www.conairgroup.com USER GUIDE UGD033-0311 MDCW Carousel Plus Dryer MDCW Models 15, 25, 50, 75, and 100 with DC-1 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-1 O p e r a t i o n The MDCW dryer: control panel DC-1 . . . . . . . . . . . . . . . . . . . . . . . 4-2 MDCW Carousel Plus Dryer control functions . . . . . . . . . . . . . . . . . 4-3 Control function flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Control function descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 To start drying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 To stop drying . . . . . . . . . . .
6-1 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 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Dewpoint troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i v l Ta b l e o f C o n t e n t s
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 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 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° - 240°F {66° - 116°C} High heat (with aftercooler)* 150° - 375°F {66° - 191°C} Low-high (with aftercooler & precooler)* 100° - 375°F {38° - 191°C} *Se
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 6 PROCESS RTD 5 REGENERATION BLOWER PROCESS HEATER BOX HIGH TEMP SHUTOFF REGENERATION AIR FILTER HIGH TEMP SHUTOFF REGENERATION HEATER 4 REGENERATION RTD HOPPER DESICCANT WHEEL 2 3 REGENERATION OUTLET RTD RETURN AIR FILTER AFTERCOOLER RETURN AIR RTD PROCESS PROCESS BLOWER COOLING REGENERATIO DRYER OPTIONS 1 SETBACK TEMPERATURE 2 DEWPOINT MONITOR / CONTROL *Standard on some DC-1 models 2-6 l Description 3 PROCESS FILTER STATUS 4
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 (machine loader) Outlet - 2 in. dia. {5.1 cm} E - Receiver dia. 4.5 in. {11.4 cm} F F - Height with viewing chamber E 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. {10.2 cm} 6 in. {15.
MDCW Carousel Plus Dryer Options • Volatile trap (use only in conjunction with aftercooler) - The volatile trap is recommended if drying materials that produce volatile 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 Connecting the main power . . . . . . . . . . . . . 3-8 Checking for proper air flow . . . . . . . . . . . . 3-9 Connecting the aftercooler . . . . . . . . . . . . 3-11 Mounting a loader on the hopper . . . . . . . .
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* MDCW Dryer Drying Hopper Direct Feed** DC-1 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 following page.
Preparing for Installation The MDCW Carousel Plus dryer has been designed for use beside the processing machine. The mobile unit also can 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. 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. *Phase detection not standard with non-conveying models.
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.
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.
Checking for Proper Air Flow IMPORTANT: This check 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: This step 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. (continued) Stop Reconnect the process filter that was discon- nected in Step 3. Process Filter Inlet 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 The aftercooler and optional precooler require a source of cooling water and a discharge or return line. ✒TIP: Make the water supply and To connect water hoses: discharge / return connections 1 Connect the water supply line to the (61 cm) long. This allows you to aftercooler inlet. If a manual shut off valve is used, it should be mounted on the inlet line. with flexible hoses at least 24 in. easily remove the aftercooler assembly for cleaning.
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. 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) ✐ NOTE: Testing loader is not applicable on non-conveying models. 5 Turn On the loader switch. • The conveying blower should turn on and the LEDs will turn off and on. ✐ NOTE: Non-conveying MDCW 50, 75 & 100 may experience an A2 alarm if 6 Turn OFF the rocker switch for the loader. Stop 7 Press the STOP button.
3-14 l Installation
SECTION 4 Operation The MDCW dryer: control panel DC-1 . . . . . . 4-2 MDCW Carousel Plus Dryer control functions . 4-3 Control function flow chart . . . . . . . . . . . . . 4-3 Control function descriptions . . . . . . . . . . . 4-5 To s t o p d r y i n g . . . . . . . . . . . . . . . . . . . . . 4 - 2 0 Conveying . . . . . . . . . . . . . . . . . . . . . . . 4-21 Using the auto start countdown function . . . 4-22 How to disable the auto start function on the DC-1 control . . . . . . . . . . . . . .
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 - 1 Increment/Decrement Buttons Used to increase and/or decrease the setpoint of a control function. Setpoint Display Actual Display Shows the setpoint value. Shows the actual temperature value. Alarm Codes See the Troubleshooting section for a more complete listing of alarms.
MDCW Carousel Plus Dryer Control Functions Dryer functions are values that you can set or monitor. Press the Scroll button until the function you want to set or monitor appears in the LED display. ✐ NOTE: Grey shaded screens denote optional functions. If the options were not purchased with the dryer, those screens will not appear. All options can be purchased and installed in the field. Control Function Flow Chart The following flow chart provides a quick summary of the control functions.
Display Menu Number ✐ NOTE: Screens 1-4 are only displayed during initialization. ✐ NOTE: Gray areas designate parameters associated with options.
Control Function Descriptions Screen Function SCREEN 1 Once power is turned on, this screen is displayed for 5 seconds while the control goes through self-checking. Pr up SCREEN 2 CPC 25 v2.0 d v2.0 SCREEN 5 (Default Screen) 1 250 250 SCREEN 6 2 350 350 This is the DEFAULT screen. It shows the process air temperature setpoint and actual temperature measured at the inlet to the drying hopper. The (+) or (-) buttons can be used to change the setpoint.
Control Function Descriptions Screen Function SCREEN 7 This screen shows the actual return air temperature measured at the inlet to the process blower. If the optional aftercooler flow control is installed, a setpoint will be displayed on this screen as well. The (+) or (-) buttons can be used to change the set point. Holding the (+) or (-) buttons in will allow the number to ramp up faster the longer the button is held.
Control Function Descriptions (continued) Screen Function SCREEN 10 (Setback Temperature Option) If the dryer has the setback on temperature option installed, this is the temperature setpoint for the air at the outlet of the drying hopper. When this setpoint is reached, the dryer will automatically change the process setpoint to the setpoint shown on Menu number 7, screen 11.
Control Function Descriptions Screen Function SCREEN 13 (Dewpoint Monitor/ Dewpoint Control Option) If the dryer has the dewpoint monitor option installed, this screen will show the actual dewpoint of the process delivery air measured at the inlet of the hopper. With the dewpoint monitor option installed, there will only be an actual display (no setpoint value). Although the dryer is capable of producing dewpoints much lower than -40° F {-40° C}, the minimum sensor range is -40° F {-40° C}.
Control Function Descriptions (continued) Function Screen Screens 15-27 require access code 754. SCREEN 16 (Set up Screen) C 375 C02 SCREEN 17 (Set up Screen) C off C03 350 C04 NOTE: Software may allow the Process temperature setpoint limit up to 450° F {232° C}, however Conair does not recommend a setpoint limit over 375° F {191° C} due ✐ to nuisance alarms.
Control Function Descriptions (continued) Function Screen Screens 15-27 require access code 754. SCREEN 20 (Set up Screen) C 10 C06 SCREEN 21 (Set up Screen) Regeneration Differential Temperature C 20 C07 SCREEN 22 (Set up Screen) Regeneration Outlet temperature C 4-10 l Operation 200 C08 This screen shows the time delay setting for the conveying blower on the MDCW. This is the minimum time the MDCW will wait before starting another load cycle.
Control Function Descriptions (continued) Function Screen Screens 15-27 require access code 754. SCREEN 23 (Set up Screen) Setback Temperature Band Option C 20 C09 off C10 Operation l 4-11 4 C This screen is the Aftercooler Flow Control Enable screen. By pressing the (+) or (-) keys, the setting can be changed. With this off or disabled, the dryer will not open the flow control valve and try and control the return air temperature. There will also be no setpoint value on Menu number 3, screen 7.
Control Function Descriptions (continued) Function Screen Screens 15-27 require access code 754. SCREEN 26 (Set up Screen) C off C12 SCREEN 27 (Set up Screen) Precooler Option C off C13 Reserved function. This should always be off. This screen shows how the precooler is set to operate. If it is set to "Off" the control assumes the precooler is not installed in the process line and will not control well below 150° F {66° C}.
Control Function Descriptions (continued) Function Screen Screen 28-43 require access code 755. SCREEN 29 (Test Mode Screen) H off 2 This is the Test Mode screen for the process heater. By pressing the (+) or (-) keys, the setting can be changed. When set to "On", the process heater output will be turned on for 3 seconds and then shut off automatically. ✐ SCREEN 30 (Test Mode Screen) H off 3 off 4 This is the Test Mode screen for the regeneration heater.
Control Function Descriptions Function Screen (continued) Screen 28-43 require access code 755. SCREEN 34 (Test Mode Screen) H off 7 SCREEN 35 (Test Mode Screen) H off 8 This is the Test Mode screen for the isolation contactor. By pressing the (+) or (-) keys, the setting can be changed. When set to "On", the isolation contactor output will be turned on for 3 seconds and then shut off automatically. This is the Test Mode screen for the alarm output (horn and/or red light).
Control Function Descriptions (continued) Function Screen Screen 28-43 require access code 755. SCREEN 39 (Test Mode Screen) H off 12 This is the Test Mode screen for the MDCW conveying blower. By pressing the (+) or (-) keys, the setting can be changed. When set to "On", the conveying blower output will be turned on for 3 seconds and then shut off automatically. ✐ NOTE: If the dryer is a non-conveying MDCW nothing will happen.
Control Function Descriptions (continued) Function Screen Access code 756 required. SCREEN 44 (Alarm Screen) 4-16 l Operation A 1 P3 A 2 A1 A 3 A5 A 4 A4 A 5 P1 A 6 P5 A 7 A7 A 8 A2 A 9 A6 A 10 P2 This is the first Alarm History screen. In this section, the last 10 alarms that have occurred are saved, starting with the most recent alarm. The number in the setpoint screen shows the list of alarms 1-10. The alarm code shows up in the actual screen.
Control Function Descriptions (continued) Function Screen Screen 45-49 require access code 754. SCREEN 45 (Setback Temperature Enable Option) C off C11 SCREEN 46 (Precooler Flow Control Enable Option) H off 13 This screen shows the setting of the setback option. It can be set to “Off” or “On”. “Off” turns the setback mode off, and the dryer will not change the process setpoint.
Control Function Descriptions Function Screen (continued) Screen 45-49 require access code 754. SCREEN 48 (Conveying Shutdown on Alarm Option) C off C16 SCREEN 49 (MDCW Shutdown Delay Option) H 4-18 l Operation off C17 This screen can be used to determine if the MDCW conveying on function will shutdown or continue to operate upon any dryer alarm. When turned off, the conveying blower will continue to cycle indefinitely if the dyer shuts off for an alarm condition.
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. Use the Scroll button to get to the Process Temperature function. Press the Adjust Setpoint (+) or (-) buttons to select the temperature. Adjust Setpoint Buttons Scroll Button 1 2 3 4 5 6 7 8 Process Temp. Regen. Temp. Return Air Temp.
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 Stop 1 Press the STOP button. The Stop LED blinks red. • The blowers continue running for a few minutes to cool the heaters.
Conveying 1 Move the MDCW to the processing machine. Lock the wheels and connect the main power source. Connect the water source if you an aftercooler or optional precooler. 2 Mount the vacuum receiver on the feed throat. Push the vacuum receiver onto the mounting bracket. 2 3 Place the appropriate material 1” opening Virgin material insert insert inside the distribution box. 4 Make sure all hoses are connected 1.25” opening Regrind material insert securely. 5 Adjust the demand sensor.
Using the Auto Start Countdown Function The countdown function allows the user to set the MDCW dryer to automatically start at a predetermined time. The countdown time can be set from 0.1 to 150.0 hours. To set the countdown time: 1 Use the Scroll button to access the function (Menu 4, Screen 8). 4 16 ON Auto Start 2 Use the Setpoint Adjust keys to set the desired countdown time, in hours. 3 Press the Start button. The Auto Start LED will blink to indicate that Auto Start is armed.
Setting the High Setpoint Limits You can protect your drying process from accidental or unauthorized settings above an acceptable level for your material. 1 Turn on the main power to the dryer. Start 2 While at the default screen (Screen 5) press the scroll button and the setpoint (-) minus button simultaneously to get to Screen 14 . 0 0 3 On screen 14 enter the password for set up screens (754) using the setpoint (+) or (-) button. 0 754 0 C 385 C02 4 Scroll to screen 16.
Using Dewpoint Control Dewpoint control is a feature that can help you to reduce energy consumption. It does this by varying the temperature of the regeneration air from its default setpoint of 350° F {177° C}, to maintain a setpoint that you have entered on the process dewpoint screen (Screen 11). Example: If your material is not difficult to dry, it may dry adequately with -20° F {-29° C} dewpoint air.
U s i n g t h e S e t b a c k Fe a t u r e (Optional) The setback function available on the Carousel Plus MDCW dryer with DC-1 control is designed to save you money on energy costs and help to keep you from over drying your material. The optional setback feature, if installed from the factory, is disabled and will need to be enabled in access code 754 (Screen 45). This is how setback operates when installed and turned on: The control monitors the temperature of the air exiting the drying hopper.
U s i n g t h e S e t b a c k Fe a t u r e (Optional) (continued) 6 Use the setback temperature band screen (Screen 23) to set the amount the return air temperature has to drop below the setpoint on Screen 10 before the original process temperature is restored.
S e t b a c k Fe a t u r e G u i d e l i n e s (Optional) (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.
4-28 l Operation
SECTION 5 Maintenance Preventative maintenance checklist . . . . . . . 5-2 Checking the dewpoint . . . . . . . . . . . . . . . . 5-3 Cleaning the hopper. . . . . . . . . . . . . . . . . . 5-5 Cleaning the process filter . . . . . . . . . . . . . 5-6 Cleaning the regeneration filter . . . . . . . . . . 5-8 Cleaning the conveying filter . . . . . . . . . . . . 5-9 Cleaning the vacuum receiver . . . . . . . . . . 5-10 Cleaning the precooler coils . . . . . . . . . . . 5-12 Inspecting hoses and gaskets . . .
Preventative Maintenance Checklist Routine maintenance will ensure optimum operation and performance of the MDCW dryer. 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. Frequency depends on how much material you process and how dusty or full of fines it is.
Checking the Dewpoint ✐ NOTE: Portable dewpoint monitors purchased from 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. Even if your dryer has a dewpoint readout, comparing it to a portable instrument periodically will confirm that the dewpoint sensor and readout is performing properly. Conair were provided with a male connector that plugs into the dewpoint check port.
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, alarm P9.
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 CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the dryer and drying hopper. the top of the filter housing in a clockwise direction to remove. 2 Remove the filter cartridge from the filter housing. 3 Clean or replace 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. Clean or replace the filter 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. CAUTION: Wear eye protection.
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.
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 Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Dewpoint troubleshooting . . . . . . . . . . . . . 6-22 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 . . . . . 6 - 2 3 R E PA I R Replacing fuses . . . . . . . . . . . . . . . . . . . .
Before Beginning 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. ✐ Before you take the covers off the dryer be sure to: NOTE: Use of test mode screens 28-43 ❏ Diagnose causes from the control panel. may assist with the determining of possi- 1 Press once to silence the optional audible alarm and display the alarm message.
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 Most dryer alarms are indicated by an illuminated Acknowledge Alarm light on the MDCW dryer control panel. Shutdown alarms will energize optional audible and visual alarm indicators. alarm will take the user ✐ directly to the Alarm History A problem can trigger two types of alarms: list.
Alarms A problem can trigger two types of alarms: • Shutdown (A#): If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. Note that once the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid. • Passive (P#): If the amber Acknowledge Alarm LED is blinking, the alarm is a passive alarm.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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. Problem Possible cause Solution A3 - Process Heater High Temperature (cont.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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. Problem Possible cause Solution A10 & P26 - Process RTD Integrity – If the process RTD is faulty, it will shut the dryer down.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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. Solution A22 & P2 - Process Low Temperature (cont.)– The process temperature is less than the low temperature setpoint for the specified time.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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. Solution A28 & P9 - Process Dewpoint (cont.) – The dewpoint has not fallen below the setpoint.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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. Solution A41 & P30 - Setback RTD Integrity - The control can not sense the setback RTD.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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. Solution A54 & P23 - Conveying Blower Overload – The conveying blower overload has tripped due to a mechanical or electrical problem.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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. Problem Possible cause Solution A55 & P31 - Wheel Rotation Failure - The regeneration temperature differential has been reached.
Alarms • Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. • Passive (P#): 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.
Additional Alarms Along with the alarm indicators, you may encounter additional messages that indicate a problem within the control. Problem Possible cause Solution CoS Er.4 or Co5 Er. 4 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. Push the alarm acknowledge button to identify the alarm, and address it as necessary. CoS Er.0 or Co5 Er.
Additional Alarms Along with the alarm indicators, you may encounter additional messages that indicate a problem within the control. Problem Possible cause Solution Er. H - There is a problem in the analog input section of the control. Defect in the main control board. Replace main control board. RTD is not connected properly or is defective. Check RTD connections, replace defective RTD Connector to all RTDs is removed.
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 to the aftercooler or increase the flow. Regeneration temperature is below normal setting.
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. 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. Location of the Process RTD at the Hopper inlet.
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 Aftercooler knockout location 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 Process Heater 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 When 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 Process Heater cover that surrounds the control cabinet.
Replacing the Desiccant Wheel A s s e m b l y (continued) 7 Remove four (4) 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 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. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use.
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.
