MAGUIRE Ultra-600 Installation Operation & Maintenance Download Page 1

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MAGUIRE PRODUCTS, INC.

ULTRA-600



- TOUCHSCREEN CONTROLLER

Rev. June 11, 2020

Maguire Products, Inc. 2020

•

INSTALLATION

•

OPERATION

•

MAINTENACE

-6

Integrated with

FLEXBUS Lite

Receiver Control System

Summary of Contents for Ultra-600

Page 1: ...MAGUIRE PRODUCTS INC ULTRA 600 TOUCHSCREEN CONTROLLER Rev June 11 2020 Copyright Maguire Products Inc 2020 INSTALLATION OPERATION MAINTENACE 6 Integrated with FLEXBUS Lite Receiver Control System...

Page 2: ...Maguire Products Inc Rev June 11 2020 ULTRA 600 Touchscreen 2 ULTRA By Maguire Ultra Low Energy Dryer...

Page 3: ...ULTRA 600 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 obs...

Page 4: ...formation 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 informa...

Page 5: ...appening when the Dryer is Running 21 Energy Saver Modes 22 Presets 23 Shutdown Options 24 Auto Stop Setup 25 Advanced Information 26 Recommended Drying Temperatures 27 Maintenance 58 Drain and purge...

Page 6: ...u 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...

Page 7: ...mperatures 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 and i...

Page 8: ...retention hopper A Total assembly weight is 1681 lb 762 kg Heating Hopper Assembly C Located on top of the vacuum chamber retention hopper assembly frame Weight is 349 lb 158 kg Other smaller componen...

Page 9: ...Maguire Products Inc Rev June 11 2020 ULTRA 600 Touchscreen 9 ULTRA By Maguire Ultra Low Energy Dryer Overall layout and Dimensions...

Page 10: ...Maguire Products Inc Rev June 11 2020 ULTRA 600 Touchscreen 10 ULTRA By Maguire Ultra Low Energy Dryer...

Page 11: ...e to the floor as possible Over extending the threads below the frame is not recommended for stability reasons Install the Heating Hopper Following proper forklift safety regulations carefully lift up...

Page 12: ...With the 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 se...

Page 13: ...d To engage the load cell tighten down the load cell transfer bolt until there is roughly a inch 6mm gap between the hanger bumper stops and the frame Tighten down the jam nut to secure the position a...

Page 14: ...inlet temperature going into the heater hopper The black connector signifies T3 which is the temperature at the top of the heating hopper Connect the level sensor cable to the corresponding CPC connec...

Page 15: ...e 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...

Page 16: ...wer 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...

Page 17: ...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 He...

Page 18: ...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 The middle three buttons are soft...

Page 19: ...ial with hot dry air until the material is conveyed away Important Inspect the ULTRA dryer verify that machine is clear of all material from all tanks heating hopper Vacuum Chamber and Retention Hoppe...

Page 20: ...commendations 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 minutes In...

Page 21: ...d 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 the h...

Page 22: ...by the ESD parameter default 30 F Example RTS 250 F ESD 30 F The heater and blower will shut down at a heating hopper exit air temperature of 220 F This logic is blocked for the first 5 minutes of a c...

Page 23: ...ound on the default navigation bar Within the interactive screen users can input edit and load material parameters which minimize material processing setup time Press the Copy to USB in the Presets Me...

Page 24: ...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 Shutdown...

Page 25: ...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 Pre...

Page 26: ...ating 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 C...

Page 27: ...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 SA...

Page 28: ...ts 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 Alar...

Page 29: ...n 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 Operates...

Page 30: ...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 will...

Page 31: ...s 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 wi...

Page 32: ...ludes 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 wide...

Page 33: ...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 dispens...

Page 34: ...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 72 Clear Alar...

Page 35: ...e Preheat Time is the duration of preheat time Parameters Parameters access See page 31 System Configuration Print Options Print Setup See page 72 Print Parameters Prints the parameter list to a USB P...

Page 36: ...e home screen including Date Time Model Number MLAN ID USB Connectivity Ethernet Connectivity Diagnostics System Information System Information displays specific system related information about the c...

Page 37: ...ed parameters For more information on Saving and Restoring Settings see Saving Parameters in the User Backup Settings on page 77 Factory Access For factory access only Restore All Restores Factory Def...

Page 38: ...evel 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 Energy Savings Limit VDR Vacuum Chamber Dump...

Page 39: ...ote this parameter is only visible on units equipped with a VFD BHF Blower High Frequency format xxxxx Hz function s Maximum allowable user enterable blower drive frequency Note this parameter is only...

Page 40: ...ran at the end of the previous vacuum cycle if the heating hopper level is below that established by the BZL parameter This is to mitigate temperature runaways caused by different airflows caused by...

Page 41: ...e that 100 of the vacuum chamber contents dispense into the retention hopper RHL Retention Hopper Low Level format xxxxx lbs or kgs function s 1 When starting if an amount of material equal or greater...

Page 42: ...owever that a timed fill will terminate prematurely if VCH is reached VDT Vacuum Chamber Dump Time format xxxxx seconds function s 1 When the most significant digit is set to a 0 0xxxx this is the max...

Page 43: ...function s The amount of time between blower shutdown and the initiation of a vacuum chamber fill This is to allow for blower wind down time VCT Vacuum Dump Threshold format xxxxx g sec function s Dur...

Page 44: ...el 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 estimate the total amount of material in the dryer which...

Page 45: ...at xxxxx counts function s Number of failed load attempts after which a Loader 2 alarm is triggered Note Loader 2 must be set to Internal mode for this parameter to have effect L2D Loader 2 Delay Time...

Page 46: ...at 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 au...

Page 47: ...rmat 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 de...

Page 48: ...ergy Saver is set to Differential mode this is the difference between the heating hopper exhaust air temperature and the current setpoint RTS that will trigger Energy Saver mode For example if T1s is...

Page 49: ...ttage format xxxxx Watts function s Wattage of the primary heater This value is used in energy consumption calculations PGS Purge Heater Setpoint ULTRA 600 and ULTRA 1000 only format xxxxx F or C func...

Page 50: ...Alarm ULTRA 600 and ULTRA 1000 only format xxxxx seconds function s Maximum amount of time after the purge heat cycle begins during which one of the following two conditions must be detected 1 the pur...

Page 51: ...tinue to run after the final 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 consu...

Page 52: ...nt of time between the closing of the vacuum chamber fill valve and the recording of the vacuum chamber load cell reading This is to allow for settling of the vacuum chamber load cell reading yy The a...

Page 53: ...eresis VSO Vacuum Shutdown Offset format xxxxx seconds function s Amount of time before the vacuum time VTS expires that vacuum pressure equalization begins This is to compensate for equalization time...

Page 54: ...econds seconds function s xx Duration of a vacuum chamber purge cycle yyy Interval between vacuum chamber purge cycles ATM Atmospheric Pressure format xxxxx mm Hg absolute function s The measured atmo...

Page 55: ...ress 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 Sys...

Page 56: ...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 keypad V...

Page 57: ...ill 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 Modbus...

Page 58: ...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 Dr...

Page 59: ...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 Press...

Page 60: ...material totals are being observed loadcell full weigh calibration is recommended every 6 months The ZERO point of the load cells is now set properly FULL weight calibration may also be done at this...

Page 61: ...lean Out The Heating Hopper has a front hatch for access to the full internal height of the Heating Hopper The Heating Hopper is non removable Prior to opening the front hatch removal of all material...

Page 62: ...s 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 will pass...

Page 63: ...cuum 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 handling...

Page 64: ...er out the sealing collar needs to be dropped It is held up using a series of magnets Grab the red handles and pull downward Locate the black lift handle and raise the Retention Hopper by rotating the...

Page 65: ...tem Configuration Preferences Display Options Enable Valve Clean Pause by checking the option as shown below In order to clean the vacuum gate valves on the fly press the vacuum chamber on the Home sc...

Page 66: ...et 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 alar...

Page 67: ...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 th...

Page 68: ...e 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 lo...

Page 69: ...e 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 The...

Page 70: ...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 default 3...

Page 71: ...this 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...

Page 72: ...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 recorded...

Page 73: ...ention 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 600 CPU Firmware N0819B I O Firmware N0819B Serial 00...

Page 74: ...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 12000...

Page 75: ...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 N...

Page 76: ...t 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 33...

Page 77: ...l 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 re...

Page 78: ...ash drive power off the controller then on When the controller restarts the display will show progress updating to the new firmware When complete the display will show UPDATES COMPLETE Toggle power At...

Page 79: ...________79 Flexbus Home Screen _________________________ 80 Flexbus Setup and Configuration __________________80 Flexbus Pump Assignment ______________________83 Receiver Assignment __________________...

Page 80: ...identify each Flexbus pump and receiver Identification and numeric assignment of each Flexbus pump and receiver is setup within the Flexbus Lite through the order that the receiver is turned on and d...

Page 81: ...ng Please see the Flexbus Lite component map on page 96 for setup details Press Display will prompt for a password default 22222 Then press Press Dryer Configuration Display will show the Dryer Config...

Page 82: ...a password PRESS 22222 Enter the password default password is 22222 Press to confirm password This enters the Setup screen This screen contains several setup specific options Pump and Receivers Setup...

Page 83: ...creen This screen contains several setup specific options To setup Pumps PRESS Press the large Pumps button on the far left of the screen This enters the PUMP assignment screen This gray screen contai...

Page 84: ...Ultra Low Energy Dryer While in the Setup screen you can go straight to setting up Receivers without re entering the password PRESS To enter the Receivers assignment screen See Next Page for Receivers...

Page 85: ...irst time setup this screen is probably blank and no Receivers have been assigned Turn on your Flexbus Receivers in the order that you want then to be assigned Your receivers will appear on the screen...

Page 86: ...by using the Receiver navigation arrows at the bottom center of this screen Receiver Navigation Receiver Navigation and Status Panel This multi function panel displays messages and receiver status all...

Page 87: ...to alarm Dump Time The time in seconds that the receiver will remain open during the dump cycle Pump Assignment The ID number of the pump that this receiver is assigned to Pulse Time Pulsed on time in...

Page 88: ...abel on the pump s image on this screen You can select another pump by using the pump navigation arrows at the bottom center of this screen Pump Overview Screen Pump Configuration Screen Pump Control...

Page 89: ...of 400ms to pressurize the charge canister Default Time Interval is 5 1 400ms IDLE TIME The time in minutes that the pump runs after the last convey request before shutting off BYPASS The time delay...

Page 90: ...n any previously assigned devices Pumps or Receivers A device must be turned off or communication must be disconnected to remove the device When a device is turned off or communication to the device i...

Page 91: ...to USB and insert USB into the controllers USB port Press this Update button Press the green check to start the update The firmware update will be copied from the flash drive to the Pumps and Receive...

Page 92: ...ory Displays red when there is an alarm notification Switch the ULTRA Home Screen Setup Enters password protected setup screens Receivers Setup of all Receivers Pump Setup of Pump Live Status Panel In...

Page 93: ...ation with receiver Cause may be receiver s power is off or a disconnected communication wire Receiver is inactive Receiver is alarming Virgin material filling receiver Regrind material filling receiv...

Page 94: ...Maguire Products Inc Rev June 11 2020 ULTRA 600 Touchscreen 94 ULTRA By Maguire Ultra Low Energy Dryer Flexbus Lite Wiring Diagrams...

Page 95: ...Maguire Products Inc Rev June 11 2020 ULTRA 600 Touchscreen 95 ULTRA By Maguire Ultra Low Energy Dryer...

Page 96: ...Maguire Products Inc Rev June 11 2020 ULTRA 600 Touchscreen 96 ULTRA By Maguire Ultra Low Energy Dryer Flexbus Lite Component Map...

Page 97: ...ted construction 4 of R 15 insulation Large Access Door Diffuser cone 304 Stainless steel internal wall construction material contact VACUUM CHAMBER Capacity 195 lb 88 kg Rail mounted for ease of remo...

Page 98: ...DC power supply 70 cfm cooling fan bottom vented 8 5 HP regenerative blower 350 SCFM w VFD RTD Inputs 3 Heating hopper inlet Heating hopper exit Dry Purge inlet DRY AIR PURGE CIRCUIT Air filter regula...

Page 99: ...6 blower max pressure 116 inches H2O 270 mbar 17 blower noise level 79 db A 74 db A 18 primary heater power 20000 watts 20000 watts 19 purge heater power 1250 watts 1250 watts 20 vacuum generator mode...

Page 100: ...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...

Page 101: ...cts 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 what...

Page 102: ...t 14 eg 40C3 circuit breaker 40 amp C trip 3 pole electrical cabinet 15 es3RT2016 motor contactor 3 pole 20A 24 VDC electrical cabinet 16 esCGC32D motor contactor 3 pole 50A 24 VDC electrical cabinet...

Page 103: ...Maguire Products Inc Rev June 11 2020 ULTRA 600 Touchscreen 103 ULTRA By Maguire Ultra Low Energy Dryer Wiring Diagrams ULTRA 600 I O Board Wiring Diagram...

Page 104: ...Maguire Products Inc Rev June 11 2020 ULTRA 600 Touchscreen 104 ULTRA By Maguire Ultra Low Energy Dryer ULTRA 600 Wiring Diagram with VFD...

Page 105: ...Maguire Products Inc Rev June 11 2020 ULTRA 600 Touchscreen 105 ULTRA By Maguire Ultra Low Energy Dryer High Voltage Wiring Diagrams...

Page 106: ...Maguire Products Inc Rev June 11 2020 ULTRA 600 Touchscreen 106 ULTRA By Maguire Ultra Low Energy Dryer...

Page 107: ...Maguire Products Inc Rev June 11 2020 ULTRA 600 Touchscreen 107 ULTRA By Maguire Ultra Low Energy Dryer...

Page 108: ...Maguire Products Inc Rev June 11 2020 ULTRA 600 Touchscreen 108 ULTRA By Maguire Ultra Low Energy Dryer...

Page 109: ...ton 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 m...

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