Mathews Company Limited Warranty for Whole Goods

Except as otherwise set forth herein, Mathews Company (Seller) warrants that the equipment supplied by Seller to Buyer shall be free from defects in materials and workmanship when properly installed and operated under normal conditions and in accordance with all applicable instruction manuals. This limited warranty shall expire two (2) years from the date of shipment from Seller's Crystal Lake, Illinois, U.S.A. facility. In addition, for a period of five (5) years from the date of shipment from Seller's Crystal Lake, Illinois, U.S.A. facility, Seller will re-balance M-C Shredder rotors for Buyer at Seller’s Crystal Lake, Illinois, U.S.A. facility, provided that the rotors did not become unbalanced through abnormal use by Buyer or were not damaged by Buyer in any way.

To obtain consideration under this limited warranty, Buyer must first notify Seller in Crystal Lake, Illinois, U.S.A., stating in what respects the equipment is believed by Buyer to be defective and providing a list of the parts at issue. Additionally, Buyer must complete a warranty request form stating the machine serial number. Upon receipt by Seller of such notice from Buyer, Buyer may receive authorization from Seller to return the parts. If parts are to be scrapped locally, Buyer will be so advised. If Seller provides Buyer with authorization to return the parts, Buyer shall return such parts to Seller’s facility in Crystal Lake, Illinois, U.S.A., transportation prepaid, for examination by Seller. No parts shall be returned to Seller unless Buyer first obtains a return authorization number from Seller. If, in Seller’s sole judgment, the parts returned by Buyer are defective and covered under this limited warranty, Seller shall have the option of repairing, rebuilding or replacing such parts. This limited warranty shall not apply to parts which, in Seller’s sole judgment, have been the subject of negligence, abuse, accident, misapplication, tampering, alteration, improper adjustment, or electrical problems caused by low voltage conditions; nor shall it apply to consumables, such as belts; nor shall it apply to parts damaged by acts of God, war or civil insurrection, acts of terrorism, improper installation, operation, maintenance or storage, or other than normal application, use or service, including, without limitation, operational failures caused by corrosion, erosion, wear and tear, rust or other foreign materials in the system in which they are utilized.

Failure to give notice within the warranty period shall be a waiver of this limited warranty and no assistance or other action thereafter taken by Seller shall be deemed to extend or revive the warranty period. This limited warranty covers only whole goods and shall not apply to replacement parts or upgrade kits. A separate warranty statement published by Seller covers the warranty on parts and upgrade kits. This limited warranty shall not apply to any products, parts, accessories or other equipment not manufactured by Seller, provided that Seller, upon request by Buyer, shall advise Buyer of any warranties known to Seller that may be offered by the manufacturer of such equipment. This limited warranty shall not cover, and Seller shall not under any circumstances be liable for, damages for injuries to persons or property; loss of crops or other products; losses caused by harvest delays; loss of profits; loss of use; cost of rental equipment; expenses of labor, travel or other items relating to the removal or replacement of defective parts; damages resulting from the removal of defective parts or the installation of repaired, rebuilt or replaced parts; expenses relating to the transportation of parts to and from Seller’s facility; any consequential, incidental, contingent or special damages, whether arising in contract, in tort or under statute; or any other damages or expenses not agreed upon in writing by Seller, even if Seller has been advised of the potential for any such damages or expenses.

THIS LIMITED WARRANTY IS IN LIEU OF ALL WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, ALL WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE OR USE. No person is authorized to give any other warranty or to assume any other liability on Seller’s behalf.

The following instructions pertain to dryers built and certified to the CSA 3.8 2021 standard and is meant for qualified personnel only.

Gas Installation

The equipment shall be installed in accordance with the Natural Gas and Propane Installation Code, CSA B149.1 and the Propane Storage and Handling Code, CSA B149.2, or applicable provincial regulations, which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.

Installation of Fuel Piping

LP

LP installations shall conform to the following:

• The LP supplier must install the appropriate supply line in Type K copper underground from the supply tank to the edge of the concrete pad as per B149.1,2. This is solely the responsibility of the fuel supplier under the Z code.

• If an underground installation is not preferred, a continuous run of black iron and copper can be installed above the concrete.

• A continuous piece of type K copper can be used through or under the concrete provided that it is protected by sleeves or in a channel. A coil at the final connection can be used as an expansion provided it is not kinked.

• A typical installation on LPG starts with the Type K copper ending at the pad followed by a swing joint attached to lengths of SK80 piping fittings with resign coated hanger brackets attached to the concrete to avoid galvanic reaction. The final connection shall have a swing joint or category 1 expansion hose no longer than 3 feet in length followed by a SK 80 union to facilitate removal and final attachment to ball valve supplied by manufacturer.

Pertinent code clauses pertaining to basic installation:

• B149.1 6.16.3 piping and tubing shall be mounted and braced to provide for vibration, contraction or jarring.

• B149.1 6.14.1 a defective section of piping or tubing shall be replaced

• B149.1 6.14.5 piping shall not be field bent

• B149.1 6.9.6 joint sealant shall conform to Can/ulc 642 and shall be applied to male threads of the pipe

• B149.1 6.8.1 piping ends shall be free of cuttings and burs

• B149.1 6.8.2 piping shall be reamed

• B149.1 6.14.2 bushings shall not be nested

• B149.1 6.11.9 provide effective swing joints at manifolds to accommodate for expansion and contraction and ground level and at appliance level

• B149.1 6.20.5 metallic gas hose can be used in commercial or industrial environments where vibrations, expansions or contractions are present

• B149.1 6.20.3 gas hose for a PERMANENT installation shall not exceed 10 feet in length a permanent installation consists of an appliance hard wired to the electrical source a generator or PTO is considered temporary and can be moved

• B149.1 6.16.1 piping exposed to atmospheres shall be painted or coated

• B149.1 6.17.1 standard practice paint Liquid propane piping RED. B149.1 union should be installed to facilitate removal of piping if required

• B149.1 6.2.2 a fitting used shall with steel shall be malleable iron or steel

• B149.1 hydrostatic relief devices shall be used where liquid propane can be trapped and vented to a safe location

• B149.1 6.4.3 schedule 80 piping and fittings shall be used on liquid phase systems or over 125 psi

• B149.1 6.16.6 when piping or tubing is run in a sleeve the sleeve shall be of a type of material that will avoid galvanic reaction and protect the tubing

• B149.1 6.15.10 when tubing is laid under pavement and re-enters above ground a sleeve shall be used to protect the tubing through the concrete

• B149.1 6.2.15 plastic pipe shall not be used in a liquid piping system

• B149.1 6.4.17 close nipples, street elbow or street T shall not be used

• B149.1 6.2.5 flare nuts shall not be externally forged or machined and shall be of the forged type

• B149.1 6.2.4 copper shall be of the type K,G or L

• B149.1 6.9.9 a joint in seamless copper shall be of a flared type

NG

NG installations shall conform to the following:

• Typically a gas meter is installed 15 feet away from the grain dryer. A pipe can be extended with a union to the pavement level with a swing joint before attaching to the pavement as the meter can move independently from the concrete pad. This can then be followed by a length of pipe to an additional swing joint, or type 2 gas hose, acting as a swing joint attached to the final connection with a union. There shall be a shut off valve after the union.

Pertinent code clauses pertaining to basic installation:

• B149.1 6.4.17 close nipples, street elbow or street T shall not be used

• B149.1 union should be installed to facilitate removal of piping if required.

• B149.1 6.2.2 a fitting used shall with steel shall be malleable iron or steel

• B149.1 6.20.3 gas hose for a PERMANENT installation shall not exceed 10 feet in length a permanent installation consists of an appliance hard wired to the electrical source a generator or PTO is considered temporary and can be moved.

• B149.1 6.16.1 piping exposed to atmospheres shall be painted or coated yellow

• B149.1 6.16.3 piping and tubing shall be mounted and braced to provide for vibration, contraction or jarring.

• B149.1 6.14.1 a defective section of piping or tubing shall be replaced

• B149.1 6.14.5 piping shall not be field bent

• B149.1 6.9.6 joint sealant shall conform to Can/ulc 642 and shall be applied to male threads of the pipe

• B149.1 6.8.1 piping ends shall be free of cuttings and burs

• B149.1 6.8.2 piping shall be reamed

• B149.1 6.14.2 Bushings shall not be nested

• B149.1 6.11.9 provide effective swing joints at manifolds to accommodate for expansion and contraction and ground level and at appliance level

• B149.1 6.20.5 metallic gas hose can be used in commercial or industrial environments where vibrations, expansions or contractions are present.

• B149.1 6.20.3 gas hose for a PERMANENT installation shall not exceed 10 feet in length a permanent installation consists of an appliance hard wired to the electrical source a generator or PTO is considered temporary and can be moved.

• B149.1 6.4.3 schedule 40 piping and fittings shall be used on systems or under 125 psi

Field Installed Wiring

Dryer wiring from the branch circuit is included in the field installation wiring schematic. All wiring is to be in accordance with the Canadian Electrical Code, Part1, CSA C22.1.

This dryer is not service rated, and will require an additional overload protection device in front of the dryer for adequate protection. All wiring is to be in accordance with the Canadian Electrical Code, Part1, CSA C22.1.

The electrical installation should follow domestic NEC standards.

Minimum wire size is 18awg unless specified.

All wire gauges shown on the drawing are recommended only! Electrical contractor should follow the local codes and authority having jurisdiction.

All wire sizing based on copper conductors, but aluminum may be used if sized correctly.

This dryer is not service rated. Proper service protection is recommended.

Pressure Testing

The dryer and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5 kPa). The dryer must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.5 kPa).

Min/Max Gas Supply

Pressures Refer to the dryer rating plate for determining the minimum gas supply pressure for obtaining the maximum gas capacity for which this dryer is specified.

Leak Tests

Gas leak tests need to be performed during dryer start-up to verify the gas-tightness of the dryer's components and piping under normal operating conditions. During the tests, observations should be made at the gauges attached to the unit. If the gauges are reading 0, there could be a leak as the system is normally under pressure. A soapy water solution can be used to check fittings for leaks while the unit is in operation by a 60/40 mixture of soap and water with a brush. Gauges can be installed before and after the safety shutoff valves. The unit can be bumped and shut off. If the gauges return to 0, a leak could be present.

Gas Tightness Check

Safety shut off valves need to be tested for tightness annually. To test, inlet connections should be soap tested up to the safety shut-off valves or solenoid. From there, install gauges in between the safety shut-off valves or solenoids. Fire up the dryer with the firing valve closed. The firing valve is the valve located just before the burner. The safety shut-off valves will open, pressurizing the system and allowing the gauges to read pressure. The dryer will fail on ignition and the gauges should remain pressurized. If the gauges drop in pressure with the firing valve closed, that would indicate a potential leak. If the gauges return to 0 soap testing should commence on all fittings.

Emergency Manual Shut-off Valve

The gas piping installer must install a manual emergency shutoff valve in an appropriate location that allows access to this valve to shut off the fuel to the dryer in case of a fire or explosion at the dryer. This installation must conform to the following:

• B149.1 6.18.2 a readily accessible manual shutoff valve must be installed as per below. Either one is acceptable.

• In the drop or rise, as close as possible to the valve train of a commercial or industrial valve train.

• In the horizontal piping of the drop or riser and the appliance valve train within 2 feet of the appliance.

Warning

If the information in the operations manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

What To Do If You Smell Gas

• Do not try to light any appliance

• Extinguish any open flames

• Do not touch any electrical switch

• Immediately call your gas supplier. Follow the gas supplier’s instructions

• If you cannot reach your gas supplier, call the fire department.

• Installation and service must be performed by a qualified installer, service agency or the gas supplier

• Improper installations, adjustment, alteration, service or maintenance can cause property damage, injury of death. Read the installation, operating, and maintenance instructions thoroughly before installing or servicing this equipment.

For Your Safety

The use and storage of gasoline and other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous. Refer to codes and standards CSA 3.8, 4.29.7.

Venting

The following specifications need to be followed in regards to venting:

• B149.1 5.4.1 hydrostats must be vented to a “safe location”

• B149.1 5.4.2 hydrostats may be vented into a common header provided the cross sectional area is equal to the cross sectional area of the multiple vents IE: 2 /12 “ hydrostats must vent into a 1” line

• B149.1 5.5.6 vents must be designed not to allow water, insects or debris simply put use a drip and a 90 at the end of the pipe with a screen

• B149.1 5.5.9 vents shall terminate 10 feet from mechanical air intake

• B149.1 5.5.8 vents shall not be capped off or made in-operable

• B149.1 5.5.4 vents shall not be reduced in size as to impede on the performance.

Overview

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".

Grain Drying Principles

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:

Air

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).

Heat

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.

Time

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.

Owner / Operator Notes

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.

Warranty Registration

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.

Model / Serial Number / Specifications

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:

Safety

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:

1. Keep ALL guards, access doors, covers, safety decals, and safety devices in place and securely fastened. Never operate the dryer while guards are removed.

2. Keep all untrained personnel away from system components and control panels at all times.

3. Never attempt to operate the unit by jumping or otherwise bypassing any safety devices.

4. 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.

5. Lock out power before removing guards, access doors, and covers.

6. Keep hands, feet and clothing away from all rotating parts.

7. Electrical repairs should be performed by trained and qualified personnel only. Failure to follow safe electrical procedures can result in serious injury.

8. 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.

9. Routinely check for any gas leaks.

10. Do not allow children or bystanders to be near the grain dryer or grain handling machinery while it is operating.

11. Do not operate the grain dryer without all safety shields in place and secure.

Lock-out / Tag-out Requirements

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:

1. 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.

2. 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.

3. 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.

4. Any mechanism under load or pressure, such as springs, should be released and blocked.

5. All energy sources that could activate the machine must be locked-out.

6. The main valve or main electrical disconnect must be tested to be sure that the power to the machine is off.

7. 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.

8. Return disconnects and operating controls to the OFF position after each test.

9. 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:

Blocks

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.

The performance figures and capacities referenced herein are only estimates, based on calculated simulations, and do not constitute express or implied warranties. Many factors influence the grain drying process, including ambient temperature, relative humidity, grain variety, grain quality, grain temperature, dryer operating temperatures, dryer add-ons and accessories, and dryer condition, maintenance and operation. Specifications and capacities are subject ot change, with or without notice.

Specifications and Capacities

All current published machine specifications and capacities can be found in our Delta Series product brochure as follows:

Delta Series Brochure, April 2024 (BRO-D01-0424)

Dimensional Drawings

Layout drawings for different models are accessible at the links below:

• D600 / D600h Layout Drawing

• D900 / D900h Layout Drawing

• D1200 / D1200h Layout Drawing

• D1500 / D1500h Layout Drawing

• D1800 / D1800h Layout Drawing

• D2100 / D2100h Layout Drawing

• D2400 / D2400h Layout Drawing

• D3200 / D3200h Layout Drawing

The performance figures and capacities referenced herein are only estimates, based on calculated simulations, and do not constitute express or implied warranties. Many factors influence the grain drying process, including ambient temperature, relative humidity, grain variety, grain quality, grain temperature, dryer operating temperatures, dryer add-ons and accessories, and dryer condition, maintenance and operation. Specifications and capacities are subject ot change, with or without notice.

Specifications and Capacities

All current published machine specifications and capacities can be found in our Fusion Series product brochure as follows:

Fusion Series Brochure, October 2023 (BRO-F01-1023)

Dimensional Drawings

Layout drawings for different models are accessible at the links below:

• F320 Layout Drawing

• F320x Layout Drawing

• F480 Layout Drawing

• F480x Layout Drawing

• F660 Layout Drawing

• F660x Layout Drawing

The performance figures and capacities referenced herein are only estimates, based on calculated simulations, and do not constitute express or implied warranties. Many factors influence the grain drying process, including ambient temperature, relative humidity, grain variety, grain quality, grain temperature, dryer operating temperatures, dryer add-ons and accessories, and dryer condition, maintenance and operation. Specifications and capacities are subject ot change, with or without notice.

Specifications and Capacities

All current published machine specifications and capacities can be found in our Legacy Series product brochure as follows:

Dimensional Drawings

Layout drawings for different models are accessible at the links below:

The performance figures and capacities referenced herein are only estimates, based on calculated simulations, and do not constitute express or implied warranties. Many factors influence the grain drying process, including ambient temperature, relative humidity, grain variety, grain quality, grain temperature, dryer operating temperatures, dryer add-ons and accessories, and dryer condition, maintenance and operation. Specifications and capacities are subject ot change, with or without notice.

Specifications and Capacities

All current published machine specifications and capacities can be found in our Modular Tower Series product brochure as follows:

Dimensional Drawings

Layout drawings for different models are accessible at the links below:

The performance figures and capacities referenced herein are only estimates, based on calculated simulations, and do not constitute express or implied warranties. Many factors influence the grain drying process, including ambient temperature, relative humidity, grain variety, grain quality, grain temperature, dryer operating temperatures, dryer add-ons and accessories, and dryer condition, maintenance and operation. Specifications and capacities are subject ot change, with or without notice.

Specifications and Capacities

All current published machine specifications and capacities can be found in our ECO Series product brochure as follows:

Dimensional Drawings

Layout drawings for different models are accessible at the links below:

The performance figures and capacities referenced herein are only estimates, based on calculated simulations, and do not constitute express or implied warranties. Many factors influence the grain drying process, including ambient temperature, relative humidity, grain variety, grain quality, grain temperature, dryer operating temperatures, dryer add-ons and accessories, and dryer condition, maintenance and operation. Specifications and capacities are subject ot change, with or without notice.

Specifications and Capacities

All current published machine specifications and capacities can be found in our Commercial Tower Series product brochure as follows:

Commercial Tower Series Brochure, October 2023 (BRO-18T01-1023)

Dimensional Drawings

Layout drawings for different models are accessible at the links below:

• 3000 Layout Drawing

• 3500 Layout Drawing

• 4000 Layout Drawing

• 4800 Layout Drawing

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.

Moisture Sensor

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.

Discharge Limit Switch

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.

Moisture Sampler Auger Motor

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.

High Limit Switch

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.

Air Pressure Switch

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.

Ignition Transformer

The Ignition Transformer supplies the high voltage to the spark plug to ignite the burner.

Flame Controller

The Flame Controller is a compact, microprocessor base, modular burner management system designed to provide automatic ignition and continuous flame monitoring.

Amplifier

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.

Programmer Module

This module, when used with the Fireye Control, provide diagnostics through LED's and alpha-numeric display.

Fenwal Ignition Board

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 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.

LPG Gas Train (Domestic)

Natural Gas Train (Domestic)

LPG Gas Train (CGA)

Natural Gas Train (CGA)

Control Valve

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.

Control Valve Actuator

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.

Strainer

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.

Solenoid Valve

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.

Pressure Relief Valve

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.

Low / High Gas Pressure Switches (CE equipped machines only)

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.

Pressure Regulator

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.

Manual Hand Valve

The purpose of a Manual Hand Valve is to manually open and close various portion of the gas train for maintenance purposes.

Valve Proving Solenoid

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 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 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.

Rotary (Bin) Fill Switch

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.

Plenum RTD

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.

Mid-Grain RTD Assembly

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.

Proximity Switch

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.

Control Power Transformer

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.

Infeed DM510 Moisture Sensor (Optional)

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

Human Machine Interface (HMI) Touch Screen

The HMI Touch Screens are where all Pinnacle 20|20 controls and related information is displayed. See the Pinnacle 20|20 Controls Manual for more information.

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.

Spark Igniter

The Spark Igniter receives high voltage current from the ignition board and sparks to provide direct spark ignition for the burner.

Flame Sense Probe(s)

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.

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.

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 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:

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 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.

During the course of the drying season, it is important to keep the dryer operating at its peak efficiency by performing periodic maintenance and cleaning of the equipment. When the ducts of a dryer are clean, the air moves freely through the grain walls. As debris builds up inside the dryer, this can result in the combustion of debris which may lead to a fire. As such, cleaning of the grain dryer should be performed on a daily basis. Try to keep the surroundings of the dryer clean at all times to prevent breeding grounds for insects and other pests

The recommended method for cleaning the dryer is air or water, preferably from a compressed-air source or even a vacuum, however, using a non-metallic brush or broom also works. Be aware that if using water to clean the dryer, the combination of water and residue can form a paste, making the surfaces sticky and more difficult to remove.

Outer Screens

For screened dryers, the outer screens of the dryer need to be kept as clean as possible for safety and performance reasons. The perforation of the screens allow heated air, saturated with moisture form the grain, to exit to the atmosphere. This process also crates a damp environment on the outside of the screens, creating a buildup of fines and dust which reduces air flow resulting in a decrease of capacity and higher cost of drying.

Cleaning of the outer screens can be done during the drying process, but it may temporarily affect the discharge capacity if water is used. The preferred way to clean is to brush down the screens while grain is being dried as this will help push material out of the perforations in the screens. The discharge rate should increase after cleaning of the dryer because more surface area is now being exposed to the heated air passing through the gain columns.

Inner Screens

For screened dryers, the procedure for cleaning the inner screens is similar to that of cleaning the outer screens. When cleaning the inside of the dyer, the use of a protective breathing mask is recommended. Using a non-metallic brush or broom, sweep the inner screens and channel rings going from top to bottom. Check the burner to make sure the wires look good and the burner is clean of debris. Sweep and floors and remove and debris.

Inverted Roof

For tower dryers, be sure to check and clean the inverted roof by removing the inverted roof panel for access. Cleaning should be done daily and includes vacuuming all debris inside the inverted cone and on top of the shelf where the inverted cone attaches.

Duct Openings

The duct openings of mixed flow dryers need to be kept as clean as possible for safety and performance reasons. These openings, facing the outside of the dryer, allow heated air, saturated with moisture from the grain, to exit to the atmosphere. This process also creates a damp environment on the outside of the ducts, creating a buildup of fines and dust which reduces air flow resulting in a decrease of capacity and higher cost of drying.

Cleaning of the outer ducts can be done during the drying process, but it may temporarily affect the discharge capacity if water is used. The inside ducts will need to be done when the dryer is off and locked out.

Inside Plenum

When cleaning the inside of the dryer, the use of a protective breathing mask is recommended. Using a non-metallic brush or broom, sweep the inner panels. Check the burner to make sure the wires look good and the burner is clean of debris. Sweep the plenum floors and remove any debris.

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 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.

Control Power Transformer

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.

Variable Frequency Drive

The Variable Frequency Drive is used to control the speed of the discharge metering/sweep system and is controlled directly by the PLC.

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.

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

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

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.

The following pre-season checks are intended to prepare your dryer for operation and bring any issues that may be present to your attention. Performing these check no later than 1-2 months before you intend to use the machine is recommended so that proper service can be performed and/or replacement parts can be ready before the harvest season begins.

Grain Fill & Discharge System

The following procedure will guide you through the grain fill and discharge system pre-season check. If the results of any of the following procedures are not consistent with what you should observe, service and/ or replacement parts may be required. Contact your dealer or refer to the Troubleshooting section of this manual for more information.

1. Turn all of the circuit breakers in the cabinet on. Turn the electric power supply to the dryer on.

2. On the Remote Control Cabinet, turn Power On through one of the HMI's by pressing the Control Power TURN ON button on the Controls page. The button should read ON and be illuminated green with a surrounding glow.

3. On the same Controls page, press the Takeaway START button. For level auger equipped dryers, pressing Takeaway START button should make the level auger start immediately.

4. On the same Controls page, press the Discharge START button. For profile style dryers, the discharge auger or conveyor (if equipped) should start immediately.

5. On the same Controls page, press the Metering START button. The metering rolls for profile dyers and the sweep arms for tower dryers should start turning.

Belt Adjustment

All belts will eventually seat themselves in the pulley grooves and the tension may have to be re-adjusted. If the belts squeal when the motor starts, they are not tight enough. Never apply belt dressing as this will damage the belt and cause early belt failure.

Discharge Auger Belt

To adjust the belt tension on the discharge auger, if equipped, loosen the unload auger motor mounting locknuts. Turn the locknut on the J-bolt to adjust the tension.

Level Auger Belt

Adjust the belt tension for the level auger, if equipped, by loosening the locknuts and raising the motor mount plate evenly with the four adjusting nuts, and then tighten the locknuts

Fans & Burners

The following procedure will guide you through the fan and burner system pre-season check. Perform this procedure for all fans and burners installed on the machine. If the results of any of the following procedures are not consistent with what you should observe, service and/or replacement parts may be required. Contact your dealer or refer to the Troubleshooting section of this manual for more information.

1. Turn the electric power supply to the dryer off.

2. Close the burner gas manifold hand valve for each burner (handle 90° relative to the piping).

3. In order to test the burners without grain in the dryer, the air pressure switches will need to be jumpered. To do this, place a jumper between terminal 343 (power) and 912 (air pressure switch 1) to jumper air pressure switch 1. If equipped with additional air pressure switches, place the jumper between 343 and the following terminals respectively: 922, 932, 942, 952, 962, 972 and finally, 982 in order to jumper air pressure switches 2 through 8.

1. 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.

2. Turn the electric power supply to the dryer on.

3. On the Remote Control Cabinet, turn Power On through one of the HMI's by pressing the Control Power TURN ON button on the Controls page. The button should read ON and be illuminated green with a surrounding glow.

4. On the same Controls page, press the Fan START button. The Fan should start immediately and the air pressure light should illuminate.

5. Open the manual gas valve 1/4 of the way open to control the fuel flow to the burner once it has been lit

6. On the same Controls page, press the Burner START button. The burner should go through it's sequence and light.

7. Let the burner run for at least two minutes to verify that it is properly operating.

The safety circuit can be diagnosed by using a voltmeter to determine which component(s) is keeping the safety circuit from closing. Below will guide you in checking the following components, if equipped: Fan protectors, high limits, linear limits, high gas pressure switches, and plenum door switches.

Fan Protectors

The Safety Circuit can also be diagnosed by using a DC voltmeter and the dryer schematic. Using the schematic as a guide, use the voltmeter to look for 24 vdc at terminals in the Low Voltage Cabinet. Be sure the Voltmeter is first set to read DC Voltage which is depicted with a straight line next to the V as opposed to a wavy line which depicts AC voltage. Take the black lead of the Voltmeter and place it in Terminal 320 (TB320). Next, move the red lead of the voltmeter to the first terminal of the Safety Circuit (TB341), followed in order by TB401 as shown below until 24 Volts no longer appears and 0 Volts measures on the Voltmeter instead.

• TB341 Beginning of the safety circuit after circuit breaker #341

• TB401 Fan protector #1

• TB402 Fan protector #2 (if equipped)

• TB403 Fan protector #3 (if equipped)

• TB404 Fan protector #4 (if equipped)

• TB405 Fan protector #5 (if equipped)

• TB406 Fan protector #6 (if equipped)

• TB407 Fan protector #7 (if equipped)

• TB408Fan protector #8 (if equipped)

High Limits

• TB421 High limit #1

• TB422 High limit #2 (if equipped)

• TB423 High limit #3 (if equipped)

• TB424 High limit #4 (if equipped)

• TB425 High limit #5 (if equipped)

• TB426 High limit #6 (if equipped)

• TB427 High limit #7 (if equipped)

• TB428 High limit #8 (if equipped)

Linear Limits

• TB431 Linear Limit #1 (if equipped)

• TB432 Linear Limit #2 (if equipped)

• TB433 Linear Limit #3 (if equipped)

• TB434 Linear Limit #4 (if equipped)

• TB435 Linear Limit #5 (if equipped)

• TB436 Linear Limit #6 (if equipped)

High Gas Pressure Switches

If the dryer is an export model dryer, the following items will be included in the Safety Circuit.

• TB451 High gas pressure switch #1

• TB452 High gas pressure switch #2

• TB453 High gas pressure switch #3

• TB454 High gas pressure switch #4

• TB455 High gas pressure switch #5

• TB456 High gas pressure switch #6

• TB457 High gas pressure switch #7

• TB458 High gas pressure switch #8

Although the following items are not in series with the previously mentioned items, tripping any of these items will disengage the safety circuit and produce a red warning screen.

Plenum Door Switches

If the dryer is an export model, the following items, if tripped will disengage the safety circuit.

• TB491 Plenum door #1 safety switch

• TB492 Plenum door #2 safety switch

• TB493 Plenum door #3 safety switch

• TB494 Plenum door #4 safety switch

• TB495 Plenum door #5 safety switch

• TB496 Plenum door #6 safety switch

• TB497 Plenum door #7 safety switch

• TB498 Plenum door #8 safety switch

Before diagnosing the Safety Circuit, it is recommended to have a good understanding of the Pinnacle 20|20 Control.

The Pinnacle 20|20 Control features a tab on the home page titled Troubleshooting. Pressing this tab populates different options. One of these options is the Safety Circuit tab. Pressing the Safety Circuit tab will bring up a page that visually illustrates the Safety Circuit and all associated components. To troubleshoot the disruption of the Safety Circuit, look for the component on the page that has a grayed out globe next to it as opposed to a green globe. Green globes indicate that the component and that particular part of the Safety Circuit is good. A grayed out globe indicates that the break in the Safety Circuit is associated with that particular component.

One thing to note is that the High Limits and Motor Overloads are wired in series respectively. Meaning, if one of the High Limits or Motor Overloads are tripped, all the High Limits or Motor Overloads proceeding the tripped one will appear on the Safety Circuit screen tripped as well. So the first High Limit or Motor Overload that appears with the grayed out globe should be addressed first as it is very likely that once addressed, all that follow may be good as well.

For more information on diagnosing the Safety Circuit via the HMI, refer to the documentation on the Pinnacle 20|20 control system.

After the drying season, the following steps are recommended to put your dryer into a condition suitable for an extended period of non-operational time.

1. Disconnect all power and turn off the gas supply.

2. Perform one final cleaning of the dryer inside and out as previously explained in the Seasonal Cleaning section of the manual. Use a power washer on the outer panels if dirt has built up in hard-to-reach areas.

3. Open the plenum access doors and sweep out all foreign material.

4. Visually inspect all bearings to see if there is indication of one in need of replacement. Inspect the drive belts and chains and note if any are in need of replacement or lubrication.

5. Grease all fan motor bearings and fan bearings as recommended in the Lubrication section of the manual.

6. Use a vacuum cleaner to remove any dirt from the control cabinet.

The safety of your dryer is in the hands of the safety circuit. These are a series of components that are tied together. If one fails, the system will shutdown insuring the safety of your grain dryer.

Safety Circuit Overview

The contacts for incoming hot and neutral are found in the High Voltage cabinet.

The 120 volt input power to the dryer circuit for dryer controls comes from the bottom side of the transformer and runs to the top of the 8 amp mini-breaker. This breaker should be turned off and the voltage should be checked before turning the mini-breaker on. If the voltage reads anything outside of 125-volts, the supply voltage needs to be checked before powering on the mini-breaker.

Next to the mini breaker is a neutral block, which feeds all neutrals throughout the entire dryer. This neutral is connected to the neutral from the secondary side of the transformer that is standard equipment.

The incoming neutral line is connected to TB5 (white wire) and the hot line is on TB33 (after circuit breaker). The incoming 120-volt supply is an 8 amp mini-breaker.

The Safety Circuit can be viewed on page 4 and 5 of the electrical schematics. Page 4 is the Dryer Control or Fault Control portion of the Safety Circuit while page 5 of the electrical schematics contains the Dryer Safety, or Human Safety portion of the Safety Circuit. Components associated with the Dryer Control, or Fault Control portion of the Safety Circuit include the Fan Motor Overloads, High Limit Switches Linear Limits (if equipped) and Gas Pressure Switches for export model dryers. The components associated with the Dryer Safety, or Human Safety portion of the Safety Circuit are the E-Stops, Safety Relay and Plenum Door Switches for export dryers.

There are two ways to troubleshoot the Safety Circuit. One is through the Safety Circuit page of the Pinnacle 20|20 control while the other involves use of a voltmeter.

Safety Circuit Schematic

The first part of the safety circuit is the Dryer Control or Fault Control portion of the Safety Circuit. Refer to page 4 of the electrical schematics to see this portion of the safety circuit that matches exactly to your particular dryer.

The second part of the safety circuit will help diagnose a dryer shut down. This is the Dryer Safety or Human Safety portion of the Safety Circuit. See page 5 of the electrical schematics to see this portion of the safety circuit that matches exactly to your particular dryer.

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.

Emergency Stops, also known as "E-Stops" come installed throughout the dryer. There may also be “Customer E-Stop”, installed by other equipped that is tied into the dryer, that if tripped, will disengage the safety circuit. To check, visually inspect if any of these red E-Stop buttons are depressed:

• Remote cabinet

• Low voltage cabinet

• High voltage cabinet

• Customer E-Stop (Optional, provided by customer)

Customer connections are for remote equipment and are used to interface the grain dryer with fill and takeaway equipment. The grain dryer does not supply power for these interfaces. An auxiliary power source should be used to power customer equipment.

Fill Customer Connections

• F1-F2 = Fill equipment status

• F3-F4 = Fill 2 dry contacts

• F5-F6 = Fill 1 dry contacts

F1-F2

F1 and F2 is a signal to the PLC confirming that customer fill equipment is not in a fault condition and can be started.

F3-F4

F3 and F4 are a dry set of normally open contacts that close when the dryer fill cycle begins. When this closes (when the call for grain happens), the dryer will start all the customer’s equipment that is associated with Fill 2. It is the last of the fill equipment to stop.

F5-F6

F5 and F6 are a dry set of normally open contacts that close when the dryer fill cycle begins. When this closes (after the delay following the call for grain expires), the dryer will start all the customer’s equipment that is associated with Fill 1. Fill 1 equipment will stop after the call for grain but before fill 2 equipment stops.

Takeaway Customer Connections

• T1-T2 = Takeaway equipment status

• T3-T4 = Takeaway 2 dry contacts

• T5-T6 = Takeaway 1 dry contacts

T1-T2

T1 and T2 is a signal to the PLC confirming that customer takeaway equipment is not in a fault condition and can be started.

T3-T4

T3 and T4 are a dry set of normally open contacts that close when the dryer Takeaway START button is pressed. This starts all customer’s equipment associated with Takeaway 2 immediately after the button is pressed. Equipment tied to this signal will stop after the Takeaway STOP button is pressed and the Takeaway 2 Stop Delay has elapsed.

T5-T6

T5 and T6 are a dry set of normally open contacts that close when the dryer Takeaway START button is pressed and the Takeaway 1 Start Delay has elapsed. This starts all customer’s equipment associated with Takeaway 1. Equipment tied to this signal will stop immediately after the Takeaway STOP button is pressed.

E-Stop Customer Connections

• E1-E2 = Customer E-Stop status

• E3-E4 = Safety Relay Circuit 1

• E5-E6 = Safety Relay Circuit 2

E1-E2

E1 and E2 is a signal to the PLC confirming that all customer equipment included in the safety circuit are satisfied

E3-E4

E3 and E4 breaks the 24V signal and initiates an emergency shutdown of the dryer.

E5-E6

E5 and E6 breaks the 24V signal and initiates an emergency shutdown of the dryer.

Listed below are common issues that may occur while operating your Mathews Company grain dryer along with suggestions on what to do.

Maintaining proper lubrication of all moving components of your dryer is key to its efficient and safe operation. The following table below outlines all recommended lubrication. Note that some of the items may not be applicable based on configured options, model or accessories.

Lubrication Table for Profile Style Dryers

Lubrication Table for Tower Style Dryers

Fault Code Description

Listed below are the fault codes and associated descriptions of the faults. Also provided are a list of actions to help resolve the issues.

Code 0001: OVERCURRENT (2310)

Code 0002: DC OVERVOLT (3210)

Code 0003: DEV OVERTEMP (4210)

Code 0004: SHORT CIRC (2340)

Code 0006: DC UNDERVOLT (3220)

Code 0007: AI1 LOSS (8110) (programmable fault function 3001, 3021)

Code 0008: AI2 LOSS (8110) (programmable fault function 3001, 3022)

Code 0009: MOT OVERTEMP (4310) (programmable fault function 3005...3009/3504)

Code 0010: PANEL LOSS (5300) (programmable fault function 3002)

Code 0011: ID RUN FAIL (FF84)

Code 0012: MOTOR STALL (7121) (programmable fault function 3010...3012)

Code 0014: EXT FAULT 1 (9000) (programmable fault function 3003)

Code 0015: EXT FAULT 2 (9001) (programmable fault function 3004)

Code 0016: EXT FAULT 2 (2330) (programmable fault function 3017)

Code 0017: UNDERLOAD (FF6A) (programmable fault function 3013...3015)

Code 0018: THERM FAIL (5210)

Code 0021: CURR MEAS (2211)

Code 0022: SUPPLY PHASE (3130) (programmable fault function 3016)

Code 0023: ENCODER ERR (7301) 5003

Code 0024: OVERSPEED (7310) 0306 bit 7

Code 0027: CONFIG FILE (630F)

Code 0028: SERIAL 1 ERR (7510) (programmable fault function 3018, 3019)

Code 0029: EFB CON FILE (6306) (programmable fault function 3018, 3019)

Code 0030: FORCE TRIP (FF90)

Code 0034: MOTOR PHASE (FF56)

Code 0035: OUTP WIRING (FF95)

Code 0036: INCOMPATIBLE SW (630F)

Code 0037: CB OVERTEMP (4110)

Code 0044: SAFE TORQUE OFF (FFA0)

Code 0045: STO1 LOST (FFA1)

Code 0046: STO2 LOST (FFA2)

Code 0101: SERF CORRUPT (FF55)

Code 0103: SERF MACRO (FF55)

Code 0201: DSP T1 OVERLOAD (6100)

Code 0202: DSP T2 OVERLOAD (6100)

Code 0203: DSP T3 OVERLOAD (6100)

Code 0204: DSP STACK ERROR (6100)

Code 1000: PAR HZRPM (6320)

Code 1003: PAR AI SCALE (6320)

Code 1004: PAR AO SCALE (6320)

Code 1005: PAR PCU 2 (6320)

Code 1006: PAR EXT RO (6320) (programmable fault function 3027)

Code 1007: PAR FBUSMISS (6320)

Code 1009: PAR PCU 1 (6320)

Code 1015: PAR USER U/F (6320)

Code 1017: PAR SETUP 1 (6320)

Soft Starter Fault Codes

In the event that your dryer comes equipped with a soft starter and you run into an error code, listed below are the display faults that will show up on the main display. Provided below are the error codes and associated recovery suggestions.

Code SF20: Software Fault

Code SF34: Shunt Fault

Code SF44: By-pass Open

Code SF50: Soft starter thermal overload

Code EF14: Phase loss fault

Code EF20: Bad network quality

Code EF34: Current lost fault

Code EF40: Fieldbus fault

Code EF50: Low supply voltage

Code EF64: High current fault