The Overview page is the second page of the three Operation pages. The Overview page provides the operator with a full rendering of the dryer that, with the use of different graphics, illustrates what components of the dryer are operating. The Overview page is unique to match the particular dryer that is loaded on the Pinnacle 20|20. The images below show the different Overview pages for a Legacy, Tower, ECO, and Delta dryer. In the Overview pages, shown below, none of the dryer components (motors, burners, etc.) are running.

Graphic Explanation

The Overview page will change when different operations/features are running or turned off. The different graphics and their meaning are as follows:

Blue arrows

Indicate a fan is running.

Red arrows

Indicate a fan and burner are both running.

Blue and white burner flame

Only shown on tower dryers to further indicate the burner is on.

Blue plenum with blue arrows

Indicate a cooling plenum with the fan running.

Red plenum with red arrows

Indicate a heating plenum with the fan running and the burner on.

Sweep flashes green

Only shown on tower dryers to indicate the sweep is turning.

Area housing metering rolls flash green

Only shown on profile and mixed flow dryers to indicate the metering rolls are turning.

Hopper glows green

The fill is on.

Hopper flashes

Level auger is running.

Green air pressure indicator

Air pressure switch is satisfied.

Gray air pressure indicator

Air pressure switch is not satisfied.

Fill and Takeaway

In addition to these graphics, there are lines shown leading to the hopper and from the discharge. The line leading to the hopper contains two tags: Fill 1 and Fill 2. When the line is white, the fill cycle is off.

When the line is green, the fill cycle is on. When any of the tags blink, that particular part of the fill cycle is running. So while the Fill 1 or Fill 2 tags are green, but not blinking, it means it's enabled but currently not running. Only when it blinks does it mean that that particular portion, the Fill 1 or Fill 2, of the fill cycle is actually running. It is the same for the line exiting the discharge. When this line is white, it means the discharge is off. When the line is green, it means the discharge is on. A blinking Takeaway 1 or Takeaway 2 tag indicates that the Takeaway 1 or Takeaway 2, whichever is blinking, is currently running. A solid green Takeaway 1 or Takeaway 2 tag simply means it is enabled but not currently running.

Read and Write Values

The Overview page also contains information on the real-time plenum temperature, discharge speed, and if equipped, the values from the inlet and outlet sensors. The values in green text are the actual values being read. The values shown in a white box with black text are desired or "Set" values that can be changed by the operator. The ability to adjust the "Set" values associated with Mid-Grain Temp, Discharge Speed, and Outlet Sensor Moisture is dependent on the selected discharge mode. If Manual mode is selected, the Discharge Speed "Set" value will be able to be adjusted. If TruDry is selected, the Mid-Grain Temp "Set" value will be able to be adjusted. Finally, if AccuDry is selected, the Outlet Sensor "Set Moist" value, which is the desired outlet grain moisture, will be able to be adjusted. One value that can always be adjusted, regardless of selected discharge mode, is the plenum temperature(s).

When first starting the dryer, the Control page will need to be accessed. The Control page layout differs slightly from dryer model to dryer model. It is here where the Control Power, Grain Fill, Discharge, Fan, Blowers, and Burners can all be started from the same page. Each function such as Grain Fill, Discharge, Fans & Burners are grouped in boxes or tiles. It is within these tiles where the associated command buttons are located. The green buttons are "START" or "ON" buttons while the red buttons are "STOP" or "OFF" buttons. These command buttons are designed to communicate to the operator the feature's status and available function by way of color and text within the button. For a pair of buttons, one will have text within it that reads the status (ON, OFF, or RUNNING) while the other button will have text that reads the available command (TURN OFF, TURN ON, or STOP). The text and color within and around the buttons change as the status and available function changes.

Control Power

Shown below is the Control page for a tower or an all-heat ECO dryer. Before any function on the Control page can be performed, the Control Power must first be on. To turn Control Power on, simply press the green "TURN ON" button within the Control Power tile. There should be a slight delay while the safety circuit verifies satisfactory conditions. During this slight delay, the text within that same button should read "TURNING ON". If Control Power is achieved, the text within that same green button should then read "ON", a green glow should surround the button, and the text within the red button will change from "OFF" to "TURN OFF".

Similarly, to turn Control Power off, press the associated red button that reads "TURN OFF" and the text within that button should change to "OFF" and the text within the associated green button should change from "ON" to "TURN ON", and the surrounding green glow should disappear.

Fans and Burners

Once Control Power is on and there are no other issues preventing the starting of the other features, the dimly lit buttons will illuminate signaling that they are ready to start. Dimly lit buttons signify those features that are equipped on the dryer. Fully illuminated buttons are for features that are ready to be started or turned on. Those buttons that appear gray, are simply place holders for features that are not currently installed on the dryer. Below is an example of a Legacy Control page where the number of fans and burners vary depending on the model. For this reason, the Control page layout varies from model to model. Shown below is the Control page for a 2 burner Legacy dryer. Since the dryer is equipped with only 2 fans and 2 burners, controls for plenums 1 and 2 are illuminated while plenums 3 and 4 are greyed out.

With Control Power on and the Fan Start buttons fully illuminated, the fans are ready to start. Starting the fans is the same as turning Control Power on. The green buttons activate while the red buttons deactivate. Both buttons communicate the status as well as control the function.

Notice the burner buttons are dimly lit. Dimly lit buttons signify features that are equipped on the dryer, but are not ready to be started or turned on. The burner buttons will not fully illuminate or be ready to start until the fans are running and air pressure is present. Once the fan status is "RUNNING" with a green glow surrounding the Start button and the air pressure is satisfied as illustrated with a green illuminated indicator, the burners can be started. Again, the buttons will communicate the available command and current status. For the burners, the start process is more complicated and it involves purging and trial for ignition. While the burners attempt to ignite, the associated buttons will communicate the current status of the ignition process via text within the buttons.

Next to each set of burner control buttons are read and write boxes. The read box in green text is the real time temperature inside that particular plenum. The white, write box, is where the operator can enter the desired temperature for that particular plenum.

Grain Fill, Discharge and Metering

The Grain Fill, Discharge and Metering tiles all contain control buttons to stop and start the fill, discharge, and metering motors. These buttons act in the same way as the rest of the buttons on the Control page by communicating the available function and current status.

Cool Down

The Cool Down function allows for a graceful shutdown of the dryer. More on this function is explained in the Cool Down Alarms section of this manual.

Quick Launches

As mentioned in the Introduction of this manual, there are quick launch buttons throughout the software. The quick launch buttons allow the operator quick access to more in depth information and settings. They are typically located in ideal places where the subject matter of the quick launch is associated with a nearby function. On the Control page, the Safety Circuit quick launch is located next to the Control Power tile since issues with getting Control Power may be associated with a break in the Safety Circuit. Similarly, quick launches for the Grain Fill and Takeaway Equipment Settings are located next to the Grain Fill and Discharge tiles. Further details on these quick launch pages and their contents are explained in the System Settings, Historical Data and Troubleshooting chapters.

Pinnacle 20|20 is the latest member of the Pinnacle family of control systems. The Pinnacle 20|20 is a completely PLC-controlled system that does not include any buttons or switches as all operator control is done through large touch screens.

The Pinnacle 20|20 control system's components are located in the High Voltage Cabinet, Low Voltage Cabinet and the Remote Control Cabinet. The high voltage components such as the motor controls are located in the High Voltage Cabinet. The low voltage components, such as the PLC, are located in the Low Voltage Cabinet, and the HMIs are located in the Remote Control Cabinet.

Touch Screens

Pinnacle 20|20 comes equipped with one or two separate HMI touch screens. If equipped with multiple screens, each screen works independently from the other. There are no restrictions to viewing pages on either touch screen. The user can choose to display the same page or different pages on both touch screens. Commands made through either touch screen will be reflected on both screens.

Discharge Information

The Monitor Page is the third of the three Operation pages. The Monitor page is divided into thirds. The top third contains quantitative values that can either be read or adjusted. The operator can also change between discharge modes from here. However, it is important to note that when changing between TruDry and AccuDry, the operator must change to Manual mode first before changing to TruDry or AccuDry.

Another area where the operator can change discharge modes and make adjustments to the discharge settings is in the Discharge Speed Control quick launch. More on the contents within the Discharge Speed Control page can be viewed in the associated section.

Trending Graphs

In the middle of the Monitor page a quick view of different trending graphs is displayed. The graph shows up to 2 hours of recorded data. The operator can choose which trending graph to display on the Monitor page by selecting either the Moisture Trending button or Mid-Grain Trending button. Selecting these buttons will cause the display to toggle between these two graphs. The button highlighted in green indicates the graph that is currently being displayed on the Monitor page.

If more information about the trending graphs is desired, the operator can quickly access it by simply pressing the "More Trending Options" button. This quick launch contains larger graphs, with more information which is further explained in the Trending section of this manual.

Running Data

The bottom third of the Monitor page is where a table containing historical running data is displayed. The data displayed is grouped into rows that correspond to a date and time at which those values were recorded. A row of data is recorded every 10 minutes, spanning a total of two hours. The data that makes up this two hour graph is collected whether the dryer is discharging or not. More data can be accessed by pressing the More Data History quick launch button. Additional explanation can be found in the Data Logging History section.

At the bottom of the Pinnacle 20|20 Home page, there are 3 tabs: System Settings, Historical Data, and Troubleshooting. Pressing any of these 3 tabs will cause the tab to turn red and a different set of options, shown as red tiles, to appear. These options will change if a different tab is selected. The Pinnacle 20|20 control system has features that are customizable with several settings that can be changed as necessary. The System Settings tab are where these customizable features can be found. These features will be explained in detail as well as how to properly set them.

The Pinnacle 20|20 control features a Home screen where all the features of the control can be accessed. The top half of the Home screen contains the dryer information, date and time. The middle of the Home screen features 3 tiles that cover the operation of the dryer. Note that the graphics for these 3 tiles will vary depending on the model dryer that is loaded on the control. At the bottom of the Home screen are 3 tabs that contain the System Settings, Historical data, and Troubleshooting tiles. Clicking on these 3 tabs at the bottom will open a different menu of red tiles to chose from. Shown below is the menu associated with the Troubleshooting tab.

The touch screen allows you to not only monitor parameters, but to also change operational and alarm set points. For the most part, values that can be changed will be displayed as black text with a white background. Values that display in green with the dark gray background are read-only values and cannot be changed.

Example of a displayed value that cannot be changed:

Example of a displayed value that can be changed:

Selecting a white field to change the numerical value will bring up a keypad. Depending on the input that is being changed, there may be a minimum and maximum range to the value which will be displayed on the keypad. When attempting to enter a value outside of the min/max range, the value will not be accepted. Once a suitable value has been entered, press "Enter" to input the value and be returned to the screen that the value was being entered on. If you do not wish to change the value, press "Esc" to return without making a change.

Many features throughout the control have a help button associated with it so that it's function or purpose can be readily explained. This will be indicated with a "?" button and simply pressing it will display a help message pop-up which can easily be closed by pressing the "x" button in the upper right hand corner.

Throughout the control, there are tiles that contain a red triangle in the upper right corner. These red triangles signify quick launch tiles. Pressing a tile containing this red triangle will navigate away from the current page and to a page containing features specific to that particular tile.

Other than the Home and pop up pages, all other pages contain a page header. In addition to the date and time, the header contains a "Back" button on the left and a "Home" button on the right. To navigate back to the previous screen, simply press the "Back" button. To navigate to the Home page, simply press the "Home" button. Every header contains an "Alarm Reset" button as well. This button will turn red, yellow or orange in the event of an alarm. The color of the button will depend on the type of alarm present. Red alarms are critical, yellow are warnings and orange are Cool Down. If no other intervention or physical reset is needed, the alarm can be cleared from any page by simply pressing the Alarm Reset button. For orange, or Cool Down alarms, pressing the Alarm Reset will cause a pop up to appear allowing the user to cancel the Cool Down if so desired.

The second of the six options under System Settings is Takeaway Equipment Settings. By selecting the Takeaway Equipment Settings option, the operator will be taken to a page dedicated to all settings pertaining to the takeaway.

Just as can be done on the Control page, the discharge system can be started and stopped from the Takeaway Equipment Settings page as well and the buttons behave in the same manner.

Discharge Speed

The upper section of the Takeaway Equipment Settings page features a rendering of the takeaway portion of the dryer as well as some values in boxes labeled Discharge Speed. The actual metering or sweep speed is shown in the box labeled "Act", and the desired speed can be entered in the box labeled "Set" provided the dryer is discharging in Manual mode.

Discharge System

It is important to have a good understanding of the discharge system and it's design. This design provides versatility for different dryer sites. Some sites will utilize the features and components that make this system versatile while others will not need to. The system consists of two signals named Takeaway 1 and Takeaway 2.

Takeaway 1 Signal

The Takeaway 1 signal runs the discharge auger on profile dryers as well as any other equipment that is connected to it. Any other equipment that shares the Takeaway 1 signal will start and stop with the discharge auger of a profile dryer. Since the tower dryers do not have a discharge auger, nothing is connected to the Takeaway 1 signal from the factory. However, the signal is there to be used to run other equipment if so desired.

Takeaway 2 Signal

The Takeaway 2 signal is meant for equipment further downstream from equipment tied to the Takeaway 1 signal. Again, this signal is provided for convenience and is only to be used to run other equipment if so desired.

Takeaway 1 Start Delay

This is an adjustable timer inside the PLC that allows the dryer's takeaway equipment to start in stages. When the Takeaway Start button is pressed, equipment tied to the Takeaway 2 signal starts operating immediately and the timer starts its countdown. When the timer expires all equipment using the Takeaway 1 signal will start.

Takeaway 2 Stop Delay

This is an adjustable timer inside the PLC that determines how long to run the Takeaway 2 equipment after the Takeaway Stop button has been pressed. The timer starts once the Takeaway Stop button has been pressed and continues to run the Takeaway 2 equipment until the timer expires.

Takeaway 1 and 2 Jog

These two jog buttons enable the user to momentarily turn equipment on that are tied to these signals. This is useful when there is a backup or blockage of grain. Pressing and holding the Takeaway 1 Jog button will turn on all equipment tied to the Takeaway 1 signal for as long as the button is pressed. Releasing the button will stop the equipment. The Takeaway 2 Jog button works the same way for equipment tied to the Takeaway 2 signal.

Metering

The metering buttons only control the metering rolls or sweep. They do not control the takeaway.

Discharge Graphic

This graphic is used to give a real-time illustration of the operating components of the discharge system. When the discharge system is off, nothing on the graphic will be illuminated and the line exiting the dryer with the Takeaway tags will be white. Once the Discharge system is turned on, the Metering, along with the line exiting the dryer with the Takeaway tags will illuminate green. A flashing green graphic of any portion of the Discharge system indicates that the equipment for that particular portion of the system is currently running.

Takeaway Sequencing Chart

The bottom half of the Takeaway Equipment Settings page contains a chart that illustrates the sequencing of the discharge system and associated timers. The green, horizontal lines within this chart indicate when different operations are starting, running, and shutting down. Under this chart are the two, previously discussed, adjustable timers used to control the timing of the equipment associated with the discharge system.

Takeaway Start-Up Sequence

Following the logic of the chart, pressing the Takeaway start button will cause the start up of the Takeaway 2 equipment. At the same time, the Takeaway 1 Start Delay timer will begin its countdown. Once the countdown expires, the Takeaway 1 equipment will begin operating.

Takeaway Shut-Down Sequence

Following the logic of the chart, pressing the Takeaway stop button will immediately stop the equipment associated with Takeaway 1. At the same time, the Takeaway 2 Stop Delay timer will begin its countdown. Once the countdown expires, Takeaway 2 equipment will shut down.

The fifth of the six options under System Settings is Burner Settings. This page contains all settings pertaining to the Burners and plenum temperature.

The Burner Settings page layout will vary depending on the model of dryer. For Legacy dryers, there are toggle buttons at the bottom of the page. These toggle buttons are used to take the operator to the burner settings for burners 1 through 4 and for burners 5 through 8. Note that the burners are labeled in an ascending manner, starting with 1 to indicate the bottom-most burner on the dryer. The ECO, Tower and Delta dryer Burner Settings page layout will have component, quick launch buttons at the bottom of the page instead. The components listed there are for convenience and are related to the burner or ignition process. The Fusion will just have the Alarm Band at the bottom with no room to accommodate these quick launch buttons.

The burners can be started from the Burner Settings page for Tower dryers. They are started in the same manner as what was described previously in the Control tile, Fans & Burners. The ability to start and stop the burners from the Burner Settings page is not possible for ECO, Legacy, Fusion and Delta dryers. This must be done from the Controls page.

Plenum Temp

The Burner Settings page displays information pertaining to the burner in 3 separate columns. The first column is the Plenum Temp. There are two values displayed: an actual plenum temperature value being read by the plenum RTD and a set value, that the operator can adjust to meet their desired plenum temperature.

Valve % Opening

The second column is the Valve % Opening. The Valve % Opening refers to the modulating valve that controls the flow of gas to the burner. It is here where the operator can set the initial valve percent opening. The initial valve percent opening is the amount the modulating valve will open upon starting the burner. Two other adjustable values the operator can enter are the max and min. The max and min values are the maximum and minimum percent the valve will open during operation. The value in between the min and max values is the actual valve percent opening the modulating value is currently open to.

Mode

The last column is a heat/cool indicator. This indicates whether the plenum is considered a heat zone or a cool zone by the AccuDry software. When the indicator globe is blue, it indicates a cool zone. When the indicator globe is red, it indicates a heat zone. The value entered as the "Dryer Off Temp" determines whether the burner is considered off or on. Access to the "Dryer Off Temp" value is through the Service Screens, in the AccuDry Settings page. If the actual plenum temperature is lower than this value, the mode will appear with the circular indicator globe colored blue. If the actual plenum temperature is above this value, the circular indicator globe will appear red.

The first of the six options under System Settings is Fan Settings. By selecting the Fan Settings option, the operator will be taken to a page dedicated to all settings pertaining to the fans.

Regardless of dryer model, this page will have a section containing the Fan Control buttons and another section containing Cool Down and Takeaway timers. The Tower, ECO, and Delta Fan Settings page also contain quick launch buttons at the bottom for specific components that relate in some way to the fans. This is common on many pages of the Pinnacle 20|20 control. If space allows, there will be quick launches for components that are related to the features on that particular page. Since space is lacking on the Legacy and Fusion Fan Settings page, those quick launches are not present at the bottom.

Fan Control Buttons

On the Fan Settings page are the buttons used to stop and start the fans. The functionality of these buttons is the exact same as the Fan Control buttons on the Control page which was discussed in previously. In addition to the control buttons, there are Air Pressure indicator lights. The Air Pressure indicator light will appear gray when the air pressure switch is not satisfied. However, when the air pressure switch senses enough air pressure to satisfy the switch, the indicator light will illuminate green to confirm this scenario.

Cool Down and Takeaway Timers

On the Fan Settings page, there is a timer associated with the Fan(s) and it is called the Cool Down Timer.

Cool Down Timer

The Cool Down Timer is an adjustable timer that determines the length of time that the dryer will be placed in Cool Down mode following a type-B fault. When activated, the numbers in green font, under "Actual", will countdown until the timer expires. During this time, the fans will continue to run but burners and other equipment will stop. After the time has elapsed, the dryer will shut down.

Takeaway Timer

The Takeaway Timer is an adjustable timer that determines the length of time the takeaway equipment will continue to run after the metering stops. This timer allows the takeaway equipment to empty when conditions allow. If the cause for the shutdown is related to the takeaway equipment, this timer is bypassed.

The fourth of the six options under System Settings is Moisture Sensor Settings. This page contains all settings pertaining to the Moisture Sensors. It is here where the Moisture Sensors can be calibrated as well.

The Moisture Sensor Settings page is separated into two halves. The top half is dedicated to the inlet moisture sensor while the bottom half is dedicated to the outlet moisture sensor. If the dryer is not equipped with one or more of these sensors, the displayed values will simply be grayed out and read "N/A".

Moisture Alarms

The Pinnacle 20|20 control can be set up to alert the operator, or even further, shut the dryer down when grain moisture, detected by the moisture sensors, reach pre-set alarm limits. There are two types of limits: high limits and low limits. There are also two types of alarms: warning alarms and critical alarms. If a warning alarm limit is exceeded, the control will trigger a warning message to be displayed on the HMI screens. If that particular reading continues further off course and exceeds the critical alarm limit, the dryer will shutdown and a critical alarm message will appear on the HMI screens.

Each sensor has it's own table of moisture alarm settings. The Inlet Moisture Alarms table is located at the top, left side of the Moisture Sensor Settings page while the Outlet Moisture Alarms table is located at the bottom, left side of the same page. The adjustable limits are shown in black text, in white boxes. The high limits are at the top of the table while the low limits are at the bottom of the table. Reference the labels to the right of the adjustable limits to decipher between a critical limit and a warning limit. In between the adjustable warning values is the actual grain moisture being read by the moisture sensor.

High Moisture Critical

If the Current Moisture exceeds the value entered for the High Moisture Critical value, the dryer will shut down. The input value for this High Moisture Critical alarm must be equal to or greater than the value entered for the High Moisture Warning value. To expand the allowable input range for the High Moisture Critical value, the High Moisture Warning value may first need to be adjusted.

High Moisture Warning

If the Current Moisture exceeds the value entered for the High Moisture Warning value, the control will display a High Moisture warning message. The input value for this High Moisture Warning alarm must be equal to or less than the value entered for the High Moisture Critical value. The lowest value allowed for this warning is equal to the Low Moisture Warning value. To expand the allowable input range for the High Moisture Warning value, the High Moisture Critical and Low Moisture Warning values may first need to be adjusted.

Current Moisture

This value is the real time grain moisture value being read by the moisture sensor.

Low Moisture Warning

If the Current Moisture falls below the value entered for the Low Moisture Warning, the control will display a Low Moisture warning message. The input value for this Low Moisture Warning alarm must be equal to or less than the value entered for the High Moisture Warning value. The lowest value allowed for this warning is equal to the Low Moisture Critical value. To expand the allowable input range for the Low Moisture Warning value, the High Moisture Warning and Low Moisture Critical values may first need to be adjusted.

Low Moisture Critical

If the Current Moisture falls below the value entered for the Low Moisture Critical, the dryer will shut down. The input value for this Low Moisture Critical alarm must be equal to or lower than the value entered for the Low Moisture Warning value. To expand the allowable input range for the Low Moisture Critical value, the Low Moisture Warning value may first need to be adjusted.

Temperature Alarms

The Pinnacle 20|20 control can also be set up to alert the operator or even shut the dryer down when grain temperatures, detected by the moisture sensors, reach pre-set alarm limits. As previously mentioned, there are high and low limits and there are critical and warning alarms.

Each sensor has it's own table of temperature alarm settings. The Inlet Temperature Alarms table is located at the top, right side of the Moisture Sensor Settings page while the Outlet Temperature Alarms table is located at the bottom, right side of the same page. The adjustable limits are shown in black text, in white boxes. The high limits are at the top of the table while the low limits are at the bottom of the table. Reference the labels to the right of the adjustable limit to decipher between a critical limit and a warning limit. In between the adjustable warning values is the actual grain temperature being read by the moisture sensor.

High Temp Critical

If the Current Temp exceeds the value entered for the High Temp Critical value, the dryer will shut down. The input value for this High Temp Critical alarm must be equal to or greater than the value entered for the High Temp Warning value. To expand the allowable input range for the High Temp Critical value, the High Temp Warning value may first need to be adjusted.

High Temp Warning

If the Current Temp exceeds the value entered for the High Temp Warning value, the control will display a High Temp warning message. The input value for this High Temp Warning alarm must be equal to or less than the value entered for the High Temp Critical value. The lowest value allowed for this warning is equal to the Low Temp Warning value. To expand the allowable input range for the High Temp Warning value, the High Temp Critical and Low Temp Warning values may first need to be adjusted. Current Temp This value is the real time grain Temp value being read by the Moisture sensor.

Current Temp

This value is the real time grain Temp value being read by the Moisture sensor.

Low Temp Warning

If the Current Temp falls below the value entered for the Low Temp Warning, the control will display a Low Temp warning message. The input value for this Low Temp Warning alarm must be equal to or less than the value entered for the High Temp Warning value. The lowest value allowed for this warning is equal to the Low Temp Critical value. To expand the allowable input range for the Low Temp Warning value, the High Temp Warning and Low Temp Critical values may first need to be adjusted.

Low Temp Critical

If the Current Temp falls below the value entered for the Low Temp Critical, the dryer will shut down. The input value for this Low Temp Critical alarm must be equal to or lower than the value entered for the Low Temp Warning value. To expand the allowable input range for the Low Temp Critical value, the Low Temp Warning value may first need to be adjusted.

Sensor Calibration

The sensor calibration procedure varies slightly between AccuDry equipped and non-AccuDry dryers. Below are the procedures for both variations.

Inlet Sensor, AccuDry

To calibrate the Inlet moisture sensor, press the “Start Calibration” button to the left of the Inlet Sensor Calibration tile. This will prompt the system to measure the grain moisture for 30 seconds, which will be indicated by the "Wait" indicator blinking green. Meanwhile, obtain a lab measurement of current Inlet grain. When the “Ready” button illuminates green, enter the lab measured values in the white box labeled “Lab Measured Moisture”. Once entered, press “Confirm Calibration” to complete the calibration process. When the “Start Calibration” button is pressed, the text for this button will change to “Cancel Calibration”, allowing the operator to cancel the calibration if desired. Note that the calibration process allows for a maximum of 0.5% change per calibration. If the sensor is off by 2%, the sensor will need to be calibrated 4 times.

Outlet Sensor, AccuDry

To calibrate the outlet moisture sensor, press the “Start Calibration” button, to the left of the Outlet Sensor Calibration box. This will prompt the system to measure the grain moisture for 30 seconds, which will be indicated by the "Wait" indicator blinking green. Meanwhile, obtain a lab measurement of current Outlet grain. When the “Ready” button illuminates green, enter the lab measured values in the white box labeled “Lab Measured Moisture”. Once entered, press “Confirm Calibration” to complete the calibration process. When the “Start Calibration” button is pressed, the text for this button will change to “Cancel Calibration”, allowing the operator to cancel the calibration if desired. Note that the calibration process allows for a maximum of 0.5% change per calibration. If the sensor is off by 2%, the sensor will need to be calibrated 4 times.

Inlet Sensor, non-AccuDry

To calibrate the Inlet moisture sensor for a non-AccuDry dryer, obtain a lab measurement of current Inlet grain. Press the white box labeled “Lab Measured Moisture” and enter the recently obtained lab measured value. Press the Calibrate button to calibrate or the Cancel button to cancel the calibration. Note that the calibration process allows for a maximum of 0.5% change per calibration. If the sensor is off by 2%, the sensor will need to be calibrated 4 times.

Outlet Sensor, non-AccuDry

To calibrate the Outlet moisture sensor for a non-AccuDry dryer, obtain a lab measurement of current Outlet grain. Press the white box labeled “Lab Measured Moisture” and enter the recently obtained lab measured value. Press the Calibrate button to calibrate or the Cancel button to cancel the calibration. Note that the calibration process allows for a maximum of 0.5% change per calibration. If the sensor is off by 2%, the sensor will need to be calibrated 4 times.

The third of the six options under System Settings is Grain Fill Settings. By selecting the Grain Fill Settings option, the operator will be taken to a page dedicated to all settings pertaining to the filling the dryer with grain.

Just as can be done on the Control page, the fill system can be started and stopped from the Grain Fill Settings page as well and the buttons behave in the same manner. The Grain Fill Settings page layout is very similar to that of the Takeaway Equipment Settings page.

Fill System

Before moving on to the different features of the Grain Fill Settings page, it is important to have a good understanding of the Grain Fill System and it's design. The design provides versatility to accommodate different dryer sites. Some sites will utilize these features while others will not need to. The system consists of two signals and five timers.

Fill 2 Signal

The Fill 2 runs the level auger on profile dryers as well as any other equipment that is connected to the Fill 2 signal. Any other equipment that shares the Fill 2 signal will start and stop with the level auger of a profile dryer. Since the tower dryers do not have a level auger, nothing is connected to the Fill 2 signal from the factory. However, the signal is there to be used to run other equipment if so desired.

Fill 1 Signal

The Fill 1 signal is provided for equipment further upstream from Fill 2 equipment. Again, this signal is provided for convenience and is only to be used to run other equipment if so desired.

Grain Flow Timer

This is an adjustable timer that is started once the Grain Fill is started. If the set time for this timer elapses before the Rotary Bin Switch paddle in the hopper stops rotating, it will be assumed there is no more grain to fill the dryer with and the dryer will enter a Cool Down mode.

Fill 2 Start Delay

This is an adjustable timer that is started once the paddle of the Rotary Bin Switch in the hopper begins to rotate. Paddle rotation is used to sense the lack of grain. When the Rotary Bin Switch begins to rotate, the call for grain is started and Fill 2 Start Delay will start counting. The time entered for the Fill 2 Start Delay is the time that needs to elapse before Fill 2 equipment is turned on.

Fill 1 Start Delay

This is an adjustable timer that is started once the Fill 2 Start Delay timer has elapsed. The time entered for the Fill 1 Start Delay is the time that needs to elapse before Fill 1 equipment is turned on.

Fill 1 Stop Delay

The Fill 1 Stop Delay is a timer that decides when to turn the Fill 1 equipment off. The timer starts when the Rotary Bin Switch paddle stops rotating, ending the call for grain. Once the entered time value for this timer expires, the Fill 1 equipment will turn off.

Fill 2 Stop Delay

The Fill 2 Stop Delay is a timer that decides when to stop the Fill 2 equipment and level auger if equipped. After the Fill 1 Stop Delay timer expires, shutting down the Fill 1 equipment, the Fill 2 equipment and level auger will continue to run for the allotted time entered for the Fill 2 Stop Delay timer.

Fill From Empty

This feature is typically used when filling an empty or near empty dryer. Checking the Fill From Empty box ignores the Grain Flow timer, allowing ample time for the dryer to be filled with grain from an empty state. After the dryer is filled, this box is automatically unchecked, allowing the PLC to control the automatic fill cycle of the dryer during operation.

Fill Graphic

This graphic is used to give a real-time illustration of the operating components of the Grain Fill System. When the Grain Fill System is off, nothing on the graphic will be illuminated and the line entering the dryer with the Fill 1 and Fill 2 tags will be white. Once the Grain Fill System is turned on, the Hopper, Fill 1 and Fill 2 will illuminate green. A flashing green graphic of any portion of the Grain Fill System indicates that the equipment for that particular portion of the system is currently running.

Fill Sequencing Chart

The bottom half of the Grain Fill Settings page contains a chart that illustrates the sequencing behind the Grain Fill System and associated timers. The green, horizontal lines within this chart indicate when different operations are starting, running, and shutting down. Under this chart are the previously discussed, adjustable timers used to control the timing of the equipment associated with the Grain Fill System.

Grain Fill Start-Up Sequence

Following the logic of the chart, the grain fill sequence starts with a call for grain. The call for grain comes when the rotary bin switch in the hopper starts rotating, due to the lack of grain. This call for grain starts all equipment associated with Fill 2 after the Fill 2 Start Delay has elapsed. After the Fill 2 Delay Timer finishes, the Fill 1 Start Delay timer will begin to countdown. Once the Fill 1 Start Delay timer expires, all equipment associated with Fill 1 will start.

Grain Fill Shut-Down Sequence

Following the logic of the chart, the shutdown sequence starts when the call for grain ends. When the call for grain ends, the equipment associated with Fill 1 and 2 will continue to run for the duration of the Fill 1 Stop Delay timer. Once the Fill 1 Stop Delay timer expires, all the equipment associated with Fill 1 will turn off but all the equipment associated with Fill 2 will continue to run for the duration of the Fill 2 Stop Delay timer. Once the Fill 2 Stop Delay timer expires, all equipment associated with Fill 2 will stop.

Regardless of which discharge mode settings page is displayed, the operator can change the discharge mode from any one of them. However, it is important to understand that in order to change discharge modes, the operator must be in Manual mode first before changing to any of the other available modes. For instance, if the dryer is currently discharging in AccuDry mode and the operator wants to change to TruDry mode, the operator must first select Manual mode, and then select TruDry mode.

In addition to being able to select the mode of discharge from any of these pages, the Manual, TruDry and AccuDry Settings pages also all contain the same information for the following tiles: Disch Speed, Disch Speed Alarms, and Mid-Grain Temperature Alarms.

Manual Settings

When discharging in Manual mode, the operator controls the speed at which the grain discharges at. This adjustable value is under the Manual Settings tile, next to the Set Discharge Speed, input box.

VFD Frequency = 12 Hz

VFD Frequency = 18 Hz

VFD Frequency = 30 Hz

VFD Frequency = 6 Hz

VFD Frequency = 36 Hz

Depending on the model dryer, the % discharge speed will correspond to an approximate bu/hr or metric tonnes/hr value for a known discharge capacity. The table below correlates discharge speed % to bu/hr based for the moisture removal (5pt or 10pt) and mode of operation (All-Heat or Heat+Cool) stated above.

VFD Frequency = 24 Hz

Each dryer model has a discharge capacity for every revolution of the metering rolls for profile dryers and sweep for tower dryers. These discharge capacities are used to calculate how much grain is being discharged from the dryer given a specific discharge speed. The chart below shows what these discharge capacities are in bushels per revolution and cubic meters per revolution.

VFD Frequency = 42 Hz

VFD Frequency = 54 Hz

VFD Frequency = 48 Hz

VFD Frequency = 60 Hz

Since the speed of the discharge impacts the mid-grain temperature, it is on any of these discharge settings pages where the operator can set the mid-grain temperature alarm limits. If the dryer is discharging and the mid-grain temperature exceeds the mid-grain temperature alarm band for a set period of time, the dryer will enter a Cool Down mode. The two alarm limits that can be entered that pertain to the mid-grain temperature are the Alarm Band and Alarm Band Delay.

Alarm Band

The Mid-Grain Temperature Alarm Band is the allowed deviation from the mid-grain temperature set point while the discharge system is running.

Alarm Band Delay

The Mid-Grain Alarm Band Delay is a user-defined time duration in minutes that will delay the Cool Down of the dryer after the Mid-Grain Band warning alarm has occurred. If the Mid-Grain temperature returns to the acceptable range within this time period, no shut down will occur.

From any of these discharge settings pages (Manual, TruDry, or AccuDry Settings pages), in the Disch Speed tile, the operator can set operational limits that pertain to the discharge speed. The two operational limits the operator can set are the max and min speeds the discharge can run at. With the operational limits in place, the user will not be able to enter a speed in the Set Discharge Speed box of the Manual Settings page that exceeds these limits.

Setting Discharge Speed Alarm Limits

Again, from any of these discharge settings pages, under Disch Speed Alarms, the operator can set alarm limits that pertain to the discharge speed. There are two types limits: high limits and low limits. There also two types of alarms: warning alarms and critical alarms. If a warning alarm limit is exceeded, the control will trigger a warning message to be displayed on the HMI screens. If that particular reading continues further off course and exceeds the critical alarm limit, the dryer will shutdown and a critical alarm message will appear on the HMI screens.

High Speed Critical

If the Current Speed exceeds the value entered for the High Speed Critical value, the dryer will shut down. The input value for this High Speed Critical alarm must be equal to or greater than the value entered for the High Speed Warning value. To expand the allowable input range for the High Speed Critical value, the High Speed Warning value may first need to be adjusted.

High Speed Warning

If the Current Speed exceeds the value entered for the High Speed Warning value, the control will display a High Speed warning message. The input value for this High Speed Warning alarm must be equal to or less than the value entered for the High Speed Critical value. The lowest value allowed for this warning is equal to the Low Speed Warning value. To expand the allowable input range for the High Speed Warning value, the High Speed Critical and Low Speed Warning values may first need to be adjusted.

Current Speed

This value is the real time metering speed of the discharge system.

Low Speed Warning

If the Current Speed falls below the value entered for the Low Speed Warning, the control will display a Low Speed warning message. The input value for this Low Speed Warning alarm must be equal to or less than the value entered for the High Speed Warning value. The lowest value allowed for this warning is equal to the Low Speed Critical value. To expand the allowable input range for the Low Speed Warning value, the High Speed Warning and Low Speed Critical values may first need to be adjusted.

Low Speed Critical

If the Current Speed falls below the value entered for the Low Speed Critical, the dryer will shut down. The input value for this Low Speed Critical alarm must be equal to or lower than the value entered for the Low Speed Warning value. To expand the allowable input range for the Low Speed Critical value, the Low Speed Warning value may first need to be adjusted.

Depending on the model dryer, the % discharge speed will correspond to an approximate bu/hr or metric tonnes/hr value for a known discharge capacity. The table below correlates discharge speed % to bu/hr based for the moisture removal (5pt or 10pt) and mode of operation (All-Heat or Heat+Cool) stated above.

Depending on the model dryer, the % discharge speed will correspond to an approximate bu/hr or metric tonnes/hr value for a known discharge capacity. The table below correlates discharge speed % to bu/hr based for the moisture removal (5pt or 10pt) and mode of operation (All-Heat or Heat+Cool) stated above.

The AccuDry Settings page is very similar to the Manual Settings page as well. The only difference, other than the component quick launches, is the "Set Discharge Speed" box displayed on the Manual Settings page has been replaced by values and information pertaining to AccuDry.

To understand the settings on the AccuDry Settings page, it is best to first have a good understanding of the AccuDry Technology and how AccuDry works.

Depending on the model dryer, the % discharge speed will correspond to an approximate bu/hr or metric tonnes/hr value for a known discharge capacity. The table below correlates discharge speed % to bu/hr based for the moisture removal (5pt or 10pt) and mode of operation (All-Heat or Heat+Cool) stated above.