continuous-flow grain dryer - · pdf filepublication number: 7713395 rev: a continuous-flow...

Publication Number:7713395

Rev: A

Continuous-FlowGrain Dryer

Effective Date: October 2012

COMMANDER Control

QWIK REFERENCE

2Dryer Rating Label

NOTE: The Dryer Rating Labelis located at the outside bottom-left corner of the control paneldoor.

Electrical Schematic Drawing(Title Block View)

NOTE: The dryer Electrical Schemeticdrawing is located on the inside of theControl Panel door.

Fuel Type _______________ # of Blowers ____________

Drawing # is ___________________ Rev Level _____________

Before you call ..........For effective communication to either your local dealer, local service tech, or NECO concerningany equipment will require the customer to provide the following basic information. The front coverof this manual shows the Publication # and Revision Level.

Please take the time to record the following information for future reference ---

Local Dealer’s Name: _____________________ Phone #: _________________

Local Service Tech’s Name: ________________ Phone #: _________________

Purchase Date: __________________ Installation Date: _________________

Model #: ____________________ Serial #: _____________________________

Motor #1 is: _______________________________

Volts _______ Phase _____ Frequency ________ Amps _______

Motor #2 is: _______________________________

Volts _______ Phase _____ Frequency ________ Amps _______

DRAWING#

REVISION#

3

Welcome to the growing number of satisfi ed NECO customers

Since 1959, NECO equipment has been proudly designed, manufactured, and supported forcustomers here in the USA and around the world. Occupational safety is one of NECO’s primaryconcerns. With proper operation and maintenance, the equipment will provide years of safe anddependable service. NECO is continually testing and improving our products in order to provideyou with the safest, most effi cient, and most economical grain handling & grain conditioningequipment available. We welcome your questions or comments and look forward to a continuedrelationship, ultimately saving you valuable time and reducing your workload.

About this manual ---

• This manual is provided to help ensure the safety of the equipmentoperator, as well as others who come into contact with the equipment.

• Failure to read, understand, and follow the instructions within thismanual constitute a misuse of the equipment and can affectpersonnel safety and the product warranty.

• Keep a copy of this manual in a safe place for future reference.Additional copies can be accessed & printed from the NECOwebsite www.neco.com or contact your local dealer forassistance.

• See the “HAVE QUESTIONS or NEED HELP” section andfi ll out the required information for correct identifi cation of theequipment and effi cient communication when needed.

• Language translations of this manual are made as accurately aspossible.If there is a confl ict or difference between the English versionand other translations of this manual, the English text will prevail.

READand

UNDERSTAND

Be alert to the possibility of serious injury or death.

It means ATTENTION - Become Alert !!

• This symbol is used to call your attention toinstructions concerning personal safety.

• It is your responsibility as an owner, opera-tor, or supervisor to know what hazardsexist and to make this information known toall persons working with the equipment orwho are in the area.

Product Changes & Improvements ---

• NECO reserves the right to make changes or improvements to its productswithout incurring any obligation with respect to previously manufactured products.

4

1. SAFETY ....................................................................... 6

2. EQUIPMENT OVERVIEW ...........................................8

3. LOG IN ...................................................................... 12

4. SETUP ....................................................................... 18

DRYER CONFIGURATION ...................................................... 20

Wiring External Transport Equipment .......................................23Wiring Starter / Overload / Air Systems ....................................24EXAMPLE: Wet 1 Auger & Dry 1 Air System ...........................25EXAMPLE: Wet 1 & Wet 2 Augers & Dry 1 Auger ....................26EXAMPLE: Wet 1 & Wet 2 Augers & Dry 1 & Dry 2 Augers .....27FILL & EMPTY SETUP ............................................................. 28TIMERS SETUP ....................................................................... 30SCREEN CONFIGURATION ...................................................32

5. OPERATION .............................................................34

CHANGE CROP ....................................................................... 38

SETUP & START BATCH DRYING ..........................................40BATCH DRYING - RUN MODE ................................................42BATCH DRYING - COOLING MODE .......................................44

TABLE OF CONTENTS

5

AUTO DRYING - MANUAL SPEED .........................................46AUTO DRYING - AUTO FIRST LOAD .....................................48AUTO DRYING - DRYERMASTER CONTROLLING ...............50AUTO DRYING - DRYER COOLING .......................................52MOISTURE CALIBRATION ......................................................54GRAIN SAMPLE BUTTON .......................................................55

APPENDIX .....................................................................56

PLC INPUT STATUS ................................................................ 60PLC OUTPUT STATUS ............................................................61DRYERMASTER STATUS & TROUBLESHOOTING ...............62DM DATA VALUES ................................................................... 63TEMP CONTROLS STATUS ....................................................64HONEYWELL STATUS ............................................................65

PLC - Program Update Procedure ...........................................66

PLC - Program Update Procedure ...........................................69HMI - Program Update Procedure ............................................69

Honeywell Burner Control Fault Codes ....................................72

Control Panel (Main) ................................................................ 74HMI Enclosure Components ....................................................76Burner Box Components ..........................................................78Ignition Components ................................................................ 79Sensors, Cables, & Misc. .........................................................80

6#036725 - DANGER_High Voltage

NOTE: Warning Label Graphics are not shown full size

WARNING LABEL IDENTIFICATIONPART # QTY HAZARD DESCRIPTION LOCATION

035691 2 WARNING - ELECTROCUTION ONE ON FRONT DOOR OF CONTROL PANELONE ON FRONT DOOR OF PLC HOUSING BOX

036725 2 DANGER - ELECTROCUTION ONE - INSIDE FRONT DOOR OF CONTROL PANELONE - INSIDE FRONT DOOR OF PLC HOUSING BOX

Grain dryers present signifi cant safety hazards.Decals must be displayed in appropriate loca-tions to provide adequate warning regardingthese hazards. BE ALERT !!!!

NECO supplies all the necessary decals withyour Dryer. Replacement decals are availableby contacting NECO at the telephone numbersor e-mail address found on the back of thismanual.

NOTE:• Actual warning labels are larger than illus-

trated in this manual.• If the warning labels become unreadable in

any way, contact NECO at 402-453-6912 ortoll free at 800-367-6208. NECO will providefree replacements.

• Surfaces must be free from oils, dirt andmoisture before applying warning labels.

Warning Labels

General Overview

#035691 - WARNING_High Voltage

• Read and Understand this manual.• Heed all warnings.• Make sure all warning decals are in

place and legible.• Call NECO for free decal

replacements.

WEAR PROTECTIVE CLOTHING

Wear personal protective clothing at all times.

OPERATOR QUALIFICATIONS

Only competent and experienced personsshould operate farm equipment.

It is your responsibility to know the regulationsin your own area Unqualifi ed persons must stayout of the work area—which is defi ned as thearea surrounding grain handling equipment.

FAILURE TO HEED THESE INSTRUCTIONSCAN RESULT IN PERSONAL INJURY

7

If an emergency requiring dryer shut down occurs:

1. Turn OFF the fuel supply - fi rst, at the main ball valve in the bottom dryer section and then at the main fuel source.

2. Turn OFF the electrical power at the main electrical disconnect.

3. If the emergency requires the dryer to be emptied quickly follow the instructions below - based on the dryer frame type:

• For STANDARD & HIGH CAPACITY dryer frames, open the cleanout doors:

• For EXTRA HIGH CAPACITY dryer frames, remove the emergency doors:

OPENING THE CLEANOUT DOORS CAUSES ANOPEN PATHWAY TO FORM (SEE ARROWS).

GRAIN WILL EXIT THE DRYER PER GRAVITY FLOWSHOWING NORMAL OPERATION WITH THECLEANOUT DOORS IN CLOSED POSITION.

EMERGENCY DOORS ARE LOCATED ALONG BOTH SIDES OF THE FRAME.USE 3/4” TOOLING TO REMOVE THE TWO BOLTS HOLDING ON EACH DOOR.

GRAIN WILL EXIT THE DRYER PER GRAVITY FLOW

CLOSED OPEN

ATTENTION : Pushing the E-STOP button will stop the 120V outputs fromthe PLC. It does NOT shut off power into either Control Panel. The PowerON lamp will remain lit on the main Control Panel.

8

Control Panel (Outside)

Control Panel (Inside)

ELECTRICALSCHEMATICS

EMERGENCYSTOP

BUTTON(E-STOP)

ELECTRICALWARNING

LABEL

POWER ONLAMP

NOTE: Pushing the E-STOPbutton will stop the 120Voutputs from the PLC. Itdoes NOT shut off power intoeither Control Panel. ThePower ON lamp will remain liton the main Control Panel.

9

HMI Front Panel

EMERGENCYSTOP

BUTTON(E-STOP)

DRYER MASTERCONTROLON / OFF

HMITOUCH

SCREEN

NOTE: Pushing the E-STOPbutton will stop the 120Voutputs from the PLC. It doesNOT shut off power into eitherControl Panel. The PowerON lamp will remain lit on themain Control Panel.

HMI Enclosure - Rear of Door

ETHERNETPORT

USB PORT(NOTE - USB MUST ALWAYS

BE PRESENT FOR DATALOGGING OF ALARMS /

GRAPHS)

REAR OF HMISCREEN

USB & Ethernet Connection

10

HMI Enclosure LocationNECO highly reccommendeds that the HMI Enclosure be located indoors. If it is necessary toplace the unit outside subject to temperature and weather extremes, an optional window kit &heater (#059242WK) is available. The following photos are shown for example only:

HMI ENLOSURE

ETHERNETSWITCH

ETHERNETCONVERTOR

DRYER MASTER CONTROLLER

11

Verify Electrical Main Disconnect Operation• Verify the location of the electrical power main disconnect & make sure it is clearly identifi ed.• During installation and at each season startup, check the system for proper operation.• Verify that anyone within the work area are familiar with both location & operation.• Turn the electrical power ON.

E-STOP Operation

Pushing either E-STOP button will stop the PLC outputs immediately for totaldryer shutdown.

However, the electrical power is still ON within both enclosures.

Power must be shut OFF at the main disconnect to completely remove power.

Verify power to the Control Panel• The white POWER ON lamp should be lit.

Verify power to the HMI Touch Screen• When power to the system is turned ON, the bottom edge of sreen may show the following:

• To clear this message, touch the “X” icon to bring up the MAIN MENU with date / time andLOG IN icons.

When a software update for the PLC and HMI occurs, the system must be completely poweredoff. Certain screen data is either lost or will return to the factory default settings and these valueswill need to be re-entered.It is reccommended to record the values for ALL screen inputs concern-ing the dryer and related support equipment. This will come in handy when on the phone with aNECO service technician or engineer.

12

• When power to the system is turned ON after being off, the bottom edge of sreen may showthe following:

• To clear this message, touch the “X” icon to bring up the MAIN MENU with date / time andLOG IN icons.

“HATCHED”ICONS ARE

NOT AVAILABLETO CHOOSE

NOTE: Icons will appear with a “HATCHED” background pattern if they can NOT be chosen. Thisbackground pattern will switch from hatched to solid, depending on availability of that option orscreen. Some icons are informational only, other icons call up screens or sub-screens.

CANCHOOSE

CAN NOTCHOOSE

13

Prior to LOG IN, the following can be ac-cessed:

SETUP

• The HMI version & PLC version can beviewed in the upper-right corner of theSETUP screen.

• No icons on the SETUP screen can beactivated until LOG IN. Touch MAIN MENUto return.

TROUBLE SHOOTING

• This screen can be activated to obtainNECO contact information.

• No icons on the TROUBLE SHOOTINGscreen can be activated until LOG IN.Touch MAIN MENU to return.

Prior to LOG IN, the following can NOT beaccessed:

ALARMSTRENDSFILL / EMPTY DRYERGO TO START DRYER

LOG IN TO OPERATE• Start LOG IN procedure.

TOUCH THIS ICONTO BEGIN THE

LOG IN PROCEDURE

SETUP SCREEN

NECO Contact Info

Dealer Contact Info(If Input)

14

Temporary keypad touchscreenwill appear here in order to enter

NAME and PASSWORD.

** Note that both entries requirecase sensitive input.

KEYPAD - LETTERS

TOUCH HERE TO TOGGLEFROM LETTERS TO NUMBERS

KEYPAD - NUMBERS

UNLOCK

“HOME” ICON

SEE TOUCHSCREEN KEYPADEXAMPLES BELOW

KEEPS ALL CAPS

15

NOTE: All entries for both NAME and PASSWORD are Case Sensitive.

Enter NAME

• Touch the box icon beside NAME and the keypad touchscreen will appear.

Choose “NAME” from the following:

• If basic operation is needed, enter U S E R

• If access to SETUP confi guration is needed, enter: O w n e r

• Touch ENTER to complete.

Enter PASSWORD

• Touch the box icon beside PASSWORD and the keypad touchscreen will appear.

Choose from the following:

• For the name U S E R the password is: 1 2 3

• For the name O w n e r the password is: M y D r y e r

• Touch ENTER to complete.

Incorrect NAME or PASSWORD

• If either entry is wrong (Including being NOT Case Sensetive) the following will appear alongthe bottom of the login screen:

NOTE: The “X” must be touched to clear the error message or it will remain, even after properinformation has been input. Touch the “X” and re-enter the necessary information.

Complete the LOG IN procedure

• After successful input of NAME and PASSWORD, touch the UNLOCK button and note that theCurrent User will show the “NAME” entered instead of “None”.

• Touch the HOME icon and the screen will proceed to MAIN MENU - AFTER LOG IN.

16

After completeing the log in procedure successfully, the MAIN MENU screen appears with thefollowing changes:

• At lower left of screen, the LOG IN icon has changed to LOG OUT.

• Directly above the LOG OUT icon, the “name” is shown.

• Based on the level of log in security, the OPERATION PERMITTED icon, along with theabsence of the “hatched” pattern, show which icons screens are available.

NOTE: Depending upon the screen, these icons can appear or change status.

The OPERATION PERMITTED icon can change to afl ashing E-STOP ACTIVE icon. The MAIN MENU iconwill come back to this screen and the BACK icon willreturn to the previous screen.

LOG IN “NAME” ISSHOWN HERE

17

SETUP• Verify or input various setup parameters

related to the dryer & auxillary equipment.

ALARMS• View any current ALARM status.

TROUBLE SHOOTING• Contact information for NECO or the local

dealer is available for viewing.• Data is used by NECO technicians.

LOG OUT• The LOG OUT icon can be activated at any

time during the drying process.

• Upon LOG OUT, the existing process willcontinue. NECO recommends not leavingthe dryer system completely unattendedfor an extended period of time even withthe DryerMaster in automated control.The moisture content should be regularlychecked and calibrated.

TRENDS• Graphs can be charted for grain moisture,

grain temperature, or grain discharge rate.Data values such as bushel throughput areshown.

FILL / EMPTY DRYER• Used for production fi lling or emptying of the

dryer.

GO TO START DRYER SCREEN• Used for seting up START DRYER

parameters, such as which blowers andburners are enabled, etc. for production.

TOUCH THIS ICONTO LOG OUTAT ANY TIME

NOTE:

• Initial setup is required for the input of auxillary equipment. This initial input can NOT be donewith basic operator log in status as USER.

• Go to SETUP, logged in as Owner, to complete the FILL & EMPTY SETUP and TIMERSSETUP.

• After SETUP data has been verifi ed or entered these screens would generally only needaccessed if there are changes to the dryer confi guration, motors replaced, or the status of anyauxillary equipment is changed.

• Either FILL / EMPTY or START DRYER would be the next step.

After LOG IN, the following icons / screens can be accessed:

18

• All SETUP sub-screens can be viewed by any log in status.• Input values for auxillary equipment, etc. must be input with O w n e r level log in status.• The current version of HMI and PLC software is shown at the top-right of the main SETUP

screen.• Some information was entered and verifi ed at the NECO factory and can NOT be edited or

changed unless the user is logged in as O w n e r.ATTENTION: It is very important to record the dryer system setup parameters for future usage.These values will need to be manually re-entered after any HMI & PLC version update. SeeAPPENDIX - PLC Update Procedures for screen copies with areas for recording the currentvalues.

NECOENTERED DATA

CUSTOMERENTERED DATA

CURRENT VERSIONOF HMI & PLC

19

NECO entered setup data:

SET TEMPERATURE MODE• Domestic (US) dryers have been set to

operate in Fahrenheit (F) mode.• CE rated dryers have been set to operate in

Celsius (C) mode.

• If needed, the mode can be switched. Touchthe required mode (C or F). Note that it willtake several minutes for the control to switchtemperature modes.

• The temperature mode stays in memory.

DRYER CONFIGURATION• These items can be viewed, but can only be

changed with NECO Technician login status.

SCREEN CONFIGURATION

• The DATE & TIME or BRIGHTNESS can bechanged with U s e r log in status.

• *** Do NOT change anything else ***

CUSTOMER entered setup data:

FILL & EMPTY SETUP• Input parameters for auxillary equipment

used in conjuction with fi lling or emptyingthe dryer.

TIMERS SETUP• Input delay parameters.

20

This information was entered and verifi ed at the NECO factory:

• Record for future reference by either circling the correct value choices orwrite the information in the blanks provided.

The following criteria are possible options concerning system Blowers / Burners:

• Blower #1 is the upper-most blower unit in the dryer system.• The current maximum number of blowers from top to bottom is six (6).• Note from the example above that if NO is entered for any blower numbered 2 thru 6, the

remaining options for that blower and remaining blowers up to #6 are blanked out.• It is possible for a group of tiers to have a blower, but no burner.• For natural gas(NG) fuel systems, the later screens do not show a Liquid Valves column.

NOTE: This screen is an example of a 24 foot dryer system that has 3 blowersand 3 burners, with each blower feeding 4 tiers. The temperature mode isFarenheit and the fuel system is Liquid Propane (LP). It has no level auger feedsystem and the gearmotor RPM driving the exit grain metering rolls is 42.

21

DRYER LENGTH

• 12’

• 16’

• 24’

• 32’

GEARMOTOR RPM (Metering Roll Drive)

• The gearmotor RPM is _________ .

LEVEL AUGER

• YES

• NO

TEMP UNITS

• Fahrenheit (F)

• Celsius (C)

GAS TYPE

• Liquid Propane (LP)

• Natural Gas (NG)

TOTAL # OF TIERS

• Total number of tiers is _________ .

DRYER HOLDING CAPACITY (BUSHELS)

• Holding capacity is _________ bushels.

BLOWERNUMBER

(#)

BLOWERPRESENT

(YES or NO)

BURNERPRESENT

(YES or NO)

# OF TIERS ATBLOWER(3, 4, or 5)

1

2

3

4

5

6

Touch MAIN MENU to return to the Main Menu (After Log In) screen or touch BACK TO SETUP toreturn to the Setup (Main Setup) screen with the two icons along bottom-right.

22

External Transport(s)

Overview

NECO provides the ability to control two transport devices to FILL the dryer and two transportdevices to EMPTY the dryer within the Commander Control system. All motor starters, startercoils, and overload contacts required are customer supplied.

These external transport systems control incoming (wet) grain and outgoing (dry) grain so that theoverall system works in conjunction with the dryer.

Examples of typical external transport systems that may be controlled within the automatedCommander system --

• One Wet Transport and one Dry Transport (W1 / D1)

• Two Wet Transports and one Dry Transport (W1 / W2 / D1)

• Two Wet Transports and two Dry Transports (W1 / W2 / D1 / D2)

Depending on what type of transport style and confi guration, the necessary data inputs must beentered in the Fill / Empty setup routine.

These data inputs consist of:

• Is a motor present that needs to be controlled ?

• Does that motor need to run continuous ?

• Does that motor need to stop after drying stops (2 min delay) ?

• Start delay (sec) ?

• Stop delay (sec) ?

The control integrates the external transport equipment actions also dependant upon the presenceof the following switches:

• Wet bin empty switch installed ?

• Dry bin full switch installed ?

• Low Level switch installed ?

23

The customer is responsible for wiring any external transport equipment. The following schematicsare reference.

24

The customer is responsible for wiring any external transport equipment. The following schematicsare reference.

25

• This example shows one wet system & one dry system to be controlled and operated by theCommander system. NOTE: Shown for example ONLY - individual confi gurations vary.

• The table information below is an example of the required Fill / Empty Setup data inputs.

MOTORPRESENT

RUNCONTINUOUS

STOP AFTERDRYING STOPS

STARTDELAY

SECONDS

STOPDELAY

SECONDS

RELAY#

WET 2 TRANSPORT(FARTHEST FROM DRYER) NO

WET 1 TRANSPORT(CLOSEST TO DRYER) YES NO 1 1 63CR

LEVEL AUGER YES NO 1 1 - -

UNLOAD AUGER YES 5 5 - -

DRY 1 TRANSPORT(CLOSEST TO DRYER) YES 1 1 62CR

DRY 2 TRANSPORT(FARTHEST FROM DRYER) NO

26

• This example shows two wet systems & one dry system to be controlled and operated by theCommander system. NOTE: Shown for example ONLY - individual confi gurations vary.


MOTORPRESENT

RUNCONTINUOUS


STARTDELAY

SECONDS

STOPDELAY

SECONDS

RELAY#

WET 2 TRANSPORT(FARTHEST FROM DRYER) YES 1 75CR

WET 1 TRANSPORT(CLOSEST TO DRYER) YES YES NO 63CR

LEVEL AUGER NO _ _

UNLOAD AUGER YES 1 5 _ _

DRY 1 TRANSPORT(CLOSEST TO DRYER) YES NO 1 15 62CR

DRY 2 TRANSPORT(FARTHEST FROM DRYER) NO

27

• This example shows two wet systems & one dry system to be controlled and operated by theCommander system. NOTE: Shown for example ONLY - individual confi gurations vary.


MOTORPRESENT

RUNCONTINUOUS


STARTDELAY

SECONDS

STOPDELAY

SECONDS

RELAY#

WET 2 TRANSPORT(FARTHEST FROM DRYER) YES 1 75CR

WET 1 TRANSPORT(CLOSEST TO DRYER) YES YES YES 63CR

LEVEL AUGER YES YES YES _ _

UNLOAD AUGER YES 1 5 _ _

DRY 1 TRANSPORT(CLOSEST TO DRYER) YES NO 1 15 62CR

DRY 2 TRANSPORT(FARTHEST FROM DRYER) YES NO 1 5 74CR

28

The following criteria are options concerning EACH of the possible choices for auxillaryequipment.

Based on the data entered, further options for that piece of equipment are possible :

• For each piece of equipment, is a “MOTOR PRESENT” ? YES or NO (If a motor is NOT present, the rest of options listed are blanked out)

• If a motor is present, does it “RUN CONTINUOUS” ? YES or NO (If a motor is NOT present, the rest of options listed are blanked out)

• If the motor runs continuous, should it stop after drying stops (2 min delay) YES or NO

• If a motor is present and does not run continuous,

• If YES, does that motor need to stop after drying stops? YES or NO

29

WET BIN EMPTY SWITCH INSTALLED

• This switch is customer supplied and in-stalled.

• If it is present, enter YES. If not, enter NO.

DRY BIN FULL SWITCH INSTALLED

• This switch is customer supplied and in-stalled.

• If it is present, enter YES. If not, enter NO.

1. WET 2 TRANSPORT (Farthest from Dryer)• This is only used with a DUAL wet transport system and would be the wet transport positioned

the FURTHEST away from the dryer. Is a motor present? YES or NO• If NO, then continue on with entering data for WET 1 TRANSPORT• If YES, does that motor need to run continuous? YES or NO• If NO, enter START DELAY & STOP DELAY and then continue to next setup requirement.• If YES, does that motor need to stop after drying stops? YES or NO

The following category setup requirements follow the same routine as shown above. Each inputdecides what the next setup choices are, and so on until that function is set:

2. WET 1 TRANSPORT (Closest to Dryer) 5. DRY 1 TRANSPORT (Closest to Dryer)

3. LEVEL AUGER 6. DRY 2 TRANSPORT (Farthest from Dryer)

4. UNLOAD AUGER

LOW LEVEL SWITCH INSTALLED

• This switch is supplied by NECO and cus-tomer installed.

• Enter YES if a functional switch is installedor NO if not.

• The operator has a choice during batch andautomatic drying to have the dryer maintaingrain level. Without the low level switch, atimer function can be set.

METERING ROLLS MAXIMUM SPEED• This maximum speed value should refl ect

the unload system capabilities.• If the value is set too high, excessive

plugged discharge alarms will occur.• If the value is set too low, production will not

be maximized.

EQUIP ID

MOTORPRESENT

(YES or NO)

RUNCONTINUOUS(YES or NO)


(YES or NO)

STARTDELAY

(SECONDS)

STOPDELAY

(SECONDS)

1

2

3

4

5

6

30

To enter or edit data:

• Touch the icon box.

• The temporary keypad will appear.

NOTE: Under the data entry box across thetop, any restrictions for MINIMUM or MAXIMUMvalues will be shown.

• Input the required data and touch ENTER.

• The data input change will show and theprevious screen returns for additional inputs,if needed.

31

FILLING DELAY (SECONDS)• Default is set to 10 seconds.

LOW LEVEL SWITCH SENSORS (SECONDS)• Default is set to 30 seconds.

MAX FILLING RUN TIME WHEN NO LOWLEVEL SWITCH IS PRESENT (MINUTES)• Default is set to 5 minutes.

BLOWER START DELAY (SECONDS)• Default is set to 5 seconds.

BURNER ENABLE DELAY (SECONDS)• Default is set to 5 seconds.

ENABLE DISCHARGE (SECONDS)• Default is set to 30 seconds.

METERING ROLL STALL (MINUTES)• Default is set to 3 minutes.

METERING ROLL PAUSE (SECONDS)• Default is set to 60 seconds.

DISCHARGE PLUGGED SWITCH IGNORE• Default is set to 1 second.

DRYER COOLDOWN (MINUTES)• Default is set to 5 minutes.

After timer data choices have been entered or edited, return to eitherthe original main menu screen or the main setup screen with the twoicons along bottom-right.

32

CHANGEDATE / TIME

CHANGELANGUAGE

CHANGEBRIGHTNESS

DO NOT CHANGE ANYTHING ELSE.

33

• Brightness

• Date / Time

• Language

Operator status or higher can change the following items. DO NOT CHANGE ANYTHING ELSE.

34

ANY OF THESE ONLY SHOW IF SETUP AS PRESENT INTHE FILL / EMPTY SETUP FOR DRYER CONFIGURATION.

TOUCH TO RESET.THE ICON WILL THEN DISAPPEAR.

DELAY TIMER(SECONDS)

UNTIL THE ITEMSTARTS OR STOPS

INDICATESIF THISITEM IS

ON OR OFF

CHOOSE TO MAINTAINA MINIMUM GRAIN

LEVEL IN THE DRYER(YES OR NO)

RESET DRY BINFULL ALARM

RESET METERINGROLL STALLED

THESE TWO ROWS ARE EITHERSTART OR STOP, DEPENDING ON

WHICH IS CHOSEN.

Stop

Stop

Stop

NOTE: Prior to fi lling the dryer, always double-checkthat the unload equipment is operating properly.

SETMETERING

ROLLSPEED

INDICATES ANALARM & WILL

RETURN TONORMAL AFTER

RESET

DRYER STATUS SHOWN HERE:

• DRYER FULL• GRAIN LEVEL OK• GRAIN LEVEL LOW• WET BIN EMPTY• DRY BIN FULL• MAX FILL TIME EXCEEDED

THIS ONLY SHOWS FOR START DRY-ER OR AUTO DRYER:

• INLET MOISTURE SENSOR ERROR

35

SET MANUAL METERING ROLL SPEED• See APPENDIX - Dryer Recommended Speeds (CORN) for metering roll speed starting point.• This speed will be used as the manual setpoint for Batch Mode drying and for initial Automatic

Drying Mode until the DryerMaster gathers enough moisture data to take full automatic control.

CHOOSE TO MAINTAIN A MINIMUM GRAIN LEVEL OR NOT• Enter NO for no grain level control.• Enter YES for grain level control.• Depending on the data entered for FILL / EMPTY DRYER SETUP, the grain level will be

maintained by either a functioning low dryer switch or the timer “MAX FILLING RUN TIMEWHEN NO LEVEL SWITCH IS PRESENT”

NOTE: Only the equipment identifi ed in SETUP - FILL / EMPTY will show up in this list.Status indicator ON or OFF. If the equipment fails to run or a motor overload trips, a faulticon will appear. Once the problem is solved, the alarm icon goes out. If OFF, push STARTor if ON, push OFF to start the delay timer for that piece of equipment:

• Wet Transport 2 (Farthest from Dryer)• Wet Transport 1 (Nearest to Dryer)• Level Auger• Unload Auger• Dry Transport 1 (Nearest to Dryer)• Dry Transport 2 (Farthest from Dryer)

FILL DRYER• Used to initially fi ll the dryer with grain• Touch START or STOP icon.

FILL & EMPTY BYPASS• Used if the grain needs to pass through the dryer, but not actually dried.• Touch START or STOP icon.

EMPTY DRYER• Used when no more fi lling of wet grain is to occur and the remaining grain needs to fi nish

drying until the dryer is empty.• Touch START or STOP icon.

METERING ROLL SPEED (%):Min: 10Max: 100

TOUCH TO RESETIF RESET PROPERLY, THE OVERLOADICON WILL CHANGE BACK TO NORMAL

36

NOTE: This screen is a “setup” for either going into either BATCH or AUTO

CHANGE CROP• Brings up the CROP SELECTION screen. The current crop can be changed or crop names

can be input or edited.

SETUP BATCH DRYING• Brings up parameters for Batch Drying - usually an all heat condition to get the initial dryer full

of grain output. During this cycle of time, the various parameters required to start ContinuousDrying with Dryer Master control can be obtained.

CURRENTCROP

SELECTION

THIS COLUMNNOT SHOWNFOR DRYERSOPERATING

WITH NATURALGAS (NG)

THE DRYER MUST BE FULLABOVE THE LOW LEVEL SWITCH &CONTINUOUS EQUIPMENT MUST

BE RUNNING BEFORE START AUTODRYING CAN BE CHOSEN

37

START AUTO DRYINGNOTE: This icon is not available to choose unless the dryer is above the low level switch and all

of the auxillary continuous run equipment is ON.• Displays AUTO DRYING screen

BLOWER ENABLE• Switches between ENABLED or DISABLED.• If DISABLED is chosen, the remaining icons for that burner row are not shown.

BURNER ENABLE• Switches between ENABLED or DISABLED.• If DISABLED is chosen, the burner system is OFF for that section or running in cooling mode.

BLOWER• Displays if the blower is ON or OFF.

LIQUID VALVES - Only shown for Liquid Propane (LP) systems• Displays if the LP liquid valves are ON or OFF.

PILOT IGNITION• Displays if the pilot ignition is ON or OFF.

FLAME VDC• Displays the DC voltage from the UV Sensor.

MAIN IGNITION• Displays if the main ignition (burner) is ON or OFF.

MAIN RUN• Displays ON after PILOT & MAIN IGNITION have occurred and the burner is running properly.

TEMP SETPOINT• Temp Setpoint can be set at any time during the Start, Batch, or Auto Drying process.• Numeric keypad will become visible - enter a temperature setpoint between 32 and 250 F.

TEMP ACTUAL• Displays the actual temperature for each burner.

38

This CROP SELECTION screen appears when CHANGE CROP is selected.This screen shows YES beside the current crop selection and the operatorcan either:

• Select a different crop

• Edit or enter a crop name or description

To select a different crop:

• Touch the NO icon beside the new crop desired.

• The NO will turn to YES and will automaticallyreturn to the START DRYER screen.

Note: Upon return to the START DRYER screen, verify that the current crop iconnear upper-left corner has changed to the newly selected crop.

GO TO EDIT SCREEN

39

To edit the crop name or description:

• Touch the EDIT CROP NAMES icon.• This icon will changed to LOCK CROP

NAMES.• Touch any crop name icon that needs to be

changed.• A temporary keypad will appear with the

current selection shown at the top.• Make the required changes. A maximum of

26 characters can be used.• Touch ENTER to input the changes.• LOCK CROP NAMES icon will lock in the

changes. This icon will change back to EDITCROP NAMES as it was before.

• Touch the MAIN MENU icon to proceed.

TOUCH ANY CROPNAME ICON TO

BRING UP THE EDITKEYPAD

Note: Upon return to the START DRYER screen, verify that the current crop iconnear upper-left corner has changed to the newly selected crop.

RICE / OTHER

40

ENTER UP TO 120 (MIN)FOR LENGTH OF BATCH(HEATED) DRYING MODE

TEMP SETPOINT CAN BE CHANGEDA BLOWER CAN BE ENABLEDOR DISABLED.

IF A BLOWER IS DISABLED, THEBURNER ENABLE ICON IS NOTSHOWN.

IF THE BURNER IS DISABLED,THAT DRYER SECTION ISOPERATING IN COOLING MODE.

41

ENTER DESIRED BATCH DRYING (HEATED) TIME• Enter the number of minutes (MAX = 120) to operate in Batch (Heated) Drying mode.

BLOWER NUMBER• Number of blowers in the dryer confi guration

BLOWER ENABLE• Switches between ENABLED or DISABLED.• If DISABLED is chosen, the remaining icons related to that blower are not shown.


BLOWER• Displays if the blower is ON or OFF.

LIQUID VALVES - Only shown for Liquid Propane (LP) systems• Displays if the LP liquid valves are ON or OFF.

PILOT IGNITION• Displays if the pilot ignition is ON or OFF.

FLAME VDC• Displays the DC voltage resistance thru the UV Sensor.

MAIN IGNITION• Displays if the main ignition (burner) is ON or OFF.


TEMP SETPOINT• Call up the temporary numeric input keypad to input a new setpoint temperature value for each

burner.

TEMP ACTUAL• Displays the actual temperature for each burner.

DISIRED BATCH (HEATED)DRYING TIME:

Min: 1Max: 120

TEMPERATURE SETPOINT: Min: 32Max: 250

42

STOP BATCH (HEATED) DRYINGTHIS ACTION WILL START THE DRYER IN

COOLING MODE, BASED ON TIMER SETTING.

A BLOWER CAN BE ENABLEDOR DISABLED.

IF A BLOWER IS DISABLED, THEBURNER ENABLE ICON IS NOTSHOWN.

IF THE BURNER IS DISABLED,THAT DRYER SECTION ISOPERATING IN COOLING MODE.

TEMP SETPOINTCAN BE CHANGED

AMOUNT OF TIME LEFT TO RUNBATCH (HEATED) DRYING MODE

43

STOP BATCH DRYING• STOP Batch Drying in Run Mode.• The dryer will proceed to BATCH DRYING - COOLING MODE.

MINUTES REMAINING• Number of minutes remaining to operate in Batch (Heated) Drying mode.

BLOWER NUMBER• Number of blowers in the dryer confi guration.

BLOWER ENABLE• Toggle between ENABLED or DISABLED.• If DISABLED is chosen, the remaining icons related to that blower are not shown.

BURNER ENABLE• Toggle between ENABLED or DISABLED.• If DISABLED is chosen, the burner system is OFF for that section or running in cooling mode.

BLOWER• Blower is ON or OFF.

LIQUID VALVES - Only shown for Liquid Propane (LP) systems• LP liquid valves are ON or OFF.

PILOT IGNITION• Pilot ignition is ON or OFF.

FLAME VDC• DC voltage resistance thru the UV Sensor. If the value falls below 2.50, clean the sensor.

MAIN IGNITION• Main ignition (burner) is ON or OFF.

MAIN RUN• Shows ON after PILOT & MAIN IGNITION have occurred and the burner is running properly.


burner.

TEMP ACTUAL• The actual temperature for each burner.


44

STOPBATCH

COOLINGAMOUNT OF TIME LEFT TO

RUN IN COOLING MODE

THIS CAN BE TOUCHEDAT ANY TIME TO STOP

COOLING AND ACTIVATEAUTO DRYING

45

STOP COOLING• STOP operating in Cooling Mode.• The time showing changes to 0, blowers shut down, and the screen holds until START AUTO

DRYING is activated.

MINUTES REMAINING• Number of minutes remaining to operate in Cooling Mode.

BLOWER NUMBER• Number of blowers in the dryer confi guration.

BLOWER ENABLE• Switches between ENABLED or DISABLED.• If DISABLED is chosen, the remaining icons related to that blower are not shown.


BLOWER• Blower is ON or OFF.

LIQUID VALVES - Only shown for Liquid Propane (LP) systems• LP liquid valves are ON or OFF.

PILOT IGNITION• Pilot ignition is ON or OFF.

FLAME VDC• DC voltage resistance thru the UV Sensor. If the value falls below 2.50, clean the sensor.

MAIN IGNITION• Main ignition (burner) is ON or OFF.



burner.

TEMP ACTUAL• Actual temperature for each burner.

START AUTO DRYING• Stop this mode and go to START AUTO DRYING screen.


46

Automatic drying, with manual metering roll speed, will continue until the DryerMaster controlgathers enough data. FOR HOW LONG -- UNTIL TOUCH ENABLE AUTO CONTROL ????

CURRENT CROP SELECTION• Displays the current crop selection.

STOP AUTO DRYING• Goes into Cool Down Mode (per timer)• Then returns to Start Dryer screen

GRAIN MOISTURE GRAPH• Displays the Moisture Graph

DRYER STATUS• Status icon showing either Dryer FULL,

Grain Level OK, Grain Level LOW, or MAXFill Time Exceeded

DISABLE FILLING• Halts wet grain entry for the amount of time

input in TIMER SETUP.

BLOWER NUMBER• Number of blowers in the dryer confi gura-

tion.

TEMP SETPOINT• Temperature setpoint for that dryer section.• Touch value and the numeric keypad screen

will appear. Any MIN or MAX values re-quired for the value will be shown. Afterentering the new value, touch ENTER tofi nalize the input.

TEMP ACTUAL• Displays the actual temperature for that

dryer section.

47

DryerMaster COLLECTING DATA --

INLET MOISTURE• Moisture content (%) of incoming grain.

INLET TEMPERATURE• Temperature of incoming grain.

ENABLE AUTOMATIC MOISTURE CONTROL• Touch to ENABLE AUTO FIRST LOAD

TARGET MOISTURE• Target Moisture Setpoint (%)• Touch value and the numeric keypad screen will appear. Any MIN

or MAX values required for the value will be shown. After enteringthe new value, touch ENTER to fi nalize the input.

MOISTURE CALIBRATION (See Page X)• Activate the Moisture Calibration routine.

OUTLET MOISTURE• Moisture content (%) of outlet grain.

OUTLET TEMPERATURE• Temperature of outlet grain.

PAUSE• Pauses the metering rolls for the amount of time input in TIMER

SETUP .

MANUAL METERING SPEED SETPOINT• This Manual Metering Roll speed was originally set during the

initial FILL / EMPTY screen input• The value can either be left as is or changed if needed.• Min value is 10 and Max value is 100.

PAUSE• Pauses the metering rolls until RESUME is activated.

STATUS ICONS --The following equipment shows status indicator for ON or OFF. If theequipment fails to run or a motor overload trips, a fault icon willappear. Once the problem is solved, the alarm icon goes out.


INDICATES AN ALARM & WILL RETURN TONORMAL AFTER RESET

KEYPAD TO ENTER NUMERIC VALUES(IF THERE ARE MIN / MAX RESTRIC-

TIONS, THOSE VALUES ARE SHOWN)

48

Automatic drying, as AUTO FIRST LOAD, will continue until the DryerMaster control gathersenough data. When enough moisture, temperature, and grain speed data has been gathered, theDryerMaster STATUS screen will appear.

CURRENT CROP SELECTION• Displays the current crop selection.


GRAIN MOISTURE GRAPH• Calls up Moisture Graph






tion.



TEMP ACTUAL• Displays the actual temperature for that

dryer section.

49

DryerMaster AUTO FIRST LOAD --



ENABLE• Touch to ENABLE AUTO FIRST LOAD



MOISTURE CALIBRATION• Activate the Moisture Calibration routine.




SETUP.









50

Automatic drying, with DryerMaster control, will continue until :• The operator should keep a continous and regular check of the moisture data values and if

needed, make small changes to the TARGET MOISTURE when needed.• MOISTURE CALIBRATION for the lower moisture sensor should be done at least every hour.

CURRENT CROP SELECTION• Shows current crop selection.








tion.



TEMP ACTUAL• Shows the actual temperature for that dryer

section.

51

DryerMaster CONTROLLING --



ENABLE• Touch to DISABLE AUTOMATIC MOISTURE CONTROL







SETUP.









52

STOP COOLING• STOPS Auto Cooling Mode.• Then returns to Start Dryer screen

TIME REMAINING IN COOLING MODE• Default timer seting is 5 minutes.







tion.

TEMP SETPOINT• This changes to BLOWER OFF

TEMP ACTUAL• Shows the actual temperature for that dryer

section.

SET IN TIMERS SETUP

53

DryerMaster CONTROLLING --



ENABLE• Touch to DISABLE AUTOMATIC MOISTURE CONTROL







SETUP.









54

CURRENT INLET MOISTURE VALUE

• Current moisture percentage value from theinlet moisture sensor.

• The combination sensing unit shown has amoisture sensing “fi n” with the temperaturesensor directly below it. The provide theCURRENT READING values seen atvarious locations on the data screens.

• One of these sensing units is located at thetop of the dryer for gathering INLET valuesand another is located within the grain exitchute to gather OUTLET values.

• Either of the INLET or OUTLET units canbe calibrated. Both units are calibrated atInstallation & Startup and should be re-calibrated on a regular basis.

“DONE” WILL NOT APPEAR UNTIL MOISTURECALIBRATION IS ACTIVATED

CURRENT OUTLET MOISTURE VALUE

• Current moisture percentage value from theoutlet moisture sensor.

INSIDE VIEW SHOWING HOWEXIT GRAIN IS DIRECTED INTO

THE POCKET AND PAST THEDRYERMASTER MOISTURE /

TEMPERATURE SENSOR

55

SAMPLE BUTTON

OBTAIN EXITGRAIN SAMPLES

CROSS AUGER SYSTEM WITH LEFT-HAND DISCHARGE / GRAIN SAMPLE CHUTE / MANUAL SAMPLE BUTTON

INITIATE

• Start the automated moisture sample routinefor either the inlet or outlet sensor. Eitherunit can be picked when using the screen.

NOTE: The Grain Sample button at the rear ofthe dryer will also bring up the Moisture Calibra-tion screen and initiate the automated moisturesample routine for testing the OUTLET grain.

• When either INITIATE icon is activated orthe SAMPLE button pushed, the DONE iconwill appear for that process.

• The DryerMaster obtains an average ofmoisture readings for the next 30 seconds.

• During this same period, collect severalexit grain samples and develop an aver-age value for the actual exit grain moisturecontent.

SAMPLE TEST MOISTURE CONTENT• Enter measured moisture content for the

sensor being calibrated.

DONE• Touch this icon to fi nish moisture calibration

routine.

56

GRAPHS OF PERFORMANCE DATA:

THIS VALUE CANBE RESET DAILY/ WEEKLY / ETC.

TO PROVIDE FORSPECIFIC TIMEFRAME

THROUGPUT ORPRODUCTION VALUES.

57

Graphs of Performance Data:

• Grain Moisture

• Discharge Rate

DRYER VOLUME BETWEEN SENSORS• Running average of bushels.

MINUTES IN DRYER AT CURRENT RATE• Minutes required for a complete cycle at the

current drying rate.

NOTE: The following data is available for editby “Owner” level login status.

BUSHEL PER METERING ROLL REVOLU-TIONS PER FOOT LENGTH• Default is .125 (ESTIMATE ONLY)• Throughput should be measured and based

on the dryer length / capacity back calculatean accurate value can be input.

• Grain Temperature

DISCHARGING RATE (Bushels per Hour)• Current running average of discharge BPH.

METERING ROLL %• Current running average of DC motor %.

BUSHEL THROUGHPUT (SINCE RESET)• This value can be used for daily tally, etc.• Reset tally to zero at any time.

TOTAL BUSHEL THROUGHPUT• Ongoing tally of total bushels ouput.

TOTAL RUN HOURS• Ongoing tally of total dryer operating hours.

58

CURRENT ALARM CODES• Shows the list of current activated alarm

codes.

• The alarm message or description and thedate and time of activation are shown.

• NOTE: The ALARM LOG icon can only beaccessed with O w n e r user or NECOtechnicians. It is a complete log of all errorsfrom installation until present and is mainlyused for gathering data for common errors.This information is used to improve softwareand equipment.

THIS SCREEN CAN BE VIEWED, BUT PRIMARILY IT ISUSED BY NECO TECHNICIANS FOR TROUBLE-SHOOTING

(SHOWN FOR REFERENCE ONLY)

59

PLC INPUTS• What the PLC is inputting per port value.

PLC ANALOG & OUTPUTS• What the PLC is outputting per port value.

DRYERMASTER STATUS• Shows the moisture content and tempera-

ture status of the DRYERMASTER systemfor both incoming grain and dryed grain.

TEMPERATURE CONTROLS• Shows the input target temperature and

actual temperature for each active burner.

HONEYWELL STATUS• Shows the HONEYWELL status.

LAST SCAN TIME• Milliseconds for PLC to communicate

LONGEST SCAN TIME• Milliseconds for PLC to communicate

SHORTEST SCAN TIME• Milliseconds for PLC to communicate

RESET• Resets the counter.

THESE SCREENS CAN BE VIEWED, BUT PRIMARILY THEY AREUSED BY NECO TECHNICIANS FOR TROUBLE-SHOOTING

(SHOWN FOR REFERENCE ONLY)

60

PLC INPUTS

• Input equipment status - ON or OFF

NOTE: FLASHING TEXT indicates wiring or confi guration error. If an overload is present, ONshould be indicated.

EXPANSION CARD INPUTS

• Various warning status - ON or OFF

FLASHING TEXT INDICATES A WIRINGOR CONFIGURATION ERROR.

61

MAIN RACK OUTPUTS• Motor contact status - ON or OFF

EXPANSION CARD OUTPUTS• DC drive enable - ON or OFF• Spare Relay

0 - 10 VDC INPUT• Motor contact status - ON or OFF

0 - 10 VDC OUTPUT• Motor contact status - ON or OFF

The following is available for enabling theMANUAL JOG MODE to trouble-shoot, etc.

Touch icon to enable:

Be sure to turn off or disable when fi nished:

NOTE: Login status U s e r can view this screen data only. Login status O w n e r or NECOtechnicians can log in and have the ability to enable a MANUAL JOG MODE which can be used totest such things as ON / OFF for operation, the direction of rotation, etc.

62

CURRENT STATUS OF DRYER MASTER(CONSULT FACTORY ONLY)

• CONTROL MODE• REMOTE MODE• SYSTEM MODE• LEARN LED• AUTO FIRST LOAD• DM CONTROLLER STATUS

DM VALUES• This screen shows various DRYERMASTER

value inputs and outputs for NECOtechnician trouble-shooting.



The DryerMaster control has gathered suffi cient information to provide status values.

TARGET MOISTURE• Target Moisture Setpoint (%)• Touch value and the numeric keypad screen

will appear. Any MIN or MAX values requiredwill be shown. After entering the new value,touch ENTER to fi nalize the input.



ENABLE AUTOMATIC MOISTURE CONTROL

• Verify the moisture and temp values.

• If within specifi cation, touch ENABLE AUTO-MATIC MOISTURE CONTROL

63

USED BY NECO TECHNICIANS FOR TROUBLE-SHOOTING(SHOWN FOR REFERENCE ONLY)

64

BLOWER NUMBER• Blower # (Numbering starts from the top)

TEMP (F or C) SETPOINT• Input temperature setpoint for that blower / burner section.

TEMP (F or C) ACTUAL• Actual temperature for that blower / burner section.

MODULATING MOTOR POSITION• % value for modulating motor butterfl y valveNOTE: 0 would be closed with no fl ow, 50 would be half open, etc.

65

BLOWER NUMBER• Blower # (Numbering starts from the top)

HONEYWELL STATUS• VP means• PV means

HONEYWELL FAULT• Normal operation will show (No Fault)• MV2 means• Call Service - contact your dealer

FLAME VDC• The DC volts to UV sensor should be 2.50 or above.• If below 2.50 VDC, clean the UV sensor• The burner will not work if VDC is below 1.25

66

CAUTION: The process of updating the PLC & HMI programs will result in loss of confi gurationdata. Most setting on the following screens will need to be manually re-entered. Either recordcurrent values by the required screen views in this manual or take a snapshot of the following:

NOTE: IF BLOWER IS NO, THE REMAININGROW AND ANY POSSIBLE ADDITIONALBLOWERS, ETC. DO NOT SHOW.

TEMPERATURE MODE (C or F)

This dryer is set to _____________

DRYER CONFIGURATION

Dryer Length _________

Gearmotor RPM _________

Level Auger _________

Blower #1

Blower Present _______

Burner Present _______

LP or NG _______

# of Tiers at Blower _____

Blower #2



LP or NG _______


67

Blower #3 Blower Present _______


LP or NG _______


Blower #4



LP or NG _______


FILL / EMPTY SETUP

Wet 2 TransportFurthest from Dryer _______

Run Continuous _______

Stop after Drying Stops ______

Start Delay _______ seconds

Stop Delay _______ seconds

Wet 1 TransportClosest to Dryer _______





Level Auger _________



Unload Auger _________



Blower #5 Blower Present _______


LP or NG _______


Blower #6



LP or NG _______


Metering Roll MAX speed _____________

68

FILL / EMPTY SETUP (Continued)

Dry 1 TransportClosest to Dryer _______





Dry 2 TransportFurthest from Dryer _______





TIMERS SETUP

Auto Filling Delay ________

Low Level SwitchIgnore ________

Max Filling Run Time withNO Low Level Switch ______Blower Start Delay ________

Burner Enable Delay ______

Enable Discharge ________

Metering Roll Stall ______

Metering Roll Pause ______

Discharge Plugged Switch Ignore _____

Dryer Cool Down _______

69

• Turn OFF power at the MAINDISCONNECT.

• Insert the EPROM program chip withthe prongs oriented towards the back ofenclosure.

• Turn ON power.• Observe blinking LED’s “RUN”, “ERROR”, &

“STAT”.• When “ERROR” & “STAT” stop blinking turn

OFF the power.• Remove the EPROM program chip.• Turn ON the power - observe “RUN” LED is

ON steady.• Wait for the main screen to load on the HMI,

touch SETUP icon

• Turn OFF power• Remove existing USB memory drive &

install the new program version USB drive.• Turn ON power.• When “Install project from USB drive?”

appears, press the “YES” button.• “Installation complete. Verify network

address 10.10.11.101” should appear.• Remove the USB version drive and replace

with the existing USB memory drive.• Press the “Restart” button.• Wait for the Main Screen to load, touch

“SETUP” button.

EPROMPROGRAM CHIP

PLC UNIT WITHIN MAIN CONTROL

HMIFLASH DRIVE

USB PORT ON RIGHT OF HMI REAR PANEL

Do NOT operate the dryer if the HMI &PLC version do NOT match. ContactNECO for assistance.

Save all program chips for re-usage.

ATTENTION

70

NOTE: The 120V power source needs to be connected to a customer supplied 400 - 500VAbattery backup unit.

The following schemetic indicates with dashed lines crossing INTO the HMI enclosure the connec-tions to be made --

• SEE following section -- Electrical Wire from Main Control into theHMI

• SEE following section -- Ethernet cable from Main Control into the HMI

E-STOP

3PB XO

XO

OG JUMPER

OG JUMPER

E-STOP

1PB XO

XO

POWER

1SS

OFF ON

OX

+

-

SERIAL GATEWAY

PC POWERSUPPLY

PC BASED - MOISTURE CONTROLLER

COM2

19200 BAUD

TO 309 TWIDO PLC

TO HMI ENCLOSURE

SPARE PORT FOR

H

N

V+

V-

GND

NULL MODEM

REMOTE ACCESS

PROGRAMMING PORT

OPTIONAL HEATERW/ THERMOSTAT

HMI ENCLOSURE (Indoors Installation Recommended)

FROM SEPERATE

POWER SOURCE120VAC, 1PH, 15A

10.10.11.101255.255.255.0

10.10.11.211255.255.255.0

MODBUS ETHERNETMGATE MB3180

12-48VDC

MOXA

71

Electrical Wire from Main Control to HMI

• Labels are provided - pull the following wirethat connects from the Main Control terminalstrip to the HMI terminal block.

ATTENTION: The 120V power source needsto be connected to a customer supplied 400 -500VA battery backup unit.

Ethernet Cable from Main Control to HMI

• Pull Cat 6 shielded ethernet cable from theMain Control ethernet receptical to the HMIehternet receptical - maximum distanceshould be less than 300 feet.

WIRELABEL

WIRECOLOR

E1A BLUEE2 BLUE

E2A BLUE24V BLUEOV WHITE

HMI ETHERNETPLUGS IN HERE

MAIN CONTROLPLC - PLUGETHERNET IN HEREPLUGS IN HERE

Terminal block - inside HMI enclosure

72BURNER BOX INTERIOR

POWER LED FAULT BLINK CODES

BLINK CODE(FAST - SLOW) FAULT DESCRIPTION

1-1 Low AC Line Voltage1-2 AC Quality Problem2-1 Unexpected Flame Signal2-2 Flame Signal Absent2-3 Flame Signal Overrange3-1 Running ILK Switch Problem3-2 Running ILK Switch in Standby3-3 Valve Proving Fault4-1 Purge Card Problem4-2 Wiring Problem/Internal Fault4-3 Flame Amplifi er Problem4-4 Confi guration Jumper Problem5-1 PII Fault5-2 HFS/LFS Fault5-3 MOS/Start Switch6-1 Output Drive Failure6-2 Internal Fault6-3 Device Specifi c Fault6-4 Accessory Fault7-7 Unrecognized Fault

GREEN POWER LED

• Blink codes are read from the green power LED when the Alarm LED is ON.

• The blink codes consist of one or more fast blinks followed by one or more slow blinks.

RED ALARM LED

COMM’S MODULE

74

7 5

LOWER-LEFT OFFRONT OF PANEL

4

ELECTRICALSCHEMATICS

21

3 SEEPLC

DETAILS

6

75

ITEM # PART # DESCRIPTION1 059266 DC DRIVE2 059298 TRANSFORMER - 1.5 KVA3 059234 PLC ASSEMBLY - TWIDO

3A 059234-1 TWIDO BASE3B 059234-2 TWIDO ANALOG3C 059234-3 TWIDO DIGITAL3D 059234-4 TWIDO COMMS3E 059234-5 TWIDO BATTERY3F 059234-6 MEMORY CARTRIDGE (NOT SHOWN)4 059230 SWITCH, E-STOP ABB CET-10R-025 059233 LUTZE 24V POWER SUPPLY 7227586 059237 LUTZE E-STOP RELAY MSI-SR47 059240 WAGO 24V ISOLATION RELAYS 857-304

ISBEHIND3A BASE

WIRES ONBOTTOM

PLCDETAILS

3A

3B

3D

3C

3E

76

1

3

2

4

5

SEE WIRINGDETAIL

6

7

8

BACKSIDEOF

DOOR

FRONTSIDEOF

DOOR

INSIDEOF

ENCLOSURE

77

HMI ENCLOSURE COMPONENTSITEM # PART # DESCRIPTION

1 059235 HMI SCREEN2 059236 ETHERNET SWITCH3 059295 ETHERNET CONVERTOR4 059249 DRYER MASTER CONTROLLER5 059230 SWITCH, E-STOP ABB CET-10R-026 059231 SWITCH, 2-POS ABB C2SS210B-107 059292 ETHERNET CABLE (BULK - SPECIFY # OF FEET)8 059288 ETHERNET END (RJ45)

NOTSHOWN 059242WK HMI WINDOW KIT AND HEATER

78

1

2

3

8

4

5

REMOTERESET

CONNECTION

6MODBUS ADDRESS

ADJUSTMENT

7

9

SEE SCHEMATIC LOCATED WITHIN BURNER BOX

THE KS45 TEMPERATURE CONTROLLERCAN BE RESET WHEN REQUIRED - SEE BELOW.

TEST&

RUN

79

BURNER BOX COMPONENTSITEM # PART # DESCRIPTION

1 F148003 AIR SWITCH1 F148004 AIR SWITCH - 3200 SERIES DRYER2 7712555 HWELL HIGH LIMIT SWITCH T675A11023 040365 HWELL SPARK GENERATOR TRANSFORMER Q652B10064 044779 HWELL RELAY MODULE RM7897A10024 045611 HWELL RELAY MODULE(CE ONLY) RM7830A10035 044781 HWELL PURGE TIMER CARD ST7800A10396 059213 HWELL MODBUS MODULE ST7810M10297 044780 HWELL FLAME SIGNAL AMP R7849A10238 059214 PMA KS45 TEMPERATURE CONTROLLER9 059240 RELAY 24VDC SPDT

IGNITION COMPONETSITEM # PART # DESCRIPTION

1 040155 IGNITER PLUG - AUBURN E5-I-31-12 7712552 UV SENSOR MINI PEEPER - C7027A10313 F912000 IGNITION WIRE 7mm - PER FOOT4 045893 SPARK PLUG BOOT5 F048017 METAL CAP (INSIDE SPARK PLUG BOOT)

23

14

5

80

1

MODULATING MOTOR(#044444)

BURNER BOX

2

3

4

5 NOTE: ITEM #5 YELLOW 5-PIN x 4M LGCABLE TO DAISY-CHAINS FROM BURNERBOX TO BURNER BOX AND ALSO GOESFROM THE BOTTOM BURNER BOX TO THEMAIN CONTROL CABINATE.

6

NOTE: USES ITEM #7 YELLOW 3-PIN x 20M LGCABLE FROM THE MAIN CONTROL CABINATE.

NOTE: USES ITEM #7 YELLOW 3-PIN x 20M LGCABLE FROM THE MAIN CONTROL CABINATE.

8

81

SENSORS, CABLES, & Misc.ITEM # PART # DESCRIPTION

1 059219 CABLE, DN P/T FEM RKC 572-1.5M2 059221 GREY TEE, DN RSC 2RKC 573 059220 GREY CABLE, DN EXT RSC RKC 572-4M4 059208 YELLOW TEE, 5 PIN RSM 2RKM 505 059209 YELLOW CABLE, 5 PIN ????????????????6 059243 SAMPLE SWITCH BOX (WITH CONNECTOR)7 059248 YELLOW CABLE, 3 PIN FEMALE PIGTAIL x 20M LG8 059118 PROX SENSOR N/O - FOR PLUGGED DISCHARGE ALARM9 059250 DRYERMASTER MOISTURE SENSOR (NO CONNECTOR)9 059250W DRYERMASTER MOISTURE SENSOR with 5-PIN CONNECTOR

10 059137 YELLOW CABLE, 5 PIN FEMALE PIGTAIL x 20M LG

DryerMaster MOISTURE SENSOR / TEMPERATURE SENSOR UNIT(ONE FOR INPUT GRAIN & ONE FOR OUTPUT GRAIN)

9MOISTURE SENSOR

FIN TEMPERATURE SENSORPROBE

NOTE: USES ITEM #10 YELLOW 5-PIN x 20M LGCABLE FROM THE MAIN CONTROL CABINATETO BOTH THE INPUT & OUTPUT SENSORS.

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NECO Grain Dryer Specifi cations

Model#

#of

Tiers

HoldingCapacity

# ofBurners

&Blowers

TOTALBlower Output

(Max)

TOTALBurner Output

(Max)MetricTonnes

CubicFeet / Min

CubicMeters / Min

MMBTU / HR kW

D1240 4 433 11 1 15,000 424 6 1758D1250 5 505 12 1 17,500 495 6 1758D1260 6 578 14 1 20,600 582 6 1758D1670 5 674 17 1 23,500 665 6 1758D1680 6 770 19 1 27,500 778 6 1758D1690 7 866 22 1 32,000 905 6 1758

D16106 8 962 24 2 36,600 1035 12 3516D16120 10 1155 29 2 47,000 1330 12 3516D16140 12 1347 34 2 55,000 1556 12 3516D16160 14 1539 39 3 65,300 1847 18 5274D16180 16 1731 44 3 78,500 2221 18 5274D24108 6 1155 29 2 41,200 1165 12 3516D24150 8 1443 36 2 55,000 1556 12 3516D24180 10 1732 44 2 62,000 1754 15 4395D24210 12 2020 51 3 82,500 2334 18 5274D24240 14 2309 58 3 89,500 2532 21 6153D24260 16 2597 66 4 110,000 3113 24 7032D24330 20 3174 80 5 137,500 3891 30 8790D24380 24 3750 95 6 165,000 4669 33 9669D32260 12 2693 68 3 108,000 3056 23 6739D32340 16 3463 88 4 144,000 4075 30 8790D32440 20 4232 107 5 182.000 5150 38 11134D32500 24 5001 127 6 216,000 6112 45 13185

Refer to following table for specifi cations on standard NECO Dryers. If the model number of yourparticular dryer is not shown below, contact your NECO representative.

NOTES:1. Calculations in this table represents data from the U.S. Grain Council website (www.grains.org).2. Holding Capacity values represent corn @ 15.5 % moisture content (56 pound bushel).

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NOTE: These speeds are recommended as a STARTING POINT only.

METERING ROLL DC MOTOR (%) PER MOISTURE POINTS TO REMOVEMODEL - RPM 3 5 7 9 11 13 15

D1240 - 27 RPM 42% 25% 18% 14% 12% 10% 9%D1250 - 27 RPM 52% 32% 23% 18% 15% 13% 11%D1260 - 27 RPM 63% 38% 27% 21% 18% 15% 13%D1670 - 27 RPM 52% 32% 23% 18% 15% 12% 11%D1680 - 27 RPM 62% 38% 27% 21% 17% 15% 13%D1690 - 27 RPM 73% 44% 32% 25% 20% 17% 15%

D16106 - 42 RPM 53% 32% 23% 18% 15% 13% 11%D16120 - 42 RPM 67% 40% 29% 22% 18% 16% 14%D16140 - 42 RPM 80% 48% 34% 27% 22% 19% 16%D16160 - 62 RPM 63% 38% 27% 21% 17% 15% 13%D24108 - 27 RPM 62% 38% 27% 21% 17% 15% 13%D24150 - 42 RPM 53% 32% 23% 18% 15% 12% 11%D24180 - 42 RPM 67% 40% 29% 22% 18% 16% 14%D24210 - 42 RPM 80% 48% 34% 27% 22% 19% 16%D24240 - 62 RPM 63% 38% 27% 21% 17% 15% 13%D24260 - 62 RPM 72% 43% 31% 24% 20% 17% 15%D24300 - 83 RPM 61% 37% 26% 20% 17% 14% 12%D24330 - 83 RPM 68% 41% 29% 23% 19% 16% 14%D24360 - 83 RPM 74% 45% 32% 25% 20% 17% 15%D24380 - 83 RPM 81% 49% 35% 27% 22% 19% 16%D32260 - 62 RPM 54% 32% 23% 18% 15% 13% 11%D32340 - 62 RPM 72% 43% 31% 24% 20% 17% 15%D32440 - 92 RPM 61% 36% 26% 20% 17% 14% 12%D32500 - 92 RPM 73% 44% 31% 24% 20% 17% 15%

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CAUTION: For all crops, machine cleanliness is important and the accumulation of debris canbe a combustion hazard. Some types of grain create more cleaning issues than others. Keep theequipment and work area clean.

Corn, Barley, Wheat and Oats:• These crops dry relatively trouble free.

• If incoming grain moisture is above 28% (especially wheat) consider two drying passes.

Rapeseed:• Due to the screenless design, rapeseed is as trouble-free as any other crop to dry.

• With rapeseed containing pods, it is advisable to clean out the machine at the end of eachdays’ operation to prevent trash from building up.

• Watch the drying temperature carefully. Combustion is known to have occurred in rapeseedwhen seed temperatures reached about 155°F (68°C).

Flaxseed:• Similar conditions exist with fl axseed as with rapeseed, but fl ax is one of the most diffi cult

crops to force air though.

• By keeping it moving, it will stay loose and more air will pass through. It will also tend to sticktogether and to the walls of the machine if it is not kept moving at all times. The blower speedmay have to be lowered or the intakes partially covered in order to prevent it from being liftedout of the ducts.

Specialty Crops:• Sunfl ower seed will lift easily with too much blower speed and the equipment typically needs to

be cleaned often.

85

High-Limit Temperature Consideration

To avoid tripping the High Temperature Limit switch, limit the drying temperature to 240°F or 110°CWhen a High Temperature Limit alarm is activated, the equipment will shut down with NO Cool-Down period (blowers OFF).

In cases where the grain has a lot of trash, or when drying high moisture grain that is immature orfrozen, drying at these temperatures may not be possible. In cases where there is blocking in themachine due to trash, it is possible for this material to become subject to spontaneous combus-tion. In this case and in any case where a person may see smoke coming from the machine, theblower(s) should be stopped immediately.

Method to Measure Actual Seed Temperatures

When the machine is operating in the initial batch mode, there is a simple check to see what themaximum operating temperature can be. To determine correct kernel temperature, take a samplefrom a duct at the lower part of the heating section. Put into an insulated (covered) container, witha thermometer directly in the grain. After 10 minutes record temperature reading. NOTE: Puttinga thermometer directly in the dryer only gives the temperature of the air between the kernels andnot the correct temperature of the actual kernels

When stopping the machine the grain should be cooled down:

• MANUAL COOL-DOWN Turn off the burners, but leave the blowers running for a period of5 - 15 minutes.

• AUTOMATIC COOL-DOWN The system has fi ve possible grain level monitors. Certainconditions can result in the equipment automatically shutting down. Most of these conditionsinclude a cool-down period. A few conditions, such as High Limit Temperature (Timer #4TR),that are reached provide a shut-down with NO cool-down period.

RECOMMENDED MAXIMUM TEMPERATURES IN THE NECO DRYERFEED COMMERCIAL SEED

°F °C °F °C °F °CBarley, Oats,Wheat, Corn

Continuous-Flow 200+ 93+ 180-200 82-93 160 71Batch 160 71 140-160 60-71 130 71

Rapeseed,Flaxseed

Continuous-Flow — — 150-170 66-77 130-140 54-60Batch — — 130-140 54-60 110 43

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MANUFACTURED BY

NECOA Division of GLOBAL Industries, Inc.

9364 North 45th StreetOmaha, Nebraska 68152TEL: 402-453-6912 FAX: 402-453-0471Toll-free (within Nebraska): 1-800-367-6210Toll-free (outside Nebraska): 1-800-367-6208www.necousa.com

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