VBD-50 - Maguire +65 6744 3370 Email: ... PART 2 INSTALLATION 9 ... 2009 – VBD-50 RUN Mode....

MAGUIRE PRODUCTS INC. VBD-50 Vacuum Batch Dryer

VBD-50 Maguire Vacuum Batch Dryer

INSTALLATION • OPERATION • MAINTENANCE

Copyright Maguire Products, Inc. 2008

Maguire Products, Inc.

Edition: May 27, 2009 – VBD-50 2

VBD - Vacuum Batch Dryer




VBD-50 - Vacuum Batch Dryer Copyright 2009 Maguire Products Inc. The information contained within this manual including any translations thereof, is the property of Maguire Products Inc. and may not be reproduced, or transmitted in any form or by any means without the express written consent of Maguire Products Inc. To every person concerned with use and maintenance of the Maguire VBD-50 it is recommended to read thoroughly these operating instructions. Maguire Products 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 operation, it is essential that these operating instructions are read and understood by all personnel who are to use the equipment. Should you have problems or difficulties with the equipment, please contact Maguire Products Inc. or your local Maguire distributor. These operating instructions only apply to the equipment described within this manual. Manufacturer’s Contact Information Maguire Products Inc. 11 Crozerville Road Aston, PA. 19014 Phone: 610.459.4300 Fax: 610.459.2700 Website: http://www.maguire.com Email: [email protected]




Accuracy of this Manual

We make every effort to keep this manual as correct and current as possible. However, technology and product changes may occur more rapidly then the reprinting of this manual. Generally, modifications made to the dryer design or to the operation of the software are may not reflected in the manual for several months. The date at the footer of this manual will indicate approximately how current this manual is. Likewise, your Dryer may have been produced at an earlier time and the information in this manual may not accurately describe your Dryer since this manual is written for the current line of Dryers in production (as of the date in the footer). We always reserve the right to make these changes without notice, and we do not guarantee the manual to be entirely accurate. If you question any information in this 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 manuals you need at any time. We welcome comments and suggestions on ways we can improve this manual. For additional information, or to download the latest copy of this manual or any other Maguire manual, please visit our website or contact us directly. On the Web at: www.Maguire.com

Maguire Products Inc. Main Headquarters 11 Crozerville Road Aston, PA 19014 Tel: 610.459.4300 Fax: 610.459.2700 Email: [email protected]

Maguire Europe Tame Park Tamworth Staffordshire B775DY UK Tel: + 44 1827 265 850 Fax: + 44 1827 265 855 Email: [email protected]

Maguire Products Asia PTE LTD 45 Kallang Pudding Road #01-02 Alpha Building Singapore 349317 Tel: +65 6848 7117 Fax: +65 6744 3370 Email: [email protected]

Maguire Italy Via Zancanaro 40 35020 Vigorovea (PD) Tel: +39 049 970 54 29 Fax: +39 049 971 18 38 Email: [email protected]

Please e-mail comments and suggestions to: [email protected]




Table of Contents

PART 1 GETTING STARTED, READ THIS PAGE 6 1.1 5 Year Warranty and Disclaimers 7 1.2 SAFETY Warnings 8 PART 2 INSTALLATION 9 2.1 Transport and Setup 9 2.2 Dryer Installation 10

2.2.1 Compressed Air Connection 10 2.2.2 Electrical Connection 11 PART 3 OPERATION 12

3.1 Standard Operation 12 3.2 Standard Operating Sequence 12 3.3 Recommended Cycle Times 13 3.4 Dryer Overview 14 3.5 Controller & Operator Station 15

PART 4 MAINTENANCE AND SERVICE 26

4.1 Cleaning the Fill Hopper 26 4.2 Cleaning the Heat Vac Vessel 27 4.3 Cleaning the Retention Hopper 27 4.4 Drain and purge Air Filter / Regulator 28 4.5 Air Pressure Adjustments 28 4.6 Updating Dryer Software 29

PART 5 TROUBLESHOOTING 30 5.1 Alarms – Cause and Solution 30 5.2 Print Outputs 31 5.3 Dryer Software – Factory Reset 33 PART 6 General Information

6.1 - Theory of Operation / Performance 34 6.2 - Warranty 35 6.3 – VBD Diagram & Supplements 36 6.4 - Technical Support / Contact Information 39




1 - Getting Started – READ THIS PAGE PLEASE READ THIS PAGE

You don't have to read the entire manual.... BUT... PLEASE READ THE NEXT FEW PAGES. 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 buttons to push.

GETTING STARTED: PROCEED TO: WARRANTY AND DISCLAIMERS NEXT PAGE




1.1 - Warranty – Exclusive 5-Year

MAGUIRE PRODUCTS offers THE MOST COMPREHENSIVE WARRANTY in the plastics auxiliary equipment industry. We warrant each MAGUIRE VBD – Vacuum Batch Dryer manufactured by us to be free from defects in material and workmanship under normal use and service; excluding only those items listed below as 'excluded items'; our obligation under this warranty being limited to making good at our factory any Dryer which shall, within FIVE (5) YEARS after delivery to the original purchaser, be RETURNED intact to us, transportation charges PREPAID, and which our examination shall disclose to our satisfaction to have been thus defective; this warranty being expressly in lieu of all other warranties expressed or implied and of all other obligations or liabilities on our part, and MAGUIRE PRODUCTS neither assumes nor authorizes any other persons to assume for it any other liability in connection with the sale of its Dryers. This warranty shall not apply to equipment repaired or altered outside MAGUIRE PRODUCTS INC. factory, unless such repair or alteration was, in our judgment, not responsible for the failure; nor which has been subject to misuse, negligence or accident, incorrect wiring by others, or installation or use not in accord with instructions furnished by Maguire Products, Inc. Our liability under this warranty will extend only to equipment that is returned to our factory in 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 equipment.

GETTING STARTED: PROCEED TO: SAFETY WARNINGS NEXT PAGE




1.2 – SAFETY WARNINGS

HOT SURFACES: As with all dryers, there are HOT SURFACES to avoid. Temperatures can reach 350F, (180C) on high temperature models. Typically these surfaces are not at dangerous temperatures, however all hot surfaces should be avoided.

Warning Label indicate HOT SURFACES

USE CAUTION when removing and installing canisters.

USE GLOVES.

DO NOT REACH into the dryer enclosure.

RISK OF SHOCK: Disconnect power supply before servicing the Dryer.

GETTING STARTED: PROCEED TO: INSTALLATION - NEXT PAGE




2 - Installation

2.1 - Transport and Setup Shipment The VBD-50 Dryer is shipped pre-assembled and bolted to a pallet with 4 bolts. Lifting and Moving Dryer The VBD Dryer can be lifted by forklift only if it is securely attached to a pallet. Once removed from the pallet, the dryer should only be rolled using the dryer’s castors.

Do not lift the VBD Dryer directly with a forklift or damage may occur to the Dryer’s retention Hopper located at the bottom of the Dryer.


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2.2 - Dryer Setup Once unbolted from the pallet, installation requires only electrical connections, pneumatic air line connection and intake and output material lines to be connected.

2.2.1 - Compressed Air Connection

Connect an air supply to the air regulator’s IN port using a male ¼ ” NPT fitting. An operating air pressure of 80 psi (5.5 bar) while the vacuum generator is running is required for proper operation of the Dryer. If your air supply has oil in it, add an oil separator (coalescing filter). Oil in the air will combine with dust drawn from the canisters forming a paste inside the vacuum generator. It will stop working and require cleaning. Observe the air pressure gauge to be sure the pressure maintains 80 psi (5.5 bar) while the vacuum generator is running as you check and adjust the regulator. If pressure drops below 80 psi, adjust the regulator. If the pressure cannot be maintained at 80 psi (5.5 bar) while the vacuum generator is running, then the air supply line is not adequate.

Do not supply Dryer with a lubricated air supply. Damage to Dryer may result. Use only a clean, dry, oil-free air supply.


Edition: May 27, 2009 – VBD-50 11


2.2.2 - Electrical Connection

RISK OF INJURY! Only qualified technicians should make electrical connections.

Connect Main Power

The electrical cable located on the left side of the Dryer on the power box supplies the power to the Dryer. Within the cable is four wires. Three of the wires are black and labeled with a number: 1, 2, and 3. The fourth wire is a green/yellow wire and is the ground wire. See Wiring Diagrams on page 36 for wiring details. THREE PHASE: 60 cycle 480 volts or 50 cycle 400 volts

Confirm Correct 3-Phase Electrical Connection

THREE PHASE Unit - CONFIRM proper 3-Phase power connection by following these instructions:

Turn power on using main power switch. On the outside of the electrical box below the power switch is a red 3-Phase indicator light. If 3-Phase power is correctly connected, the controller will power up and the red indicator light will NOT be lit.

If 3-Phase is not correctly connected, the red 3-Phase indicator light located on the outside of the electrical box below the power switch will be ON indicating in-correct 3-Phase wiring. Power off the Dryer and reverse any two leads.

PROCEED TO: OPERATION NEXT PAGE


Edition: May 27, 2009 – VBD-50 12


3 - Operation

3.1 - Standard Operation 1. Ensure all hatches are closed

2. Load material into the hopper’s primary compartment (larger forward compartment of hopper).

3. Turn on Main Power

4. Adjust your settings. LED indicators located below the Select button on the control panel will

indicate the setting you are currently adjusting. The display to the right of the Select button will show the value of the selected setting. Pressing the Select button toggles between Process Temperature, Heat Time and Vacuum Time. Up/Down arrow buttons adjust the highlighted setting. Process Temperature - The first setting in the list is Process Temperature. Confirm or adjust your desired Process Temperature using the Up/Down arrows. Refer to the “Recommended Heat Times and Temperatures” table in this manual. Temperature adjusts in 5 degree increments. Heat Time - Press Select to toggle the display to show Heat Time. Adjust if necessary using the Up/Down arrows. Refer to the “Recommended Heat Times and Temperatures” table in this manual. Heat time is adjustable in 1-minute increments. Default heat time is 20 minutes. Vacuum Time - Pressing the Select button once more will display the Vacuum Time. Adjust Vacuum Time if necessary using the Up/Down arrows. Vacuum time is adjustable in 1-minute increments. Default is 20 minutes.

5. When your adjustments have been made, Press the “Start“ button.

3.2 – Standard Operating Sequence

This section will help you understand what the dryer is doing after you press the Start button.

6. Dryer display will say: STRT on the upper display and your desired Process Temperature (Set-Point) on the lower display. As the Fill hopper dispenses material into the Heat/Vacuum Vessel the upper display will say FILL. As the Dryer heats the material, the upper display will say HEAT. During the heat process, the process temperature will display. During the ramp up of the temperature, the Process Temperature LED flashes until the actual temperature is within 2 degrees of the set point.

7. Once the temperature is within 20 degrees of the set point temperature, the Heat Time begins to count down the Target Heat Time.

8. When the Heat Time elapses the heater shuts off, and after a short delay, the dryer begins to pull a vacuum. When the absolute pressure within the vessel reaches 100mm of mercury, the Vacuum Timer will start.

9. When the vacuum timer elapses to zero, the vacuum will be released and the material will be dispensed in to the retention hopper. If material covers retention hopper level sensor, the dryer will continue to hold a vacuum on the material within the vessel until the retention hopper level sensor is uncovered.

10. While the material is being dispensed into the retention hopper the display will say DUMP.

11. After the material has been dispensed into the retention Hopper the current cycle ends and a new cycle begins.


Edition: May 27, 2009 – VBD-50 13


3.3 – Recommended Heat Times and Temperatures

MATERIAL FINAL MOISTURE % *

HEAT TIME (MINUTES)**

DRYING TEMPERATURE*** ºC ºF

ABS 0.10 30 - 35 80 - 85 180 – 190 ABS/PC 0.02 35 - 40 100 210 LCP 0.02 30 - 60 150 300 PA 0.20 - 0.10 30 - 40 80 - 85 180 – 190 PBT 0.02 30 - 35 120 250 PC 0.02 30 - 35 125 250 PC/PBT 0.02 30 - 35 125 250 PEEK 0.20 - 0.10 35 - 40 150 300 PEI 0.02 30 - 50 150 300 PES 0.05 - 0.02 35 - 40 150 300 PET (Molding Grade) 0.010 30 - 45 150 300 PET (Preform, Extrusion) 0.005 30 - 45 150 300 PMMA (Acrylic) 0.02 - 0.04 40 85 185 POM (Acetal) 0.20 - 0.10 45 80 - 110 180 – 230 PPO 0.02 45 100 - 120 210 – 250 PPS 0.02 45 150 300 PUR 0.02 45 125 - 140 260 – 280 PSU 0.02 35 - 40 150 300 SAN 0.20 - 0.10 30 - 50 80 180 * Final moisture content as recommended by the raw material manufacturer. ** Recommended heat time is based on average initial moisture content. For high initial moisture content cycle time should be extended 5 minutes. When in doubt contact Maguire Service.

*** Drying temperature as recommended by the material manufacturer. Drying is accomplished when all material reaches the proper temperature, and is then placed under sufficient vacuum for a sufficient period of time.

Measurement of moisture content of material, both prior to and after drying, is accomplished by using a moisture analyzer such as one manufactured by Arizona Instruments.


Edition: May 27, 2009 – VBD-50 14


3.4 - Dryer Overview


Edition: May 27, 2009 – VBD-50 15


3.5 – Controller & Operator Station

Control Panel Overview

The VBD control panel is divided into 3 areas. The upper area contains the Start button and LED, Shutdown Button and LED and the upper display. The middle area, highlighted in red, is the Operator Input area. The lower area is the Operation LED indicators that display what the dryer is currently doing.

Upper Region of Display

START Button Press to START the cycle. Lights when the unit is running automatically. Red LED light to indicate when Dryer is running. LED must be ON solid (not blinking) to start the drying process. Holding the START button down for 2 seconds toggles the upper display to show the current temperature within the vessel.

SHUT DOWN Button Press SHUT DOWN to end the cycle. Shut Down LED is on when the unit has been stopped by the operator or has stopped between cycles in the "clean out" mode.

DISPLAY All status information will be shown on this display.


Edition: May 27, 2009 – VBD-50 16


Center Region of Display

SET Region This region of the display allows adjustment to Process Temperature, Heat Time and Vacuum Time. Adjustments are made using the UP and DOWN arrow buttons. This region also displays the current pressure during the vacuum cycle and is indicated by the Vacuum Level LED. Press SELECT to toggle through Process Temperature (F or C), Heat Time (minutes), Vacuum Time (minutes), Vacuum Level (mm Hg). The +, - and SELECT buttons are also used to navigate parameters and other menu items.

Process Temperature

Temperature that the Dryer will heat the air to. Default is set to “150 F“. Adjustable using the UP (+) and DOWN (-) arrow buttons. Can be adjusted during operation. Fahrenheit or Celsius.

Heat Time (minutes)

Amount of time that the heated air will pass through material contained within the heat/vac vessel. Default Heat Time is 20 minutes. Range in minutes is 001 – 999. Adjustments are in 1-minute increments.

Vacuum Time (minutes)

Amount of time that the heat/vac vessel holds a vacuum after the heating process. Default is 20 minutes at 65-75 mm of mercury absolute pressure.

Vacuum Level (mm Hg)

65-75 mm of mercury absolute pressure. (Display only, no adjustment)

Lower Region of Display

Operation The Operation LEDs display only when the dryer is in a running mode (Start LED is on). These LEDs indicate what the dryer is currently doing. Blower ON – On when blower is moving heated air through the vessel. Heater ON – On when heater is heating air. Heat/Vac Level Sensor – On when the upper senor in the heat/vac vessel is covered by material. Indicates vessel is full of material. Retention Hopper Level Sensor – On when lower sensor at the base of the retention hopper is covered indicating there is material in the retention hopper. This sensor must be uncovered before material will dump from the heat/vac vessel into the retention hopper.


Edition: May 27, 2009 – VBD-50 17


Strobe Light Beeper Alarm

Silence Alarm Button This button silences the STROBE and BEEPER ALARMS, but does not remedy the cause of the alarm. Press once to silence. Press twice to clear the display of the alarm message. STROBE LIGHT and BEEPER ALARMS The Strobe light flashes and the Beeper sounds when any condition occurs requiring operator intervention.

USB PORT

This is a USB port. It allows information to be ported directly to a USB Flash Drive giving the benefit of a permanent digital record. Three printouts are available:

1. A listing of the internal parameter table.

2. A periodic printout of temperature, vacuum reading, and elapsed cycle time. There is a detailed explanation of this printout in the PRINTED OUTPUTS section of this manual.

3. A listing of the alarm log.

See Print Outputs on page 31 for more information about printouts. The USB port can also be used to update the controller’s software. For information about updating the controller software see Updating Controller Software.

Notes about printing to a USB drive When saving printout information to a USB drive, the USB drive must contain a folder named maguire. A file labeled EVENTLG.TXT will be created for Event Logs. Also note that every time a print occurs, if these files exist in the maguire folder on the USB drive, the data is appended to the end of the file and does not overwrite existing data within the file.


Edition: May 27, 2009 – VBD-50 18


Program, Clean and Run Modes

Run Mode Run Mode is the mode for standard dryer operation. You must be in run mode to start a cycle.

Clean Mode Clean Mode opens valves and locks out Run mode operation to allow the dryer to be manually emptied of all material.

Program Mode Program Mode allows modification of Parameters and settings.

Run, Clean and Program modes can be accessed by holding the SHUT DOWN button and pressing the SELECT button.

Press and hold the “SHUT DOWN” button,

then press the “SELECT” button.

Display will show: MODE RUN

Press the UP or DOWN arrow button to toggle through Run, Program and Clean modes. These Modes display as: RUN, CLEN, PRGM Run Mode: Run Mode is the mode for standard dryer operation.

Display will show:

To enter Run mode toggle to RUN then press:

Lower display will show

Setpoint temperature:

FILL 345F

Clean Mode: Clean Mode is the mode to use if you need to the remove material from the dryer. See Cleaning the Heat / Vac Vessel and Cleaning the Retention Hopper for more details on page 27.

Display will show:

To enter Clean mode toggle to CLEN then press:

Lower display will alternate between PRES (Press) and

STRT (Start button)

CLEN PRES

Program Mode: Program Mode gives the user access to parameters, test routines, preferences, password, firmware updates, reports and logs.

To enter Program mode toggle to PRGM then press:

Display will show: PASS

0000

This is prompting for the password. See next section for how to use Program Mode.


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Program Mode Program Mode gives the user access to parameters, test routines, preferences, password, firmware updates, reports and logs. To change most program options and test mode options, the machine must be stopped.

Press: the “START” button to enter Program Mode. The user is prompted for a password. The default password is 2222.

The display will show: PASS 0000

Press:

the arrow buttons to set the blinking digit in

the lower display to enter the password.

Press SELECT to toggle to the next digits and enter those digits using the arrow buttons. Default password is “2222”. Incorrect password displays INVD PASS (invalid password)

2222

You are now in Program Mode. Upper display will show: SETP PARA

Pressing:

The display will toggle through a list of test routines, preferences, password, firmware update, reports, logs and then back to parameters. An explanation of each is below. To enter any of these Modes, the “START” button. Press the “SHUT DOWN” Button to exit any of these modes.

Pressing:

the “SHUT DOWN” button to exit the current selection.

Pressing: SHUT DOWN again to return to RUN Mode.

Program Mode Options:

SETP PARA

Edit Parameters - Pressing the “START” button while PARA is displayed will enter the Parameter Edit Mode. A Full Explanation of all Parameters as well as how to Edit Parameters is covered in the Parameter section of this manual on page 22. This section covers other Program Mode options. Continue below for an explanation of each Program Mode option.

SETP PARA

TEST HEAT

Test Mode for Heater – This mode tests the dryer’s ability to control the temperature of the hot air. Press the “START” button to enter TEST HEAT Mode. The Blower will start, then the Heater will turn on. The dryer will attempt to reach and hold the Target Temperature. Press the “SHUT DOWN” Button to end and exit the heater test mode.

TEST HEAT

TEST VAC

Test Mode for Vacuum – This mode tests the dryer’s ability to pull and hold a vacuum. Press the “START” button to enter TEST VAC Mode. The vacuum will start. The dryer will attempt to reach and hold the Target vacuum pressure. Press the “SHUT DOWN” Button to end and exit the vacuum test mode.

TEST VAC


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SETP TEMP

Setup Temperature Format – This toggles all displays and logs of temperature between Celsius (CELC) and Fahrenheit (FAHR) and also allows adjustment of increments in degrees (1 degree or 5 degree). Press the or to toggle between Celsius (CELC) and Fahrenheit (FAHR). Press the “Select” on the desired format to further display the increments in degrees. Press the or to toggle between ADJ.5 (5 degree temperature increments or ADJ.1 (1 degree temperature increments). Press the “SHUT DOWN” Button to choose the format and exit.

SETP TEMP

SETP PRES

Setup Pressure Format – This toggles all displays and logs of Pressure between Absolute (ABS) and Differential (DIFF) pressure. Press the or to toggle between Absolute (ABS) and Differential (DIFF) pressure. Press the “SHUT DOWN” Button to choose the format and exit.

SETP PRES

SET TIME

Setup Time – This toggles through the complete Date and Time allowing adjustment of year, month, day, hour, minute, seconds. Press the “SELECT” button to choose a field to edit then press or to adjust. Press the “SHUT DOWN” Button to save and exit.

SET TIME

CHNG PASS

Change Password – This setting allows the password to be changed. Press the “START” button to change the password. The user will be prompted for the OLD password. Press SELECT to toggle to the next digits and enter the password digits using the arrow buttons. Default password is “2222”. Incorrect password displays INVD PASS (invalid password). After entering the OLD password, the user will be prompted for a new password. Enter the new password using the arrow buttons, using the Select button to navigate to the next digit. Pressing Select on the final digit will save new password. Pressing the “SHUT DOWN” Button will entering the new password will cancel entry of the new password.

CHNG PASS

DISP VERS

Display Version – Press the “START” button to display the VBD Dryer’s software version. DISP

VERS

UPDT FIRM

Update Firmware – This allows for software updates to be applied to the VBD Dryer. Pressing the “START” button causes the VBD Dryer to search for new software versions on a USB Drive plugged into the USB port. Press or to choose a version if multiple software versions exist on the USB

drive. Press the “SELECT” Button to choose and load the displayed software version. See Updating Dryer Software Section for More information.

UPDT FIRM

PRNT OUTS

Print Outs - This enters a submenu of reports, printouts and logs as well as an option to clear logs. Press the “START” button to enter the report submenu. See Print Outputs on page 31 for more information about printouts.

PRNT RPRT

PRNT PARA

Print Parameter Table – This prints the currently loaded parameters to a USB Drive inserted in the Dryer’s USB port. The Dryer will look for a file named PARALG.TXT located on the USB drive within a folder named MAGUIRE (this folder is required to be on the drive). If the file PARALG.TXT is not found on the drive, it will be created. If it exists, new data will be appended to the end of the file. Press the “START” button to create the parameter printout.

PRNT PARA


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PRNT ALRM

Print Alarm Log – This prints an Alarm Log to a USB Drive inserted in the Dryer’s USB port. The Dryer will look for a file named ALRMLG.TXT located on the USB drive within a folder named MAGUIRE (this folder is required to be on the drive). If the file ALRMLG.TXT is not found on the drive, it will be created. If it exists, new data will be appended to the end of the file. Press the “START” button to create the Alarm Log.

PRNT ALRM

PRNT EVNT

Print Event Log – This prints an Event Log to a USB Drive inserted in the Dryer’s USB port. The Dryer will look for a file named EVENTLG.TXT located on the USB drive within a folder named MAGUIRE (this folder is required to be on the drive). If the file EVENTLG.TXT is not found on the drive, it will be created. If it exists, new data will be appended to the end of the file. Press the “START” button to create the Event Log.

PRNT EVNT

CLR LOGS

Clear All Logs – This command clears all currently stored Alarm logs in the dryer. CLR

LOGS

Press the “SHUT DOWN” button to exit the current selection. SHUT DOWN again to return to RUN Mode.


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PARAMETERS

Changing parameters can have an impact on the Dryers performance. It is highly recommended that a supervisor change the default Program Mode password to protect the values. Prior to making any changes, make sure you understand what you are doing. If in doubt contact a Maguire Dryer Technician before making changes to your dryer.

All VBD Dryers operate according to certain internal Parameters. Because customer requirements vary, we have made the following parameters accessible for change in Program Mode. To access and edit the parameters, see Changing Parameters in this section:

TIMES Are expressed as full seconds or full minutes.

PERCENTS are expressed in full percents.

TEMPERATURES are expressed in full degrees (Fahrenheit or Celsius). PARAMETERS - FULL EXPLANATIONS – also see “Changing Parameters” on page 25.

The following parameters are listed in the order in which they are found in the Dryer’s parameter list. Parameters are accessible in Setup Mode and may be changed if necessary. Note: Most parameters are set to the optimal setting from factory. In most cases you should not have to modify parameters unless instructed to do so by a Maguire Dryer Technician.

HTS - Heat Time Setting (in minutes)

Length of time heat is blown through the material within the Heat/Vacuum Vessel. If this parameter is set to 0000, then the heat cycle time in minutes (Heat Time) displayed on the Operator Input display takes precedent and is adjustable without entering Setup Mode. If a value is entering into the HCT parameter, then the parameter value takes precedent and the Operator Input display only displays the time value and cannot be changed unless the operator enters Setup Mode (password protected) and changes the HTS parameter. Default setting is 0020.

VTS - Vacuum Time Setting (in minutes)

Length of time the Heat/Vacuum Vessel holds a vacuum. If this parameter is set to 0000, then the vacuum cycle time in minutes (Vacuum Time) displayed on the Operator Input display takes precedent and is adjustable without entering Setup Mode. If a value is entering into the VTS parameter, then the parameter value takes precedent and the Operator Input display only displays the time value and cannot be changed unless the operator enters Setup Mode (password protected) and changes the VTS parameter. Default setting is 0020.

PTS – Process Temperature Set-Point (Heat control parameter)

Target temperature that the dryer will heat the hot air to before it passes through the material. If this parameter is set to 0000, then the Process Temperature (C or F) displayed on the Operator Input display takes precedent and is adjustable without entering Setup Mode. If a value is entering into the PTS parameter, then the parameter value takes precedent and the Operator Input display only displays the temperature value and cannot be changed unless the operator enters Setup Mode (password protected) and changes the PTS parameter. Default setting is 0150.


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MAX - Maximum Process Temperature (used for PID normalization) (heat control parameter)

The highest allowable temperature that can be entered into the Process Temperature via Operator input. The MAX parameter also controls the TTP parameter setting a maximum temperature that can be entered. The maximum temperature that the dryer will allow is 350° F (180° C). Default setting is 0350 F (180° C).

OTA - Over Temperature Alarm (heat control parameter)

Parameter to determine an over temperature condition. OTA has two fields consisting of time in seconds and temperature in degrees (F or C depending on the default TEMP in Setup). The first two digits the number of continuous seconds (timer) that the OTA must be held above the target temperature over temp trip point. The 3rd and 4th digits are the number of degrees above the target temperature (over temp trip point) that will trigger the OTA parameter to start the timer. If the OTA is triggered the Dryer will automatically shut down. Default setting is 1020 (10 seconds, 20 degrees F).

ECT - End Cycle Temperature

ECT is a temperature difference between two sensors located above and below the Heat/Vacuum Vessel. The top sensor measures the hot air that enters the vessel. Hot air passes down through the material and exits out through the bottom of the Heat/Vacuum Vessel. At the bottom a second sensor measures the exiting air temperature. When the air exiting the vessel reaches the value of the ECT parameter (degrees F or C below input temperature), this indicates that the Heat Cycle is complete. Default setting is 0020 (20 degrees below input temperature).

VPD - Vacuum Pressure Delta (mmHg from Vacuum Pressure Low)

Millimeters of Mercury above VPL parameter that will cause the vacuum generator to turn on. Default setting is 0020.

VPL - Vacuum Pressure Low (OFF pressure)

Absolute pressure measured in millimeters of mercury that the vacuum system will achieve. Default setting is 0060.

VTP - Vacuum Timer Pressure

Minimum vacuum before starting VTP timer. As the vacuum system begins to pull a vacuum, it will pull down to the value set VPL plus the value set in the VTP parameter, at which time it will begin the VTP timer. Default setting is 0050 (mm of mercury absolute pressure).

NVT - No Vacuum Time

The NVT parameter has two fields. The first two digits are the number of retries and the 3rd and 4th digits are seconds (rr.ss where rr = number of retries, ss = seconds). When the vacuum generator begins to pull a vacuum, it will attempt to pull the vacuum and reach the set-point pressure for the number of seconds specified in the NVT parameter. If it does not achieve the set-point pressure within the specified number of seconds, it opens closes the valves (attempting to clear the seals of material pellets), then attempts to pull a vacuum again. It will continue this process for the number of retries specified in the NVT parameter. Default is 0310 (3 retries, 10 seconds to attempt to pull a vauum to the set-point pressure).


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VFT – Vessel Fill Time (in seconds)

Time in seconds that the fill valve will remain open if the upper level sensor is not covered. Default setting is 0020 (20 seconds).

VDT - Vessel Dump Time (in seconds)

Time in seconds that the retention hopper level sensor must remain uncovered to allow material to then be dumped into the retention hopper. Default setting is 0020 (20 seconds uncovered).

FPO - Fill Pulse Options

Pulses of the Fill Valve used to promote material flow into the heat/vacuum vessel. If material has difficulty starting to flow, increasing the number of pulses may help. As a result of increasing the number of pulses, an increase in the Fill Time may be necessary. The FPO parameter has three fields that control the pulse of the Fill Valve. The first digit is the number of seconds the Fill Valve will pulse “open”. The second digit is the number of seconds the Fill Valve will pulse “closed”. The 3rd and 4th digits are the number of pulses the Fill Valve will pulse open and closed to promote material flow. (o.f.rr where o = number of seconds open, f = number of seconds closed, rr = number of pulses) Default setting is 1102 (one second open, one second closed, two pulses).

DPO - Dump Pulse Options

Pulses of the Dump Valve used to promote material flow into the retention hopper. If material has difficulty starting to flow, increasing the number of pulses may help. As a result of increasing the number of pulses, an increase in the Dump Time may be necessary. The DPO parameter has three fields that control the pulse of the Dump Valve. The first digit is the number of seconds the Dump Valve will pulse “open”. The second digit is the number of seconds the Dump Valve will pulse “closed”. The 3rd and 4th digits are the number of pulses the Dump Valve will pulse open and closed to promote material flow. (o.f.rr where o = number of seconds open, f = number of seconds closed, rr = number of pulses) Default setting is 1102 (one second open, one second closed, two pulses).

DBO - Display Brightness Options

This parameter controls the brightness of the two LED displays. Display brightness ranges from 1 (dimmest setting) to 7 (brightest setting) with a default brightness of 4. Default setting is 0004 (where 0007 = highest setting).

LBO - LED Brightness Options

This parameter controls the brightness of the LED lights. LED brightness ranges from 1 (dimmest setting) to 7 (brightest setting) with a default brightness of 2. Default setting is 0002 (where 0007 = highest setting).

SDT - Sensor Delay Timeout

Uninterrupted time in seconds that the sensor in the retention hopper must be uncovered before the hopper is considered empty. This is to prevent false empty signals that could be caused by material being conveyed away. Default setting is 0015 (15 seconds).


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ELT - Event Logging Time

Time in seconds that the events, current settings, etc, will be logged to a USB drive that would be plugged into the USB port. Default setting is 0060 (60 seconds).

Changing Parameters

Changing parameters can have an impact on the Dryers performance. It is highly recommended that a supervisor change the default Program Mode password to protect the parameter values. Prior to making any parameter changes, make sure you understand what you are doing.

To access the internal parameters you must enter into Setup Mode. The Setup Mode default password is: 2222 To change a PARAMETER, the machine must be stopped.



Display will show:

MODE RUN

Press:

Twice to toggle the display to PRGM (Program Mode)

Lower Display will show: PRGM

Press: the “START” button to enter Program Mode. (password protected)

Upper display will show: PASS

Press:

the arrow buttons to set the blinking digit to

enter the password.


2222

Press: the “START” button to enter Program Mode.

Upper display will show: SETP (Setup). Lower display will show: PARA SETP

PARA Press: the “START” button to enter the

Parameter List. Upper display will show the current parameter. Lower display will show the parameter value.

HTS 0000

Press:

the arrow buttons to navigate the parameters.


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Press: the “SELECT” button to edit the currently selected parameter.

Press:

the arrow buttons to change the value of the displayed parameter.

Pressing the “SELECT” button moves to the left. Pressing “START” accepts the changes and exits. Pressing “SHUT DOWN” cancels and

reverts back to original parameter value.

Press: the “SHUT DOWN” button to exit the current parameter.

Press SHUT DOWN again to return to RUN Mode.

4 – Maintenance and Service 4.1 - Cleaning the Fill Hopper

The Fill Hopper is located on top of the Dryer above the Heat/Vac Vessel. The Fill Hopper can be opened for inspection and cleaning by rotating the flat-head screw latches located at the top of the hopper’s Access door.

Do Not Open the front Access Door if material is visible behind the sight glass and above the lower hinge of the door!

The Fill Hopper can also be accessed from above, through the hatch located to the rear, above the reserve hopper. To open the hatch, unhook the two latches.

Fill Hopper

Access door

Opened access door

Fill Hopper upper

access hatch

Fill Hopper upper

access hatch opened


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4.2 – Cleaning the Heat / Vac Vessel

Heat / Vac Vessel and surrounding parts may be hot. Use of gloves is recommended.

Heat / Vac Vessel and surrounding parts may be sharp or present a pinching hazard. Use of gloves is recommended. Be aware of pinch hazards.

The Heat/Vac Vessel is located in the center of the Dryer under the Fill Hopper. The Heat/Vac Vessel can be opened for inspection and cleaning by rotating and un-hooking the latches located on either side of the hatch door. The hatch then slides out of the Heat/Vac Vessel and hangs below.

Do Not Open the Access Hatch if material is visible behind the sight glass!

4.3 - Cleaning the Retention Hopper (lower take-off hopper)

The Retention Hopper is located under the heat/vac vessel. The Retention Hopper can be opened for inspection and cleaning by rotating the flat-head screw latches located at the top of the hopper’s hatch door.

Do Not Open the Access Door if material is visible behind the sight glass!


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4.4 - Drain and purge Air Filter / Regulator

The purpose of the air filter is to remove moisture and contaminants from the air supply and protect the air components of the Dryer. The air filter must be periodically purged of moisture.


4.5 – Air Pressure Adjustments

Air Pressure

Air pressure affects the ability to draw a high vacuum. We recommend a pressure setting of 80 PSI while the dryer is running. Air is used when the vacuum generator is running so observe the PSI while the Dryer is drawing a vacuum. The gauge should continue to read this setting even when the vacuum unit is on. If it does not maintain pressure your supply line is not sized properly.



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4.6 – Updating Dryer Software When the VBD is turned on, the 2nd screen displayed will show the current firmware version. The firmware in the VBD can be updated if necessary using the USB port on the controller. Maguire can supply updated VBD firmware on request if available. The following instructions detail how to do a firmware update.

Copy the new firmware update into a folder named “maguire” on a USB flash drive. Insert the USB Flash drive into the USB port on the VBD. Wait 10 seconds to allow the VBD controller to read the USB drive.



Display will show:

MODE RUN

Press:

Twice to toggle the display to PRGM (Program Mode)

Lower Display will show: PRGM

Press: the “START” button to enter Program Mode. (password protected)

Upper display will show: PASS

Press:

the arrow buttons to set the blinking digit to

enter the password.


2222

Press:

To toggle the display to UPDT FIRM

(Update Firmware)

Display will show: UPDT

FIRM Press:

To select to the Update Firmware option.

Display will show the firmware version that is found on the USB flash drive. Note: If the VBD is not able to read the USB flash drive, the display will show: NO DEV (no device).

Press:

To select to the Firmware Update.

The firmware be transferred to the VBD. The display will show a transfer in progress, then UPDT DONE. Restart the Dryer by turning it off, then on again.

UPDT DONE

Further software update information

Software updates can be supplied electronically, via email or by download. Software updates are named according to their date of release. For instance VBDIEZA.BIN can be interpreted as VBD=Vacuum Batch Dryer, I=2009 (H=2008), E=May (F=June), Z= 26th (1st=A, 27th=0, 28th=1, 29th=2, 30th=3, 31st=4), A=the first revision for that day.


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5 – Troubleshooting 5.1 - ALARMS – Cause and Solution

Typically problems are indicated by an alarm condition on the Dryer controller’s display with an audible alarm and a flashing strobe light. The following alarm troubleshooting chart will describe the alarm condition and possible causes and solutions. Over Heat Alarm

OVER TEMP

Over heat degrees is the set point plus last two digits of OTA Dryer default: Over heat degrees = 150 + 20 = 170

Over Heat Timer = First two digits of OTA Dryer default: Over heat timer = 10 seconds

Step 1. If the current temperature is above the target setpoint by OTA degrees, then the Dryer will start the over heat timer.

Step 2. If the temperature is steady or rising while the timer is running then the Dryer will continue to run the timer. Otherwise the Dryer will reset the timer and return to step 1

Step 3. If the timer expires, then the Dryer will shutdown the heater / blower sub-systems and go into an alarm state.

No Vacuum Alarm

-NO - VACM

Alarm Point is the Current pressure minus 100 mmHg ABS (default): Alarm pressure = 660 mmHg DIFF (default): Alarm pressure = 100 mmHg No Vacuum Timer = lower two digits of NVT (default): No vacuum timer = 10 seconds No Vacuum Retry = upper two digits of NVT (default): No vacuum retry = 3 Start Vacuum While waiting for Vacuum to reach minimum level the Dryer will check the no vacuum alarm Step 1. If the current pressure is lesser than the alarm pressure then the Dryer will run the no vacuum timer. Step 2. If the current pressure is still below alarm pressure and the timer expires, then the Dryer will re-cycle the vacuum gate and reset the no vacuum timer, restart at step 1 The Dryer will repeat steps 1 & 2 for the no vacuum retry count.

Step 3. If the Dryer re-cycled the vacuum gate for the “No Vacuum” retry count, then the Dryer will shutdown the vacuum sub-system and go into alarm state


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Example of a Parameter Printout: FIRMWARE: VBDHGYA VACUUM DRYER ID# 0 MODEL 20 DATE/TIME: Thu 07/24/2008 13:11 GENERAL PARAMETERS DESCRIPTION RAM ROM PPT PID Proportional 0065 0065 PDT PID Derivative Term 0015 0015 HTS Heat Time Setting 0000 0000 VTS Vacuum Time Setting 0000 0000 PTS Process Temp Set-Pt 0000 0000 MAX Maximum Temperature 0350 0350 HAO Heat Adjust Options 0307 0307 HAT Heat Adjust Time 0010 0010 OTA Over Temp. Alarm 1020 1020 ECT End Cycle Temp. 0000 0000 PAD Process Air Delay 0106 0106 VPL Vacuum Pressure Low 0060 0060 VPD Vacuum Pres. Delta 0020 0020 VTP Vacuum Timer Pres. 0050 0050 NVT No Vacuum Time 0310 0310 VGD Vacuum Gate Delay 0205 0205 VFT Vessel Fill Time 0020 0020 VDT Vessel Dump Time 0020 0020 FPO Fill Pulse Options 1102 1102 DPO Dump Pulse Options 1102 1102 DBO Display Bright Opts. 0004 0004 LBO LED Bright Options 0002 0002 SDT Sensor Delay Timeout 0515 0515 ELT Event Logging Time 0060 0060

First column is the parameter’s 3-letter acronym. Second column is the parameter’s description. Third column is the parameter’s setting in RAM, which is the currently loaded user settings. Fourth column is the parameter’s default setting in ROM (Read Only Memory). This is the factory default.


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5.3 - Dryer Software – Factory Reset

“CLEAR ALL” Routine

The "CLEAR ALL" routine resets to the VBD Dryer to its default factory settings (the hard-coded values contained within the software itself). However, a CLEAR ALL will preserve the most important user-defined settings, which are: program mode password, temperature format and pressure format. Also when new software has been installed a CLEAR ALL occurs. The only time when you want to do a CLEAR ALL. is during troubleshooting a problem and all else has failed to resolve the problem. CLEAR ALL will sometimes fix problems by restoring factory defaults and possibly clearing out incorrect settings.

To execute a "CLEAR ALL", do the following:

1. Turn power ON. The display will immediately show:

BOOT (boot up) Vxxx (Dryer’s software version)

2. After seeing the above message, immediately press the following buttons all at one time: START SHUT DOWN SELECT SILENCE ALARM

3. When done correctly, the display will say CLER ALL (Clear All) on the upper and lower display. The Dryer is now reset back to factory defaults.


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6.1 - Theory of Operation / Performance

THEORY OF VACUUM DRYING

Water boils at 212 F (100 C) degrees. However, this is only true at sea level, which is to say at standard atmospheric pressure, which is 14.7 pounds/sq in (1 bar), also expressed as 29.92 inches (760mm) of Mercury (Hg). At lower pressures the boiling point of water is reduced. Standard atmospheric pressure can support a column of Mercury 29.92 inches (760mm) high. If we pull a perfect vacuum above a column of Mercury, the mercury will rise in that column 29.92 inches and, for that reason, the number we can expect to read on the vacuum gauge, at full vacuum, is 29.92 inches. Lesser vacuums read lower numbers. No vacuum reads zero. When water is subjected to a vacuum level of 25 inches (635mm) of mercury, it will boil at 133F (56C) degrees. When plastic pellets are heated to 160F (71C) degrees, or greater, and subjected to a vacuum of 25 inches (635mm), the water vapor within wants very much to boil. This increased molecular activity within the pellet and the greatly reduced pressure surrounding the pellet drives the moisture from the pellet in a remarkably short time. This then is the reason for the remarkable short drying time of a vacuum dryer.

PERFORMANCE

The true measure of a dryer's performance is 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. Conventional "desiccant" dryers use DEW POINT as a measure of performance. This is a measure of the dryness of the air passing over the resin, but not the dryness of the resin itself. For example, for a particular resin, experience may tell us that 180f (82c) degree air dried to minus 40 dew point, and passed over the material for 4 hours, is sufficient to reduce the moisture content of that resin to the required level of dryness. Since our VBD Dryer does NOT use dry air, we have no "dew point" to measure. In our case, for the same resin, experience tells us that a vacuum of 25 inches (635mm) applied for 20 minutes to material that has been heated to 180f (82c) degrees, is sufficient to reduce the moisture content of that same resin to the correct level of dryness. Therefore, just as desiccant driers assure dry material by measuring temperature and DEW POINT over time, we assure dry material by measuring temperature and VACUUM over time. When we assure that a certain temperature has been reached and a certain vacuum level achieved for a correct length of time, we can then be assured the material is dry. You may visually assess performance by monitoring temperature and vacuum levels yourself. Of course, the final test is in the quality of the product you manufacture. We welcome your comments and observations.


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6.2 - Warranty

MAGUIRE PRODUCTS offers THE MOST COMPREHENSIVE WARRANTY in the plastics auxiliary equipment industry. We warrant each MAGUIRE VBD DRYER manufactured by us to be free from defects in material and workmanship under normal use and service; our obligation under this warranty being limited to making good at our factory any Dryer which shall, within FIVE (5) YEARS after delivery to the original purchaser, be RETURNED intact to us, transportation charges PREPAID, and which our examination shall disclose to our satisfaction to have been thus defective; this warranty being expressly in lieu of all other warranties expressed or implied and of all other obligations or liabilities on our part, and MAGUIRE PRODUCTS neither assumes nor authorizes any other persons to assume for it any other liability in connection with the sale of its Dryers. This warranty shall not apply to equipment repaired or altered outside MAGUIRE PRODUCTS INC. factory, unless such repair or alteration was, in our judgment, not responsible for the failure; nor which has been subject to misuse, negligence or accident, incorrect wiring by others, or installation or use not in accord with instructions furnished by Maguire Products, Inc. Our liability under this warranty will extend only to equipment that is returned to our factory in 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 equipment. DISCLAIMER - PRODUCTION of FAULTY PRODUCT This dryer is of a new design. We have had excellent results in all tests performed to date, but we HAVE NOT tested every material available to the plastics industry. We have not anticipated all possible materials, processing conditions, and requirements. We are not certain that our equipment will perform properly in all instances. You must observe and verify the performance level of this equipment in your plant as part of your overall manufacturing process. You must verify to your own satisfaction that this level of performance meets your requirements. We CAN NOT be responsible for losses due to product not dried correctly, even when due to equipment malfunction or design incorrect for your requirements; and/or any consequential losses due to our equipment not drying material to your requirements. We will only be responsible to correct, repair, replace, or accept return for full refund, our equipment if it fails to perform as designed, or we have inadvertently misrepresented our equipment for your application. If for any reason this disclaimer is not acceptable, we will accept return of the equipment for full refund, including freight costs both ways.


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6.3 – VBD-50 Diagrams


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Technical Support and Contact Information

Maguire Products Inc. 11 Crozerville Road Aston, PA 19014 Tel: 610.459.4300 Fax: 610.459.2700 Email: [email protected] Web: www.maguire.com Maguire Europe Tame Park Tamworth Staffordshire B775DY UK Tel: + 44 1827 265 850 Fax: + 44 1827 265 855 Email: [email protected] Maguire Products Asia PTE LTD Main Office 15 Changi North Street 1 #01-15, I-Lofts Singapore 498765 Tel: 65 6848-7117 Fax: 65 6542-8577 E-mail: [email protected]

MAGUIRE ITALIA SRL Via Cile, 14 35127 Padova ITALY TEL +39 049 970 5429 FAX +39 049 971 1838 Email: [email protected]

VBD-50 - Maguire +65 6744 3370 Email: ... PART 2 INSTALLATION 9 ... 2009 – VBD-50 RUN Mode....

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