Maguire Products ULTRA-1000 Installation, Operation, Maintenace Download

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Maguire Products, Inc.

Rev. December 18, 2019

– ULTRA-1000 Touchscreen

ULTRA By Maguire



- Ultra Low Energy Dryer

Table of Contents

INSTALLATION

Dryer Assembly

Engaging the Load Cells

Dryer Connections

Compressed Air Connection

Electrical Connection

Home Screen Overview

Setup Menu Map -Brief Explanation

Parameters Explained

Changing Parameters

Batch Mode

Communication Setup

Operation

Start Up and Operation Instructions

What is happening when the Dryer is Running

Shutdown

– Immediate or Planned

Recommended Drying Temperatures

Maintenance

Drain and purge Air Filter / Regulator

Air Pressure Adjustments

Cleanout Procedure

Loadcell Calibration

Alarms - Cause and Solution

Logs and Print Outputs

Dryer Firmware Updates

General Information

Technical Specifications

Theory of Operation / Performance

Warranty

Recommended Spare Parts List

Wiring Diagrams

Declaration of Conformity

Technical Support / Contact Information

Summary of Contents for ULTRA-1000

Page 1: ...MAGUIRE PRODUCTS INC ULTRA 1000 TOUCHSCREEN CONTROLLER Rev December 18 2019 Copyright Maguire Products Inc 2019 INSTALLATION OPERATION MAINTENACE 1 0...

Page 2: ...Maguire Products Inc Rev December 18 2019 ULTRA 1000 Touchscreen 2 ULTRA By Maguire Ultra Low Energy Dryer...

Page 3: ...ire ULTRA 1000 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...

Page 4: ...e 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 su...

Page 5: ...58 Operation 23 Start Up and Operation Instructions 23 What is happening when the Dryer is Running 25 Shutdown Immediate or Planned 26 Recommended Drying Temperatures 29 Maintenance 60 Drain and purg...

Page 6: ...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...

Page 7: ...Temperatures can reach 350F 180C Typically these surfaces are not at dangerous temperatures however all hot surfaces should be avoided Warning Label indicate HOT SURFACES USE CAUTION when removing an...

Page 8: ...ly C Located on top of the frame that encompasses the Vacuum Chamber and Retention Hopper Weight is 509 lb 231 kg Optional Sub Frame D a sub frame that elevates the Retention Hopper Assembly 16 inch a...

Page 9: ...Maguire Products Inc Rev December 18 2019 ULTRA 1000 Touchscreen 9 ULTRA By Maguire Ultra Low Energy Dryer Overall layout and Dimensions...

Page 10: ...Maguire Products Inc Rev December 18 2019 ULTRA 1000 Touchscreen 10 ULTRA By Maguire Ultra Low Energy Dryer...

Page 11: ...Maguire Products Inc Rev December 18 2019 ULTRA 1000 Touchscreen 11 ULTRA By Maguire Ultra Low Energy Dryer...

Page 12: ...surface that the ULTRA 1000 will be install on can support the weight of the ULTRA at 4 corners If the floor cannot support the weight in 4 small footprints use leveling shims on the frame instead Wh...

Page 13: ...Raise the Heating Hopper on top of section B of the ULTRA dryer Position the Hopper so that the front hatch faces the same side of the dryer as the ULTRA s control panel Install the 10 1 2 13 grade 8...

Page 14: ...Slide Gate facing up slide the Upper Vacuum Gate assembly into the slot on the mount ring as shown in the photo to the right Slide the Upper Vacuum Gate onto the mount ring until it fully seats into t...

Page 15: ...ell located below Continue turning until the Vacuum Chamber hanger is lifted 1 4 inch 6mm off of the sliding rail Lifting bolt 1 4 6mm gap Engage load cell Retention Hopper Load Cell Pair The Retentio...

Page 16: ...must be brought through the enclosure using the predrilled slotted keyholes in the top panel To install remove the top panel and locate the air lines and RTD thermometer cables On each air line and w...

Page 17: ...matching red band Secure the Heating Hopper Inlet RTD thermometer to the side heat inlet of the heating hopper Secure the cable to frame of the heating hopper Route the longer RTD thermometer cable u...

Page 18: ...ctions Heating Hopper Heater connected to blower outlet Power Junction Box Plug Purge Air Solenoid Valve Electrical Plug Electrical Field Joints Color Coded inch Purge Line 5 32 inch air lines Install...

Page 19: ...ll 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 pres...

Page 20: ...th a number 1 2 and 3 The fourth wire is a green yellow wire and is the ground wire Connect power to a properly fused disconnect See page 88 for the High Voltage Wiring Diagram THREE PHASE 60 cycle 48...

Page 21: ...g T1a Heating Hopper Air Inlet Temperature Actual T2 Dry Purge Air Temperature T2s Dry Purge Air Temperature Setting T2a Dry Purge Air Temperature Actual T3 Heating Hopper Air Outlet Temperature T3s H...

Page 22: ...current operating mode date and time Ethernet and USB status Navigation Menu Located along the right side of the screen these buttons allow quick navigation to frequently used and top level screens Th...

Page 23: ...machine is clear of all material from all tanks heating hopper Vacuum Chamber and Retention Hopper To facilitate a Clean Out use the Clean Out function accessible from the home screen Startup and Ope...

Page 24: ...e recommendations Preheat Time This is the duration of heating from a cold start Vacuum Time This is the duration of a vacuum and is what determines the cycle time The default vacuum time is 20 minute...

Page 25: ...and heating cycle begins concurrent to vacuum cycle the first vacuum cycle is timed The new batch of material in the upper portion of the heating hopper will take less time to heat Minimum time in th...

Page 26: ...ial into the machine and completely dry the remainder of the material in the machine At the end of the Smart Stop there will be no material in the ULTRA which is essential for quick cleanout Immediate...

Page 27: ...or a password default 22222 Then press Press Dryer Configuration Display will show the Dryer Configuration categories Press Auto Stop Setup Display will show the Auto Stop screen To Enable Auto Stop P...

Page 28: ...Heating Hopper temperature Fill Info The desired weight of material to be dispensed into the Vacuum Chamber Bulk Density Bulk density of material in either pounds per cubic foot or kilograms per liter...

Page 29: ...00 350 PET Preform Extrusion 0 005 150 180 300 350 PMMA Acrylic 0 02 0 04 79 175 POM Acetal 0 20 0 10 80 110 180 230 PPO 0 02 100 120 210 250 PPS 0 02 150 300 PUR 0 02 125 140 260 280 PSU 0 02 150 300...

Page 30: ...ints Alarm History to USB Flash Drive Print All Prints all above reports to USB Flash Drive Diagnostics System Information Firmware bootloader I O versions Load Cell Diagnostics Loadcell raw counts Al...

Page 31: ...on the vacuum generator Holds the vacuum on the vacuum chamber Vac Cham Purge OPEN CLOSED Located below the vacuum generator When open the vacuum on the vacuum chamber is released Blower Test Operate...

Page 32: ...l RTD Heater Test Operates heater and blower that supplies heat to the Heating Hopper T1s Heating Hopper inlet temp setpoint T1a Heating Hopper inlet temp actual Start Starts the heater test Blower wi...

Page 33: ...ons Batch Mode To enable and run the dryer in Batch Mode follow these steps from the Home Screen Press Start Batch Start Batch button is located on the Home Screen after Batch Mode is enabled Display...

Page 34: ...ncludes device specific settings such as Alarm Setup Auto Stop Setup Dry Purge Setup Preheat Setup Auto Start Setup Convey Setup Load Cell Setup and Parameters System Configuration includes system wid...

Page 35: ...p from the Vacuum Chamber This mode can be useful in lab environments Material Temperature Alarm When the Material Temp alarm is enabled during any instance where the Heating Hopper is called upon to...

Page 36: ...rm is enabled the alarm will sound when this alarm is triggered OFF Disables both the vacuum chamber dump alarm and vacuum chamber Dump retries Print Alarm Log Prints the Alarm Log See page 74 Clear A...

Page 37: ...The Preheat Time is the duration of preheat time Parameters Parameters access See page 40 System Configuration Print Options Print Setup See page 74 Print Parameters Prints the parameter list to a USB...

Page 38: ...onnectivity Ethernet Connectivity Diagnostics System Information System Information displays specific system related information about the controller and Dryer Load Cell Diagnostics Displays Vacuum Ch...

Page 39: ...ettings see Saving Parameters in the User Backup Settings on page 79 Factory Access For factory access only Restore All Restores Factory Defaults WARNING Only do a Restore All when directed by a Magui...

Page 40: ...Set Point Off Percent RHH Ret Hopper Hi Level MP1 Heat1 Max Percent RHL Retention Hopper Low Level RO1 Heat1 Restart Offset BLK Bulk Density MAX Max Temp Set Point VFR Vacuum Chamber Fill Rate ESL En...

Page 41: ...down BLF Blower Low Frequency format xxxxx Hz function s Minimum allowable user enterable blower drive frequency Note this parameter is only visible on units equipped with a VFD BHF Blower High Frequ...

Page 42: ...re drops across the heating hopper Note this parameter is only visible on units equipped with a VFD and a heating hopper level sensor BMW Blower Maximum Wattage format xxxxx watts function s The amoun...

Page 43: ...hamber dump is allowed BLK Bulk Density format xxxxx lbs ft3 or g L function s User enterable material bulk density Setting this parameter to match the material being dried ensures that a fill weight...

Page 44: ...e VDR is ignored Note however that a timed dump will terminate prematurely if RHH is reached FLA Fill Lag Time format xxxxx milliseconds function s Amount of time added to every vacuum chamber fill va...

Page 45: ...d down time VCT Vacuum Dump Threshold format xxxxx g sec function s During a vacuum chamber dump if the real time vacuum chamber dump valve flow rate reaches this low level the dump will be terminated...

Page 46: ...de energize when the throughput drops below this level HHV Heating Hopper Volume format xxxxx 10ths of cubic feet or 10ths of liters function s Volume of the heating hopper This value is used to esti...

Page 47: ...n s Number of failed load attempts after which a Loader 1 alarm is triggered Note Loader 1 must be set to Internal mode for this parameter to have effect L2T Loader 2 Timings format xxyyy seconds seco...

Page 48: ...heat temperature is automatically set to this number of degrees below the run temperature RTS PTD Preheat Target Delta format xxxxx F or C function s When Preheat mode is set to Auto the preheat will...

Page 49: ...format xxxyy seconds F or C function s xxx Amount of time that the heating hopper inlet air temperature must be above setpoint before a Heating Hopper Over Temperature alarm is triggered yy Number of...

Page 50: ...mode ESD Energy Saver Differential format xxxxx F or C function s When Energy Saver is set to Differential mode this is the difference between the heating hopper exhaust air temperature and the curre...

Page 51: ...fect CTR Cooldown Timer format xxxxx minutes function s Heating hopper cooldown time Note Cooldown mode must be enabled for this parameter to have effect H1W Heating Hopper Heater Wattage format xxxxx...

Page 52: ...n s xxx Amount of time that the heating hopper inlet air temperature must be above setpoint before a Purge Heater Over Temperature alarm is triggered yy Number of degrees that the heating hopper inlet...

Page 53: ...l vacuum chamber dispense H2W Purge Heater Wattage ULTRA 600 and ULTRA 1000 only format xxxxx watts function s Wattage of the purge heater This value is used in energy consumption calculations Load Ce...

Page 54: ...This parameter ensures that all post factory retention hopper load cell zero calibrations fall within 20 of nominal ensuring that a gross out of calibration condition does not develop LZ2 Load Cell Z...

Page 55: ...an attempt to clear a vacuum fault before a NO VACUUM alarm is triggered yyy Amount of time the vacuum generator will run before a NO VACUUM condition check is made See NO VACUUM alarm in Alarms secti...

Page 56: ...ormat xxxxx seconds function s The amount of time between event log data line entries EUS Energy Usage Settings format xxyyy 10ths of hours seconds function s xx Length of energy consumption averaging...

Page 57: ...Press Dryer Configuration Display will show the Dryer Configuration categories Press Parameters Display will show the categories of Parameters Parameters are divided into 6 categories Blower Heater S...

Page 58: ...ies Press Communications Display will show the System Communications categories Press MLAN I D Number Display will show the MLAN I D Number screen On this screen enter the new ID number using the keyp...

Page 59: ...y will prompt for a password default 22222 Then press Press Display will show the System Configuration categories Press Communications Display will show the System Communications categories Press Modb...

Page 60: ...d dry as BLUE Clean Air Filter The purpose of the air filter located on the back of the dryer enclosure is to remove contaminants from the ambient air supply and protect the heating components of the...

Page 61: ...RO FULL Calibration screen Press ZERO Display will say Confirm Vacuum Chamber is empty then press ZERO Gram weight of 0 follows successful calibration Press To return to the Load Cell Setup screen Pre...

Page 62: ...nse the material from the Heating Hopper to the Vacuum Chamber prior to entering the Full Calibration Routine If material totals are being observed loadcell full weigh calibration is recommended perio...

Page 63: ...Vacuum Chamber and then properly re install the Vacuum Chamber into the Dryer Press CONTINUE to proceed Wait while calibrating load cells Do not touch weigh bin during calibration After Full calibrati...

Page 64: ...eating Hopper The Heating Hopper is non removable Prior to opening the front access door removal of all material is recommended Material in the Heating Hopper can be evacuated using the Heating Hopper...

Page 65: ...m Chamber status window will appear Press to return to the Home Screen Clean Out Dump All Dump All opens all valves allowing material to flow freely through the dryer Material in the Heating Hopper wi...

Page 66: ...Vacuum Chamber To remove the hatch insert rotate the two butterfly latches and then unhook from the hatch faceplate Using two hands slide the hatch insert out of the Vacuum Chamber Use caution handlin...

Page 67: ...tention Hopper Skirt Raising the skirt requires two people Locate the two skirt handles Using the lift handles raise the skirt up and secure the skirt on the two Skirt Hangers Locate the black lift ha...

Page 68: ...rget temperature If neither condition is met the NO HEAT alarm will sound Such an occurrence would signal a failure of either the heater or the airflow from the blower This parameter and consequent al...

Page 69: ...nt alarm protects the purge heater from burn out in the event the compressed air failure or airflow is blocked Solution Check compressed airflow to the purge heater is adequate Check that the air line...

Page 70: ...the Retention Hopper or faulty loadcells Solution If Retention Hopper is missing replace Retention Hopper If Retention Hopper is in place ensure the tank is empty and zero calibrate the load cells If...

Page 71: ...side of the stainless steel purge heater tube Press the red reset button to reset the thermal safety switch If problem occurs repeatedly contact Maguire Technical Support VC MISSING ALARM 18 Problem T...

Page 72: ...VFA parameter Vessel Fill Adjust and pertains to filling the Vacuum Chamber The VFA parameter is a two part parameter The first three digits are the number of retries to fill the Vacuum Chamber defaul...

Page 73: ...alarm is cleared There are two main purposes of this alarm 1 To alert the operator that dry material is ready for the process 2 To act as a hold back when necessary giving the operator additional tim...

Page 74: ...to the USB flash drive Print Event and Alarms A combination of machine status lines at defined intervals as well as mechanical events as they occur Print Alarm History Prints to USB any alarms recorde...

Page 75: ...etention Hopper Loadcell Reading weight in lbs or kgs 18 THROUGHPUT 0 Throughput lbs or kgs hour Example of an ULTRA Event Log ULTRA Event Log MODEL 1000 CPU Firmware N0819B I O Firmware N0819B Serial...

Page 76: ...ght D3 Ret Hop Hi Level RHH 00375 00375 00000 00385 Weight D4 Ret Hop Low Level RHL 00025 00025 00000 00227 Weight D5 Bulk Density BLK 00035 00035 00000 65535 Weight D6 Vac Cham Fill Rate VFR 12000 12...

Page 77: ...0 00020 00000 65535 Minutes Load Cell L1 Loadcell Stable Wt KDF 00200 00006 00000 65535 Number L2 Loadcell Stable Time LST 00100 00100 00000 65535 Millisec L3 Loadcell Zero LCZ 01000 01000 00000 65535...

Page 78: ...just Off HH Level Sensor Off Loader 1 Off Loader 2 Off Loader 2 Mode Thruput Purge Chamber On Admin Settings Blower VFD T4 On T5 Off LOADCELL CALIBRATION NAME ZERO DELTA FULL LAST ZERO LAST FULL RH LC...

Page 79: ...will show Restore User Settings Save User Settings Press Save User Settings Display will prompt for confirmation to save user settings Press To save the user settings including parameters or press the...

Page 80: ...enter again to refresh the display window Highlight the version in the white panel on the left and press PROGRAM Press To proceed with the firmware update or press the red X to cancel and exit The dis...

Page 81: ...f R 15 insulation Large Access Door 18 x 18 Diffuser cone removable without tools 304 Stainless steel internal wall construction material contact VACUUM CHAMBER Capacity 400 lb 180 kg Rail mounted for...

Page 82: ...g hopper exit Dry Purge inlet Vacuum Vessel Material exit Retention Hopper DRY AIR PURGE CIRCUIT Air filter regulator Coalescing Filter 1 10th micron for removal of oil and fine particulates Exhaust S...

Page 83: ...lower noise level 78 db A 78 db A 14 primary heater power 35000 watts 35000 watts 15 purge heater power 2000 watts 2000 watts 16 maximum run temperature 375 F 190 C 17 vacuum generator model Xi 3 stag...

Page 84: ...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...

Page 85: ...ducts 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 wh...

Page 86: ...mp C trip 3 pole electrical cabinet 14 eg 60C3 circuit breaker 60 amp C trip 3 pole electrical cabinet 15 es3RT2016 motor contactor 3 pole 20A 24 VDC electrical cabinet 16 esCGC32D motor contactor 3 p...

Page 87: ...Maguire Products Inc Rev December 18 2019 ULTRA 1000 Touchscreen 87 ULTRA By Maguire Ultra Low Energy Dryer Wiring Diagrams Low Voltage Wiring Diagram...

Page 88: ...Maguire Products Inc Rev December 18 2019 ULTRA 1000 Touchscreen 88 ULTRA By Maguire Ultra Low Energy Dryer High Voltage Wiring Diagrams...

Page 89: ...Maguire Products Inc Rev December 18 2019 ULTRA 1000 Touchscreen 89 ULTRA By Maguire Ultra Low Energy Dryer...

Page 90: ...Maguire Products Inc Rev December 18 2019 ULTRA 1000 Touchscreen 90 ULTRA By Maguire Ultra Low Energy Dryer...

Page 91: ...Maguire Products Inc Rev December 18 2019 ULTRA 1000 Touchscreen 91 ULTRA By Maguire Ultra Low Energy Dryer...

Page 92: ...Aston PA 19014 Tel 610 459 4300 Fax 610 459 2700 Email info maguire com Web www maguire com Maguire Europe Tame Park Tamworth Staffordshire B775DY UK Tel 44 1827 265 850 Fax 44 1827 265 855 Email info...

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