Related Manuals for Matsui DMZ-80
Summary of Contents for Matsui DMZ-80
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Page 1: Table Of Contents
SERVICE MANUAL MAINTENANCE AND TROUBLESHOOTING GUIDE FOR MATSUI DMZ DRYERS Phone (847)290-9680 Fax (847) 290-9685 www.matsuiamerica.com ITEM: PAGE: INTRODUCTION NOMENCLATURE DAILY MAINTENANCE SCHEDULE MONTHLY MAINTENANCE SCHEDULE 6 MONTH MAINTENANCE SCHEDULE MAINTENANCE DESCRIPTIONS AND DIRECTIONS 5-12 ALARMS 13-18 TROUBLESHOOTING 19-22 FREQUENTLY ASKED SERVICE QUESTIONS... -
Page 2: Introduction
INTRODUCTION Matsui’s DMZ Desiccant Dryer is a high-performance machine designed for fast, low dew point drying of plastic pellets, easy maintenance and long life. As with any machine, some basic maintenance steps must be completed regularly to ensure proper operation and the quick, complete drying the DMZ is capable of. - Page 3 Aftercooler: Inside each DMZ there is an aftercooler for the process air. The aftercooler serves several purposes. First and foremost, it protects the desiccant rotor by catching any small fines that may get past the process filter and build up in the rotor.
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Page 4: Daily Maintenance Schedule
DAILY MAINTENANCE MAINTENANCE ITEM: PROCEDURE: Regeneration filter Blow out with compressed air Process filter Blow out with compressed air Regeneration Temperature Confirm set point being reached Process Temperature Confirm set point being reached Thermocouple on Drying Hopper Check for damage, replace if necessary Drying Hoses Check for wear, replace if necessary MONTHLY MAINTENANCE... -
Page 5: Maintenance Descriptions And Directions
Remove this filter by unscrewing the hold down wing nut and removing the nut and washer. On DMZ-80 and 120 models, the regeneration filter is accessed through a square hole at the top of the rear panel. The filter simply unscrews from the blower and removed through the hole. - Page 6 Regeneration Temperature: The regeneration temperature is factory set at 446°F (230°C). This is the optimum temperature for removing moisture from the desiccant rotor during the regeneration cycle. This temperature can be checked by pressing the “PV” button on the face of the controller until the L.E.D. indicator is under the word “REGEN”...
- Page 7 Aftercooler Water Supply: Check to make sure that water is flowing to the aftercooler. Make sure the valve is open and clean the strainer at least twice a year. To clean the strainer, shut off the water valve, and remove the strainer nut at the bottom of the strainer.
- Page 8 Magnetic Heater Contactors Cont. CHECKING INPUT VOLTAGE RESISTANCE CHECK: The second check, the resistance check must be done with the power to the machine off. Be sure to shut off the power at the breaker or buildings disconnect before proceeding. 1) Set the Multi-meter to the Ohms setting.
- Page 9 Magnetic Blower Contactors: Follow the same directions as the magnetic heater contactors. Regeneration Heater: The regeneration heater should be checked for proper resistance regularly to confirm it is working properly and ensure proper desiccant rotor operation. Like any mechanical part, heaters wear over out over time. Worn or defective magnetic contactors can also damage a heater.
- Page 10 Heaters cont. EXAMPLE OF HEATER RESISTANCE HOPPER HEATER RESISTANCE CHART (ohms) HOPPER HEATER 230V 460V HD-15R 1.5 kW 70.5 Ω 282.1 Ω HD-25R 2.4 kW 44.1 Ω 176.3 Ω HD-50R 2.4 kW 44.1 Ω 176.3 Ω HD-75R 3.3 kW 32.1 Ω 128.2 Ω...
- Page 11 ADJUSTED TO 1 ¼” DMZ-80-240 MODELS The desiccant rotor on the DMZ-80-240 models, unlike the DMZ-40, does not index, but instead turns at three revolutions per hour by means of a geared motor. This motor is geared at 1 to 32000 and is controlled by either a magnetic contactor or relay located inside the electrical panel.
- Page 12 Desiccant Rotor cont. ROTOR SPRING TENSION Check to make sure that the tension springs on the desiccant rotor top cover are tensioned properly. Improperly tensioned springs can result in premature rotor wear and can cause air leaks, which in turn can effect dryer performance.
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Page 13: Alarms
The following is a list of alarms that may be encountered on the DMZ controller. There are two types of controllers used on Matsui DMZ Dryers. The MR-1200 was used from introduction until about 1998 at which time it was replaced by the more advanced MR-2200. - Page 14 Reverse: This alarm, common to both controllers, indicates a problem with the power supply coming into the dryer. All Matsui equipment is phased A-B-C. (R- Red, S-White, T-Black). If this alarm lights, look for and correct the following: Incoming power phase is reversed. Change incoming power to correct A-B-C phase Single Phase.
- Page 15 Filter: The filter alarm is an optional alarm that works only if the optional filter clog alarm has been installed. If the filter clog alarm has been installed, and the alarm is sounding, check for the following: Filters are dirty. In the event the filter Alarm sounds, the primary cause is that the alarm is just doing its job, and alerting of a clogged filter.
- Page 16 (100 V) at the coil of the pulled in contactor. If no voltage is present, the Contactor is defective. If voltage is present, contact the Matsui Service Dept. for help. Once the problem is corrected, the ‘H’EST” alarm should clear itself. If the H’EST alarm fails to clear itself, shut off the dryer and turn off the incoming power, either at the plant disconnect, or the dryer circuit breaker, for 15 seconds.
- Page 17 Check to make sure there is voltage (100 V) at the coil of the suspect contactor. If voltage is present, and the contactor will not pull in, the contactor is defective. If voltage is not present, contact the Matsui Service Dept. for help.
- Page 18 Check to make sure there is no voltage (100 V) at the coil of the pulled in contactor. If no voltage is present, the contactor is defective. If voltage is present, contact the Matsui Service Dept. for help. Overheat Sensor adjustment. On models with adjustable overheat sensors on the drying hopper, be sure the sensor is adjusted high enough for the process temperature that is inputted in the controller.
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Page 19: Troubleshooting
TROUBLESHOOTING Checkpoints and remedies are described on the following pages. Refer to this point before seeking repair advice from the Matsui Service Department WARNING: Working around electricity can be extremely dangerous. Electrical service and troubleshooting should only be performed by those with knowledge of electrical circuits and proper training in electrical repair. -
Page 20: Troubleshooting
4) When the “RUN” switch is pushed, do the blower contactors activate? No –Check the contactor coil for 100v. If present, replace magnetic contactor. If no voltage, contact Matsui Service ▼ 5) Is the overload relay tripped? Yes –There should be an alarm sounding, but just in case Its not, reset the overload ▼... -
Page 21: Blower Airflow Is Low
TROUBLESHOOTING Blower airflow is low: 1) Have new filters been installed? No – Install new filters. ▼ 2) Are the hoses, both inside and outside of the dryer in good condition and free from kinks, holes and crushing? No – Replace hoses with the proper type hose. ▼... -
Page 22: Drying Temperature Does Not Go Up / Down
TROUBLESHOOTING Drying temperature does not go up or down: 1) Are the heater contactors activated when the controller is calling for heat, and off when it’s not? No – Check voltage at the coil of the contactor as well as the output of the controller for proper operation. -
Page 23: Frequently Asked Service Questions
FREQUENTLY ASKED SERVICE QUESTIONS Following are a few of the most common service problems encountered by our Service Personnel, and checkpoints and remedies for each problem. “ My Dew Point is high and I’ve got wet plastic. What’s wrong?” Here are the usual culprits; 1) Is the process temperature set above 130°F (55°)? No –Change to at least 130°... - Page 24 FREQUENTLY ASKED SERVICE QUESTIONS “I just changed my Regeneration Contactor and filter. Why is there smoke coming from the Regeneration exhaust port?” Here’s why: The main purpose of the regeneration system is to burn moisture and contaminants, like gases and waxes given off from the drying plastic pellets, from the desiccant rotor.
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Page 25: Frequently Asked Service Questions
Although they may look the same, there’s a vast difference between a car’s air cleaner and a Matsui filter. First off, the filter media in the Matsui filter is considerably finer, designed to take out even the minutest particle of dust. This is necessary to ensure long life of the desiccant rotor, as well as the Teflon®... -
Page 26: Common Spare Parts
AA0594 REGENERATION HEATER DMZ-40 1.5 kW 230 VOLT AA0816 REGENERATION HEATER DMZ-40 1.5 kW 460 VOLT AA0817 REGENERATION HEATER DMZ-80 2.4 kW 230 VOLT AA0826 REGENERATION HEATER DMZ-80 2.4 kW 460 VOLT AA0827 REGENERATION HEATER DMZ-120 3.0 kW 230 VOLT AA0836 REGENERATION HEATER DMZ-120 3.0 kW 460 VOLT AA0838... - Page 27 Your Matsui Service team thanks you for using our products. If you ever have any additional questions, please call our North American Headquarters at (847) 290-9680 Monday ~ Friday, 8 a.m. ~ 5 p.m. CST. Also, be sure to look at our new troubleshooting section on-line at www.matsuiamerica.com...
- Page 28 DMZ 40 CIRCUIT BOARD STYLES (A & B) DESICCANT ROTOR ADJUSTMENT VR2- VR1- On Time Off Time 0.1~ 1 sec. 0.6 ~115 sec. Factory set = 1 ¼” Factory set = 60 sec MTR-5 MTR-5 CN4- 12VDC B-460v OUTPUT A-230v Relay 1 Contacts Dry Contacts...
- Page 29 How to disassemble a Desiccant Rotor for Inspection / Cleaning Refer to the exploded view for any ( ) info. Removing the Rotor for working on a workbench. 1. Shut down dryer, allowing cooling mode to cool the rotor sufficiently (Usually about 2 hours for natural cooling).
- Page 30 Inspecting the Rotor and Mating Surfaces 21. Inspecting the Rotor- After the Rotor has been disassembled, inspect the Rotor for any internal contamination or dark discoloration. The Rotor should be a cream-white / beige color. If there is excessive dust and debris, use a vacuum and compressed air on either side of the rotor to pull all debris out.
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