www.conairgroup.com USER GUIDE UGD029-0311 MDCW Carousel Plus Dryer MDCW Models 15, 25, 50, 75 and 100 with DC-2 Controls Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.
It’s a good idea to 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 information, along with the manual number, to provide help for the specific equipment you installed. Please record your equipment’s model and serial number(s) and the date you received it in the spaces provided. Please keep this User Guide and all manuals, engineering prints and parts lists together for documentation of your equipment.
Ta b l e o f C o n t e n t s 1-1 I n t r o d u c t i o n Purpose of the user guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Your responsibilities as a user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 ATTENTION: Read this so no one gets hurt . . . . . . . . . . . . . . . . . . . 1-4 How to use the lockout device . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Connecting the aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Using communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 4-1 O p e r a t i o n The MDCW dryer: control panel DC-2 . . . . . . . . . . . . . . . . . . . . . . .
Screen filter cleaning (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Cleaning the compressed air filter (Optional) . . . . . . . . . . . . . . . . . 5-13 Cleaning the aftercooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Inspecting hoses and gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 6-1 Tr o u b l e s h o o t i n g Before beginning. . . . . .
B Appendix Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 Purpose of the user guide . . . . . . . . . . . . . . 1-2 How the guide is organized . . . . . . . . . . . . . 1-2 Yo u r r e s p o n s i b i l i t i e s a s a u s e r . . . . . . . . . . . 1 - 3 AT T E N T I O N : Read this so no one gets hurt . . . . . . . . 1-4 How to use the lockout device . . . . . . . . . . .
Purpose of the User Guide This User Guide describes the Conair MDCW Carousel Plus 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.
Yo u r R e s p o n s i b i l i t y a s a U s e r • 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.
AT T E N T I O N : 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. WA R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n , o r servicing may result in equipment damage or p e r s o n a l i n j u r y.
AT T E N T I O N : Read this so no one gets hurt (continued) CA U T I O N : H o t S u r fa c e s . 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.
How to Use the Lockout Device 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 pictured below.
SECTION 2 What is the MDCW Carousel Plus Dryer? . . . . 2-2 Optional self-loading MDCW . . . . . . . . . . . . 2-2 Ty p i c a l a p p l i c a t i o n s . . . . . . . . . . . . . . . . . . 2 - 3 How it works . . . . . . . . . . . . . . . . . . . . . . 2-5 How conveying works . . . . . . . . . . . . . . . . . 2-7 Specifications: MDCW Carousel Plus Dryers . . 2-8 MDCW Carousel Plus Dryer options. . . . . . .
What is the MDCW Carousel Plus Dryer? The MDCW Carousel Plus Dryer is a self-contained, mobile unit designed to dry plastic resin and convey it with dehumidified air directly to a processing machine.
Ty p i c a l A p p l i c a t i o n s The MDCW Carousel Plus Dryer was designed for drying and conveying beside the press. But it can also be used to pre-dry material in one location, and then transport the dried material to another location for conveying into the processing machine. ✐ NOTE: Throughput rates will vary by MDCW model and type of material. See the Specification pages for recommended throughputs.
Ty p i c a l A p p l i c a t i o n s (continued) The MDCW Carousel Plus Dryer can be used successfully in applications that require: • A contamination-free drying environment • Drying temperatures within the ranges shown in the following table: Model Drying Temperature Range Low temperature (with precooler)* 100° - 150°F {38° - 66°C} Standard 150° - 250°F {66° - 121°C} High heat (with aftercooler)* 150° - 375°F {66° - 191°C} Low-high (with aftercooler & precooler)* 100° - 375°F {38° - 191°C} * S
H o w I t Wo r k s The Process (Drying) Cycle The Regeneration Cycle The regeneration blower pulls 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.
H o w I t Wo r k s (continued) PHASE ROTATION PROTECTION 1 ALARM LIGHT PROCESS RTD ALARM BELL REGENERATION BLOWER PROCESS HEATER BOX HIGH TEMP SHUTOFF REGENERATION AIR FILTER HIGH TEMP SHUTOFF 4 4 REGENERATION HEATER 6 REGENERATION RTD HOPPER DESICCANT WHEEL 3 5 REGENERATION OUTLET RTD RETURN AIR FILTER AFTERCOOLER RETURN AIR RTD 2 PROCESS PROCESS BLOWER COOLING REGENERATION DRYER OPTIONS * 1 SETBACK TEMPERATURE 2 PROCESS CFM MONITOR *Standard on DC-2 controls 2-6 l Description * 3
H o w C o n v e y i n g Wo r k s When the conveying function is turned on, the MDCW uses dry air to move material from the drying hopper to the process machine as it is needed. 4 Material enters the vacuum receiver and falls into the 3 Positive and negative air 2 When the conveying 5 The conveying blower runs until the load time set at the MDCW control is reached. When the material level drops below the demand sensor, the sensor signals for more material. The conveying blower turns on again.
Specifications: MDCW Carousel Plus Dryers MODEL W15 W25 W50 W75 Standard hopper models* RWH14-2 RWH14-3 RWH18-6 RWH24-9 Performance characteristics (with full hopper) Air flow {SCFM}** 7.5 12.5 25 37.5 Air flow {ACFM @ 250°F}** 10 17 34 50 Drying temperature All models 150 - 375°F {66 - 191°C} with options Dew point All models -40°F {-40°C} Standard conveying dist. ft {m} 8 {2.44} vertical; 6 {1.83} horizontal Long distance option ft {m} 15 {4.57} vertical; 50 {15.
Specifications: MDCW Carousel Plus D r y e r s (continued) TLR Tube Loader (hopper loader) TLR Tube Loader (machine loader) Outlet - 2 in. dia. {5.1 cm} Outlet - 2 in. dia. {5.1 cm} E - Receiver dia. 4.5 in. {11.4 cm} G - Receiver dia. 4.5 in. {11.4 cm} F - Height with viewing chamber H - Height H 17.5 in. {44.5 cm} G 1 lb. 22 in. {55.9 cm} 2 lb. 27 in. {68.6 cm} Loader Base Plates 1.625 in. dia. {4.1 cm} through hole 1.625 in. dia. {4.1 cm} through hole 6 in. {15.2 cm} 4 in. {10.2 cm} 4 in.
MDCW Carousel Plus Dryer Options • Volatile trap (use only in conjunction with aftercooler) - The volatile trap is recommended when 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 desiccant wheel and before the process heater, enabling the dryer to control temperatures at low setpoints (100 - 150°F {38 - 66°C}).
SECTION 3 Installation Unpacking the boxes . . . . . . . . . . . . . . . . . 3-2 Preparing for installation . . . . . . . . . . . . . . 3-4 Connecting the conveying lines . . . . . . . . . 3-6 Connecting the demand sensor . . . . . . . . . . 3-7 Mounting a loader on the hopper . . . . . . . . . 3-7 Connecting material lines for self-loading (Optional) . . . . . . . . . . . . . 3-8 Connecting the main power . . . . . . . . . . . . 3-10 Connecting compressed air for self-loading (Optional) . . . . . . . .
Unpacking the Boxes The MDCW Carousel Plus Dryer comes in one to four boxes, depending on the model and options ordered. The boxes could include (depending on the options selected): Vertical Conveying Tubes* Self-loading Hopper MDCW Dryer Loader (Optional) Drying Hopper Direct Feed DC-2 Control Vacuum Receiver (Machine Loader) Viewing Chamber and Demand Sensor Conveying Filter Pump ✐ NOTE: * Depending on the model ordered, the vertical conveying tubes may be shipped detached from the unit.
Unpacking the Boxes (continued) 4 Take a moment to record serial numbers and electrical power specifications in the blanks provided on the back of the User Guide’s title page. The information will be helpful if you ever need service or parts. 5 You are now ready to begin installation. Follow the preparation steps on the next page.
Preparing for Installation The MDCW Carousel Plus Dryer has been designed for use beside the processing machine. The mobile unit can also be used for pre-drying in a remote location. 1 Make sure the location for the MDCW provides: ❒ A grounded power source supplying the correct current for your dryer model. Check the dryer’s serial tag for the correct amps, voltage, phase and cycles. Field wiring should be completed by qualified personnel to the planned location for the dryer.
Installing the MDCW The MDCW was designed to be mobile. When you move the MDCW, you will need to mount the vacuum receiver, connect the main power source, connect a water source for the aftercooler and/or optional precooler, and connect a compressed air source for the optional self-loading hopper loader. Phasing of electric power should be consistent between locations. The MDCW has built-in phase detection and will not allow the unit to operate if the phasing is incorrect.
Connecting Conveying Lines The vertical conveying tubes and flexible conveying hoses may have been removed for shipping. To assemble: 1 Insert each vertical conveying tube into its quick disconnect fitting on the MDCW. Push the tube down until you feel it seat snugly inside the disconnect fitting. Tighten the thumb screws on the fittings to secure the tubes. 2 Secure flexible conveying hoses to the vertical tubes with hose clamps. Insert the tube at least 1 inch {2.54 cm} into the flexible hose.
Connecting the Demand Sensor The capacitive demand sensor monitors the level of material in the viewing chamber of the vacuum receiver when the MDCW is conveying. The sensor signals the MDCW control to start the conveying blower whenever the level of material drops below the amount that you want to maintain at the feed throat. 1 Plug the sensor cable into the multi-pin connector on the side of the MDCW frame.
Connecting Material Lines for S e l f - L o a d i n g (Optional) When connecting the optional self-loading function of the MDCW Carousel Plus dryer you will need to make several connections for conveying tubes and the demand sensor for the hopper loader. To connect the conveying tubes and demand sensor cables: ✒TIP: Material layering of virgin and regrind material is achieved with an optional ratio valve located at the material inlet of the hopper loader. 1 Mount the loader on top of the hopper.
Connecting Material Lines for S e l f - L o a d i n g (Optional) (continued) 4 Attach the air conveying line to the outlet of the hopper loader. Secure with clamp. to the inlet of the pneumatic valve located on the side of the dryer frame. Secure with clamp.
C o n n e c t i n g t h e M a i n Po w e r 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 by turning the disconnect dial on the dryer door to the Off or “O” position. Lock out the main power (see Page 1-6 for complete lock out information). Turn the captive screw, and swing the door open.
Connecting Compressed Air for S e l f - L o a d i n g (Optional) When connecting the optional self-loading function of the MDCW Carousel Plus dryer an 80 psi {5.5 bar} compressed air source is required. To connect the compressed air source: 1 Install the 1/4 inch NPT adapter to the compressed air outlet found on the left side of the the dryer. Seal adapter threads with nylon tape. Air hose connection Installation l 3-11 3 Installation 2 Attach compressed air hose to the 1/4 inch NPT adapter.
Checking for Proper Air Flow IMPORTANT: This procedure is needed on non-conveying MDCW models 50, 75, and 100. This procedure is not required on the conveying MDCW 15 - 100 models because phase detection is standard. CAUTION: Checking for proper air flow must be performed before filling the hopper with material. Performing this step after the hopper is filled with material could cause damage to the dryer if the airflow direction is incorrect due to improper phase connection.
Checking for Proper Air Flow 4 Press the Stop button. Stop (continued) Reconnect the process filter that was discon- nected in Step 3. Process Filter 5 If the airflow is incorrect, disconnect the power, follow the proper lockout procedure, and swap any two of the three main power wires. LEADS 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.
Connecting the Aftercooler ✒TIP: Make the water supply and discharge / return connections with flexible hoses at least 24 in. (61 cm) long. This allows you to easily remove the aftercooler assembly for cleaning. The aftercooler and optional precooler require a source of cooling water and a discharge or return line. To connect water hoses: 1 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.
Te s t i n g t h e I n s t a l l a t i o n You have completed the installation. 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 hopper, disconnect the material inlet hose at the source or turn off the loader. 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 illuminate. 3 Set the drying temperatures.
Te s t i n g t h e I n s t a l l a t i o n (continued) 5 Turn ON the hopper and machine loader switches. • The conveying blowers should turn on and the LEDs will turn off and on. 6 Turn OFF the rocker switches for the hopper and machine loaders. Stop 7 Press the STOP button. • The blowers will continue running as needed to cool the heaters (until both heaters are less than 150°F {66ºC}) 8 The test is over.
SECTION 4 Operation The MDCW dryer: control panel DC-2 . . . . . . 4-2 MDCW Carousel Plus Dryer control functions . 4-3 Control function flow charts . . . . . . . . . . . . 4-3 How to navigate the menu tree . . . . . . . . . . 4-3 Control function descriptions . . . . . . . . . . . 4-11 To s t o p d r y i n g . . . . . . . . . . . . . . . . . . . . . 4 - 3 8 Using the self-loading function on the hopper loader (Optional) . . . . . . . . 4-39 Machine loader conveying . . . . . . . . . . . . .
T h e M D C W D r y e r : C o n t r o l Pa n e l D C - 2 S c r e e n Ti t l e Alpha-numeric characters display process and alarm conditions. Menu Button Scroll Buttons Press to view the main menu screen where you can 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. Press to scroll through the closed loop parameter list.
MDCW Carousel Plus 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 functions. For an explanation of each control function, see Control Function Descriptions (page 4-11).
POWER ON CONAIR CV00.06.2 CP100 DV00.09.
DRYER MAIN MENU STAT SETUP DIAG DRYER STATUS PROC REGEN OTHER 12 13 STANDARD DRYER / MDC DRYER PROCESS STATUS SCREENS 14 PROCESS TEMPERATURE ACT 325˚F SET 325˚F 3 RETURN AIR TEMP ACT 120˚F SET 120˚F 5 PROCESS HEATER OUTPUT 100% PROCESS PROTECTION ACT 350˚F TOTAL RUN HOURS 1250 CONVEYING BLOWER ON RUNNING MACHINE LOADER LOAD TIME 10 SEC 15 16 17 DRYER REGEN STATUS SCREENS 14 DRYER OTHER STATUS SCREENS 14 REGENERATION TEMP ACT 350˚F SET 350˚F 4 MODEL CP150 480 V 60 HZ 30 REGEN OUTLET TEMP
SCREEN # DRYER MAIN MENU STAT SETUP DIAG 12 DRYER SETUP PROC ALM DISP OTHER 36 SETUP PROCESS PROC REGN OTHER 37 STANDARD DRYER AND MDC SETUP PROCESS PROC PROPID RETPID SETUP PROCESS SCREENS 14 14 41 RET AIR CYCLE TIME COOL 20 SECONDS 42 RET AIR CALIBRATION OFFSET 0˚F 47 3 PROCESS POWER LIMIT LOW 0% HIGH 100% PROCESS TEMPERATURE RANGE 100˚F - 375˚F 39 PROCESS CYCLE TIME HEAT 2.0 SECONDS 42 40 PROCESS PROP BAND HEAT/COOL 30˚F 43 5 PROCESS INTERGAL HEAT/COOL 16.
SETUP REGENERATION REGEN PID SETUP REGENERATION SCREENS 14 REGENERATION TEMP ACT 350˚F SET 350˚F 4 REGEN OUTLET TEMP ACT 280 REGEN TEMP RANGE 100˚F - 375˚F REGEN PID AUTOTUNE OFF DONE REGEN CALIBRATION OFFSET 0˚F PROCESS DEWPOINT SAMPLE RATE 150 SEC DRYER SETUP PROC ALM DISP OTHER 36 SETUP PROCESS PROC REGEN OTHER 37 SETUP PROCESS OTHER SCREENS 48 SETUP REGEN HEATER PID VALUE SCREENS 14 REGEN POWER LIMIT LOW 0% HIGH 100% 41 29 42 39 REGEN PROBAND 67F 43 40 REGEN INTERGRAL 25 47 REG
ALARM ACTION This screen does not apply to the models MDCW 15-100 covered in the manual.
DRYER SETUP OPTIONS INFORMATION SCREENS 14 DRYER MAIN MENU STAT SETUP DIAG 12 DRYER SETUP PROC ALM DISP OTHER 36 DRYER SETUP OTHER OPT INSP COM PW 74 DRYER SETUP MODEL CONFIG SCREENS 14 DRYER SETUP COMMUNICATIONS 14 14 Dryer Setup Password Screen Logging Out Password … 86 IF A VALID PASSWORD IS STILL ACTIVE SETBACK ON TEMP NOT INSTALLED EDIT CFM MONITOR NOT INSTALLED FILTER CHECK INSTALLED EDIT EDIT 75 75 75 AFTERCOOLER FLOW CONT INSTALLED EDIT 75 PRECOOLER INSTALLED EDIT 75 PRECOOLER
DRYER MAIN MENU STAT SETUP DIAG Dryer Diagnostic ALRM HIST 12 I/O 91 NA KEEP 40 SHOWN DRYER DIAGNOSTICS LAST 40 ALARMS 00:S-Regen RTD 01/31/00 09:24 P DIAGNOSTIC EVENTS ALRMS ANALOG DIGITAL 14 94 INFO SNAPSHOT OF INFO FOR EACH ALARM 02:P-REGEN DEV 3/1/00 03:25P ETC. INFO INFO 92 92 Alarm Activated For 10.
Control Function Descriptions ✐ Screen Function SCREEN 1 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. CONAIR D100 CV2.21.00 DV2.21.00 SCREEN 2 MONDAY 07/22/03 07:59 AM SCREEN 3 (DEFAULT SCREEN) SET 325°F certain parameters. Additional information about the password can be found on Page 4-41 and on Page 4-32 under screen 85.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 3 (DEFAULT SCREEN) (continued) SETUP, PROC, PROC, PROC, PROCESS TEMPERATURE RANGE screen 39. The display will return to the default screen from any place in the menu structure (with the exception of the AUTOTUNE screens) if nothing is done after 10 minutes. Pressing the MENU button from any place in the menu structure will return you to the default screen.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 7 Self-loading This screen shows the amount of time the hopper loader will run. The time should be set for the time it takes to fill the loader. If the hopper loader tries three consecutive times without satisfying the demand signal, the dryer will display a passive alarm.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 11 (Dewpoint control and/or Dewpoint monitor) The dewpoint control will automatically adjust regeneration temperature to maintain dewpoint setpoint. Dewpoint control is not active with -40° F {-40° C} setpoint. PROCESS DEW POINT ACT -40°F SET -40°F ✐ NOTE: Dewpoint actual will not be live for approximately 5 to 8 minutes.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 15 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.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) ✐ NOTE: Screens labeled 75 in the display screen flow chart on page 4-9 are various option installation screens. Screen Function SCREEN 21A (Aftercooler or Precooler Flow Control Option) This screen shows if the aftercooler or precooler flow control option is enabled. If it is disabled, there will be no setpoint for the Return Air Temperature, screen 5.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 23 (Current Monitor Option) This 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.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 26 This screen shows the setpoint the process temperature will go to once the control goes into setback. When the control is in 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 temperature measured at the hopper inlet. The setpoint shown on the default screen will still show the original setpoint.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Function Screen SCREEN 30 MODEL CP150 480 V 60 Hz SCREEN 31 DISPLAY FIRM V2.21.00 DISPLAY MENU V2.21.00 SCREEN 32 SCREEN 34 AUTOSTOP COUNT DOWN 3 DAYS 11:04:23 important to know when ordering a control board. ✒ Tip: This information is important to know when 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.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 35 This screen shows the temperature inside the control enclosure. It is measured at the lower right corner of the control board.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) SCREEN 40 Before performing an autotune, set the setpoint to the desired temperature you would like the control to autotune to on 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 autotune should be started from a cold start or a minimum of 50ºF {28ºC} difference between starting and autotune temperatures.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) ✐ NOTE: Screens 41, 42, 43, 44, 45, 46 and 47 apply to process and regeneration. Screen Function SCREEN 44 This screen shows the integral value for the PID Loop. PROCESS INTEGRAL HEAT/COOL 16.0 This screen shows the derivative value for the PID Loop. SCREEN 45 PROCESS DERIVATIVE HEAT/COOL 2.0 With the proper password, (see page 4-32, screen 85) the PID values can be reset back to the factory default settings.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function This is the maximum value the dewpoint control can set the regeneration temperature to achieve the desired dewpoint. SCREEN 50 PROCESS DEWPOINT TRIM UP LIMIT 375°F ✐ NOTE: Screens 49, 50, 51, 52, 53 and 54 apply to Dewpoint Control Option. This is the minimum value the dewpoint control can set the regeneration temperature to achieve the desired dewpoint.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 56 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.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 58 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 setpoints and delay times.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 61 PROCESS LOOP BREAK 3°F 20 SEC SCREEN 62 PROCESS TEMP DEV 5°F 5 Sec SCREEN 63 REGEN DIFFERENTIAL 5°F 10 SEC SCREEN 64 RETURN AIR ALARMS 4-26 l Operation 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 time value, the dryer will alarm wheel rotation failure.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 66 (CFM Monitor Option) CFM LOW SETPOINT 1430 SCREEN 67 (Dewpoint Monitor or Dewpoint Control) DEWPOINT ALARM ACT -20°F 180 SEC SCREEN 68 DEWPOINT DEVIATION SCREEN 71 HIGH 5°F 30 SEC LOW 5°F 30 SEC This is the dewpoint high deviation alarm value. With the proper password, it can be changed (see page 4-32, screen 85).
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 70 DEWPOINT 5 MIN This is the amount of time from start-up the dryer is allowed to run before the control will try to monitor 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 password (see page 4-32, screen 85). EDIT This screen shows the units the dryer will display.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 74 DRYER SETUP OTHER OPT INSP COM PW SCREEN 75 CFM MONITOR NOT INSTALLED EDIT TAP ✐ NOTE: Screens labeled 75 in the display screen flow chart on page 4-9 are various option installation screens. This screen is used with the current monitor option and tells the control which tap is used on the current sensing board (5A, 10A, or 15A).
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 78 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 is replaced, the control may need to be reconfigured. 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.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 81 Communications This screen shows the communications protocol. Modbus, DeviceNet, Ethernet or SPI is 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).
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 85 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.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 88 This is the password logout screen. If nothing is done, the password will automatically 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.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 92 This is an example of one of the alarm history screens. The first two numbers of the first line show what alarm 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 shutdown alarm. The second line shows the date and time when the alarm occurred.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 96 This is the Diagnostic I/O screen. It can be found by pressing the Select Category button 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.
C o n t r o l F u n c t i o n D e s c r i p t i o n s (continued) Screen Function SCREEN 100 This screen can be used to determine if the MDCW conveying on function will shutdown or continue to operate upon any dryer alarm. MDCW SHUTDOWN ON ALARM ENABLED SCREEN 101 MDCW SHUTDOWN TIME 60 MIN SCREEN 102 MAP INDIRECT REG 500 0 4-36 l Operation EDIT Use this screen, in the event screen 100 is enabled, to set the amount of time the conveying function will continue to operate once the dryer has alarmed.
To S t a r t D r y i n g 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 illuminate. 3 Set the drying temperature. Press the Select Category key directly below the temperature. Then adjust the Setpoint using the (+) or (-) buttons or enter the temperature on the numeric keypad and press enter.
To S t a r t D r y i n g (continued) 4 Press the START button. Start 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. To S t o p D r y i n g 1 Press the STOP button. The Stop LED blinks red. • The blowers continue running for a few minutes Stop to cool the heaters.
Using the The Self-loading Function on the Hopper Loader (Optional) 1 Connect the conveying hose and/or pick-up wand from the material source to the inlet on the hopper loader. 2 Connect a clean, dry compressed air source supplying 80 psi of compressed air to the threaded coupling on the side of the MDCW dryer.
Machine Loader Conveying 1 Move the MDCW to the processing machine. Lock the wheels and connect the main power source. Connect the water source if you have an aftercooler. Connect compressed air if the self-loading option is being used. 2 Mount the vacuum receiver on the feed throat. Push the vacuum receiver onto the mounting bracket. 2 3 3 Place the appropriate material 1” opening Virgin material insert insert inside the distribution box. 1.
H o w t o U s e t h e S u p e r v i s o r ’s Pa s s w o r d 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.
H o w t o U s e t h e S u p e r v i s o r ’s Pa s s w o r d ( c o n t i n u e d ) 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 87 will be displayed.
U s i n g t h e A u t o Ti m e r You can set the dryer and stop automatically using the Auto Start and Auto Stop functions. The supervisor password is necessary to use this function. Programming Auto Start The Auto timer can be programmed using the Auto Countdown screen. This screen can be accessed under the SETUP, PROC, and OTHER screens from Dryer Main Menu, Screen 12.
Setting High Setpoint Limits You can protect your drying process by preventing someone from entering process temperatures above or below an acceptable level 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 Dryer Main Menu, screen 12.
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.
U s i n g t h e S e t b a c k Fe a t u r e 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 keep you from over drying your material. This is how setback operates when the control setback mode is set on Temperature.
U s i n g t h e S e t b a c k Fe a t u r e (continued) 4 Access Screen 27 and set the setback return temperature for the air exiting the hopper. This screen shows the actual temperature measured 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.
S e t b a c k Fe a t u r e G u i d e l i n e s (continued) 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.
SECTION 5 Maintenance Preventative maintenance checklist . . . . . . . 5-2 Checking the dewpoint . . . . . . . . . . . . . . . . 5-4 Cleaning the hopper. . . . . . . . . . . . . . . . . . 5-6 Cleaning the process filter . . . . . . . . . . . . . 5-7 Cleaning the regeneration filter . . . . . . . . . . 5-9 Cleaning the conveying filter . . . . . . . . . . . 5-10 Cleaning the vacuum receiver . . . . . . . . . . 5-11 Cleaning the compressed air filter (Optional) . . . . . . . . . . . . . . . . .
Preventative Maintenance Checklist Routine maintenance will ensure optimum operation and performance of the MDCW Dryer and the receiver on the hopper. We recommend the following maintenance schedule and tasks. • Whenever you change materials ❒ Drain and clean the hopper. • We e k l y, o r a s o f t e n a s n e e d e d ❒ Clean or replace the process, regeneration and conveying filters. You may need to clean filters more often than weekly.
Preventative Maintenance C h e c k l i s t (continued) • Every six months or as needed. ❒ 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. ❒ Verify dewpoint readout and performance with calibrated portable instrument. ❒ Measure current draw on all 3 legs of heater wires. This is to ensure that the heater is working properly. ❒ Examine the bolts.
✐ NOTE: Portable dewpoint Checking the Dewpoint monitors purchased from Conair were provided with a male connector that plugs into the dewpoint check port. If you purchased your portable instrument elsewhere, the 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 maximum capacity.
Checking the Dewpoint (continued) 4 Turn on the dryer. 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 disconnecting the portable instrument. Some dewpoint monitors require a substantial 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 section of the manual under Process Dewpoint alarm for DC2.
Cleaning the Hopper CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the dryer and drying hopper. The hopper, spreader cone, and discharge assembly should be cleaned thoroughly between material changes to prevent resin contamination. 1 Close the hopper slide gate. 2 Disconnect the hoses and remove the distribution box under the hopper and drain the remaining material into a bucket. 3 Remove the spreader cone. Open the hopper door. Reach into the hopper.
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 To access the filter push down and turn the top of the filter housing in a clockwise direction to remove. CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the dryer and drying hopper. 2 Remove the filter cartridge from the filter housing. 3 Clean or replace the filter.
Cleaning the Process Filter (continued) 4 Wipe the inside of the filter housing clean, then replace the filter cartridge into the housing. 5 Line up the slots in the top of the filter housing, push down and turn counterclockwise until locked into place.
Cleaning the Regeneration 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 To access the regeneration filter, use a small flat screwdriver to gently pry down on the slot in the lower right hand corner of the filter grill while pulling out on the bottom. CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the dryer and drying hopper.
Cleaning the Conveying Filter The conveying filter captures dust and fines from the air used to convey material. The filter should be cleaned regularly to maintain conveying airflow and optimum performance of the conveying blower. 1 Turn off the conveying function. There is a conveying on/off switch located on the front of the dryer. 2 Remove the filter housing cover. 3 Remove the filter cartridge, clean or replace as necessary. CAUTION: Wear eye protection.
C l e a n i n g t h e Va c u u m R e c e i v e r The vacuum receiver should be cleaned anytime you change materials. Replace the screen mesh filter if it is torn, damaged, distorted or so clogged with material that it cannot be cleaned. 1 Turn off switch to stop conveying. Disconnect the air and material hoses from the vacuum receiver. 2 Open the vacuum receiver lid. Turn the latch counterclockwise and flip the lid open. 3 Remove and clean the mesh filter. Lift the mesh filter out of the vacuum receiver.
Screen Filter Cleaning (Optional) WARNING: Disconnect power and air sources. Always disconnect the main power source and compressed air source before removing the filter. This prevents the loader from starting during servicing, which could cause injury from flying debris or moving parts. CAUTION: Wear eye protection. We recommend that you use vacuum air for cleaning filters and other parts of this equipment.
Cleaning the Compressed Air Filter (Optional) You can add a moisture trap to the compressed air supply of your loader. A moisture trap can prevent troublesome moisture, contained in the air, from entering the loader. The filter bowl of this moisture trap must be emptied regularly to drain the water from the air system.
Cleaning the Aftercooler Coils You need to clean the aftercooler coils to keep them 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. ✐ NOTE: If an optional flow control was added with the aftercooler, remove the compression fitting from the aftercooler inlet.
Cleaning the Precooler Coils If you have the optional precooler, you need to clean the cooling coils to keep them working efficiently. See Appendix B for details. Inspecting Hoses and Gaskets Loose or damaged hoses and gaskets can allow moisture to seep into the closedloop 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.
5-14 l Maintenance
SECTION 6 Tr o u b l e s h o o t i n g Before beginning . . . . . . . . . . . . . . . . . . . . 6-2 A few words of caution . . . . . . . . . . . . . . 6-3 DIAGNOSTICS How to identify the cause of a problem . . . . 6-4 Shutdown alarms Pa s s i v e a l a r m s . . . . . . . . . . . . . . . . . . 6-5 . . . . . . . . . . . . . . . . . . . 6-12 Dewpoint troubleshooting . . . . . . . . . . . . . 6-21 Po o r m a t e r i a l d r y i n g t r o u b l e s h o o t i n g . . . . .
Before Beginning ✐ NOTE: Use of test You can avoid most problems by following the 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 possible cause of an alarm. Access code 756. Before you take the covers off the dryer be sure to: ❏ Diagnose causes from the control panel.
Before Beginning (continued) ❏ Find the wiring and equipment diagrams that were shipped with your dryer. These diagrams are the best reference for correcting 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 Fe w Wo r d s o f C a u t i o n The Carousel Plus W Series dryer is equipped with numerous safety devices.
✐ How to Identify the Cause of a Problem NOTE: Pushing the Acknowledge Alarm button when there is no active alarm Most dryer alarms are indicated by an illuminated Acknowledge Alarm light on the MDCW Dryer control panel. Shutdown alarms will sound a horn and turn on the alarm beacon. will take the user directly to ✐ the Alarm History list (Screen A problem can trigger two types of alarms: 95, page 4-34).
Shutdown Alarms If the red Acknowledge Alarm LED is blinking red, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that when the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid. Solution Process High Temperature – If the process temperature exceeds the process high temperature setpoint, it shuts down the dryer. Defaults are set to 385°F {196°C} for 20 seconds.
Shutdown Alarms If the red Acknowledge Alarm LED is blinking red, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that when the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid. Problem Possible cause Solution Process Heater High Temperature – The snap switch in the process heater tube opens due to excessive temperature. There is an air flow blockage or loose hoses.
Shutdown Alarms If the red Acknowledge Alarm LED is blinking red, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that when the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid. Solution 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. The hopper does not contain enough material.
Shutdown Alarms If the red Acknowledge Alarm LED is blinking red, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that when the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid. Problem Possible cause Solution Control Communications Watchdog - The display board has lost communications with the control board. Plugs on wire harness between the display and control boards are loose or not wired correctly.
Shutdown Alarms If the red Acknowledge Alarm LED is blinking red, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that when the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid. Solution Process Protection RTD Integrity* – If the process protection RTD is faulty, it shuts down the dryer. There is a loose connection in the wiring leading to the RTD.
Shutdown Alarms If the red Acknowledge Alarm LED is blinking red, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that when the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid. Problem Possible cause Solution Process Blower overload (cont.) - If the process blower exceeds its full load amp rating or the overload has tripped due to a mechanical or electrical problem the dryer will shut down.
Shutdown Alarms If the red Acknowledge Alarm LED is blinking red, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that when the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid. Problem Possible cause Solution Process Temperature Deviation – The process temperature exceeds the deviation band as entered for the specified time. Default values are 10°F {6°C} for 5 seconds.
Pa s s i v e A l a r m s 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 when 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 Shutdown Alarms section). See page 4-26, screen 62 for instructions.
Pa s s i v e A l a r m s 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 when 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 Shutdown Alarms section). See page 4-26, screen 62 for instructions.
Pa s s i v e A l a r m s 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 when 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 Shutdown Alarms section). See page 4-26, screen 62 for instructions.
Pa s s i v e A l a r m s 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 when 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 Shutdown Alarms section). See page 4-26, screen 62 for instructions.
Pa s s i v e A l a r m s 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 when 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 Shutdown Alarms section). See page 4-26, screen 62 for instructions.
Pa s s i v e A l a r m s 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 when 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 Shutdown Alarms section). See page 4-26, screen 62 for instructions. Solution Conveying Blower Overload (cont.
Pa s s i v e A l a r m s 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 when 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 Shutdown Alarms section). See page 4-26, screen 62 for instructions.
Additional Alarms Along with the Passive and Shutdown alarms, you may encounter additional error messages that indicate a problem with the control. Problem Possible cause Solution Control Not Ready, Please Check Alarm - Displayed when the “Start” button is pushed during any active alarm. (Passive or Shutdown) The dryer will continue to run if there is a passive alarm, however it will not start if there is a active alarm.
Additional Alarms Along with the Passive and Shutdown alarms, you may encounter additional error messages that indicate a problem with the control. Problem Possible cause Solution Er. Lo - There is a problem in the sensor connection (RTD, Dewpoint sensor, etc.) for the affected function. Problem in the analog input section of the control. Check that all jumpers are in their proper place. Check to see if the dewpoint sensor is connected properly.
D e w p o i n t Tr o u b l e s h o o t i n g 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 produce undesirable results. Problem Possible cause Solution Dryer not producing desired dewpoint. Return air temperature exceeds 125°F {52°C}. Reduce the temperature of the cooling water or increase the flow. Regeneration temperature is below normal setting. Check amperage of regeneration heaters.
Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g Occasionally, processing problems that are suspected of being caused by poor drying 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.
Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) Once it is determined which of the four requirements 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 proper drying temperature for your material, as specified by your supplier. Problem Possible cause Solution The temperature of the air entering the hopper is not at proper drying temperature.
Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) Residence Time - The time your material supplier has determined that the material in use must be heated to its drying temperature to achieve proper drying. Problem Possible cause Solution Material residence time is too long or short. Material level in hopper is too low. Make sure there is an adequate supply of material to feed the loader on top of the drying hopper.
Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) 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.
Replacement dewpoint monitors are available from Conair. Contact Conair Parts (800) 458 1960 From outside of the United States, call: (814) 437 6861 Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) 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.
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. 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.
Checking Heater Solid State Relays ON O OFF 1 CAUTION: Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by qualified personnel. Disconnect and lockout the main power supply. 2 Open the electrical enclosure. 3 Locate the regeneration solid state relays. Refer to the wiring diagrams that came with your dryer.
C h e c k i n g o r R e p l a c i n g Te m p e r a t u r e Sensors The MDCW dryer uses RTD sensors to monitor the temperatures of the drying air, the return air, the regeneration outlet, and the regeneration protection and setback at the outlet heater of the hopper. Location of the Process RTD at the Hopper inlet. 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.
Replacing the Heaters R e g e n e r a t i o n H e a t e r Tu b e ✐ NOTE: It is not necessary to remove the plastic cover to perform this procedure. 1 Stop the dryer, disconnect the power, and follow proper lockout procedures. 2 Remove the hardware securing the metal cover that surrounds the control cabinet. Remove the control cabinet cover. Control Cabinet Cover 3 Working from the front of the machine, locate the regeneration heater tube.
Replacing the Heaters R e g e n e r a t i o n H e a t e r Tu b e (continued) 6 Slide the insulation off or make a straight cut in the insulation, and remove it from the defective heater tube. 7 Check the ID mark on the side of the heater tube for kW rating and voltage. The ID mark is on the outside of the tube near the end with the lead wires. 8 Place the insulation on the new heater tube. Make sure to duct tape the seam that was cut during removal, if necessary.
Replacing the Heaters P r o c e s s H e a t e r Tu b e 1 Stop the dryer, disconnect the power, and follow proper lockout procedures. 2 Disconnect the hose from the process filter, then remove the plastic cover from the back of the dryer. 3 Remove the hardware securing the metal cover that surrounds the control cabinet. Remove the control cabinet cover. Control Cabinet Cover 4 Locate the process heater tube that extends through the frame, at the back of the machine.
Replacing the Heaters P r o c e s s H e a t e r Tu b e (continued) 7 Loosen the hose clamp securing the heater tube in place and remove the tube from the unit. 8 Slide the insulation off, or make a straight cut in the insulation and remove it from the defective heater tube. Insulation 9 Check the ID mark on the side of the heater tube for the kW rating and voltage and replace with a new heater tube with the same ratings. The ID mark is on the outside of the tube near the end with the lead wires.
Replacing the Desiccant Wheel Assembly If the desiccant becomes clogged or contaminated, you should replace the desiccant wheel to ensure optimum performance. 1 Stop the dryer, disconnect the power, and follow proper lockout procedures. 2 Remove the plastic cover from the back of the dryer. 3 Disconnect wiring from the display board and loader switches, then remove the front plastic cover. 4 Remove the hardware securing the metal cover that surrounds the control cabinet.
Replacing the Desiccant Wheel A s s e m b l y (continued) 7 Remove four bolts securing the wheel assembly to the frame, then remove the desiccant wheel assembly from the dryer. 8 Position the new wheel assembly on the frame, with the motor to the right, as viewed from the front. 9 Bolt the wheel assembly to the frame. 10 Reconnect the motor wires. 11 Reconnect the hoses and RTDs to their original positions. 12 Reinstall the metal control cabinet cover using the original hardware.
We ’ r e H e r e t o H e l p 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 Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have installing and operating your equipment.
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, 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.
Cleaning the Precooler Coils If you have the optional precooler, you need to clean the coils to keep them 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. ✐ NOTE: If an optional flow control was added with the precooler, remove the compression fitting from the precooler inlet.
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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.
Ta b l e o f C o n t e n t s A-1 M o d b u s C o m m u n i c a t i o n s Description of Modbus communications . . . . . . . . . . . . . . . . . . . . . A-2 Installing the Modbus communication hardware . . . . . . . . . . . . . . A-2 Using the Modbus parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 B-1 E t h e r n e t C o m m u n i c a t i o n s Description of Ethernet communications . . . . . . . . . . . . . . . . . . . . . B-2 Installing the Ethernet communication hardware . . . . .
D-1 S P I C o m m u n i c a t i o n s Description of SPI communications. . . . . . . . . . . . . . . . . . . . . . . . . D-2 Installing the SPI communication hardware . . . . . . . . . . . . . . . . . . D-2 Configuring the SPI communication software . . . . . . . . . . . . . . . . . D-2 Supporting dryer SPI commands. . . . . . . . . . . . . . . . . . . . . . . . . . . D-4 A Appendix Modbus RS-232/485 serial communications parameters . . . . . . . .
SECTION A Description of Modbus Communications . . . . A-2 Installing the Modbus Communication Hardware . . . . . . . . . . . A-2 U s i n g t h e M o d b u s Pa r a m e t e r L i s t . . . . . . . . .
Description of Modbus Communications The common controls series of products from Conair use standard Modbus communications 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 RSView.
U s i n g t h e M o d b u s Pa r a m e t e r L i s t (continued) Modbus Communications l A-3 A Modbus 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.
A-4 l Modbus Communications
SECTION B Description of Ethernet Communications . . . . B-2 Installing the Ethernet Communication Hardware . . . . . . . . . . . B-2 U s i n g t h e E t h e r n e t Pa r a m e t e r L i s t . . . . . . . .
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 standard 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, 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.
Installing the Ethernet Communication Hardware (continued) “IP Addr Part 2” is displayed. This is the second octet (first three numbers) of the IP address and may be changed if necessary. 5 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 reinitialize the Ethernet interface.
B-4 l Ethernet Communications
SECTION C DeviceNet Communications Communication Hardware . . . . . . . . . . . C-2 Using the DeviceNet Communication Dip switch Settings . . . . . . . . . . . . . . . C-2 Using the LED Status Indicators . . . . . . . . . . C-5 Configuring the DeviceNet Software I n s t a l l i n g t h e E D S Fi l e s . . . . . . . . . . . . C - 5 E D S Fi l e Pa r a m e t e r L i s t Configuration Options . . . . . . . . . . . C-6 Adding the Gateway to the Scan List . . . . C-8 Explicitly Writing to the Gateway . . . .
Description of DeviceNet Communications The Conair Common Control board set allows you to add DeviceNet communications for information interchange with PLC systems or higher level supervisory computer systems. The DeviceNet communication is accomplished with a gateway device that converts the Modbus communications already existing on the DC-2 display board or the DC control cabinet , but may also be purchased with a DIN rail mounted enclosure.
Using the DeviceNet Communication Dip Switch Settings (continued) (continued) DeviceNet Communications l C-3 C DeviceNet Dip switch 1 provides the DeviceNet MacId address and baud rate using the standard 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 MacId address and baud rate. Factory default switch settings are 125k , Address 63.
Using the DeviceNet Communication Dip Switch Settings (continued) Dip switch set 2 identifies the Modbus addresses of controllers connected to the DeviceNet interface. From one to eight controllers can be enable for communication through a single Athena DeviceNet interface module. Dip switch set 2 position 4 identifies the baud rate used to read parameters on Modbus. Dip switch set 2 positions 1-2 identify the parameter list for the Conair controllers.
Using the LED Status Indicators There are two LEDs on the gateway which display the status of the communications. 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 and the control circuit board. The second LED (labeled “DeviceNet” on the gateways with the enclosure) display the status of the DeviceNet communications. 1.
Configuring the DeviceNet Software Installing the EDS Files (continued) Configuring the DeviceNet Software E D S F i l e Pa r a m e t e r L i s t C o n f i g u r a t i o n Options Once the EDS file has been installed the gateway may be added to a network configuration. There are a number of parameters that may be configured for each gateway to optimize it for your application. The number of parameters will vary depending on how many controllers are attached to a gateway.
Configuring the DeviceNet Software E D S F i l e Pa r a m e t e r L i s t C o n f i g u r a t i o n Options (continued) There are seven types of parameters: Parameter 1 Controller Access 1X, 10X, 100X Number of Int. Parameters 0 to 40 This field will display how many integer parameters are retrieved from the controller. This will be either 10 or 20 depending on the position of dip switch 2, switches 1 and 2.
Configuring the DeviceNet Software E D S F i l e Pa r a m e t e r L i s t C o n f i g u r a t i o n 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). ✐ NOTE: When this field is modified the change must be applied.
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 “Edit I/O Parameters” button should be accessible.
Configuring the DeviceNet Software Adding the Gateway to the Scan List (continued) Press the “Edit I/O Parameter” button to to the configure the I/O parameters.
Configuring the DeviceNet Software Adding the Gateway to the Scan List (continued) 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 “OK” button to keep the data size you have entered.
Configuring the DeviceNet Software G a t e w a y Pa r a m e t e r L i s t 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 scanner. If the dip switches are set for twenty words, Modbus parameters 500 to 519 will be transferred to the scanner.
SECTION D SPI Communications Description of SPI Communications . . . . . . . D-2 Installing the SPI Communication Hardware . . . . . . . . . . . D-2 Configuring the SPI Communication Software . . . . . . . . . . . D-2 SPI Communications l D-1 D SPI Supported Dryer SPI Commands . . . . . . . . . .
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 communicate with the various kinds of equipment in common use at a typical plastics facility. For example, a dryer is specified as Device ID 22 hex, a chiller is Device ID 21 hex.
Configuring the SPI Communication S o f t w a r e (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”SPI”. Set the slave ID to a unique address on the RS-485 network master. Once you have completed entering in your information, return to the opening menu and cycle the power on your equipment to establish the new settings.
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.
Supported Dryer SPI Commands (continued) 6. Status, Process - Indicates that the status of the process with each “bit” showing a particular condition.
Supported Dryer SPI Commands (continued) 7. Status, Machine 1 - Indicates that the status of the dryer itself with each “bit” showing a particular condition.
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.
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) Bit1 - 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.
Modbus RS-232/485 Serial C o m m u n i c a t i o n Pa r a m e t e r s D C - 2 C o n t r o l Pa r a m e t e r s Used on dryers with DC-2 Controls Read Area Modbus Register Number Description Comments 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 Product Type Process Temperature Setpoint Process Actual Temperature Process Temperature Setpoint (Setback) Return Air Temperature Out of Hopper Return Air Setpoint (Setback) Regeneration Actual Temperature Dewpoint Actual Operat
Modbus RS-232/485 Serial C o m m u n i c a t i o n Pa r a m e t e r s (continued) Modbus Register Number Description Comments 535 536 537 538 539 Start Command Stop Command Alarm Acknowledge Process Temperature Setpoint Process Temperature Setpoint 1 = start 1 = stop D C P l u s C o n t r o l Pa r a m e t e r s U s e d o n R e s i n Wo r k s a n d H o p p e r Te m p e r a t u r e Controllers (HTC) A-2 l Appendix Modbus Register Number Description Comments 500 501 502 503 504 505 506 507 508 509
Modbus RS-232/485 Serial C o m m u n i c a t i o n Pa r a m e t e r s (continued) D C P l u s C o n t r o l Pa r a m e t e r s U s e d o n R e s i n Wo r k s a n d H o p p e r Te m p e r a t u r e Controllers (HTC) Modbus Register Number Description Comments 530 531 532 533 534 535 536 537 538 539 Process Temperature Setpoint Process Temperature Setpoint (Setback) Return Air Setpoint (Setback) Load Rate Setpoint (Setback) PM 1 Dewpoint Setpoint Start Command 1 = start Stop Command 1 = stop Alarm Ackno
A-4 l Appendix Modbus TCP/IP C o m m u n i c a t i o n s Pa r a m e t e r s
Appendix l A-5
A-6 l Appendix
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