MAGUIRE LPD-100, Installation Operation & Maintenance

Page 1: ...MAGUIRE PRODUCTS INC LPD Dryer LPD Low Pressure Dryer INSTALLATION OPERATION MAINTENANCE Copyright Maguire Products Inc 2010 Models LPD 30 LPD 100 LPD 200...

Page 2: ...Maguire Products Inc Edition November 5 2010 2 LPD Dryer...

Page 3: ...ducts Inc accepts no responsibility or liability for damage or malfunction of the equipment arising from non observance of these operating instructions To avoid errors and to ensure trouble free opera...

Page 4: ...his manual or find errors please let us know so that we may make the required corrections or provide you with accurate information Additionally we will gladly provide you with an updated copy of any m...

Page 5: ...sed Air Connection 13 2 2 5 Electrical Connection 14 2 3 Installing Maguire Receiver on Process Machine 15 2 4 Using Your Own Receiver Loader 16 2 5 Using the Maguire Receiver to load the Dryer 17 2 6...

Page 6: ...s 78 4 13 Decommissioning and Disposal 80 PART 5 TROUBLESHOOTING SOFTWARE 81 5 1 Alarms Cause and Solution 81 5 2 Possible Service Issues 84 5 2 1 Loss of Vacuum 84 5 2 2 Damaged Vacuum Disks 84 5 2 3...

Page 7: ...S It will take about 10 minutes THESE PAGES COVER Warranty and Disclaimers What we Warranty and what we cannot promise SAFETY Warnings Safety warnings INSTALLATION Assembly and setup OPERATION What bu...

Page 8: ...hat we always strive to satisfy our customers in whatever manner is deemed most expedient to overcome any problems they may have in connection with our equipment Excluded Items The ability of the cani...

Page 9: ...s might cause injury Additionally the disks above and below each canister close automatically and present a pinch point For these reasons an interlock on the access door prevents all operations while...

Page 10: ...plastic wire ties to affix the canister from turning on the Series 30 units On the Series 100 and 200 models it is advisable to use packing material around the canister support brackets and ship the c...

Page 11: ...0 model Dryers Loosen thumbscrews and slide plates away from opening Insert hopper into opening so that air supply hoses are facing the same side of the Dryer as the fitting they will attach to Slide...

Page 12: ...th the boltholes in the fill hopper intake plate For easy accessibility orientate the hopper so that the manual slide gate handle and hopper access door are accessible from the side or rear of the Dry...

Page 13: ...tions in the Canister Hanger Assembly These three Positions are labeled 1 2 and 3 The number identifies the canisters position in the assembly 2 2 4 Compressed Air Connection Connect an air supply to...

Page 14: ...grams on page 95 for wiring details Confirm Correct Blower Rotation On THREE PHASE units CONFIRM CORRECT BLOWER ROTATION by following these instructions Turn power on using main power switch Press Dis...

Page 15: ...the 2 inch vacuum line to the Convey Vacuum Connection port Attach the other end of the 2 inch vacuum line to the port located on top of the Maguire Receiver vacuum again using a hose clamp Orient the...

Page 16: ...ontroller DO NOT wire tie the SENSOR cable to the MATERIAL hose This will induce static spikes into the processor Keep them separated 2 4 Using Your Own Receiver Loading System on a process machine If...

Page 17: ...have you will use one of two patterns to drill out the necessary holes in the Hopper Lid Blank Note The Hopper Lid Blank can be supplied pre drilled if requested Patterns are for ADR 1 or ADR 4 and a...

Page 18: ...ng it to face the right side if the Dryer for better access to the Convey Vacuum Connection port Next attach the material convey line to the Maguire Receiver s lower port material convey using a hose...

Page 19: ...installation of the Dual Convey Option on LPD 100 and LPD 200 Series Dryers 1 Open the front access door of the Dryer loosen the hose clamp that secures the short pipe labeled Dry Resin Takeoff Pipe...

Page 20: ...ft edge of the panel and 41 inches up from the bottom of the panel On 100 Series Dryers 2 inch in from the left edge of the panel and 37 inches up from the bottom of the panel 4 Using the supplied pip...

Page 21: ...up to the louver located to the left of the air manifold and run the line into the louver c With the back upper panel removed route the airline along with the existing airlines and wires Run the airl...

Page 22: ...Maguire Receivers on the process machines 10 Run a Vacuum Convey Line from each of the Maguire Receivers on the process machines to the appropriate Receiver Vacuum port on the Dual Convey Shifting Va...

Page 23: ...mbwheel switches See RECOMMENDED CYCLE TIMES next page These are suggested starting points only Run moisture tests to determine correct cycle times or submit your material to us for determination See...

Page 24: ...5 30 150 300 SAN 0 20 0 10 20 40 80 180 Final moisture content as recommended by the raw material manufacturer Recommended cycle time is based on average initial moisture content For high initial mois...

Page 25: ...ster at the bottom to deliver material to the process If the bottom sensor was not uncovered at the time of indexing the fill valve will delay opening until the sensor becomes uncovered 5 The canister...

Page 26: ...e someone has to manually empty the canisters after each index See Star Functions on page 37 for more information Cycle Time Alarm 36 Alarm to alert an operator that material has run out before end of...

Page 27: ...his mode Press and hold the Set Convey Time button to set the convey time When conveying starts immediately press the convey time button and hold until the desired level in the receiver is reached the...

Page 28: ...t and color change up to this point the fill point above the canister See section 4 13 Canister Removal Cleaning on page 66 under the Maintenance and Service section In the CLEAN mode CANISTERS DO NOT...

Page 29: ...rator or has stopped between cycles in the clean out mode MODE AUTO CLEAN Select AUTO for normal automatic indexing of canisters Select CLEAN to PREVENT AUTOMATIC INDEXING This is for COLOR CHANGES IN...

Page 30: ...perator must press the INDEX button to advance the canisters after cleaning SILENCE ALARM This button silences the STROBE and BEEPER ALARMS but does not remedy the cause of the alarm ALARM SPEAKER CON...

Page 31: ...of material See Recommended Cycle Times chart on page 24 Material that does not require drying may still be allowed to pass through the system by setting both thumbwheels to 000 The heater and vacuum...

Page 32: ...force a convey cycle when some additional conveying is required to keep up with the process Works only when the dryer is running in AUTO Mode EMPTY KEY Opens the bottom valve at the DISPENSE station...

Page 33: ...can also be used to update the controller s software For information about updating the controller software see Updating Controller Software and the Star function 93 Notes about printing to a USB driv...

Page 34: ...ED mode press then 33333 or your own password In Manual Program or Advanced modes automatic operation cannot occur You can enter these modes only when the dryer has been STOPPED by pressing the CYCLE...

Page 35: ...ROUTINES section The following keys operate in MANUAL and PROGRAM modes Position 1 Key Rotate the canister in Position 1 around to the Dispense station Position 2 Key Rotate the canister in Position 2...

Page 36: ...Toggles Open Close Can be operated in Auto Mode while the door is open for cleanout Convey Key Shift hot air flow valves to convey material Toggles convey On Off Also works while Dryer is running Blo...

Page 37: ...te Format Set current Date and Time 12 Restore Factory Default Settings 22 Auto Start Disable Enable Disable 23 Copy the current User Settings into the Backup Disable 24 Auto Stop Disable Enable Disab...

Page 38: ...h MONTH __ DAY __ YEAR __ HOUR __ MIN __ Use the key to step through all fields without change Enter new settings where required The correct date and time for Eastern Standard Time were entered at the...

Page 39: ...explanation of the memory areas in the Dryer software as well as the use of the Clear and Clear All Routines see page 88 Once saved this information is then available for retrieval using the CLEAR rou...

Page 40: ...n the User Backup Settings Also if you have been making changes to User Settings and now wish to restore all settings to what they were at power up this is the function to use When finished press Exit...

Page 41: ...to view log of Alarm messages Alarm message Date and Time Displays last 25 alarms in the order of most recent occurrence Use the key to toggle through alarm messages When finished press Exit then pres...

Page 42: ...TO DRYER Standard Convey In Standard Convey the Dryer will continue to dispense material to a Receiver mounted on the process until the Receiver s sensor is covered After the initial fill if the rece...

Page 43: ...operation The canisters advance index when the cycle timer times out even though it is not empty With ADVANCE ON EMPTY selected canisters advance only after the cycle time has elapsed and the caniste...

Page 44: ...be reset from Program and Advanced Modes Material Dispense Mode Vacuum Take Off Gravity Advanced Mode Only Press 5 0 to alter the operation of the dispense valve MAT DISPENSE MODE VACUUM TAKE OFF MAT...

Page 45: ...is dried When Pulsed is selected dispense valve will pulse on and off when dispensing Use the key to toggle through each dispense mode When finished press Exit to save changes then press Exit again to...

Page 46: ...ing to a USB drive When saving printout information to a USB drive the USB drive must contain a folder named maguire and within the folder a file labeled PRINTER TXT must be present It is this file PR...

Page 47: ...a file labeled PRINTER TXT must be present PRINTING Print Parameters Press 7 7 to print a copy of all internal parameters A USB printer or USB Drive must be connected and ready The printout will displ...

Page 48: ...o select the language format SELECT LANGUAGE ENGLISH Use the key to toggle between languages ENGLISH FRANCAIS ITALIANO DEUTCH CZECH Note ENGLISH 5 6 7 are placeholders for future additions to the lang...

Page 49: ...ware Flash card none When finished press Exit and then press Exit again to exit out of Advanced Mode Accessible in Advanced Mode Only Operating Mode Normal Service Press 9 7 display will say NORMAL Pr...

Page 50: ...ible for change through the keypad in Program Mode Advanced Mode parameters are separated to restrict access because these parameters are either set to defaults that should never be altered or are def...

Page 51: ...ld Inches of Mercury LRT Lock Release Time seconds PST Position Settle Time seconds LDD Lock Detect Delay seconds HOT Heater OFF Temperature ATS Anticipated Temp Sooner ATL Anticipated Temp Later NCT...

Page 52: ...HA 10060 10060 10060 STC 100 100 100 HTO 5 5 5 TDF 5 5 5 HAL 510 510 510 HCT 1 1 1 BTM 4 4 4 ECD 10 10 10 NVT 1 1 1 LRT 1003 1003 1003 PST 3 3 3 LDD 3 3 3 HOT 3 3 3 ATS 12 12 12 ATL 40 40 40 NCT 5 5 5...

Page 53: ...t least 20 degrees below the softening point of the plastic to prevent clumping of pellets but must be over 150 160 to assure boil off of moisture under vacuum The temperature thumbwheel switch is nor...

Page 54: ...00 percent on until this temperature is reached Once this point is reached temperature control begins HTO Heat Adjustment Time seconds DO NOT CHANGE THIS PARAMETER ADVANCED MODE ONLY This parameter de...

Page 55: ...fore Heat On seconds DO NOT CHANGE THIS PARAMETER ADVANCED MODE ONLY The first 3 digits 000xx indicate in seconds how long the blower will be turned off if the heater duty cycle has dropped to zero an...

Page 56: ...into the detent which assures that canister movement has stopped At the end of this time the cycle starts If this time out does not occur within 5 seconds of operation of the lock an ALARM will sound...

Page 57: ...et no adjustment occurs RCC Rate of Correction Constant DO NOT CHANGE THIS PARAMETER ADVANCED MODE ONLY Interacts with the adjustment amount math routine to fix the extent of correction that an error...

Page 58: ...alarm sounds a vacuum problem exists and must be corrected Read NOTE above PRG Vacuum Purge frequency and time This parameter instructs the software to operate the purge valve for a period of time in...

Page 59: ...gs swing widely This delays temperature adjustment until some stability is reached HFT Heat Failure Time Seconds Temperature DO NOT CHANGE THIS PARAMETER ADVANCED MODE ONLY This parameter tells the so...

Page 60: ...o 00 xxx00 it will continue pulsing until the VTA sensor is covered ATO Temperature Offset DO NOT CHANGE THIS PARAMETER ADVANCED MODE ONLY Allows setting an offset to the set point temperature always...

Page 61: ...fault password is 22222 To change a PARAMETER the sequence of keystrokes is as follows Press Display will say ENTER FIVE DIGIT PASSWORD _ _ _ _ _ Press 22222 Display will say TEMP 63 F v 0in MODE PROG...

Page 62: ...ood idea to have an exact copy of your User Settings stored in the backup for just such an emergency To copy ALL PARAMETERS into the User Backup Settings the sequence of keystrokes is as follows Press...

Page 63: ...will determine how frequently this filter should be checked or cleaned The air filter is located inside the front door of the Series 30 models and at the base of the left side panel on the Series 100...

Page 64: ...emptied from a full canister Opening the window access door will allow cleaning of this space You can then use the empty button on the control panel to manually operate the empty valve allowing mater...

Page 65: ...yer is in Auto Mode The bottom valve at the DISPENSE station will open and dispense the material in the canister above through the VTA chamber The empty key can be operated in Auto Mode while the door...

Page 66: ...follow this procedure Unhook the lower canister latches 100 series also has upper latches on each side of the canister by lifting the latch up and toward you releasing the canister Grip the two handle...

Page 67: ...NOT damage the edge of the canisters Note the flat bottom disk with holes Canisters and surrounding parts may be hot Use of gloves is recommended Canisters and surrounding parts may be sharp or presen...

Page 68: ...ter Do NOT remove any remaining parts All mounting hardware has been sealed at the factory to be vacuum tight DO NOT remove or tamper with any bolts To reassemble Install perforated cone first Install...

Page 69: ...e Gate at the base of the hopper located at the lower right side of the hopper Rotate the Fill Hopper counter clockwise and towards the right side of the Dryer until the Fill Hopper dispense port is o...

Page 70: ...Fill Hopper must first be rotated see instructions in previous section for Fill Hopper rotation After Fill Hopper has been rotated around remove the Fill Valve and disconnect the Fill Valve pneumatic...

Page 71: ...leaner Inspect the 3 seals for damage Replace if necessary Note Remove canisters prior or inspection and cleaning 4 6 Drain and purge Air Filter Regulator The purpose of the air filter is to remove mo...

Page 72: ...ls canister movement only when the cylinder to which it is mounted is de energized In other words it controls cylinder exhaust air All three must be adjusted to assure correct operation into each posi...

Page 73: ...s conveyed to the process machine the rate at which material is picked up by the air steam is important Too little takes too long to load too much may block the required flow of air This rate is adjus...

Page 74: ...WITH AN EMPTY HOPPER Adjusting sensor sensitivity 1 The adjustment screw is located at the rear of the sensor You will need a very small screwdriver to adjust it 2 Empty the hopper until the sensor i...

Page 75: ...valve should be closed cylinder retracted The CONVEY hot air valve should not be shifted 6 Turn the POWER switch on and go into PROGRAM mode 7 Press the SEAL key Confirm that all disks engage the can...

Page 76: ...inch into the center of this screen This location will be the closest to what the RTD sensor will display on the LPD dryer If the test will be done during a heating cycle orient the sensor wire so th...

Page 77: ...ed only if instructed to do so by a Maguire LPD Technician To enter the DIAGNOSTIC TEST MODE holding down the 5 key and the blank key to the right of the 6 key while turning the Dryer s power on Relea...

Page 78: ...um Heater overheat thermal switch Heater overheat is a manual reset thermal disk opens at 293 F mounted on the stainless steel tube that contains the heater elements This would signal a blower failure...

Page 79: ...d state relays each rated 25 amps cycling them on and off every second to control the heater Blower We use a contacter to control the blower motor Check Valve Opens to let air into the vacuum canister...

Page 80: ...ckets door top panels shifting valve box air filter box Rubber Parts Wheels filter vacuum hoses Stainless Steel Parts Canisters vacuum disks heater disks Vacuum Takeoff Assembly VTA box and chute cani...

Page 81: ...to 80 psi with vacuum generator engaged Check for obstructions in cabinet Check for stuck dispense valve ERROR VACUUM FAILURE Problem Vacuum failed to reach target 25 inches within 90 seconds or unabl...

Page 82: ...n Solution Check that canisters are properly installed Check that bottom disk is installed in all canisters Check Air Pressure set to 80 psi with vacuum generator engaged ERROR CYCLE TIME Problem The...

Page 83: ...et Temperature Thumbwheel is set to 000 Solution Reset Target Temperature thumbwheel Note If Target Temperature TEMP thumbwheel and Cycle Time CYCLE thumbwheel are both set to 000 then the Dryer will...

Page 84: ...mmediately to full vacuum If it is slow to reach full vacuum the vacuum generator may be contaminated from oil in the compressed air mixing with dust drawn from the canister If your air is oily add an...

Page 85: ...p this safety switch at 300 degrees F 150C The switch will break the control power to the heater relays which will result in a FAIL SAFE ALARM condition See Alarm Conditions on page 81 The switch is M...

Page 86: ...ill will be performed Fill 0 means no fill 04 26 2010 ID 002 TARGET 250 F CYCLE 060 m FILL 1 CAN 1 The first line is a header line for each cycle Date Unit ID number Thumbwheel settings Fill Valve Can...

Page 87: ...s If you are not obtaining the results you want or if you would like us to test your material to determine the optimal drying cycle time please provide us with the following information below A sample...

Page 88: ...2 see Star Functions on page 37 CLEAR Routine The CLEAR routine will copy User Backup Settings into User Settings If User Backup Settings were not intentionally saved earlier using 23 then the CLEAR r...

Page 89: ...ing weight 620 lb 280 kg 800 lb 360 kg 1010 lb 460 kg Packing dim L x W x H 40 x35 x75 100x90x190 cm 40 x35 x85 100x90x220 cm 40 x35 x95 100x90x240 cm Heater element 3 kW 13A 3 kW 13 A 5 kW 22A 5 kW 2...

Page 90: ...low for descriptions of each field in the model number LPD Low Pressure Dryer Dryer Size Series 3 Series LPD 30 1 Series LPD 100 2 Series LPD 200 10 Series LPD 1000 Heat Class S Standard H High Heat C...

Page 91: ...NO lost time 5 The routine desiccant maintenance associated with desiccant dryers is eliminated Our dryer has no routine maintenance items 6 For those who sometimes forget to plan ahead your unused in...

Page 92: ...d and costly outside service required Are parts readily available How much time will it take to get it running again 4 EASE OF USE What percentage of your employees will be able to run this equipment...

Page 93: ...s determined by the moisture content of the resin after the dryer has done its job Resin moisture content however is not easily measured so dryer manufactures use other criteria to assure performance...

Page 94: ...n Aston Pennsylvania PREPAID Please note that we always strive to satisfy our customers in whatever manner is deemed most expedient to overcome any problems they may have in connection with our equipm...

Page 95: ...5 VAC 3 60 Hz LPD 100 240 VAC 3 60 Hz LPD 100 400 VAC 3 50 Hz LPD 100 480 VAC 3 60 Hz LPD 100 575 VAC 3 60 Hz LPD 200 240 VAC 3 60 Hz LPD 200 400 VAC 3 60 Hz LPD 200 480 VAC 3 60 Hz LPD 200 575 VAC 3...

Page 96: ...Maguire Products Inc Edition November 5 2010 96 LPD Dryer LPD 30 240 VAC 3 60 Hz...

Page 97: ...Maguire Products Inc Edition November 5 2010 97 LPD Dryer LPD 30 400 VAC 3 50 Hz...

Page 98: ...Maguire Products Inc Edition November 5 2010 98 LPD Dryer LPD 30 480 VAC 3 60 Hz...

Page 99: ...Maguire Products Inc Edition November 5 2010 99 LPD Dryer LPD 30 575 VAC 3 60 Hz...

Page 100: ...Maguire Products Inc Edition November 5 2010 100 LPD Dryer LPD 100 240 VAC 3 60 Hz...

Page 101: ...Maguire Products Inc Edition November 5 2010 101 LPD Dryer LPD 100 400 VAC 3 50 Hz...

Page 102: ...Maguire Products Inc Edition November 5 2010 102 LPD Dryer LPD 100 480 VAC 3 60 Hz...

Page 103: ...Maguire Products Inc Edition November 5 2010 103 LPD Dryer LPD 100 575 VAC 3 60 Hz...

Page 104: ...Maguire Products Inc Edition November 5 2010 104 LPD Dryer LPD 200 240 VAC 3 60 Hz...

Page 105: ...Maguire Products Inc Edition November 5 2010 105 LPD Dryer LPD 200 400 VAC 3 50 Hz...

Page 106: ...Maguire Products Inc Edition November 5 2010 106 LPD Dryer LPD 200 480 VAC 3 60 Hz...

Page 107: ...Maguire Products Inc Edition November 5 2010 107 LPD Dryer LPD 200 575 VAC 3 60 Hz...

Page 108: ...Maguire Products Inc Edition November 5 2010 108 LPD Dryer LPD Wiring Diagram Terminal Board LPD 30 100 200...

Page 109: ...Maguire Products Inc Edition November 5 2010 109 LPD Dryer 6 7 Exploded View and Parts List...

Page 110: ...Maguire Products Inc Edition November 5 2010 110 LPD Dryer...

Page 111: ...D 100 1 12 as7158 Enclosure Left Side Lower LPD 100 1 13 as7158 T Enclosure Assembly Left Upper w Controller 1 14 as7159 Front Door Assembly LPD 100 1 15 as7161 Enclosure Right Side Lower LPD 100 1 16...

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Page 119: ...Maguire Products Inc Edition November 5 2010 119 LPD Dryer 6 8 ADR 1 ADR 4 Diagrams ADR 1 Dimension Diagram...

Page 120: ...Maguire Products Inc Edition November 5 2010 120 LPD Dryer ADR 4 Dimension Diagram...

Page 121: ...Maguire Products Inc Edition November 5 2010 121 LPD Dryer LPD 30 Pneumatic Diagram 1 of 2...

Page 122: ...Maguire Products Inc Edition November 5 2010 122 LPD Dryer LPD 30 Pneumatic Diagram 2 of 2...

Page 123: ...Maguire Products Inc Edition November 5 2010 123 LPD Dryer LPD 100 Pneumatic Diagram 1 of 2...

Page 124: ...Maguire Products Inc Edition November 5 2010 124 LPD Dryer LPD 100 Pneumatic Diagram 2 of 2...

Page 125: ...Maguire Products Inc Edition November 5 2010 125 LPD Dryer LPD 200 Pneumatic Diagram 1 of 2...

Page 126: ...Maguire Products Inc Edition November 5 2010 126 LPD Dryer LPD 200 Pneumatic Diagram 2 of 2...

Page 127: ...guire com Maguire Europe Tame Park Tamworth Staffordshire B775DY UK Tel 44 1827 265 850 Fax 44 1827 265 855 Email info maguire europe com Maguire Products Asia PTE LTD Main Office 15 Changi North Stre...