The information in this manual applies to all Mathews Grain Dryers, however it is important to understand that there are different configurations and options that may or may not be included on your particular machine. In most cases it is indicated where there is a feature that may not be configured on all machines with a note of "if equipped" or "optional".
Understanding fundamental grain drying principles is an important element of the operation of your grain dryer. As such, the following is a brief overview of the grain drying process. Grain drying is a mass transfer process consisting of the removal of water by evaporation from the grain. In its simplest concept, drying consists of three main components, Air, Heat and Time:
Ambient air is supplied to a fan that is mounted on the dryer which pushes it through a burner to raise its temperature, then forces it across, down and up through the column of grain. The function of the heated air is to facilitate a heat and mass transfer process. As the heated air passes over the grain, the heat from the air is transferred to the grain thereby elevating the temperature of the grain (heat transfer). Similarly, as the grain is heated, the moisture of the grain will start to exit to its surroundings as the equilibrium moisture of the grain is reached. This leads to the transfer of moisture from the grain to the air (mass transfer).
The accurate control of this heating process is what makes the equipment energy efficient. As the ambient conditions (temperature and relative humidity) change, as well as the desired plenum setpoint, the gas control system will respond to opening or closing to allow more or less fuel to flow to the burner.
The time element of grain drying refers to the time the grain is spent inside the dryer. The time that the grain is exposed to the heated air determines how much moisture is driven out of the grain. The longer the exposure, more moisture removal occurs. As such, the best method for controlling the amount of moisture removal in the grain is to increase or decrease the grain's retention time by increasing or decreasing the discharge metering or sweep speed. The slower the metering or sweep system operates, the longer the grain is exposed to the heated air and the moisture removal is increased. The faster the metering or sweep system operates, the shorter the grain is exposed to the heated air and the moisture removal is decreased. The easiest way to keep good grain quality and accurate control is to keep heat and air consistent while varying only grain retention time, which has proven to be the most common and efficient way to dry grain.
Before operating your grain dryer, it is strongly encouraged that you read the contents of this Operations Manual as well as the Pinnacle 20|20 Controls Manual. It will be important for you to become familiar with the controls, adjustments and settings required to obtain efficient operation. To keep your dryer operating at its peak efficiency, it should be cleaned, lubricated, belts tensioned, ignition system checked, and the fill/takeaway in good operating condition. Refer to the Maintenance Section to understand the required maintenance and suggested intervals. The Pre-Season check can be made when the dryer is empty. Any necessary repairs or adjustments should be completed so that the dryer will be ready to operate before your drying season begins.
It is important to send in your warranty registration card as soon as your new grain dryer is delivered. Not only does the card validate your warranty, but it also assists Mathews Company in disseminating information particular to your dryer model.
The model and serial number of your Mathews Company continuous flow grain dryer are stamped on plates located on the base of the dryer as shown:
Specifications for the machine will be located on the nameplate which is located on the inside door of the High Voltage Cabinet as well as on the inside of the Remote Cabinet. A sample nameplate is shown below:
While operating or performing maintenance on your machine, it is important to make safety a top priority. Be sure to read and understand the operations manual before attempting to operate the dryer. The following list of best practices should be followed to help ensure safe operation:
Keep ALL guards, access doors, covers, safety decals, and safety devices in place and securely fastened. Never operate the dryer while guards are removed.
Keep all untrained personnel away from system components and control panels at all times.
Never attempt to operate the unit by jumping or otherwise bypassing any safety devices.
Always open the main power supply disconnect switch and lock it in the open position with an approved lockout device prior to performing any service or maintenance work on the fan or burner unit.
Lock out power before removing guards, access doors, and covers.
Keep hands, feet and clothing away from all rotating parts.
Electrical repairs should be performed by trained and qualified personnel only. Failure to follow safe electrical procedures can result in serious injury.
If it should become necessary to perform checks on system components or high voltage test with energized circuits, proceed with extreme caution and follow all established safety practices.
Routinely check for any gas leaks.
Do not allow children or bystanders to be near the grain dryer or grain handling machinery while it is operating.
Do not operate the grain dryer without all safety shields in place and secure.
The purpose of a lock-out / tag-out procedure is to prevent injury and/or death to personnel by requiring that certain precautions be taken before servicing or repairing equipment. This includes shutting off and locking-out the electrical power source of the equipment. A standard Lock-out / Tag-out program is explained as follows:
All maintenance personnel are issued a suitable lock (or locks) that is durable. The lock has the individual's name and other identification on it. Each worker must have his/her own lock and the only key to that lock. In addition, locks can be color coded to indicate different shifts or types of services.
Each person who will be working on the machinery should put a lock on the machine’s lockout device(s). Each lock must remain on the machine until the work is completed. Only the individual who placed the lock should remove his/her lock.
Check to be sure that no one is operating the machinery before turning off the power. The machine operator must be informed before the power is turned off. Sudden loss of power could cause an accident.
Any mechanism under load or pressure, such as springs, should be released and blocked.
All energy sources that could activate the machine must be locked-out.
The main valve or main electrical disconnect must be tested to be sure that the power to the machine is off.
Electrical circuits must be checked by qualified persons with proper and calibrated electrical testing equipment. An electrical failure could energize the equipment, even if the switch is in the OFF position. Stored energy in electrical capacitors should be safely discharged.
Return disconnects and operating controls to the OFF position after each test.
Attach accident prevention tags. The tags will give the reason for placing the tag, the name of the person placing the tag, how he/she many be contacted, and the date and time the tag was placed.
The following are some images of lock out tag out material that can be used for locking out the work area:
Suitable blocks are another important safety device for making a piece of equipment safe to be repaired or serviced. Blocks must be placed under raised dies, lifts, or any equipment that might inadvertently move by sliding, falling, or rolling. Blocks, special brackets, or special stands, such as those commonly used under raised vehicles, must be available at all times. Another form of blocking is the placement of a blind. A blind is a disk of metal placed in a pipe to ensure that no air or other substance will pass through that point if the system is accidentally activated. Before installing blinds or blocks, bleed down steam, air or hydraulic lines to get rid of any pressure. Coiled springs, spring loaded devices or suspended loads must also be released so that their stored energy will not result in inadvertent movement.
