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mathews company Eco Series Operation Manual

Grain dryer
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OPERATIONS
MANUAL
Models:
E300
E400
E500
E600
E300h
E400h
E500h
E600h

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  • Page 1 OPERATIONS MANUAL Models: E300 E300h E400 E400h E500 E500h E600 E600h...
  • Page 2 OPERATIONS MANUAL - ECO SERIES © 2015 Mathews Company 500 Industrial Avenue Crystal Lake, IL 60012 USA www.mathewscompany.com...
  • Page 3 CSA 3.8 2014 Certified Dryers The following instructions pertain to dryers built and certified to the CSA 3.8 2014 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.
  • Page 4 • 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 •...
  • Page 5 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.
  • Page 6 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 “...
  • Page 7 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.

  • Page 8: Table Of Contents

    Table of Contents Introduction ............................1.1 Overview ........................1.1 Grain Drying Principles ....................1.1 Air ............................... 1.1 Heat ............................1.1 Time ............................1.1 Owner / Operator Notes ....................1.2 Warranty Registration ....................1.2 Model / Serial Number / Specifications ................1.2 Safety ..........................1.3 Lock-out / Tag-out Requirements ....................1.4 Blocks ............................
  • Page 9 Maintenance ............................5.1 Overview ........................5.1 Pre-Season Checks ......................5.1 Grain Fill & Discharge System ....................5.1 Belt Adjustment .......................... 5.1 Fans & Burners ........................... 5.2 Lubrication ........................5.3 Seasonal Cleaning ......................5.3 Outer Screens ..........................5.4 Inner Screens ..........................5.4 Post-Season Maintenance ....................5.4 Troubleshooting ............................6.1 Diagnosing a Dryer Shutdown ..................6.1 Safety Circuit Overview ......................

  • Page 12: Introduction

    Maintenance and Troubleshooting. Overview The majority of the information in this manual applies to all ECO Series 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.

  • Page 13: Owner / Operator Notes

    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: 1.2 Introduction...

  • Page 14: Safety

    ECO Series Operations Manual 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.

  • Page 15: Lock-Out / Tag-Out Requirements

    ECO Series Operations Manual 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.

  • Page 16: Blocks

    ECO Series Operations Manual 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.
  • Page 17 ECO Series Operations Manual...

  • Page 18: Specifications

    ECO Series Operations Manual Section Specifications Standard Specs Model E300 E300h E400 E400h E500 E500h E600 E600h Holding Capacity (bu) Grain Column Thickness 14" Grain Column Length 12'-0" 16'-0" 20'-0" 24'-0" Max Operating Burner Capacity (heat+cool) 2.65 3.53 4.32 5.18...

  • Page 19: Metric Specs

    ECO Series Operations Manual Metric Specs Model E300 E300h E400 E400h E500 E500h E600 E600h 10.6 14.1 17.6 21.1 Holding Capacity (m3) Grain Column Thickness 35.6 (cm) Grain Column Length Max Burner Capacity (heat+cool) kW 1035 1266 1518 Thermal Max Burner Capacity...
  • Page 20 ECO Series Operations Manual Specifications 2.3 DOC-E01-0815. i n dd...
  • Page 21 ECO Series Operations Manual 2.4 Specifications DOC-E01-0815. i n dd...
  • Page 22 ECO Series Operations Manual Specifications 2.5 DOC-E01-0815. i n dd...
  • Page 23 ECO Series Operations Manual...

  • Page 24: Equipment Overview

    ECO Series Operations Manual Section Equipment Overview The Equipment Overview section will help identify parts of the dryer and briefly explain their function. The images will physically show you what the component(s) look like and the description following will state their purpose.
  • Page 25 ECO Series Operations Manual Rotary (Bin) Fill Switch The Rotary Fill Switch is located in the wet hopper on the opposite end of the fill tube and is powered by 120V. The switch is motorized and will rotate a paddle until wet grain comes in contact with the paddle.

  • Page 26: High Voltage Cabinet

    ECO Series Operations Manual High Voltage Cabinet The High Voltage Cabinet contains all of the motor starters and protectors, main power disconnect, pro- grammable logic controller (PLC), breakers, relays, and other associated electrical hardware. Main Disconnect Handle Emergency Stop Button...

  • Page 27: Pinnacle Lite Remote Cabinet

    ECO Series Operations Manual Pinnacle Lite Remote Cabinet The Pinnacle Lite Remote Cabinet is where all of the dryer controls are located including the Pinnacle Lite HMI touch screen, power switches and indicator lights, as well as fan, burner, fill and discharge controls.

  • Page 28: Burner Control Cabinet

    ECO Series Operations Manual Burner Control Cabinet The Burner Control Cabinet houses all of the components to safely operate the fan and burner(s) which includes air pressure switches, high limit switches, ignition boards, and temperature controllers. The cabinet is mounted near the fan and burner for ease of access and/or troubleshooting purposes.
  • Page 29 ECO Series Operations Manual Ignition Board The Ignition Board 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.

  • Page 30: Discharge Moisture Sampler

    ECO Series Operations Manual Discharge Moisture Sampler (Optional) 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.

  • Page 31: Gas Train

    ECO Series Operations Manual Gas Train 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.

  • Page 32: Dual Burner Lpg Gas Train

    ECO Series Operations Manual Dual Burner LPG Gas Train Pressure Regulator Pressure Regulator Solenoid Valve Control Valve Actuator Solenoid Valve Manual Hand Valve Dual Burner NG Gas Train Control Valve Actuator Solenoid Valve Manual Hand Valve Pressure Regulator Equipment Overview 3.9...
  • Page 33 ECO Series Operations Manual 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.

  • Page 34: Burner

    ECO Series Operations Manual Burner The purpose of the burner is to provide heat to the drying air. This heat comes from the combustion of the supplied fuel and takes place in the MIDCO Burner. Models E300, E400, E500 and E600 come with two burners.
  • Page 35 ECO Series Operations Manual 3.12 Equipment Overview DOC-E01-0815. i n dd...

  • Page 36: Operating Procedures

    ECO Series Operations Manual Section Operating Procedures Overview This section will explain the operation of the primary components of the dryer as well as provide step-by- step procedures to properly start-up and shut-down the machine. Operational and functional descriptions along with adjustment details for primary components will be presented initially, followed by operational procedures for starting up and shutting down the dryer.

  • Page 37: High Limit Switch

    ECO Series Operations Manual 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 plenum 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.
  • Page 38 ECO Series Operations Manual High Limit Switch Burner Control Cabinet The safety features associated with the high limit switch(es) are for your safety and for the protection of the dryer. They should be checked for correct operation at the start of the drying season and periodically during the season as they are designed to protect the dryer from a fire that may result from fan (air flow) failure while the burner is ignited and a flame is present.

  • Page 39: Grain Fill System

    ECO Series Operations Manual Grain Fill System The dryer control system features both a manual and an automatic grain filling system. To properly fill the dryer and to measure the grain level, the dryer is equipped with a leveling auger as well as a rotary (bin) level switch and two timers (grain flow timer and fill delay timer) located in the Remote Cabinet.
  • Page 40 ECO Series Operations Manual AUTO When the grain fill switch is in the AUTO position, the grain fill system is setup to run automatically. Setting the grain fill system to run automatically means that the grain flow timer and the fill delay timer are used in conjunction with the level auger and the rotary (bin) level switch to fill the dryer.

  • Page 41: Temperature Controller

    Temperature Controller Programs The temperature controller is pre-programmed from the Mathews Company facility with one of six different programs: Tower, Tower (metric), Profile, Profile (metric), Fuel Oil, and Fuel Oil (metric). The program that is loaded on the controller establishes parameters that are specific to the type of machine the controller is installed on and determines the units of display (degrees Celsius or degrees Fahrenheit).
  • Page 42 ECO Series Operations Manual Program Parameter Function Display Name Default Profile Fuel Oil Name Level Profile Fuel Oil Values (Metric) (Metric) Device inPt nonE Units unit nonE Low Limit Lo.SC High Limit hi.SC caries Proportional bAnd Integral int.t Derivative der.T Cycle Time CYC.t...
  • Page 43 ECO Series Operations Manual Adjustments All parameters for the temperature controller can be adjusted when it is powered up and operational. While the controller is in the main operating mode, the display will show two numbers; the top number is the actual temperature detected by the thermocouple in the plenum, whereas the bottom number shows the current temperature setpoint.
  • Page 44 ECO Series Operations Manual Alarms The temperature controller not only controls the temperature in the plenum, but it also provide low temperature and high temperature alarms. When the plenum temperature drops below the low temperature setpoint or rises above the high temperature setpoint, an alarm condition will occur. The low and high temperature setpoint parameters are established in the program loaded on the controller as explained in the Programs section.

  • Page 45: Variable Frequency Drive (Vfd)

    ECO Series Operations Manual Variable Frequency Drive (VFD) The purpose of the variable frequency drive is to control the speed of the discharge metering rolls. The communication from the HMI to the PLC then correlates to the variable frequency drive.

  • Page 46: Changing Variable Frequency Drive Parameters

    ECO Series Operations Manual Changing Variable Frequency Drive Parameters Direction of the Motor Rotation DIRECTION OF THE MOTOR ROTATION Check the direction of the motor rotation. • If the drive is in remote control (REM shown on the left), switch to local control by pressing •...

  • Page 47: Operational Procedures

    ECO Series Operations Manual Operational Procedures The following operational procedures provide a step-by-step guide to starting-up and shutting-down you dryer. These procedures should be followed and used in conjunction with the Pinnacle Lite Controls Manual for HMI touchscreen adjustments. First Time Start-Up This start-up procedure assumes that the dryer has not recently been in operation and is not full of grain.

  • Page 48: Daily Shut-Down

    ECO Series Operations Manual 13. On the Remote Control Cabinet, turn the momentary spring-loaded Takeaway switch to the START position and release to the ON position. The discharge auger or conveyor (if equipped) should start immediately, the switch should illuminate and your takeaway equipment should start running. On the Remote Control Cabinet, turn the Metering switch to the ON position.

  • Page 49: End-Of-Season Shut-Down

    ECO Series Operations Manual Verify the plenum temperature setpoints for each plenum. You may refer to the table that follows for suggested drying temperatures based on model number nad grain type. Setting the plenum temperature controllers can be done on the temperature controller directly located in the burner control box as explained in the Temperature Controller potion of this section of the manual or it can be done on the HMI touchscreen as explained in the Pinnacle Lite Controls Manual.
  • Page 50 ECO Series Operations Manual 6. On the Remote Control Cabinet, turn the momentary spring-loaded Takeaway switch to the START position and release to the ON position. The discharge auger or conveyor (if equipped) should start immediately, the switch should illuminate and your takeaway equipment should start running. On the Remote Control Cabinet, turn the Metering switch to the ON position.

  • Page 51: Suggested Plenum Temperatures

    ECO Series Operations Manual Suggested Plenum Temperatures Bellow are suggested plenum drying temperatures for a variety of grain types. These numbers represent the temperature that the burner will be putting out into the heating chamber. Plenum Drying Temperature Canola, Rape, Sunflower Corn Sorghum &...

  • Page 54: Maintenance

    This section of the manual will explain the factory recommended maintenance and cleaning requirements to keep your Mathews Company grain dryer running efficiently. Failure to follow or comply with these recommendations will impact dryer performance and may limit or void your warranty.

  • Page 55: Fans & Burners

    ECO Series Operations Manual 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.

  • Page 56: Lubrication

    ECO Series Operations Manual Lubrication 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.

  • Page 57: Outer Screens

    ECO Series Operations Manual 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.

  • Page 58: Troubleshooting

    ECO Series Operations Manual Section Troubleshooting The Troubleshooting section will help with diagnosing your dryer in case of a dryer shut down. This section will explain situations that you may run into and will help you come up with a resolution to get your dryer back to operation.
  • Page 59 ECO Series Operations Manual • If the end-user has pulled the jumper and installed take away and fill equipment into the safety circuit, check to see if the customer’s remote starter equipment needs to be reset. • In the High Voltage Cabinet place the second lead on TBC6, if it shows 120-volts then move onto the next step.

  • Page 60: Safety Circuit Schematic

    Safety Circuit Schematic The safety circuit below will help you diagnose a dryer shut down. This is used to help diagnose the main components on your Mathews Company grain dryer that are linked in a series to insure safety. Troubleshooting 6.3...

  • Page 61: Customer Interface

    ECO Series Operations Manual Customer Interface Customer connections are for remote equipment, and are used to interface the grain dryer with your fill and takeaway equipment. The grain dryer does not supply power for these interfaces. An auxiliary power source should be used to power your equipment.

  • Page 62: Plenum Temperature Will Not Hold Satisfactorily

    ECO Series Operations Manual Plenum Temperature will not hold satisfactorily • Adjust the gas pressure (Lower for Overshoot : Higher for Low Temp). • Loosen the linkage on the arm connecting the modutrol motor and the proportional value. • Then attempt to move the shaft on the butterfly valve to see if the valve is in working order.

  • Page 63: Variable Frequency Drive (Vfd)

    ECO Series Operations Manual Variable Frequency Drive (VFD) In case that you run into a error code on the variable frequency drive (VFD) listed below are the display faults that will show up on the main display of the drive.
  • Page 64 356 Fault tracing ECO Series Operations Manual CODE FAULT CAUSE WHAT TO DO If the overvoltage fault appears during deceleration, possible causes are: • Overvoltage controller • Check that overvoltage controller is disabled. on (parameter 2005 OVERVOLT CTRL). • Deceleration time is •...
  • Page 65 Fault tracing 357 ECO Series Operations Manual CODE FAULT CAUSE WHAT TO DO Missing input power line Measure the input and DC voltage phase. during start, stop and running by using a multimeter or check parameter 0107 DC BUS VOLTAGE.
  • Page 66 358 Fault tracing ECO Series Operations Manual CODE FAULT CAUSE WHAT TO DO 0009 MOT OVERTEMP Motor temperature estimation is too high. (4310) Excessive load or Check motor ratings, load and cooling. insufficient motor power (programmable fault function Incorrect start-up data.
  • Page 67 Fault tracing 359 ECO Series Operations Manual CODE FAULT CAUSE WHAT TO DO 0012 MOTOR STALL Motor is operating in stall Check motor load and drive ratings. region due to eg (7121) Check fault function parameters excessive load or 3010...3012.
  • Page 68 360 Fault tracing ECO Series Operations Manual CODE FAULT CAUSE WHAT TO DO 0022 SUPPLY PHASE Intermediate circuit DC Check input power line fuses and voltage is oscillating due installation. (3130) to missing input power Check for input power supply line phase or blown fuse.
  • Page 69 Fault tracing 361 ECO Series Operations Manual CODE FAULT CAUSE WHAT TO DO 0030 FORCE TRIP Trip command received Fault trip was caused by fieldbus. See from fieldbus fieldbus user’s manual. (FF90) 0034 MOTOR PHASE Motor circuit fault due to Check motor and motor cable.
  • Page 70 362 Fault tracing ECO Series Operations Manual CODE FAULT CAUSE WHAT TO DO 0101 SERF CORRUPT Drive internal error. Replace the drive. (FF55) 0103 SERF MACRO (FF55) 0201 DSP T1 Drive internal error. If fieldbus is in use, check the OVERLOAD communication, settings and contacts.
  • Page 71 Fault tracing 363 ECO Series Operations Manual CODE FAULT CAUSE WHAT TO DO 1004 PAR AO SCALE Incorrect analog output Check parameter group 15 ANALOG AO signal scaling OUTPUTS settings. Check that (6320) following applies: • 1504 MINIMUM AO1 <...
  • Page 72 364 Fault tracing ECO Series Operations Manual CODE FAULT CAUSE WHAT TO DO 1017 PAR SETUP 1 Only two of the following Disable frequency output, frequency can be used input or encoder: (6320) simultaneously: MTAC- • change transistor output to digital...

  • Page 73: Common Diagnostic Issues

    ECO Series Operations Manual Common Diagnostic Issues If in case that you run into an issue, listed below are common issues that may occur while operating your Mathews Company grain dryer. Problem: Dryer will not reach operating temperature, or it reaches it slowly.
  • Page 74 ECO Series Operations Manual Problem: Burner will not fire, but gauge shows gas pressure. Possible Cause/Solution: 1. Check that the igniter is properly gapped and has a strong spark. 2. Inspect the porcelain and electrodes for damage or cracking. Clean or replace if necessary.
  • Page 75 ECO Series Operations Manual Problem: The burner lights but does not stay on. Possible Cause/Solution: (NOTE: This is most likely due to the flame sensing) 1. Ensure flame sense probe is located in the flame. 2. Inspect the sense wire for damage and for loose or wet connections.

  • Page 76: Notes

    ECO Series Operations Manual Section Notes ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ Notes 7.1 DOC-E01-0815. i n dd...
  • Page 77 ECO Series Operations Manual ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ 7.2 Notes DOC-E01-0815. i n dd...
  • Page 78 ECO Series Operations Manual ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ Notes 7.3 DOC-E01-0815. i n dd...
  • Page 79 ECO Series Operations Manual ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ 7.4 Notes DOC-E01-0815. i n dd...
  • Page 80 ECO Series Operations Manual ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ Notes 7.5 DOC-E01-0815. i n dd...
  • Page 81 ECO Series Operations Manual ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ 7.6 Notes DOC-E01-0815. i n dd...
  • Page 82 GRAIN DRYER SPECIALISTS Mathews Company www.MathewsCompany.com Crystal Lake, IL phone: 815-459-2210 fax: 815-459-5889 email: mcsales@mathewscompany.com DOC-E01-0815...

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