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Manual with DC-2 Control

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4. 4 3 How to navigate the menu tree 4 3 EA Control function descriptions 4 11 To Start drying 4 37 To STOP Aying 4 38 How to use the supervisor s password 4 39 Using the auto start timer 4 41 Setting the high setpoint limit 4 42 Using dewpoint 4 43 Using the setback function 4 44 Setback feature guidelines 4 45 Operation 4 1 Carousel Plus W Series Dryer Control Panel DC 2 Menu Button Scroll Buttons Press to view the main menu screen where you can Screen Title select on screen categories or press again to return to the default screen where process temperature and actual setpoint are displayed This button can be pressed at any time to return to the default screen Alpha numeric characters display process and alarm conditions Select Category Press to select on screen categories paths and options Regen Blower Auto Start Regen Heater Desiccant Indexing Numeric MEM Keypad Press numbers to enter data Clear Button Press to clear high lighted on screen data entry fields only after data has Enter Button Increment start and Stop Buttons Tederi Used to lock in Decrement e clear button a Buttons Press Start to start the dryer clears the field one Press Stop to stop the dryer Used to increase or decrease val ues number at
5. RUNNING N 24 REA Je Sa Ex pu pue p Enabled FLOW I PROCESS DEWPOINT 11 ACT 47F _ 40 PROCESS DEWPOINT 24 AVERAGE 55 F SETBACK MODE 25 OFF TEMPERATURE MANUAL ON SETBACK TEMPERATURE 26 100 SET 140 F SETBACK RETURN TEMP 27 ACT100F SET140F SETBACKTEMPBAND __ 28 SET 20 F When the DM II monitor option is purchased these screens will be displayed DRYER OTHER STATUS SCREENS 14 MODEL CP150 480V 60HZ DISPLAY FIRM V2 21 0q DISPLAY MENU V2 21 0d 31 CONTROL FIRMWARE VERSION V02 21 00 30 32 AUTOSTART COUNT DOWN 1 DAYS 23 05 53 AUTOSTOP COUNT DOWN 3 DAYS 11 04 23 PANEL INSIDE TEMP 35 34 8 8 a 8 a Operation 4 5 4 6 CENTRAL DRYER SETUP PROCESS RETPID PROC SETUP PROCESS SETUP AFTERCOOLER 44 SETUP PROCESS 44 SCREENS 14 jon off VALUE SCREENS SCREENS 1 COOL 20 SECONDS OFFSET 2F k isable Central When configured as a central 1 dryer there is no process heater i rin the system Therefore any 1 function associated with the process heater is not available for central dryer configurations Operation RI RN AIR TEMP 5 I RET AI CLE TII 42 PRO MPERATU ACT 120 F SET 120 F 1 AIR CALIBRATION 1 SCREEN DRYER MAIN MENU 12 STAT SETUP DIAG
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7. IMPORTANT Always refer to the wiring diagrams that came with your dryer to locate specific electrical components Illustrations in the User Guide are intended to be representative only Fuse Blocks To locate the appropriate fuse and replacement part refer to the wiring diagrams that came with your dryer E 22 2 0 E ea Troubleshooting 6 29 Checking Heater Solid State Relays 1 Disconnect and lockout the main power supply A 2 Open the electrical enclosure 3 Locate the process or regeneration relays Refer to the wiring diagrams that came with your dryer 4 Check continuity using an ohmmeter Regeneration heater solid state relays If ohms equal zero or infinity replace the relays Process heater solid state relays If ohms equal zero or infinity replace the relays N IMPORTANT Always refer to the wiring diagrams that came with your dryer to locate specific electrical components Illustrations in the User Guide are intended to be representative only 6 30 Troubleshooting Checking or Replacing Temperature Sensors The Carousel Plus W series dryer uses RTD sensors to monitor the temperatures of the drying air the return air the regeneration outlet the regeneration inlet process protection and setback at the outlet of the hopper IMPORTANT Always refer to the wiring diagrams that came with your dryer to locate sp
8. Therefore any function asso ciated with the process heater 15 not available for central dryer configurations Operation ACTION DRYER SETUP ALARM ACTION SCREENS PROC TEMP DEVIATION 59 EDIT PASS EDIT PROC LOW TEMP ALARM Di pass Epi 59 REGN TEMP LOOP BREAK EDIT PASS EDIT REGN TEMP DEVIATION EDIT PASS EDIT DIT PASS EDIT 59 REGEN LOW TEMP ALARM ON EDIT PASS EDIT 2 fo zm gt e m 2 m I D T E 2 RET MID HI TEMP ALRM DIT PASS _ 59 59 o z m WHEEL ROTATION EDIT PASS Epir 59 REGEN BLOWER OVRLOAD ON EDIT PASS EDIT o z DRYER MAIN MENU STAT SETUP DIAG 12 DRYER SETUP PROC ALM DISP OTHER ALARM SETUP 58 DRYER SETUP ALARM SETPOINT SCREENS 1 PROCESS HIGH TEMP 385 F 20SEC 1 1 PROCESS LOW TEMP 1 60 70 F 20 SEC oe PROCESS LOOP BREAK c ___20 PROCESS TEMP DEV 62 10 F 5 SEC 1 REGEN HIGH TEMP 60 400 5 SEC LI LI 1 REGEN LOW TEMP 60 200 5sEC 1 ee T 4 REGEN LOOP BREAK 2F 40 SEC 61 REGEN TEMP DEV 10 F REGEN DIFFERENTIAL 63 20 F 10 SEC REGEN DIFFERENTIAL TIME DELAY 5 MIN 64 RETURN AIR ALARMS PASS 125 F SHUT 180 F_ 65 RETURN AIR LOOP BRK 3F 208 ae DEWPOINT ALARM ACT 20F 180SEC 67 DEWPOINT DEVIATION HIGH 30
9. 3 7 Connecting the setback RTD probe 3 7 Checking for proper air flow 3 8 Connecting the air hoses 3 11 Connecting dryer to hopper 3 11 Connecting air hoses adapters 3 12 Connecting the aftercooler 3 13 Mounting a loader on the hopper 3 14 Testing the installation 3 14 Using communications 3 16 Installation 3 1 3 2 Installation Unpacking the Boxes The Carousel Plus W series dryer comes in one to four boxes depending on the model and options ordered The boxes could include depending on the options selected Carousel Plus W series dryer Delivery air hose 10 ft 3 05 m Insulated with High Heat option Return air hose 10 ft 3 05 m Process RTD Setback RTD User manual 1 Carefully remove the dryer and components from their shipping containers Note that the dryer is secured to its shipping container with straps that pass through the bottom of the dryer frame 2 Remove all packing material protective paper tape and plastic 3 Open the side panel and remove the cable tie securing the desiccant wheel See Installation section entitled Removing the cable tie from the desiccant wheel 4 Carefully inspect all components to make sure no damage occurred during shipping and that you have all the necessary hardware Unpacking the Boxes continued 5 Take a moment to record serial numbers an
10. 68 DEWPOINT DEVIATION LOW 5F 30sec 69 DEWPOINT TMEDELAY sMN 70 DRYER SETUP CONTROL 14 DISPLAY SCREENS UNITS 71 STANDARD EDIT METRIC TIME DISPLAY 12 HOUR 72 24 HOUR DATE TIME 5 23 2002 10 33 AM 73 When the DM II monitor option is purchased hese screens will be displayed DRYER MAIN MENU STAT SETUP DIAG DRYER SETUP IPROC ALM DISP OTHER DRYER SETUP OTHER INSP COM PW 36 74 DRYER SETUP OPTIONS INFORMATION SCREENS PROC CURRENT TAP 5A 15A PROC CURRENT SCALE 1 IREGEN CURRENT TRANS INSTALLED EDIT REGEN CURRENT 5A MODEL NUMBER DRYER SETUP MODEL 14 DRYER SETUP 14 CONFIG SCREENS COMMUNICATIONS 78 PROTOCOL 460V 575V 60 HZ 60 HZ Display Firm V9 72 95 Display Menu V2 01 00 Control Firmware 75 LVersion_V2 01 00 Dryer Setup fogging Out Password Screen Password IF A VALID PASSWORD IS STILL ACTIVE 1 02 02 75 EDIT MODBUS gom 81 CP15 75 25 SLAVE ID 82 50 alid Supervisor CP75 Enter Password CP150 19200 EDIT ren PARITY Logout Supervi CP300 84 invalid Password 85 Supervisor 75 NONE EDIT Password No CP600 jn IF 2ND AND 4TH 75 CP800 SEL KEYS ARE PRESSED CP1600 Password Yes 75 CP2400 Reset Password CP5000 IF CORRECT 86 Enter New Password 75 This screen for 100 400 Only DRYER TYPE 79 86 STD EDIT Supervisor
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13. 1 Press the Acknowledge Alarm button once to silence the optional audible alarm and display the alarm message Pressing the Acknowledge Alarm button once also changes the alarm LED from blinking to solid 2 Find the error message in the diagnostics table of this Troubleshooting section Use the information in the table to resolve the cause of the alarm 3 Note that pressing the Acknowledge Alarm button a second time will clear the alarm If at alarm reappears the cause of the alarm has not been resolved D NOTE When the dryer detects abnormally high temperature in the process heater the dryer immediately shuts down and an error message appears in the display window i drying applications these 1 shutdown alarms are not available Process High Temperature If the process temperature exceeds the process high tem perature setpoint it shuts down the dryer Defaults are set to 385 F 196 C for 20 seconds Process Temperature Loop Break If the process tem perature is outside of the oper ator entered deviation alarm band see Process High Temperature Deviation passive alarm and the process tem perature is not moving towards the setpoint at a rate greater than specified It shuts down the dryer Defaults are set at 3 F 3 C over 20 seconds Troubleshooting Shutdown Alarms If the red Acknowledge Alarm LED is blinking the alarm is a shutdown alarm The dryer will shutdown automatically to preve
14. 2 WARNING Any electrical checks should be performed by a qualified electrician Check regeneration filter and clean and or replace as necessary Check all hoses gaskets doors loaders or other potential areas where leakage may occur Replace any defective hoses or gaskets Verify proper drying temperatures and residence times If off gassing is a con dition of the material being processed contact Conair Parts at 800 458 1960 for the addition of a volatile trap Verify dryer dewpoint readings with a calibrated portable dewpoint meter Replace analog option board or sensor Troubleshooting 6 23 6 24 Troubleshooting Poor Material Drying Troubleshooting Occasionally processing problems that are suspected of being caused by poor dry ing are eventually determined to be the result of other issues in the process setup The information can assist you in determining if your drying system is performing properly However the only way to know definitely if your material is properly dried is to perform moisture analysis of small samples as it leaves the bottom of the hopper or just as it enters the process Conair does not sell moisture analyzing equipment but there are many brands of this equipment available on the market You should also be aware that some processing problems may actually be the result of over drying material Most materials will degrade to some extent if they are exposed to their specified drying t
15. Connecting the Setback RTD tion and connection of the RTD probe 1 Insert the probe in the hopper outlet at the top of the hopper The end of the and or setback probe probe must not touch the walls of the inlet The tip of the probe should be 115 not applicable approximately in the center of the tube Tighten the compression fitting to lock the probe in place 2 Plug the probe s cable into the receptacle labeled setback on the left side of the electrical enclosure Hand tighten the connector Coil any excess cable and secure it with a wire tie Installation 3 7 Select Category Buttons 3 8 Installation Checking for Proper Air Flow This procedure is needed on W 150 400 models if the phase detection option was not ordered with the dryer IMPORTANT This procedure must be performed before the dryer s air hoses are connect ed to the hopper or before loading material into the hopper A CAUTION If the air flow direction is incorrect due to improper phase con nection material from the hopper can be pulled into the process heater causing permanent damage to this equipment 1 Turn on the main power to the dryer Make sure the dryer s disconnect dial is in the ON position This powers up the control and the display lights will illu minate 2 Select the setpoint temperature by pressing the select category button under the setpoint temperature display Once selected the number will flash 3 Set the drying tem
16. From Dryer Main Menu select Setup Other OPT to get to the Dryer Setup Options Information screen 14 page 4 13 Proceed to screen 75 page 4 26 Dewpoint Monitor must be set to Installed and Dewpoint Control set to Not Installed Screen 11 page 4 12 will display the actual dewpoint readout Dewpoint Control NOTE The supervisor s password is necessary Please refer to the Using the Supervisor s Password section on page 4 36 From Dryer Main Menu select Setup Other OPT to get to the Dryer Setup Options Information screen 14 page 4 13 Proceed to screen 75 page 4 26 Dewpoint Control must be set to Installed Dewpoint Monitor can be set to Installed or Not Installed Screen 11 page 4 12 will display the actual dewpoint and the dewpoint setpoint the dryer is to maintain za NOTE Dewpoint control is inactive when the dewpoint setpoint is 40 F 40 C t NOTE For more information concerning specific dewpoint control screens see Control Function Descriptions page 4 11 Operation 4 43 Using the Setback Feature The DC 2 comes standard with setback installed but disabled You can choose to set the mode to Off Temperature or Manual On Refer to the Control Function Descriptions later in this section for more detailed information This feature is designed to save you money on energy costs and help to kee
17. SCREEN 17 This screen shows the total run time in functi iated with hours the dryer has been running since it inca TOTAL RUN HOURS was new If the control board is changed the ic heater 1 not 1250 during the life of the dryer this timer will 2 centra start over dryer configurations SCREEN 18 MDC Option This screen shows the status of the convey iControl function ing blower It will display whether the iavailable for MDC o oe off SCREEN 19 MDC Option This screen shows the time delay setting for the conveying blower on the MDC This is the minimum time the MDC will wait before starting another load cycle o s ims This is the CFM Monitor screen It dis plays the Process CFM The Process CFM is measured by a differential pressure transducer across the inlet and the outlet of the process blower The CFM Monitor option must be installed see screen 75 for this to appear SCREEN 21 A Aftercooler Flow This screen shows if the aftercooler flow Control Option control option is enabled If it is disabled there will be no setpoint for the Return Air Temperature screen 5 The aftercooler flow control option must be installed see screen 75 for this to appear Operation 4 15 amp NOTE Screens labeled 75 in 4 16 the display screen flow chart on page 4 9 are various option installation screens Operation Control Function Screen
18. 2 Insert the main power wire through the knockout in the side of the enclosure or the rear of the dryer The dryer s electrical wire connection location was a factory option and may be connected through the front or the rear of the dryer Secure the wire with an appropriate strain relief IMPORTANT Always refer to the wiring diagrams that came with your dryer before making electrical connections 3 Connect the power wires to the three terminals at the top of the power disconnect 4 Connect the ground wire to the ground lug as shown in the photo 3 6 Installation Connecting the Process RTD Probe The process RTD probe monitors the temperature of the drying air as it enters the hopper If the probe is not installed correctly temperature readings will be inaccurate 1 Insert the probe at the inlet to the hopper The end of the probe must not touch the walls of the inlet The tip of the probe should be approximately in the cen ter of the tube Tighten the compression fit ting to lock the probe in place 2 Plug the probe s cable into the E receptacle Ei W labeled process 5 on the left side of Ei the electrical enclosure Hand Central Process RTD nector Coil any 1a central dryer moni excess cable and toring the drying air secure it with a i temperature is not wire tie necessary since there is no process heater the system 1 Therefore installa
19. 4 2 W Series Dryer control 4 3 Control function flow charts 4 3 How to navigate the menu 4 3 Control function descriptions 4 11 To start drying e RR Rte Rs 4 37 TO STOP AMINO etae hr Rt eate 4 38 How to use the supervisor s password 4 39 Using the auto start 4 41 Setting high setpoint 4 42 Using dewpoint 4 43 Using the setback function 4 44 Setback feature guidelines 4 45 5 1 Maintenance Preventative maintenance checklist 5 2 Checking a 5 3 Cleaning the hopper e406 eed ae ees 5 5 Cleaning the process 5 6 Cleaning the regeneration 5 8 Cleaning the aftercooler 5 10 Cleaning the precooler 5 5 12 Cleaning the volatile trap on the demister 5 12 Inspecting hoses and 5 5 12 ii Table of Contents 6 1 Troubleshooting Before beginhif sus
20. 6 Select the OK button once you have modified your input field size to match the number of bytes shown in Parameter 7 Since the actual data size being used differs from the maximum possible data size you will get an error message noting this Click the button to keep the data size you have entered 7 Once the I O parameters have been modified the gateway may be mapped to your desired I O area using the Input tab Depending on whether your controller is 16 bit Allen Bradley Micrologix or 32 bit Allen Bradley Controllogix the data may transfer either as individual words 16 bit or two parameter words may be combined into a DINT 32 bit All parameters should now be accessible from the programmable logic controller PLC Configuring the DeviceNet Software Explicitly Writing to the Gateway As discussed above the information from the Common Controls Systems can be set up to be read directly as inputs in a PLC system In order to write data to the gateway it must be written in a DeviceNet Explicit message The method was cho sen to ensure that data is written once only when the PLC decides it should be written This reduces bandwidth on the network and ensures that the data is sent only when it is required Note that parameters 530 to 539 are set up as the registers to write to the common controls devices Please see your DeviceNet system provider s information on using explicit messaging for more details DeviceNet Comm
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23. Alarm High current not supported Bit13 Alarm Low current not supported Bit14 Alarm Phase Bit15 Not used Select NA Poll 20h 42h continued Supported Dryer SPI Commands continued 8 Status Machine 2 This word shows the status of the Dryer itself with each bit showing a particular condition The bits are defined as follows Processing dryer running Bit1 Alarm System any alarm that indicates a problem that may affect the drying operation Bit2 Alarm Process any alarm that indicates a problem with the process itself Bit3 Alarm Machine any alarm that indicates a problem with the dryer itself Bit4 Fault Sensor Bit5 Fault Calibration Bit6 Reserved Bit7 Reserved Bit8 Reserved Bit9 Reserved Bit10 Reserved Bit11 Reserved Bit12 Reserved Bit13 Reserved Bit14 Reserved Bit15 Reserved Select NA Poll 20h 44h continued SPI Communications D 7 D 8 SPI Communications Supported Dryer SPI Commands continued 9 Mode Machine This is used to start stop the dryer acknowledge alarms and observe the run status Bit0 Start Stop 1 running or start 0 stop or stopped Acknowledge Alarms Select 20h 49h Poll 20h 48h 10 Temperature To Process This is the actual the actual process drying temperature controlled by the dryer Select NA Poll 20h 70h 11 Temperature From Process This is the actual t
24. Check the process air hose for secure connections straighten any blocked or kinked hose Clean and or change the return air filter Check the RTD plug connections and make any necessary repairs Check the plug connection and tighten if needed Replace the return air RTD Replace the control board Raise the sensor to a higher lower posi tion on the bracket Adjust the sensitivity of the sensor Check for material in the hopper Make sure the slidegate is not closed Increase the load time setpoint or short en the delay time continued Passive Alarms If the amber Acknowledge Alarm LED is blinking the alarm is a passive alarm The dryer continues to operate but this problem could prevent correct drying of your material Note that once the Acknowledge Alarm button is pressed once the blinking amber LED becomes solid NOTE Passive alarms can be configured as shutdown alarms see the previous Shut down Alarms section See page 4 26 screen 62 for instructions Problem Machine Loader Conveying Demand MDC Option cont The demand sensor located at the material receiver has not been satisfied after three consecutive attempts Hopper Loader Conveying Demand MDC Option The demand sensor located at the material receiver has not been satisfied after three attempts Possible cause Conveying blower is not coming on The conveying filter is clogged Hoses have come off or are loose
25. DIAGNOSTIC 1 0 DIGITAL o o Q 2 gt m m tri tri 2 2 a START DIGITAL 1 0 DIAGNOSTICS OFF SCREEN 98 PROCESS BLOWER ON OFF JOG SCREEN 99 PROC OPEN Function This is the Diagnostic I O screen It can be found by pressing the Select Category but ton under the word I O on the Dryer Diagnostics screen 91 By pressing the Select Category button under Digital the user can access the digital outputs screen 98 and view the status of the digital inputs screen 99 The analog diagnostic I O function is not used This screen is used to enter the diagnostic mode where outputs can be turned on screen 98 Note that the dryer MUST NOT BE running to enter diagnostics This is an example of one of the digital outputs that can be manually energized All screens in this section only work when the dryer is not running and is in stand by The outputs can be turned on turned off or energized for a 3 second jog auto matically turned on for 3 seconds then turned off The process and regeneration heaters can only be jogged for 3 seconds and the index motor if jogged will rotate the wheel for 3 seconds If the stop button is pressed at any time during this testing the output will stop immediately This is an example of one of the digital Inputs screens This will show if the input is open or closed Operation 4 35 4 36 Operation Control Function Descriptions continued Screen
26. How to use the lockout device 1 6 2 1 Description What is the Carousel Plus W Series Dryer 2 2 Typical applications 2 2 How it works 2 4 Specifications Carousel Plus W Series 2 6 Carousel Plus W Series Dryer 5 2 7 3 1 Installation Unpacking the boxes 3 2 Preparing for 3 4 Positioning the dryer on the floor 3 5 Removing the cable tie from the desiccant wheel 3 5 Connecting the main power 3 6 Connecting the RTD probe 3 7 Connecting the setback RTD probe 3 7 Checking for proper air flow 3 8 Connecting the air 8 3 11 Connecting the dryer to the hopper 3 11 Connecting air hose 3 12 Table of Contents i Connecting the aftercooler 3 13 Mounting a loader the hopper 3 14 Testing the installation 3 14 Using communications Optional 3 16 4 1 Operation The W Series Dryer control panel 2
27. The bits are defined as follows Bit 0 Processing dryer running Bit1 Alarm System any alarm that indicates a problem that may affect the dry ing operation Bit3 Alarm Machine any alarm that indicates a problem with the dryer itself Bit4 Alarm High Temperature Deviation Bit5 Alarm Low Temperature Deviation Bit6 Reserved Bit7 Reserved Bit8 Alarm Filter clogged Bit9 Alarm Low flow Bit10 Alarm High Dewpoint Bit11 Reserved Bit12 Reserved Bit13 Reserved Bit14 Temperature out of band deviation Bit15 Not used Select NA Poll 20h 40h continued SPI Communications D 5 D 6 SPI Communications Supported Dryer SPI Commands continued 7 Status Machine 1 Indicates that the status of the dryer itself with each bit showing a particular condition The bits are defined as follows Processing dryer running Bit1 Alarm System any alarm that indicates a problem that may affect the drying operation Bit2 Alarm Process any alarm that indicates a problem with the process itself Bit3 Alarm Machine any alarm that indicates a problem with the dryer itself Bit4 Alarm High Temperature any temperature input Bit5 Alarm Low Temperature any temperature input Bit6 Reserved Bit7 Reserved Bit8 Reserved Bit9 Alarm Low flow Bit10 Alarm High voltage not supported Bit11 Alarm Low voltage not supported Bit12
28. able setpoint is dependent on the temperature of the return air coming back to the dryer As the return air temperature climbs the temperature that the dryer is capa ble of controlling at climbs For example if the return air to the dryer is 110 F 43 C the dryer may not be able to control at a Setback Temperature Process setpoint below 150 155 66 68 C NOTE Selecting too low of a setpoint for Screen 26 may result in nuisance Process Temperature Loop Break alarms if the dryer is not able to achieve this setpoint SECTION Maintenance Preventative maintenance checklist 5 2 Checking the dewpoint 5 3 Cleaning the hopper 150 200 5 5 Cleaning the process filfer 5 6 Cleaning the regeneration filter 5 8 Cleaning the aftercooler coils 5 10 Cleaning the precooler coils 5 12 Cleaning the volatile trap on the demister 5 12 Inspecting hoses and gaskets 5 12 E e 2 1 D Maintenance 5 1 Preventative Maintenance Checklist Routine maintenance will ensure optimum operation and performance of the W Dryer We recommend the following maintenance schedule and tasks e Whenever you change materials O Drain and clean the hopper e Weekly or as often as needed CJ Clean or replace the process and regeneration filters You may need to clean filters more often than weekly Frequency depends on
29. from the control panel to gain access to the process heater Process 3 W 200 400 models Open Heater the electrical enclosure Refer to the wiring diagram of the dryer to identify the process heater wires and or trace the wires from the process heater tube into the control box Disconnect the wires from the terminal strip and solid state relays Once disconnected pull the wires out of the control cabinet and separate them from the wiring harness along the dryer frame The high temperature switch wires can be disconnected at the quick disconnect near the heater tube Central central dryer there is no process heater in the sys item Therefore replac ing the process heater is W 150 models Disconnect the heater wires and high temperature switch wires at the quick disconnects near the heater tube Wires W 200 400 4 Remove the insulation from the process heater tube by cutting the insu lation in a straight line from top to bottom 5 Remove the hose and clamp at the bottom of the heater tube 6 34 Troubleshooting continued Replacing the Heaters Process Heater Tube continued 6 While supporting the heater tube remove the hose and clamp at the top of the heater tube 7 Loosen the clamp holding the bot tom of the heater tube to the sup port bracket and remove the heater tube from the dryer Insulation 8 Compare the markings on the out side of the heater tube to ensure the
30. such as filters liner plates etc Conair s guarantee is limited to replacing at our option the part or parts determined by us to be defective after examination The customer assumes the cost of transportation of the part or parts to and from the factory Performance Warranty Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the equipment or as detailed in engineering specifica tions provided the equipment is applied installed operated and maintained in the recommended manner as outlined in our quotation or specifications Should performance not meet warranted levels Conair at its discretion will exercise one of the following options Inspect the equipment and perform alterations or adjustments to satisfy performance claims Charges for such inspections and corrections will be waived unless failure to meet warranty is due to misapplication improper installation poor maintenance practices or improper operation Replace the original equipment with other Conair equipment that will meet original performance claims at no extra cost to the customer Refund the invoiced cost to the customer Credit is subject to prior notice by the customer at which time a Return Goods Authorization Number RGA will be issued by Conair s Service Department Returned equipment must be well crated and in proper operating condition including all parts Returns must be prepaid P
31. 27 Process Screen 26 160 71 C 120 F 49 C 150 F 66 C 240 116 C 135 F 57 C 180 F 82 C 300 149 160 F 71 C 200 F 93 C 340 171 180 F 82 C 220 F 104 C Operation 4 45 4 46 Operation Setback Feature Guidelines continues A recommended way to determine the Setback Return Temperature setpoint is to monitor the actual temperature of this function during pre drying of your material at start up and while running at your normal maximum material throughput The Setback Return Temperature setpoint should be set 10 to 20 above maximum temperature noted in these situations The Setback Temperature Process setpoint you select should be adequate to reduce the temperature significantly enough to prevent over drying of your materi al However keep in mind that the cooler the temperature selected the longer it will take for the material to heat back up to its proper drying temperature once the dryer comes out of Setback mode When drying at low temperatures for example 160 180 F 71 82 C you are able to setback the temperature only a small amount The Setback Temperature Process should not be set lower than 150 F 66 even if the control will allow it It is very likely the dryer will not be able to achieve low temperatures without adding additional cooling to the process air circuit The maximum achiev
32. 3 9 Checking for Proper Air FIOW continued t INSTALLATION NOTE Models 150 200 300 and 400 These models use a three phase process blower If the dryer shuts down and a Process Loop Break shutdown alarm is indicated within the first few minutes of operation check for proper air flow or check the Process RTD for proper installation If the air flow is reversed the process blower is turning in the wrong direc tion Turn off and lock out the main power source Open the electrical enclosure and reverse any two leads connecting the main power supply to the dryer A WARNING All wiring disconnects and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region Always maintain a safe ground Do not operate the equip ment at power levels other than what is specified on the machine serial tag and data plate 3 10 Installation Connecting the Air Hoses Using the two flexible hoses provided connect the inlets and outlets of the dry ing hopper to the dryer If you have positioned the dryer on the floor or mount ed it to an optional floor stand make sure the dryer is located as close as possi ble to the hopper to reduce heat loss 10 ft 3 05 m of hose supplied NOTE If you have ordered an insulated hose it should be installed between the dryer outlet and the hopper inlet see step 2 1 Attach one hose from the return air inlet of the dryer to the return
33. 8 00 AM 5 00 PM After hours emergency service is available at the same phone number From outside the United States call 814 437 6861 You can commission Conair service personnel to provide on site service by con tacting the Customer Service Department Before You Call If you do have a problem please complete the following checklist before calling Conair CJ Make sure you have all model control type and serial numbers from the serial tag and parts list numbers for your particular equipment Service personnel will need this information to assist you g Make sure power is supplied to the equipment 7 Make sure that all connectors and wires within and between control systems and related components have been installed correctly Check the Troubleshooting guide of this manual for a solution Thoroughly examine the instruction manual s for associated equipment especial ly controls Each manual may have its own Troubleshooting guide to help you 1 Check that the equipment has been operated as described in this manual 3 Check accompanying schematic drawings for information on special considerations Equipment Guarantee Conair guarantees the machinery and equipment on this order for a period as defined in the quotation from date of shipment against defects in material and workmanship under the normal use and service for which it was recommended except for parts that are typically replaced after normal usage
34. Communications What is SPI communications Installing the SPI communication hardware Configuring the SPI communication software Supporting dryer SPI Appendix Modbus RS 232 485 serial communications parameters DC 2 control parameters used on dryers with DC 2 controls DC plus control parameters used on ResinWorks or Hopper Temperature Controllers HTC Related drawings oeaoedd auahatanga Vaud dane ea Modbus TCP IP communications parameters SECTION Modbus Communications Description of Modbus Communications Installing the Modbus Communication Hardware Using the Modbus Parameter List A 2 Modbus Communications A 1 A 2 Modbus Communications Description of Modbus Communications The common controls series of products from Conair use standard Modbus com munications protocol to allow the user to access the control boards for supervisory type functions For example you may want to display the drying temperature for all hoppers in a facility in one central location By connecting all the dryers to a central computer the temperatures and setpoints can be displayed in one location using a standard SCADA software program such as Wonderware or RS View Depending on the particular common controls board the Modbus
35. MDC Your dryer should be configured from the facto ry However if the control were changed from one machine to another the control may need to be reconfigured With the proper password see page 4 32 screen 85 the dryer type can be changed by pressing the Select Category button under the word Edit The ENTER key must be pressed to lock in the selection This screen defines the voltage and fre quency at which the dryer will be running This setting should match the electrical label on the side of the control box Your dryer should be configured from the facto ry However if the control were changed to run on a different voltage this screen may need to be reconfigured With the proper password see page 4 32 screen 85 the voltage frequency can be changed by pressing the Select Category button under the word Edit The ENTER key must be pressed to lock in the selection Control Function Descriptions continuea Screen PROTOCOL DEVICENET EDIT SCREEN 82 Communications SLAVE ID 1 EDIT SCREEN 83 Communications BAUD RATE 9600 EDIT SCREEN 84 Communications PARITY NONE EDIT Function This screen shows the communications protocol DeviceNet SPI Modbus and Ethernet are available This is set at the factory If adding to an existing dryer the communications protocol can be changed with the proper password see page 4 32 screen 85 This screen shows the Slave ID number The ID number can be
36. air outlet from the top of the hop per Return Air Inlet Dry 2 Attach one hose from the deliv Delivery ery air outlet of the dryer to the Air delivery air inlet of the hopper 3 Secure hoses with clamps The hose clamp should be secured at least 1 4 in 0 64 cm from the end of the inlet or outlet tube Connecting the Dryer to the Hopper W 150 has a 2 1 2 inch 63 5 mm inlet and outlet hose connections W 200 W 300 and W 400 have a 5 inch 127 mm inlet and outlet hose connec tions If your dryer hose connection and your hopper hose connection are not the same size you will need a hose adapter Contact Conair Parts 1 800 458 1960 Q NOTE Do not allow the flexible hoses to kink or crimp NOTE Water to cooler should be turned off when the dryer is not running to prevent condensation Installation 3 11 3 e A D Et o ES Connecting Air Hose Adapters Depending on the hopper you purchased you may need to install an air hose adapter to connect the hopper to your dryer To connect the air hose adapter 1 Place high temperature gasket half way down over the dryer outlet to the hopper 2 Place hose adapter inside high temperature gasket flush to the dryer outlet secure with pressure clamp C Pressure clamp 3 Attach the hopper inlet hose over the adapter secure with clamp 3 12 Installation Connecting the Aftercooler The aftercooler
37. air through the regeneration filter into the dryer s regeneration heater The air is heated to 350 F 177 C before it is pushed into the wet section of the wheel The hot air purges moisture from the desiccant The moist air is blown out the exhaust at the back of the dryer The Cooling Cycle Regenerated desiccant must be cooled before it rotates back into the process cycle The process blower pushes a small amount of air through the cooling section of the desiccant wheel The cooling air then passes through the aftercooler and repeats the circuit How It Works continued 96 REGENERATION BLOWER HIGH TEMP SHUTOFF PROCESS HEATER BOX REGENERATION 2 AIR FILTER ee TS HIGH TEMP SHUTOFF REGENERATION HEATER REGENERATION RTD DESICCANT WHEEL RETURN AIR FILTER 9g PROCESS COOLING ll REGENERATION BLOWER DRYER OPTIONS 1 PROCESS CFM MONITOR 4 PROCESS FILTER STATUS 6 PHASE ROTATION PROTECTION 2 SETBACK TEMPERATURE 5 CURRENT METER 7 PRECOOLER 3 DEWPOINT MONITOR CONTROL Standard on DC 2 Central Description 2 5 i oO n gt gt Specifications Carousel Plus W Series Dryers Performance characteristics with full hopper Air flow SCFM 75 100 150 200 Air flow 250 F 101 134 201 268 Drying temperature All models 100 375 F 38 1
38. an additional Ethernet module is soldered on to the main control board of the dryer This Ethernet module can not be added to an existing dryer control board Adding the option to an existing dryer will require replacing the main control board with a new board containing the Ethernet module Depending on the revision level and display type the display beard may need to be replaced For easier set up a short length of Ethernet cable is run from the connector on the control board to an Ethernet receptacle mounted on the control enclosure This allows you to plug into the Ethernet port without having to open the control enclosure Installing the Ethernet Communication Hardware The control boards are shipped with a default Internet Protocol IP address of 010 001 010 254 In order for your dryer to communicate with your network this default IP address should be changed to match the network structure used in your plant Changing the IP address is accomplished through the DC 2 operator inter face display board To change the IP address 1 Enter the supervisory level password 0210 See your dryer manual for directions if necessary 2 Once the password has been entered go to Setup Other Comm 3 When the Comm menu is displayed scroll down through the list until IP Addr Part 1 is displayed This is the first octet first three numbers of the IP address For example if the IP address is 192 168 0 100 192 would be shown
39. and the control circuit board The second LED labeled DeviceNet on the gateways with the enclosure display the status of the DeviceNet communications 1 Controller Status LED between dip switches Color State Indication None Off No power Red Solid No controllers online Red Flashing Illegal Date error Green Solid Normal operation All controllers online Green Flashing or more controllers offline or not present 2 DeviceNet Status LED Color State Indication None Off No power Red Solid Unrecoverable DeviceNet fault Red Flashing Output error or configuration error Green Solid Normal operation Green Flashing Device is in idle mode or not allocated to a master Configuring the DeviceNet Software Installing the EDS Files There are multiple EDS electronic date sheet files associated with the gateway depending on how many controllers are attached to a gateway The files are named based on the number of controllers i e an EDS file for a gateway with three con trollers attached is named 3Conair EDS Choose the appropriate file for your application and install it using your DeviceNet network s EDS installer options Once the EDS files are installed they will be shown under the Conair Common Control heading in the EDS file manager If you install more than one of the EDS files the files will all be named Conair Common Control with the hexadecimal designator to differentiate the different files By op
40. been confirmed as accurate you can now program in your new or additional data NOTE The list of parameters that may be read and written to via Modbus TCP IP is extensive Some of these parameters are naturally a part of the operation of the machine and others may be obscure configuration settings The parameter list in Appendix A page A 4 includes a column with a recommendation as to whether the parameter should be accessed by a user program Addresses that are not consecutive indicate that there are other parameters present which are not recommended for usage by the user Ethernet Communications B 3 B 4 Ethernet Communications SECTION DeviceNet Communications Description of DeviceNet Communication C 2 Installing the DeviceNet Communication Hardware C 2 Using the DeviceNet Communication Dip switch 1 lt C 2 Using the LED Status Indicators C 5 Configuring the DeviceNet Software Installing the EDS Files C 5 EDS File Parameter List Configuration Options C 6 Adding the Gateway to the Scan List C 8 Explicitly Writing to the Gateway C 11 Gateway Parameter List C 12 DeviceNet Communications C 1 TEST VESTE TO C 2 DeviceNet Communications Description of DeviceNet Communications The Conair Common Control board set allows you to add DeviceNet communica tions for information interchange with PLC systems or higher level
41. but this problem could prevent correct drying of your material Note that once the Acknowledge Alarm button is pressed once the blinking amber LED becomes solid NOTE Passive alarms be configured as shutdown alarms see the previous Shut down Alarms section See page 4 26 screen 62 for instructions Problem Process Filter Clogged Option The process filter differential pressure switch is tripped Low Option The CEM calculated from the process blower differential pressure is less than the set point 1 CFM for 30 seconds see screen 66 entered on the operator display Return Air Temperature RTD Integrity The dryer continues to run with a passive alarm Machine Loader Conveying Demand MDC Option The demand sensor located at the material receiver has not been satisfied after three consecutive attempts Troubleshooting Possible cause The process air filter is clogged The air hoses are loose blocked or kinked The return air filter needs cleaned There is a loose connection in the wiring leading to the RTD The connection of the RTD plug on the control board is loose The return air RTD has failed The control board has failed Sensor is out of position The sensor is not adjusted properly No material is being conveyed The conveying load time is too short or the delay time is too long Solution Remove and clean or replace the process air filter
42. for the material You can also set the high and low limits equal to the process temperature to prevent accidental or unauthorized changes to the setting during operation 1 Turn on the main power to the dryer 2 Use the Scroll keys to access the SETUP PROC PROC and PROC screens under the Dryer Main Menu screen 12 SCREEN 36 SCREEN 37 DRYER SETUP SETUP PROCESS PROC DISP OTHER PROC REGEN OTHER SCREEN 38 SCREEN 14 SETUP PROCESS DRYER PROCESS PROC PROPID RETPID SETUP SCREEN 3 Then select the PROCESS TEMPERATURE RANGE screen SCREEN 39 PROCESS TEMPERATURE RANGE 100 F 450 F 4 The PROCESS TEMPERATURE RANGE screen shows the allowable temperature range for setpoint temperatures With the supervisory password this range can be narrowed See page 4 32 screen 85 By NOTE Conair is not responsible for damage caused by excessively high drying set points that are not in accordance with your drying material recommendations Using Dewpoint Control Your dryer is equipped with a dewpoint monitor and dewpoint control features You can choose to use it as a monitor only device or to maintain a steady dewpoint that you select with the dewpoint control Dewpoint control will vary the regeneration air temperature to condition the desiccant to the level necessary to maintain the desired dewpoint Dewpoint Monitor NOTE The supervisor s password is necessary Please refer to the Using the Supervisor s Password section on page 4 36
43. keep them working efficiently See Appendix C for details Cleaning the Volatile Trap on the Demister If you have the optional volatile trap you need to clean the trap to keep it working efficiently See Appendix D for details Inspecting Hoses and Gaskets Loose or damaged hoses and gaskets can allow moisture to seep into the closed loop drying system 1 Follow the hose routing of all the hoses within the dryer and inspect all hoses clamps fittings and gaskets 2 Tighten any loose hose clamps or fittings 3 Replace worn or damaged hoses and gaskets SECTION Troubleshooting Before 6 2 few words of caution 6 3 DIAGNOSTICS How to identify the cause of a problem 6 4 Shutdown alarms 6 5 Passive COINS 6 13 Dewpoint troubleshooting 6 23 Poor material drying troubleshooting 6 24 REPAIR Replacing 6 29 Checking heater solid state relays 6 30 Checking or replacing temperature sensors 6 31 Replacing the heaters cu 4 22 20 gt Regeneration heater tube 6 32 Process heater tube ere 6 34 Replacing the desiccant wheel 6 36 Replacing the desiccant wheel motor 6 37 Troubleshooting 6 1 Before Beginning NOTE Use of test You can avoid most problems by following t
44. of the Alarm Action screens With the proper password see page 4 32 screen 85 some alarms can be turned on or off by either pressing the Select Category button under the word Edit or by pressing the Select Category button under the word On or Off Once the word begins to blink the or keys will change the setting The ENTER key must be pressed to lock in the value The same sequence works for the Pass or Shut down Pass or Passive means the alarm will not shut the dryer down but the alarm will be logged in the Dryer Diagnostics Alarm Log A Shut means Shutdown in which case the dryer would shutdown if the alarm occurs This is an example of an Alarm Setup screen that has a minimum or maximum temperature With the proper password see page 4 32 screen 85 refer to pass word the temperature setpoint can be changed as well as how long the dryer has to stay at that temperature before alarming i When supplied for i central drying appli cations this function 115 not available Operation 4 25 4 26 Operation Control Function Descriptions continued Screen SCREEN 61 PROCESS LOOP BREAK 3 F 20 SEC SCREEN 62 PROCESS TEMP DEV 5 F 5 Sec SCREEN 63 REGEN DIFFERENTIAL 20 F 10 SEC SCREEN 64 REGEN DIFFERENTIAL TIME DELAY 5 MIN SCREEN 65 RETURN AIR ALARMS PASS 150 F SHUT 180 F Function This is an example of an Alarm Setup Loop Break screen When actual tem
45. over 150 F 66 C pers Standard Dryer Features Dewpoint monitor dewpoint control Audible and visual alarm Temperature setback MDC Options models 150 amp 200 only Non dry air conveying Machine loading only Self loading machine and hopper loading Description 2 3 2 4 Description Central precooler if installed where a spreader cone evenly distributes the How It Works The W dryer achieves continuous closed loop drying by passing air simultaneous ly through two heaters and a continuously rotating desiccant wheel THE Process DRviNc CYCLE The process blower pulls moist air from the top of the drying hopper The air passes through the process filter and aftercooler into the desiccant wheel where moisture is removed The now dry air moves through the optional precooler if installed and process heater where it is heated to the drying temperature selected by the operator The hot dry air is delivered to the hopper where a spreader cone evenly distributes the air through the material THE Process DRYING CYCLE The process blower pulls moist air from the top of the drying hopper The air passes through the process filter and aftercooler ithen into the desiccant wheel where moisture is removed The dry air is delivered to the hopper after it passes through the optional air through the material The Regeneration Cycle The regeneration blower pulls
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47. process RTD has failed The control board has failed There is a loose connection in the wiring leading to the RTD The connection of the RTD plug on the control board is loose The regeneration RTD has failed The control board has failed Solution Make sure your material supply system is working properly Ensure water flow to the aftercooler Turn on the water supply or fix any leaks or blockages Clean the aftercooler coils See Maintenance section entitled Cleaning the aftercooler coils Check the connection to the receptacle and tighten if needed Check the RTD plug connection and tighten if needed Check the plug connection and tighten if needed Replace the process RTD Replace the control board Check the RTD plug connection and make the necessary repairs Check the plug connection and tighten if needed Replace the regeneration RTD Replace the control board Troubleshooting 6 7 Shutdown Alarms If the red Acknowledge Alarm LED is blinking the alarm is a shutdown alarm The dryer will shutdown automatically to prevent damage to the equipment or personnel Note that once the Acknowledge Alarm button is pressed once the blinking red LED becomes solid i drying applications these 1 shutdown alarms are not available 6 8 Problem Control Communications Watchdog The display board has lost communica tions with the control board Phase Error Phase Option STD
48. record the model and serial number s of your equipment and the date you received it in the User Guide Our service department uses this infor mation along with the manual number to provide help for the specific equipment you installed Please keep this User Guide and all manuals engineering prints and parts lists together for documentation of your equipment Date Manual Number UGD025 0407 Serial Number s Model Number s See Screens 31 and 32 for Software Version Display Firmware Version Display Menu Version Control Firmware Version NOTE Displayed upon initialization during power up or on a data tag inside the door DISCLAIMER The Conair Group Inc shall not be liable for errors contained in this User Guide or for incidental consequential damages in connection with the furnishing performance or use of this information Conair makes no warranty of any kind with regard to this information including but not limited to the implied warranties of merchantability and fitness for a particular purpose All rights reserved Table of Contents 1 1 Introduction Purpose of the user 1 2 How the guide is organized 1 2 Using the Carousel Plus W Series as a central dryer 1 3 Your responsibilities as a 1 3 ATTENTION Read this so no one gets hurt 1 4
49. sent to the equipment to specify what communication action to take The following list shows the Select and Poll bytes along with a description of the information that may be retrieved from Conair dryers 1 Echo Allows the master to test a piece of equipment by writing 4 bytes of information to the equipment and then reading it back Select 20h 21h Poll 20h 20h 2 Version Read the SPI version from the equipment Select NA Poll 20h 22h 3 Setpoint Process Temperature Sets and retrieves the process temperature setpoint Select 20h 31h Poll 20h 30h 4 Alarm High Temperature Deviation Sets and retrieves the high temperature deviation alarm setpoint Not that in Conair dryers there is actually only devia tion setpoint that is used for both high and low temperature deviation The last value written to either the high or the low will be the value that is used Select 20h 33h Poll 20h 34h 5 Alarm Low Temperature Deviation Sets and retrieves the low temperature deviation alarm setpoint Not that in Conair dryers there is actually only devia tion setpoint that is used for both high and low temperature deviation The last value written to either the high or the low will be the value that is used Select 20h 35h Poll 20h 34h continued Supported Dryer SPI Commands continued 6 Status Process Indicates that the status of the process with each bit showing a particular condition
50. supervisory computer systems The DeviceNet communication is accomplished with a gateway device that converts the Modbus communications already existing on the DC 2 dis play board or the DC control cabinet but may also be purchased with a DIN rail mounted enclosure It is available with RS 232 for the DC 2 control or RS 485 DC control communications capability These instructions assume the user is familiar with basic DeviceNet configuration and use If not please refer to manuals from your DeviceNet provider before attempting to use this function Installing the DeviceNet Communication Hardware The DeviceNet Gateway is designed to mount to three standoffs which are attached to the door of the control cabinet below the main control board Note that the gateway circuit board has two holes to mount the gateway and the board just rests on the third standoff to help stabilize the board Cable 188629 04 connects between the gateway s three pin connector and the control board connector J4 The DeviceNet drop cable is then ran to the five pin connector on the gateway Using the DeviceNet Communication Dip Switch Settings The gateway has two groups of DIP switches for setup The first set of switches labeled S1 on the circuit board or next to the address label on the enclosure is used to configure the address of the gateway on the DeviceNet network and the baud rate used by the gateway for DeviceNet communications The second set of switc
51. 2 screen 85 This screen shows the alarm setpoint for a dewpoint alarm With the proper pass word it can be changed see page 4 32 screen 85 The defaults are 3 F for 180 seconds If the control senses 3 F or high er for 180 seconds the dryer will alarm This is the dewpoint high deviation alarm value With the proper password it can be changed see page 4 32 screen 85 When in dewpoint control if the actual dewpoint goes above the setpoint in screen 67 for the set amount of time the dryer will alarm Dewpoint Deviation High This is the dewpoint low deviation alarm value With the proper password it can be changed see page 4 32 screen 85 When in dewpoint control if the actual dewpoint goes below the setpoint by this value for this amount of time the dryer will alarm Dewpoint Deviation Low Operation 4 27 4 28 Operation Control Function Descriptions continued Screen SCREEN 70 DEWPOINT TIME DELAY SCREEN 71 UNITS STANDARD SCREEN 72 TIME DISPLAY 12 HOUR SCREEN 73 DATE 10 25 2004 MON 5 MIN EDIT TIME 10 33 AM Function This is the amount of time from start up the dryer is allowed to run before the con trol will try to control the dewpoint Five minutes is the default This gives the dryer time to warm up and reach a steady state It can be changed with the proper pass word see page 4 32 screen 85 This screen shows the units the dryer will display It
52. 6 2 few words of caution 6 3 DIAGNOSTICS How to identify the cause problem 6 4 ohu t down alarms x t o o ec es 6 5 Passive ETET 6 13 Dewpoint troubleshoot 6 23 Poor material drying troubleshooting 6 24 REPAIR Replacing 10569 x or cde pta oon eT ee 6 29 Checking heater solid state 6 30 Checking or replacing temperature sensors 6 31 Replacing the heaters Regeneration heater tube 6 32 Process heater fake cake 6 34 Replacing the desiccant 6 36 Replacing the desiccant wheel 6 37 Appendix We re here to help A 1 How to contact customer service A 1 Before YOu seat baka Pes A 1 Equipment guarantee A 2 Performance warranty A 2 Warranty A 2 B Appendix Installing precooler Optional B 1 Table of Contents iii iv Table of Contents C Appendix Cleaning the aftercooler and precooler coils C 1 Appendix Cleaning the Volatile Trap on the
53. 87 will be displayed VALID SUPERVISOR PASSWORD ENTERED You can now make changes to screens where the supervisor s password is required Once the desired parameter has been changed follow the previous steps to go to screen 88 see the flow chart on page 4 4 LOGOUT SUPERVISOR PASSWORD YES Push the Select Category button under No Once it begins to flash push the Adjust Setpoint button to display Yes then push ENTER Push the MENU button to return to the main display NOTE The supervisor s password can be changed by going to screen 89 see page 4 4 for the map of the screens See page 4 33 screen 89 for additional information on changing the supervisory password Using the Auto Start Timer You can set the dryer to start and stop automatically using the Auto Start and Auto Stop functions Supervisor Password is necessary to use this function Programming Auto Start The Auto Start time and date can be programmed using the Auto Start Countdown screen This screen can be accessed under the SETUP PROC and OTHER screens from the Dryer Main screen 12 SCREEN 36 SCREEN 37 Dryer Setup Setup Process Proc Alm Disp Other Proc Regen Other SCREEN 56 MONDAY START TIME ON 8 00 AM Once the Auto Start time and date has been programmed the Auto Start Countdown screen screen 33 will show the amount of time remaining before the dryer will automatically start The LED on the front of the dis
54. 91 C with options dewpoint All models 40 F 40 C Dimensions inches cm A Height 70 4 178 8 Overall width 29 73 7 C Control width 24 61 0 D Depth 51 5 130 8 Control depth 8 20 3 Outlet inlet tube size OD Weight 165 kg Standard Dryer Installed 600 272 660 300 710 322 760 345 Voltage Total Amps 230 V 3 phase 60 Hz 400 V 3 phase 50 Hz 460 V 3 phase 60 Hz 575 V 3 phase 60 Hz Total kilowatts kW BTU min 6 2 353 8 455 11 625 14 800 Water requirements for optional aftercooler or precooler Recommended temperature 45 85 F Water flow gal min liters min 3 11 4 Water connections NPT 3 4 in NPT gt SPECIFICATION NOTES The term SCFM stands for Standard Cubic Feet Per Minute referenced to a pre specified pressure tempera ture and relative humidity In most cases SCFM is referenced to 14 7 PSIA 68 F and 36 relative humidity ACFM stands for Actual Cubic Feet Per Minute and must be supplied with a temperature reference due to the change in air density with temperature Because dryers operate at a relatively low pressure the effects on air den sity are negligible T Dryers running at 50 HZ will have 17 less airflow and a 17 reduction in material throughput Specifications may change without notice Consult a Conair representative for the most current inform
55. CONAIR www conairnet com USER GUIDE UGD025 0407 Carousel Plus Dryer W Series Models 150 200 300 and 400 with DC 2 Controls INTRODUCTION Purpose of the User Guide How the guide is organized Your responsibilities as a user ATTENTION Read this so no one gets hurt How to use the lockout device e DESCRIPTION e What is the W Dryer e Typical applications How it works Specifications W Dryer INSTALLATION Unpacking the boxes Preparing for instal lation e Mounting the dryer and hopper a Processing Machine e Positioning the dryer on the floor Mounting the hop per on the throat Mounting the dryer on the floor stand Hopper on the throat Mounting the dryer and hopper on the mobile floor stand Connecting the main power Checking for proper air flow Connecting the air hose Connecting air hose adapters Connecting water hoses Connecting the RTD probe e Connecting the setback RTD Mounting a loader on the hopper e OPERATION e How it works The W dryer control panel e W dryer control functions Control Function Description e To start drying To stop drying Using the auto start timer Corporate Office 412 312 6000 Instant Access 24 7 Parts and Service 800 458 1960 Parts and Service 814 437 6861 Please record your equipment s model and serial number s and the date you received it in the spaces provided Copyright 2007 The Conair Group It s a good idea to
56. DRYER MAIN MENU PROC REGEN OTHER STAT SETUP DIAG 12 36 SETUP PROCESS 37 SETUP PROCESS 14 OTHER SCREENS AUTOSTART TIMER 55 ENABLED EDIT DISABLED MONDAY START TIME 56 ON 8 00 p RESEN CYCLE TIME 421 5 s o REGEN PROBAND 6 43 REGEN INTERGRAL 44 MONDAY STOP TIME 57 lOFF 800 TUESDAY START TIME 56 JON _ 8 00 TUESDAY STOP TIME 57 r WEDNESDAY START TIME REGEN CALIBRATION 56 lon 8 00 471 ESE DERIVATIVE 45 1 B WEDNESDAY STOP TIME 57 PROCESS DEWPOINT SAMPLERATE 150 SEC 49 PEREN PID RESET 46 OFF 6 00 PM PROCESS DENPONT nce mn THURSDAY STARTTIME 56 oS PROCESS DEWPOINT 54 MS TRIM LOW LIMIT 100F PROCESS DEWPOINT ER DAY M 56 GAIN o B2 PROCESS DEWPOINT ___ 3 RIDA STOR TINE 57 DEAD BAND 1 5 00 SATURDAY START 56 CONTROL RESET 54 31 SATURDAY STOP TME 57 57 571 57g 57h When configured as a central dryer i there is no process heater in the sys 1 1 1 tem Therefore any function associ ated with the process heater is not 1 1 1 1 1 1 1 1 available for central dryer configura tions 57n Central a 70 When the DM II monitor option is purchased these screens will be displayed a 7 Operation 4 7 4 8 i dryer there is no process heater in the system
57. DRYER SETUP PROC ALM DISP OTHER SETUP PROCESS PROC REGN OTHER STANDARD DRYER AND MDC SETUP PROCESS PROC PROPID RETPID 38 SETUP PROCESSHEATER 14 PID VALUE SCREENS wo PRO MPERATUR RANGE 100 450 F 39 PROCESS PID DONE 40 PROCESS PROP BAND 3 AUTOTUNE OFF HEAT COOL 30 F RETURN AIR TEMP 5 PROCESS INTERGAL 44 ACT 120 F SET 120 F HEAT COOL 16 0 6 PROCESS DERIVATIVE 45 HEAT COOL 2 0 PROCESS CYCLE TIME 42 PRECOOLER20 SECS 1 PROC PID RESET 9 HEATICOOL 46 I PROCESS CALIBRATION 10 OFFSET 4 MDC SHUTDOWN ALARM ENABLED EDIT MDC SHUTDOWN 21 N PROCESS DEWPOINT Disable Enable Automatic ACT 47 F SET 40 F 11 BACK MOD OFF 25 TEMPERATURE MANUAL ON ETBACK TEMPERATURE 26 140F SET 140 F RETURN TEMP 140 SET 1402 27 BACK TEMP BAND SET 20 F 28 SETUP AFTERCOOLER lon off VALUE SCREENS 14 if POWER LIM an RET AIR CYCLE TIME 1 LOW 0 HIGH 100 1 ICOOL 20 SECONDS 42 YOLETIM E 8 42 ON J47 HEAT 2 0 SECONDS OFFSET 4 REGEN SETUP REGENERATION 44 SCREENS REGENERATION TEMP 4 ACT 350 F SET 350 F REGEN OUTLET TEMP ACT 280 29 9 REGEN TEMP RANGE 100 F 375 F REGEN PID DONE 4o AUTOTUNE OFF SETUP REGENERATION PID SETUP REGEN HEATER PID VALUE SCREENS REGEN POWER LIMIT 41 LOW 0 HIGH 100 14
58. Demister D 1 Addendum Communication protocols for common controls DC 2 SECTION gt 2 25 c zl 2 Introduction Purpose of the user 1 2 How the guide is organized 1 2 Using the Carousel Plus W Series as a central 1 3 Your responsibilities as user s 1 3 ATTENTION Read this so no one gets hurt 1 4 How to use the lockout device 1 6 Introduction 1 1 1 2 Introduction ue Purpose of the User Guide This User Guide describes the Conair Carousel Plus W Series Dryers and explains step by step how to install operate maintain and repair this equipment Before installing this product please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet You also should review manuals covering associated equipment in your system This review won t take long and it could save you valuable installation and operating time later How the Guide is Organized Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation Symbols within triangles warn of conditions that could be hazardous to users or could damage equipment Read and take precautions before proceeding Numbers indicate tasks or steps to be performed by the user A diamond indicates th
59. E The alarm is not active for the first 5 minutes Possible cause The regeneration heater has failed The regeneration RTD is loose or has fallen out The regeneration blower is not running The output on the control board has failed or the fuse is blown Defective dewpoint sensor The hose or wiring connections to the sensor block are loose or have fallen off Poor regeneration air flow The desiccant wheel may be contaminated Desiccant wheel not turning Leaks in the process air stream down Alarms section See page 4 26 screen 62 for instructions Solution Check the heater fuses and resistance across each leg of the process heater Check the regeneration RTD and tighten if needed Correct the cause of the non functioning blower Replace the control board or fuse Replace the sensor Check wiring and hose connections to the sensor re secure if needed Remove the air flow restrictions dirty filters etc Check the desiccant for contamination replace if needed Install plasticizer volatile trap for severe situations Replace the desiccant wheel See Troubleshooting section entitled Replacing the desiccant wheel See Troubleshooting section entitled Passive alarms Wheel rotation failure Check for worn or lose hoses Troubleshooting 6 15 6 16 Passive Alarms If the amber Acknowledge Alarm LED is blinking the alarm is a passive alarm The dryer continues to operate
60. ET 40 F ACT 163 F i DM T1 BOTTOM 12 ACT 165 F 108 5 DRYER MAIN MENU STAT SETUP DIAG amp NOTE If you have purchased the DM II drying monitor option see the DM II Appendix for information pertaining to its operation i When the DM II monitor option is purchased i these screens will be displayed central dryer there is no process heater in the i system Therefore any function associated with the process heater is not 1available for central dryer configurations 4 4 Operation CENTRAL DRYER IDRYER PROCESS STATUS SCREENS x RETURN AIR TEMP ACT 120 F SET 120 F a TOTAL RUN HOURS 17 1250 DISABLED 21 FLOW ON 23 PROCESS DEWPOINT 47 F SET 100 F PROCESS DEWPOINT AVERAGE 55 i central dryer there is no process heater in the system Therefore function associated with the process heater is not 1 available for central dryer configurations DRYER MAIN MENU STAT SETUP _DIAG DRYER STATUS PROC REGEN OTHER 13 STANDARD DRYER MDC DRYER PROCESS 14 STATUS SCREENS DRYER REGEN STATUS SCREENS PROCESS TEMPERATURE REGENERATIONTEMP ACT 325 SET 325 F ACT 350 F_ SET 350 F REGEN OUTLETTEMP 5 280 REGEN HEATER 15 OUTPUT 68 15 RETURN AIR TEMP ACT 120 F SET 120 F PROCESS HEATER OUTPUT 100 TOTAL RUN HOURS 1250 eog
61. GH TEMP 95 ACT 425 F SET 425 F 93 5 0 P 0 WHEEL MOTOR 98 OFF REGEN OUTLET TEMP REGEN LOOP BREAK 95 AET dud 93 8 0 0 PROCHI TEMP SWITCH 99 OPEN pame js prese OUTPUT 68 REGNHITEMPSWITCH gg REGEN TEMP DEVIATION 95 SEEN 5 0 0 SS 93 FILTER CHECK SWITCH 99 REGEN LOW TEMP 95 OPEN S 0 0 CLOSED Ere os oo 5 0 CLOSED m ______ ENT os WHEEL ROTATION FAILURE REGEN OUTLET RTD CLOSED 93 95 e RETURN AIR HIGH TEMP 95 RET AIR MID HI TEMP 5 0 0 95 3 P 0 5 0 5 0 PROCESS PROT HIGH PROCESS DIFFERENTIAL 95 8 0 PROCESS PROT RTD 8 0 95 Central PROCESS BLOWER OVERLOAD 5 0 95 Wm numm eee m 95 When configured as a Ere mE central dryer there is asia 95 no process heater in the l system Therefore any 1 1 function associated with ae 1 the process heater is not uos 1 1 available for central EGRESS os 1 8 dryer configurations 1 1 __ 95 pem 4 10 Operation Control Function Descriptions Screen SCREEN 1 CONAIR CV2 21 00 SCREEN 2 07 22 03 D100 DV2 21 00 MONDAY 07 59 AM Function Once power is turned on this screen is displayed for 3 seconds It shows CONAIR and the dryer type on the first line and the control program version and display program version on the second line Once power is t
62. It is measured at the lower right corner of the control board This is the Dryer Setup screen It can be found by pressing the Select Category but ton under the word Setup on the Main Menu screen 12 By pressing the Select Category buttons under the titles the user can select to see setup information for Process Alarms Display or Other This is the Setup Process screen It can be found by pressing the Select Category but ton under the word Proc on the Dryer Setup screen 36 By pressing the Select Category buttons under the titles the user can select to see setup information for Process Regeneration or Other This is the second Setup Process screen It can be found by pressing the Select Category button under the word Proc on the Setup Process screen 37 By press ing the Select Category buttons under the titles the user can select to see setup infor mation for Process Process PID or Return Air PID if the optional aftercooler flow control is installed Note When config ured as a central dryer you will not see the process PROPID This screen shows the allowable tempera ture range for setpoint temperatures With the proper password see page 4 32 screen 85 this range can be narrowed Control Function Screen SCREEN 40 PROCESS PID DONE AUTOTUNE OFF Descriptions continued Function Before performing an autotune set the set point to the desired temperature you would like the control to autotune t
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64. NOTE In the flow charts of the display screens that follow this page the grey shaded screens denote optional functions If the options were not purchased with the dryer those screens will not appear Most options can be purchased and installed in the field How to Navigate the Menu Tree To scroll through main menu use scroll buttons Next Previous Push Menu to access Dryer Main Menu To access the Status Setup Diagnostic and Password screens use the select category buttons under the digital read out and then the scroll buttons Next Previous to scroll through the parameter lists Menu Button Select Category Buttons Scroll Buttons Operation 4 3 i 5 POWER ON CONAIR CP100 CV00 06 2 _DV00 09 8 DELAY MONDAY 7 22 2003 07 59 AM 3 SEI STD DRYER PROCESS TEMPERATURE Act 140 F 140 ae SS REGENERATION TEMP 350 F SET 350 4 2 DELAY Central Dryer REGENERATION TEMP ACT 425 F SET 425 F RETURN AIR TEMP RETURN AIR TEMP 5 ACT 120 F SET 120 F ACT 120 F SET 120 F PROCESS DEWPOINT MDC HOPPER LOADER MDC ACT ATE SET AGE MDC HOPPER LOADER AND RATIO pepe e P i ___ 150 F 103 ifomts PRESS MENU 155 F 194 KEY H pw T4 158 105 PROCESS DEWPOINT 11 Hacrieor 109 ACT S
65. Password Enter Now P d 76 CENTRAL Reset to Default ae 90 1 HOPPER MDC IF INCORRECT New Supervisor Pw Is 77 1111 2 02 Unknown Password APPEARS FOR 3 SECONDS 3 SECONDS Voltage FREQ lao 1 iz T 240V 60 HZ 02 02 1 i dryer there is no process i heater in the system Therefore any function asso ciated with the process heater 15 not available for central i dryer configurations 1 When the DM II monitor t option is purchased these i screens will be displayed Operation 4 9 DRYER MAIN MENU ISTAT_SETUP DIAG 12 Dryer Diagnostic ALRM HIST 91 KEEP 40 SHOWN DIAGNOSTIC EVENTS 14 ALRMS ANALOG DIGITAL 96 LAST 40 ALARMS 00 5 RTD 92 01 31 00 09 24 INFO SNAPSHOT OF INFO FOR EACH ALARM DRYER DIAGNOSTIC 14 Activated For DOWN 10 3 Minutes 93 EVENT FREQ SCREENS START DIGITAL VO 97 OR UP PROCESS HIGH TEMP 95 DIAGNOSTICS OFF ARROW PROCESS TEMP 93 5 0 KEY 325 F SET 325 F PROCESS BLOWER 98 PROCESS LOOP BREAK 95 ON OFF JOG PROCESS HEATER 5 0 93 01 P REGEN DEV 92 OUTPUT 68 PROG TEMP DEVIATION REGEN BLOWER 98 2 1100 03 45 INFO 8 0 0 95 OFF JOG PRECOOLER 02 P REGEN DEV 92 93 PROCESS HEAT BOX HI PROCESS HEATER 98 3 1 00 03 25P INFO 5 0 95 Jos RETURN AIR TEMP 120 SET 120 F 93 95 REGEN HEATER 98 Joc Ere REGENERATION TEMP REGEN HI
66. RATURE RANGE screen 39 The display will return to the default screen PROCESS TEMPERATURE from anyplace in the menu structure with ACT 325 F SET 325 F the exception of the AUTOTUNE screens When supplied for i central drying appli cations this function 115 not available if nothing is done after 10 minutes Pressing the MENU button from anyplace in the menu structure will also return to the default screen SCREEN 4 Shows the regeneration air setpoint and REGENERATION TEMP actual temperature The setpoint can be changed with the correct password ACT 350 F SET 350 F NOTE Lowering the regeneration setpoint decreases the capacity of the dryer and nor mally is not recommended Use the dew point control function instead SCREEN 5 Shows the actual return air temperature RETURN AIR TEMP measured at the inlet to the process blow E er If the optional aftercooler flow control ACT 100 F SET 100 F is installed a setpoint will be displayed on this screen The setpoint can be changed with the correct password 4 12 Operation Control Function Descriptions continued SCREEN 6 MDC Option MACHINE LOADER LOAD TIME 10 SEC SCREENS 7 8 9 and 10 SCREEN 11 Dewpoint Control and or Dewpoint Monitor PROCESS DEW POINT ACT 47 F SET 40 F SCREEN 12 Main Menu DRYER MAIN MENU STAT SETUP DIAG Function Control function iavailable for MDC only This screen shows the amount o
67. SCREEN 100 MDC SHUTDOWN ON ALARM ENABLED EDIT SCREEN 101 MDC SHUTDOWN TIME 60 MIN SCREEN 102 MAP INDIRECT REG 500 0 Function This screen can be used to determine if the MDC conveying on function will shut down or continue to operate upon any dryer alarm Use this screen in the event screen 100 is enabled to set the amount of time the con veying function will continue to operate once the dryer has alarmed If screen 100 is disabled the conveying function will continue indefinitely These parameters map which internal vari ables are accessible from the user commu nication port on the DC 2 operator display A default set of variables has been chosen that represent the most important variables for the majority of uses These values should not be changed except under the direction of Conair Engineering or Service To Start Drying 1 Make sure there is material in the hopper 2 Turn on the main power to the dryer Make sure the dryer s disconnect dial is in the ON position This powers up the control and the display lights will illu minate 3 Set the drying temperature Press the appropriate Select Category button then the Adjust Setpoint or buttons or enter the temperature on the numeric keypad and press enter NOTE When changing a setpoint use the Select Category Key directly below the value to be changed Once pressed the value will blink then use the keypads or adjustment setpo
68. SCREEN 21 B Aftercooler Flow Control Option SCREEN 21C Precooler Disable Enable SCREEN 21 D Precooler Flow Control Option SCREEN 22 Current Monitor Option SCREEN 23 Current Monitor Option Descriptions continued Function This screen shows if the control is opening the solenoid valve The aftercooler flow control option must be installed see screen 75 for this to appear This screen shows the disable enable function of the precooler The precooler display will read Disabled when not acti vated The Precooler Flow Control must be installed see screen 75 for this to appear This screen shows if the control is opening the precooler flow control solenoid valve The Precooler Flow Control option must be installed see screen 75 for this to appear This screen shows the measured current on each leg of the 3 phase power going to the process heater The Current Monitor option see screen 75 needs to be installed for this screen to appear The screen shows the calculated total power for the dryer The calculation includes the measured current for the process and regeneration heaters the control voltage set for the dryer and pre determined power consumption values for the blowers and the control The Current Monitor option see screen 75 needs to be installed for this screen to appear Control Function Descriptions continued Screen Function SCREEN 24 Dewpoint Control This screen displays
69. Software EDS File Parameter List Configuration Options continued Parameter 6 Input Assembly Type Status only Status w data Data only This field will choose whether the data retrieved consists of only the process data from the controller data only the status bytes from the gateway status only or the data and the status bytes status w data amp NOTE When this field is modified the change must be applied The size of the data block being retrieved see parameter 7 will change based on the configuration of this parameter Parameter 7 Input Assembly Size 0 to 160 This field will display the actual size of the input data that is being retrieved from the gateway to the master on the DeviceNet network See the section on adding the gateway to the scan list for further information on the parameter Configuring the DeviceNet Software Adding the Gateway to the Scan List Adding the gateway to a scan list requires that the data area is sized correctly and mapped to the correct locations To add the gateway to the scan list 1 Set all dip switches as described in the DeviceNet communications section entitled Using the DeviceNet communication dip switch settings 2 Go online with the device on the network and set the parameters described in the DeviceNet communications section entitled Configuring the DeviceNet software EDS File Parameter List Configuration Options 3 Once the parameters are set download the parameter
70. a time amp NOTE When changing a setpoint use the Select Category Key directly below the value to be changed Once pressed the value will blink then use the keypads or adjustment setpoints to enter the new value Then press enter for the new value to be recognized 4 2 Operation Press to scroll through the closed loop parameter list The Prev button scrolls the user up the list while the Next button scrolls the user down the list to the last screen and then back to the parameter list title screen at the top Status Display Alpha numeric characters dis play process and alarm con ditions Dryer Status Illuminated lights show the status of the dryer Acknowledge Alarm Button Press once to silence the option al audible alarm and display alarm messages Press again to clear the alarm Carousel Plus W Series Dryer Control Functions Dryer functions are values that you can set or monitor in the Screen Title and Status Display windows Press the Menu button then the Scroll List Next or Prev buttons until the function you want to set or monitor appears in the Screen Title window Control Function Flow Charts The charts beginning on page 4 4 provide a quick summary of the control func tions For an explanation of each control function see Control Function Descriptions page 4 11 The screen numbers correspond with the numbers beside each block in the flow chart
71. ace the setback RTD Replace the control board Check the motor plugs and fuses Change the tensioner spring or replace the belt Check the heater fuses and heater Check the RTD plug connections and make any necessary repairs Check the plug connection and tighten if needed Replace the regeneration outlet RTD Replace the control board Troubleshooting 6 19 Passive Alarms If the amber Acknowledge Alarm LED is blinking the alarm is a passive alarm The dryer continues to operate but this problem could prevent correct drying of your material Note that once the Acknowledge Alarm button is pressed once the blinking amber LED becomes solid NOTE Passive alarms be configured as shutdown alarms see the previous Shut down Alarms section See page 4 26 screen 62 for instructions Problem Dewpoint Deviation High Displayed when the actual dewpoint goes above the set point by a specified amount of time and degrees Defaults are set for 5 F 3 C for 30 seconds Dewpoint Deviation Low Displayed when the actual dewpoint goes below the set point by a specified amount of time and degrees Defaults are set for 5 F 3 C for 30 seconds 6 20 Troubleshooting Possible cause The hose or wiring connections to the sensor block are loose or have fallen off Poor regeneration air flow The desiccant wheel is not turning The desiccant wheel may be contami nated Leaks in th
72. and optional precooler require a source of city tower or chiller water and a discharge or return line You can use water at temperatures of 45 to 85 F 7 to 29 C But the water flow should be at least 3 gal min 11 4 liters min See Appendix B for installation and water connection instructions for the optional precooler 1 Secure the aftercooler assembly in the aftercooler housing using the six screws N gt 2 Connect the water supply line to the aftercooler inlet If a manual shut off valve is used it should be mounted on the inlet line ec TIP Make the water supply and dis charge return connections with flexible hoses at least 24 in 61 long This allows you to easily remove the aftercooler assembly for cleaning 3 Connect the water discharge or return line to audit ec TIP If an optional flow control is also being installed with the aftercooler the manual shut off valve should be installed on the inlet line for the flow control IMPORTANT Turn the water off when the dryer is not in use to prevent condensation Installation 3 13 Mounting a Loader on the Hopper If you have a Conair loader or vacuum receiver you can use the flange and mounting clips provided on the top of the hopper Refer to the manuals that came with your receiver or loader for detailed installation instructions Testing the Installation You have completed the ins
73. as the value in this field If desired change the first octet at this location 4 Once you have entered the correct value scroll down one more time until IP Addr Part 2 is displayed This is the second octet first three numbers of the IP address and may be changed if necessary continued Installing the Ethernet Communication Hardware continued 4 Once you have entered the correct value scroll down one more time until IP Addr Part 2 is displayed This is the second octet first three numbers of the IP address and may be changed if necessary Scrolling further down you will see additional fields for the remaining IP address octets the subnet mask and the gateway Once all fields have been changed cycling the power to the dryer will complete the process and reinitial ize the Ethernet interface Using the Ethernet Parameter List Please refer to page Appendix A page A 4 for a list of the parameters that are available with the Modbus TCP IP interface A CAUTION Writing to a location with improper data or writing to an incorrect loca tion outside of the specified range may cause your common controls system to become inoperative or to operate in a manner that may damage your process Be certain that you understand each parameter and its effect before changing any thing Conair recommends that you initially attempt to read from the registers and do not complete any writes Once the information you are trying to read has
74. ation TPDS018 0705 REV 2 6 Description Carousel Plus W Series Dryer Options Volatile trap only in conjunction with aftercooler The volatile trap is recommended if drying materials that produce volitales that condense into a waxy or oily residue and or if the material contains excessive fines Precooler The precooler reduces the temperature of air flow after the desic cant wheel and before the process heater Filter check The Filter check sensor will activate a passive alarm when the process filter is clogged or needs to be replaced Heater current monitor The heater current monitor measures the total amperage across both the process and regeneration heaters and the pre deter mined power consumption values for the blowers and the control CFM monitor The CFM monitor measures the cubic feet per minute of air flow across the inlet outlet of the process blower DeviceNet or SPI communications Allows the dryer to be networked to industrial control systems DeviceNet communications are standard Alternate communications are available Description 2 7 2 8 Description SECTION Installation Unpacking the 3 2 Preparing for installation 3 4 Positioning the dryer on the floor 3 5 z Removing the cable tie from the W desiccant wheel 3 5 S Connecting the main power 3 6 Connecting the process RTD probe
75. can be changed with the proper password see page 4 32 screen 85 to either Standard or Metric Press the Select Category button below the word Edit to change the setting and press the ENTER key to lock in the value This screen shows the time unit the dryer will display It can be changed with the proper password see page 4 32 screen 85 to either 12 hour AM PM Clock or 24 hour Military Time Press the Select Category button below the words 12 hour to change the setting and press the ENTER key to lock in the value This screen shows the date and time With the proper password see page 4 32 screen 85 the date and time can be changed Control Function Descriptions continued Screen Function SCREEN 74 This is the Dryer Setup Other screen It DRYER SETUP OTHER can be found by pressing the Select Category button under the word Other on OPT INSP COM PW the Dryer Setup Screen 36 By pressing the Select Category buttons under the titles the user can select to see setup infor mation for Options Inspection Com munications or Password t NOTE Screens labeled 75 in This is an example of an Option the display screen flow chart Installation screen With the proper pass on page 4 9 are various word see page 4 32 screen 85 and hard option installation screens ware installed an option can be turned on by pressing the Select Category screen under the word Edit This will change an option from N
76. cessary Allow the over load to reset then try to restart the dryer Disconnect and lock out main power Check the regeneration blower for elec trical shorts or open circuits Replace if necessary Allow the overload to reset then try to restart the dryer Check for a blown fuse in the dryer or main power supply Allow the overload to reset then try to restart the dryer Disconnect and lock out main power Check the overload settings and con firm that the settings match the full load amps listed on the process blower motor Allow the overload to reset then try to restart the dryer Replace the overload Troubleshooting 6 11 6 12 Problem Process Protection Differential If the difference between the process tempera ture exiting the process heater and the temperature of the air entering the hopper is greater than 175 F 97 C for longer than 180 seconds it shuts down the dryer Troubleshooting Shutdown Alarms If the red Acknowledge Alarm LED is blinking the alarm is a shutdown alarm The dryer will shutdown automatically to prevent damage to the equipment or personnel Note that once the Acknowledge Alarm button is pressed once the blinking red LED becomes solid Possible cause The air lines between the dryer and hop per are restricted or loose The dryer is located too far away from the hopper The process RTD is loose or has fallen out The process blower is not running The proces
77. changed with the proper password see page 4 32 screen 85 by pressing the Select Category button below the word Edit and entering a value on the keypad or scrolling to the desired value using the Adjust Setpoint keys The ENTER key needs to be pressed to lock in the new number This screen shows the baud rate The baud rate can be changed with the proper password see page 4 32 screen 85 Press the Select Category key below the word Edit and enter a value on the keypad or scroll to the desired value using the Adjust Setpoint keys This screen shows the parity The parity can be changed with the proper password see page 4 32 screen 85 to Even Odd or None by pressing the Select Category button below the word Edit The ENTER key needs to be pressed to lock in the new number Operation 4 31 4 32 Operation Control Function Descriptions continued Screen SCREEN 85 ENTER PASSWORD 0210 SCREEN 86 RESET PASSWORD PRESS HERE SCREEN 87 VALID SUPERVISOR PASSWORD ENTERED Function This screen shows the password entry screen By pressing the Select Category button under the word Press Here the user can enter a password by using the keypad Once a password has been entered the ENTER key must be pressed If the password is valid the display will show screen 87 If the password was incorrect it will display Invalid Password Try Again and go back to the Enter Password screen The defa
78. d DeviceNet Communications C 3 C 4 DeviceNet Communications Using the DeviceNet Communication Dip Switch Settings continued Number SWS SW6 SW SW8 Controllers ON OFF OFF OFF 2 OFF ON OFF OFF 3 ON ON OFF OFF 4 OFF OFF ON OFF 5 ON OFF ON OFF 6 OFF ON ON OFF 7 ON ON ON OFF 8 OFF OFF OFF ON Table 3 Dipswitch Set 2 Enable Athena Controllers Dip switch set 2 identifies the Modbus addresses of controllers connected to the DeviceNet interface From one to eight controllers can be enable for communica tion through a single Athena DeviceNet interface module ModBus Baud Rate SWA 19200 ON 9600 OFF Table 4 Dipswitch Set 2 Modbus Baud Rate Dip switch set 2 position 4 identifies the baud rate used to read parameters on Modbus Modbus Parameters SWI SW2 User Configurable OFF OFF Parameters 500 519 OFF ON Parameters 500 509 ON OFF User Configurable ON ON Table 5 Dipswitch Set 2 Modbus Parameter List Dip switch set 2 positions 1 2 identify the parameter list for the Conair controllers continued Using the LED Status Indicators There are two LEDs on the gateway which display the status of the communica tions The first LED which is located between the dip switches labeled Controllers on the gateways with the enclosure display the status of the Modbus communications between the gateway
79. d electrical power specifications in the blanks provided on the back of the User Guide s title page The informa tion will be helpful if you ever need service or parts 6 You are now ready to begin installation Follow the preparation steps on the next page then choose one of the four mounting options Dryer on the floor hopper on a floor stand see page 3 5 Dryer on the floor hopper machine mounted Dryer and hopper on a mobile floor stand Models W150 W200 only Central dryer with ResinWorks system t NOTE Conair also sells an MDC dryer and hopper on a mobile floor stand with convey ing capabilities version of this dryer in the 150 and 200 Models Contact Conair Sales for additional information Installation 3 3 e Material and conveying lines installed If you plan to use vacuum or compressed air loaders to fill the hopper install conveying lines to the drying hopper location 3 4 Installation Preparing for Installation The Carousel Plus W Series Dryer is easy to install if you plan the location and prepare the mounting area properly 1 Make sure the mounting area provides CJ A grounded power source supplying the voltage and correct current for your dryer model Check the dryer s serial tag for the correct amps volt age phase and cycles Field wiring should be completed by qualified person nel to the planned location for the dryer All electrical wiring should comply with your region s
80. e equipment s response to an action performed by the user An open box marks items in a checklist A circle marks items in a list Indicates a tip A tip is used to provide you with a suggestion that will help you with the maintenance and the operation of this equipment Indicates a note A note is used to provide additional information about the steps you are following throughout the manual Using the Carousel Plus W Series as a Central Dryer This manual incorporates the information necessary to use the Conair Carousel Plus W series dryer as a central dryer Throughout this manual information particular to central dyer application of the W series dryer is called out by the following treatment This box will contain information or highlight system differ rences particular to the application of the W series dryer as a central dryer i E Central Your Responsibility as a User You must be familiar with all safety procedures concerning installation opera tion and maintenance of this equipment Responsible safety procedures include Thorough review of this User Guide paying particular attention to hazard warnings appendices and related diagrams Thorough review of the equipment itself with careful attention to voltage sources intended use and warning labels Thorough review of instruction manuals for associated equipment Step by step adherence to instructions outlined in this User Guide Introductio
81. e overload to reset automatically Troubleshooting Shutdown Alarms If the red Acknowledge Alarm LED is blinking the alarm is a shutdown alarm The dryer will shutdown automatically to prevent damage to the equipment or personnel Note that once the Acknowledge Alarm button is pressed once the blinking red LED becomes solid Possible cause The process blower current draw has exceeded the full load amps rating of the motor The process blower has mechanically failed or is unable to rotate freely The process blower has failed electri cally Loss of phase of power to the motor starter The overload is set incorrectly The overload is defective Solution Press alarm acknowledge and allow the overload to reset then try to restart the dryer If the alarm condition occurs again have a qualified electrician check the current draw to the motor Disconnect and lock out main power Check the process blower for mechani cal failure and free rotation Replace if necessary Allow the overload to reset then try to restart the dryer Disconnect and lock out main power Check the process blower for electrical shorts or open circuits Replace if nec essary Allow the overload to reset then try to restart the dryer Check for a blown fuse in the dryer or main power supply Allow the overload to reset then try to restart the dryer Disconnect and lock out main power Check the overload settings and con firm that th
82. e process air stream The dewpoint can not control to the desired setpoint The dewpoint sensor has failed Solution Check wiring and hose connections to the sensor re secure if needed Remove the air flow restrictions dirty filters etc See Troubleshooting section entitled Passive alarms Wheel rotation failure Check the desiccant for contamina tion replace if needed Install plasti cizer volatile trap for severe situations Replace the desiccant wheel See Troubleshooting section entitled Replacing the desiccant wheel Check for worn or lose hoses Material and or ambient conditions may be too dry to increase the actual dewpoint Please wait several hours to determine if the setpoint can be reached Increase the dewpoint low deviation value Replace the dewpoint sensor Additional Alarms Along with the Passive and Shutdown alarms you may encounter additional error messages that indicate a problem with the control Problem Control Not Ready Please Check Alarm Displayed when the Start button is pushed during any active alarm Passive or Shutdown Lost Comm w Ctrl Bd Indicates there is a problem in the communication between the control board and the dis play board Error Incorrect Firm Version Indicates a mismatch of software between the dis play board and the control board Possible cause The dryer will continue to run if there is a passive alarm however it will not
83. e settings match the full load amps listed on the process blower motor Allow the overload to reset then try to restart the dryer Replace the overload Problem Regeneration Blower Overload If the regenera tion blower exceeds its full load amp rating or the over load has tripped due to a mechanical or electrical prob lem the dryer will shut down NOTE Once the overload has tripped you must wait 2 to 15 minutes with the power on for the overload to reset automatically Shutdown Alarms If the red Acknowledge Alarm LED is blinking the alarm is a shutdown alarm The dryer will shutdown automatically to prevent damage to the equipment or personnel Note that once the Acknowledge Alarm button is pressed once the blinking red LED becomes solid Possible cause The regeneration blower current draw has exceeded the full load amps rating of the motor The regeneration blower has mechani cally failed or is unable to rotate freely The regeneration blower has failed electrically Loss of phase of power to the motor starter The overload is set incorrectly The overload is defective Solution Press alarm acknowledge and allow the overload to reset then try to restart the dryer If the alarm condition occurs again have a qualified electrician check the current draw to the motor Disconnect and lock out main power Check the regeneration blower for mechanical failure and free rotation Replace if ne
84. e wrong direction blower blown fuse etc or reverse the rotation of the blower The isolation contactor failed in the Replace the isolation contactor closed position The heater solid state relays SSRs failed Replace the failed heater solid state relays SSRs The regeneration heater output on the Replace the board board has failed 6 6 Troubleshooting Problem Return Air High Temperature If the return air temperature at the inlet to the blower is greater than 180 F 82 C it shuts down the dryer Process RTD Integrity If the process RTD is faulty it shuts down the dryer Regeneration RTD Integrity If the regeneration RTD is faulty it shuts down the dryer Shutdown Alarms If the red Acknowledge Alarm LED is blinking the alarm is a shutdown alarm The dryer will shutdown automatically to prevent damage to the equipment or personnel Note that once the Acknowledge Alarm button is pressed once the blinking red LED becomes solid Possible cause The hopper does not contain enough material You are drying at a high drying tempera ture above 240 F 116 C or you are running at low throughputs The aftercooler does not have enough water The aftercooler coils are dirty The process RTD connection to the con trol box is loose The connection in the electrical enclo sure for the process RTD is loose The connection of the RTD plug on the control board is loose The
85. each leg of the regeneration heater Troubleshooting 6 13 Passive Alarms If the amber Acknowledge Alarm LED is blinking the alarm is a passive alarm The dryer continues to operate but this problem could prevent correct drying of your material Note that once the Acknowledge Alarm button is pressed once the blinking amber LED becomes solid Q Problem Return Air Mid High Temperature If the return air temperature is between 150 and 180 F 66 and 82 C Regeneration Low Temperature The regenera tion temperature is less than the low temperature setpoint for the specified time Defaults are 200 F 93 C for 20 seconds Regeneration High Temperature If the regener ation temperature exceeds the high temperature limit for the specified time Default values are 400 F 204 C for 20 seconds Troubleshooting NOTE Passive alarms can be configured as shutdown alarms see the previous Shut down Alarms section See page 4 26 screen 62 for instructions Possible cause The hopper does not contain enough material You are drying at a high drying tempera ture above 240 F 116 C or running at low throughputs The aftercooler does not have enough water The aftercooler coils are dirty The regeneration heater has failed The output on the control board has failed or the fuse has blown The regeneration RTD is loose or has fallen out One of the solid state relays SSRs failed in
86. ecific electri cal components Illustrations in the User Guide are intended to be Location of representative only the Process f RTD at the Hopper inlet To check or replace RTD sensors 1 2 Disconnect and lockout the main power supply A Remove dryer panels as necessary Locate the RTD sensors Check the sensor positions and conditions Temperature readings will be incorrect if the sensors are touching the wall of an air hose or pipe or if the sen sor or wiring is damaged The tip of the sensor should be centered within the air hose or pipe Sensor wires should be attached to the appropriate connection points on the dryer s electrical enclosure or microprocessor board E 22 a E check with ohm meter measure the resistance across RTDs The resistance should be approx 110 ohm at room temperature Replace the sensor if necessary Troubleshooting 6 31 Replacing the Heaters Regeneration Heater Tube 1 Stop the dryer disconnect the power and follow proper lockout A procedures 2 Open or remove the right side panel of the dryer as viewed from the control panel to gain access to the regeneration heater 3 Disconnect the regeneration heater wires and high tem perature switch wires at the quick disconnects near the heater tube Regeneration Heater 4 Remove the insulation from the regeneration heater tube by cutting the insulation in a straight l
87. ect your portable dewpoint meter to the dewpoint check port of the dryer available through the Conair 2 Turn on the portable instrument and ensure parts department there is positive airflow through the sensor NOTE The dewpoint check port 3 Monitor the readout and allow ample time for it to stabilize before was not included on early dry disconnecting it Some dewpoint monitors require a substantial amount of ers It can be added easily time for residual moisture to be purged from the sensor Contact the Conair parts depart ment or follow the alternate 4 In the event the dewpoint in not satisfactory refer to the Troubleshooting procedure section of the manual alarm P9 Replacement dewpoint moni tors male connectors and Alternate Procedure for dryers with no dewpoint check port dewpoint check ports are available from Conair 1 Stop dryer and allow it to cool Contact Conair Parts 800 458 1960 From outside of the United States call 3 Atthe bottom end cool air inlet of the process heater tube remove 814 437 6861 1 8 inch NPT pipe plug and connect your portable dewpoint monitor at this location If there are existing connections for the dryer s dewpoint sensor locate a 2nd 1 8 inch NPT port or connect your dewpoint sensor in series with the dryer sensor Do not install a tee to split the air between the dryer s sensor and your portable instrument This may cause one of them to be starved for adeq
88. ed properly Disconnect the ribbon cable connect ing any analog option boards to the main control board If the display returns to normal for all values except those that are generated through the analog options boards replace the option board Replace main control board Check RTD connections Replace defective RTD Check connections between analog option board and the main control board Disconnect the ribbon cable connect ing any analog option boards to the main control board If the display returns to normal for all values except those that are generated through the analog options boards replace the option board Replace main control board Problem Dryer not producing desired dewpoint Dewpoint Troubleshooting Under normal operating conditions the dryer will produce dewpoints in the range of 40 to 20 F 40 to 29 C However you may experience situations that pro duce undesirable results Possible cause Return air temperature exceeds 125 F 92 C Regeneration temperature is below nor mal setting Low regeneration air flow Leaks in process lines Contaminated desiccant due to off gassing too long of a residence time or drying temperature is too high for the grade of material being processed Analog option board sensor malfunction Solution Reduce the temperature of the cooling water or increase the flow Check amperage of regeneration heaters Replace heaters if necessary
89. electrical codes CJ A source of water if you have an aftercooler and or optional precooler The W dryer s aftercooler and optional precooler require 3 gals min 11 4 liters min tower city or chiller water at temperatures of 45 to 85 F 7 to 29 C Pipe should be run to the planned dryer location Use flexible hose to connect the water pipes to the aftercooler and or optional precooler 0 Minimum clearance for safe operation and maintenance You should maintain 24 in 61 cm clearance on all sides of the dryer Positioning the Dryer on the Floor 1 Lift the dryer from the shipping container using a fork truck 2 Position the dryer on the floor near the processing machine Make sure the location allows for the connection of all hoses Removing the Cable Tie from the Desiccant Wheel 1 Open the dryer side panels and remove the cable tie securing the desiccant wheel if it was not done while unpacking the dryer 77 w D Desiccant cable tie Installation 3 5 Connecting the Main Power AN CAUTION Always disconnect and lock out the main power sources before making electrical connections Electrical connections should be made only by qualified personnel 1 Open the dryer s electrical enclosure Turn the discon nect dial on the dryer door to the Off or position Lock out the main power see Page 1 6 for complete lock out information Turn the captive screw and swing the door open
90. emperature measured at the hopper outlet and the set point temperature for the air at the hopper outlet that will initiate the control to go into setback This shows how much lower the hopper outlet temperature must drop from the Setback Return Temperature setpoint screen 27 before the dryer control should restore the original process setpoint This screen shows the actual temperature measured at the regeneration outlet of the desiccant wheel manifold This screen shows the model number volt age and frequency for which the dryer control is setup These values can be changed with the proper password see page 4 32 screen 85 under SETUP OTHER INSP Model screen 78 and Voltage FREQ screen 80 Control Function Descriptions continued Screen SCREEN 31 DISPLAY FIRM V2 21 00 DISPLAY MENU V2 21 00 SCREEN 32 CONTROL FIRMWARE VERSION V2 21 00 SCREEN 33 AUTOSTART COUNT DOWN 1 DAYS 23 05 53 SCREEN 34 AUTOSTOP COUNT DOWN 3 DAYS 11 04 23 Function This screen shows the current versions of program for the Display Firmware and Menus This screen shows the current versions of program for the Control Firmware If the dryer is set with an auto start time this screen will appear and show the amount of time remaining before the dryer will automatically start The LED on the front of the display beside the word Auto Start will flash if the dryer is set to start automatically The auto start feature can be
91. emperature as read by the RTD at the exit of the drying hopper This is the temperature that is used for setback control in the dryer Note that this is an optional feature and the value may be invalid if the feature is not installed on the dryer Select NA Poll 20h 72h 12 Flow To Process This is the flow of dry air to the process Note that this is an optional feature and the value may be invalid if the feature is not installed on the dryer Select NA Poll 20h 78h 13 Dewpoint This is the actual dewpoint of the process air Note that this is an optional feature and the value may be invalid if the feature is not installed on the dryer Select NA Poll 20h 7Ch 14 Setpoint High Dewpoint Alarm This is the setpoint for the dewpoint alarm triggered by 13 Select 20h 81h Poll 20h 80h Modbus RS 232 485 Serial Communication Parameters DC 2 Control Parameters Used on dryers with DC 2 Controls Read Area Modbus Register Number Description Comments 500 Product Type 501 Process Temperature Setpoint 502 Process Actual Temperature 503 Process Temperature Setpoint Setback 504 Return Air Temperature Out of Hopper 505 Return Air Setpoint Setback 506 Regeneration Actual Temperature 507 Dewpoint Actual 508 Operational Mode 509 Running Status 510 Return Air Actual 511 Shutdown Alarms 512 Passive Alarms 513 Load Rate Setpoint Setback 514 Average Load Rate Actual Setback 515 Process Heater O
92. emperature for a time significantly longer than the residence time specified by the supplier If you want to maintain its dry ness it is recommended that you reduce the process air temperature If your Conair dryer is equipped with the Setback feature you should familiarize yourself with it and make use of it If not you may want to contact Conair to determine if it can be added to your dryer A majority of customer questions to Conair are related to dewpoint It is important to realize that dewpoint is one of four requirements that need to be satisfied There are four requirements listed in order of importance necessary to properly dry hygroscopic plastic resins amp b Drying temperature of the air entering the hopper must be at the proper drying temperature for your material as specified by your material supplier Residence time is the time determined by your material supplier that the material in use must be heated to achieve proper drying temperature Airflow during the process drying circuit must be adequate to carry and distribute the heat throughout the entire bed of material inside the hopper Dewpoint of the process air must be low so it can efficiently collect the moisture as it is released from the heated material and carry it to the dryer to be removed in the desiccant Problem The temperature of the air Poor Material Drying Troubleshooting continued Once it is determined which of the four requiremen
93. ening the devices parameter list you can tell how many controllers are associated with the EDS file continued DeviceNet Communications C 5 Configuring the DeviceNet Software Installing the EDS Files continued General Parameters 1 0 Data EDS File Select the parameter that you want to configure and initiate an P action using the toolbar Groups v Me amp ID S Parameter Current value Controller 1 Access Num of Int Parameters I Num of Fit Parameters I Controller 2 Access Num of Int Parameters I Num of Fit Parameters I Dip Switch 1 00000000 Dip Switch 2 00000000 Input Assembly Type Data Only Input Assembly Size 40 Bytes 2 3 4 5 6 7 8 9 e OK Apply Help Configuring the DeviceNet Software EDS File Parameter List Configuration Options Once the EDS file has been installed the gateway may be added to a network con figuration There are a number of parameters that may be configured for each gate way to optimize it for your application The number of parameters will vary depending on how many controllers are attached to a gateway C 6 DeviceNet Communications Configuring the DeviceNet Software EDS File Parameter List Configuration Options continued There are seven types of parameters Parameter 1 Controller Access 1X 10X 100X This parameter controls the format of the data that is retrieved from the cont
94. er remove the compres Sion fitting from the aftercooler inlet Loosen the fitting on the flow control then swing the copper water supply tube out and away from the aftercooler inlet 3 Remove the screws securing the aftercooler in the aftercooler housing eC TIP If the aftercooler without a flow control was installed using the recommended 24 inch 61 cm of flexible hoses there is no need to disconnect the hoses from the aftercooler inlet and outlet 4 Remove the aftercooler assembly from the aftercooler housing continued 5 10 Maintenance Cleaning the Aftercooler Coils 5 Clean the assembly using a mild soap and water Let the assembly dry thoroughly before installation In severe situations steam cleaning or use of solvents maybe necessary A CAUTION During the cleaning process DO NOT cut or remove the stainless steel wire that holds the assembly together 6 Inspect the condition of the gasket If it is damaged replace the gasket 7 Reassemble by repeating the steps in reverse order 8 Connect the water supply line to the inlet If a manual shut off valve is used it should be mounted on the inlet line as well 9 Connect the outlet of the aftercooler to the inlet of the flow control valve using the pre shaped copper tubing and compression fittings provided Maintenance 5 11 5 12 Maintenance Cleaning the Precooler Coils If you have the optional precooler you need to clean the cooling coils to
95. f time the conveying blower will run Based on the position of the demand sensor in the mate rial receiver this time may need adjusted The time should be set for the time it takes to satisfy the demand sensor second If the MDC tries to load three consecutive times without satisfying the demand sig nal the dryer will display a passive alarm These control screens are not used for the W 150 400 DC 2 This screen will show the actual dewpoint of the process delivery air measured after the desiccant wheel and before the process heater The dewpoint control will automat ically adjust the regeneration temperature to maintain the dewpoint setpoint Dewpoint control is not active with 40 F 40 C setpoint amp NOTE Dewpoint actual will not be live for approximately 5 to 8 minutes This is the dryer MAIN MENU It can be located by pressing the MENU key while at the DEFAULT screen By pressing the Select Category buttons under the titles the user goes to STATUS screens SETUP screens or DIAGNOSTIC screens Operation 4 13 When supplied for i central drying appli cations this function 115 not available 4 14 Operation Control Function Descriptions continued Screen SCREEN 13 DRYER STATUS PROC REGEN OTHER SCREEN 14 DRYER PROCESS STATUS SCREEN Function This is the Dryer Status screen It can be found by pressing the Select Category but ton under the word Stat on the Main Menu sc
96. form troubleshooting procedures that require access to the electrical enclosure while power is on continued ATTENTION Read this so no one gets hurt continued We design equipment with the user s safety in mind You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide A CAUTION Hot Surfaces Always protect yourself from hot surfaces inside the dryer and hopper Also exercise caution around exterior surfaces that may become hot during use These include the hopper door frame the exterior of an uninsulated hopper the return air hose and the dryer s process filter housing and moisture exhaust outlet 2 WARNING Do not place aerosol compressed gas or flammable materials on or near this equipment The hot temperatures associated with the drying process may cause aerosols or other flammable materials placed on the dryer or hopper to explode Introduction 1 5 1 6 Introduction How to Use the Lockout Device A CAUTION Before performing maintenance or repairs on this product you should disconnect and lockout electrical power sources to prevent injury from unexpected energization or start up A lockable device has been provided to isolate this product from potentially hazardous electricity Lockout is the preferred method of isolating machines or equipment from energy sources Your Conair product is equipped with the lockout device
97. he recommended installation and maintenance procedures outlined in this User Guide If you do have a problem this section will help you determine what caused it and how to fix it mode screens 28 43 may assist with the determining of possi ble cause of an alarm Access code 756 Before you open the side panels of the dryer be sure to 0 Diagnose causes from the control panel 1 Press once to silence the optional audible alarm and display alarm message 2 Address the alarm message and fix the problem Refer to the alarm descriptions later in this section 3 Press again to clear the alarm If the alarm reappears the problem was not fixed Process Blower Regen Blower Auto Start Process Heater Regen Heater Desiccant Indexing sessione Acknowledge Alarm Button 6 2 Troubleshooting Before Beginning continued 1 Find the wiring and equipment diagrams that were shipped with your dryer These diagrams are the best reference for correct ing a problem The diagrams also will note any custom features such as special wiring or alarm capabilities not covered in this User Guide See warnings below Open the electrical enclosure to check fuses and heater contactors A Few Words of Caution The Carousel Plus W Series dryer is equipped with numerous safety devices Do not remove or disable them Improper corrective action can lead to haz ardous conditions and should never be attempted to su
98. heel to ensure optimum performance 1 Stop the dryer disconnect the power and follow proper AX lockout procedures Remove the side panels of the dryer AA Note the position of all the hoses and RTDs Disconnect the hoses and RTDs from both manifolds and the wires from wheel assembly motor 4 10 Remove the plastic roof panel from the dryer Remove 4 bolts securing the wheel assem bly support bracket to the dryer frame Using a crane or forklift lift the entire wheel assembly out of the dryer frame Remove the wheel support bracket from the wheel assembly then lift the wheel assembly out of the dryer Lift the new wheel assembly into place in the dryer frame with the motor toward the rear of the dryer and bolt it into place Replace the plastic roof panel Reconnect the hoses and RTDs to the mani folds and the wiring to the wheel assembly motor Connect the power and start the dryer Verify the wheel rotates smoothly and in the correct direction Replace side panels Replacing the Desiccant Wheel Motor eh 10 11 12 Stop the dryer disconnect and lockout the main power AX Open both side panels Disconnect wiring to the motor Loosen the belt tensioner and remove the pivot bolt securing the belt ten sioner to the motor bracket Be sure to retain the flat washers located under the tensioner Disconnect the spring and remove the tensioner Remove the belt from the motor pulley t
99. hen remove the pulley from the motor Remove the screws securing the motor to the upper and lower bracket and remove the motor Secure the new motor to the bracket Install the pulley on the new motor and position the belt on the pulley Connect the spring to the tensioner then secure the tensioner to the motor bracket Be sure to install flat washers between the motor bracket and the tensioner Connect the wires to the motor Connect the power to the dryer Turn the dryer on and ensure that the desic cant wheel is rotating in the correct direction Replace the side panels Troubleshooting 6 37 Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Department for a nominal fee Most manuals can be downloading free of charge from the product section of the Conair website www conairnet com A 1 Appendix We re Here to Help Conair has made the largest investment in customer support in the plastics indus try Our service experts are available to help with any problem you might have installing and operating your equipment Your Conair sales representative also can help analyze the nature of your problem assuring that it did not result from misapplication or improper use How to Contact Customer Service To contact Customer Service personnel call PARTS amp SERVICE 458 1960 24 HOURS A DAY 7 DAYS A WEEK NOTE Normal operating hours are
100. hes labeled S2 on the circuit board or next the number of controllers label is used to set the number of controllers attached to the gateway only for RS 485 communications to set the baud rate used to communicate between the gateway and the dryer and to set the number of words of data transferred from the gateway to the DeviceNet scanner 10 or 20 words of data See next page for dip switch configuration continued Using the DeviceNet Communication Dip Switch Settings continued ON ON ON E u OFF 12 34 56 7 8 12 34 56 7 8 Dipswitch Set 1 DeviceNet Address amp Dipswitch Set 2 Temperature Baudrate Controller Enable Figure I Dipswitch Layout Address SW1 SW2 SW3 SW4 SWS SW6 Decimal 2 2 0 2 21 P3 Default 01 ON OFF OFF OFF OFF OFF 15 ON ON ON ON OFF OFF 40 OFF OFF OFF ON OFF ON Table 1 Dipswitch Set 1 DeviceNet Address Baud Rate SWT SWS8 Mode p 2 125K OFF OFF 250K ON OFF 500K OFF ON Software ON ON Table 2 Dipswitch Set 1 DeviceNet Baud Rate Dip switch 1 provides the DeviceNet Macld address and baud rate using the stan dard switch configurations found in most DeviceNet products Switches 7 and 8 of switch set 1 allow the user to use DeviceNet software configuration tools to set the Macld address and baud rate Factory default switch settings are 125k Address 63 continue
101. how much material you process and how dusty or full of fines it is O Inspect hoses and hose connections Check for damage kinks or loose hose clamps Replace any hoses that show signs of damage or wear Reposition and tighten loose hose clamps Monthly CJ Clean the optional aftercooler and precooler coils You may need to clean the coils more often than monthly Frequency will depend on the type and volume of material you process e Every six months O Inspect gaskets for damage or wear Damaged gaskets can allow moisture to seep into the closed loop drying system Replace any gasket that is torn or cracked CJ Verify dewpoint readout and performance with a calibrated portable dewpoint instrument O Measure current draw on all 3 legs of heater wires This is to ensure the heater is working properly 5 2 Maintenance Checking the Dewpoint It is a good idea to monitor the dewpoint performance of your dryer periodically with a calibrated portable dewpoint monitor to ensure it is performing at maxi mum capacity Even if your dryer has a dewpoint readout comparing it to a portable instrument periodically will confirm that the dewpoint sensor and readout NOTE Portable dewpoint moni tors purchased from Conair are provided with a male connector that plugs into the Dewpoint Check port If you purchased your portable instrument else where the male connector is is performing properly To check dewpoint 1 Conn
102. ieve proper drying Possible cause Material level in hopper is too low Material throughput is too high Solution Make sure there is an adequate supply of material to feed the loader on top of the drying hopper Correct any problems with the convey ing system that may be preventing your loader from filling the hopper If your hopper has a level sensor for maintaining a material level less than completely full be sure this sensor is adjusted properly Take any necessary steps such as slow ing down the process to ensure the material usage is within design specifi cations of the dryer and hopper Poor Material Drying Troubleshooting continued Airflow The airflow in the process drying circuit must be adequate to carry and distribute the heat throughout the entire bed of material inside the hopper If the airflow is too low the material in the center of the hopper may get heated fully to the drying temperature but the material against the sidewalls will not In most cases the material 2 3 to 3 4 of the way toward the top of the hopper should be heated to the proper drying temperature Problem Possible cause Solution Too much or too little air Dirty process air filter Clean or replace the process filter flow Collapsed hoses or holes leaks in the Replace any worn or damaged hoses hoses and hose connection Tighten all hose clamps to eliminate NOTE If there is too much airflow the material ma
103. in the conveying loop The air operated valves are not operat ing The sensor is not adjusted properly No material is being conveyed The conveying load time is too short Conveying blower is not coming on The conveying filter is clogged Hoses have come off or are loose in the conveying loop The air operated valves are not operat ing Solution Check the blower fuses in the control and the overload settings Clean or replace the conveying filter Check for loose hoses and make sure all hose clamps are secure Make sure compressed air is con nected and that the solenoid valves are operating properly Adjust the sensor as needed Check material supply Increase the load time setpoint Check the blower fuses in the control and the overload settings Clean or replace the conveying filter Check for loose hoses and make sure all hose clamps are secure Make sure compressed air is con nected and that the solenoid valves are operating properly Troubleshooting 6 17 6 18 Passive Alarms If the amber Acknowledge Alarm LED is blinking the alarm is a passive alarm The dryer continues to operate but this problem could prevent correct drying of your material Note that once the Acknowledge Alarm button is pressed once the blinking amber LED becomes solid NOTE Passive alarms be configured as shutdown alarms see the previous Shut down Alarms section See page 4 26 screen 62 for i
104. ine from top to bot tom 5 Remove the hose and clamp Clamp at the bottom of the heater tube 6 While supporting the heater tube disconnect the hose clamp and hose from the top insulation of heater tube and remove the heater tube from the dryer 7 Compare the markings on the outside of the regeneration heater tube to ensure the new one has the same voltage and kW ratings as the original heater tube This information is on the end nearest the wires Wires Clamp 8 Connect the hose from the reactivation inlet to the top of the new regen eration heater tube with a clamp The heater tube wires should be at the bot 6 32 Troubleshooting tom of the heater tube when installed into the dryer continued Replacing the Heaters Regeneration Heater Tube continued 9 Connect the hose and clamp to the bottom of the new regeneration heater tube 10 Put the original insulation back on the regeneration heater tube Apply duct tape to the seam that was cut during removal 11 Connect the heater wires and high temperature switch wires to the quick disconnects near the heater tube 12 Replace the side panel of the dryer 13 Make sure the regeneration heater fuses are not blown before applying power to the new heater Troubleshooting 6 33 Replacing the Heaters Process Heater Tube 1 Stop the dryer disconnect the power and follow proper lockout procedures 2 Open or remove the right side panel of the dryer as viewed
105. inlet tube Correct the cause of the non functioning blower Straighten any crimps in the hoses Tighten any loose hoses Move the dryer closer to the hopper and shorten the hoses Insulated hose is required for high dry ing temperatures i drying applications these 1 shutdown alarms are not available Problem Possible cause Process Protection RTD There is a loose connection in the Integrity If the process pro wiring leading to RTD tection RTD is faulty it shuts down the dryer The connection of the RTD plug on the control board is loose The process protection RTD has failed The control board has failed Shutdown Alarms Solution Check the RTD plug connections and make any necessary repairs Check the plug connection and tighten if needed Replace the process protection RTD Replace the control board If the red Acknowledge Alarm LED is blinking the alarm is a shutdown alarm The dryer will shutdown automatically to prevent damage to the equipment or personnel Note that once the Acknowledge Alarm button is pressed once the blinking red LED becomes solid Troubleshooting 6 9 6 10 Problem Process Blower Overload If the process blower exceeds its full load amp rating or the overload has tripped due to a mechanical or electrical prob lem the dryer will shut down SE NOTE Once the overload has tripped you must wait 2 to 15 minutes with the power on for th
106. ints to enter the new value Then press enter for the new value to be recognized When configured as central dryer the drying temperature not be set since there is no process heater in the system 7 5 ct Process Blower Regen Blower Auto Start Process Heater Regen Heater Desiccant Indexing SetBack Temp Select Setpoint Category adjustment buttons buttons Operation 4 37 continued To Sta rt D ryi n g continued 4 Press the START button If everything is installed correctly The green light on the start button will illuminate The process and regeneration blowers turn on and the display LEDS will illuminate The process and regeneration heaters turn on and the display LEDs will illuminate The desiccant wheel starts turning The green light on the start button will illuminate The process and regeneration blowers turn on and the dis play LEDS will illuminate The regeneration heater turns on and the display LED will illuminate The desiccant wheel starts turning Central To Stop Drying 1 Press the STOP button The Stop LED blinks red The blowers continue running for a few minutes to cool the heaters 2 Be sure to disconnect and lockout the main power if you have stopped the dryer to perform maintenance or repair IMPORTANT Do not use the main power switch to stop the dryer Turning off power to the control and dryer d
107. ion with the furnishing performance or use of this information Conair makes no warranty of any kind with regard to this information including but not limited to the implied warranties of merchantability and fitness for a particular purpose Copyright 2007 The Conair Group All rights reserved Table of Contents A 1 Modbus Communications Description of Modbus communications A 2 Installing the Modbus communication hardware A 2 Using the Modbus parameter 151 A 2 B 1 Ethernet Communications Description of Ethernet B 2 Installing the Ethernet communication hardware B 2 Using the Ethernet parameter 5 B 3 C 1 DeviceNet Communications Description of DeviceNet communications C 2 Installing the DeviceNet communication hardware C 2 Using the DeviceNet communication dip switch settings C 2 Using the LED status C 5 Configuring the DeviceNet software Installing the EDS files C 5 EDS file parameter list configuration options C 6 Adding the Gateway to the scan list C 8 Explicitly writing to the Gateway C 11 Gateway parameter 151 C 12 Table of Contents i ii Table of Contents D 1 SPI
108. k the current draw to the motor Replace the overload Problem Setback RTD Integrity The control can not sense the setback RTD Wheel Rotation Failure The Passive Alarms If the amber Acknowledge Alarm LED is blinking the alarm is a passive alarm The dryer continues to operate but this problem could prevent correct drying of your material Note that once the Acknowledge Alarm button is pressed once the blinking amber LED becomes solid NOTE Passive alarms can be configured as shutdown alarms see the previous Shut down Alarms section See page 4 26 screen 62 for instructions Possible cause The connection in the electrical enclosure for the hopper RTD is loose The connection of the RTD plug on the control board is loose The setback RTD has failed The control board has failed The wheel motor is not turning regeneration temperature differ ential has been reached Regeneration Outlet RTD Integrity The control can not The belt tensioner is loose or the belt is slipping The regeneration heater is not working There is a loose connection in the wiring leading to the RTD sense the regeneration outlet RTD The connection of the RTD plug on the control board is loose The regeneration outlet RTD has failed The control board has failed Solution Check the RTD plug connection and tighten if needed Check the plug connection and tighten if needed Repl
109. ll not make a change to the regeneration temper ature This will reset the dewpoint control back to the factory default values This screen is used to enable or disable the auto start function If the function is enabled the dryer can be started or stopped once each day The start and stop times can be set on screens 56 and 57 NOTE Screens 49 50 51 52 53 and 54 apply to the dewpoint control option Operation 4 23 4 24 Operation Control Function Screen SCREEN 56 MONDAY START TIME ON 8 00 AM SCREEN 57 MONDAY STOP TIME ON 8 00 PM Q NOTE If you purchased the DM II Drying Monitor Option there will be additional screens present in this area See the DM II Appendix for information pertaining to the control func tion descriptions for the DM II Descriptions continued Function This is the auto start screen for the first day of the week Each day has a screen similar to this By pressing the Select Category button under On or Off the dryer can be set to start on Monday The start time can be set by pressing the Select Category button under time and entering a new time on the numeric keypad The AM PM can be changed only after a time value has been entered The button will set PM and the button will set AM The ENTER key must be pressed to lock in the new time The dryer can be manually started at anytime If the auto start time runs out and the dryer has been manually sta
110. mperature Controllers HTC or ResinWorks Using the Modbus Parameter List continued A CAUTION The list of data that may be read and written to by the user is arranged in a specific location parameters 500 to 540 Writing to a location with improper data or writing to an incorrect location outside of the specified range may cause your common controls system to become inoperative or to operate in a manner that may damage your process Be certain that you understand each parameter and its effect before changing anything Conair recommends that you initially attempt to read from the registers and do not attempt any writes Once the infor mation you are trying to read has been confirmed as accurate you can program your new additional data Modbus Communications A 3 A 4 Modbus Communications SECTION r 20 gt Ethernet Communications Description of Ethernet Communications 2 Installing the Ethernet Communication Hardware B 2 Using the Ethernet Parameter List B 3 Ethernet Communications B 1 B 2 Ethernet Communications Description of Ethernet Communications Modbus TCP IP is a protocol that takes the basic Modbus command set that was originally developed for serial communications and applies it to the Ethernet stan dard via TCP IP protocol Beginning in 2006 this protocol can be ordered as an option on the Common Control s dryers When the option is ordered
111. n 1 3 1 4 Introduction ATTENTION Read this so no one gets hurt We design equipment with the user s safety in mind You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should be installed adjusted and serviced by qualified technical personnel who are familiar with the construction operation and potential hazards of this type of machine All wiring disconnects and fuses should be installed by qualified elec trical technicians in accordance with electrical codes in your region Always maintain a safe ground Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate WARNING Voltage hazard This equipment is powered by three phase alternating current as specified on the machine serial tag and data plate A properly sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical enclosure Improper grounding can result in severe personal injury and erratic machine operation Always disconnect and lock out the incoming main power source before opening the electrical enclosure or performing non standard operating procedures such as routine maintenance Only qualified personnel should per
112. nal Band value for the PID loop 44 45 46 and 47 apply to process and regeneration When configured asa_ central dryer there is no process heater in the 1 system Therefore any function associated with i the process heater is not available for central 1 1 1 dryer configurations Operation 4 21 Control Function Descriptions continued Screen Function Sz NOTE Screens 41 42 43 SCREEN 44 This screen shows the integral value for the D PID Loop 44 45 46 and 47 apply to PROCESS INTEGRAL P process and regeneration HEAT COOL 16 0 SCREEN 45 This screen shows the derivative value for the PID Loop PROCESS DERIVATIVE HEAT COOL 2 0 SCREEN 46 With the proper password see page 4 32 screen 85 the PID values can be reset back PROG PID to the factory default settings Press the HEAT COOL Select Category button under the word Heat to reset the values for the process heater or Cool to reset the values for the precooler flow control when this option is installed 1 SCREEN 47 This screen shows the temperature offset i i PROCESS CALIBRATION for the RTD This screen is used if the process readout needs to be calibrated When configured OFFSET 2 F central dryer there is sese __ __ __ ______________________ _ no process heater in the SCREEN 48 This is the Setup Regeneration screen It 1 system Therefore an i y SETUP REGENERATION can be found by pres
113. new one has the same voltage and kW ratings as the original heater tube This information is on the end When configured as a nearest the wires i central dryer there is no process heater in the sys 9 Secure the new heater tube to the support bracket with the clamp with tem Therefore replac the wires of the heater tube to the bottom ing the process heater is Clamp Central 10 Connect the hose and clamp at the top of the heater tube 11 Connect the hose and clamp at the bottom of the heater tube 12 Put the original insulation back on the heater tube Apply duct tape to the seam that was cut during removal 13 W 200 400 models Route the heater wires with the existing harness to the control box Put petroleum jelly on the tips of the cable and push it through the holes in the control box Reference the wiring diagram and connect the heater wires to the solid state relays Connect the high temper ature switch wires to the quick disconnect near the heater tube W 150 models Connect the heater wires and high temperature switch wires to the quick disconnects near the heater tube E oO e 2 EJ Q 14 Replace the side panel of the dryer 15 Make sure the process heater fuses are not blown before applying power to the new heater Troubleshooting 6 35 6 36 Troubleshooting Replacing the Desiccant Wheel When desiccant becomes clogged or contaminated you should replace the desic cant w
114. ning the Regeneration Filter 2 Clogged filters reduce air flow and dryer efficiency Cleaning frequency depends on how much material you process and how dusty or full of fines it is 1 Push in on the sides to release the tabs on the front cover Remove the cover 2 Remove outer filter and clean it with soapy Let the outer filter air dry 3 Loosen the hose clamp holding the regenera tion filter onto the regeneration inlet and remove the filter 5 8 Maintenance Cleaning the Regeneration Filter continuea 4 Clean dust fines and dirt from the filter or replace it with a new filter Clean the filter by laying it on its side and gently tapping it on the floor Replace damaged worn or clogged filters A CAUTION Wear eye protection If you use compressed air to clean the equipment you must wear eye protection and observe all OSHA and other safety regulations pertaining to the use of compressed air 5 Reverse the procedure to reinstall the regeneration filter Maintenance 5 9 S Cleaning the Aftercooler Coils The aftercooler coils will need to be kept clean to keep the aftercooler working efficiently Cleaning frequency depends on the type and amount of material you process 1 Stop the dryer and lockout the main power 2 Turn off the water flow to the water supply line Disconnect supply and return lines S NOTE If an optional flow control was added with the aftercool
115. nstructions Problem Conveying Blower Overload The conveying blower over load has tripped due to a mechanical or electrical prob lem S NOTE Once the overload has tripped you must wait 2 to 15 minutes with the power on for the overload to reset automatically Troubleshooting Possible cause The conveying blower has mechanically failed or is unable to rotate freely The conveying blower has failed electri cally The overload is set incorrectly The conveying blower current draw has exceeded the full load amps of the motor The overload is defective Solution Disconnect and lock out main power Check the conveying blower for mechan ical failure and free rotation Replace if necessary Allow the overload to reset automatically then try to restart the con veying blower Disconnect and lock out main power Check the conveying blower for electri cal shorts or open circuits Replace if necessary Allow the overload to reset automatically then try to restart the con veying blower Disconnect and lock out main power Check the overload settings and confirm that the settings match the full load amps listed on the conveying blower motor Allow the overload to reset automatically then try to restart the conveying blower Press alarm acknowledge and allow the overload to reset automatically then try to restart the conveying blower If the alarm condition occurs again have a qualified electrician chec
116. nt damage to the equipment or personnel Note that once the Acknowledge Alarm button is pressed once the blinking red LED becomes solid Possible cause The process high temperature setpoint is not at least 10 F 6 C above the drying setpoint One of the process solid state relays has failed The air lines are restricted or loose The process setpoint is too low The process heater output on the control board has failed Process RTD is loose or has fallen out The process heater has failed The air lines are restricted or loose The process blower is not running or is running in the wrong direction The process heater output on the board has failed or the output fuse has failed Process setpoint is too low Setback setpoint is too low Solution Reset the process high temperature setpoint at least 10 F 6 C above the drying setpoint Replace the solid state relay Straighten any crimps in the hoses Tighten any loose hoses Set the process setpoint higher or install an optional precooler Replace the control board Check the process RTD and tighten if needed Check the heater fuses and resistance across each leg of the process heater Straighten any crimps in the hoses Tighten any loose hoses Correct the cause of the non running blower blown fuse etc or reverse the rotation of the blower Replace the board or the fuse for the output Adjust the setpoint or add a precooler Adju
117. ntinuous supply of hot dehumidified air while preventing contamination from moisture in the plant Typical Applications 1 Dryer on the floor hopper on the throat 2 Hopper on a floor stand the dryer next to it 3 Dryer and hopper on a mobile floor stand MDC version 150 and 200 only 4 Central dryer with ResinWorks system The W Series Dryer can be used successfully in applications that require A contamination free drying environment Drying temperatures within the ranges shown in the following table continued 2 2 Description Typical Applications continued Model Drying Temperature Range Low temperature with precooler 100 150 F 38 66 C Standard 150 240 F 66 116 C High heat with aftercooler 150 375 F 66 191 C Low high with aftercooler amp precooler 100 375 F 38 191 C See page 3 13 and Appendix B and C When supplied for Throughput rates of 150 to 400 Ibs 68 1 to 149 2 kg per hour some central drying appli materials can be run at a higher rate cations the W oma Dewpoints of 40 F 40 C dryer is not equipped I with a process heater Therefore as a cen Use the aftercooler when tral dryer the W You are drying at temperatures over 240 F 116 C dryer will only sup Throughput rates are less than 50 of the dryer s rated capacity i ply dry air to the hop You are pre drying material at temperatures
118. o at screen 3 for process and screen 4 for regeneration Screen 40 shows the autotune function for the selected heater The dryer must not be running to initiate an autotune The auto tune should be started from a cold start or a minimum of 50 F 28 C difference between starting and autotune tempera tures With the proper password see page 4 32 screen 85 press the Select Category button under the word Off Once selected the word should start to blink Press the or button to toggle the Off to On and then press the ENTER key to start the autotune The display will show Wait then Heat then Done when it is complete Pressing STOP during an autotune will cancel the autotune and not change PID values The PID values can be set back to factory defaults by going to the Reset screen 46 This screen shows the power output range for the heater It is set by default to 0 for the low and 100 for the high t NOTE Screens 41 42 43 This screen shows the PID cycle time for the heater Heat or with a precooler Cool This time value is the time for one on off cycle For example with a heater running at 50 and the cycle time set at 2 sec the heater would be on second and off 1 second and REGEN PID DONE AUTO SCREEN 41 PROCESS POWER LIMIT LOW 2 HIGH 80 SCREEN 42 PROCESS CYCLE TIME HEAT 2 0 SECONDS SCREEN 43 PROCESS PROP BAND HEAT COOL 30 F This screen shows the Proportio
119. on MDC s One of the three power wires is connect ed wrong or one or more phase of power missing EEProm Write Error Process Protection High Temperature If the process protection temperature exceeds the process protection high temperature setpoint it shuts down the dryer Defaults are set to 600 F 316 C for 10 seconds Troubleshooting Possible cause Plugs on wire harness between the display and control boards are loose or not wired correctly Display board or communications boards have failed One of the three power wires are out of phase A fuse has blown Loose wire between the phase board and the control board Phase detection board has failed Internal control board problem The process RTD temperature probe is not installed correctly The process blower is not running The air lines between the dryer and hop per are restricted or loose The dryer is too far from the hopper The process hose is not insulated Solution Make sure plugs are tight on board connections and match the wiring dia gram Replace the defective boards Switch the position of two of the incom ing lead power wires at the dryer See Installation section entitled Checking for proper air flow Check and replace the fuse Make sure the wires are connected and secure Replace the phase detection board Replace the control board Make sure the RTD temperature probe tip is in the center of the hopper
120. ot Installed to Installed The ENTER key must be pressed to lock in the change Once an option is installed there may be additional screens that show in the menu structure that need to be setup Contact Conair Service to determine what S options should be installed on your dryer SCREEN 76 Current Monitor This screen is used with the current moni Option tor option and tells the control which tap is used on the current sensing board 5A SCREEN 77 Current Monitor This screen is used with the current moni Option tor option and is used to scale the reading to the proper reading Operation 4 29 4 30 Operation Control Function Descriptions continued Screen SCREEN 78 MODEL NUMBER CP150 EDIT SCREEN 79 DRYER TYPE STD EDIT SCREEN 80 VOLTAGE FREQ 208 V 60 HZ EDIT Function This screen further defines the dryer type to a model number Based on the dryer type the selections on this menu will change Your dryer should be configured from the factory However if the control were changed from one machine to anoth er the control may need to be reconfig ured With the proper password see page 4 32 screen 85 the Model Number can be changed by pressing the Select Category button under the word Edit The ENTER key must be pressed to lock in the selection This screen is used to tell the control what dryer it is controlling The selections are Standard Central or 1 Hopper
121. p you from over drying your material itral drying applications ithe W series dryer does inot have setback capabil tities Therefore the set This is how setback operates when the control setback mode is set on Temperature The control monitors the temperature of the air exiting the drying hopper If that tempera ture reaches a customer entered setpoint Screen 27 the delivery process air temperature will automatically setback to a customer entered setpoint Screen 26 Then if the air exiting the drying hopper drops below the customer entered temperature on Screen 27 by an amount greater than what is shown on Screen 28 the process temperature will auto matically reset back to the original value Screen 3 function is not applicable To Activate Setback Screen 25 is used to set the setback mode Screen 25 can also be used to change or moni tor the setback mode while in operation 1 Reference the flow chart starting on Page 4 4 and follow the Menu Tree Path to access Screen 25 2 Set the Setback mode Off turns the setback mode off and the dryer will not change the process setpoint The Temperature setting tells the control the dryer should go into setback when the hopper outlet temperature reaches the setpoint on Screen 27 3 Once you have selected your setback mode go to Screen 26 and set the setback process temperature This screen shows the setpoint at which the process tempe
122. pe of equipment is defined in the standard For a dryer or other piece of equipment to be in compliance with the SPI standard you must be able to retrieve certain parameters such as the setpoint process tempera ture high and low temperature deviation alarms temperature to the process tem perature to the process etc Some parameters are also designated as optional parameters that may or may not be available depending on the equipment provider s discretion Installing the SPI Communication Hardware The SPI option is available with the DC 2 display boards The display boards have a RS 232 port built into the board The RS 232 to RS 485 converters are provided and mount on the inside of the door of the electrical cabinet The RS 485 SPI sig nal is then brought to the outside of the cabinet by a 9 pin D sub connector Refer to Conair drawing 130024 and 188629 in Appendix A page A 3 for details of the installation The RS 485 SPI signal is available on pins 4 and 5 of the DB 9 con nector Pins 8 and 9 also have the RS 485 connection parallel with pins 4 and 5 to assist in daisy chaining equipment together Configuring the SPI Communication Software The SPI protocol option must be turned on and configured in the operator display before it may be used To setup the SPI communications 1 Enter the supervisory level password 0210 See your dryer manual for directions if necessary continued Configuring the SPI Communication Soft
123. pera ture is outside the deviation band if the temperature is not moving toward the set point at a rate greater than or equal to X F over Y seconds then the dryer will alarm on Loop Break Once the actual tempera ture is within the deviation band the Loop Break is ignored This is an example of an Alarm Setup deviation screen If the actual temperature goes outside this temperature band High or Low for a set amount of time the dryer will give a deviation alarm With the proper password see page 4 32 screen 85 these values can be changed This set value is the minimum difference between the regeneration inlet and outlet temperature for the wheel rotation alarm Once this difference is reached for the the set time value the dryer will alarm wheel rotation failure This is a delay time for the wheel rotation alarm from start up so regeneration can come up to temperature This screen shows the return air tempera tures at which the dryer will give a passive alarm and when the dryer will shutdown on High Return Air Temperature Control Function Descriptions continued Screen SCREEN 66 CFM Monitor Option CFM LOW SETPOINT 1430 SCREEN 67 DEWPOINT ALARM ACT 20 F 180 SEC SCREEN 68 DEWPOINT DEVIATION HIGH 5 30 SEC SCREEN 69 DEWPOINT DEVIATION LOW 5 F 30 SEC Function This screen shows the low CFM setpoint The default is 1 CFM The default can be changed with the proper password see page 4 3
124. perature Press Setpoint Adjust or buttons or enter a low temperature 150 F 66 C on the numeric keypad and press enter When configured as a central dryer the drying temperature can not be set since there is no process heater in the system I Central Q Auto Start ProcessHester Heater Desiccantindexing EHE ps Gao we Setpoint adjustment Checking for Proper Air FIOW continued 4 Press the START button Hold your hand near the delivery air outlet You should feel air blowing out of the outlet Hot surface Do not place your hand directly on the delivery air outlet The outlet and the air can get hot enough to burn your hand E NOTE If the dryer is running for more than 20 to 30 seconds the 9 Press the STOP button Process Loop Break alarm may occur because the Process RTD is not seeing the expected tempera Return ture rise Air Inlet fab Dry Delivery a 9 Air is Moisture Exhaust 6 If air flow is incorrect disconnect power follow proper lockout procedures and swap any 2 of the 3 main power wires N WARNING All wiring disconnects and fuses should be installed by quali fied electrical technicians in accordance with electrical codes in your region Always maintain a safe ground Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate Installation
125. pictured below To use the lockout device 1 Stop or turn off the equipment 2 Isolate the equipment from the electric power Turn the rotary disconnect switch to the OFF or O position 3 Secure the device with an assigned lock or tag Insert a lock or tag in the holes to prevent movement 4 The equipment is now locked out N WARNING Before removing lockout devices and returning switches to the ON position make sure that all personnel are clear of the machine tools have been removed and all safety guards reinstalled To restore power to the dryer turn the rotary disconnect back to the ON position 1 Remove the lock or tag 2 Turn the rotary disconnect switch to the ON 1 position SECTION Description 4 72 ZN S gt What is the Carousel Plus W Series Dryer 2 2 Typical 5 2 2 HOW RW EAR 2 4 Specifications Carousel Plus W Series Description 2 1 What is the Carousel Plus W Series Dryer The Carousel Plus W Series dehumidifying dryer produces hot low dewpoint air that removes moisture from hygroscopic plastics The dryer pulls warm moist air from a drying hopper and circulates it through a dehumidifying desiccant wheel The dryer then heats the air to the drying temperature you selected and circulates it through the material in the hopper The dryer s closed loop design ensures a co
126. play beside the word Auto Start will flash if the dryer is set to start automatically The dryer can be set to automatically start each day Programming Auto Stop The Auto Stop time and date can be programmed using the Auto Stop Countdown screen This screen can be accessed under the SETUP PROC and OTHER screens from the Dryer Main screen 12 SCREEN 36 SCREEN 37 Dryer Setup Setup Process Proc Disp Other Proc Regen Other SCREEN 57 MONDAY STOP TIME ON 8 00 PM Once the Auto Stop time and date has been programmed the Auto Stop Countdown screen screen 34 will show the amount of time remaining before the dryer will automatically stop The dryer can be set to automatically stop each day NOTE To use the Auto Start or Auto Stop Timer you must have the Auto Start function enabled see screen 55 page 4 23 Operation 4 41 4 42 i central dryer the high setpoint limits can not be set since there is no i process heater in the system 1 1 NOTE Software may allow the Process temperature setpoint limit up to 450 F 232 C however Conair does not recommend a set point limit over 375 F 191 C due to nuisance alarms NOTE Conair does not recommend low setpoints under 150 F 66 C due to nuisance alarms Operation Setting the High Setpoint Limit You can protect your drying process by preventing someone from entering process temperatures above or below an acceptable level
127. precooler housing 6 Connect a piece of hose from the bot tom of the aftercooler housing to the inlet of the process heater Precooler housing continued Precooler outlet Inlet to heater B 1 Appendix Installing a Precooler optiona continued 7 Prepare the precooler for installation Make sure the gasket is put in place Apply the gasket material to the inside of the precooler flange ec TIP Make the water supply and discharge return connections with flexible hoses at least 24 inch 61 cm long This allows you to easily remove the precooler assembly for cleaning Precooler Installed 8 Install the coils in the housing Make sure the staggered holes in the precooler mounting plate align with the holes in the precooler housing eC TIP If an optional flow control is also being installed with the precooler the manual shut off valve should be installed on the inlet line for the flow control 9 Connect the water supply line to the pre cooler inlet If a manual shut off valve is used it should be mounted on the inlet line Water solenoid Optional NOTE Your dryer may not be equipped with optional water solenoids 10 Connect the water discharge or return line with the pressure relief valve to the pre cooler outlet Use the bracket supplied to secure the pressure relief valve to the back of the dryer IMPORTANT Turn the water off when the dryer is not in use to prevent con densa
128. programmed under SETUP PROC PROC OTHER screens 55 56 57 The dryer can be set to automatically start and stop each day If the dryer is set to auto stop this screen will appear and show the amount of time remaining before the dryer will automati cally stop The auto stop feature can be programmed under SETUP PROC PROC OTHER screens 55 56 57 The dryer can be set to automatically start and stop each day Tip This information is important to know when ordering a control board ec Tip This information is important to know when ordering a display board Operation 4 19 By NOTE Conair is not responsi ble for damage caused by excessively high drying setpoints that are not in accordance with your drying material recommendations NOTE Software may allow the Process temperature setpoint limit up to 450 F 232 C however Conair does not recommend a set point limit over 375 F 191 C due to nuisance alarms NOTE Conair does not recommend low setpoints under 150 F 66 C due to nuisance alarms 4 20 Operation Control Function Descriptions continued Screen SCREEN 35 PANEL INSIDE TEMP ACT 100 F SCREEN 36 DRYER SETUP PROC DISP OTHER SCREEN 37 SETUP PROCESS PROC OTHER SCREEN 38 SETUP PROCESS PROC PROPID RETPID SCREEN 39 PROCESS TEMPERATURE RANGE 70 F 450 F Function This screen shows the temperature inside the control enclosure
129. r door 3 Clean the spreader cone and the inside of the hopper Make sure you also clean the return air screen at the return air outlet of the hopper 4 Repeat the steps in reverse order to reassemble the hopper before adding material Maintenance 5 5 aoueualuleW S Cleaning the Process Filter Clogged filters reduce air flow and dryer efficiency Cleaning frequency depends on how much material you process and how dusty or full of fines it is 1 Push in on the sides to release the tabs on the front cover Remove the cover 2 Remove the cover wing nut then pull the cap off 3 Remove the filter wing nut then remove the filter 5 6 Maintenance Cleaning the Process Filter continued 4 Remove outer filter and clean it with soapy water Let air dry 5 Clean the filter by laying it on its side and gently tapping it on the floor Replace damaged worn or clogged filters A CAUTION Wear eye protection If you use compressed air to clean the equipment you must wear eye protection and observe all OSHA and other safety regulations pertaining to the use of compressed air 6 Reverse the procedure to reinstall the process filter Ensure that the gasket on filter cap is in place and in good condition m E 2 0 D o TIP If gasket on the process filter cap becomes loose or detached from the filter cap resecure with high tempera ture silicone adhesive Maintenance 5 7 Clea
130. rature will go to once the control goes into setback Note Make sure your setback tempera ture is approximately 40 F above your return air temperature when using this feature When the control is in the setback mode the LED on the dryer display beside SET BACK will illuminate The actual temperature on the default screen will still show the actual temperature measured at the hopper inlet The setpoint shown on the default screen will still show the original setpoint 4 44 Operation Using the Setback Feature continued 4 Access Screen 27 and set the setback return temperature for the air exiting the hopper This screen shows the actual temperature meas ured at the hopper outlet and the setpoint temperature for the air at the hopper outlet that will initiate the control to go into setback 5 Access Screen 28 and set the setback temperature band This screen shows how much lower the hopper outlet temperature must drop from the Setback Return Temperature setpoint Screen 27 before the dryer control should restore the original process setpoint Setback Feature Guidelines Careful selection of setpoint values in these functions is necessary for the setback to operate properly The following table is only a guideline of recommended settings for these setpoints It will be necessary for each customer to determine the best setpoints for their application based on experience Normal Setback Return Temp Setback Temp Drying Temp Screen
131. reen 12 Any information under the status section is read only NO CHANGES can be made from the status sections The operator can select to see status information for Process Regeneration or Other This is a column title screen To navigate to screens within a column reference the flow charts beginning on Page 4 4 the operator must use the scroll buttons Next or Prev The Next button will scroll one screen at a time down a list of screens Once the last screen in the list is displayed the Next button will return the operator back to this Title screen When the Prev button is pressed it will scroll one screen at a time up the list of screens Once the title screen is displayed the Prev button will go up to the next high screen in this case the Dryer Status screen 13 SCREEN 15 PROCESS HEATER OUTPUT 100 This is an example of a Heater Output screen It displays the actual percentage output of the heater which can also be interpreted as the percentage on time The on time can be checked by looking at the heater LED s in the Dryer Status section of the display Control Function Descriptions continuea Screen Function SCREEN 16 The screen shows the process protection PROCESS PROTECTION actual temperature measured at the process heater outlet ACT 350 F 1 When configured as a 1 1 central dryer there is not 1 1 1 process heater in the system Therefore any
132. roller If 1X is chosen the data will be retrieved as a whole number with no implied deci mal place For example if a process temperature was retrieved and the real value of the temperature was 225 3927 the temperature would be read as 225 using the 1X register format If 10X was chosen the raw data would be retrieved as 2253 requiring the user to add the implied decimal point to show the temperature as 225 3 Similarly if the data was retrieved in the 100X format the raw data would be 22539 requiring the user to add the decimal place to display it as 225 39 Parameter 2 Number of Int Parameters 0 to 40 This field will display how many integer parameters are retrieved from the con troller This will be either 10 or 20 depending on the position of dip switch 2 switches 1 and 2 Parameter 3 Number of Parameters 0 to 10 This field will display how many floating point parameters are retrieved from the controller The default is zero and is not normally changed by the user If your application requires the use of floating point numbers please consult with a Conair representative Parameter 4 Dip switch Combination of 1 s and 0 This field shows the actual positions of dip switch 1 on the gateway Parameter 5 Dip switch 2 Combination of 1 s and 0 s This field shows the actual positions of dip switch 2 on the gateway continued DeviceNet Communications C 7 C 8 DeviceNet Communications Configuring the DeviceNet
133. rted nothing will happen This is the auto stop screen for the first day of the week Each day has a screen similar to this By pressing the Select Category button under On or Off the dryer can be set to stop on Monday The stop time can be set by pressing the Select Category button under time and entering a new time on the numeric keypad The AM PM can be changed only after a time value has been entered The button will set PM and the button will set AM The ENTER key must be pressed to lock in the new time If the auto stop time runs out and the dryer has already been manually stopped nothing will happen If the dryer was auto started on Monday morning and the Monday auto stop is set to off the dryer will continue running until it hits a day of the week when the auto stop is set to On at that time the dryer will turn off Control Function Descriptions continued Screen SCREEN 58 ALARM ACTION ALARM SETUP Function This is the alarm action and setup screen With the proper password see page 4 32 screen 85 the Select Category button can be pressed under Alarm Action or Alarm Setup Alarm Action screens can be used to assign an alarm as Off Passive or Shutdown screen 59 Alarm Setup screens can be used to change alarm set points and delay times screens 60 70 SCREEN 59 PROC TEMP DEVIATION ON EDIT SCREEN 60 PROCESS HIGH TEMP 250 F 1 SEC PASS EDIT This is an example
134. ry button under the word Yes No Setting it to Yes and pressing the ENTER Key will change the display to screen 90 If the user does not want to change the pass word pressing the Next key will return the control to the Dryer Setup Password screen 14 This screen shows the password entry screen Pressing the Select Category but ton under the word Press Here will allow the user to enter a new password by using the key pad Once a new password has been entered the ENTER key must be pressed The display will show the new password for 3 seconds then return to the Change Supervisor Password screen 89 To exit press the Next key and the con trol will return to the Dryer Setup Password Screen This is the Dryer Diagnostic screen It can be found by pressing the Select Category button under the word Diag on the Dryer Main Menu screen 12 By pressing the Select Category buttons under the titles the user can select to see diagnostic infor mation for Alarms Alarm History or Inputs and Outputs Operation 4 33 4 34 Operation Control Function Descriptions continued Screen SCREEN 92 00 S REGEN RTD 1 31 00 09 24 P INFO SCREEN 93 ALARM ACTIVATED FOR 10 3 MINUTES SCREEN 94 DIAGNOSTIC EVENTS ALARMS ANALOG DIGITAL SCREEN 95 PROCESS HIGH TEMP 5 0 0 Function This is an example of one of the alarm his tory screens The first two numbers of the first line show what alarm
135. s hose is not insulated Solution Check for air flow blockages or loose hoses between the outlet of the dryer and the inlet of the hopper Straighten any crimps in the hoses Tighten any loose hoses The dryer and the hopper should not be located more than 10 feet 3 m apart Check the process RTD and tighten if needed Correct the cause of the non functioning blower Insulated hose is required for high dry ing temperatures Passive Alarms If the amber Acknowledge Alarm LED is blinking the alarm is a passive alarm The dryer continues to operate but this problem could prevent correct drying of your material Note that once the Acknowledge Alarm button is pressed once the blinking amber LED becomes solid D NOTE Passive alarms can be configured as shutdown alarms see the previous Shut down Alarms section See page 4 26 screen 62 for instructions Problem Process Temperature Deviation The process tem perature exceeds the deviation band as entered for the speci fied time Default values are 10 F 6 C for 5 seconds Process Low Temperature The process temperature is less than the low temperature setpoint for the specified time Default values are 70 F 21 C for 20 seconds Regeneration Temperature Deviation The regeneration temperature exceeds the devi ation band for the specified time Default values are 10 F 6 C for 5 seconds Possible cause One of the solid state rela
136. s to the gateway using the Apply button continued Configuring the DeviceNet Software Adding the Gateway to the Scan List continued 4 Close the parameter list and reopen once you have applied your parameters Check Parameter 7 to see how many bytes of data are in the input assembly size 5 Go online with the scanner and move the gateway from the Available Devices area to the Scanlist area using the arrow key After the gateway has been moved the I O Parameters button should be accessible 1769 SDN Scanner Module E 2 x General Module Scanlist Input Output ADR Summary Available Devices Scanlist 01 Conair Common Control 02 Conair Common Contr B 03 Conair Common Contr lt lt 9 20 a gt ER Automap on Add Node Active Upload from Scanner Electronic Key Device Type Download ta Scanner T Vendor Edit 1 0 Parameters Product Code Major Revision Minor 7 or higher DeviceNet Communications C 9 C 10 DeviceNet Communications Configuring the DeviceNet Software Adding the Gateway to the Scan List continued 02 Conair Common Contr B 03 Conair Common Contr Upload from Scanner F Minor For higher f Change of State Cyclic Use Output Bit continued Configuring the DeviceNet Software Adding the Gateway to the Scan List continued
137. serial communi cation interface maybe be either RS 232 DC 2 control board or RS 485 DC con trol board Converters may be ordered with the product to convert from one to the other The RS 485 standard allows multiple controllers to be daisy chained togeth er over longer distances while the RS 232 allows direct connection to most person al computers without an interface adapter Installing the Modbus Communication Hardware The hardware required for Modbus communications is included with the product when it is shipped Connectors and cabling must be supplied by the user or ordered from Conair A converter is available if your controls do not use the standard com munications you desire See Appendix A page A 3 for the proper cabling and con nection information for both types of interface Using the Modbus Parameter List The Modbus interface uses standard Modbus protocol to communicate with a com mon controls system The data that may be retrieved is arranged in a parameter list By using the Modbus register read and write commands the desired data may be read from or written to the controller The list of data that may be set or retrieved with the common controls system is arranged in Modbus registers 500 to 539 See Appendix A page 1 for the data contained in this area for your particular type of equipment DC 2 control parameters are used on a dryer with a DC 2 con trol panel and DC plus control parameters are used with Hopper Te
138. sing the Select function associated with Category button under the word Regen on i the process heater is not REGEN PID the Setup Process screen screen 37 By available for central pressing the Select Category buttons under dryer configurations the titles the user can select to see setup i i information for Regeneration or Regeneration PID SCREEN 49 This is the amount of time the control amp NOTE Screens 49 50 51 PROCESS DEWPOINT waits before checking the dewpoint value 52 53 and 54 apply to after making a change This time value the dewpoint control SAMPLE RATE 150 SEC gives the system time to respond to a option process change 4 22 Operation Control Function Descriptions continued Screen SCREEN 50 PROCESS DEWPOINT TRIM UP LIMIT 375 F SCREEN 51 PROCESS DEWPOINT TRIM LOW LIMIT 100 F SCREEN 52 PROCESS DEWPOINT GAIN 0 7 SCREEN 53 PROCESS DEWPOINT DEADBAND 1 SCREEN 54 PROCESS DEWPOINT CONTROL RESET SCREEN 55 AUTO START TIMER ENABLED EDIT Function This is the maximum value the dewpoint control can set the regeneration tempera ture to achieve the desired dewpoint This is the minimum value the dewpoint control can set the regeneration tempera ture to achieve the desired dewpoint This is the proportional gain value for the dewpoint control This is the deadband range If the actual dewpoint value is within this range of the dewpoint setpoint the control wi
139. st the setpoint or add a precooler 6 5 Shutdown Alarms If the red Acknowledge Alarm LED is blinking the alarm is a shutdown alarm The dryer will shutdown automatically to prevent damage to the equipment or personnel Note that once the Acknowledge Alarm button is pressed once the blinking red LED becomes solid i drying applications these 1 shutdown alarms are not available Problem Possible cause Solution Process Heater High There is an airflow blockage or loose Locate and remove any airflow restric Temperature The snap hoses tions switch in the process heater tube opens due to excessive Tighten any loose hoses temperature The process blower is not running or run Correct the cause of the non running ning in the wrong direction blower blown fuse etc or reverse the rotation of the blower The isolation contactor failed in the Replace the isolation contactor closed position The process heater output on the board Replace the board has failed The heater solid state relays SSRs failed Replace the failed heater solid state relays SSRs Regeneration Heater High The regeneration exhaust is blocked or the Locate and remove any airflow restric Temperature The snap air hoses are loose tions switch in the regeneration heater tube activated due to Tighten any loose hoses excessive temperature The regeneration blower is not running or Correct the cause of the non running running in th
140. stain production A WARNING Only qualified service personnel should examine and correct problems that require opening the dryer s electrical enclosure or using electrical wires to diagnose the cause A WARNING High voltage Always stop the Carousel Plus dryer disconnect and lock out the main power source before troubleshooting or performing repairs CAUTION Hot surfaces Always protect yourself from hot surfaces inside E and outside of the dryer and hopper Troubleshooting 6 3 S Pushing the Acknowledge Alarm button when there is no active alarm will take the user directly to the Alarm History list Screen 95 page 4 34 Qd NOTE The dryer cannot be started if a passive alarm is present on power up 6 4 Troubleshooting How to Identify the Cause of a Problem Dryer alarms are indicated by an illuminated Acknowledge Alarm light on the W series dryer control panel Shutdown alarms will sound the alarm horn and turn on the alarm beacon A problem can trigger two types of alarms Shutdown The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer Passive The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer Acknowledge Alarm LED and Button When the alarm light is displayed
141. start if there is a active alarm Loose or improperly connected wire Improper dip switch setup on control board Defective display or control board The software revision of the display board and control board are not compati ble Solution Push the acknowledgement button to identify the alarm and address it as nec essary Check wiring between control board and display board Check dip switch setup on control board Replace boards as a set In most cases both display and control boards will need to be replace as a set Troubleshooting 6 21 6 22 Additional Alarms Along with the Passive and Shutdown alarms you may encounter additional error messages that indicate a problem with the control Problem Er Lo There is a problem in the sensor connection RTD Dewpoint sensor etc for the affected function Er Hi There is a problem in the analog input section of the control Troubleshooting Possible cause Problem in the analog input section of the control Defect in the main control board RTD is not connected properly or is defective The ribbon cable between an analog option board and the main control board is not connected properly Connector to all RTDs is removed Problem in the analog input section of the control Defect in the main control board Solution Check that all jumpers are in their proper place Check to see if the dewpoint sensor is connect
142. tallation Now it s time to make sure everything works 1 Make sure there is no material in the hopper If you have mounted a loader or vacuum receiver on the hop per disconnect the material inlet hose at the source or turn the loader off 2 Turn on the main power to the dryer Make sure the dryer s disconnect dial is in the ON position This pow ers up the control and the display lights will illuminate 3 Set the drying temperatures Press temperature select with the select category button and then press the Setpoint Adjust or buttons or enter the low setpoint temperature 150 F 66 C on the numeric keypad and press enter Central When configured as a central dryer drying temper rature can not be set since there is process heater 1 1 1 Regen E Auto Start Process Heater Regen Heater Desiccant Indexing in the system Set Back Temp Select Category Buttons Setpoint adjustment Buttons continued 3 14 Installation Testing the Installation continued 4 Press the START button If everything is installed correctly The green light on the start button will illuminate The process and regeneration blowers turn on and the display LEDS will illuminate The process and regeneration heaters turn on and the display LEDs will illuminate The desiccant wheel starts turning The green light on the start button will ill
143. the average dewpoint and or Dewpoint Monitor over the last hour of run time DEWPOINT CONTROL AVG 35 F SCREEN 25 Setback on This screen shows the setting of the set T back feature see page 4 44 The supervi emperature sor password is required to make changes SETBACK MODE to this screen It can be set to OFF OFF Temperature or Manual On Off turns the setback mode off and the dryer will not change the process setpoint The tempera ture setting tells the control the dryer should go into setback when the hopper outlet temperature reaches the setpoint screen 27 The Manual On setting tells the dryer to go into setback now SCREEN 26 This screen shows the setpoint the process SETBACK TEMPERATURE temperature will go to once the control goes into setback When the control is in ACT 140 F SET 140 F the setback mode the LED on the dryer display beside SETBACK will illuminate The actual temperature on the default screen will still show the actual tempera ture measured at the hopper inlet The set point shown on the default screen will still show the original setpoint Operation 4 17 4 18 Operation Control Function Descriptions continued Screen SCREEN 27 SETBACK RETURN TEMP ACT 140 F SET 140 F SCREEN 28 SETBACK TEMP BAND SET 20 F SCREEN 29 Regeneration Outlet Temperature REGEN OUTLET TEMP ACT 280 SCREEN 30 MODEL CP150 480 V 60 Hz Function This screen shows the actual t
144. the closed position The output on the board has failed Solution Make sure your material supply system is working properly Ensure water flow to the aftercooler Turn on the water supply or fix any leaks or blockages Clean the aftercooler coils See Maintenance section entitled Cleaning the aftercooler coils Check the heater fuses and resistance across each leg of the process heater Replace the control board or the fuse Check the regeneration RTD and tighten if needed Replace the failed solid state relays SSRs Replace the board Passive Alarms If the amber Acknowledge Alarm LED is blinking the alarm is a passive alarm The dryer continues to operate but this problem could prevent correct drying of your material Note that once the Acknowledge Alarm button is pressed once the blinking amber LED becomes solid NOTE Passive alarms can be configured as shutdown alarms see the previous Shut Problem Regeneration Temperature Loop Break The regenera tion temperature is outside of the operator entered deviation alarm band see Regeneration Temperature Deviation passive alarm and the regeneration temperature is not moving towards the setpoint at a rate greater than specified Default values are 2 F 1 C over 40 seconds Process Dewpoint The dew point has not fallen below the setpoint If the dewpoint goes below the setpoint for 180 second the alarm should go away NOT
145. the dewpoint with a portable dewpoint instrument Conair sells a variety of portable dewpoint meters Contact Conair Parts Possible cause Low regeneration temperature reaching proper setpoint 6 28 Troubleshooting Poor regeneration airflow High dewpoint ambient air leaking into the closed loop drying circuit Return air temperature to the dryer is too high Poor desiccant performance Solution Replace or check defective heaters fuses etc Clean or replace the regeneration filter Ensure the regeneration blower is oper ating properly and rotating in the correct direction Remove obstructions in the air stream such as crimped hoses etc Replace damaged hoses and seal any leaks in the process air circuit If using a vacuum loader on the hopper ensure that the loader shroud is installed in the hopper and that the hopper is completely filled with material If partially filling your hopper ensure that the hopper loader is sealed against ambient air Install a gasket between the loader and the top of the hopper Clean the aftercooler coils See Maintenance section entitled Cleaning the aftercooler coils See Troubleshooting section entitled Replacing the desiccant wheel assembly Replacing Fuses 1 Disconnect and lockout the main power supply 2 Open the electrical enclosure door 3 Check the fuse If necessary pull the fuse out and replace it with a fuse of the same type and rating
146. tion Appendix B 2 Cleaning the Precooler Coils If you have the optional precooler you need to clean the coils to keep it working efficiently Cleaning frequency depends on the type and amount of material you process 1 Stop the dryer and lockout the main power A 2 Tur off the water flow to the water supply line Disconnect supply and return lines 83 NOTE If an optional flow control was added with the precooler remove the compression fitting from the precooler inlet Loosen the fitting on the flow control then swing the copper water supply tube out and away from the precooler inlet 3 Remove the screws securing the precooler in the housing ec TIP If the precooler without a flow control was installed using the recommended 24 inch 61 cm of flexible hoses there is no need to disconnect the hoses from the precooler inlet and outlet 4 Remove the precooler assembly from the precooler housing continued C 1 Appendix Cleaning the Precooler Coils continued 5 Clean the assembly using a mild soap and water Let the assembly dry thoroughly before installation In severe situations steam cleaning or use of solvents maybe necessary CAUTION During the cleaning process DO NOT cut remove the stainless steel wire that holds the assembly together 6 Inspect the condition of the gasket If it is damaged replace the gasket 7 Reassemble by repeating the steps in reverse order 8 Connect the
147. ts that is not being satisfied refer to the following list and possible causes and solutions Temperature The temperature of the air entering the hopper must be at the prop er drying temperature for your material as specified by your supplier Possible cause Incorrect setpoint entering the hopper is not at proper drying tempera ture Not able to achieve setpoint Inaccurate process temperature readout Solution Refer to the drying specifications for your material and adjust the setpoint to the recommended setpoint If your dryer has the Setback option make sure it is not active unless you have specifically activated it If neces sary refer to the Operation section of this manual for assistance in using the Setback function Replace any defective process heater contactors fuses etc Ensure the selected drying temperature is within the design specifications of your dryer Ensure the Process RTD is properly positioned in the air stream Determine if there is a problem in the temperature control circuit and repair or replace any defective components such as RTD temperature control circuit boards etc Troubleshooting 6 25 6 26 Problem Material residence time is too long or short Troubleshooting Poor Material Drying Troubleshooting continued Residence Time The time your material supplier has determined that the material in use must be heated to its drying temperature to ach
148. uate sample air 2 Open the right side panel of the dryer and locate the process heater tube 4 Turn on the dryer continued Maintenance 5 3 5 4 Maintenance Checking the Dewpoint continues 5 Turn on the portable instrument and ensure there is positive airflow through the sensor 6 Monitor the readout and allow ample time for it to stabilize before discon necting the portable instrument Some dewpoint monitors require a substan tial amount of time for residual moisture to be purged from the sensor 7 In the event the dewpoint is not satisfactory refer to the Troubleshooting sec tion of the manual under Process Dewpoint alarm for DC2 8 Stop the dryer and allow it to cool down Then disconnect your portable instrument and replace any pipe plugs that may have been removed 9 Close side panels and start the dryer Cleaning the Hopper 150 200 A CAUTION Hot surfaces Always protect yourself from hot surfaces inside and out side the dryer and drying hopper The hopper spreader cone and discharge assembly should be cleaned thoroughly between material changes to prevent resin contamination 1 Drain the hopper Place a con tainer beneath the hopper s drain port to catch the material 2 Remove the spreader cone Open the hopper door Reach into the hopper Grasp the spreader cone tube lift up slightly twist and then push down to release it Tilt the cone assembly and pull it out through the hoppe
149. ult supervisor password is 0210 The supervisor can change this password on screen 89 This is the Reset Password screen It will only be shown when the second and fourth Select Category buttons are pressed at the same time when at screen 85 By pressing the Select Category button under the word Press Here the user can enter the default password by using the keypad Once the default password has been entered the ENTER key must be pressed This will change the password back to the factory default password see page 4 32 screen 85 This is the display screen that appears when a valid password has been entered Pressing the Previous button will take you screen 14 Pressing Next will take you to screen 88 Control Function Descriptions continued Screen SCREEN 88 LOGOUT SUPERVISOR PASSWORD YES SCREEN 89 CHANGE SUPERVISOR PASSWORD YES SCREEN 90 ENTER NEW PASSWORD PRESS HERE SCREEN 91 DRYER DIAGNOSTIC ALRM EVENT HIST 1 0 Function This is the password logout screen If nothing is done the password will auto matically be logged out after 30 minutes To logout use the Select Category button under the word Yes No Setting it to Yes and pressing the ENTER Key will change the display to Logging Out Password Screen 86 will display for 3 seconds then will automatically go to screen 14 This screen allows the supervisor to change the password To change the pass word use the Select Catego
150. uminate The process and regeneration blowers turn on and the dis play LEDS will illuminate he regeneration heater turns on and the display LED will illuminate he desiccant wheel starts turning 5 Press the STOP button If everything is installed correctly The blowers will continue running as needed to cool the heaters until both heaters are less than 150 F 66 C or ten minutes whichever is shorter 6 The test is over If the dryer performed the normal operating sequences as out lined you can load the hopper and begin operation If it did not refer to the Troubleshooting section of the User Guide IMPORTANT Be sure the cable tie has been removed from the desic cant wheel t NOTE If the Process Loop Break alarm occurs the blow er rotation may be incorrect see Page 3 8 or the Process RTD may be installed incor rectly see Page 3 7 Installation 3 15 3 16 Installation Using Communications optionay To use the optional Modbus Ethernet SPI or standard DeviceNet communica tions see the Addendum for hardware installation and configuration SPI connection DeviceNet connection Ethernet connection amp NOTE These communications be left disconnected if in use SECTION Operation Carousel Plus W series dryer control panel DC 2 4 2 Carousel Plus W series dryer control functions 4 3 Control function flow
151. unications C 11 C 12 DeviceNet Communications Configuring the DeviceNet Software Gateway Parameter List Similarly to the Modbus communications the Common Controls parameters that are available are stored in registers 500 to 539 The dip switches determine how much of the list is transferred to the PLC If the dip switch is set for ten words Modbus parameters 500 to 509 will be transferred to the input image of the scan ner If the dip switches are set for twenty words Modbus parameters 500 to 519 will be transferred to the scanner See Appendix A page A 1 for the actual parame ters that are available from the type of common control device that your system is using SECTION SPI Communications Description of SPI Communications D 2 Installing the SPI Communication Hardware D 2 Configuring the SPI Communication Software D 2 Supported Dryer SPI Commands D 4 SPI Communications D 1 D 2 SPI Communications Description of SPI Communications The Society of Plastics Industry SPI has defined a standard protocol to be used for interconnecting plastics equipment This protocol uses the RS 485 standard as the physical connection and defines stand addresses and commands to communi cate with the various kinds of equipment in common use at a typical plastics facili ty For example a dryer is specified as Device ID 22 hex a chiller is Device ID 21 hex The data retrieved for each ty
152. urchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is being made Warranty Limitations Except for the Equipment Guarantee and Performance Warranty stated above Conair disclaims all other warranties with respect to the equipment express or implied arising by operation of law course of dealing usage of trade or otherwise including but not limited to the implied warranties of merchantability and fitness for a particular purpose Appendix A 2 Installing a Precooler Precoolers are available from Conair You can add a precooler to the Carousel Plus W series dryer by ordering the Contact Conair Parts optional precooler assembly Installation is easy 800 458 1960 From outside of the United States call 814 437 6861 The optional precooler requires a source of city tower or chiller water and a dis charge or return line You can use water at temperatures up to 85 F 30 C But the water flow should be at least 3 gal min 11 4 liters min for W dryer models 150 400 1 Stop the dryer and lockout the main power 2 Remove the side panels 3 Remove the knockout for the precooler housing on the dryer 4 Install the precooler housing Bolt the precooler housing in place with the hose connection to the Knockout bottom 5 Disconnect the hose from the bottom of the process heater tube Connect the hose to the inlet of the
153. uring normal operation prevents the necessary cool down period and can trigger the shut down high temperature alarm during your next drying cycle A Caution Improper shut down can cause damage to your dryer 4 38 Operation How to Use the Supervisor s Password The supervisor s password must be entered before you can use or make changes to some screens on the dryer control To enter the supervisor password 1 Go to screen 12 and press the Select Category button under Setup DRYER MAIN MENU STAT SETUP DIAG 2 This will take you to screen 36 On Screen 36 press the Select Category button under Other DRYER SETUP PROC ALM DISP OTHER 3 This will take you to screen 74 On Screen 74 press the Select Category button under PW DRYER SETUP OTHER OPT INSP COM PW This will take you to screen 14 DRYER SETUP PASSWORD SCREEN 4 On Screen 14 press the Scroll List Next button This will take you to screen 85 ENTER PASSWORD 0210 continued Operation 4 39 4 40 Operation How to Use the Supervisor s Password continuea 5 This is the screen where you will need to enter the supervisor s password The default supervisory password in 0210 Enter this number to make changes to screens where the supervisor s password is necessary to use or change a function of the dryer ENTER PASSWORD 0210 Be sure to push Enter after entering the password If the password is entered successfully screen
154. urned on and screen 1 is displayed for 3 seconds this screen is dis played for another 3 seconds It shows the day of the week on the first line and the date and time on the second line If this information is not correct it can be changed under the SETUP DISP DATE TIME screen 73 NOTE The supervisory pass word is required to change certain parameters More detail about the password can be on Page 4 39 and under screen 85 on page 4 32 SCREEN 3 Default Screen PROCESS TEMPERATURE ACT 325 F SET 325 F This is the DEFAULT screen It shows the process air temperature setpoint and actual temperature measured at the inlet to the drying hopper The setpoint can be changed by pressing the Select Category button under the Setpoint Value Once the button is pressed the setpoint will begin to flash The numeric keys can be used to enter a new setpoint or the or Increment Decrement buttons can be used to change the setpoint Holding the or buttons in will allow the number to ramp up faster the longer the button is held The ENTER key must be pressed to accept the new number The temperature setpoint range can be changed under the continued Central When supplied for central drying appli cations this function is not available Operation 4 11 Control Function Descriptions continued Screen Function SCREEN 3 Default Screen SETUP PROC PROC PROC PROCESS continued TEMPE
155. us Control Parameters Used on ResinWorks and Hopper Temperature Controllers HTC Modbus Register Number Description Comments 530 Process Temperature Setpoint 531 Process Temperature Setpoint Setback 532 Return Air Setpoint Setback 533 Load Rate Setpoint Setback 534 PM 1 Dewpoint Setpoint 535 Start Command 1 start 536 Stop Command 1 stop 537 Alarm Acknowledge 538 Process Temperature Setpoint 539 Process Temperature Setpoint Related Drawings 130023 Common Controls DeviceNet Gateway Assemblies D dryers 130023 02 CDDS DeviceNet Gateway Assembly 130023 03 Common Controls DeviceNet Gateway Assemblies W dryers 13024 Common Controls SPI Communications Assembly 188629 Common Controls 24 VAC Power and Comms Cables 18865201 W15 100 Dryer SPI Control Communications Assembly 18865202 WMDC15 100 Dryer SPI Control Communications Assembly 18865203 W150 5000 Dryer SPI Control Communications Assembly 18865204 W15 100 Dryer Modbus Control Communications Assembly 18865205 WMDC15 100 Dryer Modbus Control Communications Assembly 18865206 W150 500 Dryer Modbus Control Communications Assembly 18865207 W15 100 Dryer DeviceNet Control Communications Assembly 18865208 WMDC15 100 Dryer DeviceNet Control Communications Assembly 18865209 W150 5000 Dryer DeviceNet Control Communications Assembly 18865210 W Dryer Ethernet Control Communications Assembly Appendix A 3
156. utput Actual 96 516 Regeneration Heater Output Actual 96 517 Process Protect Actual Temperature 518 Product Type 519 Product Type Write Area Modbus Register Number Description Comments 530 Process Temperature Setpoint 531 Process Temperature Setpoint Setback 532 Return Air Setpoint Setback 533 Load Rate Setpoint Setback 534 PM 1 Dewpoint Setpoint continued Appendix A 1 A 2 Appendix Modbus RS 232 485 Serial Communication Parameters continued Modbus Register Number Description Comments 935 Start Command 1 start 536 Stop Command 1 stop 537 Alarm Acknowledge 538 Process Temperature Setpoint 539 Process Temperature Setpoint DC Plus Control Parameters Used on ResinWorks and Hopper Temperature Controllers HTC Modbus Register Number Description Comments 500 Product Type 501 Process Temperature Setpoint 502 Process Actual Temperature 503 Process Temperature Setpoint Setback 504 Return Air Temperature Out of Hopper 505 Return Air Setpoint Setback 506 Load Rate Setpoint Setback 507 Average Load Rate Actual Setback 508 Operational Mode 509 Running Status 510 Process Heater Output Actual 511 Alarms 512 RTD Integrity Alarms 513 Regeneration Actual Temperature 514 Regeneration Heater Output Actual 515 Process Protect Actual Temperature 516 Product Type 517 Product Type 518 Product Type 519 Product Type Modbus RS 232 485 Serial Communication Parameters continued DC Pl
157. ware continued 2 Once the password has been entered go to Setup Other Comm 3 When the Comm menu is displayed scroll down through the menu and set the Protocol to SPT Set the slave ID to a unique address on the RS 485 network master Once you have completed entering in your informa tion return to the opening menu and cycle the power on your equipment to establish the new settings In order to connect Conair equipment to a host computer system Conair can pro vide an SPI DDE server which will allow DDE compliant software packages such as Wonderware or Excel to connect to the SPI network with minimal programming required For more information on the SPI protocol you can obtain the SPI Communication protocol manual by contacting The Society of Plastics Industry Inc 1801 K Street NW Suite 600K Washington D C 20006 202 974 5200 Fax 202 296 7005 www plasticsindustry com SPI Communications D 3 D 4 SPI Communications Supported Dryer SPI Commands SPI protocol defines two different modes Select and Poll Select commands are used to set or change the information in the dryer For example to change a temperature setpoint from 200 F to 250 F 93 C to 121 C a Select command is used Poll commands are used to read the information without changing or modifying it For example when you simply want to display the actual process temperature In either case two hex command bytes are
158. water supply line to the inlet If a manual shut off valve is used it should be mounted on the inlet line as well 9 Connect the outlet of the aftercooler to the inlet of the flow control valve using the pre shaped copper tubing and compression fittings provided Appendix C 2 E 1 Appendix Cleaning the Volatile Trap on the Demister 1 Stop the dryer and lockout the main power AN 2 Remove the thumbscrews then remove the volatile demister cover 3 Remove the demister by pulling it out from the housing 4 Clean the assembly using a mild soap and water Let the assembly dry thor oughly before installation SE In cases of heavy volitales steam cleaning or the use of solvents such as acetone may be necessary Be sure to test a small area with the solvent you have selected to be sure there is no adverse reaction 5 Insert the demister carefully back into the housing 6 Inspect the condition of the gasket If it is damaged replace the gasket 7 Secure the cover in place using the original thumbscrews Make sure the cable is not pinched between the housing and the cover Addendum Communication Protocols for Common Controls Modbus Communications Ethernet Communications DeviceNet Gateway Communications and SPI Communications DISCLAIMER The Conair Group Inc shall not be liable for errors contained in this User Guide or for incidental consequential damages in connect
159. y fluidize inside the Airflow restrictions Remove any obstructions in the process hopper resulting in incon air circuit sistent material flow T Process blower running backwards or Verify the process blower is running in SUD de hopper when performing poorly the correct direction If backwards can negatively impact reverse direction by switching any 2 legs residence time of high voltage to the motor A WARNING Any electrical checks should be performed by a qualified electrician Repair or replace motor Material level in the hopper too low Other than running out of material to complete a job the material level inside the hopper must be a minimum of 50 full If the hopper is not at least half full the material in the cone section will not get adequate airflow to dry properly Troubleshooting 6 27 Replacement dewpoint monitors are available from Conair Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 Problem Dryer dewpoint is not Poor Material Drying Troubleshooting continued Dewpoint The process air must be at a low dewpoint so it can efficiently collect the moisture as it is released from the heated material and carry it to the dryer to be removed in the desiccant In most cases the dryer will dry your material satisfactory if the dewpoint of the air is 20 to 40 F 29 to 40 C If your dryer does not have a dewpoint readout you can check
160. you are viewing in the list This example is the first alarm in the list 00 The letter after the P or S shows if the alarm was a passive or shut down alarm The second line shows the date and time when the alarm occurred By pressing the Select Category button under the word Info the display can show a number of screens that are a snapshot of information that was happening when the alarm occurred This is an example of one of the Information screens for an alarm This is the first screen under the Info shown on screen 92 It shows how long the alarm was active The time shown is from when the alarm occurred until the alarm was acknowledged and cleared The Next button can be pressed while at this screen to see other items in the list of snapshot info that was happening when the alarm occurred This is the Dryer Diagnostic screen It can be found by pressing the Select Category button under the word Hist on the Dryer Diagnostics screen 91 By pressing the Select Category buttons under the titles the user can select to see diagnostic infor mation for Alarms This is an example of the Event Freq screens This shows the number of times an alarm has occurred By pressing the Next key in this section the user can see info for all alarms The S indicates how many times it was a shutdown alarm and the P indicates how many times it was a passive alarm Control Function Descriptions continued Screen
161. ys SSRs failed in the closed position Defective process heater The output on the board has failed The process RTD is loose or has fallen out The air hose connections are loose Precooler water is too cold or the water flow rate is too high The output on the board has failed Flow control solenoid is stuck open The process RTD is loose or has fallen out Process heater has failed One of the SSRs has failed The regeneration RTD is loose or has fallen out The air hose connections are loose The output on the board has failed Defective regeneration heater 1 1 i drying applications these pas 1 sive alarms are not available Replace the failed solid state relays SSRs 1 1 Check the heater fuses and resistance across each leg of the process heater Replace the board Check the process RTD and tighten if needed Tighten all air hose connections Adjust as necessary Replace the board Replace the valve Check the process RTD and tighten if needed 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Check water temperature and flow settings 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Check the heater fuses and resistance across each leg of the process heater Replace the failed SSRs Check the regeneration RTD and tighten if needed Tighten all air hose connections Replace the board Check the heater fuses and resistance across

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