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Conair W Series User Manual

Carousel plus dryer
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U S E R G U I D E
UGD030-0407
Carousel Plus Dryer
W Series 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 U S E R G U I D E UGD030-0407 Carousel Plus Dryer W Series 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

    D e s c r i p t i o n What is the Carousel Plus W Series Dryer? ....2-2 Typical applications ........2-2 How it works .
  • Page 4 Carousel Plus W Series Dryer: control panel DC-2....4-2 Carousel Plus W Series Dryer control functions ....4-3 Control function flow charts .
  • Page 5 Tr o u b l e s h o o t i n g Before beginning........6-2 A few words of caution .
  • Page 6 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 Carousel Plus W Series Dryers and explains step-by-step how to install, operate, maintain, and repair this equipment.

  • Page 9: Using The Carousel Plus W Series As A Central Dryer

    This manual incorporates the information necessary to use the Conair Carousel Plus W Series Dryer as a central dryer. Throughout this manual, information particular to central dyer application of the W Series Dryer is called out by the following treatment.

  • 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 C a r o u s e l P l u s W S e r i e s D r y e r ? . . 2 - 2 Ty p i c a l a p p l i c a t i o n s .

  • Page 14: Typical Applications

    Dryer on the floor; hopper on the throat (15 - 100). Hopper on a floor stand; the dryer next to it. Central dryer with ResinWorks. The W Series Dryer can be used successfully in applications that require: • A contamination-free drying environment.
  • Page 15 * See page 3-12 and Appendix B. When supplied for central drying • applications, the W Series Dryer Throughput rates of 15 to 100 lbs {6.8 to 37.3} per hour (some materials is not equipped with a process can be ran at a higher rate).

  • Page 16: How It Works

    H o w I t Wo r k s The Carousel Plus W Series Dryer achieves continuous, closed loop drying by passing air simultaneously through two heaters and a continuously rotating desiccant wheel. ROCESS RYING YCLE The process blower pulls moist air from the top of the drying hopper. The air passes through the process filter and aftercooler, then into the desiccant wheel, where moisture is removed.
  • Page 17 2 CURRENT METER The components identified by this type of box in the drawing are not supplied with the W Series Dryer when it is configured as a central dryer. Central D e s c r i p t i o n l...

  • Page 18: Specifications: Carousel Plus W Series Dehumidifying Dryer

    ‡ When drying below 150°F {66°C} a precooler is required. § 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. TPDS017-0305-REV 2 - 6...

  • Page 19: Carousel Plus W Series Dehumidifying Dryer Options

    C a r o u s e l P l u s W S e r i e s D e h u m i d i f y i n g D r y e r O p t i o n s •...
  • Page 20 2 - 8 l D e s c r i p t i o n...

  • Page 21: 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 22: Unpacking The Boxes

    U n p a c k i n g t h e B o x e s The Carousel Plus W Series Dryer comes in one to four boxes, depending on the model and options ordered. The boxes could include (depending on the options selected): •...
  • Page 23 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 information will be helpful if you ever need service or parts.

  • Page 24: Preparing For Installation

    P r e p a r i n g f o r I n s t a l l a t i o n The Carousel Plus W Series Dryer is easy to install if you plan the location and prepare the mounting area properly.

  • Page 25: 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 26: Connecting The Process Rtd Probe

    C o n n e c t i n g t h e P r o c e s s RT D P r o b e The process RTD probe monitors the temperature of the drying air as it enters the hopper.

  • Page 27: 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 This procedure is required on W 50 - 100 models if the phase detection option was not ordered with the dryer.
  • Page 28 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 START button. Hold your hand near the delivery air Start outlet.
  • Page 29 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 ) INSTALLATION NOTE: Models 50, 75 and 100 These models use a three-phase process blower.

  • Page 30: Connecting The Air Hoses

    (800) 458 1960 NOTE: If your dryer hose connection and your hopper hose connection are not the same From outside of the size, you will need a hose adapter. Contact Conair Parts 1 800-458-1960. United States, call: (814) 437 6861...

  • Page 31: Connecting Air Hose Adapters

    C o n n e c t i n g A i r H o s e A d a p t e r s Depending on the hopper you purchased you may need to install an air hose adapter to connect the hopper to your dryer. To connect the air hose adapter: Place a high temperature gasket approximately half way down from the end of the dry air delivery outlet.

  • Page 32: Connecting The Aftercooler And Optional Precooler

    The aftercooler and optional precooler require IMPORTANT: Do not move the 2 gals./min. {7.6 liters/min.} tower, city or Carousel Plus W series 15 -100 dryer chiller water and a discharge or return line. with the aftercooler and/or optional precooler water hoses attached. You...

  • Page 33: Mounting A Loader On The Hopper

    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 If you have a Conair loader or vacuum receiver, you can use the flange and mounting clips provided on the top of the hopper.
  • Page 34 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 ) Start Press the START button. NOTE: If the dryer is running for If everything is installed correctly: more than 20 to 30 seconds, the •...

  • Page 35: Using Communications

    U s i n g C o m m u n i c a t i o n s The DeviceNet cable feature is a standard feature on W 15 - 100 dryers with DC-2 controls. It allows the dryer to be connected your communications network. If the communications feature will NOT be used for your application, simply coil the cable to keep it out of the way.
  • Page 36 3 - 1 6 l I n s t a l l a t i o n...
  • Page 37 S E C T I O N O p e r a t i o n C a r o u s e l P l u s W S e r i e s D r y e r : c o n t r o l p a n e l D C - 2 .

  • Page 38: Carousel Plus W Series Dryer: Control Panel Dc-2

    C a r o u s e l P l u s W S e r i e s D r y e r : C o n t r o l Pa n e l D C - 2 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...

  • Page 39: Carousel Plus W Series Dryer Control Functions

    C a r o u s e l P l u s W S e r i e s D r y e r C o n t r o l 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 40 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 Central Dryer Act 140˚F Set 140˚F DM T6 TOP REGENERATION TEMP ACT 150˚F REGENERATION TEMP ACT 425˚F SET 425˚F ACT 350˚F 350˚F...
  • Page 41 DRYER MAIN MENU STAT SETUP DIAG DRYER STATUS PROC REGEN OTHER CENTRAL DRYER STANDARD DRYER DRYER REGEN DRYER PROCESS DRYER PROCESS DRYER OTHER STATUS SCREENS STATUS SCREENS STATUS SCREENS STATUS SCREENS RETURN AIR TEMP REGENERATION TEMP PROCESS TEMPERATURE MODEL CP150 ACT 120˚F SET 120˚F ACT 350˚F SET 350˚F...
  • Page 42 SCREEN # DRYER MAIN MENU STAT SETUP DIAG DRYER SETUP PROC ALM DISP OTHER SETUP PROCESS PROC REGN OTHER CENTRAL DRYER STANDARD DRYER AND MDC SETUP PROCESS SETUP PROCESS PROC RETPID PROC PROPID RETPID SETUP AFTERCOOLER SETUP PROCESS SETUP PROCESS HEATER SETUP AFTERCOOLER SETUP PROCESS on off VALUE SCREENS...
  • Page 43 DRYER MAIN MENU STAT SETUP DIAG DRYER SETUP PROC ALM DISP OTHER SETUP PROCESS PROC REGEN OTHER SETUP PROCESS SETUP REGENERATION REGEN OTHER SCREENS AUTOSTART TIMER ENABLED EDIT SETUP REGEN HEATER DISABLED SETUP REGENERATION PID VALUE SCREENS SCREENS MONDAY START TIME DRYER MAIN MENU 8:00 REGEN POWER LIMIT...
  • Page 44 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 45 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 46 Central When configured as a central dryer, there is no process heater in the system. Therefore, any function associated with the process heater is not available for central dryer configurations. 4 - 1 0 l O p e r a t i o n...
  • Page 47 SCREEN 1 Page 4-37 and under displayed for 3 seconds. It shows CONAIR D100 CONAIR and the dryer type on the first screen 85 on page 4-31. CV2.21.00 DV2.21.00 line, and the control program version and display program version on the second line.
  • Page 48 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 3 (Default Screen) SETUP, PROC, PROC, PROC, PROCESS...
  • Page 49 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 screen will show the actual dewpoint SCREEN 11 (Dewpoint Control...
  • 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 ) F u n c t i o n S c r e e n SCREEN 14 This is a column title screen.
  • 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 ) F u n c t i o n S c r e e n This screen shows the total run time in SCREEN 17...

  • Page 52: Control Function Descriptions

    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 measured current on SCREEN 22 (Current Monitor...
  • 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 26 This screen shows the setpoint the process...
  • 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 ) F u n c t i o n S c r e e n SCREEN 30 This screen shows the model number,...
  • Page 55 Setup on the Main PROC DISP OTHER Menu (screen 12). 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, Alarms, Display, or Other.
  • 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 ) F u n c t i o n S c r e e n Before running an autotune, set the set- SCREEN 40...
  • 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 NOTE: Screens 41, 42, 43, 44, 45, SCREEN 44...
  • Page 58 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 maximum value the SCREEN 50...
  • 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 56 This is the auto start screen for the first...
  • 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 This is the alarm action and setup screen.
  • 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 ) F u n c t i o n S c r e e n SCREEN 61 This is an example of an Alarm Setup...
  • 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 ) S c r e e n F u n c t i o n This screen shows the low CFM setpoint.
  • 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 SCREEN 70 This is the amount of time from start-up...
  • 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 the Dryer Setup Other screen.
  • 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 ) F u n c t i o n S c r e e n SCREEN 78 This screen further defines the dryer type...
  • 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 SCREEN 81 Communications This screen shows the communications...
  • 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 ) F u n c t i o n S c r e e n This screen shows the password entry SCREEN 85...
  • 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 This is the password logout screen.
  • 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 SCREEN 92 This is an example of one of the alarm his-...
  • Page 70 These values should not be changed except under the direction of Conair Engineering or Service. 4 - 3 4 l O p e r a t i o n...

  • Page 71: 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 72: 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 73: How To Use The Supervisor's Password

    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 74 H o w t o U s e t h e S u p e r v i s o r ’s Pa s s w o r d ( c o n t i n u e d ) This is the screen where you will need to enter the supervisor's password.

  • Page 75: Using The Auto Start Timer

    U s i n g t h e A u t o S t a r t Ti m e r You can set the dryer to start and stop automatically using the Auto Start and Auto Stop functions. The Supervisor Password is necessary to use this NOTE: To use the Auto function.

  • Page 76: Setting The High Setpoint Limits

    NOTE: Software may allow PROCESS TEMPERATURE the Process temperature RANGE 100 F - 450 F setpoint limit up to 450 ° however Conair does not recommend a setpoint limit The PROCESS TEMPERATURE RANGE screen shows the over 375 ° F {191 °...

  • Page 77: Using The Dewpoint Monitor And Dewpoint Control

    U s i n g t h e D e w p o i n t M o n i t o r a n d 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.

  • Page 78: Using The Setback Feature

    This is how setback operates when the control setback mode is set on Temperature. tral drying applications, the W Series Dryer does The control monitors the temperature of the air exiting the drying hopper. If that tempera- not have setback capabil- ture reaches a customer-entered setpoint (Screen 27), the delivery process air temperature ities.

  • Page 79: 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 80 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 81: 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 82 Routine maintenance will ensure optimum operation and performance of the W Series Dryer. We recommend the following maintenance schedule and tasks. • W h e n e v e r y o u c h a n g e m a t e r i a l s Ì...
  • Page 83 NOTE: Portable dewpoint a portable instrument periodically will confirm that the dewpoint sensor and monitors purchased from readout is performing properly. Conair are provided with a male connector that plugs into the To Check Dewpoint: dewpoint check port. If you...

  • Page 84: Checking The Dewpoint

    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 85: 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 86: 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. CA U T I O N : H o t S u r fa c e s .

  • Page 87: 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 88: 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 The aftercooler coils will need to be kept clean to keep the aftercooler working efficiently.

  • Page 89: 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 90 5 - 1 0 l M a i n t e n a n c e...

  • Page 91: Tr O U B L E S H O O T I N G

    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 92: Before Beginning

    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 NOTE: Use of test maintenance procedures outlined in this User Guide. If you do have a problem, mode screens 28-43 this section will help you determine what caused it and how to fix it.

  • Page 93: A Few Words Of Caution

    A Fe w Wo r d s o f C a u t i o n The Carousel Plus W Series Dryer is equipped with numerous safety devices. Do not remove or disable them. Improper corrective action can lead to hazardous conditions and should never be attempted to sustain production.
  • Page 94 Dryer alarms are indicated by an illuminated Acknowledge Alarm light on the Acknowledge Alarm button Carousel Plus W Series Dryer control panel. Shutdown alarms will sound the when there is no active alarm horn and turn on the alarm beacon.
  • Page 95 S h u t d o w n A l a r m s Central If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer will shut down automatically to prevent damage to the When supplied for central equipment or personnel.

  • Page 96: Shutdown Alarms

    S h u t d o w n A l a r m s Central If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer will shut down automatically to prevent damage to the When supplied for central equipment or personnel.
  • Page 97 S h u t d o w n A l a r m s If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer will shut down 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 98 S h u t d o w n A l a r m s Central If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer will shut down automatically to prevent damage to the When supplied for central equipment or personnel.
  • Page 99 S h u t d o w n A l a r m s Central If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer will shut down automatically to prevent damage to the When supplied for central equipment or personnel.
  • Page 100 S h u t d o w n A l a r m s If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer will shut down 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 101 S h u t d o w n A l a r m s If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer will shut down 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 102: Passive Alarms

    Pa s s i v e A l a r m s Central 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.
  • Page 103 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 104 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 105 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 106 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 107 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 108 A d d i t i o n a l A l a r m s Along with the alarm indicators, you may encounter additional messages that indicate a problem within the control. Problem Possible cause Solution The dryer will continue to run if there is Push the acknowledgement alarm button Control Not Ready, Please Check Alarm - Displayed...
  • Page 109 A d d i t i o n a l A l a r m s Along with the alarm indicators, you may encounter additional messages that indicate a problem within the control. Problem Possible cause Solution Er. Lo - There is a problem in Problem in the analog input section of Check that all jumpers are in their the sensor connection (RTD,...

  • Page 110: Dewpoint Troubleshooting

    If off-gassing is a drying temperature is too high for the condition of the material being grade of material being processed. processed, contact Conair Parts for the addition of a volitale trap. Analog option board/sensor malfunction Verify dryer dewpoint readings with a calibrated portable dewpoint meter.

  • Page 111: 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 112 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 113 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 114 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 115 -20 to -40° F {-29 to -40° C}. If your dryer does not From outside of the have a dewpoint readout, you can check the dewpoint with a portable dewpoint United States, call: instrument. Conair sells a variety of portable dewpoint meters. Contact Conair (814) 437 6861 Parts. Problem...

  • Page 116: 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 117: 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 Disconnect and lockout the main power supply. Open the electrical enclosure. Locate the process or regeneration relays.
  • Page 118 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 Carousel Plus W Series Dryer uses RTD sensors to monitor the temperatures of the drying air, the return air, the regeneration outlet, the regeneration inlet process protection and setback at the outlet of the hopper.

  • Page 119: 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 Stop the dryer, disconnect the power, and follow proper lockout procedures.
  • Page 120 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 ) Connect the wiring harnesses from the regeneration heater tube to the existing harnesses from the control box.

  • Page 121: 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 122 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 ) Connect the wiring harnesses from the process heater tube to the existing harnesses from the control box.
  • Page 123 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 desiccant wheel assembly to ensure optimum performance.
  • Page 124 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 M o t o r Stop the dryer, disconnect and lockout the main power. Remove the plastic cover from the dryer.

  • Page 125: Appendix

    Conair equipment may be ordered through the Customer Conair has made the largest investment in customer support in the plastics indus- Service or Parts Department for a try. Our service experts are available to help with any problem you might have nominal fee.

  • Page 126: 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 127: 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 The precooler coils will need to be kept clean to keep the precooler working efficiently. Cleaning frequency depends on the type and amount of material you process.
  • Page 128 C - 2 l A p p e n d i x...
  • Page 129 www.conairgroup.com Addendum Communication Protocols for Common Controls Modbus Communications, Ethernet Communications, DeviceNet Gateway Communications and SPI Communications...
  • Page 130 DISCLAIMER: The Conair Group, Inc., shall not be liable for errors contained in this User Guide or for incidental, consequential damages in connection with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information, including, but not limited to the implied warranties of merchantability and fitness for a particular purpose.
  • Page 131 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 132 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 133: 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 134: 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 page A-3 for the proper cabling and con- nection information for both types of interface.
  • Page 135 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 136 A - 4 l M o d b u s C o m m u n i c a t i o n s...

  • Page 137: 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 138: 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 139: 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 140 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 141 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 142: 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 143 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 144 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 145: 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 146: E D S Fi L E Pa R A M E T E R 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 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 147 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 148: Eds File Parameter List Configuration Options

    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 149: 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 150 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 151: 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 152: 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 153 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 154: Description Of Spi Communications

    9 pin D-sub connector. Refer to Conair drawing 130024 and 188629 in Appendix A page A-3 for details of the installation. The RS-485 SPI signal is available on pins 4 and 5 of the DB-9 con- nector.
  • Page 155 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 156 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 157 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 158 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 159 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 160 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 161: 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 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 162: 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 163: 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 164 A - 4 l A p p e n d i x...
  • Page 165 A p p e n d i x l A - 5...
  • Page 166 A - 6 l A p p e n d i x...
  • Page 167 A p p e n d i x l A - 7...

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