DEHUMIDIFYING DRYER DMZ 2-40~120U. Instruction Manual

Transcription

1 DEHUMIDIFYING DRYER DMZ 2-40~120U Instruction Manual WARNING Thank you for purchasing our dryer. Please use your DEHUMIDIFYING DRYER only after thoroughly reading this manual. Keep this manual near the DEHUMIDIFYING DRYER so that it can be easily accessed whenever necessary. Separate type Mono-frame type Issued in May, 2003

2 CONTENTS The chapters identified with the mark contain critical information. You should carefully read all the information before you start using the DMZ-2. TABLE OF CONTENTS...Ⅰ~Ⅱ INTRODUCTION...Ⅲ 1. Products Covered 2. Target Readers 3. Warranty Page Chapter 1 Chapter 2 Safety Precautions 1. Hazardous level labels and their Meanings Safety Precautions... 2 Equipment Explanation 1. Overview of the equipment Equipment Composition The shipping contents Name of each part (specified with the DMZ ) Control Panel description Outer dimensions Composition Flow Chart Chapter 3 Chapter 4 Installation 1. Installation of the equipment Power supply Connection Preparation for Operation 1. Inspecting inside of the hopper Checking Components and Loading Resin Control Panel setting Start-up Timer.38 - Ⅰ -

3 CONTENTS Chapter 5 Operating Procedures Chapter 6 Maintenance 1. Daily maintenance Weekly maintenance Monthly maintenance Every six months maintenance Chapter 7 Alarm Functions Chapter 8 Troubleshooting The thermal relay set-point of every model Chapter 9 Technical Manual 1. The factory set values of the control panel The start-up method for auto tuning The influence of gases that occur from the resin Relation between the dry air dew-point and ambient air condition 61 Chapter 10 Consumable Parts List Chapter 11 Options 1. The Circuit breaker The Weekly timer The External start / stop signal The General Alarm output The Alarm indicator Voltage Capabilities Chapter 12 Specifications DMZ2 specifications Drying hopper specifications ELECTRICAL LAYOUT & WIRING DIAGRAMS... See back Pages - Ⅱ -

4 INTRODUCTION 1. Product Covered This document describes how to properly perform the operations and maintenance of your DMZ-2 DEHUMIDIFYING DRYER. 2. Target Readers This document is intended for use not only by those who are using GENERAL PURPOSE DEHUMIDIFYING DRYER made by MATSUI MFG. CO., LTD. for the first time, but also by those who had experience in using the DMZ-2 DEHUMIDIFYING DRYER, or wish to ascertain any information. 3. Warranty This product was manufactured by utilizing state-of-the-art designing technology and best craftsmanship of MATSUI MFG. CO., LTD. If the products should have any defect that is recognizable by us, such defective part would be repaired or replaced in accordance with the applicable conditions shown below: 1) Scope The quality of our machines and devices is warranted and we may repair them and/or change parts when something should go wrong with any of them. However, there is NO warranty on the products manufactured with our machines or devices. Any products that are defected when using our machines or devices, are NOT the responsibility of Matsui Mfg Co, or its associate manufacturers. However, if while you are operating our machine or device in a normal way, there is a problem caused obviously as a result of a defect in design or in production of our machine or device, we may repair it or replace the part(s) free of charge within the following period: 1)-A. The relevant defective part must be returned to Matsui. 1)-B. This warranty shall remain valid for twelve (12) months starting on the date when the new products you purchased were shipped to your company. 1)-C. Only the following parts are subject to the warranty period of six (6) months after such delivery date: 1. Electrical components and parts; 2. Sealing materials; 3. Bearings; and 4. Level gauges. 2) Exceptions to which this warranty shall not be applicable 2)-A. This warranty shall not be applied to the following exceptions: 1. Any problem resulting from an environmental change; 2. Any damage or loss attributable to a failure in the delivered products; 3. Any deterioration (in paint or plating) as may occur from time-lapse; 4. Any external phenomenon which is considered to have no effect on the quality and functions; 5. Any problem resulting from your own modification; and 6. Any lamp, fuse, and other consumable part. 2)-B. Any failure or damage attributable to any of the following causes shall not be compensated for under this warranty: 1. Acts of God such as earthquake, hurricane, tornado, typhoon, and flood; accidents; and fire: 2. Use of the products in any place other than the general installation sites; 3. Failure, by intention or negligence, in observing the instructions and maintenance shown in this document; 4. Improper or wrong maintenance, service, or handling; and 5.Your own transportation, repositioning, or reinstallation of the unit. - Ⅲ -

5 INTRODUCTION 6. Improper or wrong maintenance, service, or handling; and 7.Your own transportation, repositioning, or reinstallation of our products. 2)-C. The following are excluded from the warranty: 1. Any insufficient conveying capacity, conveying defect, weighing failure resulting from property degeneration of the raw material. 2. Any clogging in pipes, conveying defects, weighing failure resulting from caking or cohesion of the raw material. 3. Life-span of friction parts such as a hose or pipe is not guaranteed. 4. Crystallization degree, or moisture ratio is not guaranteed. 5. Failure/defect resulting from deformation and cohesion of the resin. 6. Failure/defect resulting from any volatile additive yielded from the resin. 7. Failure/defect resulting from any condition that is not stated in the quotation. 3) Maintenance The following inspection and maintenance must be performed at user s responsibility and expense. This warranty does not cover any product faults due to ignoring the specified maintenance. 3)-A. Inspection for operation. 3)-B. Periodic inspection explained in the instruction manual or in the catalogue. 3)-C. Periodic replacement of parts described in the instruction manual or in the catalogue. 3)-D. Replace consumable parts when they expire. 3)-E. Inspect, supplement, replace, clean the following items: Oil, filter, sealing material, grease, bearing Ventilation duct, Freon gas (where applicable) Oil filter of air apparatus Sedimentary deposits Other related items 3)-F. Adjusting the following items may be necessary over time: V belt Chain (not common) Temperature control apparatus Valve for water supply or drain, etc. Pneumatic apparatus for compressed air Over-heat protection devices, etc. - Ⅳ -

6 CHAPTER 1 Safety Precautions This chapter describes the hazardous levels and their labels on the products, which call for your particular precaution and attention in performing the operations, maintenance, and services for the safe use of the products. WARNING In performing the operations, maintenance, and services of the products, make sure to observe the safety precautions included in this document. We shall take no responsibility and/or liability for any injury or accident attributable to your failure in observing such precautions. 1. Hazardous Level Labels and Their Meanings This manual uses the following convention for the hazardous level labels: Mark DANGER WARNING CAUTION NOTE Description Improper handling might lead to your death. This label is followed by the information provided to avoid such result. Improper handling might lead to your serious injury. This label is followed by the information provided to avoid such result. Improper handling might lead to your slight injury or a damage of the products. This label is followed by the information provided to avoid such result. This label is followed by information provided to call for your particular attention in the context of operation procedures and explanatory statements. This symbol is used to indicate a point to which you should pay particular attention in handling something. This symbol is used to indicate an exceptional condition or description in figures and tables

7 CHAPTER 1 Safety Precautions 2. Safety Precautions Be sure to observe the following precautions when operating this equipment. Precaution item Surfaces temperature DANGER Equipment use Description Since this equipment is made for drying purposes, the surface of the body reaches high temperatures. In particular, the surfaces of the hot air piping and the exhaust filter case reach temperatures exceeding 266 F / 130 C, when the dryer has run continuously with the control temperature set to its maximum (320F/160 C). Avoid careless proximity with the body when the equipment is in operation. Even when the equipment must be handled due to an emergency, do not touch with bare hands, or allow direct contact with the skin. Before performing normal maintenance and cleaning, allow to cool naturally for at least five hours after stopping the operation, to be safe. This equipment is designed for drying resin pellets. Drying of any other material may cause equipment failure. Problems resulted with materials other than resin pellets are not covered by the warranty. Drying cannot be done for the following resins pellet. Resins containing water particles, Special types of resins, and Humidified Nylon type resins. Gas is generated when resins are dried, and if the gas adheres to the Honeycomb rotor, this may decrease the dehumidifying and drying efficiency. Do not use this equipment for drying materials with volatile components or materials that are inflammable. Use with such materials may result in an explosion or fire. Environment Drying temperature Precautions during operation As for the possibility that gas occurs in drying a material, refer to " Technical Manual 3 Use this equipment indoors. Operate this equipment in ambient temperature from 0 to 40. Depending on the humidity conditions, there is possibility that enough performance will be reduced. For the relation between the humidity and the dry air dew point, refer to "Technical Manual -4 ". Set within the maximum operating temperature range as noted in the specifications. Do not use temperatures exceeding the maximum operating temperature. Otherwise, failure or an accident may result. Do not open the vertical body, the cleaning port, or the residual resin removal port. Resin and hot air will blow out extremely dangerous

8 CHAPTER 1 Safety Precautions Precaution items Opening and closing the cleaning port Maintenance Control panel Temperature controller Description Please open and close after confirming that there is not material inside from the level window. Before performing maintenance procedures, be sure to turn the circuit breaker on the front of the control panel to OFF 35, and unplug the unit. Do not jar, or spill liquid on the control panel or temperature controller. Otherwise failure or a fire may result. Only open doors when absolutely necessary. Otherwise, failure or accident may result. Overheat protection device CAUTION Warning labels Name plate Wiping clean Maintenance and repair Overheat protection device This equipment is equipped with a standard safety device (overheat protection device). When the safety device is activated, the heater stops. Therefore, the heater becomes quite high in temperature. After cooling the heaters sufficiently, upon restart, pay close attention to the set-point of the overheat protection device and monitor as needed. For details, refer to the Chapter4. Preparation for Operation. Keep all labels legible until this equipment is disposed of. Do not wipe with petroleum solvents. Benzene, paint thinner, scouring powders, etc. will damage the surface. To clean dirty equipment, wipe with a soft cloth which has been soaked in warm water, and wrung out well. Whoever performs maintenance or repairs that involves taking apart the equipment, needs sufficient knowledge of machinery and electricity. Otherwise, equipment failure or a dangerous situation may result. For guidelines regarding maintenance or repair, contact your nearest service division. (See back page)

9 CHAPTER 2 Explanation Equipment 1. Overview of the equipment This unit is a dryer for resin pellets. This equipment dehydrates air with an absorbent to provide dry air; then it heats the dried air and sends it into the hopper in order to dry resin [inside of the hopper]. Since it removes moisture contained in the ambient air with an absorbent, the moisture content in the dry air does not fluctuate, which provides a constantly stable drying condition. Also, because of the extremely low dew point, moisture contained in the air is virtually eliminated, so the evaporation rate of moisture in the material is achieved fast. This process speeds up the drying time, which in turn, increases your cycle-times, and productivity. For closed-loop models, the equipment recycles exhaust air from the drying hopper as drying air, so exhaust air does not go out of the system. This prevents odor and excessive hot air from blowing out, which also economizes power consumption. For Gas-producing materials For materials that generate gas during drying process, a single- pass model is used to protect the absorbent. Single-pass models discharge the air into the atmosphere while removing any dust through an exhaust cyclone. In cases for gas-generating materials vs. non-generating materials, the closed-loop and single pass type can be achieved alternately by moving the return-air hose (on or off the return manifold on the dryer)

10 CHAPTER 2 Explanation Equipment 2. Equipment Composition This equipment consists of following equipment specifications. Refer to your model in this chapter and nameplate of the equipment and confirm which type equipment you have bought. <Model example> DMZ Drying hopper capacity (kg) Dehumidifying unit model number(m 3 /h) 1 Drying temperature specifications Drying temperature upper limit setting value Symbol Drying temp. Upper limit setting value No symbol Standard type 266 F / 130 H High temperature type 356 F / Drying hopper construction Symbol Drying hopper construction No symbol Single type D Heat retaining type (Double) 3 When special options are employed, it will be indicated with OP 35, OM. NOTE Dehumidified air circulation method can be set only for circulation specifications. (Semi-circulation and single pass can not be set.) - 5 -

11 CHAPTER 2 Explanation Equipment 3. The shipment confirmation Please confirm whether or not there is all purchased units in the shipment. --- Mono-frame type dehumidifying dryer (Frame type) --- E quipment Name Circulation specifications Main body Dehumidifying unit Drying hopper Common frame Connecting hose Shipping Condition Above figure shows DMZ model

12 CHAPTER 2 Explanation Equipment --- D r y i ng hopper installed directly to molder (Separate type) --- E quipment Name Shipping Condition Circulation specifications Dehumidifying unit Drying hopper Above figure shows DMZ 2-80 model. Above figure shows HD-50 model. It is in shrink wrap

13 CHAPTER 2 Explanation Equipment Equipment Name Base Cap bolt 4 pieces (For installation to molder) Hexagon headed bolt 4 pieces Hexagon nut 4 pieces Plain washer 4 pieces (Above three is for fixing drying hopper to base) Shipping Condition Slide gate is fixed with adhesive tape. Above figure shows HD-25~100 model. In cases for the equipment with a matching base, it has been set to the base for shipping. Accessory Connecting hose (heat resistant hose) 5m 2 pieces Hose clamp 4 pieces For DMZ 2-170/240 Hose 2m 4 pieces Hose clamp 8 pieces Connecting inner tube extension 2 pieces These are packed separately. These connecting hoses should be connected to dehumidified air IN and OUT side of dehumidifying unit and exhaust and suction port of drying hopper

14 CHAPTER 2 Explanation Equipment 4. Name of each part (DMZ 2-80 shown) <Dehumidifying unit main body> WARNING SIGN PLATE(DRYING EQUIP.) 警告銘板 ( 乾燥設備 ) DMS2-170/240,DMZ2-80/120 のみ DEHUM.AIR IN 除湿エアー入 DEHUM.AIR OUT 除湿エアー出 REGENERATION EXHAUST 再生排気 φ38.1 WARNING SIGN PLATE(HIGH TEMP.) 警告銘板 ( 高温 ) CONNECTING HOSE PLATE 乾燥ホース接続銘板 POWER SUPPLY SIGN 電源マーク POWER SWITCH 電源スイッチ CONTROLLER コントローラー WARNING SIGN PLATE (ELECTRICAL SHOCK) 警告銘板 ( 感電 ) STANDBY SWITCH スタンバイスイッチ FLAT HANDLE 平面ハンドル CAUTION PLATE(OPERATION) 注意銘板 ( 取扱 ) FAN ファン DRYING FILTER 乾燥フィルター MACHINE ID. NO. PLATE 装置銘板 CAUTION PLATE(FILTER CLEANING) 注意銘板 ( フィルター清掃 ) E.SIGNAL 信号線 E.POWER 電源線 REGENERATION FILTER 再生フィルター COOLING WATER IN 冷却水入銘板 COOLING WATER OUT 冷却水出銘板 COOLING WATER IN 3/8B 冷却水入 COOLING WATER OUT 3/8B 冷却水出 CASTER キャスター MAINTENANCE DOOR メンテナンス扉 - 9 -

15 CHAPTER 2 Explanation Equipment <Drying hopper> --- HD-10,15,25,50 model --- Hook plate for lifting Temperature sensor Thermostat U-bolt Exhaust pipe Lid Catchclips(3) Cylindrical section Level glass Warning label Catchclips(2) Conical section Base Suction pipe Heater box Relay box Power supply sticker Heater cord Power cord (Relay cable) Hopper inside Hot air pipe Diffuser Separator Base Set pin HD-10,15 Slide gate Material outlet HD-25,

16 CHAPTER 2 Explanation Equipment <Drying hopper> --- HD-75,100,150,200 model --- Hook plate for lifting Temperature sensor Thermostat U-bolt HD-75,100 HD-150,200 Exhaust pipe Lid Suction pipe Catchclips(3) Warning label Cylindrical section Cleaning door Adjusting fastener Level glass Conical section Heater box Relay box Power supply sticker Heater cord Power cord (Relay cable) Base Hopper inside Hot air pipe Base Set pin (Handle Diffuser H D Slide gate Material outlet HD

17 CHAPTER 2 Explanation Equipment <Drying hopper> --- HD-250, 300 model --- Temperature sensor Thermostat Exhaust pipe Lid Suction pipe Warning label Cylindrical section Level glass Heater box Relay box Power supply sticker Heater cord Relay cord Conical section Hot air pipe Set pin (Handle) B ase Slide gate Diffuser Material outlet HD-250,

18 CHAPTER 2 Explanation Equipment <Dehumidifying dryer> Connecting hose(heat resistant) Drying hopper Dehumidifying unit Frame Casters(4) Casters(4) Suction box (Shape depends on user s specifications.)

19 CHAPTER 2 Explanation Equipment 5. Controller switches and indicators Dryer Drying Heater Regeneration Heater PV SV Feeder 1 Feeder 2 Feeder 3 Value 数値 indication 表示器 unit Feeder 1 Feeder 2 Feeder 3 Dryer Reset SV ENTER Switch- to 本文中の説明では unlock, and re- lock Enter any と記 settings 述 used. Indicators Dryer Lamp indicator for drying process Drying Heater Lamp indicator for drying heater Regeneration Heater Lamp indicator for regeneration heater SV Select indicator for dry temperature setting value Not used for DMZ 2: (These switches are used on Matsui s MJ3 model) Feeder Setting for convey time (not used for DMZ 2) Feeder Setting for convey time (not used for DMZ 2) Feeder Setting for convey time (not used for DMZ 2) Feeder NO.1 direction convey start indicator (not used) Feeder NO.2 direction convey start indicator (not used) Feeder NO.3 direction convey start indicator (not used) Setting switches Dryer Drying start switch Reset Switch for alarm reset SV Select switch for parameter select Switch for changing set value Switch for changing set value Enter switch for unlocking / locking set value

20 CHAPTER 2 Explanation Equipment 6. Outer dimensions (mm) (frame dimensions may differ) A B G I H D C Dehumidifying unit E F Drying hopper

21 CHAPTER 2 Explanation Equipment Dehumid ifying unit Model E F I D B C A H G DMS DMS DMS DMS DMZ DMZ DMZ Drying hopper HD-10 HD-15 HD-25 HD-50 HD-75 HD-100 HD-150 HD-200 HD-250 HD Frame type DMZ DMZ DMS2(DMZ2) DMS2(DMZ2) DMS2(DMZ2) DMS2(DMZ2) DMS DMS DMS DMS All units in millimeters (mm)

22 CHAPTER 2 Explanation Equipment 7. Composition Flow Chart Basic composition flow chart for DMZ model is shown in Figure 18. H 2 H B 7 B 8 10 Each Parts Name Item No. Name Item No. Name 1 Rotor 7 Drying blower 2 Drying heater 8 Regeneration blower 3 Drying hopper 9 Regeneration heater 4 Geared motor 10 Regeneration filter 5 Drying line filter 6 After-cooler

23 CHAPTER 3 Installation 1. Installation of the equipment Step Item Description 1 Installation Install on a level, stable floor. As shown in figure, make sure the installation location gives space to perform maintenance. (1)Dehumidifying Unit Drying Hopper Mono-frame type 600mm 600mm 600mm 600mm (2)Dehumidifying Unit (Drying Hopper is separate) 600mm 600mm 600mm 600mm

24 CHAPTER 3 Installation Step Item Description Remove any adhesive tape covering regeneration exhaust port as 2 Checking the shown in Figure. dehumidifying unit s condition

25 CHAPTER 3 Installation Step Item Description 3 Moving the equipment When lifting and moving the dehumidifying dryer main body as shown in figure, be sure that the eyebolts (4 pieces) fixed on the top are securely screwed, and then hook the load lifting rope (with hooks) on them and lift and move dehumidifying dryer using a hoist at your company. CAUTION Be sure to use a hoisting rope (with hook) which can withstand the weight of the unit

26 CHAPTER 3 Installation Step Item Description 4 Install the base to the proper position onto the I/J machine as Installing the shown in Figure. Fix it securely with 4 bolts. drying hopper HD-10,15 type base base HD-25~100 type base HD-150~300 type base After installing it, remove any adhesive tape holding the slide gate

27 CHAPTER 3 Installation Step Item Description 5 When lifting and moving the drying hopper main body, inspect the Checking the following points: drying hopper Make sure that there is no material in the drying condition hopper. Make sure that the catch-clips (2 pieces) on the cylindrical section and conical section of the drying hopper are securely set as shown in figure. (Only for HD-10~50 type) Catchclip Make sure that the U-bolt connecting the drying hopper cylindrical section and the hot air pipe of the heater box is securely fixed as shown in figure.(only for HD-10~50 type) U-bolt HD-10~

28 CHAPTER 3 Installation Step Item Description 5 Make sure that the catch-clips (2 pieces) or handle (1 piece) are Checking the fastening the cleaning door of the drying hopper cylindrical section drying hopper and is securely set (as shown in the figure). condition (Only for HD-75~300) Adjusting fastener

29 CHAPTER 3 Installation Step Item Description 6 Installing the drying hopper Install the main body to the base as shown in Figure. Caution! Before installing the main body, be sure that slide gate of the base is properly set. Fix the body with 4 bolts securely. HD-10,15 type base HD25~100 type base HD-150~300 type base

30 CHAPTER 3 Installation Step Item Description 7 Connecting the hoses between the dehumidifying unit and the drying hopper For closed-loop models, connect the dehumidifying unit and the drying hopper with connecting hoses (heat resistant hose) as shown in the figure. Heat resistant hose Hose clamp Connection port Connection should be tightened with hose clamp securely to prevent air leak. Connecting hose Exhaust Suction pipe Dehumidified air OUT Dehumidified air IN Connecting method Dehumidified air OUT Dehumidified air IN Supply pipe on heater box Exhaust pipe on lid CAUTION The positions of IN and OUT for dry-air hoses are different depending on machine types. Confirm the sticker on the body side to connect the hoses correctly

31 CHAPTER 3 Installation Step Item Description 8 Connecting the water-supply and drain hoses (or pipes) to the dehumidifying unit Connect a pipe or hose to water-supply and drain ports of dehumidifying unit as shown in figure. <In case of connecting pipe> Pipe Fasten pipes securely with seal tape to prevent water leaks. <In case of connecting hose> Hose Hose clamp Hose nipple Tighten connection securely with a hose clamp to prevent water leaks. The hose, hose clamps and hose nipples are sold separately from main body. Connecting diameter :3/8 B

32 CHAPTER 3 Installation 2.Power supply connection Step Item Description 1 Connecting the With all power off, connect the signal cord of dehumidifying unit to signal cord the relay box on the side of the drying hopper. (Only for separated type) Relay cord Relay box inside DMS2-40/80/120 DMZ2-40 DMS2-170/240 DMZ2-80/120 H1 H2 H3 R21 1 K1+ K1- H1 H2 H3 H4 H5 H6 R21 1 K1+ K1- CAUTION Be sure that all connections are tightened securely

33 CHAPTER 3 Installation Step Item Description 2 Connecting the This should only be done by a certified technician with ample power cord electrical ability! Make sure that the power breaker on control panel is turned OFF 35 and then connect power cord (15 ft.) to the power supply (also off) of the equipment at your company. R phase Red Power cord S phase White For primary power supply T phase Blue E Green For grounding (earth) CAUTION The power breaker on the control panel must be turned OFF before connecting the power cord. Fasten all connections securely and make sure that there is no looseness. Be sure to connect the ground wires. Power supply should be set securely tapped with a grounding terminal

34 CHAPTER 4 Preparation for Operation 1. Inspection Inside of the Drying Hopper (1)In case of HD-10~50 type Step 1 Description Loosen the U-bolt which connects the cylindrical section and hot-air pipe of the heater box as shown in figure. 2 U-bolt HD-10~50 Remove the catch-clips (2 pieces) which fix the cylindrical section and the conical section as shown in figure. Catchclip

35 CHAPTER 4 Preparation for Operation Step 3.1 Description Inspection and cleaning inside the hopper CAUTION Do not bump or hit the cylindrical section. Open the cylindrical section carefully not to lose the gasket a. Open cylindrical section and make sure that there is no foreign matter inside of it as shown in figure. Lid Gasket Gasket a b Diffuser fitting part Separator 3.2 Remove the following parts for cleaning. Then clean hopper inside and removed parts with compressed air or duster. Remove set pin fixing diffuser and remove diffuser. Lid Inner surface cleaning Set pin Surface cleaning Diffuser Inner and outer surface cleaning Packing Surface cleaning b Remove packing b and separator. Separator Inner and oute surface cleaning

36 CHAPTER 4 Preparation for Operation Step 4 Description After inspection and cleaning inside, attach the removed parts again. Gasket a Flange Gasket Lid As shown above set gasket iinto the groove. a Gasket b Diffuser flange Conical Gasket b flange Set pin Diffuser Fix diffuser securely with set pin. Conical and gasket b should be set into proper position as shown above. Fix lid securely with catchclips (3 pieces). Lid Catchclip 5 Remove the following parts for cleaning. Then clean inside the hopper and removed parts with compressed air or duster

37 CHAPTER 4 Preparation for Operation (2)In case of HD-75~300 type Step 1 Description Remove catch-clips or handle shown in Figure and open cleaning door to confirm that there is no foreign matter inside of it. Single type High Heat Type (double wall) CATCH CLIPS Handle 2.1 Remove the following parts for cleaning. Then clean inside the hopper and removed parts with compressed air or duster. (In case of HD-75,100) Lid Inner surface cleaning Set pin Surface cleaning Diffuser Inner and outer surface cleaning Remove set pin fixing diffuser and remove diffuser

38 CHAPTER 4 Preparation for Operation Step 2.2 (In case of HD-150,200) Description Lid Inner surface cleaning Hot air pipe Diffuser Inner and outer surface cleaning Remove diffuser by moving it up and down or rotating it along groove of hot air pipe. (In case of HD-250,300) Inner surface cleaning Hot air pipe Handle Diffuser Inner and outer surface cleaning Take the handle of diffuser and remove diffuser by moving it up and down or rotaining it along the groove of hot air pipe

39 CHAPTER 4 Preparation for Operation Step 3 Description After inspection and cleaning inside, attach the removed parts again and close cleaning door and set catch clips, or handle, securely. In case of HD-75 ~ 200 Fix lid securely with catchclip. Catchclip Lid H D - 75, 100 Diffuser fitting part Set pin Diffuser H D ~ 300 Diffuser fitting part Hot air pipe Diffuser Fix it securely with set pin. Fix it perpendicular to hot air pipe

40 CHAPTER 4 Preparation for Operation 2. Checking Components and Loading Resin Component name Drying filter Component and checking items Tighten the filter with the knob so there are no air leaks. 乾燥フィルDry ターケース filter case 乾燥フィルター Dry filter Lid 蓋 Knob ノブ Regeneration filter Confirm that the filter is set in the blower suction port as the figure. フィルターケース Filter case フィルター Filter Filter-stopper フィルター押さえ フィルター Filter Filter-stopper フィルター押さえ Hose Confirm whether or not each hose is connected per the installation section. Specifically, confirm whether the hose clamps are tightened, so there are not any air / water leaks

41 CHAPTER 4 Preparation for Operation Unit name Drying overheat protection - Setting the thermostat Confirmation unit and checking item Set the drying overheat protection device. The set value should be the actual drying temperature set-value, plus 15 to 20 degrees. 乾燥過温設定器 Drying overheat Protection device Slide gate Material outlet Be sure that the slide gate for material outlet at the lower part of hopper base is closed securely, (as shown in Figure 55) and then load material into drying hopper. HD-10,15type HD-25~300type

42 CHAPTER 4 Preparation for Operation 3. Controller setting Step Turn the power supply ON Preparations for operation Confirmation unit and checking item Set the front power breaker to ON. Press the STANDBY button on the front. This energizes the unit. The display of the controller lights up. Setting the drying temperature Push the SV button once. The set-value (SV) and the actual present setting value (266) are alternately displayed on the monitor. Press the switch to unlock the set value. The present setting value blinks on the monitor. Push the switches to change the setting value. By pushing these switches, the value becomes higher or lower. Push and hold to increase or decrease the value. Push the switch to set the setting value. If you don t push this switch, the setting will not be changed. Make sure to press when finished. 1.Setting range 32~ 266 (356) F / 0~350 2.Factory setting value 266 F / Standard setting value.176~266 F (356) F 80~130 (180) Note: Descriptions in ( ) are for high temperature specifications

43 CHAPTER 4 Preparation for Operation Step Using the Start timer This is a 100 Hour count-down timer for automatic start-up. Confirmation unit and checking item Push the SV switch twice until dly 35 appears. The timer setting and present setting value are alternately displayed on the monitor. Press the switch to unlock the setting. The present setting value blinks on the monitor. Push the switches to change the setting value. By pushing these switches, the value becomes higher or lower. Push and hold to increase or decrease the value. Push the switch to input the setting value. If you don t push this switch, the setting will not be changed. Make sure to press when finished. 1.Setting range 0.0~99.5 (0.1h=10min) 2.Shipment setting value 0.0h 3. When a power failure happens while the start timer is active, this setting may be re-set. Refer to the section manual start 35 in CHAPTER 5- Operating procedures

44 CHAPTER 5 Operating Procedures Step Operation Description 1 Power ON Turn the power breaker on the front door to ON. 2 Preparations for Press the STANDBY switch in the front. This energizes the unit. operation The display of the controller lights up. 3 Drying start-up When pressing the Dryer switch, the Dryer indicator lights up and the dry operation starts. 4 Drying stop 1) Press the Dryer switch. The heater turns OFF, and the cooling operation starts (only the blowers remain operating). The Dryer indicator changes from ON (solid) to blinking. 2) After the cooling timer times up (10 minutes), the Dryer indicator turns OFF and the unit stops. Except for an emergency, until the Dryer indicator turns OFF, do not cut off the power. 5 Power off After the stop operation in procedure 7, step 4, turn the front power 6 Recovery after a power failure breaker OFF. CAUTION For stopping the unit as described in procedure 7, during blower operation, don't turn the power breaker OFF. If the power breaker is turned OFF during blower operation, the blowers stop, but the unit is filled with stagnant heat in the heated areas. This may damage the heaters, and the material may harden, or become sticky. During unit operation, in case of the power failure, the operation stops. In cases longer than a 40 ms. power failure, the unit stops. After the recovering the power, confirm that the problem doesn't occur again when restarting, then restart the unit as needed

45 CHAPTER 5 Operating Procedures ADJUSTING THE SUCTION NOZZLE Adjusting the amount of secondary air into the suction nozzle Put the suction nozzle into the material and adjust the secondary air regulator to achieve smooth material conveyance. Secondary air regulator ring 二次空気調整リング NOTE Throttling secondary airflow excessively may cause the hose to be clogged with material

46 CHAPTER 6 Maintenance DANGER HOT! After the dryer stops, the unit will remain hot for awhile. For maintenance and inspections, wait until the unit gets cold (5h are a standard for natural cooling). Even if the outside of the unit seems cold, be careful, because the inside, and the dried material, may still be hot. 1. Daily maintenance Maintenance item Confirmation of cooling water Description Check the cooling water inlet and outlet (shown in the figure) to see if cooling water is flowing. It is recommended to install a flow meter for inspection of the cooling water flow rate. NOTE If the cooling water is not flowing, the drying dew-point temperature may not go down, which causes inadequate drying. Also, it will be harder to achieve low set temperatures. Cooling water inlet Cooling water outlet *Removal of dust in dust tube (option) (*This option is not common) For single pass and semi-circulation specifications only; Remove dust remained in the dust tube as shown in Figure 69. Remove the dust cap under the dust tube to remove dust. After dust removal, replace the dust cap. Dust tube Dust cap

47 CHAPTER 6 Maintenance Maintenance item Confirmation of temperatures Description Confirm that the drying and regeneration temperatures are controlled per the setting of the controller. <Confirming method> To check the drying temperature 1. By pushing the SV switch of the controller once, the SV indicator displays SU and the existing set-point, alternately (for 4 seconds). 2. After confirming the set-value, the display defaults back to the current temperature (at the sensor on the drying hopper). Compare them. 3. If the actual value is ±2~3 degrees, the drying temperature is normal. To check the regeneration temperature 1. This temperature will also be shown at the controller display. 2. Push and hold the RESET and SV switches at the same time. While these switches are pushed, the actual temperature of regeneration zone is displayed on the indicator. Hint: It is best to push RESET first, then SV second (as if playing a piano), in order not to hit SV alone accidentally. 3. If the regeneration temperature is 356~428 F / 180~220, it is normal. If the temperature moves up and down slightly, this is normal, and not a malfunction

48 CHAPTER 6 Maintenance 2. Weekly maintenance Maintenance item Check the hoses for air- leaks Description Check that the hoses connecting the DMZ 2 and the drying hopper are tight. ( orange, heat resistant hoses) If there is an air leak, change the hose. [Example of how to check for an air leak] As a checking method, hang a string or a thread near the hose. If the string or a thread is shaking, there may be air leaking. Filter cleaning CAUTION 1. Use a mask because loose debris may blow in your eyes when cleaning. 2. When a filter is clogged, it affects the temperature and airflow rate. Extremely dirty filters could start a fire. When a filter is clogged, remove the filter and blow clean, dry air to remove debris. The environment around the dryer will affect the filter. Keep the perimeter of the unit as clean as possible. After checking, set the filter at its original position and tighten. When the filter clog is dirty, exchange it with a new filter. Electromagnetic switches and contactors CAUTION Before checking any components, turn the unit OFF and unplug it, for safety. There are no short-cuts for safety! Periodically check the contactors and mechanical contacts of the electromagnetic switches and contactors in the control panel. When there is deterioration of any contacts, replace the contactor

49 CHAPTER 6 Maintenance Maintenance item Drying filter Description Remove the filter, check and clean any debris. 乾燥フィルターケース乾燥フィルター蓋ノブ Dry filter case Dry filter Lid Knob Regeneration filter Remove the filter, check and clean any debris. フィルターケース Filter case フィルター Filter Filter フィルター押さえ stopper フィルター Filter Filter フィルター押さえ stopper Cleaning the cooling water line Clean the strainer of the cooling water line of the equipment at your company. If cooling water does not run because of dirt, etc., the drying dew point will not go down, and this may cause inadequate drying. CAUTION A strainer is not supplied for this equipment

50 CHAPTER 6 Maintenance 3. Monthly maintenance Maintenance item Check for loose wires Description CAUTION Before checking any components, turn the unit OFF and unplug it, for safety. There are no short-cuts for safety! Check for any loose wires due to vibration, etc. 4. Every six months maintenance Maintenance item Bolts and Nuts of each component Rotor belt, Tension of Spring plate Description Check for loosened bolts and nuts for all components. Tighten as needed. Check for any cracks, broken portions, and looseness of the belt, or any unusual conditions. Consult Matsui for belt replacements

51 CHAPTER 7 Alarm Functions CAUTION Before checking for any malfunctions and recovery, always turn the power breaker for the control panel OFF. If working with the power ON, an accident or death may occur. Do not attempt hot work. If a malfunction occurs during operation of the equipment, the alarm turns on, and the alarm code is displayed on the control panel while the alarm buzzer sounds and informs the malfunction. To acknowledge the buzzer and stop it, press the Reset key. Alarm indicator EPROM Error Character indicator E0 Malfunction contents/interlock This alarm occurs when it isn t possible to read the correct data of the ROM chip. Measure Perform Chapter 5.preparations for operation after turning off the power once. If this alarm displays again, the controller is defective. Exchange the controller. Reverse phase E1 Occurs when the connection of the power cord phases are reversed. Refer to CHAPTER Power supply connection and apply the correct phases. Drying blower Overload E2 Occurs when high current flows through the blower, and the thermal relay (under the contactor) trips. Refer to CHAPTER 8. Troubleshooting. Open the control panel and press the reset button of the thermal relay. The Drying blower labeled is MS-1. The operation stops automatically. When pushing the Reset switch after fixing the malfunction cause, the alarm indicator turns off. Convey blower Over load Not used on DMZ -2 E3 Occurs when high current flows through the blower, and the thermal relay (under the contactor) trips. The operation stops automatically. Refer to CHAPTER 8. Troubleshooting and restore extraordinary occurrence cause. Open a control panel and press the reset button of the thermal relay. By pushing the Reset switch after removing of the malfunction cause, the alarm indicator turns off

52 CHAPTER 7 Alarm Function Alarm indicator Dry temperature or regeneration temperature High alarm Character indicator E4 Malfunction contents/interlock Occurs when the drying or regeneration temperature rises above the setting temperature + high limit set-point. The operation stops automatically. Measure Refer to CHAPTER 8. Troubleshooting. By pushing the Reset switch after fixing the malfunction cause, the alarm turns off. Dry sensor broken E5 The drying thermocouple is damaged, or has a severed or loose wire. (K-type sensor) The operation stops automatically. Refer to CHAPTER 8. Troubleshooting. By pushing the Reset switch after fixing the malfunction cause, the alarm turns off. Regeneration sensor broken E6 The regeneration thermocouple Refer to CHAPTER 8. Troubleshooting is damaged, or has a severed, and restore extraordinary occurrence or loose wire. (K-type sensor) cause. The operation stops automatically. By pushing the Reset switch after fixing the malfunction cause, the alarm turns off. No.1 Convey Malfunction Not used for DMZ-2 E7 After start-up of the Refer to CHAPTER 8. Troubleshooting No.1direction conveys, occurs and restore extraordinary occurrence when not becoming full in the cause. constant time. Or, it occurs when primary If the end of convey becomes full, convey does not affect the automatically, alarm is canceled. secondary convey. When canceling alarm compulsorily, turn the convey switch OFF or press a Reset switch. No.2 Convey Malfunction Not used for DMZ-2 E8 After start-up of the Refer to CHAPTER 8. Troubleshooting No.2 direction conveys,the and restore extraordinary occurrence alarm occurs after not becoming cause. full in the constant time. If the end of convey becomes full, automatically, alarm is canceled. When canceling alarm compulsorily, make the convey switch OFF or press a Reset switch

53 CHAPTER 7 Alarm Function Alarm indicator No.3 Convey Malfunction Not used on DMZ-2 Character indicator E9 Malfunction contents/interlock Measure After start-up of the Refer to CHAPTER 8. Troubleshooting No.2 direction conveys, occurs and restore extraordinary occurrence when not becoming full in the cause. constant time. If the end of convey becomes full, automatically, alarm is canceled. When canceling alarm, turn the convey switch OFF or press a Reset switch. Dry / Regen. Overheat E10 Occurs when the drying / Refer to CHAPTER 8. Troubleshooting. regeneration temperatures reach excessively high levels. Check the overheat dial on the hopper. The heater turns off, and the alarm is activated. Reset by pushing the standby button after the sensor has cooled

54 CHAPTER 8 Troubleshooting CAUTION Before investigating problems Stop the equipment, and unplug it before working on it, or checking it. After the equipment has stopped, allow all parts to cool to avoid any burns. Malfunction Symptom See page The blower does not rotate. 50 Drying blower The blower is overloaded, and the thermal relay trips. 51 There is little air flow rate from the blower. 52 Drying temperature The drying temperature is erratic. 52 The dry temperature doesn't move up and down. 53 Drying inadequate The moisture content in the resin does not go down. 54 Controller The PV value indicator on the controller doesn't come ON with primary power applied. Power breaker The power breaker trips. 55 Overheat The overheat alarm occurs. 55 The thermal setting value for every model For the checkpoints and methods specified on the next pages, examine before requesting a repair. For the method of removing a filter, refer to CHAPTER 6- Maintenance

55 CHAPTER 8 Troubleshooting The drying blower does not rotate. Check point Remedy Note Confirm whether or not the indicator of the controller lights up. Set the primary power and the front power breaker in ON. Has the Standby switched been pushed? When the following disposal doesn't correct it, look at page 63; [The indicator with the PV value of the controller doesn't display the condition of ON in primary power]. Confirm whether or not the Dryer indicator of the controller lights up. Open the door of control panel and check for degradation of the magnet point of the contactor. When the power is ON, check the opening and shutting motion for the magnet. Has the Standby switched been pushed? Has a delay timer been activated? (see page 38) When not lighting up, press the Dryer switch. If the indicator doesn't light up even after pushing the switch, call for service. If the contactor is expired, replace it. When the start timer is set, after the setting time, the dry operation is started. Tolerance: times Confirm whether or not the malfunction character of E2 isn't displayed at the controller indicator. If the blower is overloaded, check the overload relay under the contactor (MS-1). This has a reset button which can be pushed. For overload causes, see page

56 CHAPTER 8 Troubleshooting The blower is overloaded and the thermal relay trips. Check point Remedy Note Remove the dry filter and check the filter debris When there is dirt and dust, blow clean, dry air into the filter and remove the clinging particles. When the degradation of filter progresses and it isn't possible to remove clinging particles, exchange the filter. Open the door of control panel and are there not dissolving and consumption of the magnet point of the electromagnetic switch unit, and At the time of power ON, check the opening and shutting motion for the magnet. Check whether or not the thermal set-point in the control panel is set to the standard value. Are all 3 phases at the supply to the contactor? Check your facility wall fuses. If the contactor is damaged, replace it. Refer to [The thermal setting value of every model] and set a thermal to the standard value. Tolerance: times Check only after turning primary power OFF

57 CHAPTER 8 Troubleshooting There is low air flow rate of the blower. Check point Remedy Note Remove the cartridge filter in the filter case and check the filter for debris. Check for damage or a loose connection hose on the dehumidifying unit, and the connection hose between the dehumidifying unit and the drying hopper. When there is dirt and debris, blow clean, dry air into the cartridge filter and remove any clinging particles. If the hose is damaged, exchange with a new hose. When there is loosening in the hose connection, tighten up the hose clamp. When the degradation of cartridge filter progresses and it isn't possible to remove clinging particles, exchange it with a new cartridge filter. After confirming an air leak, and stop the unit. Be careful as not to get burned on any heated parts. The drying temperature is erratic. Check point Remedy Note Remove the cartridge filter in the dry filter case, and check the filter for debris. When there is dirt and debris, blow clean, dry air into the cartridge filter and remove any clinging particles. When the degradation of cartridge filter progresses and it isn't possible to remove clinging particles, exchange it with a new cartridge filter. Remove the regeneration filter and check the filter. Inspect the thermocouple. When there is dirt and debris, blow clean, dry air into the cartridge filter and remove any clinging particles. Is the thermocouple sensor loose? Does it need adjustment? Is the polarity correct? When the degradation of filter progresses and it isn't possible to remove clinging particles, change the filter. If temperature is still erratic call a serviceman

58 CHAPTER 8 Troubleshooting 1. Hoses 2. Standby button 3. Thermocouple 4. Controller The dry temperature doesn't go up or down. Check point Remedy Note Check the cooling water flow for a lack of water volume. 1. Inspect all hose connections. 2. Did you hit the Standby switch on the front door? 3. Is the thermocouple loose, or need adjustment? 4. Check connections at controller. When cooling water isn't flowing, confirm that all valves are open. The air temperature that is discharged from the dehumidifying unit is hot and the dry temperature sometimes can not be set below 176 F (80~ 90 ). In this case, always use cooling water. Check if the dry heater is broken. When the heater is broken, replace the heater. After the unit stops, turn the power breaker OFF. Wait for the dryer to cool, then check

59 CHAPTER 8 Troubleshooting The moisture content of resin does not go down. Check point Remedy Note Check the cooling water flow and water volume. When cooling water isn't flowing, confirm the open condition of each valve. Don't set the water supply pressure for more than 0.49MPa. Remove the cartridge filter in the dry filter case and check the filter. Remove the regeneration filter and check the filter debris. When there are dirt and debris, blow clean, dry air into the cartridge filter and remove any clinging particles. When there are dirt and debris, blow clean, dry air into the cartridge filter and remove the clinging particles. When the degradation of cartridge filter progresses and it isn't possible to remove clinging particles, exchange it with a new cartridge filter. When the degradation of filter progresses and it isn't possible to remove clinging particles, exchange it. Check for damage or a loose connection hose on the dehumidifying unit, and the connection hose between the dehumidifying unit and the drying hopper. If the hose is damaged, exchange at the new hose. When there is loosening in the hose connection, tighten up a hose clamp. After finding the place of air leak, stop the unit. Wait for the dryer to cool, the check it. Check the regeneration temperature. Check if the regeneration heater is broken. The regeneration temp. is factory set at 428 F (220 C). If the heater is broken, replace the heater. After the unit stops turn the power breaker OFF. Wait for the dryer to cool, the check it

60 CHAPTER 8 Troubleshooting The controller does not light up, even after pushing the Standby switch. Check point Remedy Note Check whether or not the front power breaker of the control panel is ON. If not turned ON, turn the power breaker "ON" and press STANDBY switch once again. Check whether or not the circuit protector (CP-1) inside the control panel is OFF. After checking the electric wiring and the part in the control panel, set to ON. Only check inside the panel with the power supply OFF. The power breaker trips. Check point Remedy Note Check for a short circuit. Remove the short circuit. Only qualified personnel should attempt this. The overheat alarm (E-10) occurs. Check point Remedy Note Check the setting value of the dry overheat thermostat. Setting value The dry overheat setting value: Dry temperature +20 Remove the cartridge filter in the dry line filter case and check the filter. If it has too low of value, increase it. When there is dirt and debris, blow clean, dry air into the cartridge filter and remove any clinging particles. Check only after turning the power breaker OFF to prevent a shock. When the degradation of cartridge filter progresses and it isn't possible to remove clinging particles, exchange it. Remove the regeneration filter and check the filter. Check the solid state relays. When there is dirt and stuff, blow clean, dry air into the cartridge filter and remove any clinging particles. There is possibility of a defective solid state relay. After checking, replace as needed. When the degradation of filter progresses and it isn't possible to remove clinging particles, exchange it. Check only after turning the power breaker OFF to prevent a shock

61 CHAPTER 8 Troubleshooting The thermal setting value of every model (A) Thermal relay dry blower (OCR-1) Power supply Model Setting value (A) Setting range (A) 50Hz 60Hz DMZ2-40U ~2.2 AC230V DMS2-80/120U DMZ2-80U ~6 DMS2-170U DMZ2-120U ~6 DMS2-240U ~11 DMZ2-40U ~1.45 AC460V DMS2-80/120U DMZ2-80U ~3.4 DMS2-170U DMZ2-120U ~3.4 DMS2-240U ~6-56 -

62 CHAPTER 9 Technical Manual 1. The factory setting values of the controller The parameters of the user setting mode By pushing the SV switch, the parameter indicator scrolls over. But if you push the SV switch more than 5 seconds, it changes to the engineering setting mode, so be careful. Use Character Setting range initial setting value Dry temperature SV 32~266/256 F 266 F Start-up timer DLY 0.0~99.5 hour 0.0 hour NO.1 Convey time (not used) Fd1 0~999 sec. 20 sec. NO.2 Convey time (not used) Fd2 0~999 sec. 15 sec. NO.3 Convey time (not used) Fd3 0~999 sec. 15 sec. NO.1 Discharge time (not used) dc1 0~999 sec. 25 sec. NO.2 Discharge time (not used) dc2 0~999 sec. 25 sec. NO.3 Discharge time (not used) dc3 0~999 sec. 25 sec. NO.2 Raw material beginning time bt2 0~99 sec. 2 sec. NO.2 Raw material beginning time bt3 0~99 sec. 2 sec. The parameters for the engineering settings mode By pushing the SV switch more than 5 seconds, it changes to the engineering setting mode. By pushing the SV switch in the engineering setting mode, the character scrolls over. Use Character Setting range initial setting value Upper limit temperature alarm detection delay time Ult 0~999 sec. 5 sec. Feed 1 Convey malfunction detection count LCt 0~999 count 50 count Dry unit level gage malfunction count FCt 0~999 count 20 count Feed 1 Convey malfunction detection delay time 1Ed 0~999 min. 120 min. Feed 2 Convey malfunction detection delay time 2Ed 0~999 sec. 180 sec. Feed 3 Convey malfunction detection delay time 3Ed 0~999 sec. 180 sec. Upper limit temperature alarm (dry temperature deviation) DUS 0~40 18 F / 10 Upper limit temperature alarm (regeneration temperature deviation) RUS 0~40 18 F / 10 Dry system broken detection time (dry) DLP 0~999 min. 0 min. Regeneration system broken detection time (regeneration) RLP 0~999 min. 0 min. Feed1 Level switch demand delay L1d 0~999 sec. 15 sec. Feed2 Level switch demand delay L2d 0~999 sec. 15 sec. Feed3 Level switch demand delay L3d 0~999 sec. 15 sec

63 10 TECHNICAL MANUAL 2. Using the auto-tuning mode When the dryer unit is operating, the auto tuning mode can be started by pushing and holding the and keys at the same time for 2 seconds, while displaying the drying temperature value. (During auto tuning, the display switches alternately every 1-second, between the drying temperatures, and At display) When the auto tuning ends, the PV display returns to normal, and the controller uses PID control per the auto-tuned adjustment results. The operation for stopping auto tuning manually is the same procedure as step. Because this controller does not display any alarms during the auto tuning mode, when an auto tuning alarm occurs, (i.e. when a sensor is broken, or if the auto-tuning time passes for equal to, or more than 3 hours) neither the alarm information, nor the buzzer will alarm. Also, if an alarm happens during auto tuning, a new auto tuning can not be performed unless the power is reset off and on

64 10 TECHNICAL MANUAL 3. For the influence of gas that occurs from the resin The information on influence of gas that occurs from the resin The unit sometimes can not function normally with influence of gas that occurs from the resin. As for the resin that has this possibility, it is necessary to suppress this gas from entering. There are one-pass methods and methods of installing the gas gathering unit etc. in compatible method. However, the proper method must be chosen considering the dried material. Also, there is not a sure-fire way for all resins at the present. Therefore, depending on the resin used, the constant regular maintenance and parts replacement of consumables may be necessary. When the following phenomenon is confirmed during use, there is a possibility that the unit undergoes influence by gas. In such cases, please consult Matsui. 1) The liquid of oil oozes from the filter box, the pipe connection ports, or the dry hopper etc. 2) There is discoloration in the filter box, or if oil adheres to it. 3) A thin smoke occurs from the regeneration exhaust port. 4) Oil dirties the whole unit. 5) Oil adheres to the floor. As for resins that the influence of gas is estimated, refer to the list on the next page

65 10 TECHNICAL MANUAL The resin list which gas is estimated as a bi-product of drying: (The resin that gas compatible column in the table had mark needs compatible. mark is unnecessary but depending on kind of the compounding material, it has possibility that the compatible becomes necessary.) (Research in 2002) Name of resin Necessity of gas compatible Name of resin Necessity of gas compatible Name of resin Necessity of gas compatible ABS PAR PPO ABS+PBT PBT PPS APEL PBT+PC PSF A-PET PBT+PET PTFE AS PC PU BTP PC+ABS PUR CA PC+PET PVC Special grade CAB PCT+PET SPS CAP PCTFE TPE CN PC Optical grade TPO COP PDAP TPX CP PEEK Reinforcement PET DL PEI Flame resisting ABS EC PES EVA PETG EVOH PET Bottle grade LCP PET Fiber grade MTPA PFA PA+POM PMMA PA+Carbon fiber PMMA Optical PA6,66 POAM PA6,66+G POLYSUL PA612 POM PAMXD6 PP+ Filler PAN PPE

66 CHAPTER 9 Technical Manual 4. Relation between the dry air dew point and the ambient air condition Relation between the ambient air condition and the dry air dew-point is shown. The dry air dew-point is influenced by the ambient air condition (Dew point). Be careful because there is a possibility that the dry air dew-point is affected with the ambient air scondition. The following graph shows how the DMZ (and DMS) dew-point is affected by the ambient air condition. Change of dry air dew point to fresh air dew point (DMZ80) Dry air dew point Fresh air dew point Change of dry air dew point to fresh air dew point (DMS-1) 5 Outlet dew point Fresh air dew point

67 CHAPTER 10 Consumable Parts List 1. DMZ 2-40U Part name Manufacture Model Qty Dry blower Ho Hsing RB30-53U 1 Regeneration blower Matsui Mfg. 170FLJ2-A AC100V 60Hz 1 Dry heater Matsui Mfg. 1.5 kw (2.1kW) 1 Regeneration heater Matsui Mfg. 1.5 kw 1 Dry filter Matsui Mfg. φ Regeneration filter Matsui Mfg. φ150 t10 PS/ DMZ 2-80U Part name Manufacture Model Qty Dry blower Ho Hsing RB40-53U 1 Regeneration blower Matsui Mfg. 170FLJ2-C AC100V 60Hz 1 Dry heater Matsui Mfg. 2.4 kw (4kW) 1 Regeneration heater Matsui Mfg. 2.4 kw 1 Dry filter Matsui Mfg. φ Regeneration filter Matsui Mfg. φ150 t10 PS/ DMZ2-120U Part name Manufacture Model Qty Dry blower Ho Hsing RB50-53U 1 Regeneration blower Matsui Mfg. 170FLJ2-C AC100V 60Hz 1 Dry heater Matsui Mfg. 3.3 kw (6kW) 1 Regeneration heater Matsui Mfg. 3.1 kw 1 Dry filter Matsui Mfg. φ Regeneration filter Matsui Mfg. φ150 t10 PS/150 1 Note) Descriptions in ( ) are for high temperature specifications

68 CHAPTER 11 Options 1. The short circuit breaker (option) There is a short circuit breaker installed on the power breaker. Then, protect earth fault, overload, and short circuit and prevent from a short circuit. Symbol Name Maker Model ELB-1 Short circuit breaker Mitsubishi Electric. Refer to Plan No fuse breaker (NFB-1) isn't installed in the installation of the short circuit breaker. 2. The weekly timer (option) By settings of a weekly timer, the dryer does an "Automatic start " or "Automatic stop ". When turning the selection switch to "ON" by the weekly timer setting, it "Starts" and "Stops " automatically. As for the weekly timer, refer to the manufacturer instruction manual (OMRON, H5S-A time switch). NOTE When not using a weekly timer, make the selection switch (S-A) in "OFF". WEEKLY TIMER 1 2 R21 TR S10 A S-A TR-A OFF ON 35 34A 34 WEEKLY TIMER EXT.START SIGNAL No Symbol Name Maker Model 1 TR-A Weekly timer OMRON H5S-A 2 S-A Select switch Fuji Electric. AR22PR-210B

69 CHAPTER 11 Options 3. The external start / stop Signal This dryer is equipped with an "Operation- Start / Stop signal. (The external start signal terminal points are dry-contact, or non-voltage) The external start signal connects a signal line to the terminal board in the control panel. The external start signal starts in "ON" and stops at "OFF" CN3 4 5 EXT. RUN SIGNAL Your application range NOTE During extension start input, can not to do the stop of the dryer with the control panel. (Make the extension start signal in "OFF" and stop the dryer) 4. The general alarm output Output of the general alarm is from the terminal board inside the control panel. As for the terminal points, the alarm output time comes in an "ON" condition. (Non-voltage relay output, Resistance load 250 V 5A Max.) GENERAL ALARM SIG. 45 CR 2 S10 GENERAL ALARM SIG. AL1 CR-2 AL2 GENERAL ALARM SIG. DRY CONTACT

70 CHAPTER 11 Options 5. The alarm indicator It is possible to see an alarm from a distance when an alarm occurs. REVOLVING LIGHT GENERAL ALARM IND. 45 PL-AL S10 R REVOLVING LIGHT Symbol Name Maker Model PL-AL Revolving light Arrow Electron. ASD-200-R(AC200V) ASD-100-R(AC100V) 2) Revolving light ( with BUZZER) REVOLVING LIGHT GENERAL ALARM IND. 45 R PL-AL S10 REVOLVING LIGHT(W/BUZZER) SG COM SHORT Symbol Name Maker Model PL-AL Stack type light Arrow Electron. ASJA-200-R(AC200V) ASJA-100-R(AC100V)

71 CHAPTER 11 Options 6. Voltage Capabilities The North America versions (U) are available in 230 VAC, or 460 VAC as the primary power supply. Control voltages include both 100VAC and 24V DC, depending on component. This dryer is compatible with different voltages for the options. Please ask your sales representative for details if needed

72 CHAPTER 12 Specifications 1.DMZ 2 specifications Dry air dew point Equipment model 40U 80U 120U Fresh air condition: temp. 30 Relativity humidity 75% (DP+25 ) Fresh air mixing10 % of assuming -40( F / ) The dry air dew point depends on drying conditions. Dry air flow rate m 3 /h Dry temperature F / Dry blower Regeneration blower 176 ~ 320 (356) F / 80 ~130 (180) C Model RB30-53U RB40-53U RB50-53U Motor output kw Model 170FLJ2-A AC100V 60Hz 170FLJ2-C AC100V 60Hz Motor output W Regeneration heater Capacity kw Absorption Rotor Name Zeolite rotor Model MZC-200H20 MZC-250H20 MZC-250H30 Outside diameter mm φ200 φ250 φ250 Height mm Absorption Rotor Motor output W 15 motor Speed reduction ratio 1/1800 Dry filter Model φ φ Filtration area m Regeneration Model 160 x t 20 Fil-don filter Filtration area m Hose diameter After-Cooler Drying mm φ38 φ50 Cooling mm Regenerating mm φ20 φ38 Heat transfer area m Cooling water quantity 1/min Connection diameter B 3/8B female screw

73 CHAPTER 12 Specifications Control Equipment model 40U 80U 120U Dry temperature control PID control Regeneration temperature control PID control Automatic dry start timer Setting time range:10 min.~99 Hrs. 50 min. Overheat ( process and regeneration ) Alarm and Protection circuit Motor overload Power Phase reverse prevention Cooling timer, when stopped Power supply AC230V 60Hz AC460V 60Hz 3P Compatible options Outer dimensions Operation circuit voltage Power breaker capacity (A) 230/460V (high temperature type) 20/15 (20/15) AC100V 1P 30/20 (30/20) Weekly timer Short circuit breaker Dew point indicator Alarm light indicator Assignment power supply Filter clog alarm W mm D mm H mm /20 (40/30) Outline mass kg Note: Descriptions in ( ) are for high temperature specifications

74 Electric Circuit Diagram 3.Drying hopper specifications Drying temperature Model HD-10 HD ー 15 Standard 130(Max.) High temperature 180(Max.) Standard kw Heater capacity High temperature kw 2.1 Effective volume L Material for powder contacting area SUS430 W mm 606 Dimensions D mm 331 H mm Drying temp. 1 Model Standard High temperature HD-25 HD-50 HD-75 HD-10 0 HD (Max.) 180(Max.) HD-20 0 HD-25 0 HD-30 0 Heater Standard kw capacity High temperature kw Effective volume L Material for powder contacting area SUS430 W mm Dimensions D mm H mm Heater capacity in case of standard combination with dehumidifying unit

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