The purpose of the Air Pressure Switch is to prove airflow from the fan for safe operation of the burner. Once the pressure switch has been satisfied, operation of the burner and its ignition system are permitted. In the event that air pressure is lost as indicated by a non-illuminated air pressure light, the burner will extinguish.

Depending on the number of burners, this will determine the number of air pressure switches, with one installed per 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 High Voltage cabinet for tower dryers and in the burner control cabinet(s) for all other dryers. Reaching the air pressure switch's setpoint is indicated by the green air pressure light on the outside of the cabinet housing the air pressure switch.

Setpoint Check

The following procedure shall be utilized to properly check the air pressure switch(es) setpoint. Note that the air pressure switch for each fan/burner must be checked and set independently.

1. After the dryer has been filled with grain and before the burner is ignited, the operation of each air pressure switch must be checked.

2. All of the fans must be running (including the cooling fans) before the air pressure switches can be accurately adjusted.

3. Start all fans and determine if the air pressure switch light (for the switch that is being verified) on the burner control cabinet illuminates once the respective fan has reached its normal operating speed.

4. If the indicator light does not illuminate or comes on too soon (before the fan reaches operating speed), the air pressure switch must be adjusted.

Switch Adjustment

In the event that the indicator light does not illuminate or comes on too soon (before the fan reaches operating speed), the following procedure shall be used to properly set the air pressure switch:

1. Remove the cap on the air pressure switch. Inside the air pressure switch use the slotted screw to make adjustments by turning clockwise or counter-clockwise.

2. Turn the adjusting screw counter-clockwise until the air pressure light comes on. After the air pressure light comes on, turn the adjusting screw counter-clockwise an additional ¼ to ½ turn to allow for normal changes in static pressure.

If all air pressure switch adjustment is used and the air pressure light does not illuminate, the air pressure switch is defective and must be replaced. Once the switch is replaced, check its operation and make adjustments as previously outlined.

The sections that follow provides details needed to properly operate the different components of the dryer and to make any adjustments necessary. The components included do not comprise of everything that can be adjusted on the dryer, but rather the components that need to be adjusted based on normal operation.

The purpose of the High Limit Switch is to provide a safety shutdown in the event that the temperature in any of the plenums has exceeded the high limit setpoint. The high limit switch senses the temperature in the plenum that it is monitoring by means of a capillary bulb temperature sensing device.

Depending on the number of burners, this will determine the number of high limit switches, with one installed per burner. The high limit switch is adjustable and should be set once at the start of a drying season or for a given grain. Adjustment of the switch is done in the ignition box for tower dryers and in the burner control cabinet for all other dryers. Note that when a high limit setpoint is exceeded, the high limit for the applicable fan/burner will become tripped as well as all other high limit switches above it because the wiring of the switches are in series. For example, if the high limit switch in plenum #1 is exceeded, the high limit for plenum 2 will no longer show to be in good status.

Setpoint Check and Switch Adjustment

The following procedure shall be utilized to properly check the high limit switch(es) setpoint. Note that the high limit switch for each fan/burner must be checked and set independently. Once the high limit setpoint has been reached, the switch will need to be reset by pressing the small reset button on the top of the device. After the dryer has been filled with grain and after the burner is ignited, the operation of each high limit switch must be checked.

1. Start the fan, ignite the burner and establish a stable temperature in the plenum.

2. Inside the ignition box for tower dryers and burner control cabinet(s) for all other dryers, adjust the high limit switch setpoint by turning the small dial counterclockwise to a temperature below the current temperature in the plenum.

3. Once the high limit switch determines that the temperature in the plenum has exceeded the high limit setpoint, the switch will cause the dryer to shutdown.

4. If the high limit switch does not shut down the dryer, it is defective and must be replaced. Once the switch is replaced, check its operation and make adjustments as previously outlined.

5. If the setpoint is exceeded and properly shuts down the dryer, the setpoint can be adjusted to a value that is approximately 40 deg F above the desired plenum temperature.

The variable frequency drive (VFD) controls the speed of the dryer's metering/sweep discharge. The VFD's parameters depend on the type of dryer and the machine's voltage. Select from the options on the following pages:

Applicable Models

• 10' Modular Tower Models (10530 - 101375)

• 12' Modular Tower Models (12-20-100 - 12-28-150)

The variable frequency drive controls the speed of the sweep arms for all tower dryers. The communication from the HMI to the PLC then correlates to the variable frequency drive. It is important to note that some of the parameters listed below will vary such as voltage, amperage and motor speed. These values should match the motor name plate.

Applicable Voltages

• 208V/3ph

• 230V/3ph

• 460V/3ph

• 230V/1ph

Parameters

The following parameters apply to the dryer model(s) and voltage(s) as shown.

Motor Data

Standard AI

Start / Stop / Direction

Start / Stop Mode

Frequency Reference Chain

Limits

Panel Display

Applicable Models

• 10' Modular Tower Models (10530 - 101375)

• 12' Modular Tower Models (12-20-100 - 12-28-150)

The variable frequency drive controls speed of the sweep arms for all tower dryers. The communication from the HMI to the PLC then correlates to the variable frequency drive. It is important to note that some of the parameters listed below will vary such as voltage, amperage and motor speed. These values should match the motor name plate.

Applicable Voltages

• 380V/3ph/50Hz

• 575V/3ph/60Hz

Parameters

The following parameters apply to the dryer model(s) and voltage(s) as shown.

Group 99 Start Up Data

Group 10 Start / Stop / Direction

Group 11 Reference Select

Group 12 Constant Speeds

Group 14 Relay Outputs

Group 15 Analogue Outputs

Group 16 System Controls

Group 20 Limits

Group 34 Panel Display

Applicable Models

• Delta Series Models (D600/D600h - D3200/D3200h)

• Fusion Series Models (F320/F320x - F660/F660x)

• ECO Series Models (E300/E300h - E700/E700h)

• Legacy Series Models (L1000 - L6000)

The variable frequency drive controls the speed of the metering rolls for all profile and mixed-flow dryers. The communication from the HMI to the PLC then correlates to the variable frequency drive. It is important to note that some of the parameters listed below will vary such as voltage, amperage and motor speed. These values should match the motor name plate.

Parameters

The following parameters apply to the dryer model(s) and voltage(s) as shown.

Group 99 Start Up Data

Group 10 Start / Stop / Direction

Group 11 Reference Select

Group 12 Constant Speeds

Group 14 Relay Outputs

Group 15 Analogue Outputs

Group 16 System Controls

Group 20 Limits

Group 21 Parameters

Group 22 Parameters

Group 34 Panel Display

The following operational procedures provide a step-by-step guide to starting-up and shutting-down your dryer. These procedures should be followed and used in conjunction with the Pinnacle 20|20 Controls Manual for HMI touchscreen adjustments.

Daily Shut-Down

This shutdown procedure assumes that the dryer will be put back into operation within 24-48 hours. If the grain drying operation will not resume within 24-48 hours, it is suggested that the dryer be emptied and the grain placed back into the appropriate storage. Grain dryers are not designed to be grain storage devices. Once all the grain has been dried, it needs to be emptied from the dryer and stored appropriately. Grain stored in a dryer for more than one week may cause damage to the machine. For an end-of season shutdown procedure, see the End-of-Season Shut Down portion of this section of the manual.

1. On the Remote Cabinet, from the Controls Page on one of the HMI's, press the Metering STOP button. Once takeaway equipment is clear of grain, press the Takeaway STOP button.

2. On the same Controls page, press the Grain Fill STOP button. The grain fill system will now be shutdown and your fill equipment will no longer be commanded to run.

3. Close the manual hand valves supplying fuel to the dryer. This will ensure the burners will run until all of the fuel in the line has been cleared out. Once the burners are extinguished, from the Controls page on one of the HMI's, press the Burner STOP buttons for each burner.

4. Let the fans continue to run for at least 15-20 minutes to cool the grain in the dryer. Once the grain has been cooled down, shutoff the fans by pressing the Fan STOP buttons on the Controls page.

5. From the Controls page, press the Control Power TURN OFF button.

6. Turn the main disconnect located on the High Voltage Cabinet(s) to the off position.

Daily Start-Up

This start-up procedure assumes that the dryer has recently been in operation and is full of grain. For a first time start-up, see the Daily Start-Up procedure portion of this section of the manual.

1. Turn the main disconnect located on the High Voltage Cabinet(s) to the on position.

2. On the Remote Cabinet, go to the Controls page on one of the HMI's and press the Control Power TURN ON button.

3. On the same Controls page, press one of the Fan START buttons. The fan should start immediately. Repeat this procedure for all of the fans, allowing time for each fan to get up to speed before starting the next.

4. Set the plenum temperature setpoints for each plenum. Refer to the table at the end of this section for suggested drying temperatures based on model number and grain type. Setting the plenum temperature can be done on the HMI touchscreens as explained in the Pinnacle 20|20 Controls Manual.

5. Open all manual gas supply valves so that fuel is free to flow to the burner once the gas valves controlled by the ignition system are opened.

6. On the Remote Cabinet, from the Controls page on one of the HMI's, press the Burner START button. After a 15 second delay, the burner should be lit. Repeat for all necessary burners.

7. On the Remote Cabinet, from the Grain Fill Settings page on one of the HMI's, uncheck the Fill From Empty box. The grain fill system will now operate automatically as outlined in the Grain Fill Settings portion of the Pinnacle 20|20 Controls manual.

8. Refer to the Pinnacle 20|20 Controls Manual for the requirements prior to starting the dryer's discharge. At a minimum, set the discharge mode to Manual on the HMI touchscreen and set the discharge speed setpoint (%) in accordance with the table that follows.

9. On the Remote Cabinet, from the Control page on one of the HMI's, press the Takeaway START button. Once the discharge auger or conveyor (if equipped) as well as customer takeaway equipment are running, press the Metering START button. The dryer is now discharging grain and the discharge rate will be established by the Pinnacle 20|20 Control System. Refer to the Pinnacle 20|20 Controls Manual for more information.

The following operational procedure provides a step-by-step guide to shutting-down your dryer at the end of the season. This procedure should be followed and used in conjunction with the Pinnacle 20|20 Controls Manual for HMI touchscreen adjustments.

This shutdown procedure assumes that the dryer will not be put back into operation for an extended period of time and that all of the grain in the dryer will be dried and then subsequently emptied.

1. When the last of the grain to be dried has been put into the dryer, press the Metering STOP button. Once takeaway equipment is clear of grain, press the Takeaway STOP button.

2. Dry the remaining grain for approximately six minutes per point of moisture to be removed.

3. Close the manual hand valves supplying fuel to the dryer. This will ensure the burners will run until all of the fuel in the line has been cleared out. Once the burners are extinguished, from the Controls page on one of the HMI's, press the Burner STOP buttons for each burner.

4. Let the fans continue to run for at least 15-20 minutes to cool the grain in the dryer. Once the grain has been cooled down, shutoff the fans by going to the Controls page on one of the HMI's, and press the Fan STOP buttons for each fan.

5. Set the discharge mode to Manual on one of the HMI touchscreens and set the discharge speed setpoint (%) as high as your takeaway system will allow.

6. On the Remote Cabinet, from the Control page on one of the HMI's, press the Takeaway START button. Once the discharge auger or conveyor (if equipped) as well as customer takeaway equipment are running, press the Metering START button. The dryer is now discharging grain and the discharge rate will be established by the Pinnacle 20|20 Control System. Refer to the Pinnacle 20|20 Controls Manual for more information.

7. Allow the grain to be completely emptied from the dryer.

8. On the Remote Control Cabinet, from the Controls Page, press the Control Power TURN OFF button.

9. Turn the main disconnect located on the High Voltage Cabinet(s) to the off position.

10. Refer to the Maintenance section of this manual for additional information on preparing your dryer for an extended shutdown.

The following operational procedure provides a step-by-step guide to starting-up your dryer. This procedure should be followed and used in conjunction with the Pinnacle 20|20 Controls Manual for HMI touchscreen adjustments.

This start-up procedure assumes that the dryer has not recently been in operation and is not full of grain. For a repeated daily start-up, see the Daily Start-Up procedure portion of this section of the manual.

1. Adjust the high limit switch setpoint to approximately 40 deg F above the desired plenum temperature as explained in the High Limit portion of this section of the manual. This should be done for all plenum high limit switches.

2. Set the grain fill timers as explained in the Settings Chapter of the Pinnacle 20|20 Controls Manual.

3. Turn the main disconnect located on the High Voltage Cabinet(s) to the on position.

4. On the Remote Cabinet, go to the Controls page on one of the HMI's and press the Control Power TURN ON button.

5. On the same Controls page, press one of the Fan START buttons. The fan should start immediately. Repeat this procedure for all of the fans, allowing time for each fan to get up to speed before starting the next.

6. On the Remote Cabinet, go to the Grain Fill Settings page on one of the HMI's and check the "Fill From Empty" box. Next, press the Grain Fill START button. The level auger, if equipped, should start immediately and your grain fill equipment should be commended to deliver grain to the dryer.

7. Once the dryer is full of grain, adjust each of the air pressure switches so the air pressure light illuminates as explained in the Air Pressure Switch portion of this section of the manual.

8. Set the plenum temperature setpoints for each plenum. Refer to the table at the end of this section for suggested drying temperatures based on model number and grain type. Setting the plenum temperature can be done on the HMI touchscreens as explained in the Pinnacle 20|20 Controls Manual.

9. Open all manual gas supply valves so that fuel is free to flow to the burner once the gas valves controlled by the ignition system are opened.

10. On the Remote Cabinet, from the Controls page on one of the HMI's, press the Burner START button. After a 15 second delay, the burner should be lit. Repeat for all necessary burners.

11. Allow the dryer to warm up and dry the initial load of grain as a batch operation or be prepared to cycle the first batch back into the wet bin so that it may be processed through the dryer again on a continuous flow basis.

12. On the Remote Cabinet, from the Grain Fill Settings page on one of the HMI's, confirm that the Fill From Empty box is unchecked. This should automatically uncheck once the dryer is full. The grain fill system will now operate automatically as outlined in the Grain Fill Settings portion of the Pinnacle 20|20 Controls manual.

13. Refer to the Pinnacle 20|20 Controls Manual for the requirements prior to starting the dryer's discharge. At a minimum, set the discharge mode to Manual on the HMI touchscreen and set the discharge speed setpoint (%) in accordance with the table that follows.

14. On the Remote Cabinet, from the Control page on one of the HMI's, press the Takeaway START button. Once the discharge auger or conveyor (if equipped) as well as customer takeaway equipment are running, press the Metering START button. The dryer is now discharging grain and the discharge rate will be established by the Pinnacle 20|20 Control System. Refer to the Pinnacle 20|20 Controls Manual for more information.

All MicroM Programmer Modules have 5 LED lights to indicate the operating status of the control and also to display the coded sequence under locked out conditions. The function of the lights under a normal operating condition is:

Operating Control

This LED is energized whenever the burner control switch and all other various limit switches are closed and power is applied to Terminal #7.

Interlock or Air Flow

This LED is illuminated whenever power is detected on Terminal #6, indicating the air flow switch or other running interlock is closed. If the operating control is closed and the running interlock switch remains open, this LED will flash at a 1 second rate indefinitely for the MEP100 and MEP200 family. Lockout will occur if the switch remains open for 10 minutes in the MEP500 family. This LED will blink when configured as a flame switch and flame detected.

PTFI

This LED is illuminated only during the pilot trial for ignition period and the stabilization period when so equipped.

Flame

This LED is on whenever a flame signal is detected, and the control is not in a locked out state.

Alarm

This LED flashes when an alarm condition is detected and is used as an address indicator (see communication).

During an alarm condition, the Alarm LED is made to flash at approximately a 1 second rate. The remaining four LEDs are illuminated as a coded sequence identifying the reason for the lockout. For instance, for a LOCKOUT - FLAME FAIL- PTFI, the INTERLOCK, PTFI and FLAME LED’s will all be lit steady, with the Alarm LED flashing. This remains true if power is removed and then restored in a locked out condition.

While in the Idle or Off state, the LEDs are made to flash sequentially to show the operational status of the control every minute. The LEDs can be tested by pressing and releasing the Reset push button, while in the Idle or Off state.

The table containing the list of lockout codes as well as the diagnostic messages and troubleshooting guide can be found below.

The purpose of the soft starter, if equipped, is to control the ramp speed of the fan motor in order to reduce the stress the motor experiences during startup. The table below contains the M-C settings that comes standard from the M-C Factory.

Navigating Soft Starter Parameters

The menu is navigated by the keypad. The Navigation keys are used to scroll up or down. The Select key is used to select a setting and save. The Exit key is used to cancel without selecting or saving a setting, and go to a higher level of the menu, as illustrated in the figure below.

1. Turn on the backlight by pressing any key.

2. On the Information level use the Navigation keys for scrolling the different operational information.

3. Press the Select key to Enter the Settings level. See (A) on the figure. A cursor is marking the accessible parameter, in this case Rated Current Ie.

4. Press Select key again to enable editing of the parameter Rated Current. See (B) on the figure. A flashing value on the middle row indicates that the parameter is available for scrolling and for selection.

5. Increase or decrease the value by pressing Navigation key repeatedly. Holding the key down will speed up the scrolling. See (C) on the figure.

6. When the rated current of the motor is reached, press the Select key again to save. See (D) on the figure.

7. It is possible to select and adjust the other parameters by following the same procedure.

8. At any point, press Exit to cancel a setting and return to the information level.

Applicable Models

• 18' Commercial Tower Models (3000 - 4800)

The variable frequency drive controls speed of the sweep arms for all tower dryers. The communication from the HMI to the PLC then correlates to the variable frequency drive. It is important to note that some of the parameters listed below will vary such as voltage, amperage and motor speed. These values should match the motor name plate.

Applicable Voltages

• 208V/3ph

• 230V/3ph

• 460V/3ph

Parameters

The following parameters apply to the dryer model(s) and voltage(s) as shown.

Motor Data

Standard AI

Start / Stop / Direction

Start / Stop Mode

Frequency Reference Chain

Limits

Panel Display

Below are suggested operating setpoints for all Mathews Company Dryers.

Discharge Speed Setpoints

Below are suggested discharge rates for all Mathews Company Dryers when drying at a variety of moisture levels. These numbers represent the speed of how fast or slow the dryer unloads the grain.

Plenum Temperature Setpoints

Below are suggested plenum temperatures for all Mathews Company Dryers when drying a variety of grains.

Delta Series

Fusion Series

ECO Series

Legacy Series

Modular & Commercial Tower Series