MULTI JET 3 MJ3-15~300U Instruction Manual

Transcription

1 MULTI JET 3 MJ315~300U Instruction Manual MATSUI AMERICA, INC. CHICAGO HEADQUARTERS 5825 Turnberry Dr. Hanover Park, IL TEL. (847) FAX. (630) Thank you for purchasing the MJ3 series dryerloader. To properly use your MULTI JET 3, please thoroughly read this manual. Keep this manual near the MULTI JET 3 so that it can be easily accessed whenever necessary. Issued in Dec.., 2015 [WO11233]

2 CONTENTS The chapters identified with the mark contain critical information. You should carefully read and understand them before you can start using the MULTI JET 3. TABLE OF CONTENTS...I~II INTRODUCTION... III 1. Products Covered 2. Target Readers 3. Warranty Page Chapter 1 Chapter 2 Chapter 3 Chapter 4 Safety Precautions 1. Hazardous level marks and their Meanings Safety Precautions...2 Explanation Equipment 1. Overview of the equipment Name of each part The shipment confirmation Name and the function of each controller part...6 Installation 1. Installation for equipment Power, Air and Cooling Water supply Connection...9 Preparation for Operation 1. Inspecting inside of the hopper Checking the condition of each component Controller setting Setting the Overheat Protector Jet clone operations 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 setting values Chapter 9 Technical Manual 1. The factory setting values for the controller Using the AutoTuning mode About influence of gas that occurs from the resin Relation between the dry air dew point and ambient air condition 41 Chapter 10 Consumable Parts List Chapter 11 Chapter 12 Options 1. The shortcircuit breaker The weekly timer The external start / stop signal The general alarm output The alarm light Different control voltages Primary conveying: Jet selector connection Secondary conveying: Two press directions Specifications 1. Specifications Electric Circuit Diagram II

4 INTRODUCTION 1. Product Covered This document describes how to properly perform the operations and maintenance of your MULTI JET Target Readers This document is intended for use not only by those who are using the MULTI JET 3 made by MATSUI MFG. CO., LTD. for the first time, but also by those who have experience in using the MULTI JET 3, and wish to confirm any information. 3. Warranty This product was manufactured by making the full use of the stateoftheart designing technology and best craftsmanship of MATSUI MFG. CO., LTD. If the product 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 are warranted and we will repair them and/or change parts when something should go wrong with any of them. However, there is NO warranty on the products made with our machines or devices. Any abnormal or defective products produced by your company, when using our machines or devices, are NOT the responsibilities of Matsui Mfg. Co.. However, if while you are operating our machine or device in a normal way and there is a problem caused obviously as a result of a defect in design, or in production of our machine or device, we will repair it, or replace the parts free of charge, within the following period: 1)A. The relevant defective part shall be returned to us. 1)B. This warranty shall remain valid for twelve (12) months starting on the date when the new products you purchased, ship from our facility. 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 our products; 3. Any deterioration (in paint or plating) as may occur from a timecourse change; 4. Any adverse 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, 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 products. III

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

6 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 is run continuously with the control temperature set to its maximum (320 F/160 C). Avoid careless proximity with the body when the equipment is in operation. Even when the equipment must be handled in 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 operation. This equipment is designed for loading and drying resin pellets. Drying of any other materials may cause equipment failure. Problems caused by materials other than resin pellets are not covered by the warranty. Gas is generated when resins are dried, and the dried resin gets stuck on the Honeycomb rotor, this may decrease the Dehumidifying and Drying efficiency. Drying cannot be done for the following resins pellet. Resins containing water particles, Special type of resin, and Humidified Nylon type resin. Environment Drying temperature Precautions during operation Do not use this equipment for drying materials with volatile components or materials that are flammable. Use with such materials may result in an explosion or fire. As for the material of possibility that gas occurs in drying, refer to "Technical Manual 3". This equipment should be used indoors. This equipment should be used at ambient temperatures from 0 C to 40 C (32 F to 104 F) and an ambient humidity of 2585%. Depending on the humidity condition, there is possibility that enough performance can not be performed. As 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. 2

7 CHAPTER 1 Safety Precautions Precaution item 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 left side of the control panel to OFF. Then unplug the power cord. Do not jar the controller, or spill liquid on the control panel or temperature controller. Otherwise failure, serious damage, or fire may result. Only open the door when absolutely necessary. Otherwise, failure or an accident may result. Overheat protection device CAUTION Warning labels Name plate Cleaning the exterior Maintenance and repairs When disposing of product and parts Overheat protection device This equipment is equipped [standard] with the safety device (overheat protection device). When the safety device is activated, the operation power is turned off and the heater and the blower are stopped. Therefore, the heater element sometimes remains quite high temperature. After cooling the heater sufficiently before restart, doublecheck the set point on the overheat protection device, as to not reactivate the alarm. For details, refer to the Chapter4. Preparation for Operation. Keep the label readable at all times. Do not wipe with oilbased solvents. Benzene, paint thinner, scouring powders, etc. will damage the surface. When the equipment is dirty, wipe it with a soft cloth, soaked in water at 104 F/40 C and well wrung out. Any maintenance or repairs should be performed only by a qualified technician with ample experience in electrical and mechanical repairs. For guidelines regarding maintenance or repair, contact your nearest service division. (See back page). When disposing of product and parts, you must obey laws that are applicable in the country of use. 3

8 Feed2( Secondary) Signal Cable Feed2( Secondary) Material Hose CHAPTER 2 Equipment Explanation 1. Overview of the equipment This equipment is designed for drying and loading resin pellets. Drying This unit dehydrates air with an absorbent to create superdry dry air, and then the air is heated (to your desired temperature) as it is sent into the hopper to dry the resin pellets (inside of the hopper). Since it removes moisture in the airflow with a continuously regenerated absorbent, the moisture content in the drying air does not change, and it can provide a constantly stable drying condition. Because of the low dew point in the airflow, moisture contained in the air is virtually eliminated, and the evaporation rate of moisture in the material is achieved fast. Utilizing a closed loop system, this equipment recycles air from the drying hopper as drying air, so hopper exhaust air does not leave the system. This prevents fumes, odor, and a lot of excess hot air from blowing out, which also economizes power consumption. Loading This unit is also equipped with a separate loading blower and a vacuumshift valve, which conveys the material: 1) into the dryer, 2) to the injection machine and 3) to a second injection press (as an available option). The user settings in the control panel allow you to regulate the amount of material to each press on a just in time basis which can eliminate material sitting in the hose, and excessive residence time in the receiving hopper(s). 2. Name of each part (specifically for the MJ350 shown) Vacuum Ports for Conveyor Regeneration Air Exhaust Drying Air Return from Hopper Feed2 Secondary Receiver Feed2 Vacuum Hose Primary Receiver Drying Hopper Feed 1( Primary) Material Hose Regeneration Filter Conveyor Filter only for MJ315~25 Drying Filter only for MJ 3 50~300 Conveyor Filter only for MJ3 50~300 Drying Filter only for MJ315~ 25 Maintenance door Deffuser Cone Control Panel CONTROL Standby ON Switch Switch Control Box Filter Regulator Compressed Air Supply Port φ 6 OD Tube Suction Nozzle Streainer Cooling Water Out Cooling Water IN Air Cooled Models do not have Water inlet and Outlet 4

9 CHAPTER 2 Equipment Explanation 3. The shipment confirmation Please confirm all purchased parts for your order. Primary Receiver JC3 / JC6 / JC9 / JC18 MJ3 Unit MVH3 / MVH6 or APH3 / APH6 Secondary Receivers (one of these) Suctionnozzle (one of these) Material Hose (PVC Hose) Omron Proximity sensor (In blue & white box, usually shipped behind the MJ3 Door). Hose Clamps Vacuum Hose (GTG Hose) Items Items MJ315U~150U Q ty MJ3200U~300U Q ty Suction nozzle (SUS) 1 1/ Suction nozzle (SUS) for Gaylord 1 1/2 Option 2 Option Material Hose (For primary convey) 1 1/2 x x30 1 Primary Receiver JC3/6/9 1, (2) MVH10 1, (2) Secondary Receiver(s) MVH or APH3/6/9/18 Option APH8 Option Material Hose (For secondary convey) 1.5 x30 1, (2) 2 x30 1, (2) Hose Clamps (For Material Hose) 1.5 4, (6) 2 4, (6) Vacuum Hose 1.5 x30 1, (2) 2.5 x30 1, (2) Hose Clamps (For Vacuum Hose) 1.5 2, (4) 2.5 2, (4) Length and quantity of the hose differ for optio ns. In case of the Second ary 2 direction convey; the quantity use (). 5

10 CHAPTER 2 Equipment Explanation 4. Name and the function of each controller part Status of Indicator (SV) Drying Temp. Setting Value Feeder 1~3 Convey Time Setting Status Light Value Indicator Drying Start / Stop switch Dryer Run Process Heater Reg. Heater #1 (Primary) convey Start / Stop switch #2 (Secondary) convey Start / Stop switch #3 (Optional) convey Start / Stop switch Alarm reset switch Dryer Drying Heater SV Feeder 1 Regeneration Heater Feeder 2 Feeder 1 Feeder 2 Reset SV Feeder 3 Feeder Dryer Select switch for Setting Parameter Increase Switch for setting value Decrease Switch for setting value Enter and Read Switch 6

11 CHAPTER 3 Installation 1. Installation for equipment Step Item Description 1 Installation Install on the level, stable floor. As shown in figure, make sure the installation location gives space to perform maintenance. 2 Caster brake As shown in figure, apply the brake of the caster. 3 Moving the unit As shown in the figure, when lifting and moving this unit, confirm the condition of the installation eyebolts on the upper section. Then, hang and move a hoisting rope (with hook) in the lift with your plant s crane. Make sure the hopper is empty CAUTION Be sure to use a hoisting rope (with hook) which can withstand the unit s weight. 7

12 CHAPTER 3 Installation Step Item Description 4 Installation of Install a hopper on the feed port of the molding machine. the hopper on Install surely with the gasket and the bolt for avoids air leakage. the molding Connect material hose (PVC hose) to the primary side and the suction nozzle. Machine and Fasten the hose clamps securely. connection of Connect the material hose to the secondary side. the hoses. Fasten the Hose clamps securely. Connect vacuum hose (GTG gray hose) to the secondary side. Fasten the Hose clamps securely. Connect the signal cable to the secondary receiver. See schematic on chapter 24 Name of each part section. If you use an APH type receiver, refer to the schematic below. Secondary Vacuum Hose Primary Material Hose Signal Cable Secondary Material Hose 8

13 CHAPTER 3 Installation 2. Power, Air and Cooling Water supply connections Step Item Description 1 Connection of Open the door of the control panel, and connect the power cord (within the power cord electrical codes of your Facility, State, etc.) at the power terminal board of this unit. 3phase alternating current (AC) power R: S: T: Earth (L1, L2, L3, E) When there is an attachment power cord, connect a power cord with your power terminal. CAUTION Before connecting a power cord, make sure the power breaker is OFF. Fasten tightly to avoid loose connections. Make sure the ground wire is connected. 2 Supply cooling water and compressed air Connect the cooling water and compressed air. Cooling water IN/Out: Rc1/2 See schematic on chapter24 Name of each part section. Compressed air port: Dia.6 tube (OD 6mm). Open the stop valve and set the pressure with the regulator. The setting pressure: 0.39~0.59Mpa (56~86PSI) Filter regulator Slide valve (Stop valve) Open Close 9

14 CHAPTER 4 Preparation for Operation 1. Inspecting inside of the hopper Step Description 1 Open the maintenance door before loading any material. Confirm that it is completely empty and clean. 2 Please confirm if the damper and residue discharge port at the bottom of the drying hopper is closed or not. Damper: push close, pull open Drying hopper Damper Residue discharge port Air regulating filter of secondary side This device is not existed while dehumidifying air is cycling. 2. Condition confirmation of each component. Unit name Process filter Confirmation unit and checking item Check that the process filter was set properly to avoid air leaks. Process Filter Case Process Filter Lid Knob Regeneration filter Confirm that the filter is set in the blower suction port as in the figure. Filter Case Filter Stopper 10

15 CHAPTER 4 Preparation for Operation Unit name Conveying filter Confirmation unit and checking item Tighten the filter; fasten with the butterfly nut and the knob to avoid air leaks. Convey filter case Convey filter Butterfly nut Lid Knob Receiver (filter and gasket) Set the filter and gasket securely. APH6 MVH6 11

16 CHAPTER 4 Preparation for Operation Unit name Hose Checking the sensitivity of the proximity sensor. (for the hopper on the injection machine) Confirmation unit and checking item Confirm whether or not each hose is connected as in the installation section. Specifically, confirm whether the hose clamps are tightened up so there are no air/ water leaks. Check the detecting condition of the level sensor for the suction hopper on the molding machine. If the sensor is Capacitive Proximity type (common) 1. Mount the sensor tightly. The glass and sensor clearance need 0~1mm. 2. Turn on the power and CONTROL ON switch. Indicator Screw Cap 3. Take out the Screw Cap. Sensitivity Volume 4. Remove all resin in the glass tube, and turn the sensitivity volume CLOCKWISE until indicator illuminates. 5. Turn the sensitivity volume COUNTERCLOKWISE until indicator goes out. 6. Set the Sensitivity to the midpoint between ON and OFF. 7. So, No material= Light OFF / Material Full = Light ON. If the sensor is Photoelectric type (Asian Style Only) Usually, the photoelectric switch does not need adjustment. (It is used at the maximum sensitivity.) However, if the light blocking condition with molding materials charged is not sufficient, make an adjustment by turning the sensitivity adjusting volume counterclockwise so that the green lamp lights. 12

17 CHAPTER 4 Preparation for Operation 3. Controller setting Step Power supply ON Confirmation unit and checking item Turn the front power breaker ON. Preparations for operation Dry temperature setting Press the CONTROL ON switch in the front. The display of the controller lights up. Push SV key until SV light turn on. The indicator shows SV character and present value alternately. Press the Enter switch. The present setting value blinks on the indicator. Push the switch and change the setting value. When the UP / DOWN switch is pushed continuously, the value will scroll quickly. Push the Enter switch and input the setting value. If you don t push this switch, the setting value cannot be changed. Please make sure to press. Setting range.176~320 F(80~160 C) Make sure of the correct temperature for resin you want dry. 13

18 CHAPTER 4 Preparation for Operation Step Start timer Confirmation unit and checking item Push SV key until dly character displayed. The indicator shows dly character and present value alternately. Press the Enter switch. The present setting value blinks on the indicator. Push the switch and change the setting value. Push the Enter switch to input the setting value. If you don t push this switch, the setting value cannot be changed. Please make sure to press. Push the Dryer switch and set the beginning time of the dry operation. 1. Setting range 0.0~99.5 (0.1h=10min) 2. Cancel : Please reset to 0.0h 3. If a power failure occurs during startup timing, auto startup will not begin. Please startup manually. Please see chapter 5. No.1~3 Convey timer This setting is for the total blower ontime in order to sweep the line clear of resin. To send more or less material to the press, see No. 2, 3 Batch Timer on pg. 15. (No.1: Primary Line) To Dryer bin (No.2: Secondary Line) from Dryer to #1, IMM (No.3: Option Line) from Dryer to #2, IMM Push SV key until Fd1, Fd2 or Fd3 character displayed. The indicator shows Fd_ character and present value alternately. Press the Enter switch. The present setting value blinks on the indicator. The conveying time depends on the distance, and the material. Set the time in order for the dryer receiver to get full. For filling the injection hopper, see No. 2, 3 Batch Timer on pg. 15. Push the switch and change the setting value. Push the Enter switch and input the setting value. If you don t push this switch, the setting value cannot be changed. Please make sure to press. 1. Setting range 0~999 sec. 14

19 CHAPTER 4 Preparation for Operation Step No.1~3 Discharge timer The discharge time is from when the blower stops, until the material is completely discharged, plus 5~10sec. (Usually No.1 discharge time is around 15 sec., No.2, 3 are 0sec.) No.1: Primary Line (To Dryer bin) No. 2: Secondary Line (from Dryer to #1, IMM) No. 3: (Optional Line) (from Dryer to #2, IMM) *No. 2, 3 Batch timer The "Batch time is how much material is dropped into the vacuum box for each cycle. The dry bin has an automatic gate to purge the hose. The Batch time is from the gateopen to closed. Usually the setting is around 2~10sec. (Too much time causes pellets to remain in the hose.) (The Batch timer is only for No.2 and 3 directions.) Confirmation unit and checking item Push the SV key until dc1, dc2 or dc3 character displayed. The indicator shows dc_ character and present value alternately. Press the Enter switch. The present setting value blinks on the indicator. These discharge timers need enough time to discharge resin from the receiver. (If No.2 / 3 direction use a vacuum hopper without a discharge gate, it does not need a discharge time.) Push the switch and change the setting value. Push the Enter switch and input the setting value. If you don t push this switch, the setting value cannot be changed. Please make sure to press. Setting range.. 0~999 sec. Push SV key until bt2, bt3 character is displayed. The indicator shows bt character and present value alternately. Press the Enter switch. The present setting value blinks on the indicator. Set the time to allow the push damper to open, until the desired amount of material is sent. Set this time lower than the Convey timer (fd1~3) setting to allow the line to be swept clear of resin. This time depends on the conveying distance, and the kind of the material used. Push the switch and change the setting value. Push the Enter switch and input the setting value. If you don t push this switch, the setting value cannot be changed. Please make sure to press. Setting range.. 0~999 sec. 15

20 CHAPTER 4 Preparation for Operation 4. Setting the overheat protector For safety, this unit has an overheat protector as a standard device. If the sensor (temperature detector) reaches a temperature higher than the temperature setting of the overheat protector, the unit will automatically shut off. Step Confirmation unit and checking item 1 Dry overheat protector unit (Liquid expansion type thermostat) Set the temperature setting of the overheat protector to a value about 20 C higher than the drying temperature (SV temperature setting). When temperature set up revision is needed, rotate dial to 220 C firstly, then to needed temperature. For standard specifications, set the temperature setting of the overheat protector to or less than 180 C. Dryingoverheat set device [REMARKS] The temperature controller has high and low limit alarm settings. When the high limit alarm occurs, the heater is turned OFF and, after the cooling time has elapsed, the blower is turned OFF, and operation stops. (Both the high and low limits are set to 10 C (18 F) at the factory before shipping.) 2 Regeneration overheat protector unit (Bimetal thermostat) Setting temperature Dry temperature +20 C (36 F) MJ315/25 the image drawing of an example. MJ310/15/25/50/75/100/ previous Since 2012 Top 255 setting Top 140 setting Bottom None Bottom 255 setting MJ3200/300 to 255 setting one 3 If the sensor (temperature detector) reaches a temperature higher than the temperature setting of the overheat protector, the unit automatically shuts off, and the E10 alarm is triggered. When the E10 alarm is triggered, perform the recovery operation according to Chapter 7 Alarm Function and Heater Overheat E10. 16

21 CHAPTER 4 Preparation for Operation NOTE When the overheat protector is tripped, the unit requires one hour or longer to cool. The overheat protector will not reset while the unit is still inadequately cooled. As the recovery operation cannot be performed in this state, please allow the heater to cool adequately before recovery. 5. Jet Clone operation The discharge timer operates when pressing the Feeder 1 switch ON, and the blower starts, when the time is up. The damper of the Jet Clone closes at the same time. The material for conveying timer (Fd1) is conveyed into the collection unit per the timer setting. The blower stops after timeup of the conveying timer. The damper of the Jet Clone opens when the suction pressure drops, and discharges material (by the setting time of discharge timer (dc1)) into the drying hopper below. The above operation is repeated. When the drying hopper becomes full, the limit switch on the Jet clone generates a full signal. After this, when the material level decreases, it sends a request signal from the limit switch. After a delayed NO.1 demanddelay timer (L1d) for the settime, then the blower cycles again. <Damper operations> (1) Normal condition (2) Close condition (suction type) (3) Material full condition Li mi t Swi tch Cam Damper Materi al 17

22 CHAPTER 5 Operating Procedures Step Operation Description 1 Power ON Set the power breaker in front to ON. 2 Preparations for operation 3 No.1 Convey startup (primary conveying) 4 Drying startup or Bypass StartTimer Press the CONTROL ON switch on the front panel. The display of controller lights up. Press the Feeder 1 switch; the lamp of Feeder 1 switch lights up and the material conveying of No.1directions starts. During the conveying operation, the lamp blinks, and when waiting, the demand signal lamp is lit up continually. When pressing Dryer switch, the Dryer indicator lights up and the dry operation starts. (When wanting to bypass the drying startup timer, press the Reset switch and Enter switch at the same time). 5 No.2 Convey startup (Secondary convey) No.3 Convey startup (In case of secondary convey two directions) Press the Feeder 2 switch; the lamp of Feeder 2 switch lights up and the material conveying of No.2 directions starts. During the conveying operation, the lamp blinks, and when waiting, the demand signal lamp is lit up continually. CAUTION Convey to the molding unit only after the initial drying is sufficient. If the initial drying is insufficient, it may cause defective molding. Press the Feeder 3 switch; the lamp of Feeder 3 switch lights up and the material conveying of No.3 directions starts. During the conveying operation, the lamp blinks, and when waiting, the demand signal lamp is lit up continually. CAUTION Convey to the molding unit only after the initial drying is sufficient. If the initial drying is insufficient, it may cause defective molding. [Adjusting the amount of secondary air used by 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. 18

23 CHAPTER 5 Operating Procedures Step Operation Description 7 No.1 Convey stop 1) Press the Feeder 1 switch. The indicator turns off and the convey (primary convey) operation to the No.1 direction stops. Drying stop 2) Press the Dryer switch. The heater turns OFF, but the blowers remain on in order to cool the heaters. No.2 Convey stop No.3 Convey stop (In case of secondary convey two directions) 3) After the coolingtimer times up (10 minutes), the Dryer indicator turns OFF and the unit stops. Unless there is an emergency, wait until the Dryer indicator turns OFF, don't cut off the power (at the breaker). 4) Press the Feeder 2 switch. The indicator turns off, and the convey operation to the No.2 direction stops. 5) Press the Feeder 3 switch. The indicator turns off, and the convey operation to the No.3 direction stops. 8 Power off After finishing the stop operation of procedure 7, turn the front power breaker to OFF. 9 Recovery in the power failure CAUTION For the stop operation of procedure 7, during blower operation, don't turn the power breaker OFF. When the power breaker is turned off during blower operation, the blower stops immediately, resulting in internal, stagnant heat. This may cause damage to the components, and / or hardening of material. During unit operation, if there is a power failure, the operation stops. In cases of more than 0.04 sec. Power failure occurs, and the unit stops. After the recovery of the power failure, confirm that the problem doesn't reoccur upon restart, and then use the dryer as needed. 19

24 CHAPTER 6 Maintenance DANGER HOT! 1. Daily maintenance Maintenance item Confirmation of cooling water Confirmation of drying Temperature After the dryer operation stops, the unit will still be hot for a while. Wait for maintenance and inspection until the unit gets cold (5 hours are standard for natural cooling). And even if the outside of the unit is cold, be careful, because the inner parts, or the dried material, may remain hot. Description Confirm that the pressure of the cooling water inlet port is at 0.49Mpa (71PSI). (For the equipment protection) Also, check whether or not cooling water is flowing. When cooling water isn't flowing, the drying dew point may not decrease, which affects standard drying performance. Confirm whether the dry temperature and regeneration temperature are controlled at the setting temperature on the controller. Confirming the regeneration Temperature Factory setting = 428 F (220 C) THIS SETTING SHOULD NOT BE READJUSTED! Confirming the drying temperature 1. After pushing the SV switch of the controller once, the SV indicator lights up and confirms a setting value for the drying temperature. 2. By Pressing the SV switch, the dry temperature is displayed. Compare it with the setting value. 3. If the setting value is a degree as +/3~6 F (2~3 C), the dry temperature is normal. Confirming the regeneration temperature 1. Make sure the drying temperature is displayed on the controller. 2. Press RESET and SV switches at the same time. While these switches are pushed, the actual temperature of the regeneration zone is displayed on the indicator. 3. If the regeneration temperature is between 356~428 F (180~220 C), it is normal. (It is normal that the regeneration temperature changes with the ambient temperature.) 20

25 CHAPTER 6 Maintenance 2. Weekly maintenance Maintenance item Air Hose Leaks Description Check the air leak on hoses. When there is an air leak, replace with a new hose. Dust hopper for Conveying air Remove the dust hopper, and remove the dust inside. Lid The dust hopper has gasket on the edge. A scratched gasket or no gasket may be a cause of conveying problems. Catch clip Dust hopper Air kit C heck the pressure a s 0.39~0.59Mpa (56~ 86PSI). Adjusting 調整ノブ knob O pen the drain valve and purge drain, if needed. Pressure 圧力計 gauge Bowl ボウル Drain ドレンバルブ valve Electromagnetic switch unit and contact unit Confirm whether or not there is degradation, or deterioration on the electromagnetic switch unit and contactor unit in the control panel. When there is obvious deterioration of the component, exchange it with a CAUTION new one. When checking, or changing any components, turn off the power and unplug the power cord. 21

26 CHAPTER 6 Maintenance Maintenance item Filter cleaning CAUTION Process filter cleaning (for Dryer) Description 1. Use a mask, because the clinging particles of the filter may disperse when cleaned or inspected. 2. When a filter is clogged, airflow through the unit is reduced, reducing the drying performance greatly. In severe cases, this may cause unit damage and create a potential fire hazard. When a filter is clogged, remove the filter and blow clean, dry air to remove any clinging particles. The environment around the unit body influences the condition of filter changes. Keep the surroundings around the unit clean. After checking, set the filter in the original position and fasten securely. When the filter is extremely clogged, exchange it with a new filter. Remove the filter, check and clean the filter clog. Process Filter Case Process Filter Lid Knob Regeneration filter cleaning Remove the filter, check and clean the filter clog. Filter Case Filter Filter Stopper Filter Filter Stopper Conveying filter cleaning (for Loader) Remove the filter, check and clean the filter clog. Convey filter case Convey filter Butterfly nut Lid Knob 22

27 CHAPTER 6 Maintenance Maintenance item Jet Clone Collection unit on each dryer unit Description Open the suction hopper lid, remove the screen filter and check for clogging. Blow clean and dry air to remove the adhered dust when clogged. Screen filter cleaning Sensitivity adjustment by the paddle type level gage (Using the paddle type level gage) When dry air cannot blow the accumulated dust off, use a sharp wire point to remove it. Replace the gasket when it is excessively deteriorated, discolored, or hardened. CAUTION Handle the filters with care and avoid deformation. A deformed filter may cause a conveying failure due to air leaks. Straighten any deformed area by tapping with a wooden or rubber hammer. If the defect cannot be corrected, replace the filter. To avoid dust inhalation, wear a mask when removing dust from the filters by blowing dry air. A clogged suction filter may overload the rootsblower, or hinder the conveying performance. When the level gage doesn't sense correctly by the kind of material, the sensitivity adjustment is necessary. [Adjusting method] Adjust sensitivity to the specific gravity of conveyed material. (1) Remove the cover of the level switch by turning it. (2) Change the position of the installation hole for the spring. When moving the spring to the low position, the sensitivity is increased. When moving the spring to the high position, the sensitivity is decreased. 23

28 CHAPTER 6 Maintenance Maintenance item Adjustment for the Jet Clone damper cam on the primary receiver Description Due to static electricity, instances shown below may occur. When this happens, loosen the 2 setscrews on the balancer and slide the weight backwards 5mm at a time, until the damper lies horizontal on its own weight. After adjusting, please don t forget to retighten the setscrews. Air leaks Check for hose air leaks. When there is a leak, change the hose. 3. Monthly maintenance Maintenance item Description Check for loose wires Sometimes vibration may lead to loose wires. Check periodically. CAUTION When checking, or changing any components, turn off the power and unplug the power cord. 24

29 CHAPTER 6 Maintenance Jet clone inspection A:Make sure the two M6 screws are not loose. If loose follow the instructions given in the next page. B:Take off the cover and make sure the hex bolts are not loose. At this time, open and close the damper to check for possible LS faults. C:Check the balancer for loose setscrews. D:Check for anomalies with springs, bolts, pins and nuts. Exchange any faulty parts with new components. A B C D 4. Every six months maintenance Maintenance item Check for any loose nuts or bolts Description Check whether there is any loosening of bolts or nuts on each part of the unit. Then tighten as needed. 25

30 CHAPTER 7 Alarm Functions Before checking of the cause of a malfunction or problem, always turn off the power and unplug the unit before proceeding. Working with the power ON may cause danger or an accident. Absolutely DO NOT ATTEMPT LIVE POWER REPAIRS! When a malfunction occurs during operation of the equipment, the alarm system operates, and the alarm character is displayed on the control panel as the alarm buzzer sounds, to inform of a malfunction. When you press the Reset CAUTION key, the buzzer will stop. Alarm indicator EPROM Error Reverse phase Dry blower Overload Convey blower Over load Character Malfunction contents/interlock Measure indicator E0 Read error of EPROM Perform Chapter 5.preparations for operation after turn off the power once. When the alarm displays again, the controller has a problem. Exchange the controller, or call a service center. E1 E2 E3 Occurs when the connection of the power cord activates a reverse phase. Occurs when the overcurrent flows through the blower and the thermal relay trips. The operation stops automatically. Occurs when the overcurrent flows through the blower and the thermal relay of the electromagnetic switch unit trips. The operation stops automatically. Refer to CHAPTER Power supply connection and adjust the correct phase. Check any outlet fuses also. Refer to CHAPTER 8. Troubleshooting and restore the occurrence causes. Open the control panel and press the reset button of the thermal relay. When pushing a Reset switch, after fixing the malfunction cause, the character indicator turns off. Refer to CHAPTER 8. Troubleshooting and restore the occurrence causes. Open the control panel and press the reset button of the thermal relay. When pushing a Reset switch after fixing the malfunction cause, the character indicator turns off. 26

31 CHAPTER 7 Alarm Function Alarm indicator Dry temperature or Regeneration temperature Upper limit Dry sensor Broken Regeneration sensor Broken No.1 Conveying Malfunction No.2 Conveying Malfunction Character indicator E4 E5 E6 E7 E8 Malfunction contents/interlock Occurs when the dry temperature, or regeneration temperature rise above the setting temperature + upper limit setting temperature. The operation stops automatically. When wiring or thermocouple (CA sensor) for the process (hopper) temp controller is broken. The operation stops automatically. When wiring or thermocouple (CA sensor) for the regeneration temp controller is broken. The operation stops automatically. After startup of the No.1 direction conveying, this alarm occurs when not becoming full within the LCt counter, or 1Ed (No.1 feed alarm timer) timer setting. Or, it occurs when a Jet clone demand signal hasn t activated after the FCt counter setpoint. (If material bridges inside of hopper, manual slide gate closed, etc). Factory settings: Lct = 50 counts 1Ed = 120 minutes FCt = 20 counts After startup of the No.2 direction conveys, this alarm occurs when not becoming full in the 2Ed (No.2 feed alarm timer) timer setting. Factory setting=180sec. Measure Refer to CHAPTER 8. Troubleshoot and probable causes. When pushing the Reset switch after fixing the malfunction cause, the character indicator turns off. Refer to CHAPTER 8. Troubleshooting and probable cause. By pushing the Reset switch after fixing the malfunction cause, the alarm turns off. Refer to CHAPTER 8. Troubleshooting and restore extraordinary occurrence cause. When pushing the Reset switch after fixing the malfunction cause, the character alarm turns off. Refer to CHAPTER 8. Troubleshooting and restore extraordinary occurrence cause. If the hopper becomes full, automatically, the alarm is cancelled. To cancel the alarm manually, turn the conveying switch OFF, and press the Reset switch. Refer to CHAPTER 8. Troubleshooting and restore extraordinary occurrence cause. If the hopper becomes full, automatically, the alarm is cancelled. To cancel the alarm manually, turn the conveying switch OFF, and press the Reset switch. 27

32 CHAPTER 7 Alarm Function Alarm indicator No.3 Convey Malfunction Character indicator E9 Malfunction contents/interlock After startup of the No.3 direction conveying, this alarm occurs when not becoming full in the 3Ed time. Factory setting = 180 sec. Measure Refer to CHAPTER 8. Troubleshooting and restore extraordinary occurrence cause. If the hopper becomes full, automatically, the alarm is cancelled. To cancel the alarm manually, turn the conveying switch OFF, and press the Reset switch. Drying or Regen. Overheat alarm E10 Occurs when the drying heater and regeneration heater reaches an abnormally high temperature. The unit is automatically shut off. DANGER The E10 alarm is an important alarm that detects abnormally high temperatures and automatically shuts the unit off. If improper measures such as modifying the unit to prevent the E10 alarm from being triggered are taken, the unit will continue to operate in a state of abnormally high temperature for a long period of time, which is extremely dangerous. Be sure to follow the correct measures as described in the column at the right. Replacement of parts should be conducted by a certified electrical engineer after turning off the power breaker. After cooling for one hour or longer, press the CONTROL ON button. If the E10 alarm triggers again, the overheat protector is defective. Replace the recycle overheat protector. If the E10 alarm triggers again even after the recycle overheat protector is replaced, replace the drying overheat protector. Press the Dryer key to operate the unit. Inspect the drying blower and replace the blower if it does not rotate. Inspect the recycle blower and replace the blower if it does not rotate. If the cause is not identified and the E10 alarm triggers again, an inspection by a service engineer is necessary. Contact our Service Division to request an inspection. 28

33 CHAPTER 8 Troubleshooting CAUTION Before troubleshooting Stop the equipment, turn off the breaker, and unplug it from the power supply before troubleshooting. After disconnecting power, wait for the machine to cool as to ensure you do not get any burns from hot pipes, material, etc. Descriptions of malfunctions in this chapter: Malfunction Contents page The blower does not rotate. 30 Conveying blower The blower is overloaded and the thermal relay trips. 32 The airflow rate of the blower is decreased. 33 The blower does not rotate. 31 Dry blower The blower is overloaded and the thermal relay trips. 33 The airflow rate of the blower is decreased. 33 Dry temperature The drying temperature is unstable or is too high / low. 33 The drying temperature doesn't move up or down. 34 Material isn t Dry The moisture content of resin does not go down. 35 Controller The indicator with the PV value of the controller doesn't come ON with primary power, even after pushing CONTROL ON switch. Power breaker The power breaker trips. 36 Overheat The overheat alarm occurs. 36 The specific thermal setting value of each model For checkpoints and repair methods specified for the next pages, please examine before requesting a repair. Also, for the removing methods of a filter, refer to CHAPTER 6. Maintenance. 29

34 CHAPTER 8 Troubleshooting The Conveying blower does not rotate. Check point Remedy Note Confirm whether or not the indicator of the controller lights up. Set the primary power and a front power breaker in ON. Press CONTROL ON switch. When the following remedy doesn't correct the problem, see page 49 [The PV value indicator of the controller doesn't come ON with primary power]. Confirm whether or not the Feeder indicator of the controller lights up. Open the door of control panel and look at the magnet point of the electromagnetic switch unit, and with power ON, check the opening and closing motion for the contactor. Confirm whether or not the malfunction character of E2" is displayed on the controller indicator. Confirm whether or not the limit switch on the jet clone at the end of convey doesn't become ON in spite of not being in the full material condition. Check the sensitivity of the proximity sensor for the injection hopper. If lamp is not lighting up, press Feeder switch. When the indicator doesn't light up even if it pushes the switch, exchange the controller. If the contactor appears damaged, perform an ohm check on the contactor (with power down), and replace as needed. If the problem is on the overload of the blower, after repairing, open the control panel door and press the reset button on the thermal relay. When turning ON, refer to page 24 and adjust the limit switch. Refer to page 12 and perform the sensitivity adjustment of the proximity sensor. Contact your service contact. Tolerance: times As for the overloaded cause of the blower, refer to page 45 [The blower is overloaded, and the thermal relay trips]. When the correct adjustment isn't performed, the conveying may not stop, or may not start. Therefore, be careful. When the correct adjustment isn't performed, the conveying may not stop, or may not start. Therefore, be careful. 30

35 CHAPTER 8 Troubleshooting The drying blower does not rotate. Check point Remedy Note Confirm whether or not the indicator of the controller lights up. Confirm that the primary power and the front power breaker are ON. Push the CONTROL ON switch. If the following remedy doesn't correct it, look at page 49; [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 look at the magnet point of the electromagnetic switch unit, and with power ON, check the opening and closing motion for the contactor. Confirm whether or not the malfunction character of E3" is displayed on the controller indicator. When not lighting up, press Dryer switch. When the indicator doesn't light up even if it pushes the switch, exchange a controller. If the contactor appears damaged, perform an ohm check on the contactor (with power down), and replace as needed. For causes of the overload of blower, after repairing, open the control panel door and press the reset button on the thermal relay. Check the start timer. If the start timer is set, after the setting time, the dry operation is started. Tolerance: times As for the overloaded cause of the blower, refer to page 45; [The blower does overloaded operation and the thermal relay trips]. 31

36 CHAPTER 8 Troubleshooting The blower is overloaded and the thermal relay trips. Check point Remedy Note Remove the cartridge filter in the filter case of the conveying line and check the filter condition. When there is dirt and debris, blow the clean dry air into the cartridge filter and remove the clinging particles. When the degradation of the cartridge filter progresses and it isn't possible to remove clinging particles, exchange it with a new cartridge filter. Remove the drying filter and check the filter condition. Open the door of control panel and look at the magnet point of the electromagnetic switch unit, and with power ON, check the opening and closing motion for the contactor. Check whether or not the thermal device in the control panel is set to the standard value. When there are dirt and debris, blow the clean dry air into the filter and remove the clinging particles. When normal operation is impossible, replace the electromagnetic switch unit. Refer to [The thermal setting value of every model] and set a thermal to the standard value. When the degradation of filter progresses and it isn't possible to remove clinging particles, exchange it with a new filter. Tolerance: times Work only after setting primary power to OFF, and unplugging the power cord! 32

37 CHAPTER 8 Troubleshooting The air flow of the blower is decreased. Check point Remedy Note Remove the cartridge filter in the conveying filter case and check the filter condition. When there are dirt and debris, blow clean, dry air into the cartridge filter to remove the clinging particles. When the degradation of the cartridge filter progresses and it isn't possible to remove clinging particles, exchange it with a new cartridge filter. Remove the cartridge filter in the dry filter case and check the filter condition. Check whether there is any damage or loose connections in the hose on the dehumidifying unit, or on the connection hose between the dehumidifying unit and the drying hopper. When there are dirt and debris, blow clean, dry air into the cartridge filter and remove the clinging particles. When the hose is damaged, exchange it with a new hose. When there is looseness in the hose connection, tighten up the hose clamp. When the degradation of the cartridge filter progresses and it isn't possible to remove clinging particles, exchange it with a new cartridge filter. After finding the air leak, stop the unit. Then wait until machine is cool, and repair it. The drying temperature is unstable. Check point Remedy Note Inspect the position of the thermocouple on the heater tank. Remove the regeneration and drying filters and check the filter conditions. The thermocouple should be in the center of the diameter of the pipe. When there is dirt and debris, blow the clean dry air into the cartridge filter and remove the clinging particles. Check for any looseness in the fitting. When the degradation of the cartridge filter progresses and it isn't possible to remove clinging particles, exchange with a new cartridge filter. Refer to the technical manual and confirm each setting of the controller s engineering modes. When there is a mistake in the setting value, change to the right setting value. 33

38 CHAPTER 8 Troubleshooting The drying temperature doesn't go up or down. Check point Remedy Note Check whether there is damage or loose connections on the connection hose in the dehumidifying unit, and in the connection hose between the dehumidifying unit and the dry hopper. When the hose is damaged, exchange it with a new hose. When there is looseness in the hose connection, tighten up the hose clamp. After finding the air leak, stop the unit and repair it. Check the cooling water flow and water volume. When cooling water isn't flowing, confirm the open condition of each valve. The air temperature that is discharged from the desiccant rotor is always 176~194F (80~90 C). 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. Make sure it cools to avoid burns. 34

39 CHAPTER 8 Troubleshooting The moisture content of resin does not go down. Check point Remedy Note Check the cooling water flow and water volume. Remove the cartridge filter in the dry filter case and check the filter condition. When cooling water isn't flowing, make sure all water valves are open. When there is dirt and debris, blow clean, dry air into the cartridge filter and remove the clinging particles. Don't set the water supply pressure for more than 0.49MPa (71 PSI). When the degradation of the cartridge filter progresses and it isn't possible to remove clinging particles, exchange with it a new cartridge filter. Remove the regeneration filter and check the filter condition. When there are dirt and debris, blow clean, dry air into the cartridge filter and remove the clinging particles. When the degradation of the cartridge filter progresses and it isn't possible to remove clinging particles, exchange with it a new cartridge filter. Check the supply air Dewpoint value. Check the Dew Point value from the air supply from the desiccant rotor. (There is a pipefitting supplied). It should be 40 F / C. Do not check the return hose for proper dewpoint readings. (There should be some moisture reading there, as the pellets are heated!) Check if the regeneration heater is broken. Perform an ohm check with power off. If the heater is broken, replace the heater. After the unit stop and perform the power breaker OFF. After falling to the range that the heating part temperature doesn't get a burn, and perform working. 35

40 CHAPTER 8 Troubleshooting The indicator of the PV value on the controller doesn't come ON with primary power, even after pushing the CONTROL ON switch. Check point Remedy Note Check whether or not the front power breaker of the control panel is ON. Check whether or not the circuit protector (CP1) of the control panel does not go OFF. When not ON, turn the power breaker "ON", and press the CONTROL ON switch once again. After checking the electric wiring and the part in the control panel, set it to ON. Also check any power supply causes power cord, outlet, fuses, etc. After setting the primary power and the front power breaker to OFF, check. The power breaker trips. Check point Remedy Note Check for a short circuit. Remove the short circuit. Only qualified electricians should do this! The overheat alarm occurs. Check point Remedy Note Check whether or not the dial setting value of the dry overheat unit (inside the control panel) is adjusted to the correct set point. < Setting value The dry overheat setting value: Dry temperature +36 F(20 C) Remove the cartridge filter in the dry line filter case and check the filter debris. Remove the regeneration filter and check the filter debris. The output of the solid state relay goes out. When there is an incorrect setting value, set it to the right value. Or check the regeneration fixed thermostat inside of the dryer unit (located on the regen. heater tank). When there is dirt and debris, blow clean, dry air into the cartridge filter to remove any clinging particles. When there is dirt and debris, blow clean, dry air into the cartridge filter to remove any clinging particles. There is a possibility of a problem in the solid state relay. After checking, replace if needed. Check only after turning the power breaker to OFF, and unplugging the unit, for shock prevention. When the degradation of cartridge filter progresses and it isn't possible to remove clinging particles, exchange with a new cartridge filter. When the degradation of filter progresses and it isn't possible to remove clinging particles, exchange with it a new filter. Check after turning the power breaker to OFF, for shock prevention. 36

41 CHAPTER 8 Troubleshooting The specific thermal setting value of each model (A) Power Model AC230V 60Hz AC460V 60Hz MJ315U 25U MJ350U 75U MJ3100U 150U Dry Blower M1 OCR1 Convey Blower M2 OCR2 Dry Blower M1 OCR1 Convey Blower M2 OCR2 Dry Blower M1 OCR1 Convey Blower M2 OCR Power Model AC230V 60Hz AC460V 60Hz Dry Blower M1 OCR1 MJ3200U Convey Blower M2 OCR2 Regeneration Blower M3 OCR3 Dry Blower M1 OCR1 MJ3250U 300U Convey Blower M2 OCR2 Regeneration Blower M3 OCR

42 CHAPTER 9 Technical Manual 1. The factory setting values for the controller The parameters for the user setting mode When you push SV, the parameter indicator switches over. But when pushing the SV switch more than 5 seconds, it changes to the engineering setting mode, so be careful. initial Use Character Setting range setting value Dry temperature SV 0~160 C(32~320 F) 80 C(176 F) Startup timer dly 0.0~99.5 hour 0.0 hour NO.1 Convey time Fd1 0~999 sec. 20 sec. NO.2 Convey time Fd2 0~999 sec. 15 sec. NO.3 Convey time Fd3 0~999 sec. 15 sec. NO.1 Discharge time dc1 0~999 sec. 25 sec. NO.2 Discharge time dc2 0~999 sec. 25 sec. NO.3 Discharge time dc3 0~999 sec. 25 sec. NO.2 Batch time bt2 0~99 sec. 2 sec. NO.3 Batch time bt3 0~99 sec. 2 sec. The parameters for the engineering setting mode When 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 switches over. initial Use Character Setting range 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 Dryer level gauge 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 C(0~72 F) 10 C(18 F) Upper limit temperature alarm (regeneration temperature deviation) rus 0~40 C(0~72 F) 10 C(18 F) 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. Reverse phase alarm status rst 0(disregard),

43 CHAPTER 9 Technical Manual 2. Using the autotuning mode (1) 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 1second, between the drying temperatures, and At display) (2) When the auto tuning ends, the PV display returns to normal, and the controller uses PID control per the autotuned adjustment results. (3) The operation for stopping auto tuning manually is the same procedure as step (1). 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 autotuning 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 cannot be performed unless the power is reset off and on. 3. About influence of gas that occurs from the resin (Not Common) 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 releases gases, suppressing the influence of gas becomes necessary. There are different methods of installing a gas collecting unit which are compatible. However, the method must be chosen by the dry material. Also, currently there is not a solution to all resins. Therefore, depending on the resin, the constant regular maintenance and the replacements of consumable parts become necessary. When the following phenomenon is confirmed during use, there is possibility that the unit undergoes influence by gas. In such case, please consult with us. 1) The oily liquid that oozes from the filter box, the pipe connection part and the dry hopper etc. 2) There is discoloration in the filter box. Or, adheres to oil. 3) The thin smoke from the regeneration exhaust port. 4) Oil covering the whole unit. 5) Oil adheres to the floor. As for the resin that has possible influence of gas, refer to the list the next page. 39

44 CHAPTER 9 Technical Manual The resin list which needs the unit measure that has possible influence of gas. (The resin that gas compatible column in the table has mark needs compatible. mark is unnecessary but depending on kind of the compounding material, it has possibility that the compatible becomes necessary.) Name of resin Necessity of gas compatible Necessity Name of resin of gas compatible Name of resin Necessity of gas compatible ABS PAR PPO ABS+PBT PBT PPS APEL PBT+PC PSF APET 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 PMMA fiber Optical PA6,66 POAM PA6,66+G POLYSUL PA612 POM PAMXD6 PP+ Filler PAN PPE 40

45 Outlet dew point Dr y ai r de w po in 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 undergoes influence by the fresh air condition (Dew point). Be careful because there is possibility that the dry air dew point becomes wrong with the fresh air condition. The following graph shows how the change of fresh air dew point of DMZ and DMS that is our typical model changes the dry air dew point. C hange of dry air dew point to fresh air dew point (D M Z80) Fresh air dew point F C hange of dry air dew point to fresh air dew point (D M S1) Fresh air dew point F 41

46 CHAPTER 10 Consumable Parts List 1. MJ315U, MJ325U Part name Manufacture Model Qty Drying blower HOHSING RB3053U 1 Conveying blower HOHSING RB4063U 1 Regeneration blower SOWA T170 1 Drying heater Matsui Mfg. 2.1kW 1 Regeneration heater Matsui Mfg. 1.89/2.49kW (230/460V) 1 Drying filter Matsui Mfg. MXF16SP 1 Conveying filter Matsui Mfg. MXF16SP 1 Regeneration filter Matsui Mfg. Fildon Dia.150xt10 1 Material hose Tigers Polymer WBS150 15ft (Dia.1 1/2 ) 2 (3) Vacuum hose Tigers Polymer GTG150 15ft (Dia. 1 1/2 ) 1 (2) TEMP. Controller Matsui Mfg. G2422MJ3 1 Cooling Fan (Top) OMRON R87FA1A13HP 1 Cooling Fan (Bottom) OMRON R87TA1A05H 1 Honeycomb Timing belt General parts 345L V If the MJ3 has secondary conveying 2way option (No.3), use qty in ( ). NFB1 (Main Breaker) Mitsubishi NF30SW 3P 20A 1 MS1, OCR1 (Drying Blower) Fuji SW03/3HT A 1 MS2, OCR2 (Loading Blower) Fuji SW03/3HT A 1 MS3, OCR3 (Regen. Blower) SSR 11, SSR12 (Drying Heater) OMRON G3NA210B (AC100120) 2 SSR 21, SSR22 (Regen Heater) OMRON G3NA210B (AC100120) 2 MC0 (Heater Circuit On/Off) Fuji SC03/T (AC100V Coil) 1 460V Nonfuse Circuit Breaker Mitsubishi NF30SW 3P 10A 1 MS1, OCR1 (Drying Blower) Fuji SW03/3HT A 1 MS2, OCR2 (Loading Blower) Fuji SW03/3HT A 1 MS3, OCR3 (Regen Blower) SSR 11, SSR12 (Drying Heater) OMRON G3NA410B (AC100240) 2 SSR 21, SSR22 (Regen Heater) OMRON G3NA410B (AC100240) 2 MC0 (Heater Circuit On/Off) Fuji SC03/T (AC100V Coil) 1 42

47 CHAPTER 10 Consumable Parts List 2. MJ350U, MJ375U Part name Manufacture Model Qty Drying blower HOHSING RB4053U 1 Conveying blower HOHSING RB4063U 1 Regeneration blower SOWA ST Drying heater Matsui Mfg. 4.0kW 1 Regeneration heater Matsui Mfg. 2.4/3.2kW (230/460V) 1 Drying filter Matsui Mfg. MJ3D200x250 1 Conveying filter Matsui Mfg. MXF16SP 1 Regeneration filter Matsui Mfg. Fildon Dia.150xt10 1 Material hose Tigers Polymer WBS150 15ft (Dia.1 1/2 ) 2 (3) Vacuum hose Tigers Polymer GTG150 15ft (Dia. 1 1/2 ) 1 (2) TEMP. Controller Matsui Mfg. G2422MJ3 1 Cooling Fan (Top) OMRON R87FA1A13HP 1 Cooling Fan (Bottom) OMRON R87TA1A05H 1 Honeycomb Timing belt General parts 367L100 1 If the MJ3 has a secondary conveying 2way option (No.3), use qty in ( ). 230V NFB1 (Main Breaker) Mitsubishi NF32SV 3P 30A 1 MS1, OCR1 (Drying Blower) Fuji SW03/3HT 46A 1 MS2, OCR2 (Loading Blower) Fuji SW03/3HT 46A 1 MS3, OCR3 (Regen Blower) SSR 11, SSR12 (Drying Heater) OMRON G3NA220B (AC100120) 2 SSR 21, SSR22 (Regen Heater) OMRON G3NA210B (AC100120) 2 MC0 (Heater Circuit On/Off) Fuji SC41/T (AC100V Coil) 1 460V Nonfuse Circuit Breaker Mitsubishi NF32SV 3P 20A 1 MS1, OCR1 (Drying Blower) Fuji SW03/3HT A 1 MS2, OCR2 (Loading Blower) Fuji SW03/3HT A 1 MS3, OCR3 (Regen Blower) SSR 11, SSR12 (Drying Heater) OMRON G3NA410B (AC100240) 2 SSR 21, SSR22 (Regen Heater) OMRON G3NA410B (AC100240) 2 MC0 (Heater Circuit On/Off) Fuji SC41/T (AC100V Coil) 1 43

48 CHAPTER 10 Consumable Parts List 3. MJ3100U, MJ3150U Part name Manufacture Model Qty Dry blower HOHSING RB5053U 1 Convey blower HOHSING RB4063U 1 Regeneration blower SOWA ST vac 1 Dry heater Matsui Mfg. 6.0kW 1 Regeneration heater Matsui Mfg. 3.0/4.0kW (230/460V) 1 Dry filter Matsui Mfg. MJ3D200x250 1 Convey filter Matsui Mfg. MXF16SP 1 Regeneration filter Matsui Mfg. Fildon Dia.150xt10 1 Material hose Tigers Polymer WBS150 15ft (Dia.1 1/2 ) 2 (3) Vacuum hose Tigers Polymer GTG150 15ft (Dia. 1 1/2 ) 1 (2) TEMP. Controller Matsui Mfg. G2422MJ3 1 Honeycomb Timing belt General parts 367L100 1 If the MJ3 has a secondary conveying 2way option (No.3), use qty in ( ). 230V NFB1 (Main Breaker) Mitsubishi NF63CV 3P 40A 1 MS1, OCR1 (Drying Blower) Fuji SW03/3HT 46A 1 MS2, OCR2 (Loading Blower) Fuji SW03/3HT 46A 1 MS3, OCR3 (Regen Blower) SSR 11, SSR12 (Drying Heater) OMRON G3NA220B (AC100120) 2 SSR 21, SSR22 (Regen Heater) OMRON G3NA210B (AC100120) 2 MC0 (Heater Circuit On/Off) Fuji SCN1/T (AC100V Coil) 1 460V Nonfuse Circuit Breaker Mitsubishi NF32SV 3P 20A 1 MS1, OCR1 (Drying Blower) Fuji SW03/3HT A 1 MS2, OCR2 (Loading Blower) Fuji SW03/3HT A 1 MS3, OCR3 (Regen Blower) SSR 11, SSR12 (Drying Heater) OMRON G3NA410B (AC100240) 2 SSR 21, SSR22 (Regen Heater) OMRON G3NA410B (AC100240) 2 MC0 (Heater Circuit On/Off) Fuji SCN1/T (AC100V Coil) 1 44

49 CHAPTER 10 Consumable Parts List 4. MJ3200U Part name Manufacture Model Qty Dry blower(60hz) HOHSING RB5053U 1 Convey blower(60hz) HOHSING RB5063U 1 Regeneration blower Akamatsu Elec. RS301P 1 Dry heater Matsui Mfg. 7.5kW 1 Regeneration heater Matsui Mfg. 5.8/7.7kW (230/460V) 1 Dry filter Matsui Mfg. MJ3D200x250 1 Convey filter Matsui Mfg. MJ3D200x250 1 Regeneration filter Matsui Mfg. Fildon Dia.150xt10 1 Material hose Tigers Polymer WBS200 30ft (Dia.2 ) 2 (3) Vacuum hose Tigers Polymer GTG250 30ft (Dia. 2 1/2 ) 1 (2) TEMP. Controller Matsui Mfg. G2422MJ3 1 Honeycomb Timing belt General parts 435L V If the MJ3 has a secondary conveying 2way option (No.3), use qty in ( ). NFB1 (Main Breaker) Mitsubishi NF63CV 3P 60A 1 MS1, OCR1 (Drying Blower) Fuji SW03/3HT 58A 1 MS2, OCR2 (Loading Blower) Fuji SW03/3HT 69A 1 MS3, OCR3 (Regen. Blower) Fuji SW03/3HT A 1 SSR 11, SSR12 (Drying Heater) OMRON G3NA240B (AC100120) 2 SSR 21, SSR22 (Regen Heater) OMRON G3NA220B (AC100120) 2 MC0 (Heater Circuit On/Off) Fuji SCN2/T (AC100V Coil) 1 460V Nonfuse Circuit Breaker Mitsubishi NF32SV 3P 40A 1 MS1, OCR1 (Drying Blower) Fuji SW03/3HT A 1 MS2, OCR2 (Loading Blower) Fuji SW03/3HT A 1 MS3, OCR3 (Regen Blower) Fuji SW03/3HT A 1 SSR 11, SSR12 (Drying Heater) OMRON G3NA420B (AC100240) 2 SSR 21, SSR22 (Regen Heater) OMRON G3NA420B (AC100240) 2 MC0 (Heater Circuit On/Off) Fuji SCN2/T (AC100V Coil) 1 45

50 CHAPTER 10 Consumable Parts List 5. MJ3250U, MJ3300U 230V Part name Manufacture Model Qty Dry blower(60hz) MUTO MI10X/6M 1 Convey blower(60hz) HOHSING RB5063U 1 Regeneration blower Akamatsu Elec. RS301P 1 Dry heater Matsui Mfg. 12.4kW 1 Regeneration heater Matsui Mfg. 9.0kW 1 Dry filter Matsui Mfg. MJ3D200x350 1 Convey filter Matsui Mfg. MJ3D200x250 1 Regeneration filter Matsui Mfg. Fildon Dia.150xt10 1 Material hose Tigers Polymer WBS200 30ft (Dia.2 ) 2(3) Vacuum hose Tigers Polymer GTG250 30ft (Dia. 2 1/2 ) 1(2) TEMP. Controller Matsui Mfg. G2422MJ3 1 Honeycomb Timing belt General parts 510L100 1 If the MJ3 has a secondary convey 2way option (No.3), use qty in ( ). NFB1 (Main Breaker) Mitsubishi NF100CW 3P 100A 1 MS1, OCR1 (Drying Blower) Fuji SW03/3HT 46A 1 MS2, OCR2 (Loading Blower) Fuji SW03/3HT 58A 1 MS3, OCR3 (Regen Blower) Fuji SW03/3HT A 1 SSR 11, SSR12 (Drying Heater) OMRON G3NA240B (AC100120) 2 SSR 21, SSR22 (Regen Heater) OMRON G3NA220B (AC100120) 2 MC0 (Heater Circuit On/Off) Fuji SCN3/T (AC100V Coil) 1 460V Nonfuse Circuit Breaker Mitsubishi NF50CW 3P 50A 1 MS1, OCR1 (Drying Blower) Fuji SW03/3HT A 1 MS2, OCR2 (Loading Blower) Fuji SW03/3HT A 1 MS3, OCR3 (Regen Blower) Fuji SW03/3HT A 1 SSR 11, SSR12 (Drying Heater) OMRON G3NA420B (AC100240) 2 SSR 21, SSR22 (Regen Heater) OMRON G3NA420B (AC100240) 2 MC0 (Heater Circuit On/Off) Fuji SCN3/T (AC100V Coil) 1 46

51 CHAPTER 10 Consumable Parts List 6. MJ315/25/50/75/100/150 Overheat thermostat setting unit Part name Manufacture Model Qty Regeneration overheat setting unit (Top) NGT/Wako Elec. A255(255 ) 1 Regeneration overheat setting unit (Bottom) NGT/Wako Elec. CH15(140 ) 1 Dry overheat setting unit Matsui Mfg. TR/711~M12 L MJ3200/300 Overheat thermostat setting unit Part name Manufacture Model Qty Regeneration overheat setting unit NGT/Wako Elec. A255(255 ) 1 Dry overheat setting unit Matsui Mfg. TR/711~M12 L

52 CHAPTER 11 Options 1. The short circuit breaker Install a short circuit breaker on the power breaker. It protects ground fault, overload, and short circuit and prevents a short circuit. Symbol Name Maker Model ELB1 Short circuit breaker Mitsubishi Electric. Refer to Plan A Nonfuse breaker (NFB1) is not installed in the installation of the short circuit breaker option. 2. The weekly timer By setting the weekly timer, the dryer does an "Automatic start " or "Automatic stop ". When selecting the switch to "ON" for the weekly timer setting, it will "Start" and "Stop" automatically. As for the weekly timer, refer to the manufacturer s instruction manual (OMRON, H5SA time switch). NOTE When not using a weekly timer, make the selection switch (S1) in "OFF". 1 WEEKLY TIMER 2 R21 TR 1 S20 S1 OFF ON TR A 34 WEEKLY TIMER EXT.START SIGNAL No Symbol Name Maker Model 1 TR1 Weekly timer OMRON H5SA 2 S1 Select switch 48

53 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 drycontact, or nonvoltage) 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 While using the external start input option, you can not stop of the dryer at the control panel. (You must make the external start signal "OFF" to 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. (Nonvoltage relay output, Resistance load 250 V 5A Max.) GENERAL ALARM SIG. 45 CR 2 S20 GENERAL ALARM SIG. AL1 CR2 AL2 GENERAL ALARM SIG. DRY CONTACT 49

54 CHAPTER 11 Options 5. The alarm indicator It is possible to see an alarm from a distance when an alarm occurs. 6. Dual Voltage Capabilities This dryer is compatible with different voltages for the options. Please ask your sales representative for details if needed. 50

55 CHAPTER 11 Options 7. Primary conveying: Jet selector connection Use the jet selector (sold separately) for feeding (primary conveying) to the dryer for combining and mixing virgin material, and regrind material easily JET CLONE JET SELECTOR 4 JSV 62 S20 DRY HOPPER No. Name Maker Model Q ty 1 JSV mount bracket Matsui Mfg. 1 2 PVC hose Tigers Polymer PVC 1.5 x1m 1 3 Hose band Commercial For Metal plug Nanaboshi Kagaku. NJC

56 CHAPTER 11 Options 8. Secondary conveying: Two press directions One MJ3 unit can dry, and load for two separate injection presses. Connect the hoses per the following figure. Connect a hose with the convey port position of "Feeder2", "Feeder3" of the control panel correctly. No. Name Maker Model Q ty 1 2 direction branch unit Matsui Mfg. 1unit 2NVN38 AC100V 1unit 2 3 direction select valve Matsui Mfg. 3VNDia.38(MJ315~150) 1 3VNDia.63(MJ3200~300) 1 Manifold electromagnetism 3 valve Matsui Mfg. For 3VN direction valve mounting 3VNDia.38(MJ315~150) 1 Matsui Mfg. bracket 3VNDia.63(MJ3200~300) 1 5 Material hose Tigers Polymer WBS15015ft(MJ315~150) 1 WBS20030ft(MJ3200~300) 1 6 Hose band Commercial (For PVC hose) For 2 (MJ3200~300) 4 For 1 1/2 (MJ315~150) 4 7 Vacuum hose Tigers Polymer GTG15015ft(MJ315~150) 1 GTG25030ft(MJ3200~300) 1 8 Hose band Commercial (For GL hose) For 2 1/2 (MJ3200~300) 1 For 1 1/2 (MJ315~150) 2 Change the hose length by specification. 52

57 CHAPTER 12 Specifications Dry hopper Dry air dew point Equipment model 15U 25U 50U 75U 100U 150U Liter kg/bd: kg/bd: Thermal Glass wool heat cut + Exterior board Fresh air condition: temp. 86 F (30 C) Relativity humidity 75% DP+45 F (25 C) Fresh air mixing10 % of assuming 40 F(40 C) The dry air dew point depends on ambient conditions. Dry air flow rate m 3 /h Dry temperature C / F 80~160 / 176~320 Dry blower Model RB3053U RB4053U RB5053U Motor output 0.5HP(0.42kW) 1.5HP(1.15kW) 2.33HP(1.75kW) Regeneration blower Model T170MS ST3170 Motor output W Dry heater Capacity kw Regeneration heater Capacity kw (230/460V) 1.89/ / /4.0 Honeycomb Name Zeolite rotor Outside diameter mm (inch) Dia.200 (7.87) Dia.250 (9.84) Dia.250 (9.84) Honeycomb Motor Height mm (inch) 200 (7.87) 200 (7.87) 300 (11.81) Motor output W 25 Speed reduction ratio 1/1800 Drying filter Model MXF16SPG1 Dia.200x250 Filtration area m Convey filter Model MXF16SPG1 Filtration area m Regeneration filter Model Filtration area m 2 Fildon (Dia150x t10mm) Hose diameter Drying Exhaust Air mm Dia.38/Dia.50 Dia.50 Cooling mm Dia.20 Aftercooler Regen. Exhaust mm Dia.38 Heat transfer area m Cooling water quantity 1/min Connection diameter B 1/2 female screw 53

58 CHAPTER 12 Specifications Compressed air Conveying Distance Convey pipe Conveying blower Equipment model 15U 25U 50U 75U 100U 150U Pressure MPa 0.5 Flow rate L/h 10 Connection diameter mm Primary side ft. / (m) Secondary side ft. / (m) Model Motor output Dia.6 15ft. (4.5m) 15 ft. (4.5m) Dia.38 PVC hose RB4063U 2.0HP (1.5kW) Control Dry temperature control PID control Regeneration temperature control PID control Automatic dry start timer Setting time range: 10min. ~99time50min. Compatible options Outer dimensions Alarm and Protection circuit Power supply Operation circuit voltage Overheat ( dryness and regeneration ) Motor over load Motor reverse prevention When stopping, cooling delay 50 Hz 60 Hz AC230 V / 460V, 3P AC100V, 1P Power Breaker Cap. (230/460V) 20A/10A 30A/20A 40A/20A Weekly timer Short circuit Protector Dew Point Meter Convey dust collection cyclone Secondary #2 direction conveying W 38 (960mm) 45 5/8 (1158mm) 50 5/8 (1285mm) D 22 1/4 (564mm) 25 5/32 (639mm) 25 5/32 (639mm) H 70 1/4 (1811mm) 81 1/8 (2061mm) 81 1/4 (2065mm) 93 1/8 (2365mm) 84 1/2 (2221mm) 102 3/4 (2611mm) Weight Lbs. (Kg) 470(212) 490(221) 630 (284) 650 (294) 730 (331) 765 (346) 54

59 CHAPTER 12 Specifications Dry hopper Dry air dew point Equipment model 200U 250U 300U Liter kg/bd:0.6 kg/bd:0.8 Thermal Fresh air condition: temp. 89 F (30 C) Relativity humidity 75% (DP+25 C) Fresh air mixing10 % of assuming Glass wool heat cut + Exterior board F( C) The dry air dew point changes in the use condition. Dry air flow rate m 3 /h Dry temperature C / F 80~160 C / 176~320 F Dry blower Model RB5053U MI10X/6M (IE3) Motor output 2.34HP 1.75kW 2.0HP 1.5kW Regeneration blower Model Motor output RS301P 215W Dry heater Capacity kw Regeneration heater Absorption tower Name Absorption tower motor Capacity kw (230/460V) 5.8/ Zeolite rotor Outside diameter mm Height mm Motor output W Dry filter Model Dia.200x250 Dia.200x350 Filtration area m Convey filter Model Dia.200x250 Filtration area m Regeneration filter Model Filtration area m 2 Dia. 150 x T10 Fildon (Dia150x t10mm) Hose diameter Drying Exhaust Air mm Dia.65 Dia.90 Cooling mm Dia.38 Circulation refrigerator Regen. Exhaust mm Dia.65 Dia.90 Heat transfer area m Cooling water quantity 1/min 20 Connection diameter B 1/2female screw 55

60 CHAPTER 12 Specifications Equipment model 200U 250U 300U Compressed air Pressure MPa 0.5 Flow rate L/h 20 Connection diameter mm Dia.6 Convey Primary side m 30ft (9m) Secondary side m 30ft (9m) Convey hose Dia.50 PVC hose Convey blower Model RB5063U Motor output 3.42HP 2.55kW Control Dry temperature control PID control Regeneration temperature control PID control Compatible option Automatic dry start timer Setting time range: 10min. ~99time50min. Alarm and Protection circuit Overheat ( dryness and regeneration ) Power supply Motor over load Motor reverse prevention When stopping, cooling delay 50Hz 60Hz Operation circuit voltage Power breaker capacity (A) AC230V / 460V,3P AC100V,1P Weekly timer Short circuit breaker Dew point indicator Convey dust collection cyclone Secondary 2 direction convey Outer dimensions W 57 1/2 (1460mm) 67 5/16 (1710mm) D 29 1/8 (740mm) 35 7/16 (900mm) H 122 7/8 (3121mm) 98 3/8 (2500mm) 102 3/8 (2600mm) Weight Lbs. (Kg) 1,100 lbs. (500kg) 1,510 lbs.(685kg) 1,550 lbs.(700kg) 56

61 MJ3(15150U) 57

62 MJ

63 MJ

64 MJ3(15150U) 60

65 MJ3(200300) 61

66 62 MJ3(15300)

67 Motor Maintenance Manual The gear head and motor should be handled, installed and maintained by trained technicians. Carefully read this manual and all accompanying documents before use. A copy of this manual should be sent to the actual user of the gear unit. This manual should be maintained by the user. 1. Safety and other precautions CAUTION General. The gear head and motor should be operated only within its name plate and catalogue ; otherwise, electric shock, injury or damage to a system may occur.. Keep hands and all foreign objects from the internal moving part of the gear unit and motor; otherwise, electric shock, injury, fire or damage to a system may occur.. Damaged units should be taken offline; otherwise, injury or fire may occur.. Do not remove the nameplate.. Any modifications or alterations of any kind, to the unit, will void the warranty and all subsequent claims. Transport. Exercise ample care not to drop the unit and fall during transport. Installation. Do not place any inflammables around the gear head and motor; otherwise, fire may result.. Do not place any objects that will hinder ventilation around motor; otherwise, cooling effect is reduced, and may lead to a possible fire hazard and a burn due to excessive heat builtup.. Do not touch the key way at the shaft end or on the inside of the dear unit and motor; otherwise, injury may result.. When the unit is used in food processing applications vulnerable to oil contamination, install an oil pan or other such device to cope with rare oil leaking. Otherwise, oil leakage may damage products. Coupling with other machines. Install appropriate guard devices around rotation parts ; otherwise, injury may result.. Confirm the direction of rotation before coupling the unit with its driven machine. Difference in the direction of rotation may cause injury or damage to the system. Wiring. Do not touch lead wire when measuring the insulation resistance. Electric shock may result. DANGER Wiring. Connect a power cable to the motor according to the connection diagram or maintenance manual; otherwise, electric shock or fire may result. (Without terminal box, exercise insulation in the connecting part.). Do not forcibly curve, pull or clamp the power cable and lead wires; otherwise, electric shock may result.. Correctly ground the grounding bolt; otherwise, electric shock may result.. Use power source stated in the nameplate; otherwise, motor's burning or fire may result. Operation. Never approach or touch any rotating parts (shaft, etc.) during operation; otherwise, loose clothing caught in these rotation parts may result in severe injury.. When the power supply is interrupted, be sure to turn off the power switch. Unexpected resumption of power may cause injury or damage to the equipment. Daily inspection and maintenance. Never approach or touch any rotating parts (shaft, etc.) during maintenance ; otherwise, loose clothing caught in these rotating parts may result in severe injury. Inspection upon delivery. Verify that the unit received is in fact the one ordered. When a different product is installed, injury or damage to the system may result. 2. Wiring diagram. Rotating direction viewed from the shaft end of motor. Fig.1 Wiring diagram CW : clockwise CCW : counter clockwise Induction (6W) Singlephase (100/110,115,200/220V) CW CCW Singlephase(220/240V) CW, CCW Reversible (6W) Singlephase (100/110,115,200/220V) CW, CCW Singlephase(220/240V) CW, CCW CW M Black Brown White Gray Cap. M CCW Black Gray White Brown Cap. CW M CCW Black White CW Brown Cap. CCW Black CW M White CW Cap. CCW Gray CCW CW Black M White CW CCW Cap. Brown CCW Induction (15 90W) Singlephase (100/110,115,200/220V) CW CCW CW M TP Black Orange Brown White Gray Cap. M CCW TP Black Gray Orange White Brown Cap. Singlephase(220/240V) CW, CCW CW M CCW TP Black White CW Brown Cap. CCW Reversible (15 90W) Singlephase (100/110,115,200/220V) CW, CCW CW M CCW TP Black White CW Cap. Gray CCW 3phase (200/220V) CW CCW 3phase (380/440V) CW CCW Singlephase(220/240V) CW, CCW Black(U) R Black(U) S Black(U) R Black(U) S TP Black CW M White(V) TP Gray(W) TP S T M CCW White(V) TP Gray(W) TP R T CW M Red(V) TP Brown(W) TP S T M CCW Red(V) TP Brown(W) TP R T CW M CCW White CW Cap. Brown CCW Note : Change the rotating direction of motor after motor stops completely. When changing rotating direction during motor's running, it may take some time or it may be impossible to change it. 63

68 3. Inspection upon delivery. Confirm the contents of nameplates for motor type and condenser.. Gearhead and motor which have same model No.s and same heat treatment symbols can be combined. Please refer to Fig.2 as an example. Fig.2 Combination ex. of motor and gearhead zmotorx zgearheadx 1) A8 M 25 D G8 K 2) A9 M 60 A H G9B K H Model No. Model No. : Reduction ratio Heat treatment symbol Table 1 Combination table of motor type and condenser Induction motor Motor Type A6M06A A6M06B A6M06C A6M06D A7M15A A7M15B A7M15C A7M15D A8M25A A8M25B A8M25C A8M25D Condenser Type DMF25255 DMF25205 DMF45704 DMF45604 DMF25505 DMF25405 DMF45125 DMF45904 DMF25605 DMF25455 DMF45155 DMF45135 Motor Type A9M40A A9M40B A9M40C A9M40D A9M60AH A9M60BH A9M60CH A9M60DH A9M90AH A9M90BH A9M90CH A9M90DH Condenser Type DMF DMF25805 DMF45255 DMF45205 DMF DMF DMF45405 DMF45355 DMF DMF DMF45605 DMF45505 Reversible motor Motor Type A6R06A A6R06B A6R06C A6R06D A7R15A A7R15B A7R15C A7R15D A8R25A A8R25B A8R25C A8R25D Condenser Type DMF25305 DMF25235 DMF45804 DMF45704 DMF25605 DMF25455 DMF45155 DMF45125 DMF DMF25705 DMF45255 DMF45205 Motor Type A9R40A A9R40B A9R40C A9R40D A9R60AH A9R60BH A9R60CH A9R60DH A9R90AH A9R90BH A9R90CH A9R90DH Condenser Type DMF DMF DMF45355 DMF45305 DMF DMF DMF45605 DMF45505 DAL DMF DMF45705 DMF Overheat protection device 1) Thermally protect type. When motor is run with overload or is stopped and overheated, in order to protect motor coil, overheat protection device, T/P (Thermally protect), is built in the coil.. This T/P has an automatic reset system. So, if temperature in the coil returns to the normal level, this motor runs automatically. 2) Impedance protect type. Impedance protect motor is designed to enlarge impedance of coil winding, reduce the input current at motor restriction, and not to exceed the allowable max. temperature. Allowable temperature at classa restriction of UL is less than 150 C. (Our UL approval motor is classa). "ZP" as impedance protect is displayed in the nameplate. Our 60a motor is equivalent. 5. Rating. Motor is designed to be suited to the usage conditions, and its usage limitation to fit to the usage conditions is called rating.. There are some ratings, like continuous, shorttime, and repetition rating. SHI's induction motor is continuous rating and reversible motor is shorttime rating (30min). 6. How to install motor and gearhead. Install motor and gearhead, putting both contact surfaces together like fig.2 while rotating them little by little. Forcing into motor shaft and bumping into the inside of gearhead, at assembly, may cause abnormal noise by broken gear and shorten the operating life.. When holding down transfer systems, such as chain, pulley, and sprocket, to the gearhead shaft with keyway, process keyway in the system side as well and hold them down by attached key.. When holding transfer fittings down to gearhead shaft, giving impacts may cause damages or shortening operation life of gearhead. Please do not hit the gearhead shaft. 7. Ambient conditions Location Indoors (Minimal dust and humidity) Temperature 10 C 40 C Humidity Under 85% Elevation Under 1,000m Atmosphere Well ventilated location, free of corrosive gases, explosive gases, vapors and dust. Fig.2 Name plate POWER TRANSMISSION & CONTROLS GROUP 5911,KITASHINAGAWA SHINAGAWAKU,TOKYO , JAPAN PHONE: (03) FAX: (03) Call center Astero Group Tel (0562) Fax (0562)

69 Gearhead Maintenance Manual The gear head and motor should be handled, installed and maintained by trained technicians. Carefully read this manual and all accompanying documents before use. A copy of this manual should be sent to the actual user of the gear unit. This manual should be maintained by the user. 1. Safety and other precautions 2. Inspection upon delivery. Gearhead and motor which have same model No.s and same heat treatment symbols can be combined. Please refer to Fig.1 as an example. zmotorx zgearheadx zmotorx zgearheadx Fig.1 Combination ex. of motor & gearhead 1) A8 M 25 D G8 K : reduction ratio CAUTION General. The gear head and motor should be operated only within its name plate and catalogue ; otherwise, electric shock, injury or damage to a system may occur.. Keep hands and all foreign objects from the internal moving part of the gear unit and motor; otherwise, electric shock, injury, fire or damage to a system may occur.. Damaged units should be taken offline; otherwise, injury or fire may occur.. Do not remove the nameplate.. Any modifications or alterations of any kind, to the unit, will void the warranty and all subsequent claims. Transport. Exercise ample care not to drop the unit and fall during transport. Installation. Do not place any inflammables around the gear head and motor; otherwise, fire may result.. Do not place any objects that will hinder ventilation around motor; otherwise, cooling effect is reduced, and may lead to a possible fire hazard and a burn due to excessive heat builtup.. Do not touch the key way at the shaft end or on the inside of the dear unit and motor; otherwise, injury may result.. When the unit is used in food processing applications vulnerable to oil contamination, install an oil pan or other such device to cope with rare oil leaking. Otherwise, oil leakage may damage products. Coupling with other machines. Install appropriate guard devices around rotation parts ; otherwise, injury may result.. Confirm the direction of rotation before coupling the unit with its driven machine. Difference in the direction of rotation may cause injury or damage to the system. Wiring. Do not touch lead wire when measuring the insulation resistance. Electric shock may result. DANGER Wiring. Connect a power cable to the motor according to the connection diagram or maintenance manual; otherwise, electric shock or fire may result. (Without terminal box, exercise insulation in the connecting part.). Do not forcibly curve, pull or clamp the power cable and lead wires; otherwise, electric shock may result.. Correctly ground the grounding bolt; otherwise, electric shock may result.. Use power source stated in the nameplate; otherwise, motor's burning or fire may result. Operation. Never approach or touch any rotating parts (shaft, etc.) during operation; otherwise, loose clothing caught in these rotation parts may result in severe injury.. When the power supply is interrupted, be sure to turn off the power switch. Unexpected resumption of power may cause injury or damage to the equipment. Daily inspection and maintenance. Never approach or touch any rotating parts (shaft, etc.) during maintenance ; otherwise, loose clothing caught in these rotating parts may result in severe injury. Inspection upon delivery. Verify that the unit received is in fact the one ordered. When a different product is installed, injury or damage to the system may result. Model No. 2) A9 M 60 A H G9B K H Model No. Heat treatment symbol 3. Allowable maximum torque. Allowable maximum torque is max. Torque during motor operation. It is limited by motor torque, temperature raising, and combined gearhead strength. This torque depends on reduction ratio. Please refer to catalogue for details. 4. Rotating direction. There are two rotating directions for output shaft of gearhead, same direction as motor and counterdirection, determined by reduction ratio. Refer to (table 1).. Direction of intermediate gearhead (1/10) is the same as a single unit. Table 1. Rotating direction of gearhead output shaft Ratio Model G6 D G7 K G8 K G9A K G9B KH : Reduction ratio 65 : same direction as motor : counterdirection

70 5. Operation life & service factor (S.F.) of gearhead. Apply each service factor corresponding to the load type. Refer to (table 2).. The operating life of gearhead with service factor 1.0 would be 5,000hrs. 6. Radial load & axial load. Radial load can be obtained by following formula. Pr=Pr Cf S.F./R Where Pr : Radial load [N] Pr : Actual transmitted torque on output shaft [N. m] Cf : Coupling factor refer to (table 3) S.F. : Service factor refer to (table 2) R : Radius of gear or pulley [m] Table 2. Ex. of service factor & load type Load type Example of load Service factor Uniform load Continuous running 1.0 Light duty Frequent start/stop running 1.5 Medium duty Frequent cw/ccw running 2.0 Table 3. Coupling factor for operating type Operating type Cf Chein, sprocket 1 Gear 1.25 Pulley 1.5. When gearhead whose radial load exceeds the allowable value (Table 4) is used, bearing's shortterm damage, bend of output shaft, and fatigue damage by repeating loads may result.. In the case gear which generates axial load, such as helical gear, is applied, on the gearhead output shaft do not exceed both allowable values of radial and axial loads. Gearhead 7. Load moment of inertia Radial load Axial load Table 4. Allowable radial & axial loads Model Reduction ratio Max.allowable torque (N. m) Allowable radial load (N) G6 D G7 K G8 K G9A K G9B KH Note: Allowable maximum torque depends on reduction ratio. Allowable axial load (N) Load moment of inertia on motor shaft can be obtained by following formula. JM=J/i 2 Ratio < =50 J : Load moment of inertia [kg. m 2 ] JM=J/ <Ratio JM : Load moment of inertia on motor shaft [kg. m 2 ]. When gearhead whose load moment of inertia exceeds the allowable value (Table 5) is used, gear's and bearing's shortterm damages may result. Table 5. Allowable load moment of inertia on motor shaft (10 4 kg. m 2 ) Model Capa. (W) 1phase 3phase A A A A A A How to install motor and gearhead. Install motor and gearhead, putting both contact surfaces together like fig.2 while rotating them little by little. Forcing into motor shaft and bumping into the inside of gearhead, at assembly, may cause abnormal noise by broken gear and shorten the operating life.. When holding down transfer systems, such as chain, pulley, and sprocket, to the gearhead shaft with keyway, process keyway in the system side as well and hold them down by attached key.. When holding transfer fittings down to gearhead shaft, giving impacts may cause damages or shortening operation life of gearhead. Please do not hit the gearhead shaft. Fig.2 Name plate 9. Ambient conditions Location Indoors (Minimal dust and humidity) Temperature 10 C 40 C Humidity Under 85% Elevation Under 1,000m Atmosphere Well ventilated location, free of corrosive gases, explosive gases, vapors and dust. POWER TRANSMISSION & CONTROLS GROUP 5911,KITASHINAGAWA SHINAGAWAKU,TOKYO , JAPAN PHONE: (03) FAX: (03) Call center Astero Group Tel (0562) Fax (0562)

71 TOTAL FACTORY AUTOMATION SYSTEMS MATSUI AMERICA, INC. CHICAGO HEADQUARTERS 5825 Turnberry Dr. Hanover Park, IL TEL. (847) FAX. (630) Energy Saving Device Operation Manual Congratulations on equipping your unit with the energy savings option! When used, this feature monitors the exhaust air temperature from the drying hopper, and reduces the drying heater s energizing cycle time, in an effort to reduce consumed power. This feature not only makes the drying process more efficient, but also, over time, will reduce the energy consumed dramatically. The Energy saving mode is engaged by the ESave Start switch. If the dryer was started by hitting the DRY switch on the controller, it is in normal / standard control mode. P r e c au t i o n s : 1. Cool Down Function: When the EnergySaving function is engaged, the main controller s DRYER switch will be inactive. To put the dryer in Cooldown mode, the EnergySaving switch must first be switched OFF. 2. AutoStart Timer: The Energy Savings mode cannot be used in conjunction with the auto starttimer feature. Please check that the dly setting = 0, before starting. (Push the SV key two times on the MJ3 controller, and check that dly (StartDelay Timer) is 0.) DRYER switch inactive during Esave mode, so Cool Down function must be done after turning off ENERGY SAVE switch. 2. Press SV key twice to check dly = 0 ENERGY SAVE switch, Start / Stop ExhaustTemperature Monitor / Control

72 1. How to Set: Checking the standard exhaust air temperature during normal running. 11. Set the process drying temperature (SV), as specified by the Resin Manufacturer. (i.e. SV=176 F) 12. Run the dryer for 1~2 hours without the injection or extruder running (Predry). 13. Check the Exhaust Air Monitor. When the exhaust temp stops rising, note that temp as A. (i.e. A =146 F) 14. Start production (run the injection or extruder) for 1 hour, and note the exhaust temp as B. (i.e. B =130 F) 15. Calculate the control Exhaust Set Value temperature ( ESV ). ESV = B + Midpoint of A and B = B + ( A B 2). Example: (i.e. ESV = ( B ) 130 F + ( A 146 F B 130 F 2) = 8 So, ESV = 138 F) 16. Set the ESV on the ExhaustAir Temperature Monitor, which is located on bottom door of the MJ3. 2. Setting the Exhaust Temp Monitor Value (E5CSR1KJXF): 21. Push the Enter (Arrow) Key. The SP indicator will turn ON. 22. Set the ESV value with the UP and Down keys. 23. Push the Enter (Arrow) Key. The AL indicator will turn ON. 23. Set the value to Zero with the UP and Down keys. 24. Push the Enter (Arrow) key to return to the normal display. SP AL UP/Down Exhaust Air Monitor 3. How it works when the dryer runs by the ESave start switch: Enter 31. The energysaving function will start after 2.5 hours of the dryer running. (For predrying purposes) 32. If the exhaust air temp hits the target ESV for 10 minutes, the drying heater will stop for the next 20 minutes. During the energysaving function, the Start Switch will be blinking and the process drying temp is reduced. 33. After 20 minutes, the dryer returns to normal drying mode, and checks the exhaust airtemp again, and the process repeats, as needed.