Conair Carousel Plus W Series, Carousel Plus W300, Carousel Plus W200, Carousel Plus W150, Carousel Plus W400 User Manual

U S E R G U I D E

UG D 05 1-0 4 14

Carousel Plus Dryer

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

www.conairgroup.com

Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861

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: UGD051-0414

Serial Number(s):

Model Number(s):

*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: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential damages in connection with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information, including, but not limited to the implied warranties of merchantability and fitness for a particular purpose.

C o p y ri g ht 20 14 l Co n ai r l A l l ri gh t s re se rv ed

Ta b l e o f C o ntents

1-1 I ntr o d uct i o n

Purpose of the User Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

How the Guide Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Using the Carousel Plus W Series as a Central Dryer. . . . . . . . . . . . . . . . . . . 1-2

Your Responsibility 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 D esc r i pti o n

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

Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

How the Carousel Plus W Series Dryer Works . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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

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

3-1 I nst a l lat i o n

Unpacking the Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Positioning the Dryer on the Floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Removing the Cable Tie from the Desiccant Wheel . . . . . . . . . . . . . . . . . . . . 3-3

Connecting the Main Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Connecting the RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Connecting the Setback RTD Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Checking for Proper Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Connecting the Air Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Connecting the Dryer to the Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Connecting Air Hose Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Connecting the Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Mounting a Loader on the Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Using Communications (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

4-1 O per a t ion

The Dryer System control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

How to navigate the control screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

DC-T Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Ta b le o f Co nt en ts l i

Operation - ResinWorks Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Control Function Flow Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Control Function Descriptions - ResinWorks Configuration. . . . . . . . . 4-16

Operation - Stand Alone Dryer Configuration . . . . . . . . . . . . . . . . . . . . . 4-45

Control Functions Flow Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Control Function Descriptions - Stand Alone Configuration . . . . . . . . 4-56

General Operation - Stand Alone and

ResinWorks Dryer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

DC-T Security Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

Starting the Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83

Adjusting the temperature setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

Stopping the Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85

Stopping the Dryer in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . 4-86

Understanding the Control LED Lights . . . . . . . . . . . . . . . . . . . . . . . . 4-86

Alarm Email and Text Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87

Ethernet TCP/IP Adress Setup to Enable Email/Text Notification . . . . . 4-87

Email Alarm Activation and Address Setup. . . . . . . . . . . . . . . . . . . . . 4-88

Configuring the Email and Text Addresses . . . . . . . . . . . . . . . . . . . . . 4-89

Text Messaging Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90

Enabling and Disabling Notification for Individual Alarms . . . . . . . . . . 4-90

DC-T Web Access Logon and Security . . . . . . . . . . . . . . . . . . . . . . . . 4-94

Web Server Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95

5-1 Ma inten an ce

Preventative Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Checking Dewpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Cleaning the Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Cleaning the Process Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Cleaning the Regeneration Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Cleaning the Aftercooler Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Cleaning the Precooler Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Cleaning the Volatile Trap on the Demister. . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Inspecting Hoses and Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Cleaning the DC-T HMI Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

i i

l Tab l e of C on te nt s

6-1 Tr ou bl eshoo ti ng

Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Diagnostics

How to Identify the Cause of a Problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Shutdown Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Passive Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Additional Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Dewpoint Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

Poor Material Drying Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

Repair

Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Checking Heater Solid State Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Checking or Replacing Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . 6-32

Replacing the Heaters

Regeneration Heater Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Process Heater Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

Replacing the Desiccant Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

Replacing the Desiccant Wheel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

A A ppe n d ix

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 A ppe n d ix

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

C A d den d u m

DC-T Modbus TCP/IP Read Only Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Ta b le o f Co nt en ts l ii i

i v l Ta b l e of C on te nt s

I n troduc t i o n

P u r p o s e of t he U se r Gui de . . . . . . . . . . . . . . . . . 1 - 2

H o w t he Gu id e Is Or ga ni ze d . . . . . . . . . . . . . . . . 1 - 2

U s i n g the Ca ro us el P l u s W S er ie s

a s a C e n t r a l Dr ye r . . . . . . . . . . . . . . . . . . . . 1- 2

S E C T I O N

I n tro d uc ti o n

Yo ur Re sp on si bi li ti es a s a U se r . . . . . . . . . . . . . . 1 -3

A t t e n t i o n : R ea d Th is s o No One Ge ts H ur t . . . . . . . 1- 4

H o w t o U se t he Lo ck ou t De vi ce . . . . . . . . . . . . . . 1- 6

I n t r od u ct i on l 1 - 1

P u r p o s e o f t h e U ser Gu i d e

This User Guide describes the Conair Carousel Plus W Series Dryers and explains step-bystep how to install and 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.

H o w t h e G u i d e i s O r g an i z e d

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.

U s i n g t h e C a r ou s e l P l u s W S e r i es a s a C e n t r a l D r y e r

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.

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

1 - 2 l In tr o du ct i on

u r

R e

p o

n s

i b i l i t

U s

Yo m

• T

• S

, an

, o

saf

. Re

ce o

war

zar

e, p

User

ces,

e so

, wi

sel

war

se a

sso

s User

I n tro d uc ti o n

I n t r od u ct i on l 1 - 3

AT T E N TI O N : R e a d T h i s S o N o O n e G e t s H urt

We design equipment with the user’s safety in mind. You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide.

WA RN IN G: I mp ro pe r i ns ta ll at io n, o p e r a t i o n , o r s er vi c i n g may re su lt i n equ ip me nt da ma ge o r per so na l i n j u r y.

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.

WA RN IN G: V ol ta ge h az ar d

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 In tr o du ct i on

AT T E N TI O N : R e a d T h i s S o N o O n e G e t s H urt

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.

( c o nt i nu ed )

CA UT IO N: H ot Su rfa ce s.

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

WA RN IN G: D o n ot p la ce ae ro so l, c o m p r e s s e d ga s o r f l a m m a b l e mat er ia l s on o r nea r t hi s eq u i p m e n t .

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

I n tro d uc ti o n

I n t r od u ct i on l 1 - 5

H o w t o U s e t h e L o c k o ut De v i c e

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

nect 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:

Stop or turn off the equipment.

Isolate the equipment from the electric power. Turn the rotary

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

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

in the holes to prevent movement.

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:

Remove the lock or tag.

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

1 - 6 l In tr o du ct i on

S E C T I O N

D e script i o n

W h a t is th e Ca ro us el Pl us W Ser i e s Dr ye r? . . . . . . . 2- 2

Typ ic al A pp li ca t i o n s . . . . . . . . . . . . . . . . . . . . . . 2- 2

H o w I t Wo r k s . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -4

S p e c i f i c a ti on s: C a r o u s e l Pl us W S er ie s

D r y er . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 6

C a r o u s e l Pl us W S er ie s D ry er Op ti on s . . . . . . . . . . 2- 7

D e scr i pt io n

D e s c ri p ti o n l 2 - 1

W h a t i s t h e C a r o use l P l u s W S e r i e s D r y er?

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.

Ty p i c al Ap p l i c a ti o n s

1 Dryer on the floor; hopper on the throat.

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

3 Dryer on the floor, multiple hoppers in central configuration (ResinWorks) with separate

heat source for each hopper.

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.

2 - 2 l De sc r ip ti o n

( C o nt i nu ed )

Ty p i c al Ap p l i c a ti o n s ( co n ti nu ed )

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:

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

D e scr i pt io n

D e s c ri p ti o n l 2 - 3

H o w I t Work s

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 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, 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.

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.

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.

2 - 4 l De sc r ip ti o n

EGENERATION

AIR FILTER

DESICCANT

WHEEL

REGENERATION

BLOWER

REGENERATION

EATER

HIGH TEMP

SHUTOFF

REGENERATION

RTD

HOPPER

PROCESS

BLOWER

RETURN

AIR

FILTER

4 PROCESS FILTER STATUS

RETURN

AIR

RTD

ROCESS

2 SETBACK TEMPERATURE

IGH TEMP

SHUTOFF

PROCESS

HEATER BOX

7 PRECOOLER

DRYER OPTIONS

3 DEWPOINT MONITOR / CONTROL

PROCESS

COOLING

REGENERATION

ROCESS

ROTECTION

REGENERATION

OUTLET

RTD

6 PHASE ROTATION PROTECTION

AFTERCOOLER

LARM LIGHT

LARM BELL

5 CURRENT METER

1 PROCESS CFM MONITOR

H o w I t Work s ( c o nt i nu ed )

D e scr i pt io n

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.

D e s c ri p ti o n l 2 - 5

S p e c i f ic a t i o n s: C ar o u s e l P l us W S e ri e s D r y ers

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

Drying temperature

†

All models 100°- 375°F {38°- 191°C} with options

Dew point All models -40°F {-40°C}

Dimensions inches {cm}

A - Height 64.3 {163.3} B - Overall width 29 {73.7} C - Depth 51.5 {130.8} Outlet/inlet tube size OD 2.5 {63.5} 5.0 {127.0} 5.0 {127.0} 5.0 {127.0}

Weight lbs {kg}

Standard dryer installed 600 {272} 660 {300} 710 {322} 760 {345}

Voltage - Full load amps Standard/Central drying

230 V/3 phase/60 Hz 47.1 / 16.7 57.6 / 19.9 67.7 / 30.0 N/A 400 V/3 phase/50 Hz

23.4 / 8.9 32.1 / 10.4 37.9 / 16.2 64.5 / 21.1 460 V/3 phase/60 Hz 21.0 / 8.4 28.9 / 10.0 34.0 / 15.1 56.3 / 18.6 575 V/3 phase/60 Hz 16.8 / 6.7 23.7 / 8.6 27.3 / 12.2 43.2 / 13.0

Water requirements {for aftercooler or optional precooler}

Recommended temperature Water flow Water connections NPT 3/4 inch NPT

SPECIFICATION NOTES:

gal./min.{liters/min.}

‡

45°- 85°F

3 {11.4}

†

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

†

When drying below 150°F {66°C} a precooler is required.

‡

Temperatures above or below the recommended levels may affect dryer performance. Tower, chiller or municipal water sources can be used.

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

APPLICATION NOTES:

All dryers are supplied with an aftercooler as standard. The aftercooler reduces the temperature of the return air from the drying hopper, improving the efficiency of the desiccant. The aftercooler must be connected with the proper water flow rate and temperature to attain the rated throughput.

When to use central models

Central dryers do not have process heaters. These models should be used when drying multiple materials that require different drying temperatures. Central models dehumidify the process air, which is then heated to the correct setpoint by a Heater Pack mounted on the hopper and controlled from the dryer.

When to use additional filtration

The standard return air cartridge filter is sized for the airflow of each dryer model and is suited for most applications. You should consider adding an optional dust collector and/or volatile trap if:

●

The material contains excessive fines. An

additional dust collector or cyclone will extend time between filter cleaning.

●

The material produces volatiles during

drying which condense into a waxy or oily residue. A volatile trap will help to protect the desiccant.

2 - 6 l De sc r ip ti o n

TPDX018-0113

C a r o u s el P lu s W Ser i e s D r y e r O p t i o n s

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

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

• Precooler - The precooler reduces the temperature of air flow after the desiccant 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 airflow across

the inlet/outlet of the process blower.

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

trol systems. DeviceNet communications are standard. Alternate communications are available.

D e scr i pt io n

( C o nt i nu ed )

D e s c ri p ti o n l 2 - 7

2 - 8 l De sc r ip ti o n

I n stalla t i o n

U n p a c k i n g the Bo xe s . . . . . . . . . . . . . . . . . . . . . 3- 2

P r e p a r i n g for In st al la ti on . . . . . . . . . . . . . . . . . . 3- 3

Po si ti on in g t he D r y e r on t h e Fl oo r . . . . . . . . . . . . 3 -3

R e m o v i n g th e C a b l e Ti e fr om th e D e s i c c a n t Wh ee l . . 3 - 3

S E C T I O N

I n sta l la ti on

C o n n e c t i n g th e M a i n Po we r . . . . . . . . . . . . . . . . . 3- 4

C o n n e c t i n g th e P r o c e s s RT D Pro be . . . . . . . . . . . . 3 -5

C o n n e c t i n g th e S e t b a c k RT D Pro be . . . . . . . . . . . . 3 -5

C h e c k i n g fo r P r o p e r A ir Fl ow . . . . . . . . . . . . . . . . 3 -6

C o n n e c t i n g th e Ai r Ho se s . . . . . . . . . . . . . . . . . . 3 - 9

C o n n e c t i n g th e D r y er t o the Ho pp er . . . . . . . . . . . 3 -9

C o n n e c t i n g A ir Ho se A d a pt er s . . . . . . . . . . . . . . 3 -1 0

C o n n e c t i n g th e Af te rc oo le r . . . . . . . . . . . . . . . . 3- 11

M o u n t i n g a L o a d e r on t h e Ho pp er . . . . . . . . . . . . 3- 12

Te st in g t he I ns ta ll a t i o n . . . . . . . . . . . . . . . . . . . 3 -1 2

U s i n g Com mu ni ca t io ns ( Op ti on al ) . . . . . . . . . . . . 3 - 1 3

I n s t al l at io n l 3 - 1

U n p a c k in g th e B o x e s

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

• 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.

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

• Central dryer, with ResinWorks system.

3 - 2 l In st a ll at io n

P r e p a r in g fo r I n s t a l la t i o n

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

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.

Posit i o n i n g t he Dr y e r o n t h e F l oo r

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.

I n sta l la ti on

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.

R e m o v in g t h e C a b l e T i e f r o m t h e D e s i c c an t Wh e e l

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

it was not done while unpacking the dryer.

Desiccant cable tie

I n s t al l at io n l 3 - 3

C o n n e c ti n g t h e M a i n Po w e r

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

nections. 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.

Insert the main power

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.

wire through the knockout in the

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

3 - 4 l In st al la ti on

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.

C o n n e c ti n g t h e P r o c e ss RTD P r obe

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.

Setback RTD

Process RTD

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.

C o n n e c ti n g t h e S e t b a ck 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 elec-

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

I n sta l la ti on

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.

I n s t al l at io n l 3 - 5

O N

✐

NOTE: Users must be

logged in as Maint 1

(user level 3) in order to

perform this operational

test.

C h e c k i ng for Pr o p e r A i r F l o w

IMPORTANT: This procedure must be performed before loading material into the hopper.

CAUTION: If the airflow direction is incorrect due to improper phase connection, material from

the hopper can be pulled back into the dryer, 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 will illuminate.

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

2 From the Home Screen , press the “Setup” button.

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 - 6 l In st a ll at io n

C h e

3 Pr

4 Pr

5 Pr

powe

Pr one

k i

O S

“

“De

ss the

button to star

button agai

ss the

ond to stop the

d )

i n u e

n t

(

l o

”

“

”

“

I n sta l la ti on

”

owe

t the

about

n afte

owe

✐

NOTE: On initial test (first time

in Dryer I/O Test Mode) the

process blower will automati-

cally start. Press the button

beside “Delivery Air Blower” to

stop the blower.

ear the

your

6 Ho

feel

sho

tlet.

e o

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.

If air flow is incorrect disconnect

power, follow proper lockout proce dures and swap any 2 of the 3 main power wires.

delivery

lowin

air b

Return

Air Inlet

Dry Delivery Air

Moisture Exhaust

( C o nt i nu ed )

I n s t al l at io n l 3 - 7

C h e c k i ng for Pr o p e r A i r F l o w ( co nt i nu ed )

✐

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 blo wer is turning in the wrong direction. Turn

off and lock out the main power source. Open the electrical enclosure and reverse

any two leads connecting the main power supply to the dryer.

LEADS

3 - 8 l In st a ll at io n

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.

C o n n e c ti n g t h e A i r H o s e s

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 dr yer 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.

Return Air Inlet

Dry

2 Attach one hose from the delivery

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

Delivery Air

I n sta l la ti on

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.

C o n n e c ti n g t h e D r ye r to th e Ho p p e r

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.

✐

NOTE: Water to cooler

should be turned off

when the dryer is not

running to prevent

condensation

I n s t al l at io n l 3 - 9

C o n n e c ti n g A i r H o s e A d a pte r s

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

To connect the air hose adapter:

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.

Pressure clamp

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

3 - 1 0 l In st al la ti o n

( C o nt i nu ed )

C o n n e c ti n g t h e A f t e r co o l e r ( O pt io n al )

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 after-

cooler housing using the six screws.

Aftercooler

2 Connect the water supply line to the aftercool-

er inlet. If a manual shut off valve is used, it should be mounted on the inlet line.

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.

I n sta l la ti on

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 preventcondensation.

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.

I n s t al l at io n l 3 - 1 1

M o u n t i ng a L o ad e r o n t h e H o p p e r

If you have a Conair loader or vacuum receiver, you can use the flange and mounting clips provided on the top of the hopper. Refer to the manuals that came with your receiver or loader for detailed installation instructions.

Tes t i n g t h e I n sta l l a t ion

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 From the Home Screen, press the

“System Overview” button.

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

3 - 1 2 l In st al la ti o n

4 From the Overview Screen, press the

magnifying glass button beside the dryer. (Also referred to as the “Dryer Zoom” button.)

5 From the Dryer Screen, verify that set-

points are correct, and press the dryer start button.

125

-40

350

( C o nt i nu ed )

Tes t i n g t h e I n sta l l a t ion (c o n ti nu ed )

If everything is installed correctly:

• The regeneration and process blowers turn on

• The regeneration heater turns on

• The process heater will energize (if configured as a stand alone dryer)

• The dryer’s desiccant wheel starts turning. (If the desiccant wheel does

not turn, turn off the dryer, disconnect from power, and verify that the desiccant wheel tie has been removed

6 From the Dryer Detail screen, press the dryer stop button.

If everything is installed correctly:

• The blowers will continue running as needed to cool the

heaters. (Until regeneration heaters are less than 150°F {66°C}.)

7 The test is over. If the dryer performed the normal operating

sequences as outlined, reconnect the material source to the optional hopper receiver and begin normal operation. If it did not, refer to the Troubleshooting section of the User Guide.

125

-40

IMPORTANT: Be sure the cable tie

has been removed from the desic-

cant wheel.

I n sta l la ti on

U s i n g C o m m un i c a t i on s ( O p ti o na l)

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

SPI connection

Ethernet connection

DeviceNet connection

✐

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

I n s t al l at io n l 3 - 1 3

3 - 1 4 l In st al la ti o n

O p eratio n

The Dryer System Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

How to navigate the Control Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

DC-T Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Operation - ResinWorks Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Control Function Flow Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Control Function Descriptions - ResinWorks Configuration . . . . . . . . 4-16

Operation - Stand Alone Dryer Configuration . . . . . . . . . . . . . . . . . . . . 4-45

Control Functions Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

S E C T I O N

O p era tio n

Control Function Descriptions - Standard Configuration . . . . . . . . . . 4-56

General Operation - Stand Alone and

ResinWorks Dryer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

DC-T Security Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

Starting the Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83

Adjusting the Temperature Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

Stopping the Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85

Stopping the Dryer in An Emergency . . . . . . . . . . . . . . . . . . . . . . . . 4-86

Understanding the Control LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86

Alarm Email and Text Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87

Ethernet TCP/IP Address Setup to Enable Email/Text Notification . . . 4-87

Email Alarm Activation and Address Setup . . . . . . . . . . . . . . . . . . . . 4-88

Configuring the Email and Text Addresses . . . . . . . . . . . . . . . . . . . . 4-89

Text Messaging Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90

Enabling and Disabling Notification for Individual Alarms . . . . . . . . . 4-90

DC-T Web Access Logon and Security . . . . . . . . . . . . . . . . . . . . . . . 4-94

Web Server Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95

O p e r at io n l 4 - 1

D r y er S ys t e m C o n t rol Panel

✐

NOTE: The bottom of the Home

screen displays valuable infor-

mation, including the current

date and time, the HMI software

version, the dryer board ver-

sion, and Conair’s copyright.

The software version and board

version will be helpful for serv-

ice and troubleshooting purpos-

es.

Dryer board version

HMI software version

On power-up, the Carousel Plus Dryer control displays the initial system Home screen.

At start-up, the system security level is "Default". Once the operator clicks the Login button and enters the user name and password, access is permitted to various areas of the control. The user, depending on security access level, can access the various system and setup screens for the entire Carousel Plus Dryer system.

4 - 2 l O pe ra ti on

Stand alone dryer

Central or ResinWorks dryer

Your DC-T Carousel Plus Dryer Control has been configured at the factory based on the configuration you chose when placing the order. The DC-T can be configured for use with a ResinWorks dryer with multiple hoppers, a central dryer with separate heat source to multiple hoppers, or as a stand alone dryer with a single hopper. Once this factory configuration is set (based upon your order) a customer can not change this configuration. The screens, the screen flow, and operation will differ greatly depending on which configuration you are using. The Operation section of this user guide covers each of the three configurations individually.

H o w t o N a v i g a te th e Co n t r o l S c re e n s

Navigate through the DC-T control screens by touching any navigation "buttons" and/or magnifying glass icons.

Navigation Buttons

Touching the navigation buttons will take the user to the control screen selected.

O p era tio n

Magnifying Glass Icons

Touching the magnifying glass icons will take the user to screens that contain detailed information about the system component selected.

(continued)

O p e r at io n l 4 - 3

H o w t o N a v i g a te th e Co n t r o l S c re e n s

( c o nt i nu ed )

The user name, password and other information can be entered using the pop-up keyboard window that appears when an appropriate field is touched.

✐

NOTE: Changing most parame-

ters will require a user login at

the proper security level.

the Operation section of this

User Guide entitled DC-T

System Security Levels for

more information about user

See

350

Set points can be entered within fields with a heavy black boundaries. Values shown within colored boxes are “actual” values and can not be changed.

Actual Values (NonChangeable)

Set point Field (User Changeable)

350

-40

4 - 4 l O pe ra ti on

(continued)

H o w t o N a v i g a te th e Co n t r o l S c r e e n s ( c on t in ue d)

All beveled grey buttons on the DC-T control screen are selectable and will direct you to another screen. At any point, pressing the Home button will return you to the home screen.

O p era tio n

O p e r at io n l 4 - 5

Screen name

Indicates what screen you are currently l

ooking at.

T h e D C - T C o n t ro l Panel

Below is a screen from the DC-T while in operation. This screen is shown as a sample of functionality of a typical DC-T screen. See the functional descriptions below. The following pages are helpful in understanding how to use the DC-T Control.

Displayed data

isplays the current

live data for the piece o

f equipment. If this

data displays as all dashes or blanks, t

here is a communi-

cation error.

Magnifying glass / “Zoom button”

Use these buttons to zoom to more information about the equipment. In this example, this Dryer Zoom button takes you to the ResinWorks Dryer screen.

Date and Time

This area displays the current date and time.

Enabled Options

This area displays icons to let you see what options are currently being used. For example, this dryer is using the Temperature Setback feature, the Dewpoint Control, and Autostart and Autostop.

✐

NOTE: Depending upon which options were ordered or are enabled, different icons may appear as available or una vailable.

System status

This area displays messages to let you know the current status of the dryer.

Help Overview button

Help for the current screen.

Previous button

Returns to the previous list of items.

Next button

Moves to the next list of items.

Hopper Selection button

Go to the Hopper Selection s

creen.

Alarms button

Go to the Alarms area.

Trending buttons

Go to the Trend Selection screen.

Setup button

Go to the Setup screen.

Home button

Go to the Home screen.

4 - 6 l O pe ra ti on

System Overview button

Go to the System Overview screen.

This button is used to login or log out as a user.

O p eratio n - R e s i n W orks C o n f i g u r a t i o n

The following pages (screen flow charts, screen descriptions, and basic operation) describe the operation of the dryer when factory configured as a ResinWorks dryer attached to multiple hoppers, or as a central dryer attached to one or multiple hoppers with delivery air heat at each hopper.

O p era tio n

O p e r at io n l 4 - 7

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Hom e sc r ee n

Home

Help Overview

ResinWorks Overview

Active Alarms

Trend Selection

4 - 8 l O pe ra ti on

Setup

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Ove r vie w sc r ee n

System Overview

Dryer Detail

Hopper Selection

O p era tio n

In eq

al h

creen

Ready to Run

al h

er DM3-e (if

) s

creen

al h

settings screen

O p e r at io n l 4 - 9

Home

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Ala r m s c re e n

Alarms

4 - 1 0 l O pe ra ti on

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Tr e nd S ele c ti o n s c ree n

Air Temp. Trending

DM3-e Hopper Trend Selection

DM3-e Individual Hopper Trend

Trend Selection

Dewpoint Trending

O p era tio n

Hopper Heater Trend Selection

Individual Hopper Air Temp. Trend

( C o nt i nu ed )

O p e r at io n l 4 - 1 1

Setup

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Set u p s c re e n

ResinWorks Setup

RW Dryer Options

Autostart Setup

4 - 1 2 l O pe ra ti on

Hopper Names

Hopper Setup

Hopper Comms

( C o nt i nu ed )

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Set u p s c re e n (c on ti n ue d)

Setup

Set Time and Date

Regen Setup

Regen PID Auto Tune

O p era tio n

PID Values Reset To Default

Dewpoint Setup

Temp Sensor Setup

Digital Output Test

(continued)

I/O Setup

Digital I/O Status

O p e r at io n l 4 - 1 3

Setup

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Set u p s c re e n (c on ti n ue d)

Alarm Setup

Shutdown Alarm Setup 2

User Manager

Clean Screen

Ethernet Setup

Shutdown Alarm Setup 1

Passive Alarm Setup 1

Passive Alarm Setup 2

4 - 1 4 l Op er at io n

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Log i n/ L og o ut s c re e n

Security Manager

Home

O p era tio n

O p e r at io n l 4 - 1 5

✐

NOTE: On this Overview screen, live data is displayed. Data is displayed as colored text inside a solid black box. Set points boxes are white with heavy black borders. Set points can be changed, if the user has logged in at the proper security level, by pressing the set point boxes. This will launch a pop-up keypad window that can be used to change the

See Operation section

set point.

entitled, How to Navigate the Control Screens.

set point value has been entered, press the "Enter" key to lock in the new set point.

After the new

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n

System Overview Screen

To access the System Overview Screen:

1 Press the System Overview button located on the home screen.

The System Overview screen provides the user with the current live information concerning the delivery air dewpoint, the total run hours, and the control panel temperature.

This screen also allows the user to use the zoom buttons and select the dryer detail information or the hopper(s) detail information.

4 - 1 6 l O pe ra ti on

Dryer zoom

Hopper zoom

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n

System Overview Screen

To access the System Overview screen:

( c o nt i nu ed )

350

-40

1 Press the Magnifying Glass (zoom) button associated with the dryer on the System

Overview screen.

O p era tio n

The System Overview screen provides the user with the current live information concerning the processes within the dehumidifying dryer including:

• Regeneration Temperature (Regen. Temp)

• Return Air Temperature (Temp)

• Dewpoint

• Wheel Out Temperature (Temp)

It also tells the user the current status of the dryer blower (running or idle), as well as which features (Autostart, Autostop, Setback, Dewpoint Control) are enabled.

If the user is logged-in at the proper security level, setpoint changes can be made to:

• Regeneration Temperature Setpoint - Conair recommends not changing this setting.

• Dewpoint Setpoint (optional)

This screen also allows the user to start or stop the dryer. The user can also view the other system parameters, view alarms, view trending, view hopper settings, return to the System Overview screen, or return to the Home screen by pressing the applicable buttons on the right of the screen.

✐

NOTE: Live data is displayed as colored text inside a solid black box. Set points boxes are white with heavy black borders. Set points can be changed, if the user has logged in at the proper security level, by pressing the set point boxes. This will launch a pop-up keypad window that can be used to change the set point.

See Operation section entitled, How to Navigate Control Screens.

After the new set point value has been entered, press the "Enter" key to lock in the new set point.

(continued)

O p e r at io n l 4 - 1 7

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n ( c on ti nu e d)

Hopper Selection Screen

To access the Hopper Selection screen:

1 Press the Magnifying Glass (zoom) button associated with the hopper on the System

Overview screen.

The Hopper Selection screen provides the user with the list of enabled hoppers. If the list is empty, or does not show the proper number of hoppers, Setup has not been completed yet.

See Operation section entitled: Hopper Setup.

✐

NOTE: Depending on which options your dryer has been configured with, and whether or not you have the DM3-e Drying Monitor enabled, your screens and icons may appear different. For example, if your ResinWorks system is DM3-e equipped, your hoppers will display as Drying Monitor hoppers.

4 - 1 8 l O pe ra ti on

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n ( c on ti nu e d)

Individual Hopper Screen

Ready to Run

✐

NOTE: Depending on which options your dryer has been configured with, and whether or not you have the DM3-e Drying Monitor enabled, your screens and icons may be different from what is shown here. For example, if your ResinWorks system is DM3-e equipped, your hoppers will display as Drying Monitor hoppers (as shown in these graphics).

To access the Individual Hopper screen:

1 Press the hopper button of the hopper you would like to view.

The Individual Hopper screen provides the user with the current live information concerning the processes within the hopper including:

• Current temperature in each of the six DM3-e sensor zones (if equipped).

• DM3-e status (if equipped).

• Hopper process heater status (if equipped).

• Hopper Outlet Temperature (Temp)

• Setback status (if equipped)

• Process Temperature

• Process Heater Output %

• Dryer Status

• Dryer features active (Setback, Dewpoint Control, Autostart, Autostop)

This screen allows the user to start or stop the hopper heater.

It also tells the user the current status of the dryer (running or idle), as well as which features (Autostart, Autostop, Setback, Dewpoint Control) are active.

If the user is logged-in at the proper security level, they can use the Magnifying Glass (zoom) button near the tempeature zones to access DM3-e Settings, and the Magnifying Glass (zoom) button near the bottom of the hopper to access the hopper setpoint settings.

The user can also view the other system parameters, view alarms, view trending, view hopper settings, return to the System Overview screen, or return to the Home screen by pressing the applicable buttons on the right of the screen.

O p era tio n

✐

NOTE: See the Appendix of this

User Guide for more information about using the DM3-e Drying Monitor.

✐

NOTE: In addition to starting and stopping the dryer, the Start and Stop buttons indicate whether the dryer can currently be started or stopped. A faded or not vibrant button indicates that the dryer is not ready/able to complete that function. For example, a faded Stop button indicates the dryer is not ready to stop.

(continued)

O p e r at io n l 4 - 1 9

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W

✐

NOTE: Set points boxes are white with heavy black borders. Set points can be changed, if the user has logged in at the proper security level, by pressing the set point boxes. This will launch a pop-up keypad window that can be used to change the set point.

section entitled, How to Navigate the Control Screens.

set point value has been entered, press the "Enter" key to lock in the new set point.

See Operation

After the new

C o n f i g ur a t i o n

( c o nt i nu ed )

Hopper Setpoint Settings screen

350

Ready to Run

280

To access the Hopper Setpoint Settings screen:

1 Press the Magnifying Glass (zoom) button associated with the hopper on the

Individual Hopper screen.

The Hopper Settings Screen allows the user to establish the setpoints for the Delivery Air, the Setback, the Hopper Outlet Temperature, and to enable/disable the Setback feature. These setpoints can be adjusted for each hopper in your drying system (if equipped with setback).

✐

NOTE: Setback must be inistalled and enabled at each HTC in a central drying system.

✐

NOTE: See the Appendix of this

User Guide for more information about using the DM3-e Drying Monitor.

4 - 2 0 l O pe ra ti on

Temperature Setback explained:

The purpose of Temperature Setback is to save on delilvery air heat (energy) and to minimize resin degradation due to overheating the material.

Temperature Setback works by monitoring the air temperature at the top of the hopper. The setback features drops the delivery air temperature if the air temperature at the top of the hopper gets too high. This saves energy and keeps the material from overheating.

✐

NOTE: High temperature at the top of the hopper could be the result of dried resin not leaving the hopper as it should, or fresh resin not entering the hopper as it should. Check the conveying system to make sure that material is entering and exiting the hopper when it should be.

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n

DM3-e Hopper Settings Screen (if equipped)

Ready to Run

To access the DM3-e Hopper Settings screen:

( c o nt i nu ed )

1 Press the Magnifying Glass (zoom) button associated with the Drying Monitor (beside

the temperature zones).

✐

NOTE: See the Appendix of this

User Guide for more information about using the DM3-e Drying Monitor.

✐

NOTE: The Drying Monitor board version number is listed on the bottom of this p op up window. This information is helpful for service and troubleshooting.

O p era tio n

The DM3-e Hopper Settings Screen provides the user with the current alarm location zone, and the Alarm Setpoint, as well as a button to enable or disable DM3-e for this hopper. These settings can be adjusted for each hopper in your DM3-e system.

(continued)

O p e r at io n l 4 - 2 1

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W

✐

NOTE: Your DC-T control should have been configured at the factory for your ResinWorks system. These settings should not need changed unless your system changed, or the control was replaced. Proper login is required to change these settings.

C o n f i g ur a t i o n

ResinWorks System Setup screen

To access the ResinWorks Setup screen:

( c o nt i nu ed )

1 Press the Settings button from the Home screen.

2 Press the ResinWorks Setup button.

✐

NOTE: See the Appendix of this

User Guide for more information about using the DM3-e Drying Monitor.

The ResinWorks System Setup screen provides the user with the ability to change the system settings of this ResinWorks system.

This screen allows you to change:

• Hopper and hopper heater count

• Units selection (Fahrenheit and Celsius)

• Drying Monitor (DM3-e) enabling

• Dryer model

• Clock display (12 hour and 24 hour)

• Voltage selection

4 - 2 2 l O pe ra ti on

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n

ResinWorks Dryer Options screen

To access the ResinWorks Dryer Options screen:

( c o nt i nu ed )

1 Press the Settings button from the Home screen.

2 Press the ResinWorks Dryer Options button.

The ResinWorks Dryer Options screen provides the user with the ability to enable or disable options.

O p era tio n

This screen allows you to change:

• Filter Check Monitor

• Dewpoint Monitor

• Dewpoint Control

• Regen Heater Current

✐

NOTE: Proper login is required to change these settings.

(continued)

O p e r at io n l 4 - 2 3

✐

NOTE: Proper login is required to change these settings.

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n ( c on ti nu e d)

Autostart Setup screen

To access the ResinWorks Autostart screen:

1 Press the Settings button from the Home screen.

✐

NOTE: Autostart timer uses 24 hour time format. 00:00 is midnight. Note that this is a seven (7) day repeating calendar, and not real time.

2 Press the Autostart Setup button.

The ResinWorks Autostart Setup screen provides the user with the ability to enable or disable and set the start and stop time for dryer for each day of the week.

To setup Auto Start and Auto Stop:

1 Press the Enable button to enable Dryer Auto Start.

2 Press the Enable button next to each day of the

week you would like to set the Auto Start time.

3 Set the Auto Start time for each day you have

enabled.

4 Press the Enable button next to each day of the week you

would like to set the Auto Stop time.

5 Set the Auto Stop time for each day that you have enabled.

4 - 2 4 l Op er at io n

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n ( c on ti nu e d)

ResinWorks Hopper Setup screen

To access the ResinWorks Hopper Setup screen:

1 Press the Settings button from the Home screen.

2 Press the Hopper Setup button.

O p era tio n

The ResinWorks Hopper Setup screen provides the user with the ability to move to a screen where you can:

• Customize hopper names

• Enable hopper heater communication

• Enable DM3-e communication (if equipped)

• Enable DM3-e alarms (if equipped)

✐

NOTE: Proper login is required to change these settings.

✐

NOTE: See the Appendix of this

User Guide for more information about using the DM3-e Drying Monitor.

(continued)

O p e r at io n l 4 - 2 5

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W

✐

NOTE: Proper login is required to change these settings.

C o n f i g ur a t i o n

Hopper Names screen

To access the Hopper Names screen:

( c o nt i nu ed )

1 Press the Settings button from the Home screen.

2 Press the Hopper Setup button.

✐

NOTE: Changing the hopper display name does not change the order of the hoppers. This order is based on the hopper communications settings and can not be changed.

✐

NOTE: Hopper names can be changed multipe times as necessary. Conair recommends naming the hopper using whatever system works for your application. Some users may choose to name hoppers by material type or color; others may choose to name hoppers based on physical characteristics, such as CH-54 Hopper.

3 Press the Hopper Names button.

The Hopper Names screen provides the user with the ability to customize the name of any hopper in the system. This name will be displayed as the hopper name on all future screens.

To customize a hopper name:

1 Press the text inside the box of the hopper you would like to rename. All hoppers

are factory named “16c Hopper Name”. (This is simply a space holder for a user entered hopper name up to 16 characters.)

2 Use the keypad to

enter your new hopper name. Hopper

names can be up to 16 characters in total length.

3 Press the enter button

when complete.

4 Use steps 1 through 3

to change the name of each hopper you would like to customize.

4 - 2 6 l O pe ra ti on

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n ( c on ti nu e d)

Hopper Comms (Communications) screen

To access the Hopper Comms screen:

1 Press the Settings button from the Home screen.

2 Press the Hopper Setup button.

3 Press the Hopper Comms button.

The Hopper Comms screen provides the user with the ability to enable or disable communications to the hopper heater(s).

To enable communications to a hopper heater:

1 Press the Enable button beside the hopper heater you would

like to enable. The button will illuminate green. If communications are successful, the LED beside the button will change from grey to green.

2 Enable communications to any other hopper heaters you

would like to enable.

✐

NOTE: Proper login is required to change these settings.

O p era tio n

✐

NOTE: The ID # refers to the RS-485 Modbus ID address. This number will never change. The text “16c Hopper Names” will change to whatever name you change it to in the hopper name screen.

Descriptions - RW Configuration, Hopper Names screen.

(continued)

See Operation: Control Function

O p e r at io n l 4 - 2 7

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W

✐

NOTE: Proper login is required to change these settings.

C o n f i g ur a t i o n

Regen Setup screen

To access the Regen Setup screen:

( c o nt i nu ed )

1 Press the Settings button from the Home screen.

2 Press the Regen Setup button.

✐

NOTE: It is not typically necessary to use the Regen PID Auto Tune or the Reset PID Values to Factory button. Contact the Conair Service department if you have questions about these items. Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861.

4 - 2 8 l O pe ra ti on

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n

I/O Setup screen

To access the I/O Setup screen:

( c o nt i nu ed )

1 Press the Settings button from the Home screen.

2 Press the I/O Setup button.

The Dryer I/O Setup screen provides the user with the ability to open the Dewpoint Sensor Setup, the Temp Sensor Setup, the Digital I/O Status or the Digital Output Test screen.

✐

NOTE: Proper login is required to change these settings.

O p era tio n

(continued)

O p e r at io n l 4 - 2 9

✐

NOTE: Proper login is required to change these settings.

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n ( c on ti nu e d)

Dewpoint Setup screen

To access the Dryer Dewpoint Sensor Setup screen:

✐

NOTE: These are factory settings and should not need changed. Consult with Conair before making any changes to these settings. Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861.

1 Press the Settings button from the Home screen.

2 Press the I/O Setup button.

3 Press the Dewpoint Setup button.

The Dryer Dewpoint Sensor Setup screen provides the user with the ability to adjust the settings for the Dewpoint sensors. This screen allows for adjustment of:

• Sensor minimum and maximum

• Delivery air dewpoint sample rate, sample averages, and offset

• Return air dewpoint sample rate, sample averages, and offset

To change a setpoint:

1 Press the text inside

white box with thick black outline of the setting you would like to change.

4 - 3 0 l O pe ra ti on

2 Use the keypad to enter

the new setting. Setting range will be displayed at the bottom of the pop up keypad.

3 Press the enter key.

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n

Digital I/O Status screen

To access the I/O Status screen:

( c o nt i nu ed )

1 Press the Settings button from the Home screen.

2 Press the I/O Setupbutton.

3 Press the I/O Status button.

The I/O Status screen allows for a visual display of active outputs attached to the DC-T control. Inputs or outputs that are active will turn green. Inactive inputs and outputs will appear grey.

✐

NOTE: Proper login is required to test the outputs. Depending on the configuration of your dryer, some inputs and outputs may not be available.

O p era tio n

(continued)

O p e r at io n l 4 - 3 1

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W

✐

NOTE: The dryer must be stopped in order to perform the test mode.

✐

NOTE: Proper login is required to test the outputs. Depending on the configuration of your dryer, some inputs and outputs may not be available.

C o n f i g ur a t i o n

Digital Output Test screen

To access the Test screen:

( c o nt i nu ed )

1 Press the Settings button

from the Home screen.

2 Press the I/O Setup button.

3 Press the Digital Output Test button.

The test screen allows for digital output tests of various outputs attached to the DC-T control. This screen allows for testing of:

✐

NOTE: On intial test, the delivery air blower will start automatically. This is not unusual and should be expected.

• Delivery air blower

• Regen blower

• Regen heater (jog)

• Wheel motor

• Alarm horn/red light

• Heater isolation contactor

• Delivery air heater (jog)

• Alarm yellow light

• Alarm green light

To test an output:

1 Press the power button to enable the Dryer I/O Test

Mode. The button should illuminate and the LED beside the button should change from grey to green indicating that test mode is enabled.

2 Press the power button beside the output you would

like to test. The button should illuminate and the LED beside the button should change from grey to green indicating power has been sent to the output.

3 Press the power button beside the output again to stop the test. Note that some tests

are a jog test and will not require pressing the button again to stop. Jog tests are programmed to run for three (3) seconds.

4 - 3 2 l O pe ra ti on

4 Press the power button beside the Dryer I/O Test

Mode text to disable test mode.

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n ( c on ti nu e d)

Temperature Sensor Setup screen

To access the Temperature

Sensor Setup screen:

1 Press the Settings button

from the Home screen.

2 Press the I/O Setup button.

3 Press the Temperature Sensor Setup button.

The test screen allows the user to set the setpoints for the Temperature Sensors:

• Regen Temperature Sensor

O p era tio n

To change a setting:

1 Press the white outlined setpoint box. A pop up number pad will appear.

2 Enter the desired setting. Press enter after you have entered the numbers.

3 Repeat steps 1 and 2 for all settings you would like to adjust. Note that depending

on your dryer configuration and your enabled options, your screen may appear different than what is shown here.

✐

NOTE: Proper login is required to change these settings.

(continued)

O p e r at io n l 4 - 3 3

✐

NOTE: Proper login is required to change these settings.

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n ( c on ti nu e d)

Ethernet Setup screen

To access the Ethernet Setup screen:

1 Press the Settings button

from the Home screen.

2 Press the Ethernet Setup button.

The Ethernet Setup screen provides the user with the ability to view current HMI Ethernet settings, load factory default Ethernet settings, or to change and apply new Ethernet settings.

To load the factory default Ethernet settings:

1 Press the Load Factory Default Ethernet Settings button.

2 Press the button to confirm that you want to load the factory

default settings. Press the X button if you want to exit without loading the default factory settings.

✐

NOTE: The default IP address established by Conair is 10.1.12.1

4 - 3 4 l O pe ra ti on

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n ( c on ti nu e d)

Ethernet Setup screen

To apply new Ethernet settings:

1 Enter the new settings in the white boxes with

thick black borders. When you touch the setting inside the box, a pop up number pad will appear.

2 Use the number pad to enter the new setting.

Press the enter button on the number pad to enter the new setting.

3 Repeat steps 1 and 2 for each address setting.

4 Press the Apply NEW Ethernet Address

Settings Now button.

5 Press the button to confirm that you want to apply the new

settings. Press the X button if you want to exit without applying the new settings.

O p era tio n

✐

NOTE: Proper login is required to change these settings.

(continued)

O p e r at io n l 4 - 3 5

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W

✐

NOTE: Proper login is required to change these settings.

C o n f i g ur a t i o n

Alarm Setup screen

To access the Alarm Setup screen:

( c o nt i nu ed )

1 Press the Settings button from the Home screen.

2 Press the Alarm Setup button.

The Alarm Setup screen provides the user with the ability to enable, disable and adjust setpoints for alarms in the ResinWorks system. Both passive and shutdown alarms can be modified from these screens.

4 - 3 6 l O pe ra ti on

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n

Passive Alarm Setup (1 & 2)

To access the Passive Alarm Setup screens:

( c o nt i nu ed )

1 Press the Settings button from the Home screen.

2 Press the Alarm Setup button.

3 Press the Passive Alarm Setup button for the Passive

alarms you would like to configure (screen 1 or screen 2 - if applicable).

4 Enter the desired setpoint and delay (if applicable) for

each alarm.

O p era tio n

✐

NOTE: Some alarms require the user to enable the alarm, and to choose between Passive or Shutdown alarm type. The first “power” button enables or disables the alarm. The second button chooses between Passive or Shutdown alarm.

✐

NOTE: Proper login is required to modify alarm settings. Depending on your dryer configuration, your alarm choices and screen configurations may vary from what is shown in this User Guide.

IMPORTANT: Factory default alarm setpoints should not be changed without first consulting with Conair.

Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861.

(continued)

O p e r at io n l 4 - 3 7

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n ( c on ti nu e d)

Shutdown Alarm Setup (1 & 2)

To access the Shutdown Alarm Setup screens:

✐

NOTE: Proper login is required to modify alarm settings.

IMPORTANT: Factory default alarm setpoints should not be changed without first consulting with Conair.

Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861.

1 Press the Settings button from

the Home screen.

2 Press the Alarm Setup button.

3 Press the Shutdown Alarm

Setup button for the Shutdown alarms you would like to configure (screen 1 or screen 2 - if applicable).

4 Enter the desired setpoint

and delay for each shutdown alarm.

4 - 3 8 l O pe ra ti on

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n

Trending

To access the Trending screens:

( c o nt i nu ed )

1 Press the Trending button from the Home screen.

The Trend Selection screen allows you to choose which trending screens you would like to view. From this screen, you can choose to view:

• Dryer Air Temperature Trend

• Dryer Dewpoint Trend

• Hopper Heater Temperature Trends

• Hopper Drying Monitor Trends (if equipped)

✐

NOTE: Depending on your DC-T configuration, and system security, different users may not be able to access the trending screens. Also, if you do not have DM3-e enabled, or the Drying Monitor equipment at your drying hoppers, you will not be able to view Drying Monitor Trends.

O p era tio n

Trending Screen Navigation

Each trending screen will allow the user to scroll through data. When the screen first opens, it will be displaying a two (2) hour window, and will have saved the data for the last seven (7) day period. The scroll buttons near the bottom of the screen allow the user to scroll back to an earlier time or forward to the present time, or jump immediately to live data. The user can also touch any point on the trend line and the display will show the data reading, date, and time for that spot in the trend.

Scroll to the beginning or end of the record.

Scroll back or forward one point at a time (30 seconds).

Move to live data.

Zoom in (Instead of seeing 2 hours of trend in the window, you will see 1 hour, 30 minutes, 15 minutes, etc.) Zoom out (Instead of seeing 2 hours of trend in the window, you will see 3 hours, 4 hours, 5 hours, etc.)

(continued)

✒

TIP: A dashed line or a

break in the trend line

represents a time where

power to the dryer was

off (either due to shut-

down or to power outage).

O p e r at io n l 4 - 3 9

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W

✐

NOTE: Using the scroll backward and scroll foward arrows will move the line 30 seconds at a time.

C o n f i g ur a t i o n

Dry Air Temperature Trend

To access the Dry Air Temperature Trend screen:

( c o nt i nu ed )

1 Press the Trending button

from the Home screen.

2 Press the Dryer Air

Temperature Trend button.

The Dryer Air Temperature Trending screen allows the user to view the air temperature trend vs. time at several locations in the Carousel Plus Dryer. The air temperature reading locations are denoted by various colors. The colors associated with the locations are:

Yellow: Regeneration Temperature (within the dryer) Blue: Return Air Dryer Inlet Temperature Purple: Wheel Outlet Temperature

The Dryer Air Temperature Trending screen shows a snap shot of the last two (2) hours of operation and records and saves trending data for the last seven (7) day period. The scroll buttons near the bottom of the screen allow the user to scroll back to an earlier time or forward to the present time, plus jump to the present (Live) time from any time within the trending record.

✐

NOTE: See Trending Screen Navigation (Operation Section: Control Function Descriptions- RW

Configuration: Trending) for more information on how use the navigation buttons to navigate through individual trending screens.

4 - 4 0 l O pe ra ti on

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n

Dryer Dewpoint Trend

To access the Dryer Dewpoint Trend screen:

( c o nt i nu ed )

1 Press the Trending button

from the Home screen.

2 Press the Dryer Dewpoint

Trend button.

The Dewpoint Trending screen allows the user to view the dewpoint trend vs. time in the Carousel Plus Dryer.

The Dewpoint Trending screen shows a snap shot of the last two (2) hours of operation and records and saves trending data for the last seven (7) day period. The scroll buttons near the bottom of the screen allow the user to scroll back to an earlier time or forward to the present time, plus jump to the present (Live) time from any time within the trending record.

✐

NOTE: Using the scroll backward and scroll foward arrows will move the line 30 seconds at a time.

O p era tio n

✐

NOTE: See Trending Screen Navigation (Operation Section: Control Function Descriptions- RW

Configuration: Trending) for more information on how use the navigation buttons to navigate through individual trending screens.

(continued)

O p e r at io n l 4 - 4 1

✐

NOTE: Using the scroll backward and scroll foward arrows will move the line 30 seconds at a time.

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n ( c on ti nu e d)

Hopper Heater Temperature Trends

To access the Hopper Heater Temperature Trends screen:

1 Press the Trending button from the Home screen.

2 Press the Hopper Heater Temperature Trend button.

3 Press the Hopper trend you would like to view.

The Hopper Heater Temperature Trending screen allows the user to view the air temperature trend vs. time in two locations related to the hopper. The temperature reading locations are denoted by various colors. The colors associated with the locations are:

Yellow: Hopper Delivery Air Temperature Blue: Hopper Outlet Temperature (if equipped with setback)

The Hopper Heater Temperature Trending screen shows a snap shot of the last two (2) hours of operation and records and saves trending data for the last seven (7) day period. The scroll buttons near the bottom of the screen allow the user to scroll back to an earlier time or forward to the present time, plus jump to the present (Live) time from any time within the trending record.

✐

NOTE: See Trending Screen Navigation (Operation Section: Control Function Descriptions- RW

Configuration: Trending) for more information on how use the navigation buttons to navigate through individual trending screens.

4 - 4 2 l O pe ra ti on

(continued)

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n ( c on ti nu e d)

Hopper Drying Monitor Trends (if equipped)

To access the Hopper Drying Monitor Trend screen:

1 Press the Trending button from the Home screen.

2 Press the Hopper Trend button.

3 Select the individual hopper you want to see trending for.

The Hopper Drying Monitor Trending screen allows the user to view the temperatures at each of the six (6) temperature zones of the DM3-e probe.

The DM3-e Trending screen shows a snap shot of the last two (2) hours of operation and records and saves trending data for the last seven (7) day period. The scroll buttons near the bottom of the screen allow the user to scroll back to an earlier time or forward to the present time, plus jump to the present (Live) time from any time within the trending record.

✐

NOTE: See Trending Screen Navigation (Operation Section: Control Function Descriptions- RW Configuration:

Trending) for more information on how use the navigation buttons to navigate through individual trending screens.

✐

NOTE: Using the scroll backward and scroll foward arrows will move the line 30 seconds at a time.

✐

NOTE: See the DM3-e User

Guide for more information about using the DM3-e Drying Monitor.

O p era tio n

(continued)

O p e r at io n l 4 - 4 3

C o n t r o l F u nc t i o n D e s cr i p t i o ns - R W C o n f i g ur a t i o n ( c on ti nu e d)

Alarms

When an alarm occurs, an audible

sound will be triggered and the operator interface will display a flashing alarm message.

To view an alarm from any opera-

tor screen, press the Alarm button.

1 Press the Alarms button.

2 View the current alarms.

3 Decide if you want to Acknowledge Alarms, Silence and Acknowledge Alarms,

Reset All Alarms or clear individual alarms.

The following buttons are available from the Alarms log screen:

Previous - The previous button is used to select the previous alarm when

multiple alarms are displayed.

Next - The next button is used to select the next alarm when multiple alarms

are displayed.

Alarm History- Pressing the Alarm History button will show a detailed listof the alarm history.

Acknowledge All - The acknowledge all button is used to acknowledge all the alarms on the list.

Reset All Alarms - The Reset button is used to clear all alarms on the list. If the condition has not been remedied, the alarm will reappear.

4 - 4 4 l O pe ra ti on

O p

e rat

i o n

- St

C o nfigura t i o n

a n

A l o n

e D r ye r

O p era tio n

creen flow

The follow the operation of the dryer w deli

ing pages

very air heat) attached to a s

charts

hen factory conf

ingle hopper

creen des

igured as

and bas

criptions

tand alone dryer (providing internal

a s

ic operation) des

cribe

O p e r at io n l 4 - 4 5

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Hom e sc r ee n

Home

Help Overview

Dryer Overview

Alarms

Trend Selection

4 - 4 6 l O pe ra ti on

Setup

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Ove r vie w sc r ee n

Dryer Overview

Dryer DM-II Drying Monitor

250

Air Heater

r D

O p era tio n

Dryer Delivery

DM-II Low A

lar

Set

O p e r at io n l 4 - 4 7

Home

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Ala r m s c re e n

Alarms

Alarm Banner Pop-up

4 - 4 8 l O pe ra ti on

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Tr e nd S ele c ti o n s c ree n

Air Temp. Trending

Trend Selection

Dewpoint Trending

O p era tio n

Material Temperature Trending (if installed)

( C o nt i nu ed )

O p e r at io n l 4 - 4 9

Setup

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Set u p s c re e n

Dryer System Setup

Dryer Options

Autostart Setup

4 - 5 0 l O pe ra ti on

Apply Settings

Ethernet Setup

Default Settings

( C o nt i nu ed )

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Set u p s c re e n (c on ti n ue d)

Setup

Set Time and Date

Regen Setup

Regen PID Auto Tune

O p era tio n

PID Values Reset To Default

Dewpoint Setup

Temp Sensor Setup

Digital Output Test

( C o nt i nu ed )

I/O Setup

Digital I/O Status

O p e r at io n l 4 - 5 1

Setup

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Set u p s c re e n (c on ti n ue d)

Alarm Setup

Shutdown Alarm Setup 2

User Manager

Clean Screen

Shutdown Alarm Setup 1

Passive Alarm Setup 1

Passive Alarm Setup 2

4 - 5 2 l O pe ra ti on

( C o nt i nu ed )

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Set u p s c re e n (c on ti n ue d)

Setup

Delivery Air Heater Setup

Delivery Air PID Autotune

O p era tio n

PID Values Reset To Default

( C o nt i nu ed )

O p e r at io n l 4 - 5 3

Setup

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Set u p s c re e n (c on ti n ue d)

Delivery Air SP Setup

4 - 5 4 l Op er at io n

(continued)

C o n t r o l F u nc t i o n F l o w C ha r t s

F ro m th e Log i n/ L og o ut s c re e n

Security Manager

Home

O p era tio n

O p e r at io n l 4 - 5 5

✐

See Operation section

set point.

entitled, How to Navigate the Control Screens.

set point value has been entered, press the "Enter" key to lock in the new set point.

After the new

C o n t r o l F u nc t i o n D e s cr i p t i o ns S t a n d A l o ne C on f i g u r at i o n

Dryer Overview Screen

To access the Dryer Overview Screen:

1 Press the Dryer Overview button located on the home screen.

The Dryer Overview screen provides the user with the current live information concerning the delivery air temperature, the process dewpoint, the total run hours, and the ambient temperature.

This screen also allows the user to use the zoom buttons and select the dryer detail information or the hopper(s) detail information.

✐

NOTE: The dots on the Heater Pack and dryer (shown as red on the screen to the right) indicate current operating status. Red=stopped Green=on/running

During the shut down process, the dot on the dryer stays green until has cooled down.

Cycling between red and green on the heater pack is normal. This indicates that the heater is turning on and off as necessary.

4 - 5 6 l O pe ra ti on

DM-II zoom (if applicable)

Delivery Air Heater zoom

Dryer zoom

C o n t r o l F u nc t i o n D e s cr i p t i o ns S t a n d A l o ne C on f i g u r at i o n

Dryer Detail Screen

350

-20

To access the Dryer Detail screen:

( c o nt i nu ed )

1 Press the Magnifying Glass (zoom) button associated with the dryer on the Dryer

Overview screen.

O p era tio n

This screen allows the user to start or stop the dryer.

The Dryer Detail screen provides the user with the current live information concerning the processes within the dehumidifying dryer including:

• Hopper Outlet Temperature (if equipped with setback)

• Heater Output

• Regeneration Temperature (Regen. Temp)

• Dewpoint

• Wheel Out Temperature (Temp)

It also tells the user the current status of the aftercooler and precooler (if applicable), as well as which features (Autostart, Autostop, Setback, Dewpoint Control) are enabled.

If the user is logged-in at the proper security level, setpoint changes can be made to:

• Regeneration Temperature Setpoint

• Dewpoint Setpoint

The user can also view the other system parameters, view alarms, view trending, return to the Dryer Overview screen, or return to the Home screen by pressing the applicable buttons on the right of the screen.

✐

See Operation section entitled, How to Navigate Control Screens.

After the new set point value has been entered, press the "Enter" key to lock in the new set point.

O p e r at io n l 4 - 5 7

✐

NOTE: Depending on which options your dryer has been configured with, and whether or not you have the DM-II Drying Monitor enabled, your screens and icons may appear different.

C o n t r o l F u nc t i o n D e s cr i p t i o ns -

S t a n d A l o ne C on f i g u r at i o n ( c on ti nu e d)

Delivery Air Heater Screen

280

250

To access the Delivery Air Heater screen:

1 Press the Magnifying Glass (zoom) button associated with the heater on the Dryer

Overview screen.

✐

NOTE: On this screen, live data is displayed as well as setpoints which can be changed. Data is displayed as colored text inside a solid black box. Setpoints boxes are white with heavy black borders. Setpoints can be changed, if the user has logged in at the proper security level, by pressing the set point boxes. This will launch a pop-up keypad window that can be used to change the setpoint.

See Operation section entitled, How to Navigate the Control Screens.

setpoint value has been entered, press the "Enter" key to lock in the new set point.

After the new

The Dryer Detail screen provides the user with the current live information concerning the processes within the dehumidifying dryer including:

• Heater Output

• Process Protection Temperature

• Delivery Air Temperature

It also tells the user the current status of the heater, as well as which features of the dryer (Autostart, Autostop, Setback -if equipped, Dewpoint Control) are enabled.

If the user is logged-in at the proper security level, setpoint changes can be made to:

• Hopper Outlet Temperature Setpoint

• Delivery Air Temperature Setpoint

• Delivery Air Temperature Setpoint (for setback - if equipped)

• Hopper Setback activation

This screen also allows the user to view the other system parameters, view alarms, view trending, return to the Dryer Overview screen, or return to the Home screen by pressing the applicable buttons on the right of the screen.

4 - 5 8 l O pe ra ti on

C o n t r o l F u nc t i o n D e s cr i p t i o ns S t a n d A l o ne C on f i g u r at i o n

DM-II Drying Monitor Screen (if equipped)

To access the DM-II Drying Monitor screen:

1 Press the Magnifying Glass (zoom)

button associated with the Drying Monitor (beside the hopper).

( c o nt i nu ed )

✐

NOTE: Depending on which options your dryer has been configured with, and whether or not you have the DM-II Drying Monitor enabled, your screens and icons may be different from what is shown here.

O p era tio n

The DM-II Drying Monitor screen provides the user with the current alarm location zone, and the Alarm Setpoint, as well as a button to zoom to DM-II settings. These settings can be adjusted.

✐

NOTE: On these screens, live data is displayed as well as setpoints which can be changed. Data is displayed as colored text inside a solid black box. Setpoints boxes are white with heavy black borders. Setpoints can be changed, if the user has logged in at the proper security level, by pressing the set point boxes. This will launch a pop-up keypad window that can be used to change the setpoint.

Operation section entitled, How to Navigate the Control Screens.

entered, press the "Enter" key to lock in the new set point.

After the new setpoint value has been

See

✐

NOTE: See the Drying Monitor

User Guide for more information about using the Drying Monitor.

O p e r at io n l 4 - 5 9

C o n t r o l F u nc t i o n D e s cr i p t i o ns -

✐

NOTE: Your DC-T control should have been configured at the factory for your Dryer. These settings should not need changed unless your system changed, or the control was replaced. Proper login is required to change these settings.

S t a n d A l o ne C on f i g u r at i o n

Dryer System Setup screen

To access the Dryer System Setup screen:

1 Press the Settings button from the Home screen.

2 Press the Dryer System Setup button.

( c o nt i nu ed )

✐

NOTE: See the DM-II User

Guide for more information about using the DM-II Drying Monitor.

The Dryer System Setup screen provides the user with the ability to change the system settings of this Dryer.

This screen allows you to change:

• Units selection (Fahrenheit and Celsius)

• Dryer model

• Clock display (12 hour and 24 hour)

• Voltage selection

4 - 6 0 l O pe ra ti on

C o n t r o l F u nc t i o n D e s cr i p t i o ns S t a n d A l o ne C on f i g u r at i o n

Dryer Options screen

To access the Dryer Options screen:

1 Press the Settings button from the Home screen.

2 Press the Dryer Options button.

The Dryer Options screen provides the user with the ability to enable or disable options.

( c o nt i nu ed )

O p era tio n

This screen allows you to change the status of:

• Filter Check Monitor

• Drying Monitor

• Setback

• Dewpoint Monitor

• Dewpoint Control

• Process Heater Current

• Regen Heater Current

• Phase Detector

✐

NOTE: Depending on the configuration of your dryer and your drying system, some of the options may not be available or visible on your screen. Your screen may appear different from what is shown here.

✐

NOTE: Proper login is required to change these settings.

O p e r at io n l 4 - 6 1

✐

NOTE: Proper login is required to change these settings.

C o n t r o l F u nc t i o n D e s cr i p t i o ns S t a n d A l o ne C on f i g u r at i o n ( c on ti nu e d)

Autostart Setup screen

To access the Autostart screen:

1 Press the Settings button from the Home screen.

✐

NOTE: Autostart timer uses 24 hour time format. 00:00 is midnight. Note that this is a seven (7) day repeating calendar, and not real time.

2 Press the Autostart Setup button.

The Autostart Setup screen provides the user with the ability to enable or disable and set the start and stop time for dryer for each day of the week.

To setup Auto Start and Auto Stop:

1 Press the Enable button to enable Dryer Auto Start.

2 Press the Enable button next to each day of the

week you would like to set the Auto Start time.

3 Set the Auto Start time for each day you have

enabled.

4 Press the Enable button next to each day of the week you

would like to set the Auto Stop time.

5 Set the Auto Stop time for each day that you have enabled.

4 - 6 2 l O pe ra ti on

C o n t r o l F u nc t i o n D e s cr i p t i o ns S t a n d A l o ne C on f i g u r at i o n ( c on ti nu e d)

Alarm Setup screen

To access the Alarm Setup screen:

1 Press the Settings button from the Home screen.

2 Press the Alarm Setup button.

The Alarm Setup screen provides the user with the ability to enable, disable and adjust setpoints for alarms in the Drying system. Both passive and shutdown alarms can be modified from these screens.

✐

NOTE: Proper login is required to change these settings.

O p era tio n

O p e r at io n l 4 - 6 3

✐

C o n t r o l F u nc t i o n D e s cr i p t i o ns S t a n d A l o ne C on f i g u r at i o n ( c on ti nu e d)

Passive Alarm Setup (1 & 2)

IMPORTANT: Factory default alarm setpoints should not be changed without first consulting with Conair.

Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861.

To access the Passive Alarm Setup screens:

1 Press the Settings button from the Home screen.

2 Press the Alarm Setup button.

3 Press the Passive Alarm Setup button for the Passive alarms you would like to config-

ure (screen 1 or screen 2- if applicable).

4 Enter the desired setpoint and delay (if applicable) for each alarm.

✐

NOTE: Proper login is required to modify alarm settings. Depending on your dryer configuration, you may have different alarm settings or different screen configurations.

4 - 6 4 l O pe ra ti on

C o n t r o l F u nc t i o n D e s cr i p t i o ns S t a n d A l o ne C on f i g u r at i o n ( c on ti nu e d)

Shutdown Alarm Setup (1 & 2)

To access the Shutdown Alarm Setup screens:

1 Press the Settings button from the Home screen.

2 Press the Alarm Setup button.

3 Press the Shutdown Alarm Setup button for the Shutdown

alarms you would like to configure (screen 1 or screen 2 - if applicable).

4 Enter the desired setpoint and delay for each shutdown

alarm.

O p era tio n

✐

NOTE: Proper login is required to modify alarm settings.

IMPORTANT: Factory default alarm setpoints should not be changed without first consulting with Conair.

Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861.

O p e r at io n l 4 - 6 5

C o n t r o l F u nc t i o n D e s cr i p t i o ns -

✐

NOTE: Proper login is required to change these settings.

S t a n d A l o ne C on f i g u r at i o n

Regen Setup screen

To access the Regen Setup screen:

1 Press the Settings button from the Home screen.

2 Press the Regen Setup button.

( c o nt i nu ed )

✐

NOTE: It is not typically necessary to use the Regen PID Auto Tune or the Reset PID Values to Factory button. Contact the Conair Service department if you h ave questions about these items. Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861.

4 - 6 6 l O pe ra ti on

Conair Carousel Plus W Series, Carousel Plus W300, Carousel Plus W200, Carousel Plus W150, Carousel Plus W400 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual