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The Pinnacle 20|20 Remote Cabinet and associated sub-panel, shown below, is where the Pinnacle 20|20 HMI touch screens are located.
The following rendered image shows an overall view of the dryer with some of the main components highlighted. The pages following will explain these components or assemblies more in depth as well as explain the function of any associated parts.
The Rotary Fill Switch is located in the wet hopper of the tower and on the opposite end of the fill tube, or on the end of a gravity fill hopper for profile dryers. It is powered by 24V. The switch is motorized and will rotate a paddle until wet grain comes in contact with the paddle. Once this happens, grain stops the rotation and proves the level of grain in the hopper.
The Plenum RTD (Resistance Temperature Device) is a temperature sensing device located in the plenum used to send a signal to the PLC to establish and maintain plenum temperature.
The two Mid-Grain RTD (Resistance Temperature Device) Assemblies are located around the perimeter of the dryer and are used to detect the temperature of the grain in the column. Each of these two RTD assemblies is equipped with a 4-20mA transmitter which provides an analog input signal sent to the PLC.
The Proximity Switch is used to detect the rotation of the discharge metering system for profile dryers and the sweep for tower dryers, by sensing the proximity of a detector on the discharge metering shaft for profile dryers and on the shaft of the sweep motor for tower dryers. If the rotation of the shaft goes undetected for a set duration of time, the machine will be shutdown.
The Control Power Transformer is used on profile dryers to transform a portion of the incoming electrical power to reliable 120V control power which is used to supply power to various electrical components including the PLC. These are only used on 575V dryers.
The infeed moisture sensor is mandatory for AccuDry grain dryers, and optional for TruDry grain dryers. This sensor monitors incoming grain in real-time so that the AccuDry prediction model can react to incoming grain moisture changes. On an optional TruDry grain dryer, this will only display on the main screen, and will not affect the operation of the grain dryer
This section of the manual will physically show you what the component looks like and the description that follows will state its purpose.
The Low Voltage Cabinet and associated sub-panel, shown below, contain the PLC, I/O modules, breakers, relays and a safety relay module. There are two main variations which include an AccuDry and Non-AccuDry option. The subpanel shown below includes AccuDry.
The discharge moisture sampler is used to continuously collect a sample of grain, move it past the discharge moisture sensor in a controlled and steady fashion, and return the sampled grain back to the discharge of the dryer.
The Moisture Sensor is an electronic device that measures the grain moisture indirectly by measuring the capacitance of the field of grain and correlating it to a voltage. Additionally, there is a small thermistor, which also produces an analog output voltage, mounted on the face of the sensor to measure the grain's temperature to compensate the moisture reading and to provide a real-time indication of the grain's temperatures. These voltages are input to the PLC and when calibrated, will display the discharge grain moisture as well as the temperature on the HMI touchscreens.
The Discharge Limit Switch is a spring-loaded lever that maintains a normally open contact which is held closed. The purpose of this switch is to detect a discharge grain overload condition that may be a result of a failed discharge auger or takeaway equipment. Once an overload condition exists, the top door on the discharge auger will lift up and the switch will return to its normally open position; in doing so, the safety circuit is opened and the dryer is shutdown.
The Moisture Sampler Auger Motor is a small fractional HP motor that slowly augers a sample of grain past the moisture sensor and returns the sampled grain back to the primary discharge of the dryer.
The Burner Control Cabinet and associated sub-panel, shown below, house all of the components to safely operate the fan and burner which includes an air pressure switch, high limit switch, and an ignition board or Flame Controller, Amplifier, Ignition Transformer and Programmer Module if upgraded from an ignition board. The cabinet is mounted near the fan and burner for ease of access and/or troubleshooting purposes. There is one Burner Control Cabinet per burner and are different for each dryer series. As previously mentioned, all dryers come standard with the Fire Eye (Flame Controller, Amplifier, Ignition Transformer and Programmer Module) except for next generation Legacy dryers in which the Fireye is an option and the Fenwal Ignition board is standard. Shown below is the burner box housing the Fireye Ignition system.
The High Limit Switch utilizes a capillary bulb to sense an over-temperature condition in the plenum which will cause the dryer to shutdown. The high limit setpoint is adjustable on the switch and should be set approximately 40 deg F higher than the plenum temperature setpoint.
The purpose of the Air Pressure Switch is to prove airflow from the fan for safe operation of the burner. The air pressure switch is adjustable and should be set once the dryer is full of grain. Adjustment of the switch is done in the burner control cabinet and indication of reaching the air pressure switch's setpoint is indicated by the illumination of the green light on the outside of the burner control cabinet.
The Ignition Transformer supplies the high voltage to the spark plug to ignite the burner.
The Flame Controller is a compact, microprocessor base, modular burner management system designed to provide automatic ignition and continuous flame monitoring.
The amplifier module provides flame scanning capabilities using any of the Fireye standard scanners. Measuring of flame signal strength is available on this module. Insert DC voltmeter leads in the two test jacks labeled “ NORMAL DC TEST VOLTAGE 4.0 TO 5.5 VDC”. Red for positive (+) polarity and black for minus (-) polarity. A DC voltage reading of 4.0 to 10 volts for all amplifier types should be obtained when the control is detecting flame and 0 volts when no flame is present. Wildly fluctuating readings are an indication of an unstable flame or flame sensor requiring maintenance.
This module, when used with the Fireye Control, provide diagnostics through LED's and alpha-numeric display.
The Fenwal Ignition Board is a 120 Volt board and controls the overall operation of the burner by supplying high voltage from the coil to the spark plug to ignite the burner, sending signals to open/close the gas valves, and continuously monitoring the presence of a flame for safe and reliable operation
The High Voltage Cabinet and associated sub-panel, shown below, contain all of the motor starters and protectors, main power disconnect, variable frequency drives (VFD's), breakers, relays, and other associated electrical hardware.
The Control Power Transformer transforms a portion of the incoming electrical power to reliable 120V control power, used to supply power to various electrical components.
The Variable Frequency Drive is used to control the speed of the discharge metering/sweep system and is controlled directly by the PLC.
The Pinnacle 20|20 Customer Equipment Cabinet is provided as the designated junction for wiring in customer equipment that is to be used in conjunction with the dryer operation.
It is extremely important not to wire any customer equipment directly into any of the dryer cabinets except for the Customer Equipment Cabinet. The Customer Equipment Cabinet is the sole, designated place to wire in customer equipment. Failure to follow this may cause damage to other dryer components and will void the warranty
The purpose of the gas train is to safely and efficiently supply fuel at the correct pressures and flow rates to the burners. There are several variations of the gas train depending on what model and options are equipped on the machine. If the dryer is equipped for LPG fuel, there will be liquid lines sending LPG to the vaporizer and back to the manifold. CE equipped machines will have gas pressure switches to meet local codes. CGA equipped machines will have valve proving shut-off valves as well as liquid and vapor venting to meet local codes. Shown below are illustrations of two burner gas trains, for both LPG and Natural gas arrangements as well as for both domestic and CGA configurations. While your particular gas train may vary in size/design/arrangement, the components used are the same. Use these illustrations to familiarize yourself with the components that may be found on your particular dryer's gas train.
The Control Valve is a throttling butterfly valve that controls the fuel flow rate to the burner which is precisely positioned by the control valve actuator. The control valve is connected to the control valve actuator through a mechanical linkage.
The Control Valve Actuator is an electrical actuator that is connected to the control valve through a mechanical linkage that precisely positions it based on the output of the PLC. As the plenum temperature drops below the setpoint, the PLC commands the control valve actuator to open more, whereas if the plenum temperature rises above the setpoint, the PLC commands the control valve actuator to close more.
The purpose of the Strainer is to collect any foreign material with a wire mesh filter that may find its way into the fuel supply line.
The Solenoid Valve is to start and stop the flow of fuel to the burner. The opening/closing actuation of the solenoid valve is monitored and performed by the ignition board.
The purpose of the Pressure Relief Valve is to automatically open and relieve excess pressure when the line pressure becomes too high. Once the pressure drops, the valve will close and seal again for continued proper operation.
The Low / High Gas Pressure Switches are adjustable switches used to detect either low gas or high gas pressure in the gas train and shutdown the dryer. These switches are used for CE equipped machines to meet local codes.
The Primary purpose of a Pressure Regulator is to continuously control the supply pressure of the fuel to the gas train manifold. There are various sizes and configuration based on model and configured options, however the primary purpose is the same.
The purpose of a Manual Hand Valve is to manually open and close various portion of the gas train for maintenance purposes.
The valve proving solenoid stops and starts the flow of fuel to the burner. The opening/ closing activation of the solenoid valve is monitored and performed by the ignition board. This solenoid detects proof of valve closure.
The burner, which consists of a cast iron burner body drilled to discharge gaseous fuel between diverging stainless steel mixing plates, is a burner which efficiently combusts the fuel/air mixture thereby producing the required process heat to the drying air.
The Spark Igniter receives high voltage current from the ignition board and sparks to provide direct spark ignition for the burner.
The Flame Sense Probe detects the presence of the flame and provides positive confirmation to the ignition board so that operation of the burner may continue. Two (2) flame sense probes may be used to detect high or low flame conditions.
