Conair MDCW Carousel Plus W15 User Manual
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Conair MDCW Carousel Plus W15 User Manual

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U S E R G U I D E
UGD029-0311
MDCW Carousel Plus Dryer
MDCW Models 15, 25, 50, 75 and 100 with DC-2 Controls
Corporate Office: 724.584.5500
l
Instant Access 24/7 (Parts and Service): 800.458.1960
l
Parts and Service: 814.437.6861

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  • Page 1 www.conairgroup.com U S E R G U I D E UGD029-0311 MDCW Carousel Plus Dryer MDCW Models 15, 25, 50, 75 and 100 with DC-2 Controls Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861...
  • Page 2 * NOTE: Displayed upon initialization, during power up, or on a data tag inside the door. DISCLAIMER: Conair 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.

  • Page 3: Table Of Contents

    Ta b l e o f C o n t e n t s I n t r o d u c t i o n Purpose of the user guide ....... . 1-2 How the guide is organized .
  • Page 4 Checking for proper air flow ......3-12 Connecting the aftercooler ......3-14 Testing the installation .
  • Page 5 Screen filter cleaning (Optional)......5-12 Cleaning the compressed air filter (Optional) ....5-13 Cleaning the aftercooler coils .
  • Page 6 A p p e n d i x Cleaning the precooler coils ......B-1 A d d e n d u m Communication protocols for common controls - DC-2 l Ta b l e o f C o n t e n t s...
  • Page 7 S E C T I O N I n t r o d u c t i o n P u r p o s e o f t h e u s e r g u i d e ....1 - 2 H o w t h e g u i d e i s o r g a n i z e d .

  • Page 8: I N T R O D U C T I O N

    P u r p o s e o f t h e U s e r G u i d e This User Guide describes the Conair MDCW Carousel Plus series dryers and explains step-by-step how to install, operate, maintain, and repair this equipment.

  • Page 9: Your Responsibilities As A User

    Yo u r R e s p o n s i b i l i t y a s a U s e r You must be familiar with all safety procedures concerning installation, operation and maintenance of this equipment. Responsible safety procedures include: •...

  • Page 10: At T E N T I O N

    AT T E N T I O N : R e a d t h i s s o n o o n e g e t s h u r t 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.

  • Page 11: Attention: Read This So No One Gets Hurt

    AT T E N T I O N : R e a d t h i s s o n o o n e g e t s h u r t ( c o n t i n u e d ) We design equipment with the user’s safety in mind.

  • Page 12: How To Use The Lockout Device

    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: Stop or turn off the equipment.

  • Page 13: D E S C R I P T I O N

    S E C T I O N D e s c r i p t i o n W h a t i s t h e M D C W C a r o u s e l P l u s D r y e r ? ..2 - 2 O p t i o n a l s e l f - l o a d i n g M D C W .

  • Page 14: Optional Self-Loading Mdcw

    W h a t i s t h e M D C W C a r o u s e l P l u s D r y e r ? The MDCW Carousel Plus Dryer is a self-contained, mobile unit designed to dry plastic resin and convey it with dehumidified air directly to a processing machine.

  • Page 15: Typical Applications

    Ty p i c a l A p p l i c a t i o n s The MDCW Carousel Plus Dryer was designed for drying and conveying beside the press. But it can also be used to pre-dry material in one location, and then transport the dried material to another location for conveying into the processing machine.
  • Page 16 Ty p i c a l A p p l i c a t i o n s ( c o n t i n u e d ) The MDCW Carousel Plus Dryer can be used successfully in applications that require: •...

  • Page 17: How It Works

    H o w I t Wo r k s The Process (Drying) Cycle The process blower pulls moist air from the top of the drying hopper. The air pass- es through the process filter and aftercooler, then into the desiccant wheel, where moisture is removed.
  • Page 18 H o w I t Wo r k s ( c o n t i n u e d ) PHASE ROTATION PROTECTION ALARM LIGHT PROCESS ALARM BELL REGENERATION PROCESS BLOWER HEATER BOX HIGH TEMP SHUTOFF REGENERATION AIR FILTER HIGH TEMP SHUTOFF REGENERATION HEATER...

  • Page 19: How Conveying Works

    H o w C o n v e y i n g Wo r k s When the conveying function is turned on, the MDCW uses dry air to move material from the drying hopper to the process machine as it is needed. Material enters the vacuum receiver and falls into the Positive and negative air flow generated by the...
  • Page 20 § Temperatures above or below the recommended levels may affect dryer performance. Tower, chiller, or municipal water sources can be used. Specifications may change without notice. Consult a Conair representative for the most current information. TPDS020-0311-REV (continued) 2 - 8...
  • Page 21 S p e c i f i c a t i o n s : M D C W C a r o u s e l P l u s D r y e r s ( c o n t i n u e d ) TLR Tube Loader TLR Tube Loader (hopper loader)

  • Page 22: Mdcw Carousel Plus Dryer Options

    M D C W C a r o u s e l P l u s D r y e r O p t i o n s • Volatile trap (use only in conjunction with aftercooler) - The volatile trap is recommended when drying materials that produce volitales that condense into a waxy or oily residue and/or if the material contains excessive fines.

  • Page 23: I N S T A L L A T I O N

    S E C T I O N I n s t a l l a t i o n U n p a c k i n g t h e b o x e s ....3 - 2 P r e p a r i n g f o r i n s t a l l a t i o n .

  • Page 24: Unpacking The Boxes

    U n p a c k i n g t h e B o x e s The MDCW Carousel Plus Dryer comes in one to four boxes, depending on the model and options ordered. The boxes could include (depending on the options selected): Vertical Conveying Tubes* Self-loading Hopper...
  • Page 25 U n p a c k i n g t h e B o x e s ( c o n t i n u e d ) Take a moment to record serial numbers and electrical power specifications in the blanks provided on the back of the User Guide’s title page. The informa- tion will be helpful if you ever need service or parts.

  • Page 26: Preparing For Installation

    Mounting bracket your order. If you need a larger 4 in. {101.6 mm} Gasket mounting bracket, call Conair Parts at 1-800-458-1960. 4 in. {101.6 mm} 3 - 4 l I n s t a l l a t i o n...

  • Page 27: Installing The Mdcw

    I n s t a l l i n g t h e M D C W The MDCW was designed to be mobile. When you move the MDCW, you will need to mount the vacuum receiver, connect the main power source, connect a water source for the aftercooler and/or optional precooler, and connect a compressed air source for the optional self-loading hopper loader.

  • Page 28: Connecting The Conveying Lines

    C o n n e c t i n g C o n v e y i n g L i n e s The vertical conveying tubes and flexible conveying hoses may have been removed for shipping. To assemble: Insert each vertical conveying tube into its quick disconnect fitting on the MDCW.

  • Page 29: Connecting The Demand Sensor

    M o u n t i n g a L o a d e r o n t h e H o p p e r IMPORTANT: Check to ensure that all If you have a Conair loader or vacuum receiver, you can material conveying hoses are placed use the flange and mounting clips provided on the top of away from the control panel.

  • Page 30: C O N N E C T I N G M A T E R I A L L I N E S F O R

    Secure with clamp. Ratio valves are available from Conair. Contact Conair Parts (800) 458 1960 From outside of the United States, call: Connect a gaylord wand to the...

  • Page 31: S E L F - L O A D I N G ( O P T I O N A

    C o n n e c t i n g M a t e r i a l L i n e s f o r S e l f - L o a d i n g ( O p t i o n a l ) ( c o n t i n u e d ) Attach the air conveying line to the outlet of the hopper loader.

  • Page 32: Connecting The Main Power

    C o n n e c t i n g t h e M a i n Po w e r CAUTION: Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by qualified personnel.
  • Page 33 C o n n e c t i n g C o m p r e s s e d A i r f o r S e l f - L o a d i n g ( O p t i o n a l ) When connecting the optional self-loading function of the MDCW Carousel Plus dryer an 80 psi {5.5 bar} compressed air source is required.

  • Page 34: Checking For Proper Air Flow

    C h e c k i n g f o r P r o p e r A i r F l o w IMPORTANT: This procedure is needed on non-conveying MDCW models 50, 75, and 100. This procedure is not required on the conveying MDCW 15 - 100 models because phase detection is standard.
  • Page 35 C h e c k i n g f o r P r o p e r A i r F l o w ( c o n t i n u e d ) Press the Stop button. Reconnect the process filter that was discon- Stop nected in Step 3.

  • Page 36: Connecting The Aftercooler

    C o n n e c t i n g t h e A f t e r c o o l e r The aftercooler and optional precooler require a source of cooling water and a discharge or return line. TIP: Make the water supply and discharge / return connections To connect water hoses:...

  • Page 37: Testing The Installation

    Te s t i n g t h e I n s t a l l a t i o n You have completed the installation. Now it’s time to make sure everything works. Make sure there is no material in the hopper. If you have mounted a loader or vacuum receiver on the hop- per, disconnect the material inlet hose at the source or turn off the loader.

  • Page 38: Using Communications

    Te s t i n g t h e I n s t a l l a t i o n ( c o n t i n u e d ) Turn ON the hopper and machine loader switches. •...
  • Page 39 S E C T I O N O p e r a t i o n h e M D C W d r y e r : c o n t r o l p a n e l D C - 2 ..4 - 2 M D C W C a r o u s e l P l u s D r y e r c o n t r o l f u n c t i o n s .

  • Page 40: The Mdcw Dryer: Control Panel Dc-2

    T h e M D C W D r y e r : C o n t r o l Pa n e l D C - 2 M e n u B u t t o n S c r o l l B u t t o n s Press to scroll through the closed loop parameter Press to view the main menu screen where you can list.

  • Page 41: Mdcw Carousel Plus Dryer Control Functions

    M D C W C a r o u s e l P l u s D r y e r C o n t r o l F u n c t i o n s Dryer functions are values that you can set or monitor in the Screen Title and Status Display windows.
  • Page 42 POWER ON CONAIR CP100 CV00.06.2 DV00.09.8 3 SEC DELAY MONDAY 7/22/2003 07:59 AM 3 SEC DELAY STD DRYER PROCESS TEMPERATURE Act 140˚F Set 140˚F REGENERATION TEMP ACT 350˚F 350˚F RETURN AIR TEMP ACT 120˚F SET 120˚F MDC HOPPER LOADER MDC HOPPER LOADER AND RATIO...
  • Page 43 DRYER MAIN MENU STAT SETUP DIAG DRYER STATUS PROC REGEN OTHER STANDARD DRYER / MDC DRYER PROCESS DRYER REGEN DRYER OTHER STATUS SCREENS STATUS SCREENS STATUS SCREENS PROCESS TEMPERATURE REGENERATION TEMP MODEL CP150 ACT 325˚F SET 325˚F ACT 350˚F SET 350˚F 480 V 60 HZ REGEN OUTLET TEMP...
  • Page 44 SCREEN # DRYER MAIN MENU STAT SETUP DIAG DRYER SETUP PROC ALM DISP OTHER SETUP PROCESS PROC REGN OTHER STANDARD DRYER AND MDC SETUP PROCESS PROC PROPID RETPID SETUP PROCESS SETUP PROCESS HEATER SETUP AFTERCOOLER SCREENS PID VALUE SCREENS on off VALUE SCREENS PROCESS TEMPERATURE PROCESS POWER LIMIT RET AIR CYCLE TIME...
  • Page 45 DRYER MAIN MENU STAT SETUP DIAG DRYER SETUP PROC ALM DISP OTHER SETUP PROCESS PROC REGEN OTHER SETUP PROCESS SETUP REGENERATION OTHER SCREENS REGEN AUTOSTART TIMER ENABLED EDIT SETUP REGEN HEATER DISABLED SETUP REGENERATION PID VALUE SCREENS SCREENS MONDAY START TIME 8:00 REGEN POWER LIMIT REGENERATION TEMP...
  • Page 46 DRYER MAIN MENU STAT SETUP DIAG DRYER SETUP PROC ALM DISP OTHER ALARM ALARM DRYER SETUP CONTROL ACTION SETUP DISPLAY SCREENS UNITS STANDARD EDIT DRYER SETUP ALARM DRYER SETUP ALARM METRIC ACTION SCREENS SETPOINT SCREENS TIME DISPLAY PROC TEMP DEVIATION PROCESS HIGH TEMP 12 HOUR 385˚F...
  • Page 47 DRYER MAIN MENU STAT SETUP DIAG DRYER SETUP PROC ALM DISP OTHER DRYER SETUP OTHER OPT INSP COM PW Logging Out Dryer Setup DRYER SETUP OPTIONS DRYER SETUP MODEL DRYER SETUP Password … Password Screen INFORMATION SCREENS CONFIG SCREENS COMMUNICATIONS IF A VALID PASSWORD IS STILL ACTIVE SETBACK ON TEMP MODEL NUMBER...
  • Page 48 DRYER MAIN MENU STAT SETUP DIAG Dryer Diagnostic ALRM HIST KEEP 40 SHOWN DIAGNOSTIC EVENTS DIAGNOSTIC I/O ALRMS ANALOG DIGITAL DRYER DIAGNOSTICS DIGITAL LAST 40 ALARMS 00:S-Regen RTD 01/31/00 09:24 P INFO DRYER DIAGNOSTIC SNAPSHOT OF INFO FOR EACH ALARM DIGITAL I/O DRYER DIAGNOSTICS Alarm Activated For...

  • Page 49: Control Function Descriptions

    SCREEN 1 Once power is turned on, this screen is Additional information about displayed for 3 seconds It shows CONAIR CONAIR D100 the password can be found and the dryer type on the first line, and the CV2.21.00...
  • Page 50 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) S c r e e n F u n c t i o n SCREEN 3 (DEFAULT SCREEN) SETUP, PROC, PROC, PROC, PROCESS...
  • Page 51 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) S c r e e n F u n c t i o n SCREEN 7 Self-loading This screen shows the amount of time the...
  • Page 52 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) S c r e e n F u n c t i o n The dewpoint control will automatically SCREEN 11 (Dewpoint control...
  • Page 53 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n S c r e e n SCREEN 15 This is an example of a Heater Output...
  • Page 54 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) S c r e e n F u n c t i o n SCREEN 21A (Aftercooler or This screen shows if the aftercooler or pre-...
  • Page 55 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) S c r e e n F u n c t i o n SCREEN 23 (Current Monitor This screen shows the calculated total...
  • Page 56 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) S c r e e n F u n c t i o n SCREEN 26 This screen shows the setpoint the process...
  • Page 57 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n S c r e e n SCREEN 30 This screen shows the model number, volt-...
  • Page 58 "Proc" on the Dryer PROC REGEN OTHER Setup (screen 36). By pressing the Select NOTE: Conair is not responsi- Category buttons under the titles, the user ble for damage caused by can select to see setup information for excessively high drying Process, Regeneration, or Other.
  • Page 59 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n S c r e e n SCREEN 40 Before performing an autotune, set the set-...
  • Page 60 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n S c r e e n SCREEN 44 This screen shows the integral value for the...
  • Page 61 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) S c r e e n F u n c t i o n SCREEN 50 This is the maximum value the dewpoint...
  • Page 62 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n S c r e e n This is the auto start screen for the first SCREEN 56...
  • Page 63 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n S c r e e n This is the alarm action and setup screen.
  • Page 64 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) S c r e e n F u n c t i o n This is an example of an Alarm Setup SCREEN 61...
  • Page 65 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) S c r e e n F u n c t i o n SCREEN 66 (CFM Monitor This screen shows the low CFM setpoint.
  • Page 66 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n S c r e e n This is the amount of time from start-up SCREEN 70...
  • Page 67 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) S c r e e n F u n c t i o n SCREEN 74 This is the Dryer Setup Other screen.
  • Page 68 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n S c r e e n SCREEN 78 This screen further defines the dryer type...
  • Page 69 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n S c r e e n This screen shows the communications SCREEN 81 Communications...
  • Page 70 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n S c r e e n This screen shows the password entry SCREEN 85...
  • Page 71 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n S c r e e n SCREEN 88 This is the password logout screen.
  • Page 72 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n S c r e e n This is an example of one of the alarm his- SCREEN 92...
  • Page 73 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n S c r e e n This is the Diagnostic I/O screen.
  • Page 74 These values should not be changed except under the direction of Conair Engineering or Service. 4 - 3 6 l O p e r a t i o n...

  • Page 75: To Start Drying

    To S t a r t D r y i n g Make sure there is material in the hopper. Turn on the main power to the dryer Make sure the dryer’s disconnect dial is in the ON position. This powers up the control and the display lights will illuminate.

  • Page 76: To Stop Drying

    To S t a r t D r y i n g ( c o n t i n u e d ) Press the START button. Start If everything is installed correctly: • The green light on the start button will illuminate. •...
  • Page 77 U s i n g t h e T h e S e l f - l o a d i n g F u n c t i o n o n t h e H o p p e r L o a d e r ( O p t i o n a l ) Connect the conveying hose and/or pick-up wand from the material source to the inlet on the hopper loader.

  • Page 78: Machine Loader Conveying

    M a c h i n e L o a d e r C o n v e y i n g Move the MDCW to the processing machine. Lock the wheels and connect the main power source. Connect the water source if you have an aftercooler. Connect compressed air if the self-loading option is being used.
  • Page 79 H o w t o U s e t h e S u p e r v i s o r ’s Pa s s w o r d The supervisor's password must be entered before you can use or make changes to some screens on the dryer control.
  • Page 80 H o w t o U s e t h e S u p e r v i s o r ’s Pa s s w o r d ( c o n t i n u e d ) This is the screen where you will need to enter the supervisor's password.
  • Page 81 U s i n g t h e A u t o Ti m e r You can set the dryer and stop automatically using the Auto Start and Auto Stop functions. The supervisor password is necessary to use this function. P r o g r a m m i n g A u t o S t a r t The Auto timer can be programmed using the Auto Countdown screen.

  • Page 82: Setting High Setpoint Limits

    SCREEN 36 SCREEN 37 SETUP PROCESS DRYER SETUP PROC REGEN OTHER PROC DISP OTHER NOTE: Conair is not responsible for damage SCREEN 38 SCREEN 14 caused by excessively high drying setpoints that SETUP PROCESS DRYER PROCESS are not in accordance PROC...

  • Page 83: Using Dewpoint Control

    U s i n g D e w p o i n t C o n t r o l Your dryer is equipped with a dewpoint monitor and dewpoint control features. You can choose to use it as a monitor only device, or to maintain a steady dewpoint that you select with the dewpoint control.

  • Page 84: Using The Setback Feature

    U s i n g t h e S e t b a c k Fe a t u r e The DC-2 comes standard with setback installed, but disabled. You can choose to set the mode to "Off", "Temperature", or "Manual On". Refer to the Control Function Descriptions later in this section for more detailed information.

  • Page 85: Setback Feature Guidelines

    U s i n g t h e S e t b a c k Fe a t u r e ( c o n t i n u e d ) Access Screen 27 and set the setback return temperature for the air exiting the hopper.
  • Page 86 S e t b a c k Fe a t u r e G u i d e l i n e s ( c o n t i n u e d ) A recommended way to determine the “Setback Return Temperature” setpoint is to monitor the actual temperature of this function during pre-drying of your material at start-up, and while running at your normal maximum material throughput.

  • Page 87: M A I N T E N A N C E

    S E C T I O N M a i n t e n a n c e P r e v e n t a t i v e m a i n t e n a n c e c h e c k l i s t ..5 - 2 C h e c k i n g t h e d e w p o i n t .

  • Page 88: Preventative Maintenance Checklist

    P r e v e n t a t i v e M a i n t e n a n c e C h e c k l i s t Routine maintenance will ensure optimum operation and performance of the MDCW Dryer and the receiver on the hopper.
  • Page 89 P r e v e n t a t i v e M a i n t e n a n c e C h e c k l i s t ( c o n t i n u e d ) •...

  • Page 90: Checking The Dewpoint

    It is a good idea to monitor the dewpoint performance of your dryer periodically Conair were provided with a with a calibrated portable dewpoint monitor, to ensure it is performing at maxi- male connector that plugs into mum capacity.
  • Page 91 C h e c k i n g t h e D e w p o i n t ( c o n t i n u e d ) Turn on the dryer. Turn on the portable instrument and ensure there is positive airflow through the sensor.

  • Page 92: Cleaning The Hopper

    C l e a n i n g t h e H o p p e r CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the dryer and drying hopper. The hopper, spreader cone, and discharge assembly should be cleaned thoroughly between material changes to prevent resin contamination.

  • Page 93: Cleaning The Process Filter

    C l e a n i n g t h e P r o c e s s F i l t e r Clogged filters reduce air flow and dryer efficiency. Cleaning frequency depends on how much material you process and how dusty or full of fines it is. To access the filter push down and turn the top of the filter housing in a clockwise direction to remove.
  • Page 94 C l e a n i n g t h e P r o c e s s F i l t e r ( c o n t i n u e d ) Wipe the inside of the filter housing clean, then replace the filter cartridge into the housing.

  • Page 95: Cleaning The Regeneration Filter

    C l e a n i n g t h e R e g e n e r a t i o n F i l t e r Clogged filters reduce air flow and dryer efficiency. Cleaning frequency depends on how much material you process and how dusty or full of fines it is.

  • Page 96: Cleaning The Conveying Filter

    C l e a n i n g t h e C o n v e y i n g F i l t e r The conveying filter captures dust and fines from the air used to convey material. The filter should be cleaned regularly to maintain conveying airflow and optimum performance of the conveying blower.

  • Page 97: Cleaning The Vacuum Receiver

    C l e a n i n g t h e Va c u u m R e c e i v e r The vacuum receiver should be cleaned anytime you change materials. Replace the screen mesh filter if it is torn, damaged, distorted or so clogged with material that it cannot be cleaned.

  • Page 98: S C R E E N F I L T E R Cl E A N I N

    NOTE: The filter in your Conair TLR Tube Loader performs double-duty as an effective seal between the hopper body and the lid of the loader, so be sure to examine the integrity of the rubber seal at the top to ensure that the lid will seal effectively when reclamped.

  • Page 99: F I L T E R ( O P T I O N A

    C l e a n i n g t h e C o m p r e s s e d A i r F i l t e r ( O p t i o n a l ) You can add a moisture trap to the compressed air supply of your loader.

  • Page 100: Cleaning The Aftercooler Coils

    C l e a n i n g t h e A f t e r c o o l e r C o i l s You need to clean the aftercooler coils to keep them working efficiently. Cleaning frequency depends on the type and amount of material you process.

  • Page 101: Cleaning The Precooler Coils

    C l e a n i n g t h e P r e c o o l e r C o i l s If you have the optional precooler, you need to clean the cooling coils to keep them working efficiently.
  • Page 102 5 - 1 4 l M a i n t e n a n c e...
  • Page 103 S E C T I O N Tr o u b l e s h o o t i n g B e f o r e b e g i n n i n g ....6 - 2 A f e w w o r d s o f c a u t i o n .

  • Page 104: Tr O U B L E S H O O T I N G

    B e f o r e B e g i n n i n g 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. NOTE: Use of test mode screens 28-43 Before you take the covers off the dryer be sure to:...

  • Page 105: A Few Words Of Caution

    B e f o r e B e g i n n i n g ( c o n t i n u e d ) Find the wiring and equipment diagrams that were shipped with your dryer. These diagrams are the best reference for correcting a problem.

  • Page 106: How To Identify The Cause Of A Problem

    H o w t o I d e n t i f y t h e C a u s e o f a P r o b l e m NOTE: Pushing the Most dryer alarms are indicated by an illuminated Acknowledge Alarm light on Acknowledge Alarm button the MDCW Dryer control panel.

  • Page 107: Shutdown Alarms

    S h u t d o w n A l a r m s If the red Acknowledge Alarm LED is blinking red, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that when the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid.
  • Page 108 S h u t d o w n A l a r m s If the red Acknowledge Alarm LED is blinking red, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that when the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid.
  • Page 109 S h u t d o w n A l a r m s If the red Acknowledge Alarm LED is blinking red, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that when the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid.
  • Page 110 Call Conair Service for assistance. 6 - 8 l Tr o u b l e s h o o t i n g...
  • Page 111 If the alarm does occur it is a indica- tion that the software is not con- figured properly. Call Conair Service for assistance. Process Blower overload - If The process blower current draw has...
  • Page 112 Correct the cause of the non-functioning alarm does occur it is a indica- blower. tion that the software is not configured properly. Call Conair The process hose is not insulated. Insulated hose is required for high dry- Service for assistance.
  • Page 113 S h u t d o w n A l a r m s If the red Acknowledge Alarm LED is blinking red, the alarm is a shutdown alarm. The dryer will shutdown automatically to prevent damage to the equipment or personnel. Note that when the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid.

  • Page 114: Passive Alarms

    Pa s s i v e A l a r m s If the amber Acknowledge Alarm LED is blinking, the alarm is a passive alarm. The dryer continues to operate, but this problem could prevent correct drying of your material. Note that when the Acknowledge Alarm button is pressed once, the blinking amber LED becomes solid.
  • Page 115 Pa s s i v e A l a r m s If the amber Acknowledge Alarm LED is blinking, the alarm is a passive alarm. The dryer continues to operate, but this problem could prevent correct drying of your material. Note that when the Acknowledge Alarm button is pressed once, the blinking amber LED becomes solid.
  • Page 116 Pa s s i v e A l a r m s If the amber Acknowledge Alarm LED is blinking, the alarm is a passive alarm. The dryer continues to operate, but this problem could prevent correct drying of your material. Note that when the Acknowledge Alarm button is pressed once, the blinking amber LED becomes solid.
  • Page 117 Pa s s i v e A l a r m s If the amber Acknowledge Alarm LED is blinking, the alarm is a passive alarm. The dryer continues to operate, but this problem could prevent correct drying of your material. Note that when the Acknowledge Alarm button is pressed once, the blinking amber LED becomes solid.
  • Page 118 Pa s s i v e A l a r m s If the amber Acknowledge Alarm LED is blinking, the alarm is a passive alarm. The dryer continues to operate, but this problem could prevent correct drying of your material. Note that when the Acknowledge Alarm button is pressed once, the blinking amber LED becomes solid.
  • Page 119 Pa s s i v e A l a r m s If the amber Acknowledge Alarm LED is blinking, the alarm is a passive alarm. The dryer continues to operate, but this problem could prevent correct drying of your material. Note that when the Acknowledge Alarm button is pressed once, the blinking amber LED becomes solid.
  • Page 120 Pa s s i v e A l a r m s If the amber Acknowledge Alarm LED is blinking, the alarm is a passive alarm. The dryer continues to operate, but this problem could prevent correct drying of your material. Note that when the Acknowledge Alarm button is pressed once, the blinking amber LED becomes solid.
  • Page 121 A d d i t i o n a l A l a r m s Along with the Passive and Shutdown alarms, you may encounter additional error messages that indicate a problem with the control. Problem Possible cause Solution Control Not Ready, Please The dryer will continue to run if there Push the acknowledge alarm button...
  • Page 122 A d d i t i o n a l A l a r m s Along with the Passive and Shutdown alarms, you may encounter additional error messages that indicate a problem with the control. Problem Possible cause Solution Er.

  • Page 123: Dewpoint Troubleshooting

    Conair Parts at (800) 458 1960 for the addition of a volatile trap. Analog option board/sensor malfunction Verify dryer dewpoint readings with a calibrated portable dewpoint meter.

  • Page 124: Poor Material Drying Troubleshooting

    If your Conair dryer is equipped with the Setback feature, you should familiarize yourself with it, and make use of it. If not, you may want to contact Conair to determine if it can be added to your dryer.
  • Page 125 Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) Once it is determined which of the four requirements that is not being satisfied, refer to the following list and possible causes and solutions.
  • Page 126 Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) Residence Time - The time your material supplier has determined that the material in use must be heated to its drying temperature to achieve proper drying.
  • Page 127 Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) Airflow - The airflow in the process drying circuit must be adequate to carry and distribute the heat throughout the entire bed of material inside the hopper.
  • Page 128 -20 to -40° F {-29 to -40° C}. If your dryer does not United States, call: have a dewpoint readout, you can check the dewpoint with a portable dewpoint (814) 437 6861 instrument. Conair sells a variety of portable dewpoint meters. Contact Conair Parts. Problem Possible cause Solution Dryer dewpoint is not Low regeneration temperature.

  • Page 129: Replacing Fuses

    R e p l a c i n g F u s e s Disconnect and lockout the main power supply. Open the electrical enclosure door. Check the fuse. If necessary, pull the fuse out and replace it with a fuse of the same type and rating.

  • Page 130: Checking Heater Solid State Relays

    C h e c k i n g H e a t e r S o l i d S t a t e R e l a y s CAUTION: Always disconnect and lock out the main power sources before making electrical connections.
  • Page 131 C h e c k i n g o r R e p l a c i n g Te m p e r a t u r e S e n s o r s The MDCW dryer uses RTD sensors to monitor the temperatures of the drying air, the return air, the regeneration outlet, and the regeneration protection and setback at the outlet heater of the hopper.

  • Page 132: Replacing The Heaters

    R e p l a c i n g t h e H e a t e r s R e g e n e r a t i o n H e a t e r Tu b e NOTE: It is not necessary to remove the plastic cover to perform this procedure.
  • Page 133 R e p l a c i n g t h e H e a t e r s R e g e n e r a t i o n H e a t e r Tu b e ( c o n t i n u e d ) Slide the insulation off or make a straight cut in the insulation, and remove it from the defective heater tube.

  • Page 134: Process Heater Tube

    R e p l a c i n g t h e H e a t e r s P r o c e s s H e a t e r Tu b e Stop the dryer, disconnect the power, and follow proper lockout procedures.
  • Page 135 R e p l a c i n g t h e H e a t e r s P r o c e s s H e a t e r Tu b e ( c o n t i n u e d ) Loosen the hose clamp securing the heater tube in place and remove the tube from the unit.

  • Page 136: Replacing The Desiccant Wheel

    R e p l a c i n g t h e D e s i c c a n t W h e e l A s s e m b l y If the desiccant becomes clogged or contaminated, you should replace the desic- cant wheel to ensure optimum performance.
  • Page 137 R e p l a c i n g t h e D e s i c c a n t W h e e l A s s e m b l y ( c o n t i n u e d ) Remove four bolts securing the wheel assembly to the frame, then remove the desiccant wheel assembly from the dryer.

  • Page 138: Appendix

    Additional manuals and prints for your Conair equipment may be ordered through the Customer Conair has made the largest investment in customer support in the plastics Service or Parts Department for industry. Our service experts are available to help with any problem you might a nominal fee.

  • Page 139: Equipment Guarantee

    (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.
  • Page 140 C l e a n i n g t h e P r e c o o l e r C o i l s If you have the optional precooler, you need to clean the coils to keep them work- ing efficiently.
  • Page 141 www.conairgroup.com Addendum Communication Protocols for Common Controls Modbus Communications, Ethernet Communications, DeviceNet Gateway Communications and SPI Communications...
  • Page 142 DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential damages in connection with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information, including, but not limited to the implied warranties of merchantability and fitness for a particular purpose.
  • Page 143 Ta b l e o f C o n t e n t s M o d b u s C o m m u n i c a t i o n s Description of Modbus communications ..... A-2 Installing the Modbus communication hardware .
  • Page 144 S P I C o m m u n i c a t i o n s Description of SPI communications......D-2 Installing the SPI communication hardware .

  • Page 145: Description Of Modbus Communications

    S E C T I O N M o d b u s C o m m u n i c a t i o n s D e s c r i p t i o n o f M o d b u s C o m m u n i c a t i o n s ..A - 2 I n s t a l l i n g t h e M o d b u s C o m m u n i c a t i o n H a r d w a r e .

  • Page 146: Installing The Modbus Communication Hardware

    Connectors and cabling must be supplied by the user or ordered from Conair. A converter is available if your controls do not use the standard com- munications you desire. See Appendix A for the proper cabling and connection information for both types of interface.
  • Page 147 Be certain that you understand each parameter and its effect before changing anything. Conair recommends that you initially attempt to read from the registers and do not attempt any writes. Once the infor- mation you are trying to read has been confirmed as accurate, you can program your new/additional data.
  • Page 148 A - 4 l M o d b u s C o m m u n i c a t i o n s...

  • Page 149: Description Of Ethernet Communications

    S E C T I O N E t h e r n e t C o m m u n i c a t i o n s D e s c r i p t i o n o f E t h e r n e t C o m m u n i c a t i o n s ..B - 2 I n s t a l l i n g t h e E t h e r n e t C o m m u n i c a t i o n H a r d w a r e .

  • Page 150: Installing The Ethernet Communication Hardware

    D e s c r i p t i o n o f E t h e r n e t C o m m u n i c a t i o n s Modbus TCP/IP is a protocol that takes the basic Modbus command set that was originally developed for serial communications, and applies it to the Ethernet stan- dard via TCP/IP protocol.

  • Page 151: Using The Ethernet Parameter List

    Conair recommends that you initially attempt to read from the registers and do not complete any writes. Once the information you are trying to read has been confirmed as accurate, you can now program in your new or additional data.
  • Page 152 B - 4 l E t h e r n e t C o m m u n i c a t i o n s...
  • Page 153 S E C T I O N D e v i c e N e t C o m m u n i c a t i o n s D e s c r i p t i o n o f D e v i c e N e t C o m m u n i c a t i o n s . . . C - 2 I n s t a l l i n g t h e D e v i c e N e t C o m m u n i c a t i o n H a r d w a r e .

  • Page 154: Installing The Devicenet Communication Hardware

    D e s c r i p t i o n o f D e v i c e N e t C o m m u n i c a t i o n s The Conair Common Control board set allows you to add DeviceNet communica- tions for information interchange with PLC systems or higher level supervisory computer systems.
  • Page 155 U s i n g t h e D e v i c e N e t C o m m u n i c a t i o n D i p S w i t c h S e t t i n g s ( c o n t i n u e d ) Dip switch 1 provides the DeviceNet MacId address and baud rate using the stan- dard switch configurations found in most DeviceNet products.
  • Page 156 Athena DeviceNet interface module. Dip switch set 2 position 4 identifies the baud rate used to read parameters on Modbus. Dip switch set 2 positions 1-2 identify the parameter list for the Conair controllers. (continued) C - 4...

  • Page 157: Using The Led Status Indicators

    DeviceNet network’s EDS installer options. Once the EDS files are installed they will be shown under the “Conair Common Control” heading in the EDS file manager. If you install more than one of the EDS files the files will all be named “Conair Common Control”...

  • Page 158: Installing The Eds Files

    C o n f i g u r i n g t h e D e v i c e N e t S o f t w a r e I n s t a l l i n g t h e E D S F i l e s ( c o n t i n u e d ) C o n f i g u r i n g t h e D e v i c e N e t S o f t w a r e E D S F i l e Pa r a m e t e r L i s t C o n f i g u r a t i o n...
  • Page 159 This field will display how many floating point parameters are retrieved from the controller. The default is zero and is not normally changed by the user. If your application requires the use of floating point numbers, please consult with a Conair representative.

  • Page 160: Adding The Gateway To The Scan List

    C o n f i g u r i n g t h e D e v i c e N e t S o f t w a r e E D S F i l e Pa r a m e t e r L i s t C o n f i g u r a t i o n O p t i o n s ( c o n t i n u e d ) Parameter 6 Input Assembly Type...

  • Page 161: A D D I N G T H E G A T E W A Y T O T H E S C A N L I S T

    C o n f i g u r i n g t h e D e v i c e N e t S o f t w a r e A d d i n g t h e G a t e w a y t o t h e S c a n L i s t ( c o n t i n u e d ) Close the parameter list and reopen, once you have applied your parameters.
  • Page 162 C o n f i g u r i n g t h e D e v i c e N e t S o f t w a r e A d d i n g t h e G a t e w a y t o t h e S c a n L i s t ( c o n t i n u e d ) Press the “Edit I/O Parameter”...

  • Page 163: Explicitly Writing To The Gateway

    C o n f i g u r i n g t h e D e v i c e N e t S o f t w a r e A d d i n g t h e G a t e w a y t o t h e S c a n L i s t ( c o n t i n u e d ) Select the “OK”...

  • Page 164: Gateway Parameter List

    C o n f i g u r i n g t h e D e v i c e N e t S o f t w a r e G a t e w a y Pa r a m e t e r L i s t Similarly to the Modbus communications, the Common Controls parameters that are available are stored in registers 500 to 539.
  • Page 165 S E C T I O N S P I C o m m u n i c a t i o n s D e s c r i p t i o n o f S P I C o m m u n i c a t i o n s ..D - 2 I n s t a l l i n g t h e S P I C o m m u n i c a t i o n H a r d w a r e .

  • Page 166: Description Of Spi Communications

    9 pin D-sub connector. Refer to Conair drawing 130024 and 188629 in Appendix A for details of the installa- tion. The RS-485 SPI signal is available on pins 4 and 5 of the DB-9 connector.
  • Page 167 In order to connect Conair equipment to a host computer system, Conair can pro- vide an SPI-DDE server which will allow DDE compliant software packages such as Wonderware or Excel to connect to the SPI network with minimal programming required.
  • Page 168 Poll: 20h, 30h 4. Alarm, High Temperature Deviation - Sets and retrieves the high temperature deviation alarm setpoint. Not that in Conair dryers there is actually only devia- tion setpoint that is used for both high and low temperature deviation. The last value written to either the high or the low will be the value that is used.
  • Page 169 S u p p o r t e d D r y e r S P I C o m m a n d s ( c o n t i n u e d ) 6. Status, Process - Indicates that the status of the process with each “bit” showing a particular condition.
  • Page 170 S u p p o r t e d D r y e r S P I C o m m a n d s ( c o n t i n u e d ) 7. Status, Machine 1 - Indicates that the status of the dryer itself with each “bit” showing a particular condition.
  • Page 171 S u p p o r t e d D r y e r S P I C o m m a n d s ( c o n t i n u e d ) 8. Status, Machine 2 - This word shows the status of the Dryer itself with each bit showing a particular condition.
  • Page 172 S u p p o r t e d D r y e r S P I C o m m a n d s ( c o n t i n u e d ) 9. Mode, Machine - This is used to start/stop the dryer, acknowledge alarms and observe the run status.

  • Page 173: Appendix

    M o d b u s R S - 2 3 2 / 4 8 5 S e r i a l C o m m u n i c a t i o n Pa r a m e t e r s D C - 2 C o n t r o l Pa r a m e t e r s - U s e d o n d r y e r s w i t h D C - 2 C o n t r o l s Read Area...

  • Page 174: Dc Plus Control Parameters

    M o d b u s R S - 2 3 2 / 4 8 5 S e r i a l C o m m u n i c a t i o n Pa r a m e t e r s ( c o n t i n u e d ) Modbus Register Number Description Comments...

  • Page 175: Related Drawings

    M o d b u s R S - 2 3 2 / 4 8 5 S e r i a l C o m m u n i c a t i o n Pa r a m e t e r s ( c o n t i n u e d ) D C P l u s C o n t r o l Pa r a m e t e r s - U s e d o n R e s i n Wo r k s a n d H o p p e r Te m p e r a t u r e...
  • Page 176 A - 4 l A p p e n d i x...
  • Page 177 A - 5 A p p e n d i x l...
  • Page 178 A - 6 l A p p e n d i x...
  • Page 179 A p p e n d i x l A - 7...

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