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D Dryer DC-1 Central.qxd

1. P2 Process Low Temperature The process temperature is less than the low temperature setpoint for the specified time Default values are 70 F 21 1 C for 20 sec P3 Regen Temperature Deviation The regeneration temperature exceeds the devi ation band for the specified time Default values are 43 F 6 C for 5 sec 6 10 Troubleshooting Passive Alarms If the amber Acknowledge Alarm LED is blinking the alarm is a passive alarm The dryer continues to operate but this problem could prevent correct drying of your material Note that once the Acknowledge Alarm button is pressed once the blinking amber LED becomes solid One of the solid state relays SSRs failed in the closed position The process RTD is loose or has fallen out The air hose connections are loose Precooler water is too cold or the water flow rate is too high The process RTD is loose or has fallen out Process heater has failed One of the solid state relays SSRs failed in the closed position The regeneration RTD is loose or has fallen out The air hose connections are loose Replace the failed solid state relays SSR Check the process RTD and tighten 1f needed Tighten all air hose connections Check water temperature and flow settings Adjust as necessary Check the process RTD and tighten 1f needed Check the heater fuses and resistance across each leg of the process heater Replace the failed solid s
2. Reference the wiring diagram and or trace the wires from the process heater tube into the control box Remove the wires from the relays and terminal strips Once disconnected pull the wires from the control box into the dry housing toward the heater tube Check the ID on the side of the heater tube for kW rating and voltage The ID mark on the outside of the tube near the end with the lead wires Make sure the kW and voltage is the same as the replacement heater Reinstall the plugs or hose fittings toward the top of the heater tube Reattach the lower 2 1 2 63 5 mm hose and clamps to the top and bottom Put the insulation back on Make sure to duct tape the seam that was cut during removal Install the hose clamp holding the heater tube to the dryer frame Put petroleum jelly on the tips of the new heater wire leads to make it easier to go through the holes in the back of the control box Reference the wiring diagram to reattach the heater wires and the two snap switch wires Make sure the heater fuses are not blown before trying the new heater Replacing the Desiccant Tanks The D Carousel Dryer has refillable desiccant tanks When desiccant becomes clogged or contaminated you should replace the desiccant in all three tanks to ensure optimum performance or purchase new prefilled tanks from Conair 1 Stop the dryer then disconnect and lockout the main power AN 2 Remove the right side panel from the dryer IMPORT
3. This is the Test Mode screen for the alarm output yellow light By pressing the or keys the setting can be changed When set to On the alarm output will be turned on for 3 sec and then shut off auto matically amp Q Note If the optional tricolor light is not installed nothing will happen This is the Test Mode screen for the alarm output green light By pressing the or keys the setting can be changed When set to On the alarm output will be turned on for 3 sec and then shut off auto matically Note If the optional tricolor light is not installed nothing will happen continued Operation 4 15 4 16 Operation Screen Access code 756 required SCREEN 44 Alarm Screen Fey EEE Ee Ee Control Function Descriptions continued Function 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 Some of the alarm codes are shown on the display label Please refer to the alarm section of this manual for all alarm code definitions These are the additional alarm screens See the explanation above To Start Drying 1 Make sure there is material in the hopper 2 Turn on the main power to the dryer Make sure the dryer s disconnect dial is in the ON position This powers
4. 0 eee eee eee ee A few words of caution 00 ev aes DIAGNOSTICS How to identify the cause of aproblem Shut down alarms 0 00 c cee eee Passive alarms i ost iwdGreebeweddeeaiweaaee ea DCI ACIG sre wae cae wt wae sue cre on ee we ee ee ene eee he REPAIR Replacing fuseS 0 0 cc cece eee eens Checking heater solid state relays Checking or replacing temperature sensors Adjusting the limit switch 0 Replacing the heaters 000000 Replacing the desiccant tanks Refilling the desiccant tanks A Appendix We re Here to Help 1 es How to Contact Customer Service Before You Call noe exd sechan ge etaenenan geen Equipment Guarantee 00000 0 Performance Warranty 0 00 B Appendix Mounting the Dryer on a Floor Stand Mounting the Dryer and Hopper on a Mobile Floor stand e oc b c4 42 hcerave ecco amp che See e Saeed Table of Contents iii C Appendix Installing an aftercooler optional 0000 eee C 1 Cleaning the aftercooler 0 0 0c C 3 D Appendix Installing the flow control optional 00000 0 D 1 E Appendix Installing a precooler Optional 0 0 0 cee ee E 1 Cleaning the precooler 0 0 ccc cee E 3 F Appendix Installing the dew point senso
5. If an optional aftercooler is installed it does not have enough water The aftercooler coils are dirty Solution Check that the bed plates are in the proper position lined up with the hoses See Adjusting the limit switch Tighten any loose hoses Replace the isolation contactor Replace the failed heater solid state relays SSRs Adjust the limit switch so that it drops into the groove and stops the bed plates See Adjusting the limit switch Adjust the limit switch so that it drops into the groove and stops the bed plates Replace the bed drive motor Tighten the set screw Make sure it is on the flat of the D shaped shaft Replace the bed drive motor relay Make sure your material supply system is working properly Add an optional aftercooler if one is not currently installed Turn on the water supply or fix any leaks or blockages Clean the aftercooler coils See Cleaning the Aftercooler Shut Down Alarms Problem A8 Process Blower Pressure If the process blower pres sure switch opens loss of pressure it shuts down the dryer A24 Regen Blower Pressure The regeneration blower pressure switch opens loss of pressure and the regeneration heater shuts down Q NOTE The system may index one more time after the alarm then stop indexing A36 Control Communications Watchdog The display board has lost communications with the control board A38 Phas
6. O four 5 16 18 self locking bolts O four hose clamps Support frame option G eight 3 8 16 self locking bolts O four 5 16 18 self locking bolts ae O four hose clamps amp Support Frame Mobile Floor Stand amp NOTE You must posi tion the dryer on the Slide Gate floor or mount it to a floor stand if your pro cessing machine throat Opening is 1 inch 2 54 Frame with Casters r cm diameter or small f Carefully remove the dryer and components from their shipping containers er and requires a 3x3 and set upright Note that the dryer is secured to its shipping container with inch 7 6x7 6 cm or four bolts that pass through the bottom of the dryer frame These bolts are smaller bolt pattern accessed by removing the side panels of the dryer 2 Remove all packing material protective paper tape and plastic including any inserted in the top section of the dryer Be sure to remove the side panels from the dryer and cut and remove three 3 tie wraps securing the bedplates Also cut and remove the tie wrap on the bedplate limit switch 3 Carefully inspect all components to make sure no damage occurred during shipping and that you have all the necessary hardware 3 2 Installation 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 the User Guide s title page The infor mation will be helpful if
7. a the display board software version SCREEN 5 Default Screen This is the DEFAULT screen It shows the process air temperature setpoint and actual temperature measured at the inlet to the drying hopper The buttons can be used to change the setpoint Holding the buttons in will cause the number to ramp up faster the longer the button is held The display will return to the default screen from anyplace in the menu structure if nothing is done after 10 min Fe en eee M M 2 2 SCREEN 5 Default Screen Indicates configuration as a central dryer i E as OOT ntral SCREEN 6 Shows the regeneration air setpoint and Centra actual temperature The setpoint can not be changed from this screen it is shown only as a reference Operation 4 5 Control Function Descriptions continued Screen Function SCREEN 7 This screen shows the actual return air temp measured at the inlet to the process blower If the optional aftercooler flow control is installed a setpoint will be dis played on this screen as well The buttons can be used to change the set point Holding the buttons in will cause the number to ramp up faster the longer the button is held SCREEN 8 This screen is used to set the dryer to auto start The dryer must be on but not run 4 ning to set auto start The value shown is the countdown time setpoint It is adjustable from 0 1 hrs to 150 hrs Once the countdown time is set press
8. temperature Tighten any loose hoses The isolation contactor failed in the Replace the isolation contactor closed position The heater solid state relays SSRs Replace the failed heater solid state failed relays SSRs Troubleshooting 6 5 Shut Down Alarms Problem A4 Regen Heater High Temperature The snap switch in the regeneration heater tube activated due to excessive tem perature A5 Carousel Index Too Long Alarm If the carousel index was more than 1 5 times the normal index time it shuts down the dryer A6 Carousel Index Failure If the carousel index is requested but no contact transi tion from on to off is seen within 5 sec it shuts down dryer A7 Return Air High Temperature If the return air temperature at the inlet to the blower is greater than 180 F 82 2 C it shuts down the dryer 6 6 Troubleshooting Possible cause The regeneration exhaust is blocked or the air hoses are loose The isolation contactor failed in the closed position The heater solid state relays SSRs failed The limit switch is not adjusted correctly The limit switch is not adjusted correctly The bed drive motor is damaged The set screw on the bed drive motor shaft plate is loose The bed drive motor relay has failed The hopper does not contain enough material You are drying at a high drying temp above 250 F 121 1 C or you are run ning at low throughputs
9. PARTS amp SERVICE 800 458 1960 A C i 24 HOURS A DAY 7 DAYS A WEEK From outside the United States call 814 437 6861 You can commission Conair service personnel to provide on site service by con tacting the Customer Service Department Standard rates include an on site hourly rate with a one day minimum plus expenses Before You Call If you do have a problem please complete the following checklist before calling Conair Make sure you have all model control type from the serial tag and parts list numbers for your particular equipment Service personnel will need this infor mation to assist you Make sure power is supplied to the equipment Make sure that all connectors and wires within and between control systems and related components have been installed correctly O Check the troubleshooting guide of this manual for a solution Thoroughly examine the instruction manual s for associated equipment especial ly controls Each manual may have its own troubleshooting guide to help you Check that the equipment has been operated as described in this manual g Check accompanying schematic drawings for information on special considerations Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Department for a nominal fee Appendix A 1 A 2 Appendix Equipment Guarantee Conair guarantees the machinery and equipment on this orde
10. The MDC was designed to be mobile So every time you move the MDC you will need to mount the vacuum receiver connect the main power source and connect a water source for the optional aftercooler Phasing of electric power should be consistant between locations When configured as 1a central dryer the i MDC option is not available Conveying lines Vacuum receiver Tools for installation j Demand sensor ii O Phillips screwdriver g Flathead screwdriver The first time you install the MDC 1 Move the MDC to the processing area Lock the wheels on the drying cart 2 Mount the vacuum receiver on the feed throat Push the vacuum receiver onto the mounting bracket 3 Connect the conveying lines 4 Connect the RTD probe 5 Connect the demand sensor to the electrical enclosure of the dryer 6 Connect the main power source 7 Connect a source of water for the optional aftercooler Appendix G 9 When configured as a central dryer the i MDC option is not available Vacuum receiver 1 Insert each vertical conveying tube into amp S NOTE Do not allow the flexible hoses to kink or crimp G 10 Appendix 2 Secure flexible conveying hoses to the vertical tubes Connecting Conveying Lines The vertical conveying tubes and flexible conveying hoses may have been removed for shipping To assemble A 1 5 in diameter g A material conveying hose E Vertical conveyi
11. 1 Turn on the main power to the dryer Make sure the dryer s disconnect dial is in the ON position This powers up the control and the display lights will illu minate 2 Set the drying temperature Press Setpoint Adjust A or W buttons to set the temperature When configured as a central dryer the drying temperature can not be set since there is no process heater in the system Central CONAIR a A Set Point Actual 1 Process Temp 2 Regen Temp Process Blower Regen Blower Auto Start 3 Return Air Temp 4 Auto Start 5 Load Time MDC Process Heater Regen Heater Set Back Temp Process Pressure Regen Pressure Desiccant Indexing 6 Activate Setback Temp 7 Setback Temp Process 8 Setback Load Rate 9 PM1 Dewpoint j Checking for Proper Air FIOW continuea 3 Press the START button Hold your hand near the delivery air outlet You should feel air blowing out of the outlet 4 Press the STOP button Return Return Air Inlet Air Inlet ALANA 4 7 g a WRAL 3 a5 a5 P a a qp 3 TE Moisture aAa Moisture exhaust Delivery air outlet Delivery air 15 25 and 50 outlet 75 and models 100 models CAUTION Hot surface Do not place your hand on the delivery air outlet The outlet and the air can get hot enough to burn your hand Installation 3 13 Checking for Proper Air FIOW continuea amp __ INSTALLATION NOTE
12. Press Start to start the dryer Press Stop to stop the dryer Regen Blower Process Pressure Regen Pressure Regen Heater Actual Display Shows the actual temperature value Actual Auto Start PESE ne Set Back Temp ia Acknowledge Alarm Button Press once to silence the optional audible alarm and display alarm messages Press again to clear the alarm Menu Number Display Displays the menu number corresponding to what is shown in the set point and actual displays Can also display letters for alarm and setup screens Scroll Button Press to scroll through the closed loop menu list Pressing the scroll button moves you down the list D Dryer DC 1 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 D 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 For an explanation of each control function see Control Function Description Operation 4 3 POWER ON screen if up 5 sec 2 25 5sec 3 c 09 5 1 sec 4 d voo 01 0 lal wn oO O 0 5 1 CNT DRY 5 250 Process Temp Default
13. To prevent accident and injury lift the empty hopper onto the throat of the processing machine using a hoist and the lifting lugs provided Also lift the dryer from the shipping container using a hoist and the lifting lugs provided 1 Lift the hopper onto the throat Lift the hopper with a hoist using the lifting lugs provided Make sure you align the bolt holes in the throat with the bolt holes on the discharge assembly 2 Bolt the hopper to the throat of the machine Using four 3 8 in 16 M 10 self locking bolts fasten the support frame discharge and slide gate to the throat The bolts must be long enough to reach at least 1 2 in 1 25 cm into the mounting adapter or processing machine throat after passing through the discharge and slide gate Positioning the Dryer on the Floor 1 Lift the dryer from the shipping container using a hoist and the lifting lugs provided 2 Position the dryer on the floor near the processing machine Make sure the location allows for the connection of all hoses Installation 3 9 3 10 Installation Mounting the Dryer on the Floor Stand Hopper on the Throat For information about mounting the dryer on the floor stand and the hopper on the throat refer to Appendix B Mounting the Dryer and Hopper on the Mobile Floor Stand For information about mounting the dryer and hopper on the mobile floor stand refer to Appendix B Connecting the Main Power A CAUTION Alwa
14. customer at which time a Return Goods Authorization Number RGA will be issued by Conair s Service Department Returned equipment must be well crated and in proper operating condition including all parts Returns must be prepaid Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is being made Warranty Limitations Except for the Equipment Guarantee and Performance Warranty stated above Conair disclaims all other warranties with respect to the equipment express or implied arising by operation of law course of dealing usage of trade or otherwise including but not limited to the implied warranties of merchantability and fitness for a particular purpose Mounting the Dryer on a Floor Stand AN Caution to prevent accident and injury lift the dryer onto the floor stand using a hoist and lifting lugs provided 1 Lift the dryer onto the floor stand Lift using a hoist and the lifting lugs pro Tools for vided installation J 3 8 and 9 16 2 Align the four bolt holes on the bottom of the dryer with the four bolts holes wrench on the top of the floor stand JT Hoist 3 Bolt the dryer to the stand using the four 5 16 18 bolts provided Appendix B 1 Mounting the Dryer and Hopper on a Mobile Floor Stand CAUTION To prevent accident and injury lift t
15. the dryer will shutdown on alarm Al This is the process heater autotune screen The autotune function can be turned on by pressing the key Once the key is pressed the screen will show On and then start the autotune process This may take a minute or so to complete When finished the display will read don The new PID values are automatically saved central drying appli i cations these func tions are not available SCREEN 18 Set up Screen SCREEN 19 Set up Screen This is a regeneration temperature screen This is the regeneration heater autotune screen The autotune function can be turned on by pressing the key Once the key is pressed the screen will show On and then start the autotune process This may take a minute or so to complete When finished the display will read don The new PID values are automatically saved Operation 4 9 4 10 Control Function Descriptions continued Screen Function Screens 15 27 require access code 754 SCREEN 20 Set up Screen This screen shows the time delay setting MDC Option for the conveying blower on the MDC j l i This is the minimum time the MDC will Central drying appli wait before starting another load cycle cations this function is not available SCREEN 21 Set up Screen This screen shows how the dryer is set to index the bedplates on Time tim or Dewpoint dew To have the selection for indexing on Dewpoint the
16. 5 Replace the gasket on the flange if necessary 6 Fill the tank with fresh desiccant Fill the tank with the weight of desiccant indicated in the following table 15 amp 25 1 Ib 0 37 kg 2 Ib 0 75 kg s TTT Ke OPW continued Refilling the Desiccant Tank continuea IMPORTANT After filling with fresh desiccant vibrate the tank occur for at least 15 minutes 7 Vibrate the tank for 15 minutes Important no further settling can 8 Reinstall the screen cap Place the cap on the band Install one of the 1 4 20 nuts on the center post and tighten Do not over tighten Install the second 1 4 20 nut and tighten 9 Reinstall the tank end plate Place the end plate on the tank and tighten the six 10 32 screws 10 Shake the tank beside your ear If properly filled you will not be able to hear any desiccant rattling in the tank 11 Reinstall the desiccant tank on the carousel See Replacing Desiccant Tanks Troubleshooting 6 27 6 28 Troubleshooting We re Here to Help Conair has made the largest investment in customer support in the plastics indus try Our service experts are available to help with any problem you might have installing and operating your equipment Your Conair sales representative also can help analyze the nature of your problem assuring that it did not result from misapplication or improper use How to Contact Customer Service To contact Customer Service personnel call
17. MDC option is not available 6g a z 4 3 Place the appropriate material cma 1 opening Virgin material insert LA ow 1 25 opening Regrind material insert insert inside the distribution box 4 Make sure all hoses are connected securely 5 Adjust the demand sensor Position the sensor at the lowest level of material that you want to maintain in the viewing chamber before another load cycle begins Make sure the sensor rests against the sight glass 6 Set the load time Once the load time is set above zero conveying will start See page 4 6 Screen 9 Appendix G 13 To Stop Conveying 1 Set the load time to zero Once the load time is set to zero conveying will stop See page 4 6 Screen 9 Transporting the MDC When configured as a central dryer the i MDC option is not available The MDC can be moved to another processing machine to a pre drying area or to an area away from the processing machine for cleaning and maintenance To trans port safely 1 Disconnect the power and water sources 2 Place the vacuum receiver on its transport bracket on the MDC cart Tighten the thumbscrew to secure the vacuum receiver to the bracket 3 Unlock the wheels and move the MDC by pushing or pulling with the handles on the cart G 14 Appendix Preventative Maintenance Schedule See Preventative Maintenance Checklist page 5
18. PM1 option must be installed By pressing the or keys the setting can be changed When the dryer is set to index on Dewpoint it will index on time 20 min for the first 3 indexes so that the desiccant tanks have time to dry out Then it will index on dew point The regeneration cycle will still be 20 min If at the end of the 20 min regen eration cycle the process dewpoint is still below the setpoint the dryer will turn off the regeneration blower and heater and wait for the process dewpoint to reach its setpoint If however the process dew point stays below setpoint for 2 hrs the dryer will index automatically SCREEN 22 Set up Screen This screen is the Setback Temperature Setback Temperature Option Band screen This temperature is the amount the return air out of the hopper has to drop below the activate setback temper ature before the original process tempera ture is restored For example if the acti vate setback temperature was 180 F 82 2 C and the dryer was in setback The I I I i actual temperature measured at the outlet to the hopper would have to drop below I central drying appli i cations this function is not available 5 T REAO eel 160 F 71 C to restore the original process Operation setpoint Control Function Descriptions continued Screen Function Screens 15 27 require access code 754 SCREEN 23 Set up Screen This screen is the Aftercooler Flow Aftercooler
19. Screen 6 Regen Temp 7 Return Air Temp 8 Auto Start t 9 f5 10 LoadTime moe I I i 10 6 Activate Setback Temp Option I 11 145 250 Setback Temp Process Option 7 1 When supplied for central P1218 Setback Load Rate Option drying applications these I I I l l 13 9 L 0 Dewpoint Monitor or PM1 Options control functions are not I I available 14 o C o Password Screen Access Code Access Code Alarm Access Code Setup 754 Test Mode 755 History 756 15 0 Lo cor 2h Loft 44 A Ci P I I 16 400 C02 1 29 off 44 i7 off C03 30 H 44 A 18 425 C04 31 off 44 19 off 32 44 20 6 0 eos sE aa A 44 A zl x 3 E e E EE e DOl ILIS TE lal eI IISI Poy ys 22 e 2 cos 3f aa a 20 m oe sE sa A 24 ronl eol 37 H 44 A oO 00 O O O 4 4 Operation Control Function Descriptions Screen Function SCREEN 1 Once power is turned on this screen is dis played for 5 sec while the control does some self checking SCREEN 2 Once power is turned on and screen 1 is displayed for 5 sec this screen is dis played for another 3 sec It shows the dryer model number for which the control is configured SCREEN 3 After the model number is displayed this screen flashes for sec and displays the control board software version SCREEN 4 After the control versions is shown the screen flashes again for 1 sec and displays
20. a mobile floor stand MDC version rn Dryer on a floor stand hopper on the a throat 2 2 Description Typical Applications continued The D carousel 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 150 250 F 66 121 C r 150 375 F 66 191 C Low high with aftercooler amp precooler 100 375 F 38 191 C Note See instruction on page 4 12 for setpoints over 150 F 66 C When supplied for central drying Throughput rates of 15 to 100 Ibs 6 8 to 37 3 kg per hour some materials 2 applications the D series dryer is not equipped with a process can be run at a higher rate Dew points of fee 40 C heater Therefore as a central dryer the D dryer will only sup ply dry air to the hoppers If you are drying material at temperatures over 250 F 121 C you will need the high temperature package that includes an aftercooler An aftercooler is standard equipment on the High heat and Low high models Description 2 3 2 4 Description How It Works The D carousel dryer achieves continuous closed loop drying by passing air simul taneously through two heaters and three tanks of molecular sieve desiccant THE Proce
21. air density with temperature Because dryers operate at a relatively low pressure the effects on air density are negligible When drying below 150 F a precooler is required When drying above 250 F an aftercooler and insulated drying hose is required Dryers running at 50 HZ will have 17 less airflow and a 17 reduction in material throughput Temperatures above or below the recommended levels may affect dryer performance Tower chiller or municipal water sources can be used Throughputs will vary by type of material Consult Conair for throughput information Specifications may change without notice Check with a Conair representative for the most current information Appendix G 5 Unpacking the Boxes The MDC comes fully assembled on a mobile drying cart You should have received the following components Vertical conveying tubes I I a central dryer the l RTD probe i a Drying _ MDC option is not 1 are hopper 1G available ee 7 S lc Direct fee ee vacuum receiver Viewing chamber and demand sensor Dryer Vacuum receiver mounting bracket amp Demand sensor a cable PA B te Pump Material inserts mp pa 3 Dust r J Collector Virgin 1 opening a a y Regrind 1 25 opening J Two lengths of flexible lt a conveying hose 1 Carefully remove the dryer and components from the shipping
22. cen ter of the tube Tighten the nuts to lock the probe in place 2 Plug the probe s cable into the recep tacle on the left side of the electrical enclosure Hand tighten the connector Coil any excess cable and secure it with a wire tie E pf a wm Connecting the Optional Setback RTD 1 Insert the probe in the hopper outlet at the top of the hopper The end of the probe must not touch the walls of the inlet The tip of the probe should be approximately in the center of the tube Tighten the nuts to lock the probe in place 2 Plug the probe s cable into the receptacle on the left side of the electrical enclosure Hand tighten the connector Coil any excess cable and secure it with a wire tie Mounting a Loader on the Hopper If you have a Conair loader or vacuum receiver you can use the flange and mounting clips provided on the top of the hopper Refer to the manuals that came with your receiver or loader for detailed installation instructions Testing The Installation You have completed the installation Now it s time to make sure everything works T Make sure there is no material in the hopper If you have mounted a loader or vacuum receiver on the hop per disconnect the material inlet hose at the source 2 Turn on the main power to the dryer Make sure the dryer s disconnect dial is in the ON position This pow a qD Jp 4 OO tr D ers up th
23. cone Open the hopper door Reach into the hopper Grasp the spreader cone tube lift up slightly twist and then push down to release it Tilt the cone assembly and pull it out through the hopper door a a 2 Ql S O D 4 Clean the spreader cone and the inside of the hopper Make sure you also clean the return air screen at the return air outlet of the hopper 5 Repeat the steps in reverse order to reassemble the hopper before adding material Maintenance 5 3 Cleaning the Process Filter Clogged filters reduce air flow and dryer efficiency Cleaning frequency depends on how much material you process and how dusty it is D Clean the filter tube 3 Using compressed air clean 1 Remove the process filter Remove the black plastic knob Pull the cap off Remove the wing nut Remove the filter cap and filter the process filter by blowing air from the inside out Replace damaged worn or clogged filters CAUTION Wear eye protection If you use compressed air to clean the equipment you must wear eye protection and observe all OSHA and other safety regulations pertaining to the use of compressed air gt 4 Reverse the procedure to reinstall the process filter Cleaning the Regeneration Filter Clogged filters reduce air flow and dryer efficiency Cleaning frequency depends on how much material you process and how dusty it is 1 Remove the regeneration filter Remove the two bolts an
24. container The vacuum receiver and material inserts will be on the built in holders on the drying cart The RTD probe and extension cable may have been shipped inside the dryer s electrical enclosure 2 Remove all packing material protective paper tape and plastic Be sure to remove the plastic tie and wrap that protects the desiccant tank and bed plate assembly during shipment continued G 6 Appendix Unpacking the Boxes continued 3 Carefully inspect all components to make sure no damage occurred during shipping and that you have all the necessary hardware 4 Take a moment to record serial numbers and electrical power specifications Central in the blanks provided on the back of the the User Guide s title page The rgpr r72 7 3 I be helpful if When configured as information will be helpful if you ever need service or parts a centraldrverthe MDC option is not 9 You are now ready to begin installation Follow the preparation steps on the 1 available next page Appendix G 7 When configured as a central dryer the i MDC option is not available amp NOTE You will receive a 4 x4 or 6 x6 mounting bracket as specified in your order If you need a larger mounting bracket call your Conair sales representative G 8 Appendix Preparing for Installation The MDC has been designed for use beside the processing machine The mobile unit also can be used
25. delivery process air temperature will automatically set back to a customer entered set point Screen 11 Then if the air exiting the drying hopper drops below the customer entered temperature on Screen 10 by an amount greater than what is shown on Screen 22 the process temperature will automatically reset back to the original process temperature Screen 5 This is how setback operates when the control setback is set to On on the Load Rate option screen Screen 25 optional on DC 1 controls When operating the setback option on the load rate setting the control counts how many times the loader attempts to load The load rate setting tells the dryer to go into setback when the load rate reaches its set number of loads per hour Screen 12 If the load rate drops below the customer entered setpoint Screen 12 the delivery process air temperature will automatically set back to the original process temperature Screen 5 To set up setback on the temperature option 1 Reference the flow chart on Page 4 4 and follow the menu tree path to access Screen 24 2 Turn the setback function for the temperature option to On or Off Off turns the setback mode off and the dryer will not change the process set point On tells the control the dryer should go into setback when the hopper outlet temperature reaches its setpoint Menu 6 Screen 10 3 If you have decided to turn the temperature setback to On go to Screen 10 This is wh
26. loads per hour Menu 9 Screen 12 If you have decided to turn the temperature setback to On go to Screen 12 This screen shows the number or load dumps per hour set point and actual When the actual drops below the setpoint the dryer will go into setback mode When the actual goes above the setpoint the dryer will return to the normal process temperature Screen 5 Replacing Fuses 1 Disconnect and lockout the main power supply AN 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 Fuse Blocks To locate the appropriate fuse and replacement part refer to the wiring diagrams that came with your dryer cD r Q Troubleshooting 6 17 6 18 Troubleshooting Regeneration heater solid state relays If ohms equal zero or infinity replace the contactor Checking Heater Solid State Relays 1 Disconnect and lockout the main power supply AN 2 Open the electrical enclosure 3 Locate the process or regeneration contactors Refer to the wiring diagrams that came with your dryer 4 Check continuity using an ohmmeter IMPORTANT Always refer to the wiring diagrams that came
27. loose The connection of the RTD plug on the control board is loose The process RTD has failed Solution With the power removed check the MDC blower for mechanical failure and free rotation Replace if neces sary Wait 3 to 15 minutes with power on until the dryer indicates the overload condition has cleared then try to restart the dryer With the power removed check the MDC blower for electrical shorts or open circuits Replace if necessary Wait 3 to 15 minutes with power on until the dryer indicates the overload condition has cleared then try to restart the dryer With the power removed check the overload settings and confirm that the settings match the full load amps listed on the conveying blower motor Wait 3 to 15 minutes with power on until the dryer indicates the overload condition has cleared then try to restart the dryer Press alarm acknowledge and wait 2 to 3 minutes for the overload to auto matically reset If the alarm condi tion occurs again have a qualified electrician check the current draw to the motor Check the RTD plug connection and tighten if needed Check the plug connection and tight en if needed Replace the process RTD Troubleshooting 6 13 Passive Alarms Problem P26 Regen RTD Integrity If the process RTD 1s faulty P28 Return Air RTD Integrity Alarm If the return air RTD is faulty P30 Out of Hopper RTD Integrity The dryer continues to run with
28. the RUN button The display will show ON to tell the operator that the auto start is ON and counting The auto start LED on the dis play also flashes green when the auto start is armed and counting down The LED will turn solid green when the dryer starts The dryer will begin operating when the control has finished counting down SCREEN 9 MDC Option This screen shows the amount of time the conveying blower will run Based on the position of the demand sensor in the mate rial receiver this time may need adjusted The time should be set for the time it takes to satisfy the demand sensor 1 sec If the MDC tries to load 3 times without sat isfying the demand signal the dryer will display a passive alarm The range for this time setting is 5 to 20 sec central drying appli i cations this function is not available 4 6 Operation Control Function Descriptions continued Screen SCREEN 10 Setback Temperature Option 6 0 1207 SCREEN 11 Setback Options SCREEN 12 Setback Load Rate Option Function If the dryer has the setback on temperature option installed this is the temperature setpoint for the air at the outlet of the dry ing hopper When this setpoint is reached the dryer will automatically change the process setpoint to the setpoint shown on Menu number 7 Screen 11 When the temperature at the outlet of the hopper drops below the setpoint menu number 6 by the value shown under C07
29. the dewpoint reaches the entered setpoint After the normal regeneration cycle is complete the regen eration heaters and regeneration blower will turn off and wait for the dewpoint to reach setpoint before turning on again This saves energy by only regenerating when you need to if your material is not that wet The maximum time it will wait to index is 2 hr This is the password entry screen that gives the user access to the Set Up Test Mode and Alarm History screens and also password protected control functions The user can get to the non password protected control functions through this screen by pressing the scroll button and the button at the same time This works only if you are on menu 1 default screen The access codes are as follows Set Up Screens 754 Test Mode Screens 755 Alarm History Screens 756 To exit the password section enter 500 and press scroll Control Function Descriptions continued Screen Screens 15 27 require access code 754 Function SCREEN 15 Set up Screen SCREEN 16 Set up Screen SCREEN 17 Set up Screen This is the process deviation temperature screen The range is 5 20 F 15 0 6 7 C This is the deviation temperature band around the set point If the dryer goes outside this band the dryer will dis play a passive alarm P1 This is the process high temperature screen This is the high temperature limit If the process temperature reaches this set point
30. the recommended 24 in 61 cm of flexible hoses there is no need to disconnect the hoses from the precooler inlet and outlet E 3 Appendix Cleaning the Precooler If you have the optional precooler 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 AN power 2 Turn off the water flow to the water supply line Disconnect supply and return lines 3 Remove the plastic precooler cover amp NOTE If an optional flow control was added with the precooler remove the compression fitting from the precooler inlet Loosen the compression fitting on the flow control then swing the copper water supply tube out and away from the precooler inlet 4 Remove the five screws securing the precooler assembly in the precooler housing continued Cleaning the Precoolel continued 5 Remove the precooler assembly from the precooler housing 6 Clean the precooler assembly using a mild soap and water Let the precooler dry thoroughly before installation CAUTION During the cleaning process DO NOT cut or remove the stainless steel wire that holds the precooler assembly together 7 Inspect the condition of the gasket If the gasket is damaged replace the gasket 8 Reassemble by repeating the steps in reverse order Appendix E 4 Installing the Dew Point Sensor Optional am
31. up the con trol and the display lights will illuminate 3 Set the drying temperature Use the Scroll button to get to the Process Temp function Press the Adjust Setpoint A or W buttons to 6 select the temperature Central TONA C Set Point 5 D o A ae 1 Process Temp 2 Regen Temp Process Blower Regen Blower Auto Start 3 Return Air Temp 4 Auto Start Process Pressure Regen Pressure Desiccant Indexing 5 Load Time MDC Process Heater Regen Heater Set Back Temp 6 Activate Setback Temp 7 Setback Temp Process 8 Setback Load Rate 9 PM1 Dewpoint continued Operation 4 17 To Sta rt D ryl ng continued 4 Press the START button If everything is installed correctly The green light on the start button will illuminate The process and regeneration blowers turn on The process and regeneration heaters turn on Central If the desiccant tanks are not in their correct position the carousel will turn clockwise and stop in the correct position To Stop Drying 1 Press the STOP button The drying light stays on The blowers continue running for a few minutes to cool the heaters 2 Be sure to disconnect and lockout the main power if you have stopped the dryer to perform maintenance or repair IMPORTANT Do not use the main power switch to stop the dryer Turning off power to the control and dryer during normal operation prevents t
32. 1 cm g for mounting CH10 1 inch 2 5 cm diameter 6 inches and CH14 hoppers diameter Nt 4 inches 15 2 cm independent of dryer 10 2 cm 7 16 inches 1 1 cm square only 7 16 inches 1 1 cm square diameter diameter Description 2 7 2 8 Description SECTION Installation Unpacking the boxes 3 2 Preparing for installation 3 4 Mounting the dryer and hopper ona 7 processing machine 3 6 ZW Positioning the dryer on the floor 5 mounting the hopper on the throat 3 8 Mounting the hopper 3 9 Positioning the dryer on the floor 3 9 Mounting the dryer on the floor stand hopper on the throat 3 10 Mounting the dryer and hopper on the mobile floor stand 2 one beuacwee da eee eee amp 3 10 Connecting the main power 3 10 Checking for proper air flow 3 12 Connecting the air hoses 3 15 Connecting the water hoses 3 15 Connecting the RID probe 3 16 Connecting the Optional Setback RID 3 16 Mounting a loader on the hopper 3 17 Testing the installation 3 17 Installation 3 1 Unpacking the Boxes The D carousel dryer comes in one to four boxes depending on the model and options ordered The boxes could include depends on options selected RTD i Hoses D Carousel Dryer Ne Hopper Mounting i Hardware Floor stand option
33. 2 Cleaning the Hopper When configured as See Cleaning the Hopper page 5 3 1a central dryer the i MDC option is not available Cleaning the Conveying Lines This method should be used only after most of the material has been drained from the drying hopper 1 Disconnect the material line from the loader 2 Place the disconnected hose inside a container 3 Turn conveying on by setting the load time above zero See page 4 6 Screen 9 Appendix G 15 Cleaning the Vacuum Receiver 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 the conveying system by setting the load time to zero See Page 4 6 Screen 9 Disconnect the air and material hoses from the vacuum receiver When configured as a central dryer the i MDC option is not available A CAUTION Wear eye protection If you use compressed air to 3 Remove and clean the mesh filter Rotate the mesh filter clean these components wear safety glasses to protect your self from air borne materials 2 Remove the vacuum receiver lid Release the twist clamps and lift the lid against the vacuum receiver lid so that it will release Use vacuum or compressed air to clean the screen 4 Remove and clean the vacuum receiver body Lift the vacuum receiver body to release it from the viewin
34. 3 15 Connecting water hoSeS 0 0 ccc e eee eee eee 3 15 Connecting the RTD probe 0 eee ees 3 16 Connecting the Optional Setback RID 055 3 16 Mounting a loader on the hopper 00 eee eee 3 17 Testing the installation 0 0 0 0 0 0 ccc ee 3 17 4 1 Operation The DC 1 dryer control panel 0 0 0 ccc cee ee 4 2 D dryer DC 1 control functions 0 0 eee eee 4 3 Control function flow chart 00 cece eee ees 4 3 Control function descriptions 0 00 cee ee eee 4 5 To start drying swe vere eee amp oebceee berseees reer es 4 17 To stop GIVING oh oho ee eee eo ek eee kee eee uses 4 18 Using the auto start countdown function 4 19 How to enable the auto start on the DC 1 control 4 19 How to disable the auto start on the DC 1 control 4 19 Setting high and low setpoint limits 4 20 5 1 Maintenance Preventative maintenance checklist 000 eee 5 2 Cleaning the hopper 0 ccc eee eee eee ee eee 5 3 Cleaning the process filler 0 0 0 0 ccc ee eee 5 4 Cleaning the regeneration filter 00 0 5 4 Cleaning the aftercooler coilS 0 0 0 ccc eee eee 5 5 Cleaning the precooler coillS 0 0 e eee eee eee 5 5 Inspecting hoses and gaskets 0000s 5 5 ii Table of Contents 6 1 Troubleshooting Before beginning
35. 54 0 100 254 0 100 254 0 100 254 0 100 254 0 100 254 0 100 254 0 100 254 0 100 254 0 105 266 7 C Width 48 121 9 48 121 9 48 121 9 48 121 9 48 121 9 54 137 2 54 137 2 54 137 2 54 137 2 54 137 2 D Depth 30 76 2 30 76 2 30 76 2 30 76 2 30 76 2 36 91 4 36 91 4 36 91 4 36 91 4 36 91 4 Weight Ib kg Voltages Total amps STD LONG DIST STDLONG DIST STANDARD LONG DIST STANDARD LONG DIST STANDARD LONG DIST 208V 3 phase 60 Hz 8 6 11 19 5 11 9 12 1 14 5 20 2 22 6 NA NA 240V 3 phase 60 Hz 7 7 10 1 18 5 10 9 10 8 13 2 17 8 20 2 27 3 29 7 400V 3 phase 50 Hz 4 3 5 4 14 7 5 8 6 2 120 10 3 11 4 14 8 15 9 480V 3 phase 60 Hz 3 8 4 6 4 2 5 0 5 4 6 2 8 9 9 7 12 7 13 5 575V 3 phase 60 Hz 3 1 4 5 13 4 4 8 4 4 5 8 7 3 8 7 10 4 11 8 Total kilowatts w eej 34 aif a7 40 46 o7 73 96 102 Water requirements for optional aftercooler Recommended temperature 70 90 F 21 32 C Water flow gpm liters min 3 11 36 1 2 inch NPT female fittings SPECIFICATION NOTES Consult Conair about other available hopper selections t SCFM stands for standard cubic feet per minute referenced to a pre specified pressure temperature and relative humidity In most cases SCFM is referenced to 14 7 PSIA 68 F and 0 relative humidity ACFM stands for actual cubic feet per minute and must be supplied with a temperature reference due to the change in
36. ANT It s important that the new tanks are connected to the correct hoses Mark the hoses as they are disconnected or replace one tank at a time to ensure that you install the new tanks in the cor rect positions 3 Disconnect the hose from the desiccant tank Loosen the hose clamp with a screw driver foe 4 Lift the tank off the carousel assembly 5 Refill the tank with fresh desiccant See Refilling the Desiccant Tank Section 6 6 Check the O rings in the carousel coupling Replace any O rings that are cracked worn or damaged Apply petroleum jelly on the inside of the cou pling around the O ring 7 Place the refilled tank on the carousel assembly Make sure the inlet outlet tube of the tank seats fully into the O rings on the carousel pipe 8 Connect the hose to the top of the tank Secure with the hose clamp 9 Reinstall the side panel o D 2 0 r Troubleshooting 6 25 6 26 Troubleshooting Refilling the Desiccant Tanks When desiccant becomes clogged or contaminated you should replace the des iccant in all three tanks to ensure optimum performance 1 Remove the desiccant tank from the carousel See Replacing Desiccant Tanks 2 Remove the the tank end plate Remove the six 10 32 self tapping screws from the end plate 3 Remove the screen cap Remove the two 1 4 20 nuts from the center post and pull the screen cap out 4 Remove the old desiccant
37. D MOUNTING BRACKET Hopper Mounting Frame Dimensions inches cm A Insulated hopper diameter 12 5 13 8 12 5 31 8 12 5 31 8 17 43 2 17 43 2 17 43 2 B Overall height 32 81 3 43 109 2 54 137 2 45 114 3 56 142 2 67 170 2 C Base plate square 7 5 19 7 5 19 7 5 19 6 5 16 5 6 5 16 5 6 5 16 5 D Width with insulated hopper 39 99 1 39 99 1 39 99 1 41 104 1 41 104 1 41 104 1 20 80 Mounting Frame Weight lb kg 30 13 6 Hopper Weight Ib kg Insulated 40 18 1 50 22 7 70 31 7 80 36 32 95443 1 110 48 9 HOPPER MODEL CH18 4 CH18 6 CH24 8 CH24 12 CH24 15 Hopper Mounting Frame Dimensions inches cm A Insulated hopper diameter 21 53 3 21 53 3 27 68 58 27 68 58 27 68 58 B Overall height 48 121 9 68 172 7 64 162 6 79 200 7 90 228 6 C Base plate square 6 5 16 5 6 5 16 5 6 5 16 5 6 5 16 5 6 5 16 5 D Width 47 63 121 0 47 63 121 0 47 63 121 0 50 63 128 6 50 63 128 6 Volume ft liters 4 113 3 6 169 9 8 226 5 12 339 8 15 424 8 Capacity lb kg 40 lb ft 160 72 5 240 108 9 320 145 1 480 217 7 600 272 2 Mounting Frame Weight lb kg 50 22 7 50 22 7 70 31 7 70 31 7 70 31 7 Hopper Weight Ib kg 145 66 165 75 210 95 235 107 255 116 MOUNTING PATTERNS i Optional Base Plate l Standard Base Plate gt hes 12 7 cm square nite 3 inches 7 6 cm square IB02 2 inches 5
38. Flow Control Option 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 set point value on Menu number 3 Screen 7 SCREEN 24 Set up Screen This screen shows the setting of the set Setback Temperature Option back option It can be set to Off or On Off turns the setback mode off and the dryer will not change the process set point On tells the control the dryer should go into setback when the hopper outlet tem perature reaches its set point Menu 6 Screen 10 i central drying applica i SCREEN 25 Set up Screen This screen shows the setting of the set i tions these functions i Setback Load Rate Option back load rate option It can be set to Off are not available or On Off turns the setback load rate 9 TTT TTT TTT function off and the dryer will not change the process set point The On setting tells the dryer to go into setback when the load rate gets to its set number of loads per hour Menu 8 Screen 12 continued next page Operation 4 11 4 12 Control Function Screen Screens 15 27 require access code 754 Descriptions continued Function When supplied for central drying appli i cations these func tions are not available SCREEN 26 Set up Screen Precooler Option WARNING
39. IMPORTANT The distance the RTD extends into the heater is critical for proper functioning The distance from the metal heater tube to the outside surface of the curve on the RTD must be 2 5 63 5 mm see photo To take the measurement peel back but do not remove any existing insulation to access the metal heater tube 6 22 Troubleshooting Replacing the Heaters Regeneration Heater continued 12 Put petroleum jelly on the tips of the new heater wire leads to make it eas ier to go through the holes in the back of the control box Reference the wiring diagram to re attach the heater wires and the two snap switch wires 13 Install the RTD fitting and RTD in the 1 8 3 18 mm NPT hole toward the top of the heater tube 14 Put the insulation back on Make sure to duct tape the seam that was cut during removal 15 Put the hose barb back in the lower 1 8 3 18 mm NPT hole and connect the plastic hose 16 Reattach the lower 2 1 2 63 5 mm hose and hose clamp 17 Make sure the heater fuses are not blown before trying the new heater Replacing the Heater Process Heater 3 Disconnect and lockout the main power AN Gain access to the process heater by removing the left dryer side panel Open the electrical enclosure door For D15 D25 and D50 Dryers 4 9 10 11 Remove the hose and hose clamp at the bottom of the heater tube Remove the insulation from the heater tube by cutting the insulation
40. M 10 self locking bolts fasten the support frame and discharge assembly to the throat The bolts must be long enough to reach at least 1 2 in 1 25 cm into the processing machine throat or mounting adapter after passing through the discharge assembly and support frame Q NOTE If you removed the hopper from the sup port frame lift the hopper onto the frame using a hoist Make sure the slide gate is positioned in the recess on the bottom of the hopper base plate Align the bolt holes and fasten the base plate to the discharge assembly using the four 3 8 in 16 M 10 self locking bolts provided 3 Lift the dryer onto the support frame using a hoist and the lifting lugs provided Align the four bolt holes on the bottom of the dryer with the four bolt holes on the top of the support frame Fasten the dryer to the frame with 5 16 in 18 bolts Installation 3 7 Positioning the Dryer on the Floor Mounting the Hopper on the Throat WARNING You are responsible for the structural integrity of this installation We recommend that you Use bolts no smaller than 3 8 in M 10 to mount the hopper on the throat of a processing machine Tools for installation O 9 16 wrench O Flathead screwdriver O Hoist The hopper bolts to the throat of the processing machine as pictured above The dryer can be positioned on the floor near the processing machine 3 8 Installation Mounting the Hopper A CAUTION
41. Models 50 75 and 100 These models use a three phase process blower If the dryer shuts down and a Process Loop Break shutdown alarm is indicated within the first few minutes of operation check for proper air flow AN lf the air flow is reversed the process blower is turning in the wrong direction Turn off and lock out the main power source Open the electrical enclosure and reverse any two leads connecting the main power supply to the dryer 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 3 14 Installation Connecting the Air Hoses Using the two flexible hoses provided connect the inlets and outlets of the dry ing hopper to the dryer If you have positioned the dryer on the floor or mount ed it to an optional floor stand make sure the dryer is located no more than 5 feet 1 5 m from the hopper to reduce heat loss If you ordered an insulated hose it should be installed between the dryer outlet and the hopper inlet Return Air Inlet If you have ordered an optional aftercooler or precooler see Appendices C and E AURAL ALLL AMARA Return Air Inlet 1 Attach the hose to the return air outlet at the top of the hopper labeled From Hopper 2 At
42. NDEl ew i 0c ve geek we ane eea soe ee eae as G 15 Cleaning the conveying lines 0 0 cee ee eee G 15 Cleaning the vacuum receiver 0 0000 G 16 Cleaning the dust collector 0 000000 0 cae G 17 Cleaning the process filler 0 0 0 ee eee G 18 Cleaning the regeneration filter 0000 G 18 Cleaning the aftercooler coils 0000 08 G 18 Cleaning the precooler coils 00 000 0c eee G 18 Inspect hoses and gaskets 0c eee e ee eaee G 18 Table of Contents v vi Table of Contents SECTION Introduction Purpose of the user guide 1 2 How the guide is organized 1 2 Using the D series as a central dryer 1 3 Your responsibilities as a user 1 3 ATTENTION Read this so no one gets hurt 1 4 How to use the lockout device 1 5 Introduction 1 1 1 2 Introduction Q Purpose of the User Guide This User Guide describes the Conair D series of carousel dehumidifying dryers and explains step by step how to install operate maintain and repair this equipment Before installing this product please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet You also should review manuals covering associated equipment in your system This review won t take long and it could save you valuable installation and opera
43. The precooler must NOT be installed in the process line for temperature setpoints above 150 F 65 5 C The precooler hosing will absorb too much heat and will result in poor process temperature control SCREEN 27 Set up Screen Precooler Flow Control Option WARNING The precooler must NOT be installed in the process line for temperature setpoints above 150 F 65 5 C The precooler hosing will absorb too much heat and will result in poor process temperature control This screen shows how the precooler is set to operate If itis set to Off the control assumes the precooler is not installed in the process line and will not control well below 150 F 65 5 C If the screen is set to On the control will assume the pre cooler is connected in the process line and will only allow setpoints from 100 to 150 F 37 8 to 65 5 C The control will also assume that the water flow rate is set manually with a ball valve and make no attempt to control water flow The pre cooler option must be installed for this screen to appear This screen shows how the precooler flow control is set to operate The precooler flow control option must be installed for this screen to appear If the screen is set to On the control will assume the precool 1 only allow setpoints from 100 to 150 F sy 37 8 to 65 5 C It will also assume the 1 water flow solenoid valve is piped in the water line and the dryer control will regu late w
44. The return air RTD has failed The regeneration heater has failed The regeneration RTD is loose or has fallen out Solution Make sure your material supply system is working properly Add an optional aftercooler if one is not currently installed Turn on the water supply or fix any leaks or blockages Clean the aftercooler coils Tighten all air hose connections Replace the failed solid state relays SSRs Check the regeneration RTD and tighten if needed Check the heater fuses and resistance across each leg of the process heater Check the regeneration RTD and tighten if needed Replace the return air RTD Check the heater fuses and resistance across each leg of the process heater Check the regeneration RTD and tighten if needed Troubleshooting 6 11 6 12 Passive Alarms Problem P9 Process Dew Point PMI Option The dew point has not fallen below the setpoint If the dew point goes below the setpoint the alarm should go away amp Note The alarm is not active for the first 3 indexes P10 Process Filter Clogged Option The process filter differential pressure switch is tripped P17 Conveying Demand MDC Option The demand sensor located at the material receiver has not been satisfied after 3 attempts Troubleshooting Possible cause The hose or wiring connections to the sensor block are loose or have fallen off Desiccant level low The desiccant may b
45. WARNING Reliance on this Manual Could Result in Severe Bodily Injury or Death This manual is out of date and is provided only for its technical information data and capacities Portions of this manual detailing procedures or precautions in the operation inspection maintenance and repair of the product forming the subject matter of this manual may be inadequate inaccurate and or incomplete and cannot be used followed or relied upon me Contact Conair at info conairgroup com or 1 800 654 6661 for more current information warnings and materials about C more recent product manuals containing warnings information precautions and procedures that may be more adequate than those contained in this out of date manual www conairnet com USER GUIDE UGD024 0304 D Carousel Dryer DC 1 Models 15 25 50 75 and 100 with DC 1 Controls INTRODUCTION e Purpose of the User Guide e How the guide is organized Your responsibilities as a user e ATTENTION Read this so no one gets hurt How to use the lockout device e DESCRIPTION e Whatis the D Carousel Dryer e Typical applications e How it works e Specifications D Dryer e INSTALLATION e Unpacking the boxes e Preparing for installation e Mounting the dryer and hopper on a Processing Machine e Positioning the dryer on the floor Mounting the hopper on the throat e Mounting the dryer on the floor stand Hopper on the throat Mounting the dryer and hopper on the mobile floor stand Conn
46. a passive alarm 6 14 Troubleshooting Possible cause The connection in the electrical enclo sure for the regen RTD is loose The connection of the RTD plug on the control board is loose The regen RTD has failed The connection in the electrical enclo sure for the return air RTD is loose The connection of the RTD plug on the control board is loose The connection of the RTD plug on the control board is loose The return air RTD has failed Solution Check the RTD plug connection and tighten if needed Check the plug connection and tighten if needed Replace the regen RTD Check the RTD plug connection and tighten if needed Check the plug connection and tighten if needed Check the plug connection and tighten if needed Replace the return air RTD Setback The setback function available on the DC 1 Dryer is designed to save you money on energy costs and keep you from over drying your material Setback is available as separate options on both the temperature and load rate setting This is how setback operates when the control setback is set to On on Temperature Screen 24 optional on DC 1 controls idrying applications the D iseries dryer is not equipped with a process heater Therefore the Setback func ition is not applicable The control monitors the temperature of the air exiting the drying hopper If that temperature reaches a customer entered setpoint Screen 10 the
47. ams that were shipped with your dryer These diagrams are the best reference for correcting a prob lem The diagrams also will note any custom features such as special wiring or alarm capabilities not covered in this User Guide A Few Words of Caution The D Carousel dryer is equipped with numerous safety devices Do not remove or disable them Improper corrective action can lead to hazardous conditions and should never be attempted to sustain production WARNING Only qualified service personnel should examine and correct problems that require opening the dryer s electrical enclosure or using electrical wires to diagnose the cause AN WARNING High voltage Always stop the D Carousel dryer disconnect and lock out the main power source before troubleshooting or performing repairs CAUTION Hot surfaces Always protect yourself from hot surfaces inside and outside of the dryer and hopper o y Troubleshooting 6 3 6 4 Troubleshooting How to Identify the Cause of a Problem Most dryer malfunctions are indicated by an illuminated Acknowledge Alarm light on the D carousel dryer control panel A problem can trigger two types of alarms Shut Down The dryer has automatically shut down because it detected a serious problem that could damage your material or dryer Passive The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem cou
48. an 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 AN 2 Turn off the water flow to the water supply line Disconnect supply and return lines 3 Remove the plastic aftercooler cover amp NOTE If an optional flow control was added with the aftercooler remove the compres sion fitting from the aftercooler inlet Loosen the fitting on the flow control then swing the copper water supply tube out and away from the aftercooler inlet 4 Remove the five screws securing the aftercooler in the aftercooler housing TIP If the aftercooler without a flow control was installed using the recommended 24 in 61 cm of flexible hoses there is no need to disconnect the hoses from the aftercooler inlet and outlet continued C 3 Appendix Cleaning the Aftercooler continuea 5 Remove the aftercooler assembly from the aftercooler housing 6 Clean the aftercooler assembly using a mild soap and water Let the after cooler dry thoroughly before installation CAUTION During the cleaning process DO NOT cut or remove the stainless steel wire that holds the aftercooler assembly together 7 Inspect the condition of the gasket If it is damaged replace the gasket 8 Reassemble by repeating the steps in reverse order continued Appendix C 4 C 5 Appendix Cleaning the Aftercooler co
49. ater flow to control temperature Operation Screen 28 43 require access code 755 SCREEN 28 Test Mode Screen fH of fi This is the Test Mode screen for the process blower By pressing the or keys the setting can be changed When set to On the process blower output will be turned on for 3 sec and then shut off automatically Control Function Screen Screen 28 43 require access code 755 SCREEN 29 Test Mode Screen E G SCREEN 30 Test Mode Screen D of m SCREEN 31 Test Mode Screen H of 4 SCREEN 32 Test Mode Screen G of 5 SCREEN 33 Test Mode Screen fH off 6 Descriptions continued Function 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 sec and then shut off automatically Q Note The isolation contactor will not be pulled in so no electricity will go the heater The solid state relay contacts should close This is the Test Mode screen for the regen eration blower By pressing the or keys the setting can be changed When set to On the regeneration blower output will be turned on for 3 sec and then shut off automatically This is the Test Mode screen for the regen eration heater By pressing the or keys the setting can be changed When set to On the regeneration heater output will be turned on fo
50. aters 6 21 a Replacing the desiccant tanks 6 25 a Refilling the desiccant tanks 6 26 Troubleshooting 6 1 6 2 Troubleshooting 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 side panels off of the dryer be sure to LJ 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 3 Press again to clear the alarm If the alarm reappears the problem was not fixed If the alarm is a passive alarm you will see P in the screen title display If the alarm is a shut down alarm you will see A in the screen title display Set Point Actual 1 Process Temp 2 Regen Temp Process Blower Reg Auto Start 3 Return AirTemp j 4 Auto Start Process Pressure Reg Desiccant Indexing 5 Load Time MDC Process Heater Regen eee Acknowl edge 6 Activate Setback Temp 7 Setback Temp Process 8 Setback Load Rate alarm b utton 9 PM1 Dewpoint LJ Diagnose causes from the front of the dryer You can locate any problem from the front of the dryer Open the electrical enclosure to check fuses and heater contactors J Find the wiring and equipment diagr
51. be connected to the chassis ground terminal inside the electrical enclosure Improper grounding can result in severe personal injury and erratic machine operation Always disconnect and lock out the incoming main power source before opening the electrical enclosure or performing non standard operating procedures such as routine maintenance Only qualified personnel should perform troubleshooting procedures that require access to the electrical enclosure while power is on 1 4 Introduction How to Use the Lockout Device CAUTION Before performing maintenance or repairs on this product you should disconnect and lockout electri cal power sources to prevent injury from unexpected energization or start up A lockable device has been provid ed 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 To use the lockout device T Stop or turn off the equipment 2 Isolate the equipment from the electric power Turn the rotary disconnect switch to the OFF or O position 3 Secure the device with an assigned lock or tag Insert a lock or tag in the holes to prevent movement 4 The equipment is now locked out AN WARNING Before removing lockout devices and returning switches to the ON position make sure that all personnel are clear of the machine tools have been re
52. d the metal screen 2 Clean the regeneration filter Clean dust fines and dirt from the filter or replace it with a new filter 3 Reverse the procedure to reinstall the regeneration filter 5 4 Maintenance Cleaning the Aftercooler Coils If you have the optional aftercooler you need to clean the cooling coils to keep them working efficiently See Appendix C for details Cleaning the Precooler Coils If you have the optional precooler you need to clean the cooling coils to keep them working efficiently See Appendix E for details Inspecting Hoses and Gaskets Loose or damaged hoses and gaskets can allow moisture to seep into the closed loop drying system 1 Follow the hose routing of all the hoses within the dryer and inspect all hoses clamps fittings and gaskets 2 Tighten any loose hose clamps or fittings 3 Replace worn or damaged hoses and gaskets Maintenance 5 5 5 6 Maintenance SECTION Troubleshooting Before beginning 008 6 2 A few words of caution 6 3 DIAGNOSTICS How to identify the cause of a problem 6 4 shut down alarms 0 6 5 Passive alarms 244 ues 44s ue ow we oe os 6 10 Setback sae4ne0e3 5086p 5ee eee oa eee 6 15 REPAIR Replacing fuses 00 6 17 Checking heater solid state relays 6 18 Checking or replacing temperature sensors 6 19 m Adjusting the limit switch 6 20 3 Replacing the he
53. der TLM Tube Loader dry air conveying non dry air conveying Outlet 2 in dia 5 1 cm p T Inlet 1 5 in dia 4 3 8 cm Inlet 1 5 in dia O 3 8 cm E E Receiver diameter F 7 4 5 in 11 4 cm G neoENe diameter F Height with 4 5 in 11 4 cm viewing chamber H Height with 1 Ib viewing chamber 20 5 in 52 1 cm 1 Ib 2 Ib 24 4 in 62 0 cm 25 75 in 65 4 cm 2 lb 25 6 in 65 0 cm LOADER BASE PLATES 1 625 in dia 1 625 in dia 4 1 cm 4 1 cm through hole NX through hole TT 4in 10 2 mm continued G 4 Appendix Specifications MDC continued ured as a central dryer the MDC option is not available Hopper selection CH10 1 CH10 1 5 CH14 2 _CH14 3 CH14 4 CH18 4 CH18 6 CH24 8 CH24 12 Performance characteristics Air flow SCFM t po nR 2 35 S o Air flow ACFM 250 16 Drying temperature All models 100 375 F 38 191 C with options Dew point All models 40 F 40 C Maximum conveying distance ft m 8 2 44 vertical 6 1 83 horizontal with long distance option 15 4 57 vertical 50 15 24 horizontal Dimensions inches cm A Height to top of hopper 56 142 2 67 170 2 58 147 3 69 175 3 80 203 2 66 167 6 78 198 1 76 193 0 89 226 1 105 266 7 B Total height 100 2
54. e Error Phase Option STD on MDC s One of the three power wires is connected wrong A39 EEProm Write Error Possible cause The tubing going to the pressure switch is cut or has come loose The process blower overload has tripped The blower motor starter has failed The tubing going to the pressure switch is cut or has come loose The blower motor relay has failed Plugs on wire harness between the display and control boards are loose Display board or Communications boards have failed One of the three power wires are out of phase Phase Detector Board has failed Internal Control board problem Solution Check the tubing for cracks and make sure it is secure on the fittings Check the process blower overload If it is tripped check the process blower to make sure its not locked Make sure the overload is set slightly above the full load current shown on the motor name plate Refer to your wiring diagram for proper settings Check the process blower motor starter Check the tubing for cracks and make sure it is secure on the fittings Check the regeneration blower motor relay Make sure plugs are tight on board connections Replace the boards Switch the position of two of the incom ing lead power wires at the dryer Replace the Phase Detection Board Replace the Control board Troubleshooting 6 7 Shut Down Alarms A49 Process Protection High Temperature If the proces
55. e contaminated Leaks in the process air stream The process air filter is clogged Sensor is out of position The conveying load time is too short Conveying blower is not coming on Hoses have come off or are loose in the conveying loop Solution Check wiring and hose connections to the sensor re secure if needed Replace tanks or repack desiccant See Replacing the Desiccant Tanks Page 6 21 Refilling the Desiccant Tanks Page 6 22 Check the desiccant for contamination replace if needed Check for worn or loose hoses Remove and clean or replace the process air filter Raise the sensor to a higher lower posi tion on the bracket Increase the load time setpoint Check the blower fuses in the control and the overload settings Check for loose hoses and make sure all hose clamps are secure Passive Alarms Problem P23 The MDC conveying blower exceeded the full load amps rating for the blower motor This is a passive alarm so the dryer will continue run ning but the material convey ing function will stop P25 RID Integrity If the process RTD is faulty Possible cause The MDC blower has mechanically failed or is unable to rotate freely The MDC blower has failed electri cally The overload is set incorrectly The MDC conveying blower has exceeded the full load amps rating for the blower motor The connection in the electrical enclosure for the process RTD is
56. e control and the display lights will illuminate 3 Set the drying temperature Press the Setpoint Adjust A or W buttons to set the temperature Central CONAIR EE Set Point Actual 1 Process Temp 2 Regen Temp Process Blower Regen Blower Auto Start 3 Return Air Temp Pi Pr Regen P Desiccant Indexin 4 Auto Start Process Pressure Regen Pressure Desiccant Indexing 5 Load Time MDC Process Heater Regen Heater Set Back Temp 6 Activate Setback Temp 7 Setback Temp Process 8 Setback Load Rate 9 PM1 Dewpoint continued Installation 3 17 Testing The Installation continued 4 Press the START button If everything is installed correctly The green light on the start button will illuminate The process and regeneration blowers turn on The process and regeneration heaters turn on Central If the desiccant tanks are not in their correct position the carousel will turn clockwise and stop in the correct position 5 Press the STOP button If everything is installed correctly The blowers will continue running as needed to cool the heaters 6 The test is over If the dryer performed the normal operating sequences as out lined you can load the hopper and begin operation If it did not refer to the TROUBLESHOOTING section of the User Guide 3 18 Installation SECTION Operation The DC 1 dryer control panel 4 2 D dryer DC 1 control
57. ecting the main power e Checking for proper air flow e Connecting the air hoses eConnecting water hoses e Connecting the RTD probe e Mounting a loader on the hopper e OPERATION e How it works e The DC 1 dryer control panel e D dryer DC 1 control functions Control Function Description e To start drying To stop drying Using the auto start countdown function Setting high and low setpoint limits e MAINTENANCE Corporate Office 412 312 6000 Instant Access 24 7 Parts and Service 800 458 1960 Parts and Service 814 437 6861 Please record your equipment s It s a good idea to record the model and serial number s of your equipment and model and serial number s and the date you received it in the User Guide Our service department uses this infor metal yon POE ENOC ate mation along with the manual number to provide help for the specific equipment spaces provided you installed Please keep this User Guide and all manuals engineering prints and parts lists together for documentation of your equipment Date Manual Number UGD024 0304 Serial Number s Model Number s 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 fitnes
58. er s rated capacity You are pre drying material at temperatures over 150 F 66 C How Conveying Works When the conveying function is turned on the MDC 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 receiver and viewing chamber The blower pulls air through the vacuum receiver filter into the return air conveying line 1 Dry material drops into the distribution box when the slide gate on the drying hopper is opened 5 The conveying blower runs until the load time set at the MDC control is reached When the material level drops Starts below the demand sensor the sensor signals for more material The conveying blower turns on again 6 The dust collector traps dust and fines before the returning air reaches the 3 Positive and negative air flow generated by the blower moves the material from the distribution box beneath the drying hopper to the vacuum receiver blower 2 When the conveying function is turned on the conveying blower ured as a cen 1 1 tral dryer the 1 MDC option is not available Appendix G 3 Specifications MDC MOBILE DRYING AND CONVEYING MDC Small Carousel Models CD When configured as 1a central dryer the i MDC option is not available TLR Tube Loa
59. er supply and dis charge return connections with flexible hoses at least 24 in 61 cm long This allows you to easily remove the precooler assembly for Cleaning Installing a Precooler Optional You can add a precooler to the D Carousel Dryer by ordering the optional precool er assembly Installation is easy The optional precooler requires a source of city tower or chiller water and a dis charge or return line You can use water at temperatures up to 85 F 30 C But the water flow should be at least 1 gal min 3 8 liters min for models D15 D25 D50 or 2 gal min 7 6 liters min for models D75 and D100 D D Stop the dryer and lockout the main power AN Remove the left dryer side panel Mount the precooler to the back of the dryer using existing holes and the 5 16 8 bolts provided Note that for D 15 25 and 50 models the precooler is mounted to the dryer with the water fittings and precooler air outlet at the top On D 75 and 100 models the precooler is mounted with the water fittings and precooler air outlet at the bottom Connect the process air outlet hose to the precooler air inlet tube and tight en the clamp provided Connect the hopper air inlet air hose to the precooler air outlet tube and tighten the clamp provided Note If an optional flow control was ordered with the precooler see Appendix E Optional Flow Control for information on connecting the water supply Note If the optional C
60. ere you will set the temperature setpoint for the air at the outlet of the drying hopper When this setpoint is reached the dryer will automatical ly change the process setpoint to the setpoint shown on Screen 11 When the temperature at the outlet of the hopper drops below the setpoint by the value shown on Screen 22 the dryer will return to the normal drying setpoint Screen 5 Troubleshooting 6 15 6 16 Troubleshooting S etb ac k continued 4 Use Screen 11 to set the temperature setpoint to which the process air will revert to once the air at the outlet of the drying hopper has reached its setpoint Use the setback temperature band screen Screen 22 to set the amount the return air temperature has to drop below to activate setback temperature before the original process temperature is restored For example if the activate setback temperature was 180 F 82 2 C and the dryer was in setback the actual temperature measured at the outlet to the hopper would have to drop below 160 F 71 C to restore the original process set point To set up setback on the load rate option 1 Reference the flow chart on Page 4 4 and follow the menu tree path to access Screen 25 Turn the setback function for the load rate option to On or Off Off turns the setback load rate option off and the dryer will not change the process set point The On setting tells the dryer to go into setback when the load rate gets to its set number of
61. erial You can also set the high limit equal to the process temperature to prevent accidental or unauthorized changes to the setting during operation 1 Turn on the main power to the dryer 2 While at the default screen screen 5 press the scroll button and the minus button simultaneously to get to screen 14 ey tL tLe On screen 14 enter the password for set up screens 754 e 754 Le Scroll to screen 16 This is your current high setpoint limit Press keys to set a new high setpoint limit ec Tip We recommend that you set your high setpoint limit 10 higher than your maxi mum high temperature setpoint to avoid unwanted alarms To lock in your new high setpoint limit and exit the password protected screens scroll back to screen 14 e 754 Lo then enter 500 and hit scroll SECTION Maintenance Preventative maintenance checklist 5 2 Cleaning the hopper 5 3 Cleaning the process filter 5 4 Cleaning the regeneration filter 5 4 Cleaning the aftercooler coils 5 5 Cleaning the precooler coils 5 5 Inspecting hoses and gaskets 5 5 s jab F S ab ap q2 Maintenance 5 1 Preventative Maintenance Checklist Routine maintenance will ensure optimum operation and performance of the D Carousel Dryer We recommend the following maintenance schedule and tasks e Whenever you change materials O Dra
62. for pre drying in a remote location 1 Make sure the location for the MDC provides O 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 All electrical wiring should comply with your region s electrical codes O A source of water if you have an aftercooler The dryer s optional aftercooler can use tower or city water at temperatures of 40 to 85 F 4 to 29 C Pipe should be run to the planned dryer location Use flexible hose to connect the water pipes to the aftercooler O Minimum clearance for safe operation and maintenance The MDC should not be placed near flammable or combustible materials during operation We recommend at least 25 inches 63 5 cm clearance above the dryer for removing the carousel housing You will need at least 24 inches 61 cm clearance on any side of the MDC for access to components that need cleaning or servicing 2 Mount the vacuum receiver mounting bracket Lay out the bolt pattern of the processing machine feed throat on the blank base plate of the vacuum receiver mounting bracket and gasket Drill holes for the mounting bolts you plan to use Place the gasket between the feed throat and mounting bracket Bolt the mounting bracket to the feed throat Drill mounting bolt holes Installing the MDC
63. functions 4 3 Control function flow chart 4 3 S Control function descriptions 4 5 ER To start drying a oa 4 17 S To stop GIVING s 4 4 ce ee eee we te ee 4 18 Using the auto start countdown function 4 19 How to enable the auto start on the DC 1 conrtol 00 00 a a es 4 19 How to disable the auto start on the DC 1 control 0000 eee ees 4 19 setting high and low setpoint limits 4 20 Operation 4 1 Alarm Codes See Troubleshooting Section 6 for a more complete listing of alarm codes Menu List Numbers 1 2 3 and 4 are standard items that will always be present Numbers 5 6 7 8 and 9 are screens associated with options If the option is not Increment Decrement Buttons Used to increase or decrease values installed the screen will not be displayed Central 4 2 Operation Menu List Numbers 2 3 and 4 are standard items that will always be present Number 9 is a screen associated with an option If the option is not installed the screen will not be displayed The DC 1 Dryer Control Panel Set Point Display Shows the set point value CONAIR C u Set Point 1 Process Temp 2 Regen Temp 3 Return Air Temp 4 Auto Start 5 LoadTime MDC 6 Activate Setback Temp 7 Setback Temp Process 8 Setback Load Rate 9 PM1 Dewpoint j Process Blower Process Heater Start and Stop Buttons
64. g 6 19 Adjusting the Limit Switch 1 Stop the dryer Disconnect and lockout the main power AN 2 Remove the right side panel from the dryer IMPORTANT Note the position of the tanks 3 Loosen the screws securing the limit switch to the carousel Note that the hole for the front screw is slotted to allow for adjustment 4 Slide the switch to the left or right to position the limit switch so that its small roller drops into the valley on the bed plate The roller on the switch should not hit the stationary bottom plate 5 Test for correct indexing of the carousel Restore main power to the dryer Hold the limit switch out of the valley on the carousel bed plate while you push START It may not be necessary to push START If not in run mode the carousel will turn when the switch is out of the valley Once the bed plate starts turning release the switch If everything is adjusted correctly The carousel bed turns When the limit switch reaches the next valley in the bed plate the carousel should stop turning 6 Reset the desiccant carousel Continue indexing until the desiccant tanks return to the positions they were in 6 20 Troubleshooting when the dryer shut down Replacing the Heaters Regeneration Heater 1 2 10 11 Disconnect and lockout the main power AN Gain access to the regeneration heater by removing the right dryer side panel Open the electrical enclosure door Remove the hose and h
65. g chamber Clean inside the vacuum receiver body with a clean rag 5 Remove and clean the viewing chamber Lift the viewing chamber to release it from the mounting bracket Clean inside with a clean rag 6 Reassemble the vacuum receiver Make sure the viewing chamber and loader body seat snugly inside the O ring couplings G 16 Appendix Cleaning the Dust Collector The dust collector filters dust and fines from the air used to convey material The filter should be cleaned regularly to maintain conveying air flow and optimum performance of the conveying blower 1 Turn off the conveying system by setting the load time to zero See Page 4 6 Screen 9 a central dryer the i MDC option is not available 2 Remove the dust collector lid Loosen the knob at the base of the lid N CAUTION W tecti Wear eye protection If you use compressed air to clean these components wear safety glasses to pro tect yourself from air borne materials 3 Empty fines and dust that have collected in the lid 4 Remove the conveying filter Loosen the retaining nut 5 Inspect and clean the filter If the filter is torn or has holes in it replace it If you use compressed air to clean the filter be sure to blow from the inside out 6 Clean the inside of the dust collector housing You can use a vacuum or wipe the inside with a clean rag 7 Reassemble the dust collector Place the filter back in the hous
66. he necessary cool down period and can trigger the shut down high temperature alarm during your next drying cycle ra Caution Improper shut down can cause damage to your dryer 4 18 Operation Using the Auto Start Countdown Function The countdown function allows the user to set the D Carousel dryer to automat ically 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 ON Auto Start 2 Use the Setpoint Adjust keys to set the desired countdown time How to Enable the Auto Start on the DC 1 Control 1 Scroll to the Auto Start screen 2 Increment the Auto Atart Time with the plus key 3 Press the Start button The Auto Start LED will blink to indicate that Auto Start is armed How to Disable the Auto Start on the DC 1 Control T The Auto Start LED will be blinking to indicate that Auto Start is armed 2 Scroll to the Auto Start screen 3 Press the Stop button The Auto Start LED will quit blinking Leave the Auto Start screen by pressing the Scroll button Operation 4 19 4 20 central dryer the high setpoint limits can not be set since there is no process heater in the system Operation Setting the High Setpoint Limits You can protect your drying process by preventing someone from entering process temperatures above an acceptable level for the mat
67. he empty hopper and the dryer onto the mobile floor stand using a hoist and the lifting lugs provided Tools for installation J 5 32 Allen wrench J 3 8 and 9 16 wrench J Phillips screwdriver J Flathead screwdriver J Hoist and strap Lift the hopper onto the mobile floor stand using a hoist and the lifting lugs provided Make sure you align the bolt holes in the mobile floor stand with the bolt holes on the discharge assembly continued B 2 Appendix Mounting the Dryer and Hopper on a Mobile Floor Stand continued 2 Bolt the hopper to the mobile floor stand Using four 3 8 16 M 10 self locking bolts fasten the hopper to the mobile floor stand 3 Lift the dryer onto the mobile floor stand using a hoist and lifting lugs provided 4 Align the four bolt holes on the bottom of the dryer with the four bolts holes in the mobile floor stand stand 5 Bolt the dryer to the mobile floor stand using the four 5 16 18 self locking bolts provided Appendix B 3 Installing an Aftercooler Optional You can add an aftercooler to the D Carousel Dryer by ordering the optional after cooler assembly Installation is easy The optional aftercooler requires a source of city tower or chiller water and a dis charge or return line You can use water at temperatures up to 85 F 30 C But the water flow should be at least 1 gal min 3 8 liters min for models D15 D25 D50 or 2 gal min 7 6 liters
68. he floor or mount it to an optional floor stand if your processing machine throat requires the small discharge assembly or a mounting plate with less than a 3 x 3 in 7 6 x 7 6 cm bolt pattern and 1 in 2 54 cm diameter open ing The dryer and hopper mount on a support frame discharge assembly that bolts to the throat of the processing machine as pictured above CAUTION To prevent accident and injury lift the empty hopper and support frame onto the throat of the processing machine using a hoist and the lifting lugs provid ed After the hopper is mounted then lift the dryer onto the support frame using a a6 1 instalation hoist and the lifting lugs provided Mounting the Dryer and Hopper on a Processing Machine continued The drying hopper slide gate support frame and discharge assembly may have been shipped fully assembled You can remove the hopper from the support frame if you find it easier to lift and bolt the frame and then the hopper to the throat of the processing machine 1 Lift the hopper support frame and discharge assembly onto the process ing machine throat Use a hoist to lift the support frame and hopper Position the frame and discharge assembly so that its bolt holes line up with the holes drilled in the throat If hole patterns do not match you can place a mounting adapter between the throat and the support frame 2 Bolt the frame and discharge assembly to the throat Using four 3 8 in 16
69. hrough the regen erated desiccant tank The cooling air then passes through the optional aftercooler if mstalled and repeats the circuit How It Works continued ili REGENERATION BLOWER j REGENERATION AIR FILTER e e e e e ES eee eee e e e 4 r O HIGH TEMP a HIGHTEMP1 _ SHUTOFF SHUTOFF_ 1 O o REGENERATION PROCESS WIZJI HEATER HEATER BOX E je aes i REGENERATION RTD HOPPER DESICCANT BEAR TANKS ERS BEDPLATE RETURN f l AIR FILTER gt RETURN AIR RTD H PROCESS PROCESS _ COOLING BLOWER I REGENERATION DRYER OPTIONS 1 SET BACK TEMPERATURE 4 CURRENT METER 7 PRECOOLER 10 ALARM HORN 2 PROCESS CFM MONITOR 5 PROCESS FILTER STATUS 8 AFTERCOOLER 11 ALARM LIGHTS 3 PM1 DEW POINT MONITOR 6 PHASE ROTATION PROTECTION 9 FLOW CONTROL VALVE The components identified by this type of box in the drawing are not supplied with the D dryer when it is configured as a central dryer Central Description 2 5 OO gp 7p ap EeP a a j SG Specifications D Carousel DEHUMIDIFYING DRYERS D Small Series Carousel Dryers moot ts o o m mo Performance characteristics with fullhopper gt gt SSS o Air flow SCFM Air flow ACFM 2509 107 Drying temperature All models 100 375 F 38 191 C with options Dew point All models 40 F 40 C Dimensions inches cm A Height B Overall width C Control width D Dep
70. in a straight line from top to bottom Reference the wiring diagram and or trace the wires from the process heater tube into the control box Remove the wires from the relays and ter minal strips Once disconnected pull the wires from the control box into the dryer housing toward the heater tube Remove the heater tube by twisting the tube counterclockwise The tube is threaded into the lower bed plate You may need to use a pipe wrench or chain wrench to remove the heater Remove the plugs or hose fittings toward the top end of the heater These will need to be installed on the new heater Check the ID mark on the side of the heater tube for kW rating and volt age The ID mark is on the outside of the tube near the end with the lead wires Make sure the kW and voltage is the same as the replacement heater Reinstall the plugs or hose fittings into the 1 8 3 18 mm NPT holes near the top end of the heater tube Thread the new heater into the lower bed plate The lead wires should be pointing toward the inside of the dryer Do not over tighten Hand tight en then use a wrench for no more than one turn to put the lead wires into the correct position central dryer there is no process heater in the sys item Therefore replac ing the process heater is a ATEEN oe _ oS gt a Tock ay oe r muge i E i e TIP Depending on the model and the mounting configuration selected for the dryer ins
71. in and clean the hopper e Weekly or as often as needed O Clean 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 O Clean the return air screen in the hopper Cleaning frequency depends on how much material you process and how dusty or full of fines it is O Inspect hoses and hose connections Check for damage kinks or loose hose clamps Replace any hoses that show signs of damage or wear Reposition and tighten loose hose clamps e Monthly O Clean the optional aftercooler and precooler coils You may need to clean the coils more often than monthly Frequency will depend on the type and volume of material you process e Every six months O Inspect gaskets for damage or wear Damaged gaskets can allow moisture to seep into the closed loop drying system Replace any gasket that is torn or cracked 5 2 Maintenance Cleaning the Hopper CAUTION Hot surfaces Always protect yourself from hot surfaces inside and out side the dryer and drying hopper The hopper spreader cone and discharge assembly should be cleaned thoroughly between material changes to prevent resin contamination Place a container beneath the hopper s drain port to catch the material 1 Close the hopper slide gate 2 Remove the drain port plug Pull the pin and allow the plug to drop 3 Remove the spreader
72. include Thorough review of this User Guide paying particular attention to hazard warnings appendices and related diagrams Thorough review of the equipment itself with careful attention to voltage sources intended use and warning labels Thorough review of instruction manuals for associated equipment Step by step adherence to instructions outlined in this User Guide Introduction 1 3 ATTENTION Read this so no one gets hurt We design equipment with the user s safety in mind You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide A WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should be installed adjusted and serviced by qualified technical personnel who are familiar with the construction operation and potential hazards of this type of machine All wiring disconnects and fuses should be installed by qualified elec trical technicians in accordance with electrical codes in your region Always maintain a safe ground Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate N WARNING Voltage hazard This equipment is powered by three phase alternating current as specified on the machine serial tag and data plate A properly sized conductive ground wire from the incoming power supply must
73. ing making sure the threaded rod extends through the center Tighten the retaining nut on the rod Put the lid back onto the housing and tighten the knob e TIP You can easily remove the dust collector so that it can be replaced with a spare clean one or taken to a remote location for cleaning To remove Disconnect the hoses and lift the dust collector from its mounting bracket Appendix G 17 Cleaning the Process Filter See Cleaning the Process Filter page 5 4 Cleaning the Regeneration Filter When configured as a central dryer the See Cleaning the Regeneration Filter page 5 4 MDC option is not available A aa Cleaning the Aftercooler Coils See Cleaning the Aftercooler Coils page 5 5 Cleaning the Precooler Coils See Cleaning the Precooler Coils page 5 5 Inspect Hoses and Gaskets See Inspecting Hoses and Gaskets page 5 5 G 18 Appendix
74. l happen This is the Test Mode screen for the pre cooler flow control valve By pressing the or keys the setting can be changed When set to On the precooler flow con trol valve output will be turned on for 3 sec and then shut off automatically Note If the optional precooler flow control valve is not installed nothing will happen This is the Test Mode screen for the after cooler flow control valve By pressing the or keys the setting can be changed When set to On the aftercooler flow control valve output will be turned on for 3 sec and then shut off automatically Note If the optional aftercooler flow control valve is not installed nothing will happen This screen is not used in the current pro gram Control Function Descriptions continued Screen Screen 28 43 require access code 755 SCREEN 39 Test Mode Screen fH or 12 SCREEN 40 Test Mode Screen E SCREEN 41 Test Mode Screen a ie SCREEN 42 Test Mode Screen m Com s SCREEN 43 Test Mode Screen Lor fo Function This is the Test Mode screen for the MDC 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 sec and then shut off automatically Q Note If the dryer is not an MDC nothing will happen This screen is not used in the current pro gram This screen is not used in the current pro gram
75. ld lead to a condition that will shut down the dryer _ ONAIR C a Set Point Actual 1 Process Temp 2 Regen Temp Process Blower Regen Blower 3 Return AirTemp 4 Auto Start 5 Load Time MDC Process Heater Regen Heater 6 Activate Setback Temp 7 Setback Temp Process 8 Setback Load Rate 9 PM1 Dewpoint Process Pressure Regen Pressure Acknowledge Alarm LED and button When the alarm light is displayed 1 Press the Acknowledge Alarm button once to silence the optional audible alarm and display the alarm message Pressing the Acknowledge Alarm button once also changes the alarm LED from blinking to solid 2 Find the error message in the diagnostics table of this troubleshooting section 3 Note that pressing the Acknowledge Alarm button a second time will clear the alarm D NOTE When the dryer detects abnormally high temperature in the process heater the dryer immediately shuts down and an error message appears in the display window The alarm light does not illuminate Shut Down 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 drying applications these I shut down alarms are not available pressed once the blinking red LED becomes solid Problem Possible cause Solution Al Process High The pr
76. min for models D75 and D100 1 Stop the dryer and lockout the main power AN 2 Remove the cover plate from the right side of the aftercooler housing on the dryer by removing the five screws 3 Inspect the condition of the gasket If the gasket is damaged replace the gasket e TIP Make the water supply and dis charge return connections with Insert the aftercooler assembly into the aftercooler housing Make sure the flexible hoses at least 24 in 61 cm staggered holes in the aftercooler mounting plate align with the holes in the long This allows you to easily aftercooler housing remove the aftercooler assembly for Cleaning e TIP If an optional flow control is also being installed with the aftercooler the manual shut off valve should be installed on the inlet line for the flow control C 1 Appendix continued Installing an Aftercooler Optional continued 5 Secure the aftercooler assembly in the aftercooler housing using the five Screws W NOTE If an optional flow control was ordered with the aftercooler see Appendix E Optional Flow Control for information on connecting the water supply 6 Connect the water supply line to the aftercooler inlet If a manual shut off valve is used it should be mounted on the inlet line 7 Connect the water discharge or return line to the aftercooler outlet Appendix C 2 Cleaning the Aftercooler If you have the optional aftercooler you need to cle
77. moved and all safety guards reinstalled To turn the rotary disconnect back to the ON position 1 Remove the lock or tag 2 Turn the rotary disconnect switch to the ON or T position Introduction 1 5 1 6 Introduction SECTION Description z What is the D carousel dryer 2 2 gt Typical applications 0 2 2 How it WOEKG 25 o he 5 4 Bea we eed ec Bo 2 4 Specifications D dryer 2 6 Description 2 1 What is the D Carousel Dryer The D carousel dehumidifying dryer produces hot low dew point air that removes moisture from hygroscopic plastics The dryer pulls warm moist air from a drying hopper and pumps it through dehumidifying desiccant The dryer then heats the air to the drying temperature you selected and circulates it through the material in the hopper The dryer s three tank closed loop design ensures a continuous supply of hot dehumidified air while preventing contamination from moisture in the plant Typical Applications The D dryer can be r mounted beside the hopper on the throat of a processing machine using the optional diving board support frame or positioned on the floor near the machine using the standard casters Two mobile floor stand designs are also available ee E Tiel Dryer and hopper on the processing Dryer on the floor hopper on the throat machine throat using the optional support frame Dryer and hopper on
78. n O Minimum clearance for safe operation and maintenance You should maintain 24 in 61 cm clearance on at least three sides of the dryer If the dryer is mounted with a hopper on a processing machine throat clearance between the dryer and hopper can be 4 in 10 2 cm Regeneration exhaust Regeneration exhaust high temperature 6 in 15 24 cm needed to change filter 3 in 7 62 cm high temperature Installation A 6 in 15 24 cm Gin 15 24 6M g in 15 24 em a needed to change l TF filter B H 12 in 30 48 cm 12 in 30 48 cm ch e needed to remove H E needed to remove optional aftercooler optional aftercooler non l EL coil for cleaning coil for cleaning 3 in 7 62 cm 3 in 7 62 cm 3 in 7 62 cm L 1 a D 15 D 25 amp D 100 a Minimum Clearance Clearance Preparing for Installation continued O A mounting surface that will support the weight of the dryer support amp NOTE if your mounting frame and a fully loaded hopper or just the fully loaded ho
79. ng tubes E N 2 in diameter return air conveying hose 4 Quick disconnect fittings its quick disconnect fitting on the MDC 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 with hose clamps Insert the tube at least 1 inch 2 54 cm into the flexible hose Secure the hose clamp at least 1 4 in 0 64 cm from the end of the tube Hose clamps Attach the flexible conveying hoses to the appropriate inlet and outlet of the vacuum receiver Push the quick disconnect fitting on the material conveying hose over the material inlet tube Push the quick disconnect fitting on the return air conveying hose over the conveying air outlet of the vacuum receiver Tighten the thumb screws on amp the fitting Connecting the RTD Probe See Connecting the RTD Probe page 3 16 Connecting the Demand Sensor The capacitive demand sensor monitors the level of material in the viewing cham a central dryer the ber of the vacuum receiver when the MDC is conveying The sensor signals the i MDC option is not MDC control to start the conveying blower whenever the level of material drops available 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 MDC electrical enclosure e TIP Prevent damage to the demand sens
80. ntinuea 9 Connect the water supply line to the aftercooler precooler inlet If a manual shut off valve is used it should be mounted on the inlet line as well 10 Connect the outlet of the aftercooler precooler to the inlet of the flow control valve using the pre shaped copper tubing and compression fittings provided 11 Install the plastic aftercooler precooler cover 12 Turn on the flow control option through your control Installing the Flow Control Optional You can add optional flow controls to the D Carousel Dryer for use with the optional aftercooler or precooler Installation is easy The optional flow control requires a source of city tower or chiller water You can use water at temperatures up to 85 F 30 C But the water flow should be at least 1 gal min 3 8 liters min for models D15 D25 D50 or 2 gal min 7 6 liters min for models D75 and D100 1 Stop the dryer and lockout the main power AN 2 Mount the flow control to the back of the dryer using the existing holes and the four 8 16 sheet metal screws provided The exact location for the flow control depends on its usage and the model of the dryer see the table below Usage Dryer Model Mounting Location Looking at the Back of the Dryer Aftercooler All models Left top corner Precooler D 15 25 and 50 Models Right top corner Precooler D 75 and 100 Models Right bottom corner Appendix D 1 e TIP Make the wat
81. ocess high temperature setpoint is Reset the process high temperature set Temperature If the process not at least 37 F 3 C above the drying point at least 37 F 3 C above the dry temperature exceeds the setpoint ing setpoint process high temperature set point it shuts down the dryer The RTD temperature probe is not Make sure the RTD temperature probe Defaults are set to 385 F installed correctly tip is in the center of the hopper inlet 196 1 C for tube 20 sec The air lines are restricted or loose Straighten any crimps in the hoses Tighten any loose hoses A2 Process Temperature Process RTD is loose or has fallen out Check the process RTD and tighten if Loop Break If the process needed temperature is outside of the operator entered deviation The process heater has failed Check the heater fuses and resistance alarm band see Process High across each leg of the process heater Temperature Deviation passive alarm and the process tem The air lines are restricted or loose Straighten any crimps in the hoses perature is not moving Tighten any loose hoses towards the setpoint at a rate greater than specified It shuts down the dryer Defaults are set at 37 F 3 C over 10 sec A3 Process Heater High There is an air flow blockage or loose Check that the bed plates are in the Temperature The snap hoses proper position lined up with the hoses switch in the process heater tube opens due to excessive
82. onair flow control valve was not ordered with the dryer it is strongly recommended that a customer supplied manual flow control valve be installed on the water inlet line e TIP If an optional flow control is also 6 Connect the water supply line to the precooler inlet If a manual shut off being installed with the precooler the manual shut off valve should be installed on the inlet line for the flow control E 1 Appendix valve is used it should be mounted on the inlet line continued Installing a Precooler Optional continued 7 Connect the water discharge or return line with the pressure relief valve to the precooler outlet Use the bracket supplied to secure the pressure relief valve and discharge line to the back of the dryer Precooler installed on a D 15 25 Precooler installed on a D 75 and and 50 dryer without a flow control 100 dryer without a flow control 8 Install the plastic precooler cap over the water connections IMPORTANT For drying setpoint temperatures above 150 F 65 6 C the precooler must be bypassed by connecting the dryer supply hose from the dryer directly to the hopper inlet Pressure Relief Valve Release Pressure 100 psi 689 5 k Pa Precooler with a flow control valve Precooler with a flow control valve installed on a D 15 25 and 50 dryer installed on a D 75 and 100 dryer Appendix E 2 e TIP If the precooler without a flow control was installed using
83. or cable by attaching it to the return air conveying line with a wire tie Do not tie the cable to the smaller diameter material conveying line Material passing through the line will generate static electricity and noise in nearby electrical cables Connecting the Main Power See Connecting the Main Power page 3 10 Connecting the Water Hoses See Connecting Water Hoses page 3 15 Appendix G 11 When configured as 1a central dryer the i MDC option is not available G 12 Appendix Mounting a Loader on the Hopper See Mounting a Loader on the Hopper page 3 17 Testing the Installation See Testing the Installation page 3 17 The MDC Control Panel See The DC 1 Dryer Control Panel page 4 2 MDC Control Functions See D Dryer DC 1 Control Functions page 4 3 To Start Drying See To Start Drying page 4 17 To Stop Drying See To Stop Drying page 4 18 Using the Auto Start Countdown Function See Using the Auto Start Countdown Function page 4 19 Setting the High Setpoint Limits See Setting the High Setpoint Limits page 4 20 To Start Conveying 1 Move the MDC to the processing machine Lock the wheels and connect the main power source Connect the water source if you have an aftercooler 2 Mount the vacuum receiver on the feed throat Push the vacuum receiver Central onto the mounting bracket sess ene nnn nn a central dryer the i
84. ose clamp at the bottom of the heater tube Remove the insulation from the heater tube by cutting the insulation in a straight line from top to bottom Remove the small 1 8 3 18 mm plastic hose from the hose barb and remove the hose barb Save the barb it will need to be installed in the new heater tube Remove and save the regeneration RTD and fitting They will be installed in the new heater Reference the wiring diagram and or trace the wires from the regenera tion heater tube into the control box Remove the wires from the relays and terminal strips Once disconnected pull the wires from the control box into the dryer housing toward the heater tube Remove the heater tube by twisting the tube counterclockwise The tube is threaded into the lower bed plate You may need to use a pipe wrench or chain wrench to remove it Check the ID mark on the side of the heater tube for kW rating and volt age The ID mark is on the outside of the tube near the end with the lead wires Make sure the kW and voltage is the same as the replacement heater Thread the new heater into the lower bed plate The RTD should be point ing directly toward the back of the dryer Do not over tighten Hand tighten S Note When installed the regener and use a wrench for no more than one turn to get RTD into the correct posi ation heater tube must be oriented so the RTD is directly toward the back of the dryer tion Troubleshooting 6 21
85. p Note See instructions sent along with your upgrade kit to enable this option The dew point sensor can be mounted to the inside bottom right corner of the dryer back panel 1 Peal the tape from the dew point sensor block and place it in the bottom right side of the back panel as shown 2 Route the hose near the top of the block to the fitting near the top of the process heater tube D 15 D 25 and D 50 or the fitting near the bottom of the process heater tube D 75 and D 100 3 Route the hose near the bottom of the sensor block to the 1 8 3 18 mm NPY hose fitting on the inlet of the process blower The inlet is the tube toward the center of the dryer 4 The dew point sensor comes with a plug wire attached Reference the wiring diagram to attach this wire to the proper points on the board Represents 15 25 and 50 models Represents 75 and 100 models F 1 Appendix What is the MDG The MDC is a self contained mobile unit designed to dry plastic resin and convey it with dehumidified air directly to a processing machine This mobile unit contains the Dehumidifying dryer Drying hopper and material distribution box Conveying blower and dust collector When configured as a central dryer the i MDC option is not available Direct feed vacuum receiver and demand sensor gt Bet tee cccececccecces Mobile drying cart Quick disconnect conveying hoses The dryer produces hot lo
86. pper See the surface does not match specifications tables for weights and volumes the standard bolt pat terns available you will O Material and conveying lines installed If you plan to use vacuum or need an adapter You compressed air loaders to fill the hopper install conveying lines to the drying annie eae i provided or purchase one from Conair hopper location 2 Drill and tap mounting holes or make adapter Available discharge assemblies and slide gates fit mounting surfaces with these bolt patterns and diameters 7 16 inches 1 11 cm diameter 7 16 inches 1 11 cm diameter 6 inches inches 2 inches 15 24 cm 10 16 5 08 cm square om diameter square 1 inch a 2 54 cm 5 inches diameter 3 ee 12 7 cm 7 62 cm square square Installation 3 5 Mounting the Dryer and Hopper on a Processing Machine A WARNING You are responsible for the structural integrity of this installation We recommend that you O Use bolts no smaller than 3 8 inch M 10 when mounting the hopper dryer combination to the throat of a processing machine O Do not mount the hopper dryer combination on a plate that swings away or slides away from the processing machine throat Either remove the swing or slide plate position the dryer on the floor or mount the dryer to an optional floor stand Tools for installation O Flathead screwdriver g 9 16 and 1 2 wrench Cj Hoist Q NOTE You must position the dryer on t
87. r 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 The customer assumes the cost of transportation of the part or parts to and from the factory Performance Warranty Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the equipment or as detailed in engineering specifica tions provided the equipment is applied installed operated and maintained in the recommended manner as outlined in our quotation or specifications Should performance not meet warranted levels Conair at its discretion will exercise one of the following options Inspect the equipment and perform alterations or adjustments to satisfy performance claims Charges for such inspections and corrections will be waived unless failure to meet warranty is due to misapplication improper installation poor maintenance practices or improper operation Replace the original equipment with other Conair equipment that will meet original performance claims at no extra cost to the customer Refund the invoiced cost to the customer Credit is subject to prior notice by the
88. r optional F 1 G Appendix What is the MDC ge cet wk ire wie ste ak wie we arene acne ae ane te G 1 Typical applications oa ca owas bee waa e eat waw wae kee G 2 How conveying WOrKS 1 0 ees G 3 Specifications MDC 1 es G 4 Unpacking the boxes 0 0 cece cece ence cece eens G 6 Preparing for installation nnana ww Rw ae Kew we ew G 8 Installing the MDC 2 ee G 9 Connecting conveying lines 0 eee G 10 Connecting the RTD probe 0 cee eee G 11 Connecting the demand sensor 00 cece eee G 11 Connecting the main power 0 ee eee G 11 Connecting the water hoses 0 0 00 G 11 Mounting a loader on the hopper 00008 G 12 Testing the installation 0 0 ccc cee eee G 12 iv Table of Contents The MDC control panel 0 0 cee eee G 12 MDC control functions 0 cect eer ieee ieee eee eee ed G 12 TOS GIVING wivton teen ved hae beaded eoen seek acca ee G 12 To stop drying 6 6 cee wos on woe a ee OY a ee oe ee ee G 12 Using the auto start countdown function G 12 Setting the high setpoint limits 0000 G 12 To start conveying aw scasea aera arwrd a dre aw aoe te gan 8 ane wince Sea G 13 To stop conveying a ist dans Gaede eho eet eee oo oe eA G 14 Transporting the MDC 0 0 ce eee G 14 Preventative maintenance schedule 0005 G 15 Cleaning the NO
89. r 3 sec and then shut off automatically Q Note The isolation contactor will not be pulled in so no electricity will go the heater The solid state relay contacts should close This is the Test Mode screen for the bed drive motor By pressing the or keys the setting can be changed When set to On the bed drive motor output will be turned on until the limit switch makes the next valley and then shut off automatically This Test Mode screen is not used in the current program continued Operation 4 13 4 14 Operation Control Function Screen Screen 28 43 require access code 755 SCREEN 34 Test Mode Screen m oj SCREEN 35 Test Mode Screen a SCREEN 36 Test Mode Screen fH of P SCREEN 37 Test Mode Screen w il SCREEN 38 Test Mode Screen Lor Descriptions continued Function This is the Test Mode screen for the isola tion 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 sec and then shut off auto matically This is the Test Mode screen for the alarm output horn and or red light By pressing the or keys the setting can be changed When set to On the alarm output will be turned on for 3 sec and then shut off auto matically Note The alarm light on the membrane D switch will not come on If the optional alarm horn or red light is not installed nothing wil
90. s for a particular purpose Copyright 2004 The Conair Group All rights reserved Table of Contents 1 1 Introduction Purpose of the User Guide 00 0000000 1 2 How the guide is organized 0 ccc ee 1 2 Using the D series as a central dryer 00 cece 1 3 Your responsibilities aS a USEF ee 1 3 ATTENTION Read this so no one gets hurt 1 4 How to use the lockout device cee ee 1 5 2 1 Description What is the D Carousel Dryer 0 0 cee eee 2 2 Typical applications 0 0 0 0 cc es 2 2 HOW WOKS aei bead ance ttn 6taneeeateand pene tans henna 2 4 specifications D Dryer 0 uaaa 2 6 3 1 Installation Unpacking the DOXES ack cds dodveede a edn aaa weds eee a ee 3 2 Preparing for installation 0 0 0 eee 3 4 Mounting the dryer and hopper on a Processing Machine 3 6 Positioning the dryer on the floor Mounting the hopper ON NG Mod 44 04 44 000 baer eceeeen ce enai en i 3 8 Mounting the hopper 0 0 cee eee ee 3 9 Positioning the dryer on the floor 000 cee eee 3 9 Mounting the dryer on the floor stand Hopper on the throat 3 10 Mounting the dryer and hopper on the mobile floor stand 3 10 Connecting the main power 0000 cece eee eee 3 10 Table of Contents i Checking for proper air flow 0 00 eee eee 3 12 Connecting the air hoses 0 0 cee es
91. s protection temperature exceeds the process protection high temperature setpoint it shuts down the dryer Defaults are set to 600 F 315 6 C for 10 sec A50 Process Protection Differential Temperature If the process protection differen tial temperature exceeds the process protection differential temperature setpoint it shuts down the dryer Defaults are set to 295 F 146 1 C for 180 sec AS Process Protection RTD Integrity If the process RTD is faulty it shuts down the dryer 6 8 Troubleshooting The Process RTD temperature probe is not installed correctly The air lines are restricted or loose The process protection differential tem perature setpoint is not at least 37 F 3 C above the drying setpoint The Process RTD temperature probe is not installed correctly The air lines are restricted or loose The connection in the electrical enclo sure for the process protection RTD is loose The connection of the RTD plug on the control board is loose The process protection RTD has failed Make sure the RTD temperature probe tip is in the center of the hopper inlet tube Straighten any crimps in the hoses Tighten any loose hoses Reset the process protection differential temperature setpoint at least 37 F 3 C above the drying setpoint Make sure the RTD temperature probe tip is in the center of the hopper inlet tube Straighten any crimps in the hoses Tighten any loo
92. screen 22 the dryer will return to the normal drying setpoint If the dryer has the setback on temperature option installed this is the temperature set point to which the process air will revert once the air at the outlet of the hopper has reached its setpoint Menu number 6 If the dryer has the optional setback on load rate option this screen shows the number of load dumps per hour setpoint and actual When the actual drops below the setpoint the dryer will go into setback mode When the actual goes above the set point the dryer will return to the normal process temperature central drying applica i tions these functions are not available Operation 4 7 4 8 Operation Control Function Descriptions continued Screen SCREEN 13 PM1 and or DEW POINT MONITOR Options ee ta SCREEN 14 oy ILe Function If the dryer has the dewpoint monitor option installed this screen will show the actual dewpoint of the process delivery air measured after the desiccant tank in the process position but before the process heater If the Power Miser 1 PM1 option is installed there will also be a setpoint shown on this screen Although the dryer is capable of producing dewpoints much lower than 40 F 40 C the minimum sensor range is 40 F 40 C The PMI option when set to index on dewpoint will monitor the dewpoint of the process air and not index a new tank into the process position until
93. se hoses Check the RTD plug connection and tighten if needed Check the plug connection and tighten if needed Replace the process protection RTD Problem A53 Process Blower Overload The process blower overload has tripped due to a mechanical or electrical prob lem Shut Down Alarms Possible cause The process blower has mechanically failed or is unable to rotate freely The process blower has failed electrical ly The overload is set incorrectly Solution With the power removed check the process blower for mechanical failure and free rotation Replace if necessary Wait 3 to 15 minutes with the power on until the dryer indicates the overload condition has cleared then try to restart the dryer With the power removed check the process blower for electrical shorts or open circuits Replace if necessary Wait 3 to 15 minutes with the power on until the dryer indicates the overload condition has cleared then try to restart the dryer With the power removed check the overload settings and confirm that the settings match the full load amps listed on the process blower motor Wait 3 to 15 minutes with the power on until the dryer indicates the overload condition has cleared then try to restart the dryer Troubleshooting 6 9 P1 Process Temperature Deviation The process tem perature exceeds the deviation band as entered for the speci fied time Default values are 43 F 6 C for 5 sec
94. ss DRYING CYCLE The process blower pulls moist air from the top of the drying hopper The air pass es through the process filter and optional aftercooler if installed into the dryer s desiccant tank where moisture is removed The now dry air moves through the process heater where it is heated to the drying temperature selected by the opera tor The hot dry air is delivered to the hopper after it passes through the optional precooler if installed where a spreader cone evenly distributes the air through the material i THE Process DRYING CYCLE The process blower pulls moist air from the top of the drying hop per The air passes through the process filter and optional aftercool er if installed into the dryer s desiccant tank where moisture is removed The dry air is delivered to the hopper after it passes through the optional precooler if installed where a spreader cone evenly distributes the air through the material Mi The Regeneration Cycle The regeneration blower pulls air through the regeneration filter into the dryer s regeneration heater The air is heated to 425 F 218 C before it is pushed into the wet desiccant tank 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 A regenerated desiccant tank must be cooled before it is moved back into the process cycle The process blower pushes a small amount of air t
95. tach the hose to the hopper s delivery air inlet labeled To x Hopper Delivery air Delivery air outlet outlet 75 and 15 25 and 50 100 models models 3 Secure hoses with clamps The hose clamp should be secured at least 1 4 in 0 64 cm from the end of the inlet or outlet tube Connecting the Water Hoses S NOTE Do not allow the flexible hoses to kink or crimp The optional aftercooler flow control and precooler require a source of cooling water and a discharge or return line See Appendix C for information on installing and connecting water hoses to the optional aftercooler See Appendix D for infor mation on installing and connecting water hoses to the optional flow control See Appendix E for information on installing and connecting water hoses to the option al precooler Installation 3 15 Central a central dryer moni toring the drying air temperature is not 1 necessary since there is no process heater in the system Therefore installa tion and connection of this RTD probe is not applicable 3 16 Installation Connecting the RTD Probe The RTD probe monitors the temperature of the drying air as it enters the hopper If the probe is not installed correctly temperature readings will be inaccurate 1 Insert the probe at the inlet to the hopper The end of the probe must not touch the walls of the inlet The tip of the probe should be approximately in the
96. tallation it may be necessary to access the process heater through the right side panel or to remove the process blower to create adequate access to use a wrench to remove the process heater See Removing the Process Blower Note When installed the process heater tube must be oriented so the power wires are toward the inside of the dryer Troubleshooting 6 23 1 central dryer there is no process heater in the System Therefore I replacing the process 6 24 Troubleshooting Replacing the Heater Process Heater continued 12 13 14 15 Put petroleum jelly on the tips of the new heater wire leads to make it easier to go through the holes in the back of the control box Reference the wiring diagram to reattach the heater wires and the two snap switch wires Put the insulation back on Make sure to duct tape the seam that was cut during removal Reattach the lower 2 1 2 63 5 mm hose and hose clamp Make sure the heater fuses are not blown before trying the new heater For D75 and D100 Dryers 10 11 12 13 14 15 Remove the hose clamp holding the heater tube to the dryer frame Remove the insulation from the heater tube by cutting the insulation in a straight line from top to bottom Remove the hose and clamps at the top and bottom of the heater tube 7 Remove the plugs or hose fittings toward the top end of the heater These will need to be installed on the new heater
97. tate relays SSRs Check the regeneration RTD and tighten if needed Tighten all air hose connections Passive Alarms Problem PS Return Air High Temperature If the return air temperature is between 150 and 180 F 65 6 and 82 2 C P6 Regen High Temperature If the regeneration tempera ture exceeds the high tempera ture limit for the specified time Default values are 450 F 232 2 C for 20 sec P7 Regen Low Temperature The regeneration tempera ture is less than the low tem perature setpoint for the speci fied time Defaults are 350 F 176 7 C for 20 sec P8 Regen Temperature Loop Break The regeneration tem perature is outside of the oper ator entered deviation alarm band see Regen Temperature Deviation passive alarm and the regeneration temperature is not moving towards the set point at a rate greater than specified Default values are 36 F 2 C over 20 sec Possible cause The hopper does not contain enough material You are drying at a high drying tempera ture above 250 F 121 1 C or running at low throughputs If an optional aftercooler is installed it does not have enough water The aftercooler coils are dirty The air hose connections are loose One of the solid state relays SSRs failed in the closed position The regeneration RTD is loose or has fallen out The regeneration heater has failed The regeneration RTD is loose or has fallen out
98. th Control depth Outlet inlet tube size OD Weight lbs kg 35 5 90 2 17 3 43 9 15 7 39 9 24 8 63 0 7 3 18 5 25 35 5 90 2 17 3 43 9 15 7 39 9 24 8 63 0 7 3 18 5 25 42 1 107 22 0 55 9 15 7 39 9 30 3 77 0 7 3 18 5 42 1 107 22 0 55 9 15 7 39 9 30 3 77 0 7 3 18 5 25 Installed 340 155 Voltage t Total Amps 208 V 3 phase 60 Hz l i NA 240 V 3 phase 60 Hz 400 V 3 phase 50 Hz l i 14 480 V 3 phase 60 Hz i i 575 V3 may Hz 7 Water oo for e or A A l Recommended temperature 45 85 F 45 85 F Water flow gal min liters min 1 3 8 2 7 6 Water connections NPT 1 2 inch NPT SPECIFICATION NOTES SCFM stands for standard cubic feet per minute referenced to a pre specified pressure temperature and relative humidity In most cases SCFM is referenced to 14 7 PSIA 68 F and 0 relative humidity ACFM stands for actual cubic feet per minute and must be supplied with a temperature reference due to the change in air density with temperature Because dryers operate at a relatively low pressure the effects on air density are negligible t Dryers running at 50 HZ will have 17 less airflow and a 17 reduction in material throughput 225 102 225 102 240 109 310 141 Specifications may change without notice Consult a Conair representative for the most current information 2 6 Description Specifications D Carousel continued OPTIONAL HOPPERS AN
99. ting time later How the Guide is Organized Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation Symbols within triangles warn of conditions that could be hazardous to users or could damage equipment Read and take precautions before proceeding Numbers indicate tasks or steps to be performed by the user A diamond indicates the equipment s response to an action performed by the user An open box marks items in a checklist A circle marks items in a list Indicates a tip A tip is used to provide you with a suggestion that will help you with the maintenance and operation of this equipment Indicates a note A note is used to provide additional information about the steps you are following throughout this manual Using the D Series as a Central Dryer This manual incorporates the information necessary to use the Conair D series dryer as a central dryer Throughout this manual information particular to cen tral dyer application of the D series dryer is called out by the following treat ment This box will contain information or highlight system differ ences particular to the application of the D series dryer as a central dryer Central Your Responsibility as a User You must be familiar with all safety procedures concerning installation opera tion and maintenance of this equipment Responsible safety procedures
100. w dew point air that removes moisture from hygroscopic plastics When the conveying function is turned on the conveying blower conveys the dried resin to the vacuum receiver mounted on the processing machine The demand sensor on the vacuum receiver viewing chamber allows you to convey just enough material to satisfy the shot size required for your process Appendix G 1 When configured as a central dryer the i MDC option is not available amp NOTE Throughput rates will vary by MDC model and type of material See the Specification pages for recommended throughputs G 2 Appendix Typical Applications The MDC 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 The MDC can be used successfully in applications that require A contamination free drying environment Drying temperatures of 100 to 375 F 66 to 191 C Throughput rates of 15 to 100 Ibs 6 8 to 37 3 kg per hour some materials can be run at a higher rate Dew points of 40 F 40 C Conveying material at distances up to but not more than 8 feet 2 4 m vertically and 6 feet 1 8 m horizontally An aftercooler is required if You are drying at temperatures over 250 F 121 C Throughput rates are less than 50 of the dry
101. with your dryer to locate specific electrical components Illustrations in the User Guide are intended to be representative only Process heater solid state relays If ohms equal zero or infinity replace the contactor Checking or Replacing Temperature Sensors The D carousel dryer uses RTD sensors to monitor the temperatures of the drying air the return air the regeneration exhaust and the regeneration and process heater boxes A IMPORTANT Always refer to the wiring diagrams that came with your dryer to locate specific electri cal components Illustrations in the User Guide are intended to be representative only Location of the Process RTD at the Hopper To check or replace an RTD sensors 1 Disconnect and lockout the main power supply AN 2 Remove dryer panels as necessary 3 Locate the RTD sensors 4 Check the sensor positions and conditions Temperature readings will be incorrect if the sensors are touching the wall of an air hose or pipe or if the sen sor or wiring is damaged The tip of the sensor should be centered within the air hose or pipe Sensor wires should be attached to the appropriate connection ZI an 7 r Q points on the dryer s electrical enclosure or microprocessor board 5 To check with ohm meter measure the resistance across the RTDs The resistance should be approx 110 ohm 6 Replace the sensor if necessary Troubleshootin
102. you ever need service or parts 5 You are now ready to begin installation Follow the preparation steps on the next page then choose one of the four mounting options Dryer and hopper on the processing machine throat using the optional support frame see page 3 6 Dryer on the floor hopper on the throat see page 3 8 Dryer and hopper on a mobile floor stand MDC mounting see Appendix B Dryer on a floor stand hopper on the throat see Appendix B Installation 3 3 3 4 Preparing for Installation The D carousel dryer is easy to install if you plan the location and prepare the mounting area properly IM ake sure the mounting area provides O 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 All electrical wiring should comply with your region s electrical codes O A source of water if you have an aftercooler and or precooler The D dryer s optional aftercooler and precooler can use 1 2 gals min 3 8 7 6 liters min tower city or chiller water at temperatures of 40 to 85 F 4 to 29 C Pipe should be run to the planned dryer location Use flexible hose to connect the water pipes to the aftercooler and precooler If the dryer has an optional flow control see Appendix D for connection informatio
103. ys 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 enclo sure Turn the disconnect dial on the dryer door to the Off or O position Lock out the main power see Page 1 4 for complete lock out informa tion Turn the captive screw and swing the door open 2 Insert the main power wire through the knockout in the side of the enclosure Secure the wire with a rubber compression fitting or strain relief Connecting the Main Power continuea IMPORTANT Always refer to the wiring diagrams that came with your dryer before making electri cal connections J qp dp 4 3 Oo ce D 3 Connect the power wires to the three terminals at the top of the power discon nect holder 4 Connect the ground wire to either grounding point as shown in the photo Installation 3 11 3 12 Installation Checking for Proper Air Flow This step is only needed on 50 75 and 100 models if the phase detection option was not ordered with the dryer JN CAUTION This step must be performed before the dryer s air hoses are connected to the hopper Performing this step after the air hoses are connected could cause damage to the dryer if the air flow direction is incorrect due to improper phase connection Material from the hopper can be pulled into the process heater causing permanent damage

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