Conair 150, 200, 300, 400, Carousel Plus W150 User Manual

Carousel Plus Dryer

W Series Models 150, 200, 300 and 400 with DC-2 Controls

Corporate Office: 412.312.6000 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861

USER GUIDE

UGD025-0407

www.conairnet.com

INTRODUCTION • Purpose of the User Guide • How the guide is organized • Your responsibilities as a user • ATTENTION:

Read this so no one gets hurt • How to use the lockout device • DESCRIPTION • What is the W Dryer? • Typical

applications • How it works • Specifications: W Dryer • INSTALLATION • Unpacking the boxes • Preparing for instal-

lation • Mounting the dryer and hopper on a Processing Machine • Positioning the dryer on the floor; Mounting the hop-

per on the throat • Mounting the dryer on the floor stand; Hopper on the throat • Mounting the dryer and hopper on the

mobile floor stand • Connecting the main power • Checking for proper air flow • Connecting the air hose • Connecting

air hose adapters • Connecting water hoses • Connecting the RTD probe • Connecting the setback RTD • Mounting a

loader on the hopper • OPERATION • How it works • The W dryer control panel • W dryer control functions • Control

Function Description • To start drying • To stop drying • Using the auto start timer

Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.

It’s a good idea to record the model and serial number(s) of your equipment and
the date you received it in the User Guide. Our service department uses this infor­mation, along with the manual number, to provide help for the specific equipment
you installed.

Please keep this User Guide and all manuals, engineering prints and parts lists
together for documentation of your equipment.

Date:

Manual Number: UGD025-0407

Serial Number(s):

Model Number(s):

See Screens 31 and 32 for Software Version

*Display Firmware Version:

*Display Menu Version:

*Control Firmware Version:

* NOTE: Displayed upon initialization, during power up, or on a data tag

inside the door.

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.

Copyright 2007 l The Conair Group l All rights reserved

✐

Table of Contents

1-1 Introduction

Purpose of the user guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Using the Carousel Plus W Series as a central dryer . . . . . . . . . . . . 1-3

Your responsibilities as a user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

ATTENTION: Read this so no one gets hurt . . . . . . . . . . . . . . . . . . . 1-4

How to use the lockout device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2-1 Description

What is the Carousel Plus W Series Dryer? . . . . . . . . . . . . . . . . . . .2-2

Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Specifications: Carousel Plus W Series Dryer. . . . . . . . . . . . . . . . . . 2-6

Carousel Plus W Series Dryer options . . . . . . . . . . . . . . . . . . . . . . . 2-7

3-1 Installation

Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Positioning the dryer on the floor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Removing the cable tie from the desiccant wheel . . . . . . . . . . . . . . 3-5

Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Connecting the RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Connecting the setback RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Connecting the air hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Connecting the dryer to the hopper . . . . . . . . . . . . . . . . . . . . . . . 3-11

Connecting air hose adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Table of Contents l i

Connecting the aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Mounting a loader on the hopper . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Using communications (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

4-1 Operation

The W Series Dryer: control panel DC-2 . . . . . . . . . . . . . . . . . . . . . 4-2

W Series Dryer control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Control function flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

How to navigate the menu tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Control function descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

To start drying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

To stop drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

How to use the supervisor’s password . . . . . . . . . . . . . . . . . . . . . 4-39

Using the auto start timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Setting high setpoint limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Using dewpoint control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Using the setback function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Setback feature guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

5-1 Maintenance

Preventative maintenance checklist . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Checking dewpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Cleaning the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Cleaning the process filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Cleaning the regeneration filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Cleaning the aftercooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Cleaning the volatile trap on the demister . . . . . . . . . . . . . . . . . . . 5-12

Inspecting hoses and gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

ii l Table of Contents

6-1 Troubleshooting

Before beginning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

DIAGNOSTICS

How to identify the cause of a problem . . . . . . . . . . . . . . . . . . . . . 6-4

Shut down alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Passive alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Dewpoint troubleshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Poor material drying troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 6-24

REPAIR

Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Checking heater solid state relays. . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Checking or replacing temperature sensors . . . . . . . . . . . . . . . . . 6-31

Replacing the heaters

Regeneration heater tube . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

Process heater tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

Replacing the desiccant wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

Replacing the desiccant wheel motor . . . . . . . . . . . . . . . . . . . . . . 6-37

A Appendix

We’re here to help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

How to contact customer service . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Before you call... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Equipment guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Performance warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Warranty limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

B Appendix

Installing a precooler (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Table of Contents l iii

C Appendix

Cleaning the aftercooler and precooler coils . . . . . . . . . . . . . . . . . . C-1

D Appendix

Cleaning the Volatile Trap on the Demister . . . . . . . . . D-1

Addendum

Communication protocols for common controls - DC-2

iv l Table of Contents

Introduction

Purpose of the user guide. . . . . . . . . . . . . . 1-2

How the guide is organized . . . . . . . . . . . . . 1-2

Using the Carousel Plus W Series

as a central dryer . . . . . . . . . . . . . . . . 1-3

Your responsibilities as a user. . . . . . . . . . . 1-3

ATTENTION:

Read this so no one gets hurt . . . . . . . . 1-4

How to use the lockout device. . . . . . . . . . . 1-6

SECTION

1

Introduction l 1-1

1

Introduction

✐

Purpose of the User Guide

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.

Before installing this product, please take a few moments to read the User
Guide and review the diagrams and safety information in the instruction
packet. You also should review manuals covering associated equipment in
your system. This review won’t take long, and it could save you valuable
installation and operating time later.

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 the operation of this equipment.

Indicates a note. A note is used to provide additional information about the steps
you are following throughout the manual.

1

◆

❒

•

✒

1-2 l Introduction

Introduction l 1-3

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.

Your Responsibility as a User

You must be familiar with all safety procedures concerning installation, opera­tion and maintenance of this equipment. Responsible safety procedures include:

•

Thorough review of this User Guide, paying particular attention
to hazard warnings, appendices and related diagrams.

• Thorough review of the equipment itself, with careful attention

to voltage sources, intended use and warning labels.

• Thorough review of instruction manuals for associated equipment.

• Step-by-step adherence to instructions outlined in this User Guide.

This box will contain information or highlight system differ­ences particular to the application of the W series dryer as a
central dryer.

1

Introduction

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.

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 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 machine serial tag and data
plate.

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 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 l Introduction

(continued)

1

Introduction

Introduction l 1-5

ATTENTION:
Read this so no one gets hurt

(continued)

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.

CAUTION: Hot Surfaces.

Always protect yourself from hot surfaces inside the dryer and hopper.
Also exercise caution around exterior surfaces that may become hot
during use. These include the hopper door frame, the exterior of an
uninsulated hopper, the return air hose and the dryer’s process filter
housing and moisture exhaust outlet.

WARNING: Do not place aerosol, compressed
gas or flammable materials on or near this
equipment.

The hot temperatures associated with the drying process may cause
aerosols or other flammable materials placed on the dryer or hopper to
explode.

1-6 l Introduction

How to Use the Lockout Device

CAUTION: Before performing maintenance or repairs on this product, you

should disconnect and lockout electrical power sources to prevent injury
from unexpected energization or start-up. A lockable device has been
provided to isolate this product from potentially hazardous electricity.

Lockout is the preferred method of isolating machines or equipment from energy
sources. Your Conair product is equipped with the lockout device pictured below.
To use the lockout device:

11

Stop or turn off the equipment.

22

Isolate the equipment from the electric power. Turn the rotary

disconnect switch to the OFF, or “O” position.

33

Secure the device with an assigned lock or tag. Insert a lock or tag

in the holes to prevent movement.

44

The equipment is now locked out.

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 removed, and all safety guards reinstalled.

To restore power to the dryer, turn the rotary disconnect back to the ON position:

11

Remove the lock or tag.

22

Turn the rotary disconnect switch to the ON or “I” position.

Description l 2-1

Description

What is the Carousel Plus W Series Dryer? . . 2-2

Typical applications. . . . . . . . . . . . . . . . . . 2-2

How it works . . . . . . . . . . . . . . . . . . . . . . 2-4

Specifications: Carousel Plus W Series

Dryer . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Carousel Plus W Series Dryer options . . . . . . 2-7

SECTION

2

2

Description

Description l 2-1

What is the Carousel Plus W Series
Dryer?

The Carousel Plus W Series dehumidifying dryer produces hot, low-dewpoint air
that removes moisture from hygroscopic plastics. The dryer pulls warm, moist air
from a drying hopper and circulates it through a dehumidifying desiccant wheel.
The dryer then heats the air to the drying temperature you selected and circulates it
through the material in the hopper.

The dryer’s closed-loop design ensures a continuous supply of hot, dehumidified
air while preventing contamination from moisture in the plant.

Typical Applications

1 Dryer on the floor; hopper on the throat.

2 Hopper on a floor stand; the dryer next to it.

3 Dryer and hopper on a mobile floor stand (MDC version 150 and 200 only).

4 Central dryer, with ResinWorks system.

The W Series Dryer can be used successfully in applications that require:

• A contamination-free drying environment.

• Drying temperatures within the ranges shown in the following table:

2-2 l Description

(continued)

Description l 2-3

2

Description

Typical Applications (continued)

Model Drying Temperature Range

Low temperature (with precooler)* 100° - 150°F {38° - 66°C}

Standard 150° - 240°F {66° - 116°C}

High heat (with aftercooler)* 150° - 375°F {66° - 191°C}

Low-high (with aftercooler & precooler)* 100° - 375°F {38° - 191°C}

* See page 3-13 and Appendix B and C.

• Throughput rates of 150 to 400 lbs {68.1 to 149.2 kg} per hour (some

materials can be run at a higher rate).

• Dewpoints of -40°F {-40°C}.

Use the aftercooler when:

• You are drying at temperatures over 240°F {116°C}.

• Throughput rates are less than 50% of the dryer’s rated capacity.

• You are pre-drying material at temperatures over 150°F {66°C}

Standard Dryer Features

• Dewpoint monitor / dewpoint control

• Audible and visual alarm

• Temperature setback

MDC Options (models 150 & 200 only)

• Non dry air conveying

• Machine loading only

• Self loading (machine and hopper loading)

When supplied for
central drying appli­cations, the W series
dryer is not equipped
with a process heater.
Therefore, as a cen­tral dryer, the W
dryer will only sup­ply dry air to the hop­pers.

THE

PROCESS (D

RYING) C

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. 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.

How It Works

The W dryer achieves continuous, closed loop drying by passing air simultaneous­ly through two heaters and a continuously rotating desiccant wheel.

THE PROCESS (DRYING) CYCLE

The process blower pulls moist air from the top of the drying hopper. The air
passes through the process filter and aftercooler into the desiccant wheel, where
moisture is removed. The now dry air moves through the optional precooler (if
installed) and process heater, where it is heated to the drying temperature selected
by the operator. The hot, dry air is delivered to the hopper where a spreader cone
evenly distributes the air through the material.

The Cooling Cycle

Regenerated desiccant must be cooled before it rotates back into the process cycle.
The process blower pushes a small amount of air through the cooling section of the
desiccant wheel. The cooling air then passes through the aftercooler and repeats
the circuit.

The Regeneration Cycle

The regeneration blower pulls air through the regeneration filter into the dryer’s
regeneration heater. The air is heated to 350° F {177° C} before it is pushed into
the “wet” section of the wheel. The hot air purges moisture from the desiccant. The
moist air is blown out the exhaust at the back of the dryer.

2-4 l Description

REGENERATION

AIR FILTER

DESICCANT

WHEEL

REGENERATION

BLOWER

REGENERATION

HEATER

HIGH TEMP

SHUTOFF

REGENERATION

RTD

HOPPER

PROCESS

BLOWER

RETURN

AIR

FILTER

4 PROCESS FILTER STATUS

RETURN

AIR

RTD

PROCESS

RTD

2 SETBACK TEMPERATURE

*

HIGH TEMP

SHUTOFF

PROCESS

HEATER BOX

7 PRECOOLER

7

DRYER OPTIONS

3 DEWPOINT MONITOR / CONTROL

*

PROCESS

COOLING

REGENERATION

2

3

4

PROCESS

PROTECTION

RTD

REGENERATION

OUTLET

RTD

6

6 PHASE ROTATION PROTECTION

*

Standard on DC-2

AFTERCOOLER

ALARM LIGHT

ALARM BELL

5 CURRENT METER

5

5

1 PROCESS CFM MONITOR

1

2

Description

How It Works (continued)

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.

Description l 2-5

2-6 l Description

Specifications: Carousel Plus W
Series Dryers

MODEL W150 W200 W300 W400
Performance characteristics (with full hopper)

Air flow {SCFM}

*

75 100 150 200

Air flow {ACFM @ 250°F}

*

101 134 201 268

Drying temperature All models 100 - 375

°

F {38 - 191°C} with options

dewpoint All models -40°F {-40°C}

Dimensions inches {cm}

A - Height 70.4 {178.8}
B - Overall width 29 {73.7}
C - Control width 24 {61.0}
D - Depth 51.5 {130.8}
Control depth 8 {20.3}
Outlet/inlet tube size OD 2.5 5 5 5

Weight lbs {kg}

Standard Dryer Installed 600 {272} 660 {300} 710 {322} 760 {345}

Voltage - Total Amps

230 V/3 phase/60 Hz 47.1 61.4 67 N/A
400 V/3 phase/50 Hz 25.8 34 38.5 63.6
460 V/3 phase/60 Hz 23.6 30.7 33.5 55.3
575 V/3 phase/60 Hz 18.9 24.7 26.8 44.3

Total kilowatts kW {BTU/min} 6.2 {353} 8 {455} 11 {625} 14 {800}
Water requirements {for optional aftercooler or precooler}

Recommended temperature* 45

°

- 85°F

Water flow gal./min. {liters/min.} 3 {11.4}
Water connections NPT 3/4 in. NPT

SPECIFICATION NOTES:

* The term SCFM stands for Standard Cubic Feet Per Minute, referenced to a pre-specified pressure, tempera-

ture and relative humidity. In most cases, SCFM is referenced to 14.7 PSIA 68° F and 36% 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.

† Dryers running at 50 HZ will have 17% less airflow, and a 17% reduction in material throughput.

Specifications may change without notice. Consult a Conair representative for the most current information.

D

A

C
B

TPDS018-0705-REV

Carousel Plus W Series Dryer
Options

• Volatile trap (only in conjunction with aftercooler) - The volatile trap is

recommended if drying materials that produce volitales that condense into a
waxy or oily residue and/or if the material contains excessive fines.

• Precooler - The precooler reduces the temperature of air flow after the desic-

cant wheel and before the process heater.

• Filter check - The Filter check sensor will activate a passive alarm when the

process filter is clogged or needs to be replaced.

• Heater current monitor - The heater current monitor measures the total

amperage across both the process and regeneration heaters and the pre-deter­mined power consumption values for the blowers and the control.

• CFM monitor - The CFM monitor measures the cubic feet per minute of air

flow across the inlet/outlet of the process blower.

• DeviceNet or SPI communications - Allows the dryer to be networked to

industrial control systems. DeviceNet communications are standard. Alternate
communications are available.

2

Description

Description l 2-7

2-8 l Description

Installation l 3-1

Installation

Unpacking the boxes . . . . . . . . . . . . . . . . . 3-2

Preparing for installation . . . . . . . . . . . . . . 3-4

Positioning the dryer on the floor. . . . . . . . . 3-5

Removing the cable tie from the

desiccant wheel . . . . . . . . . . . . . . . . . . . . 3-5

Connecting the main power . . . . . . . . . . . . . 3-6

Connecting the process RTD probe . . . . . . . . 3-7

Connecting the setback RTD probe . . . . . . . . 3-7

Checking for proper air flow . . . . . . . . . . . . 3-8

Connecting the air hoses . . . . . . . . . . . . . 3-11

Connecting dryer to hopper . . . . . . . . . . . . 3-11

Connecting air hoses adapters . . . . . . . . . . 3-12

Connecting the aftercooler . . . . . . . . . . . . 3-13

Mounting a loader on the hopper . . . . . . . . 3-14

Testing the installation . . . . . . . . . . . . . . . 3-14

Using communications . . . . . . . . . . . . . . . 3-16

SECTION

3

3

Installation

3-2 l Installation

Unpacking the Boxes

The Carousel Plus W series dryer comes in one to four boxes, depending on the
model and options ordered. The boxes could include (depending on the options
selected):

• Carousel Plus W series dryer

• Delivery air hose - 10 ft {3.05 m} - Insulated with High Heat option.

• Return air hose - 10 ft {3.05 m}

• Process RTD

• Setback RTD

• User manual

1 Carefully remove the dryer and components from their shipping containers.

Note that the dryer is secured to its shipping container with straps that pass
through the bottom of the dryer frame.

2 Remove all packing material, protective paper, tape, and plastic.

3 Open the side panel and remove the cable tie securing the desiccant wheel.

See Installation section entitled, Removing the cable tie from the desiccant
wheel.

4 Carefully inspect all components to make sure no damage occurred during

shipping, and that you have all the necessary hardware.

Installation l 3-3

Unpacking the Boxes (continued)

5 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.

6 You are now ready to begin installation.

Follow the preparation steps on the next page, then choose one of the four
mounting options:

• Dryer on the floor; hopper on a floor stand (see page 3-5).

• Dryer on the floor; hopper machine mounted

• Dryer and hopper on a mobile floor stand. Models W150 - W200 only.

• Central dryer, with ResinWorks system.

3

Installation

✐

NOTE: Conair also sells an MDC (dryer and hopper on a mobile floor stand with convey-

ing capabilities) version of this dryer in the 150 and 200 Models. Contact Conair Sales

for additional information.

Preparing for Installation

The Carousel Plus W Series Dryer is easy to install if you plan the location and
prepare the mounting area properly.

1 Make sure the mounting area provides:

❒❒

A grounded power source supplying the voltage and 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.

❒❒

A source of water, if you have an aftercooler and/or optional

precooler. The W dryer’s aftercooler and optional precooler require 3

gals./min. {11.4 liters/min.} tower, city, or chiller water at temperatures of
45° to 85°F {7° to 29°C}. Pipe should be run to the planned dryer location.
Use flexible hose to connect the water pipes to the aftercooler and/or optional
precooler.

❒❒

Minimum clearance for safe operation and maintenance.

You should maintain 24 in. {61 cm} clearance on all sides of the dryer.

3-4 l Installation

Material and conveying lines

installed. If you plan to use

vacuum or compressed air

loaders to fill the hopper,

install conveying lines to the

drying hopper location.

✒

Positioning the Dryer on the Floor

1 Lift the dryer from the shipping container using a fork truck.

2 Position the dryer on the floor near the processing machine. Make sure the

location allows for the connection of all hoses.

Removing the Cable Tie from the
Desiccant Wheel

1 Open the dryer side panels and remove the cable tie securing the desiccant

wheel, if it was not done while unpacking the dryer.

3

Installation

Installation l 3-5

Desiccant cable tie

3-6 l Installation

3

Connect the power wires

to the three terminals at the top of the power disconnect.

4 Connect the ground wire to the ground lug as shown in the photo.

Connecting the Main Power

CAUTION: Always disconnect and lock out the main power sources before making

electrical connections. Electrical connections should be made only by qualified personnel.

1 Open the dryer’s electrical enclosure. Turn the discon-

nect dial on the dryer door to the Off or “O” position.
Lock out the main power (see Page 1-6 for complete
lock out information). Turn the captive screw, and
swing the door open.

2

Insert the main power

wire through the knockout in the

side of the enclosure or the rear of the dryer. ( The
dryer’s electrical wire connection location was a factory
option and may be connected through the front or the
rear of the dryer.) Secure the wire with an appropriate
strain relief.

IMPORTANT: Always refer to the
wiring diagrams that came with
your dryer before making electrical
connections.

3

Installation

Installation l 3-7

Connecting the Process RTD Probe

The process 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 cen­ter of the tube. Tighten the compression fit­ting to lock the probe in place.

2 Plug the probe’s

cable into the
receptacle
labeled process
on the left side of
the electrical
enclosure. Hand

tighten the con­nector. Coil any
excess cable and
secure it with a
wire tie.

Connecting the 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 compression fitting to lock
the probe in place.

2 Plug the probe’s cable into the receptacle labeled setback on the left side of

the electrical enclosure. Hand tighten the connector. Coil any excess cable
and secure it with a wire tie.

Process RTD

Setback RTD

When configured as
a central dryer, moni­toring the drying air
temperature is not
necessary since there
is no process heater
in the system.
Therefore, installa­tion and connection
of the RTD probe
and/or setback probe
is not applicable.

Checking for Proper Air Flow

This procedure is needed on W 150 - 400 models if the phase detection option was
not ordered with the dryer.

CAUTION: 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 to this equipment.

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 illu­minate.

2 Select the setpoint temperature by pressing the select category button

under the setpoint temperature display. Once selected, the number will
flash.

3 Set the drying temperature. Press Setpoint Adjust (+) or (-) buttons or enter a

low temperature (150ºF {66ºC}) on the numeric keypad and press enter.

3-8 l Installation

When configured as a central dryer, the drying temperature can
not be set since there is no process heater in the system.

Select Category
Buttons

IMPORTANT: This procedure must be performed before the dryer’s air hoses are connect­ed to the hopper or before loading material into the hopper.

Setpoint adjustment

Installation l 3-9

Checking for Proper Air Flow (continued)

4 Press the START button. Hold your hand near the delivery air

outlet. You should feel air blowing out of the outlet.

CAUTION: Hot surface Do not place your hand directly on the delivery air outlet.
The outlet and the air can get hot enough to burn your hand.

5 Press the STOP button.

6 If air flow is incorrect disconnect power, follow proper lockout procedures and

swap any 2 of the 3 main power wires.

WARNING: All wiring, disconnects, and fuses should be installed by quali­fied electrical technicians in accordance with electrical codes in your
region. Always maintain a safe ground. Do not operate the equipment at
power levels other than what is specified on the machine serial tag and
data plate.

Start

Stop

Moisture
Exhaust

Return
Air Inlet

Dry Delivery
Air

✐

NOTE: If the dryer is running for

more than 20 to 30 seconds, the

Process Loop Break alarm may

occur because the Process RTD is

not seeing the expected tempera-

ture rise.

3

Installation

Checking for Proper Air Flow (continued)

INSTALLATION NOTE: Models 150, 200, 300, and 400

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 or check the Process RTD for proper installation.

If the air flow is reversed, the process blower is turning in the wrong direc-

tion. 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 machine serial
tag and data plate.

3-10 l Installation

✐

LEADS

Installation l 3-11

Connecting the Air Hoses

Using the two flexible hoses provided, connect the inlets and outlets of the dry­ing hopper to the dryer. If you have positioned the dryer on the floor or mount­ed it to an optional floor stand, make sure the dryer is located as close as possi­ble to the hopper to reduce heat loss. (10 ft {3.05 m} of hose supplied)

NOTE: If you have ordered an insulated hose, it should be installed between the dryer

outlet and the hopper inlet, see step 2.

1 Attach one hose from the return

air inlet of the dryer to the return
air outlet from the top of the hop­per.

2 Attach one hose from the deliv-

ery air outlet of the dryer to the
delivery air inlet of the hopper.

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 Dryer to the Hopper

W 150 has a 2 1/2 inch {63.5 mm} inlet and outlet hose connections.
W 200, W 300 and W 400 have a 5 inch {127 mm} inlet and outlet hose connec­tions.

If your dryer hose connection and your hopper hose connection are not the same
size, you will need a hose adapter. Contact Conair Parts 1-800-458-1960.

NOTE: Do not allow the

flexible hoses to kink or

crimp.

✐

Return
Air Inlet

NOTE: Water to cooler

should be turned off

when the dryer is not

running to prevent

condensation

.

✐

Dry
Delivery
Air

3

Installation

✐

Connecting Air Hose Adapters

Depending on the hopper you purchased you may need to install an air hose
adapter to connect the hopper to your dryer.

To connect the air hose adapter:

1 Place high temperature gasket half way down over the dryer outlet to the

hopper.

2 Place hose adapter inside high temperature gasket flush to the dryer outlet,

secure with pressure clamp.

3 Attach the hopper inlet hose over the adapter, secure with clamp.

3-12 l Installation

Pressure clamp

3

Installation

Installation l 3-13

Connecting the Aftercooler (Optional)

The aftercooler and optional precooler require a source of city, tower, or chiller
water and a discharge or return line. You can use water at temperatures of 45 to
85°F {7 to 29°C}. But the water flow should be at least 3 gal/min {11.4
liters/min}. See Appendix B for installation and water connection instructions for
the optional precooler.

1 Secure the aftercooler assembly in the

aftercooler housing using the six screws.

2 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.

3 Connect the water discharge or return

line to the aftercooler outlet.

IMPORTANT: Turn the water off when the dryer is not in use to prevent
condensation.

✒

TIP: Make the water supply and dis-

charge / return connections with

flexible hoses at least 24 in.

{61 cm} long. This allows you to

easily remove the aftercooler

assembly for cleaning.

✒

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.

Aftercooler

3-14 l Installation

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.

1 Make sure there is no material in the hopper. If you

have mounted a loader or vacuum receiver on the hop­per, disconnect the material inlet hose at the source or
turn the loader off.

2 Turn on the main power to the dryer. Make sure the

dryer’s disconnect dial is in the ON position. This pow­ers up the control and the display lights will illuminate.

3 Set the drying temperatures. Press temperature select

with the select category button, and then press the
Setpoint Adjust (+) or (-) buttons or enter the low setpoint temperature (150ºF
{66ºC}) on the numeric keypad and press enter.

(continued)

When configured
as a central dryer,
the drying temper­ature can not be
set since there is
no process heater
in the system.

Select Category Buttons

Setpoint adjustment Buttons

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 and the display LEDS

will illuminate.

• The process and regeneration heaters turn on and the display LEDs will

illuminate.

• The desiccant wheel starts turning.

5 Press the STOP button.

If everything is installed correctly:

• The blowers will continue running as needed to cool the heaters (until

both heaters are less than 150°F {66ºC}) or ten minutes, whichever is
shorter.

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.

Stop

Start

• The green light on the start button will illuminate.

• The process and regeneration blowers turn on and the dis-

play LEDS will illuminate.

• The regeneration heater turns on and the display LED will

illuminate.

• The desiccant wheel starts turning.

IMPORTANT: Be sure the cable tie

has been removed from the desic-

cant wheel.

NOTE: If the Process Loop

Break alarm occurs, the blow-

er rotation may be incorrect

(see Page 3-8) or the Process

RTD may be installed incor-

rectly (see Page 3-7).

✐

3

Installation

Installation l 3-15

3-16 l Installation

Using Communications (Optional)

To use the optional Modbus, Ethernet, SPI or standard DeviceNet communica­tions, see the Addendum for hardware installation and configuration.

DeviceNet connection

SPI connection

✐

NOTE: These communications can be left disconnected, if not in use.

Ethernet connection

SECTION

4

4

Operation

Operation

Carousel Plus W series dryer:

control panel DC-2 . . . . . . . . . . . . . . . 4-2

Carousel Plus W series dryer

control functions . . . . . . . . . . . . . . . . 4-3

Control function flow charts . . . . . . . . . . . . 4-3

How to navigate the menu tree . . . . . . . . . . 4-3

Control function descriptions . . . . . . . . . . . 4-11

To start drying . . . . . . . . . . . . . . . . . . . . 4-37

To stop drying . . . . . . . . . . . . . . . . . . . . . 4-38

How to use the supervisor’s password. . . . . 4-39

Using the auto start timer . . . . . . . . . . . . . 4-41

Setting the high setpoint limit . . . . . . . . . . 4-42

Using dewpoint control . . . . . . . . . . . . . . . 4-43

Using the setback function . . . . . . . . . . . . 4-44

Setback feature guidelines . . . . . . . . . . . . 4-45

Operation l 4-1

4-2 l Operation

Carousel Plus W Series Dryer

: Control Panel DC-2

Start and Stop Buttons

Press Start to start the dryer.
Press Stop to stop the dryer.

Acknowledge
Alarm Button

Press once to
silence the option­al audible alarm
and display alarm
messages. Press
again to clear the
alarm.

Status
Display

Alpha-numeric
characters dis­play process
and alarm con­ditions.

Dryer
Status

Illuminated
lights show
the status of
the dryer.

Enter Button

Used to lock-in
data entries.

Menu Button

Press to view the main menu screen where you can
select on screen categories or press again to return
to the default screen where process temperature and
actual setpoint are displayed. This button can be
pressed at any time to return to the default screen.

Screen Title

Alpha-numeric characters
display process and alarm
conditions.

Scroll Buttons

Press to scroll through the closed loop parameter
list. The “Prev” button scrolls the user up the
list, while the “Next” button scrolls the user
down the list to the last screen and then back to
the parameter list title screen at the top.

Select
Category

Press to select on­screen categories,
paths and options.

Clear Button

Press to clear high­lighted on-screen
data entry fields,
only after data has
been entered.
The clear button
clears the field one
number at a time.

NOTE: When changing a setpoint use the Select Category

Key directly below the value to be changed. Once

pressed the value will blink, then use the keypads or (+)

(-) adjustment setpoints to enter the new value. Then

press enter for the new value to be recognized.

✐

Increment/
Decrement

Buttons

Used to increase
or decrease val­ues.

Numeric
Keypad

Press numbers to
enter data.

Carousel Plus W Series Dryer
Control Functions

Dryer functions are values that you can set or monitor in the Screen Title and
Status Display windows. Press the Menu button then the Scroll List “Next” or
“Prev” buttons until the function you want to set or monitor appears in the Screen
Title window.

Control Function Flow Charts

The charts beginning on page 4-4 provide a quick summary of the control func­tions. For an explanation of each control function, see Control Function
Descriptions (page 4-11). The screen numbers correspond with the numbers
beside each block in the flow chart.

NOTE: In the flow charts of the display screens that follow this page, the grey shaded

screens denote optional functions. If the options were not purchased with the dryer,

those screens will not appear. Most options can be purchased and installed in the field.

How to Navigate the Menu Tree

To scroll through main menu, use scroll buttons (“Next”, “Previous”). Push
“Menu” to access Dryer Main Menu . To access the Status, Setup, Diagnostic and

Password screens, use the select category buttons under the digital read-out and
then the scroll buttons (“Next”, “Previous”) to scroll through the parameter lists.

Operation l 4-3

4

Operation

✐

Scroll Buttons

Select Category Buttons

Menu Button

REGENERATION TEMP

ACT 425˚F SET 425˚F

RETURN AIR TEMP
ACT 120˚F SET 120˚F

PROCESS DEWPOINT
ACT -47˚F SET -40˚F

POWER ON

CONAIR CP100

CV00.06.2 DV00.09.8

3 SEC DELAY

MONDAY

7/22/2003 07:59 AM

3 SEC DELAY

PROCESS TEMPERATURE
Act 140˚F Set 140˚F

REGENERATION TEMP

ACT 350˚F SET 350˚F

RETURN AIR TEMP
ACT 120˚F SET 120˚F

MACHINE LOADER
LOAD TIME 10 SEC

HOPPER LOADER
LOAD TIME

10 SEC

PRESS MENU KEY
AT ANY TIME

DRYER MAIN MENU
STAT SETUP DIAG

Central Dryer

STD DRYER

1

2

3

4

5

MDC HOPPER LOADER

PROCESS DEWPOINT

ACT -47˚F SET -40˚F

6

7

11

12

4

5

11

MACHINE LOADER
LOAD TIME 10 SEC

MDC

6

PRESS
MENU
KEY

PRESS
MENU
KEY

MDC HOPPER LOADER AND RATIO

6

8

9

10

MACHINE LOADER
LOAD TIME 10 SEC

HOPPER LDR VIRGIN
LOAD TIME 20 SEC

HOPPER LDR REGRIND
LOAD TIME 20 SEC

HOPPER LOADER
LAYERING ON

DM T6 TOP
ACT 150˚F

DM T5
ACT 155˚F

DM T4
ACT 158˚F

DM T3
ACT 160˚F

DM T2
ACT 163˚F

DM T1 BOTTOM
ACT 165˚F

103

104

105

106

107

108

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.

4-4 l Operation

NOTE: If you have purchased the DM-II (drying monitor)

option, see the DM-II Appendix for information pertaining

to its operation.

✐

When the DM-II monitor option is purchased
these screens will be displayed.

4

Operation

DRYER MAIN MENU
STAT SETUP DIAG

DRYER STATUS

PROC REGEN OTHER

STANDARD DRYER / MDC

DRYER REGEN
STATUS SCREENS

DRYER PROCESS
STATUS SCREENS

REGENERATION TEMP
ACT 350˚F SET 350˚F

PROCESS TEMPERATURE
ACT 325˚F SET 325˚F

REGEN HEATER
OUTPUT 68%

RETURN AIR TEMP
ACT 120˚F SET 120˚F

REGEN CURRENT

14.3A 14.4A 14.2A

PROCESS HEATER
OUTPUT 100%

REGEN POWER
20 KWH

TOTAL RUN HOURS

1250

CONVEYING BLOWER
OFF

MACHINE LOADER
LOAD TIME 10 SEC

LOADER DELAY
TIME 5 SEC

PROCESS CFM 1600

AFTERCOOLER
ENABLED
DISABLED
AFTERCOOLER
FLOW OFF
FLOW ON
PRECOOLER
Disabled
Enabled
Automatic
PRECOOLER
FLOW OFF
FLOW ON
PROCESS CURRENTS

84.3A 84.4A 84.2A

TOTAL POWER
80 KWH

PROCESS DEWPOINT
ACT -47

˚

F SET -40˚F

PROCESS DEWPOINT
AVERAGE -55

˚

F

SETBACK MODE
OFF
TEMPERATURE
MANUAL ON

SETBACK TEMPERATURE
ACT 100˚ SET 140˚F

SETBACK RETURN TEMP
ACT 100˚F SET 140˚F

SETBACK TEMP BAND
SET 20˚F

DRYER OTHER
STATUS SCREENS

MODEL CP150
480 V 60 HZ

DISPLAY FIRM V2.21.00
DISPLAY MENU V2.21.00

CONTROL FIRMWARE
VERSION V02.21.00

AUTOSTART COUNT DOWN

1 DAYS 23:05:53

AUTOSTOP COUNT DOWN

3 DAYS 11:04:23

PANEL INSIDE TEMP
ACT 100˚F

CENTRAL DRYER

DRYER PROCESS
STATUS SCREENS

RETURN AIR TEMP
ACT 120˚F SET 120˚F

TOTAL RUN HOURS

1250

PROCESS CFM 1600

AFTERCOOLER
ENABLED
DISABLED
AFTERCOOLER
FLOW OFF
FLOW ON

PROCESS PROTECTION
ACT 350˚F

TOTAL POWER
80 KWH

PROCESS DEWPOINT
ACT -47

˚F SET -100˚F

PROCESS DEWPOINT
AVERAGE -55

˚F

REGEN OUTLET TEMP
ACT 280

12

13

14

5

17

20

21

21

23

11

24

14

3

5

15

16

17

18

6

19

20

21

21

RUNNING

28

27

26

25

24

11

23

22

21

21

HOPPER LOADER
LOAD TIME 10 SEC

HOPPER LDR VIRGIN

HOPPER LDR REGRIND
LOAD TIME 20 SEC

7

8

9

HOPPER LOADER
LAYERING

10

LOAD TIME 20 SEC

14

4

29

15

22

23

30

14

31

32

33

34

35

DM T6 TOP
ACT 150˚F

DM T5
ACT 155˚F

35a

35b

DM T4
ACT 158

˚F

DM T3
ACT 160˚F

35c

35d

DM T2
ACT 163

˚F

DM T1 BOTTOM
ACT 165˚F

35e

35f

DM PROCESS SETPOINT

SET 225˚F

DM LO ALARM SELECT
TEMPERATURE T4

35g

35h

DM LO ALARM SETPOINT

SET 150

˚F

DM LO ALARM OFFSET

SET 10˚F

35i

35j

DM LO ALARM BAND

SET 40˚F

DM LO ALARM DELAY

SET 5 MIN

35k

35l

DM LO ALARM SETPOINT
HIGH LIMIT 170˚F

DM LO ALARM SETPOINT
LOW LIMIT 130˚F

35m

35n

DM TEMP NOT MET
ALARM TIME SET 4 HRS.

DM HI ALARM SELECT
TEMPERATURE T1

35o

35p

DM HI ALARM SETPOINT

SET 190˚F

DM HI ALARM DELAY

SET 5 MIN

35q

35r

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.

Operation l 4-5

When the DM-II monitor option is purchased
these screens will be displayed.

SCREEN #

12

DRYER MAIN MENU
STAT SETUP DIAG

36

DRYER SETUP
PROC ALM DISP OTHER

37

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

ACT 325˚F SET 325˚F LOW 0% HIGH 100% COOL 20 SECONDS

PROCESS TEMPERATURE PROCESS CYCLE TIME RET AIR CALIBRATION

RANGE

100˚F - 450˚F

HEAT 2.0 SECONDS OFFSET 0˚F

PROCESS PID DONE

PROCESS CYCLE TIME

AUTOTUNE OFF

PRECOOLER 20 SECS

RETURN AIR TEMP

PROCESS PROP BAND

ACT 120˚F SET 120˚F

HEAT/COOL 30˚F

MACHINE LOADER
LOAD TIME 10 SEC

HOPPER LOADER

PROCESS INTERGAL

LOAD TIME 10 SEC

HEAT/COOL 16.0

LOADER DELAY
TIME 5 SEC

PROCESS DERIVATIVE

HEAT/COOL 2.0

PROC PID RESET

HEAT/COOL

PROCESS CALIBRATION
OFFSET 0˚F

CENTRAL DRYER

SETUP PROCESS
PROC RETPID

SETUP PROCESS

SETUP AFTERCOOLER

SCREENS

on off VALUE SCREENS

RET AIR CYCLE TIME

COOL 20 SECONDS

RET AIR CALIBRATION

OFFSET 2

˚F

RETURN AIR TEMP

ACT 120˚F SET 120˚F

AFTERCOOLER
Enabled Edit
Disabled

PROCESS DEWPOINT
ACT -47˚F SET-40˚F

BAND RATIO

PRECOOLER 1

38

38

14

5

21

11

14

42

47

14

3

39

40

5

6

7

19

AFTERCOOLER
Enabled Edit

PRECOOLER
Disabled Edit

PROCESS DEWPOINT
ACT -47˚F SET -40˚F

SETBACK MODE

OFF

TEMPERATURE
MANUAL ON

SETBACK TEMPERATURE

ACT 140F SET 140°F

SETBACK RETURN TEMP

ACT 140°F SET 140°F

SETBACK TEMP BAND

SET 20˚F

Disable

Enable
Automatic

21

21

28

27

26

25

11

HOPPER LDR VIRGIN
LOAD TIME 20 SEC

HOPPER LDR REGRIND
LOAD TIME 20 SEC

HOPPER LOADER
LAYERING ON

8

9

10

14

42

47

14

41

42

47

46

21

42

45

44

43

MDC SHUTDOWN TIME
60 MIN

101

MDC SHUTDOWN ALARM
ENABLED EDIT

100

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.

4-6 l Operation

DRYER MAIN MENU
STAT SETUP DIAG

DRYER SETUP

PROC ALM DISP OTHER

SETUP PROCESS
PROC REGEN OTHER

SETUP REGENERATION
REGEN PID

SETUP REGENERATION

SETUP REGEN HEATER

SCREENS

PID VALUE SCREENS

REGENERATION TEMP

REGEN POWER LIMIT

ACT 350˚F SET350˚F

LOW 0% HIGH 100%

REGEN TEMP

REGEN CYCLE TIME

RANGE 100˚F - 375˚F

2.0 SEC

REGEN PID DONE

REGEN PROBAND

AUTOTUNE OFF

67F

REGEN INTERGRAL

25

REGEN DERIVATIVE

4

REGEN PID RESET

HEAT

REGEN CALIBRATION

OFFSET 0˚F

SETUP PROCESS
OTHER SCREENS

AUTOSTART TIMER
ENABLED EDIT
DISABLED

MONDAY START TIME
ON 8:00 AM

MONDAY STOP TIME
OFF 8:00 PM

TUESDAY START TIME
ON 8:00 AM

TUESDAY STOP TIME
OFF 8:00 PM

WEDNESDAY START TIME
ON 8:00 AM

WEDNESDAY STOP TIME
OFF 6:00 PM

THURSDAY START TIME
ON 8:00 AM

THURSDAY STOP TIME
OFF 6:00 PM

FRIDAY START TIME
ON 8:00 AM

FRIDAY STOP TIME
OFF 8:00 PM

SATURDAY START TIME
ON 8:00 AM

SATURDAY STOP TIME
OFF 8:00 PM

SUNDAY START TIME
ON 8:00 AM

SUNDAY STOP TIME
OFF 8:00 PM

REGEN CALIBRATION

OFFSET 0˚F

PROCESS DEWPOINT
SAMPLE RATE 150 SEC

PROCESS DEWPOINT
TRIM UP LIMIT

375˚F

PROCESS DEWPOINT
TRIM LOW LIMIT 100F

PROCESS DEWPOINT
GAIN 0.7

PROCESS DEWPOINT
DEAD BAND 1

PROCESS DEWPOINT
CONTROL RESET

REGEN OUTLET TEMP
ACT 280

12

36

37

48 14

14

14

4

29

39

40

47

49

50

51

52

53

54

41

42

43

44

45

46

47

55

56

57

56

57

56

57

56

57

56

57

56

57

56

57

DM T6 TOP
ACT 150˚F

DM T5
ACT 155˚F

57a

57b

DM T4
ACT 158

˚F

DM T3
ACT 160˚F

57c

57d

DM T2
ACT 163

˚F

DM T1 BOTTOM
ACT 165˚F

57e

57f

DM PROCESS SETPOINT

SET 225˚F

DM LO ALARM SELECT
T4 EDIT

57g

57h

DM LO ALARM SETPOINT

SET 150

˚F

DM LO ALARM OFFSET

SET 10˚F

57i

57j

DM LO ALARM BAND

SET 40˚F

DM LO ALARM DELAY

SET 5 MIN

57k

57l

DM LO ALARM SETPOINT
HIGH LIMIT 170˚F

DM LO ALARM SETPOINT
LOW LIMIT 130˚F

57m

57n

DM TEMP NOT MET
ALARM TIME SET 4 HRS.

DM HI ALARM SELECT
T1 EDIT

57o

57p

DM HI ALARM SETPOINT

SET 150˚F

DM HI ALARM DELAY

SET 5 MIN

57q

57r

4

Operation

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.

Operation l 4-7

When the DM-II monitor option is purchased
these screens will be displayed.

DRYER MAIN MENU
STAT SETUP DIAG

DRYER SETUP

PROC ALM DISP OTHER

ALARM ALARM

DRYER SETUP CONTROL

ACTION SETUP

DISPLAY SCREENS

UNITS

STANDARD EDIT
METRIC

DRYER SETUP ALARM

DRYER SETUP ALARM

ACTION SCREENS SETPOINT SCREENS

TIME DISPLAY

12 HOUR

PROC TEMP DEVIATION PROCESS HIGH TEMP

24 HOUR

ON EDIT PASS EDIT

385˚F 20 SEC

DATE TIME

PROC LOW TEMP ALARM PROCESS LOW TEMP

5/23/2002 Mon 10:33 AM

ON EDIT PASS EDIT

70˚F 20 SEC

REGN TEMP LOOP BREAK PROCESS LOOP BREAK
ON EDIT PASS EDIT

3˚F 20 SEC

REGN TEMP DEVIATION PROCESS TEMP DEV
ON EDIT PASS EDIT

10˚F 5 SEC

REGN HIGH TEMP ALARM REGEN HIGH TEMP
ON EDIT PASS EDIT

400˚F 5 SEC

REGEN LOW TEMP ALARM REGEN LOW TEMP
ON EDIT PASS EDIT

200˚F 5 SEC

RET MID-HI TEMP ALRM REGEN LOOP BREAK
ON EDIT PASS EDIT

2˚F 40 SEC

MACHINE LOADER ALRM

REGEN TEMP DEV

ON EDIT PASS EDIT

10˚F 5 SEC

PROC DEWPOINT ALARM

RETURN AIR ALARMS

ON EDIT PASS EDIT

PASS 125˚F SHUT 180˚F

FILTER CHECK ALARM

RETURN AIR LOOP BRK

ON EDIT PASS EDIT

3˚F 20 SEC

LOW CFM ALARM

CFM LOW SETPOINT

ON EDIT PASS EDIT

1

HOPPER LOADER ALRM

DEWPOINT ALARM

ON EDIT PASS EDIT

ACT -20F 180 SEC

DEWPOINT DEV HIGH
ON EDIT PASS EDIT

DEWPOINT DEV LOW
ON EDIT PASS EDIT

WHEEL ROTATION
ON EDIT PASS EDIT

REGEN BLOWER OVRLOAD

ON EDIT PASS EDIT

REGEN DIFFERENTIAL

20˚F 10 SEC

REGEN DIFFERENTIAL
TIME DELAY 5 MIN

DEWPOINT DEVIATION
HIGH 5˚F 30 sec

DEWPOINT DEVIATION
LOW

DEWPOINT
TIME DELAY 5 MIN

5˚F 30 sec

12

36

14

71

72

73

58

14

60

60

61

62

60

60

61

62

63

64

65

61

66

67

68

69

70

14

59

59

59

59

59

59

59

59

59

59

59

59

59

59

59

59

DM HI ALARM
ON EDIT PASS EDIT

59

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.

4-8 l Operation

When the DM-II monitor option is purchased
these screens will be displayed.

DRYER MAIN MENU
STAT SETUP DIAG

DRYER SETUP
PROC ALM DISP OTHER

DRYER SETUP OTHER
OPT INSP COM PW

DRYER SETUP OPTIONS DRYER SETUP MODEL DRYER SETUP
INFORMATION SCREENSCONFIG SCREENS COMMUNICATIONS

SETBACK ON TEMP MODEL NUMBER PROTOCOL
NOT INSTALLED EDIT CP100 EDIT MODBUS

CP15

CFM MONITOR

CP25

SLAVE ID

NOT INSTALLED EDIT

CP50

1

EDIT

FILTER CHECK BAUD RATE
INSTALLED EDIT

DRYER TYPE

19200 EDIT

STD EDIT

AFTERCOOLER FLOW CONT

CENTRAL

PARITY

INSTALLED EDIT

1 HOPPER MDC

NONE EDIT

EVEN
PRECOOLER ODD
INSTALLED EDIT

PRECOOLER FLOW CONT
INSTALLED EDIT

PROC CURRENT TRANS
INSTALLED EDIT

PROC CURRENT TAP
5A

DEWPOINT CONTROL
INSTALLED EDIT

PHASE ROTATION
INSTALLED EDIT

Voltage FREQ
208V 60 HZ EDIT

240V 60 HZ
400V 50 HZ
460V 60 HZ
575V 60 HZ

Display Firm V9.72.95
Display Menu V2.01.00

Control Firmware
Version V2.01.00

Dryer Setup

Logging Out

Password Screen

Password …

IF 2ND AND 4TH
SEL KEYS ARE PRESSED

Valid Supervisor

9999

Password Entered

Invalid Password

Logout Supervisor

Change Supervisor
Password Yes

Reset Password

Enter New Password

Enter New Password
1111

New Supervisor Pw Is
1111

10A
15A

PROC CURRENT SCALE
1

REGEN CURRENT TRANS
INSTALLED EDIT

REGEN CURRENT TAP
5A

10A
15A

RGN CURRENT SCALE
1

CP75
CP100
CP150
CP200
CP300
CP400
CP600
CP800
CP1000
CP1600
CP2400
CP3200
CP5000

208V 60 Hz

Supervisor Password
Reset to Default

Password No

Enter Password

IF A VALID PASSWORD IS STILL ACTIVE

14

85

85

86

86

87

88

89

90

90

90

86

12

36

74

14

78

14

81

82

83

84

This screen for 100-400 Only

79

80

31

32

14

75

75

75

75

75

75

75

76

77

75

76

77

75

75

MAP INDIRECT REG 500

0

102

MAP INDIRECT REG 501

94

102

MAP INDIRECT REG 502

3

102

MAP INDIRECT REG 503

82

102

MAP INDIRECT REG 504

8

102

MAP INDIRECT REG 505

77

102

MAP INDIRECT REG 506

4

102

MAP INDIRECT REG 507

11

102

MAP INDIRECT REG 508

40

102

MAP INDIRECT REG 509

41

102

MAP INDIRECT REG 510

6

102

MAP INDIRECT REG 511

42

102

MAP INDIRECT REG 512

43

102

MAP INDIRECT REG 513

78

102

MAP INDIRECT REG 514

79

102

MAP INDIRECT REG 515

100

102

MAP INDIRECT REG 516

153

102

MAP INDIRECT REG 517

10

102

MAP INDIRECT REG 518

0

102

MAP INDIRECT REG 519

0

102

MAP INDIRECT REG 530

94

102

MAP INDIRECT REG 531

82

102

MAP INDIRECT REG 532

77

102

MAP INDIRECT REG 533

78

102

MAP INDIRECT REG 534

66

102

MAP INDIRECT REG 535

306

102

MAP INDIRECT REG 536

307

102

MAP INDIRECT REG 537

309

102

APPEARS FOR 3 SECONDS

IF CORRECT

Unknown Password

86

IF INCORRECT

APPEARS FOR
3 SECONDS

DEWPOINT MONITOR
INSTALLED EDIT

75

4

Operation

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.

Operation l 4-9

When the DM-II monitor
option is purchased these
screens will be displayed.

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.

4-10 l Operation

Screen

SCREEN 1

SCREEN 2

SCREEN 3 (Default Screen)

Function

Once power is turned on, this screen is
displayed for 3 seconds. It shows
CONAIR and the dryer type on the first
line, and the control program version and
display program version on the second
line.

Once power is turned on and screen 1 is
displayed for 3 seconds, this screen is dis­played for another 3 seconds. It shows the
day of the week on the first line and the
date and time on the second line. If this
information is not correct, it can be
changed under the SETUP, DISP, DATE
TIME screen 73.

This is the DEFAULT screen. It shows
the process air temperature setpoint and
actual temperature measured at the inlet to
the drying hopper. The setpoint can be
changed by pressing the Select Category
button under the Setpoint Value. Once the
button is pressed, the setpoint will begin
to flash. The numeric keys can be used to
enter a new setpoint or the (+) or (-)
Increment / Decrement buttons can be
used to change the setpoint. Holding the
(+) or (-) buttons in will allow the number
to ramp up faster the longer the button is
held. The “ENTER” key must be
pressed to accept the new number. The
temperature setpoint range can be changed
under the

(continued)

CONAIR D100

CV2.21.00 DV2.21.00

MONDAY

07/22/03 07:59 AM

PROCESS TEMPERATURE

ACT 325°F SET 325°F

Control Function Descriptions

4

Operation

When supplied for
central drying appli­cations, this function
is not available.

NOTE: The supervisory pass-

word is required to change

certain parameters. More

detail about the password

can be on Page 4-39 and

under screen 85 on page

4-32.

✐

Operation l 4-11

Screen

SCREEN 3 (Default Screen)
(continued)

SCREEN 4

SCREEN 5

PROCESS TEMPERATURE

ACT 325°F SET 325°F

SETUP, PROC, PROC, PROC, PROCESS
TEMPERATURE RANGE screen 39. The
display will return to the default screen
from anyplace in the menu structure (with
the exception of the AUTOTUNE screens)
if nothing is done after 10 minutes.
Pressing the MENU button from anyplace
in the menu structure will also return to
the default screen.

Shows the regeneration air setpoint and
actual temperature. The setpoint can be
changed with the correct password.

NOTE: Lowering the regeneration setpoint

decreases the capacity of the dryer and nor-

mally is not recommended. Use the dew-

point control function instead.

Shows the actual return air temperature
measured at the inlet to the process blow­er. If the optional aftercooler flow control
is installed, a setpoint will be displayed on
this screen. The setpoint can be changed
with the correct password.

REGENERATION TEMP

ACT 350°F SET 350°F

RETURN AIR TEMP

ACT 100°F SET 100°F

Function

4-12 l Operation

Control Function Descriptions(continued)

When supplied for
central drying appli­cations, this function
is not available.

✐

This screen shows the amount of time the
conveying blower will run. Based on the
position of the demand sensor in the mate­rial receiver, this time may need adjusted.
The time should be set for the time it takes
to satisfy the demand sensor + 1 second.
If the MDC tries to load three consecutive
times without satisfying the demand sig­nal, the dryer will display a passive alarm.

These control screens are not used for the
W 150-400 DC-2.

This screen will show the actual dewpoint
of the process delivery air measured after
the desiccant wheel and before the process
heater. The dewpoint control will automat­ically adjust the regeneration temperature
to maintain the dewpoint setpoint.
Dewpoint control is not active with -40

°F

{-40°C} setpoint.

NOTE: Dewpoint actual will not be live for

approximately 5 to 8 minutes.

This is the dryer MAIN MENU. It can be
located by pressing the MENU key while
at the DEFAULT screen. By pressing the
Select Category buttons under the titles,
the user goes to STATUS screens, SETUP
screens, or DIAGNOSTIC screens.

Screen

SCREEN 6 (MDC Option)

SCREENS 7, 8, 9, and 10

SCREEN 11 (Dewpoint Control
and/or Dewpoint Monitor)

SCREEN 12 (Main Menu)

MACHINE LOADER

LOAD TIME 10 SEC

PROCESS DEW POINT

ACT -47°F SET -40°F

Function

Operation l 4-13

4

Operation

Control Function Descriptions(continued)

DRYER MAIN MENU

STAT SETUP DIAG

✐

Control function
available for MDC only.

Screen

SCREEN 13

SCREEN 14

SCREEN 15

DRYER STATUS

PROC REGEN OTHER

DRYER PROCESS

STATUS SCREEN

This is the Dryer Status screen. It can be
found by pressing the Select Category but­ton under the word "Stat" on the Main
Menu (screen 12). Any information under
the status section is read only; NO
CHANGES can be made from the status
sections. The operator can select to see
status information for Process,
Regeneration, or Other.

This is a column title screen. To navigate
to screens within a column (reference the
flow charts beginning on Page 4-4), the
operator must use the scroll buttons,
“Next” or “Prev”. The “Next” button will
scroll one screen at a time down a list of
screens. Once the last screen in the list is
displayed the “Next” button will return the
operator back to this Title screen. When
the “Prev” button is pressed, it will scroll
one screen at a time up the list of screens.
Once the title screen is displayed the
“Prev” button will go up to the next high
screen, in this case the Dryer Status screen

13.

This is an example of a Heater Output
screen. It displays the actual percentage
output of the heater, which can also be
interpreted as the percentage on time. The
on time can be checked by looking at the
heater LED’s in the Dryer Status section
of the display.

PROCESS HEATER

OUTPUT 100%

Function

4-14 l Operation

Control Function Descriptions(continued)

When supplied for
central drying appli­cations, this function
is not available.

The screen shows the process protection
actual temperature measured at the process
heater outlet.

This screen shows the total run time in
hours the dryer has been running since it
was new. If the control board is changed
during the life of the dryer, this timer will
start over.

This screen shows the status of the convey­ing blower. It will display whether the
output to the conveying blower is on or
off.

This screen shows the time delay setting
for the conveying blower on the MDC.
This is the minimum time the MDC will
wait before starting another load cycle.

This is the CFM Monitor screen. It dis­plays the Process CFM. The Process CFM
is measured by a differential pressure
transducer across the inlet and the outlet of
the process blower. The CFM Monitor
option must be installed (see screen 75) for
this to appear.

This screen shows if the aftercooler flow
control option is enabled. If it is disabled,
there will be no setpoint for the Return Air
Temperature screen 5. The aftercooler
flow control option must be installed (see
screen 75) for this to appear.

Screen

SCREEN 16

SCREEN 17

SCREEN 18 (MDC Option)

SCREEN 19 (MDC Option)

SCREEN 20

SCREEN 21 A (Aftercooler Flow
Control Option)

TOTAL RUN HOURS

1250

CONVEYING BLOWER

ON

MDC DELAY TIME

10 SECONDS

PROCESS CFM 1600

Function

AFTERCOOLER

ENABLED

Operation l 4-15

4

Operation

Control Function Descriptions(continued)

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.

PROCESS PROTECTION

ACT 350°F

Control function
available for MDC only.

Screen

SCREEN 21 B (Aftercooler Flow
Control Option)

SCREEN 21C Precooler
(Disable/Enable)

SCREEN 21 D (Precooler Flow
Control Option)

SCREEN 22 (Current Monitor
Option)

SCREEN 23 (Current Monitor
Option)

PRECOOLER

FLOW ON

Function

This screen shows if the control is opening
the solenoid valve. The aftercooler flow

control option must be installed (see
screen 75) for this to appear.

This screen shows the disable/enable
function of the precooler. The precooler
display will read Disabled when not acti­vated. The Precooler Flow Control must be
installed (see screen 75) for this to appear.

This screen shows if the control is opening
the precooler flow control solenoid valve.
The Precooler Flow Control option must
be installed (see screen 75) for this to
appear.

This screen shows the measured current on
each leg of the 3-phase power going to the
process heater. The Current Monitor
option (see screen 75) needs to be installed
for this screen to appear.

The screen shows the calculated total
power for the dryer. The calculation
includes the measured current for the
process and regeneration heaters, the
control voltage set for the dryer, and
pre-determined power consumption values
for the blowers and the control. The
Current Monitor option (see screen 75)
needs to be installed for this screen to
appear.

TOTAL POWER

82 KWH

4-16 l Operation

Control Function Descriptions(continued)

PROCESS CURRENTS

84.3 A 84.2 A 84.3 A

AFTERCOOLER

FLOW ON

PRECOOLER

ENABLE

NOTE: Screens labeled 75 in

the display screen flow chart

on page 4-9 are various

option installation screens.

✐

Screen

SCREEN 24 (Dewpoint Control
and/or Dewpoint Monitor)

SCREEN 25 (Setback on

Temperature)

SCREEN 26

Function

DEWPOINT CONTROL

AVG -35°F

SETBACK MODE

OFF

This screen displays the average dewpoint
over the last hour of run time.

This screen shows the setting of the set­back feature (see page 4-44). The supervi­sor password is required to make changes
to this screen. It can be set to OFF,
Temperature, or Manual On. Off turns the
setback mode off, and the dryer will not
change the process setpoint. The tempera­ture setting tells the control the dryer
should go into setback when the hopper
outlet temperature reaches the setpoint
(screen 27). The Manual On setting tells
the dryer to go into setback now.

This screen shows the setpoint the process
temperature will go to once the control
goes into setback. When the control is in
the setback mode, the LED on the dryer
display beside SETBACK will illuminate.
The actual temperature on the default
screen will still show the actual tempera­ture measured at the hopper inlet. The set­point shown on the default screen will still
show the original setpoint.

Operation l 4-17

4

Operation

Control Function Descriptions(continued)

SETBACK TEMPERATURE

ACT 140°F SET 140°F

Screen

SCREEN 27

SCREEN 28

SCREEN 29 (Regeneration Outlet
Temperature)

SCREEN 30

Function

SETBACK RETURN TEMP

ACT 140°F SET 140°F

SETBACK TEMP BAND

SET 20°F

REGEN OUTLET TEMP

ACT 280

4-18 l Operation

Control Function Descriptions(continued)

MODEL CP150

480 V 60 Hz

This screen shows the actual temperature
measured at the hopper outlet and the set­point temperature for the air at the hopper
outlet that will initiate the control to go
into setback.

This shows how much lower the hopper
outlet temperature must drop from the
Setback Return Temperature setpoint
(screen 27) before the dryer control should
restore the original process setpoint.

This screen shows the actual temperature
measured at the regeneration outlet of the
desiccant wheel manifold.

This screen shows the model number, volt­age, and frequency for which the dryer
control is setup. These values can be
changed with the proper password see
page 4-32 (screen 85) under SETUP,
OTHER, INSP, Model # (screen 78), and
Voltage FREQ (screen 80).

Operation l 4-19

4

Operation

Screen

SCREEN 31

SCREEN 32

SCREEN 33

SCREEN 34

Function

DISPLAY FIRM V2.21.00

DISPLAY MENU V2.21.00

CONTROL FIRMWARE

VERSION V2.21.00

AUTOSTART COUNT DOWN

1 DAYS 23:05:53

This screen shows the current versions of
program for the Display Firmware and
Menus.

This screen shows the current versions of
program for the Control Firmware.

If the dryer is set with an auto start time,
this screen will appear and show the
amount of time remaining before the dryer
will automatically start. The LED on the
front of the display, beside the word Auto
Start, will flash if the dryer is set to start
automatically. The auto start feature can
be programmed under SETUP, PROC,
PROC, OTHER (screens 55, 56, 57). The
dryer can be set to automatically start and
stop each day.

If the dryer is set to auto stop, this screen
will appear and show the amount of time
remaining before the dryer will automati­cally stop. The auto stop feature can be
programmed under SETUP, PROC,
PROC, OTHER (screens 55, 56, 57). The
dryer can be set to automatically start and
stop each day.

AUTOSTOP COUNT DOWN

3 DAYS 11:04:23

Control Function Descriptions(continued)

Tip: This information is

important to know when

ordering a control board.

Tip: This information is

important to know when

ordering a display board.

✒

✒

Screen

SCREEN 35

SCREEN 36

SCREEN 37

SCREEN 37

SCREEN 38

SCREEN 38

SCREEN 39

PANEL INSIDE TEMP

ACT 100°F

Function

DRYER SETUP

PROC ALM DISP OTHER

SETUP PROCESS

PROC REGEN OTHER

SETUP PROCESS

PROC PROPID RETPID

PROCESS TEMPERATURE

RANGE 70°F - 450°F

This screen shows the temperature inside
the control enclosure. It is measured at the
lower right corner of the control board.

This is the Dryer Setup screen. It can be
found by pressing the Select Category but­ton under the word Setup on the Main
Menu (screen 12). By pressing the Select
Category buttons under the titles, the user
can select to see setup information for
Process, Alarms, Display, or Other.

This is the Setup Process screen. It can be
found by pressing the Select Category but­ton under the word Proc on the Dryer
Setup (screen 36). By pressing the Select
Category buttons under the titles, the user
can select to see setup information for
Process, Regeneration, or Other.

This is the second Setup Process screen.
It can be found by pressing the Select
Category button under the word "Proc" on
the Setup Process screen (37). By press­ing the Select Category buttons under the
titles, the user can select to see setup infor­mation for Process, Process PID, or Return
Air PID if the optional aftercooler flow
control is installed. Note: When config­ured as a central dryer, you will not see the
process PROPID.

This screen shows the allowable tempera­ture range for setpoint temperatures. With
the proper password (see page 4-32,
screen 85), this range can be narrowed.

4-20 l Operation

Control Function Descriptions(continued)

NOTE: Conair does not

recommend low setpoints

under 150

°F {66°C} due

to nuisance alarms.

✐

NOTE: Software may allow

the Process temperature

setpoint limit up to 450

°F

{232

°C}, however Conair

does not recommend a set-

point limit over 375

°F

{191

°C} due to nuisance

alarms.

✐

NOTE: Conair is not responsi-

ble for damage caused by

excessively high drying

setpoints that are not in

accordance with your drying

material recommendations.

✐

4

Operation

Operation l 4-21

Screen

SCREEN 40

and

SCREEN 41

SCREEN 37

SCREEN 42

SCREEN 43

PROCESS PID DONE

AUTOTUNE OFF

Function

PROCESS PROP BAND

HEAT/COOL 30°F

PROCESS POWER LIMIT

LOW 2% HIGH 80%

PROCESS CYCLE TIME

HEAT 2.0 SECONDS

Before performing an autotune, set the set­point to the desired temperature you would
like the control to autotune to at screen 3
for process, and screen 4 for regeneration.
Screen 40 shows the autotune function for
the selected heater. The dryer must not be
running to initiate an autotune. The auto­tune should be started from a cold start or
a minimum of 50ºF {28ºC} difference
between starting and autotune tempera­tures. With the proper password, (see page
4-32, screen 85) press the Select Category
button under the word Off. Once selected,
the word should start to blink. Press the
(+) or (-) button to toggle the Off to On
and then press the “ENTER” key to start
the autotune. The display will show
" Wait", then "Heat", then " Done" when
it is complete. Pressing “STOP” during an
autotune will cancel the autotune and not
change PID values. The PID values can be
set back to factory defaults by going to the
Reset (screen 46).

This screen shows the power output range
for the heater. It is set by default to 0%
for the low and 100% for the high.

This screen shows the PID cycle time for
the heater "Heat", or with a precooler
"Cool". This time value is the time for one
on/off cycle. For example, with a heater
running at 50% and the cycle time set at
2 sec, the heater would be on 1 second and
off 1 second.

This screen shows the Proportional Band
value for the PID loop.

Control Function Descriptions(continued)

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.

REGEN PID DONE

AUTO

NOTE: Screens 41, 42, 43,

44, 45, 46 and 47 apply to

process and regeneration.

✐

Screen

SCREEN 44

SCREEN 45

SCREEN 46

SCREEN 47

SCREEN 48

SCREEN 49

PROCESS INTEGRAL

HEAT/COOL 16.0

Function

PROCESS CALIBRATION

OFFSET 2°F

PROCESS DERIVATIVE

HEAT/COOL 2.0

PROC PID RESET

HEAT/COOL

This screen shows the integral value for the
PID Loop.

This screen shows the derivative value for
the PID Loop.

With the proper password, (see page 4-32,
screen 85) the PID values can be reset back
to the factory default settings. Press the
Select Category button under the word
Heat to reset the values for the process
heater, or Cool to reset the values for the
precooler flow control when this option is
installed.

This screen shows the temperature offset
for the RTD. This screen is used if the
process readout needs to be calibrated.

This is the Setup Regeneration screen. It
can be found by pressing the Select
Category button under the word Regen on
the Setup Process screen (screen 37). By
pressing the Select Category buttons under
the titles, the user can select to see setup
information for Regeneration or
Regeneration PID.

This is the amount of time the control
waits before checking the dewpoint value
after making a change. This time value
gives the system time to respond to a
process change.

SETUP REGENERATION

REGEN PID

4-22 l Operation

Control Function Descriptions(continued)

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.

PROCESS DEWPOINT

SAMPLE RATE 150 SEC

NOTE: Screens 49, 50, 51,

52, 53 and 54 apply to

the dewpoint control

option.

✐

NOTE: Screens 41, 42, 43,

44, 45, 46 and 47 apply to

process and regeneration.

✐

Operation l 4-23

4

Operation

Screen

SCREEN 50

SCREEN 51

SCREEN 52

SCREEN 53

SCREEN 54

SCREEN 55

Function

This is the maximum value the dewpoint
control can set the regeneration tempera­ture to achieve the desired dewpoint.

This is the minimum value the dewpoint
control can set the regeneration tempera­ture to achieve the desired dewpoint.

This is the proportional gain value for the
dewpoint control.

This is the deadband range. If the actual
dewpoint value is within this range of the
dewpoint setpoint, the control will not
make a change to the regeneration temper­ature.

This will reset the dewpoint control back
to the factory default values.

This screen is used to enable or disable the
auto start function. If the function is
enabled, the dryer can be started or
stopped once each day. The start and stop
times can be set on screens 56 and 57.

Control Function Descriptions(continued)

PROCESS DEWPOINT

TRIM UP LIMIT 375°F

PROCESS DEWPOINT

TRIM LOW LIMIT 100°F

PROCESS DEWPOINT

GAIN 0.7

PROCESS DEWPOINT

DEADBAND 1

PROCESS DEWPOINT

CONTROL RESET

AUTO START TIMER

ENABLED EDIT

NOTE: Screens 49, 50, 51,

52, 53 and 54 apply to the

dewpoint control option.

✐

Screen

SCREEN 56

SCREEN 57

MONDAY START TIME

ON 8:00 AM

Function

MONDAY STOP TIME

ON 8:00 PM

This is the auto start screen for the first
day of the week. Each day has a screen
similar to this. By pressing the Select
Category button under On or Off, the dryer
can be set to start on Monday. The start
time can be set by pressing the Select
Category button under time and entering a
new time on the numeric keypad. The AM
/ PM can be changed only after a time
value has been entered. The (+) button
will set PM and the (-) button will set AM.
The “ENTER” key must be pressed to
lock in the new time. The dryer can be
manually started at anytime. If the auto
start time runs out and the dryer has been
manually started, nothing will happen.

This is the auto stop screen for the first
day of the week. Each day has a screen
similar to this. By pressing the Select
Category button under On or Off, the dryer
can be set to stop on Monday. The stop
time can be set by pressing the Select
Category button under time and entering a
new time on the numeric keypad. The AM
/ PM can be changed only after a time
value has been entered. The (+) button
will set PM and the (-) button will set AM.
The “ENTER” key must be pressed to
lock in the new time. If the auto stop time
runs out and the dryer has already been
manually stopped, nothing will happen. If
the dryer was auto started on Monday
morning and the Monday auto stop is set
to off, the dryer will continue running until
it hits a day of the week when the auto
stop is set to On, at that time the dryer will
turn off.

4-24 l Operation

Control Function Descriptions(continued)

NOTE: If you purchased the

DM-II (Drying Monitor Option),

there will be additional screens

present in this area. See the

DM-II Appendix for information

pertaining to the control func-

tion descriptions for the DM-II.

✐

Operation l 4-25

4

Operation

Screen

SCREEN 58

SCREEN 59

SCREEN 60

ALARM ALARM

ACTION SETUP

Function

PROC TEMP DEVIATION

ON EDIT PASS EDIT

This is the alarm action and setup screen.
With the proper password, (see page 4-32,
screen 85) the Select Category button can
be pressed under Alarm Action or Alarm
Setup. Alarm Action screens can be used
to assign an alarm as Off, Passive, or
Shutdown (screen 59). Alarm Setup
screens can be used to change alarm set­points and delay times. (screens 60-70)

This is an example of the Alarm Action
screens. With the proper password, (see
page 4-32, screen 85) some alarms can be
turned on or off by either pressing the
Select Category button under the word
Edit, or by pressing the Select Category
button under the word On or Off. Once
the word begins to blink, the (+) or (-)
keys will change the setting. The
“ENTER” key must be pressed to lock in
the value. The same sequence works for
the Pass or Shut down. “Pass” or Passive
means the alarm will not shut the dryer
down but the alarm will be logged in the
Dryer Diagnostics Alarm Log. A “Shut”
means Shutdown, in which case the dryer
would shutdown if the alarm occurs.

This is an example of an Alarm Setup
screen that has a minimum or maximum
temperature. With the proper password,
(see page 4-32, screen 85, refer to pass­word) the temperature setpoint can be
changed as well as how long the dryer has
to stay at that temperature before alarming.

PROCESS HIGH TEMP

250°F 1 SEC

Control Function Descriptions(continued)

When supplied for
central drying appli­cations, this function
is not available.

This is an example of an Alarm Setup
Loop Break screen. When actual tempera­ture is outside the deviation band, if the
temperature is not moving toward the set­point at a rate greater than or equal to X°F
over Y seconds, then the dryer will alarm
on Loop Break. Once the actual tempera­ture is within the deviation band, the Loop
Break is ignored.

This is an example of an Alarm Setup
deviation screen. If the actual temperature
goes outside this temperature band (High
or Low) for a set amount of time, the dryer
will give a deviation alarm. With the
proper password (see page 4-32, screen

85), these values can be changed.

This set value is the minimum difference
between the regeneration inlet and outlet
temperature for the wheel rotation alarm.
Once this difference is reached for the the
set time value, the dryer will alarm wheel
rotation failure.

This is a delay time for the wheel rotation
alarm from start-up so regeneration can
come up to temperature.

This screen shows the return air tempera­tures at which the dryer will give a passive
alarm, and when the dryer will shutdown
on High Return Air Temperature.

Screen

SCREEN 61

SCREEN 62

SCREEN 63

SCREEN 64

SCREEN 65

Function

REGEN DIFFERENTIAL

TIME DELAY 5 MIN

4-26 l Operation

Control Function Descriptions(continued)

REGEN DIFFERENTIAL

20°F 10 SEC

RETURN AIR ALARMS

PASS 150°F SHUT 180°F

PROCESS LOOP BREAK

3°F 20 SEC

PROCESS TEMP DEV

5°F 5 Sec

Operation l 4-27

4

Operation

This screen shows the low CFM setpoint.
The default is 1 CFM. The default can be
changed with the proper password (see
page 4-32, screen 85).

This screen shows the alarm setpoint for a
dewpoint alarm. With the proper pass­word, it can be changed (see page 4-32,
screen 85). The defaults are -3°F for 180
seconds If the control senses -3°F or high­er for 180 seconds, the dryer will alarm.

This is the dewpoint high deviation alarm
value. With the proper password, it can be
changed (see page 4-32, screen 85). When
in dewpoint control, if the actual dewpoint
goes above the setpoint in screen 67 for
the set amount of time, the dryer will
alarm “Dewpoint Deviation High”.

This is the dewpoint low deviation alarm
value. With the proper password, it can be
changed (see page 4-32, screen 85). When
in dewpoint control, if the actual dewpoint
goes below the setpoint by this value for
this amount of time, the dryer will alarm
“Dewpoint Deviation Low”.

Screen

SCREEN 66 (CFM Monitor
Option)

SCREEN 67

SCREEN 68

SCREEN 69

Function

Control Function Descriptions

(continued)

DEWPOINT ALARM

ACT -20°F 180 SEC

DEWPOINT DEVIATION

HIGH 5°F 30 SEC

DEWPOINT DEVIATION

LOW 5°F 30 SEC

CFM LOW SETPOINT

1430

This is the amount of time from start-up
the dryer is allowed to run before the con­trol will try to control the dewpoint. Five
minutes is the default. This gives the dryer
time to warm up and reach a steady state.
It can be changed with the proper pass­word (see page 4-32, screen 85).

This screen shows the units the dryer will
display. It can be changed with the proper
password (see page 4-32, screen 85) to
either Standard or Metric. Press the Select
Category button below the word Edit to
change the setting and press the
“ENTER” key to lock in the value.

This screen shows the time unit the dryer
will display. It can be changed with the
proper password (see page 4-32,
screen 85) to either 12 hour (AM / PM
Clock) or 24 hour (Military Time). Press
the Select Category button below the
words 12 hour to change the setting and
press the “ENTER” key to lock in the
value.

This screen shows the date and time. With
the proper password, (see page 4-32,
screen 85) the date and time can be
changed.

Screen

SCREEN 70

SCREEN 71

SCREEN 72

SCREEN 73

Function

DEWPOINT

TIME DELAY 5 MIN

4-28 l Operation

Control Function Descriptions(continued)

TIME DISPLAY

12 HOUR

UNITS

STANDARD EDIT

DATE TIME

10/25/2004 MON 10:33 AM

4

Operation

This is the Dryer Setup Other screen. It
can be found by pressing the Select
Category button under the word Other on
the Dryer Setup Screen (36). By pressing
the Select Category buttons under the
titles, the user can select to see setup infor­mation for Options, Inspection, Com­munications or Password.

This is an example of an Option
Installation screen. With the proper pass­word (see page 4-32, screen 85) and hard­ware installed, an option can be turned on
by pressing the Select Category screen
under the word Edit. This will change an
option from Not Installed to Installed. The
“ENTER” key must be pressed to lock in
the change. Once an option is installed,
there may be additional screens that show
in the menu structure that need to be setup.
Contact Conair Service to determine what
options should be installed on your dryer.

This screen is used with the current moni­tor option and tells the control which tap is
used on the current sensing board (5A,
10A, or 15A).

This screen is used with the current moni­tor option and is used to scale the reading
to the proper reading.

Screen

SCREEN 74

SCREEN 75

SCREEN 76 (Current Monitor
Option)

SCREEN 77 (Current Monitor
Option)

Function

DRYER SETUP OTHER

OPT INSP COM PW

CFM MONITOR

NOT INSTALLED EDIT

Control Function Descriptions(continued)

Operation l 4-29

PROCESS CURRENT TAP

5 A

PROCESS CURRENT SCALE

1

NOTE: Screens labeled 75 in

the display screen flow chart

on page 4-9 are various

option installation screens.

✐

This screen further defines the dryer type
to a model number. Based on the dryer
type, the selections on this menu will
change. Your dryer should be configured
from the factory. However, if the control
were changed from one machine to anoth­er, the control may need to be reconfig­ured. With the proper password, (see page
4-32, screen 85) the Model Number can be
changed by pressing the Select Category
button under the word Edit. The
“ENTER” key must be pressed to lock in
the selection.

This screen is used to tell the control what
dryer it is controlling. The selections are
Standard, Central or 1 Hopper MDC. Your
dryer should be configured from the facto­ry. However, if the control were changed
from one machine to another, the control
may need to be reconfigured. With the
proper password, (see page 4-32, screen

85) the dryer type can be changed by
pressing the Select Category button under
the word Edit. The “ENTER” key must
be pressed to lock in the selection.

This screen defines the voltage and fre­quency at which the dryer will be running.
This setting should match the electrical
label on the side of the control box. Your
dryer should be configured from the facto­ry. However, if the control were changed
to run on a different voltage, this screen
may need to be reconfigured. With the
proper password, (see page 4-32, screen

85) the voltage frequency can be changed
by pressing the Select Category button
under the word Edit. The “ENTER” key
must be pressed to lock in the selection.

Screen

SCREEN 78

SCREEN 79

SCREEN 80

DRYER TYPE

STD EDIT

Function

MODEL NUMBER

CP150 EDIT

VOLTAGE FREQ

208 V 60 HZ EDIT

4-30 l Operation

Control Function Descriptions(continued)

Operation l 4-31

4

Operation

This screen shows the communications
protocol. DeviceNet, SPI Modbus and
Ethernet are available. This is set at the
factory. If adding to an existing dryer, the
communications protocol can be changed
with the proper password (see page 4-32,
screen 85).

This screen shows the Slave ID number.
The ID number can be changed with the
proper password (see page 4-32, screen

85) by pressing the Select Category button
below the word Edit and entering a value
on the keypad or scrolling to the desired
value using the Adjust Setpoint keys. The
“ENTER” key needs to be pressed to lock
in the new number.

This screen shows the baud rate. The
baud rate can be changed with the proper
password (see page 4-32, screen 85). Press
the Select Category key below the word
Edit and enter a value on the keypad or
scroll to the desired value using the Adjust
Setpoint keys.

This screen shows the parity. The parity
can be changed with the proper password
(see page 4-32, screen 85) to Even, Odd,
or None by pressing the Select Category
button below the word Edit. The
“ENTER” key needs to be pressed to lock
in the new number.

Screen

SCREEN 81 Communications

SCREEN 82 Communications

SCREEN 83 Communications

SCREEN 84 Communications

Function

SLAVE ID

1EDIT

PROTOCOL

DEVICENET EDIT

BAUD RATE

9600 EDIT

PARITY

NONE EDIT

Control Function Descriptions(continued)

This screen shows the password entry
screen. By pressing the Select Category
button under the word Press Here, the user
can enter a password by using the keypad.
Once a password has been entered the
“ENTER” key must be pressed. If the
password is valid, the display will show
screen 87. If the password was incorrect,
it will display "Invalid Password Try
Again" and go back to the Enter Password
screen. The default supervisor password is

0210. The supervisor can change this
password on screen 89.

This is the Reset Password screen. It will
only be shown when the second and fourth
Select Category buttons are pressed at the
same time when at screen 85. By pressing
the Select Category button under the word
Press Here, the user can enter the default
password by using the keypad. Once the
default password has been entered, the
“ENTER” key must be pressed. This will
change the password back to the factory
default password (see page 4-32, screen

85).

This is the display screen that appears
when a valid password has been entered.
Pressing the Previous button will take you
screen 14. Pressing “Next” will take you
to screen 88.

Screen

SCREEN 85

SCREEN 86

SCREEN 87

ENTER PASSWORD

0210

Function

RESET PASSWORD

PRESS HERE

VALID SUPERVISOR

PASSWORD ENTERED

4-32 l Operation

Control Function Descriptions(continued)

Operation l 4-33

4

Operation

This is the password logout screen. If
nothing is done, the password will auto­matically be logged out after 30 minutes.
To logout, use the Select Category button
under the word Yes/No. Setting it to Yes
and pressing the “ENTER” Key will
change the display to "Logging Out
Password". Screen 86 will display for 3
seconds then will automatically go to
screen 14.

This screen allows the supervisor to
change the password. To change the pass­word, use the Select Category button
under the word, Yes/No. Setting it to Yes
and pressing the “ENTER” Key will
change the display to screen 90. If the
user does not want to change the pass­word, pressing the “Next” key will return
the control to the Dryer Setup Password
screen 14.

This screen shows the password entry
screen. Pressing the Select Category but­ton under the word Press Here, will allow
the user to enter a new password by using
the key pad. Once a new password has
been entered the “ENTER” key must be
pressed. The display will show the new
password for 3 seconds then return to the
Change Supervisor Password (screen 89).
To exit, press the “Next” key and the con­trol will return to the Dryer Setup
Password Screen.

This is the Dryer Diagnostic screen. It can
be found by pressing the Select Category
button under the word Diag on the Dryer
Main Menu screen 12. By pressing the
Select Category buttons under the titles,
the user can select to see diagnostic infor­mation for Alarms, Alarm History, or
Inputs and Outputs.

Screen

SCREEN 88

SCREEN 89

SCREEN 90

SCREEN 91

CHANGE SUPERVISOR

PASSWORD YES

Function

ENTER NEW PASSWORD

PRESS HERE

DRYER DIAGNOSTIC

ALRM EVENT HIST I/O

Control Function Descriptions(continued)

LOGOUT SUPERVISOR

PASSWORD YES

This is an example of one of the alarm his­tory screens. The first two numbers of the
first line show what alarm you are viewing
in the list. This example is the first alarm
in the list 00. The letter after the : P or : S
shows if the alarm was a passive or shut­down alarm. The second line shows the
date and time when the alarm occurred.
By pressing the Select Category button
under the word Info, the display can show
a number of screens that are a snapshot of
information that was happening when the
alarm occurred.

This is an example of one of the
Information screens for an alarm. This is
the first screen under the Info shown on
screen 92. It shows how long the alarm
was active. The time shown is from when
the alarm occurred until the alarm was
acknowledged and cleared. The “Next”
button can be pressed while at this screen
to see other items in the list of snapshot
info that was happening when the alarm
occurred.

This is the Dryer Diagnostic screen. It can
be found by pressing the Select Category
button under the word Hist on the Dryer
Diagnostics (screen 91). By pressing the
Select Category buttons under the titles,
the user can select to see diagnostic infor­mation for Alarms.

This is an example of the Event Freq.
screens. This shows the number of times
an alarm has occurred. By pressing the
“Next” key in this section, the user can
see info for all alarms. The “S” indicates
how many times it was a shutdown alarm
and the “P” indicates how many times it
was a passive alarm.

Screen

SCREEN 92

SCREEN 93

SCREEN 94

SCREEN 95

00:S-REGEN RTD

1/31/00 09:24 P INFO

Function

ALARM ACTIVATED FOR

10.3 MINUTES

DIAGNOSTIC EVENTS

ALARMS ANALOG DIGITAL

PROCESS HIGH TEMP

S - 0 P - 0

4-34 l Operation

Control Function Descriptions(continued)

Operation l 4-35

4

Operation

This is the Diagnostic I/O screen. It can be
found by pressing the Select Category but­ton under the word I/O on the Dryer
Diagnostics (screen 91). By pressing the
Select Category button under Digital, the
user can access the digital outputs (screen

98) and view the status of the digital
inputs (screen 99). The analog diagnostic
I/O function is not used.

This screen is used to enter the diagnostic
mode where outputs can be turned on
(screen 98). Note that the dryer MUST
NOT BE running to enter diagnostics.

This is an example of one of the digital
outputs that can be manually energized.
All screens in this section only work when
the dryer is not running and is in “stand­by”. The outputs can be turned on, turned
off, or energized for a 3-second jog (auto­matically turned on for 3 seconds then
turned off). The process and regeneration
heaters can only be jogged for 3 seconds,
and the index motor, if jogged, will rotate
the wheel for 3 seconds. If the stop button
is pressed at any time during this testing,
the output will stop immediately.

This is an example of one of the digital
Inputs screens. This will show if the input
is open or closed.

Screen

SCREEN 96

SCREEN 97

SCREEN 98

SCREEN 99

DIAGNOSTIC I/O

DIGITAL

Function

PROCESS BLOWER

ON OFF JOG

PROC

OPEN

Control Function Descriptions(continued)

START DIGITAL I/O

DIAGNOSTICS OFF

This screen can be used to determine if the
MDC conveying on function will shut­down or continue to operate upon any
dryer alarm.

Use this screen, in the event screen 100 is
enabled, to set the amount of time the con­veying function will continue to operate
once the dryer has alarmed. If screen 100
is disabled, the conveying function will
continue indefinitely.

These parameters map which internal vari­ables are accessible from the user commu­nication port on the DC-2 operator display.
A default set of variables has been chosen
that represent the most important variables
for the majority of uses. These values
should not be changed except under the
direction of Conair Engineering or
Service.

Screen

SCREEN 100

SCREEN 101

SCREEN 102

MDC SHUTDOWN ON ALARM

ENABLED EDIT

Function

MDC SHUTDOWN TIME

60 MIN

4-36 l Operation

Control Function Descriptions(continued)

MAP INDIRECT REG 500

0

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 up the control and the display lights will illu­minate.

3 Set the drying temperature. Press the appropriate

Select Category button then the Adjust Setpoint (+) or
(-) buttons or enter the temperature on the numeric
keypad and press enter.

(continued)

When configured as a central dryer, the drying temperature

can not be set since there is no process heater in the system.

NOTE: When changing a setpoint use the Select Category Key
directly below the value to be changed. Once pressed the value
will blink, then use the keypads or (+) (-) adjustment setpoints
to enter the new value. Then press enter for the new value to
be recognized.

✐

Operation l 4-37

4

Operation

Setpoint
adjustment
buttons

Select
Category
buttons

To Start Drying

(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 and the display LEDS

will illuminate.

• The process and regeneration heaters turn on and the display LEDs will

illuminate.

• The desiccant wheel starts turning.

To Stop Drying

1 Press the STOP button. The Stop LED blinks red.

• 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 the
necessary cool-down period, and can trigger the
shut down/high temperature alarm during your
next drying cycle.

Caution: Improper shut down can cause damage to your dryer.

4-38 l Operation

Stop

Start

• The green light on the start button will illuminate.

• The process and regeneration blowers turn on and the dis-

play LEDS will illuminate.

• The regeneration heater turns on and the display LED will

illuminate.

• The desiccant wheel starts turning.

Operation l 4-39

4

Operation

How to Use the Supervisor’s
Password

The supervisor's password must be entered before you can use or make changes to
some screens on the dryer control. To enter the supervisor password:

1 Go to screen 12 and press the Select Category button under "Setup."

2 This will take you to screen 36. On Screen 36, press the Select Category

button under "Other."

3 This will take you to screen 74. On Screen 74, press the Select Category

button under "PW."

This will take you to screen 14.

4 On Screen 14, press the Scroll List Next button. This will take you to

screen 85.

DRYER MAIN MENU

STAT SETUP DIAG

DRYER SETUP

PROC ALM DISP OTHER

DRYER SETUP OTHER

OPT INSP COM PW

DRYER SETUP

PASSWORD SCREEN

ENTER PASSWORD

0210

(continued)

4-40 l Operation

How to Use the Supervisor’s
Password (continued)

5 This is the screen where you will need to enter the supervisor's password.

The default supervisory password in 0210. Enter this number to make changes
to screens where the supervisor’s password is necessary to use or change a
function of the dryer.

Be sure to push “Enter” after entering the password. If the password is entered
successfully, screen 87 will be displayed.

You can now make changes to screens where the supervisor’s password is
required. Once the desired parameter has been changed, follow the previous
steps to go to screen 88 (see the flow chart on page 4-4).

Push the Select Category button under “No”. Once it begins to flash, push the
Adjust Setpoint button to display “Yes”, then push “ENTER”. Push the
“MENU” button to return to the main display.

NOTE: The supervisor's password can be changed by going to screen 89, see page 4-4, for

the map of the screens. See page 4-33, screen 89 for additional information on changing the

supervisory password.

VALID SUPERVISOR

PASSWORD ENTERED

LOGOUT SUPERVISOR

PASSWORD YES

✐

ENTER PASSWORD

0210

4

Operation

Using the Auto Start Timer

You can set the dryer to start and stop automatically using the Auto Start and
Auto Stop functions. Supervisor Password is necessary to use this function.

Programming Auto Start

The Auto Start time and date can be programmed using the Auto Start
Countdown screen. This screen can be accessed under the SETUP, PROC, and
OTHER screens from the “Dryer Main Menu”, screen 12:
SCREEN 36 SCREEN 37

SCREEN 56

Once the Auto Start time and date has been programmed, the Auto Start
Countdown screen (screen 33) will show the amount of time remaining before
the dryer will automatically start. The LED on the front of the display beside
the word Auto Start will flash if the dryer is set to start automatically. The
dryer can be set to automatically start each day.

Programming Auto Stop

The Auto Stop time and date can be programmed using the Auto Stop
Countdown screen. This screen can be accessed under the SETUP, PROC, and
OTHER screens from the “Dryer Main Menu”, screen 12:
SCREEN 36 SCREEN 37

SCREEN 57

Once the Auto Stop time and date has been programmed, the Auto Stop
Countdown screen (screen 34) will show the amount of time remaining before
the dryer will automatically stop. The dryer can be set to automatically stop
each day.

MONDAY START TIME

ON 8:00 AM

MONDAY STOP TIME

ON 8:00 PM

Dryer Setup

Proc Alm Disp Other

Setup Process

Proc Regen Other

Dryer Setup

Proc Alm Disp Other

Setup Process

Proc Regen Other

NOTE: To use the Auto

Start or Auto Stop Timer,

you must have the Auto

Start function enabled

(see screen 55, page

4-23).

Operation l 4-41

✐

4-42 l Operation

Setting the High Setpoint Limit

You can protect your drying process by preventing someone from entering process
temperatures above or below an acceptable level for the material. You can also set
the high and low limits 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 Use the Scroll keys to access the SETUP, PROC, PROC, and PROC

screens under the Dryer Main Menu, screen 12.

SCREEN 36 SCREEN 37

SCREEN 38 SCREEN 14

3 Then select the PROCESS TEMPERATURE RANGE screen.

SCREEN 39

4 The PROCESS TEMPERATURE RANGE screen shows the

allowable temperature range for setpoint temperatures. With the

supervisory password this range can be narrowed. See page 4-32,

screen 85.

DRYER SETUP

PROC ALM DISP OTHER

SETUP PROCESS

PROC REGEN OTHER

PROCESS TEMPERATURE

RANGE 100 F - 450 F

When configured as a
central dryer, the high
setpoint limits can not
be set since there is no
process heater in the
system.

SETUP PROCESS

PROC PROPID RETPID

DRYER PROCESS

SETUP SCREEN

NOTE: Conair does not

recommend low setpoints

under 150

°F {66°C} due

to nuisance alarms.

✐

NOTE: Software may allow

the Process temperature

setpoint limit up to 450

°F

{232

°C}, however Conair

does not recommend a set-

point limit over 375

°F

{191

°C} due to nuisance

alarms.

✐

NOTE: Conair is not responsible for damage caused by excessively high drying set-

points that are not in accordance with your drying material recommendations.

✐

Operation l 4-43

4

Operation

NOTE: For more information concerning specific dewpoint control screens, see Control

Function Descriptions, page 4-11.

✐

Using Dewpoint Control

Your dryer is equipped with a dewpoint monitor and dewpoint control features.
You can choose to use it as a monitor only device, or to maintain a steady
dewpoint that you select with the dewpoint control. Dewpoint control will vary
the regeneration air temperature to condition the desiccant to the level necessary
to maintain the desired dewpoint.

Dewpoint Monitor

NOTE: The supervisor's password is necessary. Please refer to the “Using the Supervisor’s

Password” section on page 4-36.

From “Dryer Main Menu”, select “Setup, Other OPT” to get to the “Dryer
Setup Options Information” (screen 14, page 4-13). Proceed to screen 75 (page
4-26). “Dewpoint Monitor” must be set to “Installed” and “Dewpoint Control”
set to “Not Installed”. Screen 11 (page 4-12) will display the actual dewpoint
readout.

Dewpoint Control

NOTE: The supervisor's password is necessary. Please refer to the “Using the Supervisor’s

Password” section on page 4-36.

From “Dryer Main Menu”, select “Setup, Other OPT” to get to the “Dryer
Setup Options Information” (screen 14, page 4-13). Proceed to screen 75 (page
4-26). “Dewpoint Control” must be set to “Installed”. “Dewpoint Monitor”
can be set to “Installed” or “Not Installed”. Screen 11 (page 4-12) will display
the actual dewpoint and the dewpoint setpoint the dryer is to maintain.

✐

✐

NOTE: Dewpoint control is inactive when the dewpoint setpoint is -40° F {-40° C}

.

✐

When supplied for cen­tral drying applications,
the W series dryer does
not have setback capabil­ities. Therefore the set­back function is not
applicable.

Using the Setback Feature

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.

This feature is designed to save you money on energy costs and help to keep you from
over drying your material.

This is how setback operates when the control setback mode is set on Temperature.

The control monitors the temperature of the air exiting the drying hopper. If that tempera­ture reaches a customer-entered setpoint (Screen 27), the delivery process air temperature
will automatically setback to a customer-entered setpoint (Screen 26). Then, if the air
exiting the drying hopper drops below the customer-entered temperature on Screen 27 by
an amount greater than what is shown on Screen 28, the process temperature will auto­matically reset back to the original value (Screen 3).

To Activate Setback:

Screen 25 is used to set the setback mode. Screen 25 can also be used to change or moni­tor the setback mode while in operation.

1 Reference the flow chart starting on Page 4-4 and follow the Menu Tree Path to

access Screen 25.

2 Set the Setback mode. "Off" turns the setback mode off, and the dryer will not

change the process setpoint. The "Temperature" setting tells the control the dryer
should go into setback when the hopper outlet temperature reaches the setpoint on
Screen 27.

3 Once you have selected your setback mode, go to Screen 26 and set the setback

process temperature. This screen shows the setpoint at which the process temperature
will go to once the control goes into setback. Note: Make sure your setback tempera­ture is approximately 40° F above your return air temperature when using this feature.
When the control is in the setback mode, the LED on the dryer display beside SET­BACK will illuminate. The actual temperature on the default screen will still show the
actual temperature measured at the hopper inlet. The setpoint shown on the default
screen will still show the original setpoint..

4-44 l Operation

Using the Setback Feature

(continued)

4 Access Screen 27 and set the setback return temperature for the air

exiting the hopper. This screen shows the actual temperature meas­ured at the hopper outlet and the setpoint temperature for the air at the
hopper outlet that will initiate the control to go into setback.

5 Access Screen 28 and set the setback temperature band. This

screen shows how much lower the hopper outlet temperature must
drop from the Setback Return Temperature setpoint (Screen 27) before
the dryer control should restore the original process setpoint.

Setback Feature Guidelines

Careful selection of setpoint values in these functions is necessary for the
setback to operate properly. The following table is only a guideline of
recommended settings for these setpoints. It will be necessary for each
customer to determine the best setpoints for their application based on
experience.

Operation l 4-45

4

Operation

Normal Setback Return Temp Setback Temp

Drying Temp Screen #27 (Process) Screen #26

160° F {71° C} 120° F {49° C} 150° F {66° C}

240° F {116° C} 135° F {57° C} 180° F {82° C}

300° F {149° C} 160° F {71° C} 200° F {93° C}

340° F {171° C} 180° F {82° C} 220° F {104° C}

4-46 l Operation

Setback Feature Guidelines (continued)

A recommended way to determine the “Setback Return Temperature” setpoint is to
monitor the actual temperature of this function during pre-drying of your material
at start-up, and while running at your normal maximum material throughput. The
“Setback Return Temperature” setpoint should be set 10 to 20° above maximum
temperature noted in these situations.

The “Setback Temperature (Process)” setpoint you select should be adequate to
reduce the temperature significantly enough to prevent over-drying of your materi­al. However, keep in mind that the cooler the temperature selected, the longer it
will take for the material to heat back up to its proper drying temperature once the
dryer comes out of Setback mode.

When drying at low temperatures (for example 160 - 180° F {71 - 82° C}), you are
able to setback the temperature only a small amount. The “Setback Temperature
(Process)” should not be set lower than 150° F {66° C}, even if the control will
allow it. It is very likely the dryer will not be able to achieve low temperatures
without adding additional cooling to the process air circuit. The maximum achiev­able setpoint is dependent on the temperature of the return air coming back to the
dryer. As the return air temperature climbs, the temperature that the dryer is capa­ble of controlling at climbs. For example, if the return air to the dryer is 110° F
{43° C}, the dryer may not be able to control at a “Setback Temperature
(Process)” setpoint below 150 - 155° F {66 - 68°C}.

NOTE: Selecting too low of a setpoint for Screen 26 may result in nuisance Process

Temperature Loop Break alarms if the dryer is not able to achieve this setpoint

.

✐

Maintenance

Preventative maintenance checklist . . . . . . . 5-2

Checking the dewpoint . . . . . . . . . . . . . . . . 5-3

Cleaning the hopper (150 - 200) . . . . . . . . . 5-5

Cleaning the process filter . . . . . . . . . . . . . 5-6

Cleaning the regeneration filter . . . . . . . . . . 5-8

Cleaning the aftercooler coils . . . . . . . . . . 5-10

Cleaning the precooler coils . . . . . . . . . . . 5-12

Cleaning the volatile trap on the demister . . 5-12

Inspecting hoses and gaskets . . . . . . . . . . 5-12

SECTION

5

Maintenance

5

Maintenance l 5-1

5-2 l Maintenance

Preventative Maintenance
Checklist

Routine maintenance will ensure optimum operation and performance of the
W Dryer. We recommend the following maintenance schedule and tasks.

• Whenever you change materials

❒❒

Drain and clean the hopper.

• Weekly, or as often as needed

❒❒

Clean or replace the process and regeneration filters.

You may need to clean filters more often than weekly. Frequency depends
on how much material you process and how dusty or full of fines it is.

❒❒

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.

• Monthly

❒❒

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.

• Every six months

❒❒

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.

❒❒

Verify dewpoint readout and performance with a calibrated portable

dewpoint instrument.

❒❒

Measure current draw on all 3 legs of heater wires. This is to ensure
the heater is working properly.

5

Maintenance

Maintenance l 5-3

✐

NOTE: Portable dewpoint moni-

tors purchased from Conair are

provided with a male connector

that plugs into the Dewpoint

Check port. If you purchased

your portable instrument else-

where, the male connector is

available through the Conair

parts department.

NOTE: The dewpoint check port

was not included on early dry-

ers. It can be added easily.

Contact the Conair parts depart-

ment or follow the alternate

procedure.

✐

(continued)

Replacement dewpoint moni­tors, male connectors and
dewpoint check ports are
available from Conair.

Contact Conair Parts
[phone]
From outside of the
United States, call:
[phone]

Checking the Dewpoint

It is a good idea to monitor the dewpoint performance of your dryer periodically
with a calibrated portable dewpoint monitor, to ensure it is performing at maxi­mum capacity. Even if your dryer has a dewpoint readout, comparing it to a
portable instrument periodically will confirm that the dewpoint sensor and readout
is performing properly.

To check dewpoint:

1 Connect your portable dewpoint meter to the

dewpoint check port of the dryer.

2 Turn on the portable instrument, and ensure

there is positive airflow through the sensor.

3 Monitor the readout and allow ample time for it to stabilize before

disconnecting it. Some dewpoint monitors require a substantial amount of
time for residual moisture to be purged from the sensor.

4 In the event the dewpoint in not satisfactory, refer to the Troubleshooting

section of the manual, alarm P9.

Alternate Procedure: (for dryers with no dewpoint check port)

1 Stop dryer and allow it to cool.

2 Open the right side panel of the dryer, and locate the process heater tube.

3 At the bottom end (cool air inlet) of the process heater tube, remove

1/8 inch NPT pipe plug and connect your portable dewpoint monitor at
this location. If there are existing connections for the dryer’s dewpoint sensor,

locate a 2nd 1/8 inch NPT port, or connect your dewpoint sensor in series with
the dryer sensor. Do not install a tee to split the air between the dryer’s sensor
and your portable instrument. This may cause one of them to be starved for
adequate sample air.

4 Turn on the dryer.

5-4 l Maintenance

Checking the Dewpoint (continued)

5 Turn on the portable instrument, and ensure there is positive airflow through

the sensor.

6 Monitor the readout and allow ample time for it to stabilize before discon-

necting the portable instrument. Some dewpoint monitors require a substan­tial amount of time for residual moisture to be purged from the sensor.

7 In the event the dewpoint is not satisfactory, refer to the Troubleshooting sec-

tion of the manual, under Process Dewpoint alarm for DC2.

8 Stop the dryer, and allow it to cool down. Then disconnect your portable

instrument and replace any pipe plugs that may have been removed.

9 Close side panels and start the dryer.

5

Maintenance

Maintenance l 5-5

Cleaning the Hopper (150 - 200)

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.

1 Drain the hopper. Place a con-

tainer beneath the hopper’s drain
port to catch the material.

2 Remove the spreader 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.

3 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.

4 Repeat the steps in reverse order to reassemble the hopper before adding

material.

5-6 l Maintenance

Cleaning the Process Filter

Clogged filters reduce air flow and dryer efficiency. Cleaning frequency depends
on how much material you process and how dusty or full of fines it is.

1 Push in on the sides to release the

tabs on the front cover. Remove
the cover.

2 Remove the cover wing nut, then

pull the cap off.

3 Remove the filter wing nut, then

remove the filter.

5

Maintenance

Maintenance l 5-7

Cleaning the Process Filter (continued)

4 Remove outer filter and clean it with soapy water.

Let air dry.

5 Clean the filter by laying it on its side and

gently tapping it on the floor. Replace
damaged, worn, or clogged filters.

6 Reverse the procedure to reinstall the process

filter. Ensure that the gasket on filter cap is in
place and in good condition.

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.

TIP: If gasket on the process filter cap becomes loose or detached from the filter cap, resecure with high tempera­ture silicone adhesive.

✒

5-8 l Maintenance

Cleaning the Regeneration Filter

Clogged filters reduce air flow and dryer efficiency. Cleaning frequency depends
on how much material you process and how dusty or full of fines it is.

1 Push in on the sides to release the tabs on

the front cover. Remove the cover.

2 Remove outer filter and clean it with soapy

water. Let the outer filter air dry.

3 Loosen the hose clamp holding the regenera-

tion filter onto the regeneration inlet and
remove the filter.

Maintenance l 5-9

5

Maintenance

Cleaning the Regeneration Filter (continued)

4 Clean dust, fines, and dirt from the filter,

or replace it with a new filter. Clean the
filter by laying it on its side and gently
tapping it on the floor. Replace damaged,
worn, or clogged filters.

5 Reverse the procedure to reinstall the

regeneration filter.

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.

Cleaning the Aftercooler Coils

The aftercooler coils will need to be kept clean to keep the aftercooler working
efficiently. Cleaning frequency depends on the type and amount of material you
process.

1 Stop the dryer and lockout the main power.

2 Turn off the water flow to the water supply line. Disconnect supply and

return lines.

NOTE: If an optional flow control was added with the aftercooler, remove the 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.

3 Remove the screws securing the aftercooler in the aftercooler housing.

✒

TIP: If the aftercooler (without a flow control) was installed using the recommended

24 inch {61 cm} of flexible hoses, there is no need to disconnect the hoses from the

aftercooler inlet and outlet.

4 Remove the aftercooler assembly from the aftercooler housing.

✐

(continued)

5-10 l Maintenance

Cleaning the Aftercooler Coils

5 Clean the assembly using a mild soap and water. Let the assembly

dry thoroughly before installation. In severe situations, steam cleaning
or use of solvents maybe necessary.

CAUTION: During the cleaning process, DO NOT cut or remove the
stainless steel wire that holds the assembly together.

6 Inspect the condition of the gasket. If it is damaged, replace the

gasket.

7 Reassemble by repeating the steps in reverse order.

8 Connect the water supply line to the inlet. If a manual shut off

valve is used, it should be mounted on the inlet line as well.

9 Connect the outlet of the aftercooler to the inlet of the flow control

valve using the pre-shaped copper tubing and compression fittings
provided.

Maintenance l 5-11

5

Maintenance

5-12 l Maintenance

Cleaning the Precooler Coils

If you have the optional precooler, you need to clean the cooling coils to keep
them working efficiently. See Appendix C for details.

Cleaning the Volatile Trap on
the Demister

If you have the optional volatile trap, you need to clean the trap to keep it working
efficiently. See Appendix D for details.

Inspecting Hoses and Gaskets

Loose or damaged hoses and gaskets can allow moisture to seep into the closed­loop drying system.

1 Follow the hose routing of all the hoses within the dryer and inspect all

hoses, clamps, fittings, and gaskets.

2 Tighten any loose hose clamps or fittings.

3 Replace worn or damaged hoses and gaskets.

Troubleshooting

Before beginning . . . . . . . . . . . . . . . . . . . . 6-2

A few words of caution . . . . . . . . . . . . . . 6-3

DIAGNOSTICS

How to identify the cause of a problem . . . . 6-4

Shutdown alarms . . . . . . . . . . . . . . . . . . 6-5

Passive alarms . . . . . . . . . . . . . . . . . . . 6-13

Dewpoint troubleshooting . . . . . . . . . . . . . 6-23

Poor material drying troubleshooting . . . . . 6-24

REP

AIR

Replacing fuses. . . . . . . . . . . . . . . . . . . . 6-29

Checking heater solid state relays . . . . . . . 6-30

Checking or replacing temperature sensors . 6-31

Replacing the heaters

Regeneration heater tube . . . . . . . . . . 6-32

Process heater tube . . . . . . . . . . . . . . 6-34

Replacing the desiccant wheel. . . . . . . . . . 6-36

Replacing the desiccant wheel motor . . . . . 6-37

SECTION

6

6

Troubleshooting

Troubleshooting l 6-1

Before Beginning

You can avoid most problems by following the recommended installation and
maintenance procedures outlined in this User Guide. If you do have a problem,
this section will help you determine what caused it and how to fix it.

Before you open the side panels of the dryer be sure to:

❏ Diagnose causes from the control panel.

1 Press once to silence the optional audible alarm and display the

alarm message.

2 Address the alarm message and fix the problem. (Refer to the alarm

descriptions later in this section.)

3 Press again to clear the alarm. If the alarm reappears the problem

was not fixed.

Acknowledge
Alarm Button

6-2 l Troubleshooting

NOTE: Use of test

mode screens 28-43

may assist with the

determining of possi-

ble cause of an alarm.

Access code 756.

✐

Before Beginning (continued)

❏ Find the wiring and equipment diagrams that were shipped

with your dryer. These diagrams are the best reference for correct-

ing a problem. The diagrams also will note any custom features,
such as special wiring or alarm capabilities, not covered in this
User Guide.

6

Troubleshooting

A Few Words of Caution

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.

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.

WARNING: High voltage. Always stop the Carousel Plus 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.

See warnings
below. Open the
electrical enclosure
to check fuses and
heater contactors.

Troubleshooting l 6-3

How to Identify the Cause of a
Problem

Dryer alarms are indicated by an illuminated Acknowledge Alarm light on the W
series dryer control panel. Shutdown alarms will sound the alarm horn and turn on
the alarm beacon.

A problem can trigger two types of alarms:

• Shutdown: The dryer has automatically shut down because it has 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 could lead to a
condition that will shut down the dryer.

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. Use the information in the table to resolve the cause of the alarm.

3 Note that pressing the Acknowledge Alarm button a second time will clear

the alarm. If at alarm reappears, the cause of the alarm has not been resolved.

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.

Acknowledge
Alarm LED and
Button

✐

6-4 l Troubleshooting

✐

NOTE: Pushing the

Acknowledge Alarm button

when there is no active

alarm will take the user

directly to the Alarm History

list (Screen 95, page 4-34).

NOTE: The dryer cannot be

started if a passive alarm is

present on power-up.

✐

6

Troubleshooting

When supplied for central
drying applications, these
shutdown alarms are not
available.

Shutdown Alarms

If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown
alarm. The dryer will shutdown automatically to prevent damage to the
equipment or personnel. Note that once the Acknowledge Alarm button is
pressed once, the blinking red LED becomes solid.

Problem

Process High Temperature –
If the process temperature
exceeds the process high tem­perature setpoint, it shuts
down the dryer. Defaults are
set to 385°F {196°C} for
20 seconds.

Process Temperature Loop
Break – If the process tem-

perature is outside of the oper­ator entered deviation, alarm
band (see Process High
Temperature Deviation passive
alarm) and the process tem­perature is not moving
towards the setpoint at a rate
greater than specified. It shuts
down the dryer. Defaults are
set at 3°F {3°C} over
20 seconds.

Possible cause

The process high temperature setpoint is
not at least 10°F {6°C} above the drying
setpoint.

One of the process solid state relays has
failed.

The air lines are restricted or loose.

The process setpoint is too low.

The process heater output on the control
board has failed.

Process RTD is loose or has fallen out.

The process heater has failed.

The air lines are restricted or loose.

The process blower is not running or is
running in the wrong direction.

The process heater output on the board
has failed or the output fuse has failed.

Process setpoint is too low.

Setback setpoint is too low.

Solution

Reset the process high temperature
setpoint at least 10°F {6°C} above the
drying setpoint.

Replace the solid state relay.

Straighten any crimps in the hoses.
Tighten any loose hoses.

Set the process setpoint higher or install
an optional precooler.

Replace the control board.

Check the process RTD and tighten if
needed.

Check the heater fuses, and resistance
across each leg of the process heater.

Straighten any crimps in the hoses.
Tighten any loose hoses.

Correct the cause of the non-running
blower (blown fuse, etc.) or reverse the
rotation of the blower.

Replace the board or the fuse for the
output.

Adjust the setpoint or add a precooler.

Adjust the setpoint or add a precooler.

Troubleshooting l 6-5

6-6 l Troubleshooting

Problem

Process Heater High
Temperature – The snap

switch in the process heater
tube opens due to excessive
temperature.

Regeneration Heater High
Temperature – The snap

switch in the regeneration
heater tube activated due to
excessive temperature.

Possible cause

There is an airflow blockage or loose
hoses.

The process blower is not running or run­ning in the wrong direction.

The isolation contactor failed in the
closed position.

The process heater output on the board
has failed.

The heater solid state relays (SSRs) failed.

The regeneration exhaust is blocked or the
air hoses are loose.

The regeneration blower is not running or
running in the wrong direction.

The isolation contactor failed in the
closed position.

The heater solid state relays (SSRs) failed.

The regeneration heater output on the
board has failed.

Solution

Locate and remove any airflow restric­tions.

Tighten any loose hoses.

Correct the cause of the non-running
blower (blown fuse, etc.) or reverse the
rotation of the blower.

Replace the isolation contactor.

Replace the board.

Replace the failed heater solid state
relays (SSRs).

Locate and remove any airflow restric­tions.

Tighten any loose hoses.

Correct the cause of the non-running
blower (blown fuse, etc.) or reverse the
rotation of the blower.

Replace the isolation contactor.

Replace the failed heater solid state
relays (SSRs).

Replace the board.

When supplied for central
drying applications, these
shutdown alarms are not
available.

Shutdown Alarms

If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown
alarm. The dryer will shutdown automatically to prevent damage to the
equipment or personnel. Note that once the Acknowledge Alarm button is
pressed once, the blinking red LED becomes solid.