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mathews company ECO Series Operation Manual

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OPERATIONS
MANUAL
Model Year 2022
GRAIN DRYER SPECIALISTS
DOC-E01-0322

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  • Page 1 OPERATIONS MANUAL Model Year 2022 GRAIN DRYER SPECIALISTS DOC-E01-0322...
  • Page 2 OPERATIONS MANUAL - ECO SERIES © 2022 Mathews Company 500 Industrial Avenue Crystal Lake, IL 60012 USA www.mathewscompany.com...
  • Page 3 CSA 3.8 2014 Cer• fi ed Dryers The following instruc• ons pertain to dryers built and cer• fi ed to the CSA 3.8 2014 standard and is meant for qualifi ed personnel only. Gas Installa• on The equipment shall be installed in accordance with the Natural Gas and Propane Installa• on Code, CSA B149.1 and the Propane Storage and Handling Code, CSA B149.2, or applicable provincial regula•...
  • Page 4 • B149.1 6.2.2 a fi " ng used shall with steel shall be malleable iron or steel • B149.1 hydrosta# c relief devices shall be used where liquid propane can be trapped and vented to a safe loca# on • B149.1 6.4.3 schedule 80 piping and fi " ngs shall be used on liquid phase systems or over 125 psi •...

  • Page 5: Leak Tests

    Field Installed Wiring Dryer wiring from the branch circuit is included in the fi eld installa• on wiring schema• c. 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 addi• onal overload protec• on device in front of the dryer for adequate protec•...
  • Page 6 Ven• ng The following specifi ca• ons need to be followed in regards to ven• ng: • B149.1 5.4.1 hydrostats must be vented to a “safe loca• on” • B149.1 5.4.2 hydrostats may be vented into a common header provided the cross sec• onal area is equal to the cross sec•...

  • Page 7: Warranty Statement

    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 condi• ons and in accordance with all applicable instruc•...

  • 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 Registra! on ....................1.2 Model / Serial Number / Specifi ca! ons ................1.2 Safety ..........................1.3 Lock-out / Tag-out Requirements ....................
  • Page 9 Suggested Plenum Temperatures ....................4.9 Suggested Discharge Rate ......................4.9 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 Lubrica! on ........................5.3 Seasonal Cleaning ......................5.3 Outer Screens ..........................5.4 Inner Screens ..........................

  • Page 12: Introduction 1.1

    Overview The majority of the informa! on in this manual applies to all ECO Series Grain Dryers, however it is important to understand that there are diff erent confi gura! ons and op! ons that may or may not be included on your par! cular machine.

  • Page 13: Owner / Operator Notes

    Model / Serial Number / Specifi ca! ons The model and serial number of your Mathews Company con! nuous fl ow grain dryer are stamped on plates located on the base of the dryer as shown: 1.2 Introduction...

  • Page 14: Safety

    ECO Series Opera! ons Manual Specifi ca! ons 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 opera! ng or performing maintenance on your machine, it is important to make safety a top priority.

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

    ECO Series Opera! ons 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 precau! ons be taken before servicing or repairing equipment. This includes shu" ng off...

  • Page 16: Blocks

    ECO Series Opera! ons 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, li" s, or any equipment that might inadvertently move by sliding, falling, or rolling.
  • Page 17 ECO Series Opera• ons Manual...

  • Page 18: Specifications 2.1

    ECO Series Opera! ons Manual Section Specifi ca! ons Standard Specs Model E300 E300h E400 E400h E500 E500h E600 E600h E700 E700h Holding Capacity (bu) Grain Column Thickness 14" Grain Column Length 12'-0" 16'-0" 20'-0" 24'-0" 28'-0" Max Opera! ng Burner Capacity (heat+cool) 2.65...

  • Page 19: Metric Specs

    ECO Series Opera! ons Manual Metric Specs Model E300 E300h E400 E400h E500 E500h E600 E600h E700 E700h Holding Capacity (m3) 10.5 14.1 17.7 21.1 24.7 Grain Column Thickness 35.6 (cm) Grain Column Length Max Burner Capacity (heat+cool) kW 1035...
  • Page 20 ECO Series Opera! ons Manual Specifications 2.3 DOC-E01-0322...
  • Page 21 ECO Series Opera! ons Manual 2.4 Specifications DOC-E01-0322...
  • Page 22 ECO Series Opera! ons Manual Specifications 2.5 DOC-E01-0322...
  • Page 23 ECO Series Opera! ons Manual 2.6 Specifications DOC-E01-0322...
  • Page 24 ECO Series Opera! ons Manual Specifications 2.7 DOC-E01-0322...
  • Page 25 ECO Series Opera• ons Manual...

  • Page 26: Equipment Overview

    ECO Series Opera! ons Manual Section Equipment Overview The Equipment Overview sec! on will help iden! fy parts of the dryer and briefl y explain their func! on. The images will physically show you what the component(s) look like and the descrip! on following will state their purpose.
  • Page 27 ECO Series Opera! ons Manual Rotary (Bin) Fill Switch The Rotary Fill Switch is located in the wet hopper on the opposite end of the fi ll tube and is powered by 24V. The switch is motorized and will rotate a paddle un! l wet grain comes in contact with the paddle.

  • Page 28: High Voltage Cabinet

    ECO Series Opera! ons Manual High Voltage Cabinet 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 associ- ated electrical hardware.

  • Page 29: Low Voltage Cabinet

    ECO Series Opera! ons Manual Low Voltage Cabinet 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 varia! ons which include an AccuDry and Non-AccuDry op! on: Emergency Stop Bu"...

  • Page 30: Pinnacle 20|20 Remote Cabinet

    ECO Series Opera! ons Manual Pinnacle 20|20 Remote Cabinet The Pinnacle 20|20 Remote Cabinet and associated sub-panel, shown below, is where the Pinnacle 20|20 HMI touch screens are located, as well as the M-C Trax modem. HMI Touch Screen HMI Touch Screen Emergency Stop Bu"...

  • Page 31: Pinnacle 20|20 Customer Equipment Cabinet

    ECO Series Opera! ons Manual Pinnacle 20|20 Customer Equipment Cabinet The Pinnacle 20|20 Customer Equipment Cabinet and associated sub-panel, shown below, is provided as the designated junc! on for wiring in customer equipment that is to be used in conjunc! on with the dryer opera! on.

  • Page 32: Burner Control Cabinet

    ECO Series Opera! ons Manual Burner Control Cabinet 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 igni! on board.
  • Page 33 ECO Series Opera! ons Manual Igni• on Board The Igni! on Board controls the overall opera! on 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 con! nuously monitoring the presence of a fl...

  • Page 34: Discharge Moisture Sampler

    ECO Series Opera! ons Manual Discharge Moisture Sampler (Op• onal) The discharge moisture sampler is used to con! nuously 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 35: Gas Train

    ECO Series Opera! ons Manual Gas Train The purpose of the gas train is to safely and effi ciently supply fuel at the correct pressures and fl ow rates to the burners. There are several varia! ons of the gas train depending on what model and op! ons are equipped on the machine.

  • Page 36: Dual Burner Lpg Gas Train

    ECO Series Opera! ons Manual Dual Burner LPG Gas Train Solenoid Valve Pressure Regulator Control Valve Actuator Pressure Regulator Control Valve Solenoid Valves Pressure Relief Valve Strainer Pressure Regulator Manual Hand Valve Dual Burner NG Gas Train Manual Hand Valve...

  • Page 37: Dual Burner Lpg Gas Train (With Op! Onal Csa Requirements)

    ECO Series Opera! ons Manual Dual Burner LPG Gas Train (with Op! onal CSA Requirements) (Shown with older style Control Valve Actuator) Pressure Regulator Solenoid Valve Pressure Regulator Control Valve Actuator Valve Proving Solenoid Control Valve Actuator Valve Proving Solenoid...
  • Page 38 ECO Series Opera! ons Manual Control Valve The Control Valve is a thro" ling bu" erfl y valve that controls the fuel fl ow rate to the burner which is precisely posi! oned by the control valve actuator. The control valve is connected to the control valve actuator through a mechanical linkage.

  • Page 39: Burner

    ECO Series Opera! ons Manual Burner The purpose of the burner is to provide heat to the drying air. This heat comes from the combus! on of the supplied fuel and takes place in the MIDCO Burner. Models E300, E400, E500, E600 and E700 come with two burners.

  • Page 40: Operating Procedures

    ECO Series Opera! ons Manual Section Opera ng Procedures Overview This sec! on will explain the opera! on of the primary components of the dryer as well as provide step-by- step procedures to properly start-up and shut-down the machine. Opera! onal and func! onal descrip! ons along with adjustment details for primary components will be presented ini! ally, followed by opera! onal procedures for star! ng up and shu"...

  • Page 41: High Limit Switch

    ECO Series Opera! ons Manual Setpoint Check The following procedure shall be u! lized 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. A" er the dryer has been fi lled with grain and before the burner is ignited, the opera! on of each air pressure switch must be checked.
  • Page 42 ECO Series Opera! ons Manual High Limit Switch Burner Control Cabinet The safety features associated with the high limit switch(es) are for your safety and for the protec• on of the dryer. They should be checked for correct opera• on at the start of the drying season and periodically during the season as they are designed to protect the dryer from a fi...

  • Page 43: Variable Frequency Drive (Vfd)

    ECO Series Opera! ons Manual Variable Frequency Drive (VFD) The variable frequency drives control the speed of the discharge metering rolls and the takeaway auger. The communica! on 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.

  • Page 44: Changing Variable Frequency Drive Parameters

    ECO Series Opera! ons Manual Changing Variable Frequency Drive Parameters Direc• on of the Motor Rota• on 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 45: Opera! Onal Procedures

    ECO Series Opera! ons Manual Opera• onal Procedures The following opera! onal procedures provide a step-by-step guide to star! ng-up and shu" ng-down your dryer. These procedures should be followed and used in conjunc! on with the Pinnacle 20|20 Controls Manual for HMI touchscreen adjustments.

  • Page 46: Daily Shut-Down

    ECO Series Opera! ons Manual Daily Shut-Down This shutdown procedure assumes that the dryer will be put back into opera! on within 24-48 hours. If the grain drying opera! on will not resume within 24-48 hours, it is suggested that the dryer be emp! ed and the grain placed back into the appropriate storage.

  • Page 47: End-Of-Season Shut-Down

    ECO Series Opera! ons Manual 9. On the Remote Cabinet, from the Control page on one of the HMI's, press the Takeaway START bu" on. Once the discharge auger or conveyor (if equipped) as well as customer takeaway equipment are running, press the Metering START bu"...

  • Page 48: Suggested Plenum Temperatures

    ECO Series Opera! ons 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 pu" ng out into the hea! ng chamber. Plenum Drying Temperature Canola, Rape, Sunfl...
  • Page 49 ECO Series Opera• ons Manual...

  • Page 50: Maintenance

    This sec! on of the manual will explain the factory recommended maintenance and cleaning requirements to keep your Mathews Company grain dryer running effi ciently. Failure to follow or comply with these recommenda! ons will impact dryer performance and may limit or void your warranty.

  • Page 51: Fans & Burners

    ECO Series Opera! ons 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 52: Lubrica

    ECO Series Opera! ons Manual Lubrica• on Maintaining proper lubrica! on of all moving components of your dryer is key to its effi cient and safe opera! on. The following table below outlines all recommended lubrica! on. Note that some of the items may not be applicable based on confi...

  • Page 53: Outer Screens

    ECO Series Opera! ons 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 combina! on of water and residue can form a paste, making the surfaces s! cky and more diffi...

  • Page 54: Diagnosing A Dryer Shutdown

    ECO Series Opera! ons Manual Section Troubleshoo ng The Troubleshoo! ng sec! on will help with diagnosing the dryer in case of a dryer shut down. This sec! on will explain common situa! ons that may arise and will help come up with a resolu! on to get the dryer back to opera! on.
  • Page 55 ECO Series Opera! ons Manual series respec! vely. 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 fi...

  • Page 56: Safety Circuit Schema

    ECO Series Opera! ons Manual Safety Circuit Schema• c The fi rst part of the safety circuit below will help diagnose a dryer shut down for a Heat/Cool ECO dryer. This is the Dryer Control or Fault Control por! on of the Safety Circuit. See page 4 of the electrical schema! cs to see this por! on of the safety circuit that matches exactly to your par! cular dryer.
  • Page 57 ECO Series Opera! ons Manual Safety Circuit Schema• c The second part of the safety circuit below will help diagnose a dryer shut down. This is the Dryer Safety or Human Safety por! on of the Safety Circuit. See page 5 of the electrical schema! cs to see this por! on of the safety circuit that matches exactly to your par! cular dryer.

  • Page 58: Customer Interface

    ECO Series Opera! ons Manual Customer Interface Customer connec! ons are for remote equipment, and are used to interface the grain dryer with fi ll and takeaway equipment. The grain dryer does not supply power for these interfaces. An auxiliary power source should be used to power customer equipment.

  • Page 59: Variable Frequency Drive (Vfd)

    ECO Series Opera! ons Manual Variable Frequency Drive (VFD) In the case an error occurs on the variable frequency drives (VFD's) listed below are the display faults that will show up on the main display of the drive. Fault Code Descrip! on Described below is the fault code and a descrip! on of the fault.
  • Page 60 ECO Series Opera! ons 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 61 ECO Series Opera! ons 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. Blown fuse Check the condition of input fuses.
  • Page 62 ECO Series Opera! ons 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. Check start-up data.
  • Page 63 ECO Series Opera! ons 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. insufficient motor power.
  • Page 64 ECO Series Opera! ons 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 65 ECO Series Opera! ons 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 66 ECO Series Opera! ons 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 67 ECO Series Opera! ons 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 < 1505 MAXIMUM AO1.
  • Page 68 ECO Series Opera! ons 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 01 pulse encoder...

  • Page 69: Common Diagnos! C Issues

    ECO Series Opera! ons Manual Common Diagnos• c Issues Listed below are common issues that may occur while opera! ng your Mathews Company grain dryer. Problem: Dryer will not reach opera! ng temperature, or it reaches it slowly. Possible Cause/Solu• on: 1.
  • Page 70 ECO Series Opera! ons Manual Problem: Burner will not fi re, but gauge shows gas pressure. Possible Cause/Solu! on: 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 71 ECO Series Opera! ons Manual 7. Ensure ini! al % valve opening is properly set. Problem: The burner lights but does not stay on. Possible Cause/Solu! on: (NOTE: This is most likely due to the fl ame sensing) 1. Ensure fl ame sense probe is located in the fl ame.

  • Page 72: Notes

    ECO Series Opera! ons Manual Section Notes ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ Notes 7.1 DOC-E01-0322...
  • Page 73 ECO Series Opera! ons Manual ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ 7.2 Notes DOC-E01-0322...
  • Page 74 ECO Series Opera! ons Manual ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ Notes 7.3 DOC-E01-0322...
  • Page 75 ECO Series Opera! ons Manual ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ 7.4 Notes DOC-E01-0322...
  • Page 76 ECO Series Opera! ons Manual ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ Notes 7.5 DOC-E01-0322...
  • Page 77 ECO Series Opera! ons Manual ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ ____________________________________________ 7.6 Notes DOC-E01-0322...

This manual is also suitable for:

Eco e300Eco e300hEco e400Eco e400hEco e500Eco e500h ... Show all

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