Luxor 50, 80 & 120 TM Dryers
Operating Instructions
Part Number:
4006404
Issue Date:
Revision Date:
ECO Number:
Revision Level:
12.17.98
09.29.00
701
0
Motan, Inc.
Mailing Address:
Plainwell Industrial Park
320 N. Acorn Street
Plainwell, MI 49080
Phone:
(616) 685-1050
(800) 991-9921
Fax:
(616) 685-1059
Service Email:
service@motan-inc.com
Web Address:
www.plasticsnet.com/motan
www.motan.com
Shown:
Luxor 80 Dryer w/ 1 Drying Bin and Metro 6 Conveyor
Table of Contents
Section Description
Safety
General
Explanation of Safety Symbols
Operational Safety Notes
Function
Terms
Features
Distinguishing each Luxor Dryer
Behavior of the Luxor Dryers
Installation
Uncrating and Inspection
Mounting
Compressed Air Connections
Electrical Connections
Tubing Connections
Operation
Section Number
1.0
1.1
1.2
1.3
2.0
2.1
2.2
2.3
2.4
3.0
3.1
3.2
3.3
3.4
3.5
4.0
Pre-Operation
Using the Luxor Dryer Controls
Using the Luxor TM Controls
4.1
4.2
4.3
Recommended Periodic Maintenance
5.0
Troubleshooting
6.0
Spare Parts List
7.0
Electrical / Mechanical Drawings
8.0
1
SAFETY
1.1
GENERAL
 Before using the equipment, it is imperative that you read this manual thoroughly. MOTAN accepts
no responsibility or liability for damage or malfunction of the equipment arising from non-observance of
these operating instructions.
 To avoid errors and to ensure trouble-free operation, it is essential that these operating instructions
are read and understood by all personnel who are to use the equipment.
 These operating instructions must be read, understood and implemented in all respects by all
personnel who are responsible for the device or the system. These operating instructions should always
be kept in such a way that they can be rapidly made available at any time.
1.2
EXPLANATION OF SAFETY SYMBOLS
The following safety signs are recommended and approved by the Safety Sign Development Committee
of The Machinery Division of The Society of the Plastics Industry. Each is accompanied by a detailed
reason for its posting, but the symbol’s meaning alone should also be noted.
This symbol is used as an operational safety symbol for all work which involves a risk for
life and limb for personnel. In such cases, particular care and caution must be exercised
when carrying out work.
This symbol is used as an operational safety symbol for all work which
involves risk of electrocution. For instance, it can represent areas of high
voltage where power should be disconnected in advance to any servicing.
These symbols are used as
rotating blade. It is
when the guard is securely
warnings to notify the presence of a sharp knife or a
recommended that operation is only performed
in place.
This symbol is used as a warning to notify presence of a rotating screw. It is
recommended that special attention is given when working around areas with
access to the screw and that at no time should hands or feet be put near the
opening.
This symbol is used to caution handlers of the presence of unsafe vapors or
fumes. Consulting the Material Safety Data Sheets is recommended, as well as
wearing suggested safety gear.
This symbol is used as a warning to notify areas of moving parts. Special
attention should be taken so that hands are not caught. It is recommended that
operation is only performed when the guard is securely in place.
These symbols are used as warnings of areas of high temperature or hot
surfaces. Protective gear must be worn when working near these areas.
This symbol is used to warn handlers of moving belts. It is recommended that operation is
only performed when the guard is securely in place.
1.3
OPERATIONAL SAFETY NOTES
The devices and systems are built to be operationally safe, but nevertheless there are risks and hazards
that may occur during operation and particularly during maintenance and/or repair work.
 Every person who is concerned with the assembly, installation, removal, commissioning, operation,
maintenance and repair of the devices/systems, must have read and understood these operating
instructions in full. It is recommended that the user obtains written confirmation of this in each case.
 The personnel responsible for the equipment/systems shall be obliged to ensure that no unauthorized
personnel work on the system.
 Responsibility must be clearly defined and maintained during the assembly, installation, removal,
commissioning, maintenance and repair work.
 For all work which relates to transport, assembly, installation, removal, commissioning, maintenance
and repair work, the specifications issued by the manufacturer and the safety instructions especially
provided in the operating instructions must be respected.
 The user is obliged at all times to operate the equipment/system only with the safety features in
perfect condition.
 The manufacturer shall provide no further guarantee for function and safety in the event of
conversions or modifications being carried out by the user.
 Before repair work is started, the device is to be disconnected from the electrical power supply,
compressed air supply and water supply (where applicable), and secured against inadvertent
reconnection.

All pipework must be securely connected before commissioning.
 The local safety and accident prevention regulations shall apply under all circumstances to the
operation of the device.

The specified connection voltage for the unit must concur with the main voltage provided.
2.0 FUNCTION
The Motan Luxor 50, 80 and 120 press-side drying units both have the basic function of using a
combination of molecular sieve desiccant and a process heater to produce a low dewpoint air stream to
dry hygroscopic plastic pellets. Luxor 50 and 80 dryers use a single blower design with twin desiccant
beds for simultaneous process air and bed regeneration. The Luxor 120 model utilizes individual process
and regeneration blowers for increased air flow and more efficient operation. (Explanations of
hygroscopic material and the molecular sieve are given in the next section, Terms (2.1).)
2.1 TERMS
Hygroscopic
Hygroscopic material is the term used to describe resin that has absorbed moisture into its minute
interior chambers. In addition to stripping the moisture from the surface of the material, the
Luxor press-side dryers also pull moisture out of the particles’ interiors, assuring that all resin,
including hygroscopic, is thoroughly dry.
Desiccant (Molecular Sieve)
The desiccant, or “molecular sieve” is very much like small clay beads. The desiccant absorbs
moisture much in the same way a sponge absorbs water. The actual process by which desiccant
dries the material is discussed later in the Behavior of the Luxor Dryers (2.4) section.
NOTE: The desiccant, although very efficient, will “break down” or lose its effectiveness over
time. This is caused by absorption of gases or material, or just simple abrasion. This will begin
to occur after about 5 years of use. Desiccant supplies may be renewed by contacting Motan with
the number on the cover of this manual.
Dryer Phase Time
When the dryer is operational, one desiccant bed will be in the process cycle while the other is in
its regeneration cycle. After a preset time, a solenoid valve (Luxor 120) or an electric valve
(Luxor 50, 80) switches the beds and the freshly regenerated bed is now in process, while the old
process bed is being regenerated. This preset amount of time between cycle shifts is known as
the dryer’s phase time. This method of switching beds at preset intervals guarantees that a fresh
bed is always being used and that material is most efficiently dried. For the Luxor 50 ,Luxor 80,
and Luxor120, the dryer’s phase time is set to 60 minutes: 30 minutes heat-up and 30 minutes
cool down.
The Process Cycle
During the process cycle, the low dewpoint air generated by the dryer is heated to process
temperature by the external booster heaters mounted on the dryer or at the drying bin. The blower
circulates the air through the desiccant bed “in process”, across the booster heater, and then
through the material in the drying bin. The process air from the drying bin is then returned back
to the dryer in a “closed loop” process cycle. The combination low dewpoint and high
temperature of the process air stream, draws moisture out of the plastic pellets in the drying bin.
The material residence time in the bin is material dependent, usually between 2 and 4 hours.
The Regeneration (Regen) Cycle
During the regeneration cycle, the blower forces air across a regen heater and then through the
“wet” desiccant bed to “bake off” moisture absorbed during the previous process cycle. The bed
which is being regenerated is heated with 400-550º F air for a preset time and then allowed to
cool before it is again brought online to the process cycle. Luxor 50/80/120 dryers operate with a
30 min. heat-up and a 30 min. cool-down period.
2.2 FEATURES
The dryer can be utilized as a stand alone unit for a machine mount drying bin or the bin can be
attached directly to the dryer on a common frame for a portable drying system.
Luxor Portable Dryers feature
 Twin stationary desiccant design each individually performing process and regeneration
cycles
 Insulated bins reduce energy costs
 Accurate, simple to operate, easy to maintain controls
 Easy-change filter
 Two-year warranty
(2.2.1)
Number of Desiccant Beds
Maximum Temperature w/
Process Heater
Dewpoint Monitored To..
LUXOR 50
2
LUXOR 80
2
LUXOR 120
2
2kw / 350°F
-40º F
2kw / 265°F
-40º F
4kw / 300°F
-40º F
Power
208/3/60
240/3/60
380/3/60
480/3/60
575/3/60
By Request
X
By Request
X
By Request
By Request
X
By Request
X
By Request
By Request
X
By Request
X
By Request
X
X
X
X
X
X
Single
Single
Dual
Not Required
Not Required
90-100 PSI @ 1 SCFM
24" x 26" x 36"
24" x 26" x 36"
24" x 26" x 36"
30CFM / 50 lb/hr
50 CFM / 80lb/hr
80 CFM / 120lb/hr
Controls
Basic (TM)
(1, 2, or 3 Bin Configuration)
Process Htr. Interlock
Blower
Compressed Air Req.
Dimensions ( L x W x H )
Capacity
(2.2.2)
DRYER SIZE
Luxor 50
Luxor 80
Luxor 120
2.3
DRYING BIN SIZES
DBA-30
DBA-60
1 or 2
1 or 2
n/a
1 or 2
1 or 2
n/a
DBA-100 DBA-120 DBA-200 DBA-400
1 or 2
1 or 2
n/a
1 or 2
1 or 2
n/a
1
1
1 or 2
n/a
n/a
1
DISTINGUISHING EACH LUXOR DRYER
As shown in the chart (2.2.1), there is only one primary difference between the Luxor 50 and
Luxor 80—the material drying capacity. The Luxor 50 can dry up to 50lb/hr and the Luxor 80
can dry up to 80lb/hr. Although several changes are made to the Luxor’s internal components to
accommodate the difference in drying capacity, the graphics in this manual are drawn generically
to represent both dryers. The Luxor 120 is a dual blower dryer with extra valving to
accommodate two separate air flow circuits. See diagram 2.4.1b.
2.4
BEHAVIOR OF THE LUXOR DRYERS
Figure (2.4.1) illustrates the flow path of the single blower Luxor dryer at any given time. The
steps of the Luxor drying process are listed below:
 Moist air, returning from the drying bin enters the process filter where particles are removed.
 A clean air stream is combined with a small amount of ambient air and proceeds through the
process blower to the process desiccant bed.
 Air is forced through the sieve, stripping off all moisture. The dry air then passes out the
process bed.
 At this point, on single blower models, 25% of the dry air is directed to the regen desiccant
bed where it is heated to bake off moisture from that chamber of desiccant and exhausted.
 The remaining 75% of the dry air coming from the process bed continues to the process
heater where it is brought up to drying temperature before entering the drying bin.
 The hot, low dewpoint air dries the material. A thermocouple on the outlet of the booster
heater is used to monitor and regulate the process temperatures.
( 2.4.1 ) Single Blower Flow
Luxor 50 / 80
Ambient air
added
Return air
from bin(s)
Process
blower
Drying
bin
Booster
heater
Bed
Process
filter
Regen air
exhaust
Desiccant
100%
Process bed
75% process air returning to
booster heater and drying bin
75%
25%
switching
valves
Regen bed
When the dryer’s preset “phase time” expires, the bed switching valves are actuated switching
the regen bed to process and the process bed to regeneration. At this time, the regen heater on
the bed now in regeneration turns on.
( 2.4.1b ) Dual Blower Flow
Luxor 120
From
Drying
Bin
Process
Bed
To
Drying
Bin
Regen
Bed
3.0
INSTALLATION
Designed as portable systems, the Luxor Dryers have relatively quick and simple installation processes.
However it is still recommended that upon every installation of this equipment (like all Motan
equipment) each installation step in this manual is to be read thoroughly and carried out.
Doing this will assure that there is no error in installation that may hinder production and equipment will
function properly the first time.
3.1
UNCRATING AND INSPECTION
The Motan Luxor Dryer is boxed and shipped on a pallet. Inspect the dryer for any damage that
might have occurred during shipment. Normally the dryers are shipped F.O.B. from Plainwell
Michigan, any shipping damages must be resolved between the purchaser and the shipper. If any
shipping damage is discovered, immediately contact the freight company to file a claim.
Once the dryer is uncrated, check for the following items included with the unit:
 Hose Clamps
 Female power plug for main power, if specified. (voltage specific to factory requirements )
 Two sections of white hi-temp hose (for 1 drying bin) see Tubing Connections (3.5)*
*Will be pre-piped on drying sled applications.
NOTE: Additional tees or hosing that are specific to each order should also be included.
If the items listed above are not included with your particular dryer model, please contact Motan
at the phone and fax numbers listed on the front of the manual cover.
3.2
MOUNTING
If receivers are purchased to load the drying bin and / or if the Luxor will be conveying to new
machine-mount receivers, please see the mounting instructions provided in the MetroVac
Receiver users guide and carry out procedures for mounting MetroVacs at this time.
3.3
COMPRESSED AIR CONNECTIONS
Located on the top panel of the Luxor dryer frame is the 1/8” NPT compressed air inlet fitting.
Air lines to be used are ¼” OD. Compressed air requirements for the Luxor 120 Dryer are:
90-100 PSIG with a usage of 1 SCFH. The dryer is fitted with a compressed air gauge located
on the side panel adjacent to the fitting. Since operating with proper air pressure is so important,
the dryer is also fitted with a pressure switch in addition to the gauge. If the compressed air
pressure is not within the required range, The “ low air flow “ light will illuminate and the dryer
will not continue to heat until that pressure has been increased to 90PSIG. Compressed air to the
dryer should be dry and non-lubricated.
3.4
ELECTRICAL CONNECTIONS
Luxor Dryer
Along with the factory-wired cord plug option, which may be supplied with the dryer, an
accommodating female power plug would also be included. This is provided for main power
connection. A chart is provided (3.4.1) to determine what wire size is recommended for each
amperage-rated power plug. When the wiring and all other
installation steps are complete, connect the male power plug into
(3.4.1)
the female receptacle.
Plug
Gauge
30A
50A
60A
#10 AWG
#6 AWG
#4 AWG
Customer to supply a Male Plug and recommended wire for power
connection.
480V Plug Recommended: NEMA L16-3
30A
240V Plug Recommended: NEMA L15-3
30A
3.5
TUBING CONNECTIONS
Tubing connections are specific to each Luxor order, basing hose requirements such as amount,
length, material, etc. on a number of things. Some in particular are:
 The distance to the press receiver(s), etc.
 Whether material proportioning or line purging are required.
Diagram 3.5.1
As shown in this diagram (3.5.1), for each single drying bin arrangement, 2 sections of hose are
required: One from the process air delivery port (closest to the back) of the dryer to the air inlet
at the base of the booster heater; and one from the return air outlet on the top of the drying bin to
the return air port (towards the front) of the dryer. Hose clamps must be tightened to guarantee a
strong and secure connection.
NOTE: Be sure to connect the bin inlet only to the process delivery port and the bin outlet
only to the return port. If these line connections are reversed, material can be drawn into the
dryer and heat damage to the dryer may occur!
The majority of Luxor portable sled systems will be factory set-up, but for Luxor dryers and bins
shipped as stand-alone or machine mount, certain items will be the responsibility of the customer
to have installed or connected. If your dryer was supplied as a portable sled assembly, then the
thermocouples are factory-installed, so it is not necessary to perform any installation steps on
them. Damper valves on the inlet and outlet of the drying bin must be in the open position
for the Drying Bin and Booster Heater to operate and dry material. However, if a drying
bin is empty for cleaning on or other purposes, the damper valves on that bin should be
closed to force air to the bin being used.
4.0
OPERATION
Once the Luxor dryer has been installed and successfully integrated into the molding system, PreOperation steps can be taken.
Luxor Dryer Pre-Operation
Calibrating the Luxor controls to particular system specifics, including:
 Setting the drying bin process temperature at operator control counsel.
 Setting the high temperature alarm value.
 Verify that the Drying Bin Temperature Controller has the proper presets and calibration.
(Refer to Tables 4.0.1a, 4.0.1b)
4.0.1a
Temperature Control Set-up Parameters
SET-UP PARAMETERS FOR THE MOTAN / FUJI PXW-4, 1/16TH DIN, DUAL DISPLAY, TEMPERATURE CONTROLLER (1005248)
PROGRAMMING
The FUJI PXW controller programming menu consists of three blocks- Primary (Setpoint) Menu, Secondary (System) Menu, and Factory
Preset Menu.
At power up the controller will be in the operational mode, and process variable (PV) and setpoint variable (SV) will be displayed. PV is the
variable that is being controlled, and is not programmable. Listed below are the Motan settings for the temp. controller.
To set-up the temp. controller, first access the “FACTORY (PRESET) MENU” as listed below and edit or verify the settings, second move
onto the “PRIMARY (SETPOINT) MENU” and edit or verify the settings, and third finish up with the “SECONDARY (SYSTEM) MENU” and
edit or verify the settings.
NOTE: The “MOTAN SETTING” values, which are denoted by an asterisk ( * see NOTE), may change from their initial value due to the
auto-tuning function of the temperature controller.
FACTORY (PRESET) MENU
Press the “SEL” key for 9 seconds. Use the “” or the “” key to edit the setting. Use the “SEL” key to advance to the next parameter. After 30
seconds if no keys have been pushed, the controller will go back to displaying the PV & SV temperatures.
PARAMETER
RANGE
DESCRIPTION
MOTAN SETTING
P-n1
0 - 19
Control Action Mode
0
P-dF
0.0 - 900.0 sec
Input Filter Constant
5.0
P-An
0 - 50% FS
Alarm Hysteresis
1
FUZY
OFF / ON
Fuzzy control
on
dSP1
0 - 255
Parameter Mask
9
dSP2
0 - 255
Parameter Mask
240
dSP3
0 - 255
Parameter Mask
1
dSP4
0 - 255
Parameter Mask
252
dSP5
0 - 255
Parameter Mask
255
dSP6
0 - 255
Parameter Mask
240
dSP7
0 - 255
Parameter Mask
123
PRIMARY (SETPOINT) MENU
Press the “SEL” key for 3 seconds. Use the “” or the “” key to edit the setting. Use the “SEL” key to advance to the next parameter. After 30
seconds if no keys have been pushed, the controller will go back to displaying the PV & SV temperatures.
PARAMETER
RANGE
DESCRIPTION
MOTAN SETTING
Blinking red “H” led
0 - 100% FS
High Alarm Setpoint
20
Blinking red “L” led
0 - 100% FS
Low Alarm Setpoint
32
AT
0–2
Auto-tuning
1 (* see NOTE)
LoCO
0–2
Lock-out
0
4.0.1b
SET-UP PARAMETERS FOR THE MOTAN / FUJI PXW-4, 1/16TH DIN, DUAL DISPLAY, TEMPERATURE CONTROLLER (1005248)
NOTE: The “MOTAN SETTING” values, which are denoted by an asterisk ( * see NOTE), may change from their initial value due to the
auto-tuning function of the temperature controller.
SECONDARY (SYSTEM) MENU
Press the “SEL” key for 7 seconds. Use the “” or the “” key to edit the setting. Use the “SEL” key to advance to the next parameter. After 30
seconds if no keys have been pushed, the controller will go back to displaying the PV & SV temperatures.
PARAMETER
RANGE
DESCRIPTION
MOTAN SETTING
P
0.0 - 999.9% FS
Proportional band
5 . 0 (* see NOTE)
C
0 - 3200 sec
Integral Time
2 4 0 (* see NOTE)
d
0.0 - 999.9 sec
Derivative time
6 0 . 0 (* see NOTE)
TC
1 - 150 sec
Cycle Time (output #1)
30
HYS
0 - 50% FS
Hysteresis
1 (* see NOTE)
P-n2
0 - 16
Input type code
2
P-SL
-1999 - 9999
Lower range of input
32
P-SU
-1999 - 9999
Upper range of input
400
P-dP
0-2
Decimal point position
0
P-AH
0 - 11
Alarm Type 1 code
5
P-AL
0 - 15
Alarm Type 2 code
0
PUOF
-10 - 10% FS
PV offset
0
SUOF
-50 - 50% FS
SV offset
0
P-F
C / F
C / F selection
F
This section will also provide step-by-step instructions (4.2) for understanding the control panel on the
Luxor Dryer. Users should become familiar with the control panel and the purpose of each component.
Illustrations matching the Luxor control are provided in each section, making referencing control
information quick and easy to follow.
4.1
PRE-OPERATION
Once the electrical, compressed air, and drying bin connections have been made, and the process
temperature has been set to the desired drying temperature, the dryer is ready for pre-operation.
The factory process Set Point temperature is 150°F. Please refer to (4.0.1a, 4.0.1b & 4.0.1c) for
information about adjusting drying Set Point.
Blower Rotation Check
On top of the dryer are two hose connections for the drying bin, one to deliver process air to the
bin, and the other for the return air from the bin. Remove these hoses from the top of the dryer
and observe the proper process air flow as described here. Connect the main power plug to the
dryer and rotate the door mounted disconnect switch to the ON position. Locate the amber
rocker switch on the dryer’s faceplate, and depress the rocker switch to the 1 position. The
amber light in the rocker switch will illuminate. The dryer will start running.
With the dryer operational, verify that the process air is blowing out of the dryer from the dryer’s
process air outlet port and that air is being drawn into the process air inlet return port. If the
process air flow is correct, depress the amber rocker switch to 0 and the dryer will de-energize.
Re-connect the hoses to the dryer and proceed with operation.
If the process air flow is reversed, depress the amber rocker switch to 0 immediately and the
dryer will de-energize. Turn the disconnect switch on the dryer to the OFF position and remove
the main power plug.
On Luxor 120 models you must also verify that the regeneration blower is rotating in the proper
direction. Verify this by checking that air is being exhausted thru one of the two bleed air hoses
near the floor on the bottom of the dryer. Both blowers are phased together at the factory during
testing. Follow the instructions below. Do not attempt to change phase at the process blower
contactor.
NOTE: The electrical installer must change two of the “hot” phase wires in the main
power plug as described below. Only qualified personnel should attempt to change these
main power wires and all power must be “LOCKED-OUT” to the main power plug before
proceeding.
LOCK-OUT power to the main power plug and interchange two of the three phase “hot” wires
connected to the terminals of the plug. Re-connect the main power plug, re-start the dryer, and
verify that the blower rotation as been corrected (reversed).
Drying Bin Damper Valve Check
Check all drying bin inlet/outlet damper valves to ensure that they are in the open position (the
handle will be “in line” with the tube). This will prevent the dryer from loosing air flow and
damaging the regeneration heaters. Each process heater on each bin is protected by differential
pressure switch to detect the loss of air flow.
Dryer Power Up
When main power is supplied to the dryer and the dryer’s disconnect switch is rotated to the ON
position, depress the amber rocker switch labeled “POWER” to the 1 position. The rocker switch
will illuminate and the dryer will run.
4.2 LUXOR TM DRYER CONTROL PANEL
The dryer control panel is shown in Section 8.0 (Manual-A).
The four amber status lights on the left side indicate dryer regeneration status. They indicate
which bed is in regeneration and whether Bed A or Bed B is being heated or in the cool down
portion of the cycle. As viewed facing the front of the dryer, Bed A is on the left and Bed B is on
the right.
The red alarm light/alarm reset located underneath the “power” rocker switch, indicate a “high
process temperature” , “low air flow” or “motor overload” condition. The low air flow alarm
may be from any of three sources:



Loss or reduction of process drying air flow
Loss or reduction of regeneration air flow (on Luxor 120 models only).
Loss or reduction of compressed air ( below 65 psig ).
Any of the three air flow alarms will de-energize all heaters and suspend the regeneration cycle
until the alarm condition is cleared. The normal cycle will resume from the point where it was
suspended.
A “high process temperature alarm” will de-energize only the process heater until the
temperature falls within limits, when it will automatically re-energize. This alarm will have no
effect on the regeneration circuit.
4.2
USING THE LUXOR TM CONTROLS
The TM control system consists of a pre-programmed PLC and a state of the art “fuzzy logic”
P.I.D. temperature controller.
REGENERATION CONTROL
The PLC sequences through a time based regeneration program. If the program is interrupted,
through a power failure or dryer shutdown, the timer will retain its memory. Regeneration will
continue from the point of suspension when the power is re-applied.
4.2.1
PROCESS TEMPERATURE CONTROL
The process drying temperature is controlled through the 1/16 DIN controller on the front panel.












All set-up parameters are pre-set at the factory for optimum control.
SEL
Up Arrow
Down Arrow
PV
SV
C
H
L
- To modify Calibration and Set-Up Parameters. (See 4.0.1a & 4.0.1b)
- To “Increase” Process Set Value.
- To “Decrease” Process Set Value.
- Actual Process Temperature.
- Process temperature set value.
- Booster Heater is “Calling” for more heat. (This should pull 3CON/4CON in
unless the air dampers are closed on that drying bin.
- High Drying Bin Temperature. (If this condition exists for more than 1 minute,
an alarm will sound.
- Low Temperature. (Not Used)
The set-points the customer will want to check and possibly reset are:
A. To change the process set value ( SV ) drying temperature, turn the dryer on. Press the  or 
( up or down arrow key ) to increment the SV value to the desired temperature.
B. To change the high temperature alarm value:
Press and hold down the “SEL” key for three seconds. “r oFF” will appear.
Press the  to select “ r rUn/r HLd”.
Press the “SEL” key once more. The “H” LED on the top of the controller face will blink
On and off.
Press the  or  key to increment to the desired (positive) value.
Press and hold the “SEL” key for three seconds to return to the operational mode.
C. To change temperature scale selection to degrees C or F:
Press and hold down the “SEL” key for seven seconds. “P” will appear.
Press the “SEL” key again to increment through the parameters until “P-F” appears.
Press the  or  key to toggle between C or F as desired.
Press and hold the “SEL” key for three seconds to return to operational mode.
The alarm value you set will be a deviation value from the drying set point. (SV) This value
will automatically track the set point wherever it is set.
The low temperature alarm feature of this controller is not utilized.
The temperature controller is configured to use a type J ungrounded thermocouple. If any other
type is desired, consult the controller operation manual for details.
A list of controller error messages is listed below with the probable cause and the control
output result. See the controller manufacturers manual for more detailed information.
4.2.2
DEW POINT MONITOR SYSTEM (OPTIONAL with all TM Series Dryers)
The dewpoint is described as the temperature at which the air becomes saturated with moisture
and condenses to water(or frost in the case of dryers!). It is usually measured in degrees
Fahrenheit (ºF, but can be set to °C when preferred). The lower the dewpoint means the dryer the
air. The digital dew point monitor indicates the dryness of the process air.
Defining Dewpoint Status Terms


Process Dewpoint gives the current dewpoint of the process air being sent to the drying
bin. Typically during the last ¼ of the process cycle, the dewpoint may slowly begin to
rise, just prior to bed-switching (depending on the ambient humidity present).
The bed which is in the process cycle will continue to absorb moisture from the process
air loop for the process cycle duration. At the end of the cool down portion of the cycle,
the valves switch air flow direction and bring the fresh bed on line.
The moisture in the air is measured across the dew point sensor mounted in the black block
located on the dryer control back panel. The sensor is sensitive to heat, so its tap on the air stream
must be in a cool location, before the booster heater. It cannot be checked for proper operation or
resistance with a multimeter! The sensor will be damaged! If operation of the sensor is
questioned, replace it.
The monitor control board is factory calibrated and re-calibration in the field is impractical. To
insure its continued accuracy, it is recommended that the sensor be replaced annually. If the P.C.
board calibration is in question, contact Motan Inc., Service Dept. for instructions.
The display is factory configured to read in degrees Farenheit. If degrees Celsius is desired, use a
pair of needle nose pliers to move jumpers J10 and J11 to the upper position. Reference the
diagram.
4.2.3
7 DAY CLOCK (OPTIONAL with all TM Series Dryers)
Application
The Luxor Series Dryers offer an OPTIONAL Digital Time Clock which has a 7-day time base,
therefore each day of the week can be uniquely programmed. The time base control can be used
to schedule dryer up/down time when you automatically require the dryer to be turned on/off.
The control encompasses 24-hours a day, 7-day schedules as well as a “8th day” or holiday
schedule.
(Control Set-Up Parameters are enclosed separately in the control cabinet.)
Technical Data
2 Week minimum battery back-up.
Supply Voltage: 120VAC
Shortest switch time - 1 minute
Ambient Temperature Range: -20 – 140 deg. F
Accuracy +/- 4 minutes per year.
See 7.0 for Electrical Wiring Schematic.
5.0 RECOMMENDED PERIODIC MAINTENANCE
The Luxor Dryers require very little regular maintenance. Alarm conditions serious enough to affect the
dryer’s performance will be indicated through the red light and audible alarm. The items listed below, if
regularly checked, should prevent most alarm conditions from occurring.
Weekly
 Visually inspect the process filter, to monitor dirt/debris buildup before the filter pressure alarm
switches shut off the heater elements. Replace or clean the filter as often as indicated. The filter is
accessible at the lower right side of the dryer, while facing the controls.
Monthly
 Drain the compressed air supply filter of accumulated water.
 Inspect process and return air lines for leaks. Tighten clamps.
Annually
 Remove the dryer panels and visually check all hoses for wear, chafing or tears.
 Check all Teflon air lines and hose clamps for tight connections. Replace any faulty lines or clamps.
 To insure continued accuracy of the dewpoint readings, the manufacturer of the dewpoint sensor
recommends the sensor to be replaced annually. Replacement dewpoint sensor is Motan part
number: 5001245
6.0 TROUBLESHOOTING
The ultimate function of every dryer is to produce a certain capacity of air at a specified dewpoint.
When either of these two parameters (air and dewpoint) is below specifications, the dryer will not
perform the required drying task (either in amount of material dried per hour, or in the final moisture
content of the material). When a high moisture condition is encountered in the material, the most likely
cause is a decay in the dewpoint of the dryer process air. Troubleshooting this condition is detailed
below.
Initial Dewpoint Reading
The first step in a dewpoint problem is determining whether the problem is within the dryer or outside
the dryer. To determine this, a dewpoint reading must taken in two places:
1)
2)
After the desiccant bed (at the bottom of the desiccant bed which is online)
Before the desiccant bed (at the top of the desiccant bed which is online)
These two measurements will provide an indication of the dryer performance. If the dewpoint
temperature differential across the dryer is less than 30° (i.e. +10° to -10°), the dryer is not functioning
properly. Proceed to Incomplete Regeneration.
If the dewpoint temperature differential across the dryer is greater than 30° (i.e. +10° to -40°), the dryer
is functioning properly and the problem resides outside the dryer. Follow the instructions outlined in the
following section, Dryer External Diagnosis.
Dryer External Diagnosis
If the dewpoint drop across the dryer exceeds 30°, a dewpoint quality problem is caused by excessive
moisture in the return air from the drying bin(s). This excessive moisture can be caused by:
1)
2)
Leaks in the drying bin and connecting tubing and hose, or by
an extremely high moisture level of the material in the drying bin.
If the problem is caused by extremely wet material in the drying bin, the dewpoint should gradually
improve as material is dried. Refrain from adding any new material into the drying bin(s) for a couple of
hours and monitor the process dewpoint. If the dewpoint gradually improves, excessively wet material is
probably the cause. If the dewpoint does not improve, the problem is most likely caused by leaks in the
drying bin(s) and connecting hose and tubing.
In a drying system, the drying bin and return air tubing is under a slight vacuum. Therefore any leaks
will cause ambient air (and accompanying moisture) to enter the return air and cause an excessively high
return air dewpoint. Potential areas to check for leaks are:
1)
all hose connections and clamps,
2)
breaks and tears in the hose,
3)
open or poor seating discharge valves on the receiver on top of the drying bin,
4)
all tubing clamps, and gaskets around the bin lid, vacuum receiver and take-off box.
Dryer Internal Diagnosis: Incomplete Regeneration
The most common cause of low dewpoint is incomplete regeneration.
During the regeneration heating phase, 500°-550° F air is blown through the molecular sieve. When the
exit temperature of the bleed air at the top of bed being regenerated exceeds 340° F, the molecular sieve
has been sufficiently dried. Failure of the bleed air temperature to achieve 180°F at the discharge of the
bleed air hoses within 40 minutes is considered incomplete regeneration. If this condition occurs, a
failure of the regeneration heater has most likely occurred. With the dryer power disconnected, check the
heater resistance. At 240V resistance should measure 29 ohms; at 480V resistance should measure 154
ohms. A failed heater will show up as an “open” circuit.
Leaking Process Valves
If the regeneration heater system checks out, the problem may be due to a leaking process valve(s).
Monitor the process air dewpoint for both bed A and bed B. If the dewpoint readings from each bed
differ by more than 20°, the problem is probably due to a leaky valve. Also check air flow from the
regeneration bleed hoses on the bottom of the dryer. Air should only be discharged from the hose off the
bed that is being regenerated. Remove the three way valves from the molecular sieve chambers and:
1)
2)
Inspect the plungers for cracks or other wear.
Confirm that the plungers seal tightly against the inner valve tubes in both the extended and
retracted positions. Replace any plunger which does not seal properly.
Check the proper operation of the air cylinders and bed shift solenoid valve. To check the condition of
the air cylinders, remove the three-way valves from the desiccant beds. With the compressed air lines
still attached to the cylinders and air supply, depress the manual actuation button on the bottom of
solenoid valve mounted on the dryer housing. All valve plungers should move to seat against the
opposite opening in the valve block. If the solenoid valve fails to actuate the cylinders, replace it. If any
cylinder fails to actuate the plunger all the way to the opposite opening, the cylinder has failed. Replace
the air cylinder. The appropriate part numbers are located in section (7.0).
Note: Running the dryer with reversed phasing for even a short period of time will cause heat damage to
the lower valve seals!
To check the integrity of the solenoid valve coil, with power off, remove the power plug off the solenoid
valve's coil from the back of the dryer. Measure the resistance across the two spade terminals on the
valve. The resistance should be in the range of 710 to 750 ohms.
Molecular Sieve Temperature
Another cause of poor dewpoint is excessive molecular sieve temperature. The hotter the desiccant; the
less moisture it will be able to absorb This condition is usually caused by the return air from the drying
bin being too hot. To measure the temperature of the molecular sieve, reduce the temperature set-point
on the process air temperature controller to approximately 150° F.
Monitor the temperature reading. Ideally the temperature should be below 150 degrees F. If the
temperature reading exceeds 200° F continuously, the molecular sieve is at too high a temperature to
work effectively. An after-cooler may have to be installed at the dryer, before the process air return filter.
Contact the Motan sales department for assistance in obtaining an after cooler.
Process Heater Circuit
Inability to reach the desired process drying temperature may be caused by a blown fuse or open heater
element caused by the Drying Bin Interlock Pressure Switch being tripped.
After ruling out blown fusing, check to see if the damper valves on the drying bin in question are open.
If they are, then check the appropriate drying bin pressure switch to verify proper calibration of the dryer
interlock circuit. If the temperature controller is C “calling” then chances are, that the pressure switch
needs to be adjusted to the proper differential setting. Remove the cover on the appropriate pressure
switch and check the voltage between the “Normally Open” terminal and the “Common” terminal. You
should obtain 0VDC. If you are getting 120VAC with the damper valves OPEN, use a screw driver to
adjust the calibration screw CLOCKWISE until you obtain 0VAC with the damper valves OPEN. Once
you have calibrated the screw, close the damper valve to see if you obtain 120VAC and then open it to
see if you obtain 0VAC. If so, this is the proper calibration.
The drying bin interlock switches are wired “Normally Open” “Held Closed”.
Process Heater Circuit
If the pressure switches and the fuses are ok, check the heater elements and wiring connections.
Disconnect power. With an ohmmeter, check the resistance of the heater assembly at the bottom of
contactor on 3CON or 4CON. There are two to four elements wired in series / parallel depending on
model. At 240V the 2KW heater assembly resistance should be 29 ohms; at 480V the 2KW heater
assembly resistance should be 115 ohms. At 240V the 4KW heater assembly resistance should be 14.5
ohms; at 480V the 4KW heater assembly resistance should be 58 ohms. Any failed (open) elements will
not show a resistance reading and they should be replaced. See Spare parts list Section 7.0
Operational Control
Refer to the Electrical Schematics in Section 8.0 for PLC I/O (Manual-J).
7.0 SPARE PARTS LIST
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Air Cylinder, Valve Shifting
Blower, 0.3Hp, 240v/480v, Luxor 120 regen
Blower, 0.5 Hp, 240v / 480v (Luxor 50)
Blower, 1.0 Hp 240v / 480v (Luxor 80 & 120)
Caster, 4" Swivel, Locking
Desiccant Support Screen (Luxor 120)
Desiccant Support Screen (Luxor 50 & 80)
Filter Element, Process
Gasket, Air Filter Seal
Gasket, Desiccant Bed Cover
Heater Element, Process, 2 Kw 240v & 480v ( Luxor 50, 80 & 120)
Heater Element, Regeneration 480v, 1.5 Kw (Luxor 50, 80 & 120)
Heater Element, Regeneration, 240v, 1.5 Kw (Luxor 50, 80 & 120)
Hose, Air Delivery, 1.50", White (Luxor 50, 80 & 120)
Hose, air delivery, 2.50: white (Luxor 120)
Molecular Sieve Desiccant, 4a, Large Bead (Luxor 120)
Molecular Sieve Desiccant, 4a, Large Bead (Luxor 50 & 80)
Molecular Sieve Desiccant, 4a, Small Bead (Luxor 120)
Molecular Sieve Desiccant, 4a, Small Bead (Luxor 50)
Molecular Sieve Desiccant, 4a, Small Bead (Luxor 80)
Solenoid, Valve Shift, 110vac
Valve Seal, Silicone Rubber (Luxor 120)
Valve Seal, Silicone Rubber (Luxor 50 & 80)
1000851
5006095
5005050
5002663
5005631
1006090
1005651
5000577
5000812
5005150
1000971
5005633
5005632
5001075
5000753
5000814
5000814
5000734
5000734
5000734
5004448
1006092
1001288
1
2
2
1
1
10 FT.
2
1
1
10 FT.
12 FT.
3 LB.
1 LB.
17 LB.
6 LB.
7 LB
1
4
2
ELECTRICAL SPARE PARTS LISTING
FOR LUXOR 50, 80 & 120 CONTROLLER
Item #
Description
Motan
P.N.
Spares
Rec.
1
2
3
4
5
6
7
8
9
10
11
12
13
Contactor 9a 120VAC Coil A-B IEC Style M09 Used On Process & Regen Blowers
Compressed Air Pressure Switch Set @ 65psi
Contactor 12a 120VAC Coil A-B IEC Style 100-C12 Used For Bin Heaters
Control Transformer 480/240VAC To 120 VAC .050 KVA W/ Fuse Block
Dew Point Sensor
Fuses All Class CC
Overload Relay Solid State 1.0-2.9 A Range IEC
Overload Relay Solid State 1.6-5.0 A Range IEC
Overload Relay Solid State 3.7-12 A Range IEC
Pilot Light Amber W/ 120VAC Lamp
Dew Point Meter
Pressure Switch For Process Air Flow
Rocker Switch Amber Illuminated 120VAC
5003776
5005814
5005876
5001058
5001245
5003778
5003825
5003778
5001080
1006377
5005471
5001269
2
1
1
1
1
NOTE 2
NOTE 1
NOTE 1
NOTE 1
4
1
1
1
14
15
16
17
18
19
20
Temperature Switch 392 Deg. F N.C. W/ ¼" Male Tabs Used On Regen Heaters
Thermocouple Class J 3/16" OD X 3" Aspirated
Temperature Controller, 1/16 din, 120VAC
Mitsubishi PLC
Electric Valve for Luxor 120 Model
Air Pressure Switch
7 Day Clock
5004505
1005754
1005248
5007283
1006371
5005471
5002954
1
1
1
1
1
1
1
Notes:
Each Luxor dryer is specifically designed to operate at a specific customer defined voltage
1
Contact Motan for assistance in selecting the proper overload relay for your
specific Luxor dryer model.
2
The standard fuses used in the Luxor dryer are available from your local industrial
electrical supplier. If a spares fuse kit is desired, contact Motan with your specific
Luxor dryer model.
8.0 Electrical / Mechanical Prints.
Drawings A thru R
 



 







 






 

  






 

 
 
 
 
 

 





 












 




 







 



 
 
 


 



 

 











SEE NOTE # 1
SEE NOTE # 1