symptom Fix 1 System Error EEPROM Failure is displayed Replace controller 2 THERMISTOR ERROR is displayed 1. Check the A2 and A3 connections on the controller 2. Check Thermistor that is attached 3 RTD ERROR is displayed 1. Check the A1 and A2 connections on the controller 2. Check the RTD that is attached 4 Nothing is displayed on the LCD Check the input power of the controller 5 Relay(s) does not open and close as described in this manual Replace controller If problem is not resolved above, contact GSI Service Department at (217) PNEG Page 18 of 22 06/30/2009

19 6. Drill Dimensions to Scale PNEG Page 19 of 22 06/30/2009

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21 7. Warranty Limited Warranty The GSI Group, LLC. ( GSI ) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original enduser or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier. The end-user s sole remedy (and GSI s only obligation) is to repair or replace, at GSI s option and expense, products that in GSI s judgment, contain a material defect in materials or workmanship. Expenses incurred by or on behalf of the end-user without prior written authorization from the GSI Warranty Group shall be the sole responsibility of the end-user. Warranty Extensions: The Limited Warranty period is extended for the following products: Product Warranty Period Performer Series Direct Drive 3 Years Fan Motor AP Fans and All Fiberglass Housings Lifetime Flooring All Fiberglass Propellers Lifetime Apex Flooring 10 Years * Feeder System Pan Assemblies 5 Years ** Cumberland Feed Tubes (1.75" & 2.00") 10 Years * Feeding/Watering Centerless Augers 10 Years * Systems Watering Nipples 10 Years * Grain Systems Grain Bin Structural Design 5 Years Grain Systems Portable & Tower Dryers 2 Years Farm Fans Portable & Tower Dryer Frames Zimmerman and Internal Infrastructure 5 Years * Warranty prorated from list price: 0 to 3 years no cost to end-user 3 to 5 years end-user pays 25% 5 to 7 years end-user pays 50% 7 to 10 years end user pays 75% ** Warranty prorated from list price: 0 to 3 years no cost to end-user 3 to 5 years end-user pays 50% Motors, burner components and moving parts not included. Portable Dryer screens included. Tower Dryer screens not included. Conditions and Limitations: THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE LIMITED WARRANTY DESCRIPTION SET FORTH ABOVE. SPECIFICALLY, GSI MAKES NO FURTHER WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN 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 PRODUCTS. GSI shall not be liable for any direct, indirect, incidental or consequential damages, including, without limitation, loss of anticipated profits or benefits. The sole and exclusive remedy is set forth in the Limited Warranty, which shall not exceed the amount paid for the product purchased. This warranty is not transferable and applies only to the original end-user. GSI shall have no obligation or responsibility for any representations or warranties made by or on behalf of any dealer, agent or distributor. GSI assumes no responsibility for claims resulting from construction defects or unauthorized modifications to products which it manufactured. Modifications to products not specifically delineated in the manual accompanying the equipment at initial sale will void the Limited Warranty. This Limited Warranty shall not extend to products or parts which have been damaged by negligent use, misuse, alteration, accident or which have been improperly/inadequately maintained. This Limited Warranty extends solely to products manufactured by GSI. PNEG Page 21 of 22 06/30/2009

22 Prior to installation, the end-user has the responsibility to comply with federal, state and local codes which apply to the location and installation of products manufactured or sold by GSI. PNEG Page 22 of 22 06/30/2009