www.conairgroup.com USER GUIDE UGD034-0311 Carousel Plus Dryer W Series Models 600 through 5000 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 Using the Carousel Plus W Series as a central dryer . . . . . . . . . . . . 1-3 Your responsibilities as a user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 ATTENTION: Read this so no one gets hurt . . . . . . . . . . . . . . . . . . .
Opening the dryer doors (W1600-5000) . . . . . . . . . . . . . . . . . . . . . 3-9 Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Connecting the air hoses to a single hopper (W600-1000) . . . . . . 3-12 Connecting the air hoses to a single hopper (W1600-5000) . . . . . 3-13 Connecting the air hoses to a ResinWorks. . . . . . . . . . . . . . . . . . . 3-14 Connecting the dryer to the hopper . . . . . . . . . . . . . . . . . . . . . . .
-1 M a i n t e n a n c e 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Appendix We’re here to help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 How to contact customer service . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Before you call... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Equipment guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Performance warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Warranty limitations . . . . .
SECTION 1 Purpose of the user guide . . . . . . . . . . . . . . 1-2 How the guide is organized . . . . . . . . . . . . . 1-2 Using the Carousel Plus W Series as a central dryer . . . . . . . . . . . . . . . . 1-3 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 Carousel Plus W Series Dryer and explains step-by-step how to install, operate, maintain, and repair this equipment. Before installing this product, please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet. You also should review manuals covering associated equipment in your system. This review won’t take long, and it could save you valuable installation and operating time later.
Using the Carousel Plus W Series as a Central Dryer Yo u r R e s p o n s i b i l i t y a s a U s e r You must be familiar with all safety procedures concerning installation, operation and maintenance of this equipment. Responsible safety procedures include: • Thorough review of this User Guide, paying particular attention to hazard warnings, appendices and related diagrams. • Thorough review of the equipment itself, with careful attention to voltage sources, intended use and warning labels.
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 Carousel Plus W Series Dryer? . . 2-2 Ty p i c a l a p p l i c a t i o n s . . . . . . . . . . . . . . . . . . 2 - 2 How it works . . . . . . . . . . . . . . . . . . . . . . 2-4 Specifications: Carousel Plus W Series Dehumidifying Dryers . . . . . . . . . . . . . . 2-7 Carousel Plus W Series Dehumidifying Dryer options . . . . . . . . . . . . . . . . . . .
What is the Carousel Plus W Series Dryer? The Carousel Plus W Series Dehumidifying Dryer produces low-dewpoint air that removes moisture from hygroscopic plastics. The dryer pulls moist air from a drying hopper and circulates it through a dehumidifying desiccant wheel. The dryer then circulates the air through the material in the hopper. The dryer’s closed-loop design ensures a continuous supply of dehumidified air while preventing contamination from moisture in the plant.
Ty p i c a l A p p l i c a t i o n s Model (continued) Drying Temperature Range 100° - 150°F {38° - 66°C} Standard 150° - 240°F {66° - 116°C} High heat (with aftercooler/intercooler)* 150° - 375°F {66° - 191°C} Low-high (aftercooler/intercooler & precooler)* 100° - 375°F {38° - 191°C} * See page 3-17, 3-18 and Appendix B • Throughput rates of 600 to 5000 lbs {271 to 454 kg} per hour (some materials can be ran at a higher rate). • Dewpoints of -40°F {-40°C}.
H o w I t Wo r k s The Process (Drying) Cycle (W600 - 1000) Process air from the hopper is pulled into the dryer, through the process filter and then into the process blower inlet. Air exits the process blower and then enters the aftercooler, then passes through the desiccant wheel, where moisture is removed. The air exits the dryer and passes through the precooler (if installed), then into the process heat source (HTC or CGT Gas Unit).
H o w I t Wo r k s (continued) (W600 - 1600 and 3200) NOTE: Earlier W1600-5000 dryers will have their intercoolers in the W6001000 location. ****** ****** ********************** W-series 1600-5000 intercooler location only. ********************** ✐ NOTE: Carousel Plus W Series 600-1000 Dryers use an aftercooler located before the the process blower. Carousel Plus W Series 1600-5000 dryers use an intercooler located after the process blower.
H o w I t Wo r k s (continued) (W2400 and W5000) Power Purge W 2400 and 5000 models have a Power Purge (cooling fan) feature integral to the desiccant wheel assembly. ✐ NOTE: Carousel Plus W Series 600-1000 Dryers use an aftercooler located before the the process blower. Carousel Plus W Series 1600-5000 dryers use an intercooler located after the process blower. 2-6 l Description Protected under United States Patent No. 7,101,414 and other US and Foreign Patents Pending. .
Specifications: Carousel Plus W Series Dehumidifying Dryers A B C MODELS W600* Performance characteristics (with full hopper) Drying temperature Dewpoint Dimensions inches {cm} A - Height B - Width C - Depth Outlet/inlet hose diameter Approximate weight lbs {kg} Installed 1300 {590} Shipping 1495 {678} Voltage - Total amps 400 V/3 phase/50 Hz† 37.2 460 V/3 phase/60 Hz 32.0 575 V/3 phase/60 Hz 25.
Carousel Plus W Series Dehumidifying Dryer Options • Volatile trap (only in conjunction with aftercooler/intercooler) - 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.
SECTION 3 Installation . . 3-2 . . 3-3 . . 3-4 . . 3-4 . . 3-4 . . 3-5 . . 3-6 . . . . 3-7 3-8 3-9 3-9 . 3-12 . . . . . 3-13 3-14 3-15 3-15 3-16 . 3-17 . . . . 3-18 3-19 3-19 3-20 Installation l 3-1 3 . . . . Installation Unpacking the boxes . . . . . . . . . . . . . . . Preparing for installation . . . . . . . . . . . . Po s i t i o n i n g t h e d r y e r o n t h e f l o o r . . . . . . . Removing the cable tie from the desiccant wheel (W600-1000) . . . . . .
Unpacking the Boxes The Carousel Plus W Series Dryer comes in one to four boxes, depending on the model and options ordered. The boxes could include (depending on the options selected): • Carousel Plus W Series Dryer • Delivery air hose • Return air hose • User Guide 1 Carefully remove the dryer and components from their shipping containers. Note that the dryer is secured to its shipping container with metal bands that pass through the bottom of the dryer frame.
Unpacking the Boxes (continued) 6 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. 7 You are now ready to begin installation. Follow the preparation steps on the next page, then choose one of the two mounting options: • Dryer on the floor, single hopper (with HTC Hopper Temperature Control package) on a floor stand.
Po s i t i o n i n g t h e D r y e r o n t h e F l o o r 1 Lift the dryer from the shipping container using a fork truck. 2 Position the dryer on the floor near the hopper or ResinWorks sled. Make sure the location allows for the connection of all hoses, keeping hose lengths as short as possible.
Installing the Return Air Adapter The Carousel Plus W Series Dryer’s return air adapter must be installed. To install the return air adapter: 1 Remove the return air adapter that is attached to the dryer’s shipping pallet. 2 Locate the bolt pattern on the top of the dryer, on top of the return air inlet. 3 Position the return air adapter on top of the return air inlet, aligning both bolt patterns. Return Air Inlet Adapter ly sized wrench.
Installing the Return Air Inlet and A i r O u t l e t A d a p t e r s (W1600 - 5000) The Carousel Plus W Series Dryer’s return air inlet and air outlet adapters will be removed when the dryer is shipped To install the return air inlet and air outlet adapters: 1 Remove the return air inlet and air outlet adapters that are attached to the dryer’s shipping pallet. 2 Locate the bolt patterns on the top of the dryer, on top of the return air inlet and air out outlet.
Installing the Overhead Process Air D u c t (W3200 - 5000) The Carousel Plus W Series Dryer’s overhead process air duct will be removed when the dryer is shipped. To install the overhead process air duct: 1 Remove the overhead process air duct that is attached to the dryer’s shipping pallet. The piping will be shipped as one unit with included gaskets (2). 2 Locate the bolt patterns on the top of the dryer, over top of the overhead process air duct inlet and outlet.
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. Turn 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.
Opening the Dryer Doors (W1600 - 5000) Carousel Plus W Series 1600-5000 Dryers designed after August 2007 will have locking side panel door bolts. To unlock the side panel door bolts: 1 Rotate the two (2) locking door bolts on the dryer door counterclockwise with a regular screw driver. Dryer Door Locking Bolts (2) (W1600-5000) 2 Close the dryer doors and rotate the two (2) locking door bolts clockwise to resecure the dryer doors.
Checking for Proper Air Flow ✐ (continued) NOTE: Models W600-1000 dryer aftercooler and dry air delivery configuration shown. Location on larger Dry Delivery Air models are different. Refer to the labeling on your dryer. See Installation section entitled, Installing the Return/Delivery Air Adapters, for proper air line connections. 3 Visually verify the blower motor is moving in the correct direction indicated by the arrow on the blower housing.
Checking for Proper Air Flow (continued) 4 If air flow is incorrect disconnect power, follow proper lockout procedures and swap any 2 of the 3 main power wires. WARNING: All wiring, disconnects, and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region. Always maintain a safe ground. Do not operate the equipment at power levels other than what is specified on the the machine serial tag and data plate.
Connecting the Air Hoses to a S i n g l e H o p p e r (W600 - 1000) Using the two flexible hoses provided, connect the inlet of the HTC and outlet of the drying hopper to the dryer. Make sure the dryer is located as close as possible to the hopper (approximately 10 ft {3.05 m}). ✐ NOTE: Models W600-1000 dryer aftercooler and dry air delivery configuration shown. Location on larger models are different. Refer to the labeling on your dryer.
Connecting the Air Hoses to a S i n g l e H o p p e r (W1600 - 5000) Using the two flexible hoses provided, connect the inlet of the HTC and outlet of the drying hopper to the dryer. Make sure the dryer is located as close as possible to the hopper (10 ft {3.05 m} of hose supplied). 1 Attach one hose from the return air inlet, located on top of the dryer, to the outlet of the hopper. flexible hoses to kink or Return Air Inlet crimp.
Connecting the Air Hoses to a R e s i n Wo r k s Using the two flexible hoses provided, connect the delivery air and return air manifolds of the ResinWorks to the dryer. Make sure the dryer is located as close as possible to the sleds (10 ft {3.05 m} of hose supplied). 1 Attach one hose from the return air inlet of the dryer to the return air manifold of the ResinWorks. Dry Delivery Air 2 Attach one hose from the delivery air outlet of the dryer to the delivery air manifold of the ResinWorks.
Connecting the Dryer to the Hopper If your dryer hose connection and your hopper HTC hose connection are not the same size, you will need a hose adapter. Contact Conair Parts 1 800-458-1960. ✐ Connecting the Dryer to NOTE: Because the W600 - 5000 models require a separate heat source for the delivery air, all references to this heat source will be identified as “HTC” (Hopper Temperature Controller).
Connecting Air Hose Adapters Depending on the hopper you purchased you may need to install an air hose adapter to connect the hopper to your dryer. To connect the air hose adapter: 1 Place a high temperature gasket approximately half way down from the end of the dry air delivery outlet. Dryer Inlet/Outlet Connection 2 Place hose adapter inside high temperature gasket flush to the dryer outlet, secure with pressure clamp. Pressure Clamp 3 Attach the hopper inlet hose over the adapter, secure with clamp.
Connecting the Aftercooler and O p t i o n a l P r e c o o l e r (W600 - 1000) The aftercooler and/or optional precooler require a source of city, tower, or chiller water and a discharge or return line. You can use water at temperatures of 45 to 85°F {7 to 29°C}. But the water flow should be at least 3 gal/min {11.4 liters/min}. ✒TIP: Make the water supply and discharge / return connections with flexible hoses at least 24 in. (61 cm) long.
✒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 intercooler assembly for cleaning. Connecting the Intercooler and O p t i o n a l P r e c o o l e r (W1600 - 5000) The intercooler and/or optional precooler require a source of city, tower, or chiller water and a discharge or return line. You can use water at temperatures of 45 to 85°F {7 to 29°C}. But the water flow should be at least 3 gal/min {11.
Mounting a Loader on the Hopper If you have a Conair loader or vacuum receiver, you can use the flange and mounting clips provided on the top of the hopper. Refer to the manuals that came with your receiver or loader for detailed installation instructions. 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.
Te s t i n g t h e I n s t a l l a t i o n 4 Press the STOP button. Stop If everything is installed correctly: • The blowers will continue running as needed to cool the heaters. (until regeneration heaters are less than 150°F {66°C}) 5 The test is over. If the dryer performed the normal operating sequences as outlined, you can load the hopper and begin operation. If it did not, refer to the Troubleshooting section of the User Guide.
SECTION 4 Operation Carousel Plus W Series Dryer: control panel DC-2 . . . . . . . . . . . . . . . 4-2 Carousel Plus W Series Dryer control functions . . . . . . . . . . . . . . . . 4-3 How to navigate the menu tree . . . . . . . . . . 4-3 Control function descriptions . . . . . . . . . . . 4-11 To s t a r t d r y i n g . . . . . . . . . . . . . . . . . . . . 4 - 3 4 To s t o p d r y i n g . . . . . . . . . . . . . . . . . . . . . 4 - 3 5 H o w t o u s e t h e s u p e r v i s o r ’s p a s s w o r d . . .
C a r o u s e l P l u s W S e r i e s 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 regeneration temperature and actual setpoint are displayed. This button can be pressed at any time to return to the default screen.
Carousel Plus W Series Dryer Control Functions Dryer functions are values that you can set or monitor in the Screen Title and Status Display windows. Press the Menu button then the Scroll List “Next” or “Prev” buttons until the function you want to set or monitor appears in the Screen Title window. Control Function Flow Charts The charts beginning on page 4-4 provide a quick summary of the control functions. For an explanation of each control function, see Control Function Descriptions (page 4-11).
POWER ON Screen # CONAIR CV00.06.2 CP600 DV00.09.8 1 3 SEC DELAY MONDAY 7/22/2003 07:59 AM 2 3 SEC DELAY Central Dryer REGENERATION TEMP ACT 350˚F SET 350˚F 4 RETURN AIR TEMP ACT 120˚F SET 120˚F 5 PROCESS DEWPOINT ACT -47˚F SET -40˚F 11 PRESS MENU KEY ✐ 4-4 PRESS MENU KEY AT ANY TIME DRYER MAIN MENU STAT SETUP DIAG 12 NOTE: In the event new control boards are installed, screens showing Process and MDC may be present. The boards will need to be configured for a central dryer.
Screen # DRYER MAIN MENU STAT SETUP DIAG 12 DRYER STATUS PROC REGEN OTHER 13 CENTRAL DRYER DRYER PROCESS STATUS SCREENS 14 DRYER REGEN STATUS SCREENS 14 DRYER OTHER STATUS SCREENS 14 RETURN AIR TEMP ACT 120˚F SET 120˚F 5 REGENERATION TEMP ACT 350˚F SET 350˚F 4 MODEL 5000 480 V 60 HZ 30 TOTAL RUN HOURS 1250 17 REGEN OUTLET TEMP ACT 280 29 DISPLAY FIRM V2.21.00 31 DISPLAY MENU V2.21.00 PROCESS CFM 1600 20 REGEN HEATER OUTPUT 68% 15 CONTROL FIRMWARE VERSION V2.21.
SCREEN # DRYER MAIN MENU STAT SETUP DIAG 12 DRYER SETUP PROC ALM DISP OTHER 36 SETUP PROCESS PROC REGN OTHER 37 CENTRAL DRYER SETUP PROCESS PROC RETPID 14 SETUP AFTERCOOLER 14 on off VALUE SCREENS RETURN AIR TEMP ACT 120˚F SET 120˚F 5 RET AIR CYCLE TIME COOL 20 SECONDS 42 AFTERCOOLER Enabled Edit Disabled 21 RET AIR CALIBRATION OFFSET 2˚F 47 PROCESS DEWPOINT ACT -40˚F SET-40˚F 11 SETUP PROCESS SCREENS 4-6 l Operation 38
Screen # SETUP REGENERATION REGEN PID SETUP REGENERATION SCREENS 14 DRYER MAIN MENU STAT SETUP DIAG 12 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 REGEN OUTLET TEMP ACT 280 29 REGEN CYCLE TIME 2.
Screen # ALARM ACTION DRYER SETUP ALARM ACTION SCREENS l Operation 12 DRYER SETUP PROC ALM DISP OTHER 36 ALARM SETUP 58 DRYER SETUP CONTROL DISPLAY SCREENS 14 UNITS STANDARD METRIC 71 14 DRYER SETUP ALARM SETPOINT SCREENS 14 REGN TEMP LOOP BREAK ON EDIT PASS EDIT 59 REGEN HIGH TEMP 400˚F 5 SEC 60 TIME DISPLAY 12 HOUR 24 HOUR REGN TEMP DEVIATION ON EDIT PASS EDIT 59 REGEN LOW TEMP 200˚F 5 SEC 60 DATE 5/23/2002 REGN HIGH TEMP ALARM ON EDIT PASS EDIT 59 REGEN LOOP BREAK 2˚F 40 SEC
Screen # 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 Dryer Setup Password Screen 14 Logging Out Password … IF A VALID PASSWORD IS STILL ACTIVE CFM MONITOR NOT INSTALLED FILTER CHECK INSTALLED EDIT EDIT 75 75 AFTERCOOLERFLOW CONT INSTALLED EDIT 75 PRECOOLER INSTALLED EDIT 75 REGEN CURRENT TRANS INSTALLED EDIT 75 RE
Screen # 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 92 Alarm Activated For 10.3 Minutes DOWN OR UP ARROW KEY 02:P-REGEN DEV 3/1/00 03:25P RETURN AIR TEMP ACT 120˚F SET 120˚F INFO INFO 92 92 REGENERATION TEMP ACT 425˚F SET 425˚F REGEN OUTLET TEMP ACT 280 REGEN HEATER OUTPUT 68% ETC.
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. ✐ NOTE: The supervisory password is required to change certain parameters. More detail about the CONAIR D100 CV2.21.00 DV2.21.
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 This screen will show the actual dewpoint of the process delivery air measured after the desiccant wheel and before the process heater. The dewpoint control will automatically adjust the regeneration temperature to maintain the dewpoint setpoint. Dewpoint control is not active with -40°F {-40°C} 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) Screen Function SCREEN 13 This is the Dryer Status screen. It can be found by pressing the Select Category button under the word "Stat" on the Main Menu screen 12. Any information under the status section is read only; NO CHANGES can be made from the status sections. The operator can select to see status information for Process, Regeneration, or Other.
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 17 This screen shows the total run time in hours the dryer has been running since it was new. If the control board is changed during the life of the dryer, this timer will start over. TOTAL RUN HOURS 1250 ✐ SCREEN 20 NOTE: Screens labeled 75 in the display screen flow chart PROCESS CFM 1600 on page 4-9 are various option installation screens.
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 22 (Current Monitor Option) This screen shows the measured current on each leg of the 3-phase power going to the regeneration heater. The Regeneration Current Monitor option (see screen 75, page 4-26, also see note on this page) for this to appear. REGEN CURRENTS 84.3 A 84.2 A 84.3 A SCREEN 23 (Current Monitor Option) TOTAL POWER 82 KWH ✐ NOTE: Additional components required for installation.
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 30 ✒ Tip: This information is important to know when ordering a control board. ✒ Tip: This information is important to know when ordering a display board. MODEL CP600-5000 480 V 60 Hz SCREEN 31 DISPLAY FIRM V2.21.00 DISPLAY MENU V2.21.
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. PANEL INSIDE TEMP ACT 100°F SCREEN 36 DRYER SETUP SCREEN 37 PROC ALM DISP OTHER SCREEN 37 SETUP PROCESS SCREEN 38 PROC REGEN OTHER PROC RETPID This is the second Setup Process 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 40 Before performing an autotune, set the setpoint to the desired temperature you would like the control to autotune to at screen 3 for process, and screen 4 for regeneration. Screen 40 shows the autotune function for the selected heater. The dryer must not be running to initiate an autotune.
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 44 This screen shows the integral value for the PID Loop. REGEN INTEGRAL HEAT/COOL 16.0 This screen shows the derivative value for the PID Loop. SCREEN 45 REGEN DERIVATIVE HEAT/COOL 2.0 With the proper password, (see page 4-29, screen 85) the PID values can be reset back to the factory default settings. SCREEN 46 REGEN PID RESET HEAT/COOL This screen shows the temperature offset for the RTD.
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 ✐ NOTE: Screens 49, 50, 51, 52, 53 and 54 apply only when the dewpoint control is enabled. SCREEN 50 PROCESS DEWPOINT TRIM UP LIMIT 375°F This is the minimum value the dewpoint control can set the regeneration temperature to achieve the desired dewpoint. SCREEN 51 PROCESS DEWPOINT TRIM LOW LIMIT 100°F This is the proportional gain value for the dewpoint control. SCREEN 52 PROCESS DEWPOINT GAIN 0.
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 56 MONDAY START TIME ON 8:00 AM SCREEN 57 8:00 PM NOTE: Screens 56 and 57 require the supervisor’s password. This is the auto stop screen for the first day of the week. Each day has a screen similar to this. By pressing the Select Category button under On or Off, the dryer can be set to stop on Monday.
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 4-29, screen 85) the Select Category button can be pressed under Alarm Action or Alarm Setup. Alarm Action screens can be used to change whether an alarm is 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 This is an example of an Alarm Setup Loop Break screen. When actual temperature is outside the deviation band, if the temperature is not moving toward the setpoint at a rate greater than or equal to X°F over Y seconds, then the dryer will alarm on Loop Break. Once the actual temperature is within the deviation band, the Loop Break is ignored.
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) This screen shows the low CFM setpoint. The default is 1 CFM. The default can be changed with the proper password (see page 4-29, 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 TIME DELAY 5 MIN SCREEN 71 UNITS STANDARD EDIT This is the amount of time from start-up the dryer is allowed to run before the control will try to control the dewpoint. Five minutes is the default. This gives the dryer time to warm up and reach a steady state. It can be changed with the proper password (see page 4-29, screen 85). 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 This is the Dryer Setup Other screen. It can be found by pressing the Select Category button under the word Other on the Dryer Setup Screen (36). By pressing the Select Category buttons under the titles, the user can select to see setup information for Options, Inspection, Communications, or Password.
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 was replaced, the control may need to be reconfigured. With the proper password, (see page 4-29, 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 4-29, 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. You can enter a password by using the keypad. Once a password has been entered the “ENTER” key must be pressed. If the password is valid, the display will show screen 87. If the password was incorrect, it will display "Invalid Password Try Again" and go back to the Enter Password screen. The default supervisor password is 0210.
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 hitting the “ENTER” Key will change the display to "Logging Out Password" 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 102 These parameters map which internal variables are accessible from the user communication port on the DC-2 operator display. A default set of variables has been chosen that represent the most important variables for the majority of uses. These values should NOT be changed except under the direction of Conair Engineering or Service.
To 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. ✐ NOTE: When changing a setpoint use the Select Category Key directly below the value to be changed. Once pressed the value will blink, then use the keypads or (+) (-) adjustment setpoints to enter the new value. Then press enter for the new value to be recognized.
To S t a r t D r y i n g (continued) 3 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 regeneration heater turns on and the display LED will • illuminate. The desiccant wheel starts turning. To S t o p D r y i n g ✐ NOTE: Turn off the ResinWorks or HTC and allow the heaters to cool (3 to 5 minutes) before turning off the dryer.
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 "SET UP." 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 ) Be sure to push “ENTER” after entering the password. If the password is entered successfully, screen 87 will be displayed. VALID SUPERVISOR PASSWORD ENTERED Once the desired parameter has been changed, follow the previous steps to go to screen 88. LOGOUT SUPERVISOR PASSWORD YES Push the Select Category button under “No”. Once it begins to flash, push either the Adjust Setpoint button to display “Yes”, then push “ENTER”.
Using the Dewpoint Monitor and 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 A u t o S t a r t Ti m e r You can set the dryer to start and stop automatically using the Auto Start and Auto Stop functions. Supervisor Password (screen 85, page 4-29) is necessary to use this function. ✐ NOTE: To use the Auto Start Timer, you must have the Auto Programming Auto Start Start function enabled The Auto Start time and day can be programmed using the Auto Start Countdown screen.
4-40 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 aftercooler/intercooler coils . . . 5-9 Cleaning the precooler coils (W600-5000) . . 5-11 Inspecting hoses and gaskets . . . . . . . . . .
Preventative Maintenance Checklist Routine maintenance will ensure optimum operation and performance of the W Series Carousel Plus 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 and regeneration 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 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.
Checking the Dewpoint (continued) 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 Place a container beneath the hopper’s drain port to catch the material. 3 Open the drain port and allow the material to drain. 4 Open the hopper door and wipe out the inside of 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. C a r o u s e l P l u s W- s e r i e s D r y e r s 6 0 0 - 1 0 0 0 1 Push in on the sides to release the tabs on the front cover. Remove the cover. CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the dryer and drying hopper. ✐ NOTE: Larger dryer models (W1600 - 5000) do not have covers.
Cleaning the Process Filter (continued) C a r o u s e l P l u s W- s e r i e s D r y e r s 6 0 0 - 5 0 0 0 3 Remove the filter wing nut, then remove the filter. 4 Remove outer filter and clean it with soapy water. Let air dry. ✐ NOTE: On models W1600-5000 the process filter will not have an outer filter. 5 Clean the filter by laying it on its side and gently tapping it on the floor. Replace 6 Reverse the procedure to reinstall the process filter.
Cleaning the Regeneration Filter Clogged filters reduce air flow and dryer efficiency. Cleaning frequency depends on the condition of your dryer’s ambient air. 1 Push in on the sides to release the tabs on the front cover. Remove the cover. ✐ CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the dryer and drying hopper. NOTE: Larger dryer models (W1600 - 5000) do not have covers. 2 Remove the filter wing nut, then remove the filter.
Cleaning the Aftercooler/ Intercooler Coils You need to clean the aftercooler/intercooler 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/intercooler, remove the compression fitting from the aftercooler/intercooler inlet.
Cleaning the Aftercooler/ I n t e r c o o l e r C o i l s (continued) 5 Clean the assembly using a mild soap and water. Let the assembly ✐ dry thoroughly before installation. NOTE: In cases of heavy volatiles, steam cleaning or the use of solvents, such as acetone, may be necessary. Be sure to test a small area with the solvent you have selected to be sure there is no adverse reaction. 6 Inspect the condition of the gasket. If it is damaged, replace the gasket.
Cleaning the Precooler Coils You need to clean the precooler cooling coils to keep them working efficiently. See Appendix B for details. C l e a n i n g t h e Vo l a t i l e Tr a p o n t h e Demister If you have the optional volatile trap, you need to clean the trap to keep it working efficiently. See Appendix C for details. Inspecting Hoses and Gaskets Loose or damaged hoses and gaskets can allow moisture to seep into the closed-loop drying system.
5-12 l Maintenance
SECTION Tr o u b l e s h o o t i n g 6 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 . . . . . . . . . . . . . . . . . . . . 6-9 Dewpoint troubleshooting . . . . . . . . . . . . . 6-15 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 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 open the side panels of the dryer be sure to: ❏ Diagnose causes from the control panel. 1 Press once to silence the optional audible alarm and display the alarm message. 2 Address the alarm message and fix the problem.
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 Dryer alarms are indicated by an illuminated Acknowledge Alarm light on the W series dryer control panel. when there is no active alarm will take the user A problem can trigger two types of alarms: directly to the Alarm History • Shutdown: The dryer has automatically shut down because it has detected a list (Screen 95, page 4-31). ✐ serious problem that could damage your material or dryer.
Shutdown Alarms If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that once the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid. ✐ NOTE: Some alarms can be set for shutdown or passive (screen 59, page 4-22). These alarms may be listed in both sections.
Shutdown Alarms If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that once the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid. ✐ NOTE: Some alarms can be set for shutdown or passive (screen 59, page 4-22). These alarms may be listed in both sections.
Shutdown Alarms If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that once the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid. ✐ NOTE: Some alarms can be set for shutdown or passive (screen 59, page 4-22). These alarms may be listed in both sections.
Shutdown Alarms If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that once the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid. ✐ NOTE: Some alarms can be set for shutdown or passive (screen 59, page 4-22). These alarms may be listed in both sections.
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 once the Acknowledge Alarm button is pressed once, the blinking amber LED becomes solid. ✐ NOTE: Passive alarms can be configured as shutdown alarms (see the previous Shut Down Alarms section). See page 4-22, screen 59 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 once the Acknowledge Alarm button is pressed once, the blinking amber LED becomes solid. ✐ NOTE: Passive alarms can be configured as shutdown alarms (see the previous Shut Down Alarms section). See page 4-22, screen 59 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 once the Acknowledge Alarm button is pressed once, the blinking amber LED becomes solid. ✐ NOTE: Passive alarms can be configured as shutdown alarms (see the previous Shut Down Alarms section). See page 4-22, screen 59 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 once the Acknowledge Alarm button is pressed once, the blinking amber LED becomes solid. ✐ NOTE: Passive alarms can be configured as shutdown alarms (see the previous Shut Down Alarms section). See page 4-22, screen 59 for instructions.
Additional Alarms Along with the alarm indicators, you may encounter additional messages that indicate a problem within 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. Push the acknowledgement button to identify the alarm, and address it as necessary.
Additional Alarms Along with the alarm indicators, you may encounter additional messages that indicate a problem within the control. Problem Possible cause Solution Er. Lo - There is a problem in the sensor connection (RTD, Dewpoint sensor, etc.) for the effected 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. Low regeneration air flow. Check regeneration filter and clean and/or replace as necessary. Return air temperature exceeds 125°F {52°C}.
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 intent of the information provided here is to 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 of possible causes and solutions. NOTE: Concerns with drying temperature may require review of HTC or ResinWorks controls. Temperature - The temperature of the air entering the hopper must be at the proper drying temperature for your material, as specified by your supplier.
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 with an ohmmeter. If necessary, pull the fuse out and replace it with a fuse of the same type and rating. Fuse Blocks To locate the appropriate fuse and replacement part, refer to the wiring diagrams that came with your dryer. IMPORTANT: Always refer to the wiring diagrams that came with your dryer to locate specific electrical components.
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 Carousel Plus W Series Dryer uses RTD sensors to monitor the temperatures of the return air, the regeneration outlet, and the regeneration inlet. To check or replace an RTD sensors: 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. 1 Disconnect and lockout the main power supply.
Replacing the Regeneration Heater (W600 - 1000) 1 Stop the dryer, disconnect the power, and follow proper lockout procedures. 2 Remove the right side panel of the dryer, as viewed from the front of the dryer, to gain access to the regeneration heater. 3 Disconnect the regeneration heater power wires from the terminal block in the control cabinet. Feed the regeneration power cable out of the control cabinet.
Replacing the Regeneration Heater (W600 - 1000) (continued) 8 Compare the markings on the outside of the regeneration heater tube to ensure the new one has the same voltage and kW ratings as the original heater tube. This information is on the end nearest the wires. 9 Slide the original insulation over the new heater or, if the insulation was cut for removal, wrap the cut insulation sleeve around the new heater tube and secure it with duct tape.
Replacing the Regeneration Heater (W1600 - 2400) 1 Stop the dryer, disconnect and lockout the main power. 2 Locate the heater. Open the side panels of the dryer locating the heater which is secured to the inlet of the desiccant wheel assembly by hard piping, brackets and clamps. See Installation section entitled, Opening the dryer doors (W1600-5000). Clamp Gasket Clamp Gasket IMPORTANT: Always refer to the wiring diagrams that came with your dryer to locate specific electrical components.
Replacing the Regeneration Heater (W1600 - 2400) (continued) 8 Slide the original insulation over the new heater, or if the insulation was cut for removal, wrap the cut insulation sleeve around the new heater tube and secure it with heat tape. 9 Make sure the cable end of the new heater tube is to the bottom, then connect the hoses to the top and bottom of the heater tube and resecure with pressure clamps and the lower heater tube bracket that was removed in Step 5.
Replacing the Regeneration Heater (W3200 - 5000) 1 Stop the dryer, disconnect and lockout the main power. 2 Locate the heater(s). Open the side panels of the dryer locating the heaters which are secured to the inlet of the desiccant wheel assembly by hard piping, a heater tube manifold, brackets and clamps. See Installation section entitled, Opening the dryer doors (W1600-5000).
Replacing the Regeneration Heater (W3200 - 5000) (continued) 6 Loosen the two (2) lower clamps that secure the regeneration manifold and tubing to the desiccant wheel bracket. Remove the regeneration manifold and the tubing that is attached to the bottom of the manifold. Then remove the tubing from the regeneration blower outlet and check for loose particles within the tubing, clean as necessary. Reverse this procedure to reinstall the regeneration manifold and tubing.
Replacing the Desiccant Wheel A s s e m b l y (W600 - 1000) 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 upper and lower side panels from both sides of the dryer. 3 Remove the top cover from the dryer by removing the securing bolts.
Replacing the Desiccant Wheel A s s e m b l y (W600 - 1000) (continued) 10 Lift the new desiccant wheel into the dryer frame, being sure it is oriented properly. To verify the correct orientation, ensure that the regeneration air inlet is positioned closest to the regeneration heater tube. DO NOT bolt into place at this time. 11 If the dryer aftercooler is being used, slide the desiccant wheel assembly towards the front of the dryer, being careful to not let it slip off one side of the dryer frame.
Replacing the Desiccant Wheel M o t o r (W600 - 1000) 1 Stop the dryer, disconnect and lockout the main power. 2 Remove both side panels. 3 Disconnect wiring to the motor. 4 Remove the pivot bolt securing the belt tensioner to the motor bracket. Be sure to retain the flat washers located between the tensioner and bracket. Disconnect the spring and remove the tensioner. 5 Remove the belt from the motor pulley, then remove the pulley from the motor.
Replacing the Desiccant Wheel M o t o r (W1600 - 5000) 1 Stop the dryer, disconnect and lockout the main power. 2 Open the right side panel(s), as viewed from the front of the dryer. See Installation section entitled, Opening the dryer doors (W1600-5000). 3 Unbolt and remove the access panel on the side of the desiccant wheel assembly. 4 Disconnect the wiring connection to the motor.
Replacing the Desiccant Wheel M o t o r (W1600 - 5000) (continued) 9 Slip the belt onto the sprocket, and adjust the tension spring nut to its original position. 10 Connect the wires to the new motor. 11 With the access panel still removed, connect the power to the dryer and start it. Ensure the wheel turns in the correct direction. If the belt appears to be slipping, it may be necessary to increase the tension on the drive belt slightly.
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 You need to clean the precooler 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.
C l e a n i n g t h e Vo l a t i l e Tr a p o n t h e D e m i s t e r (W600 - 1000) 1 Stop the dryer and lockout the main power. 2 Remove the thumbscrews then remove the volatile demister cover. 3 Remove the demister by pulling it out from the housing. 4 Clean the assembly using a mild soap and water. Let the assembly dry ✐ thoroughly before installation. NOTE: In cases of heavy volatiles, steam cleaning or the use of solvents, such as acetone, may be necessary.
C l e a n i n g t h e Vo l a t i l e Tr a p o n t h e D e m i s t e r (W1600 - 5000) 1 Stop the dryer and lockout the main power. 2 Remove the thumbscrews then remove the volatile demister carriage and demister from its housing. 3 Remove the demister from the demister carriage by pushing it out towards the right side of the carriage. 4 Clean the assembly using a mild soap and water. Let the assembly dry ✐ thoroughly before installation.
C-3 l Appendix
www.conairgroup.
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
Appendix l A-7 ) ) ) ) ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) 52 ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) 52 ) ) 52 )
