Conair 15, 50, 75, 25, D15 User Manual

...

D Carousel Dryer - DC-1

Models 15, 25, 50, 75, and 100 with DC-1 Controls

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

USER GUIDE UGD024/0304

www.conairnet.com

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

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

Typical applications • How it works • Specifications: D Dryer • INSTALLATION • Unpacking the boxes • Preparing for

installation • Mounting the dryer and hopper on a Processing Machine • Positioning the dryer on the floor; Mounting the

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

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

•Connecting water hoses • Connecting the RTD probe • Mounting a loader on the hopper • OPERATION • How it works

• The DC-1 dryer control panel • D dryer DC-1 control functions • Control Function Description • To start drying • To stop

drying • Using the auto start countdown function • Setting high and low setpoint limits • MAINTENANCE

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: UGD024/0304

Serial Number(s):

Model Number(s):

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

Table of Contents

1-1 Introduction

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

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

Using the D series as a central dryer . . . . . . . . . . . . . . . . . . . . . . 1-3

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

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

How to use the lockout device . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2-1 Description

What is the D Carousel Dryer?. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

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

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

Specifications: D Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3-1 Installation

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

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

Mounting the dryer and hopper on a Processing Machine . . . . . . . 3-6

Positioning the dryer on the floor; Mounting the hopper

on the throat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Mounting the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Positioning the dryer on the floor . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Mounting the dryer on the floor stand; Hopper on the throat. . . . . 3-10

Mounting the dryer and hopper on the mobile floor stand . . . . . . 3-10

Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Table of Contents l i

Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Connecting the air hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Connecting water hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Connecting the RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Connecting the Optional Setback RTD. . . . . . . . . . . . . . . . . . . . . 3-16

Mounting a loader on the hopper . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

4-1 Operation

The DC-1 dryer control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

D dryer DC-1 control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Control function flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Control function descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

To start drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

To stop drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Using the auto start countdown function . . . . . . . . . . . . . . . . . . . 4-19

How to enable the auto start on the DC-1 control . . . . . . . . . . . . 4-19

How to disable the auto start on the DC-1 control . . . . . . . . . . . . 4-19

Setting high and low setpoint limits . . . . . . . . . . . . . . . . . . . . . . 4-20

5-1 Maintenance

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

Cleaning the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Cleaning the process filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Cleaning the regeneration filter . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

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

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

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

ii l Table of Contents

6-1 Troubleshooting

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

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

DIAGNOSTICS

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

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

Passive alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

REPAIR

Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Checking heater solid state relays . . . . . . . . . . . . . . . . . . . . . . . 6-18

Checking or replacing temperature sensors. . . . . . . . . . . . . . . . . 6-19

Adjusting the limit switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Replacing the heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Replacing the desiccant tanks . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

Refilling the desiccant tanks. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

A Appendix

We’re Here to Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

How to Contact Customer Service . . . . . . . . . . . . . . . . . . . . . . . . A-1

Before You Call... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Equipment Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Performance Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

B Appendix

Mounting the Dryer on a Floor Stand . . . . . . . . . . . . . . . . . . . . . . B-1

Mounting the Dryer and Hopper on a Mobile

Floor stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Table of Contents l iii

C Appendix

Installing an aftercooler (optional) . . . . . . . . . . . . . . . . . . . . . . . . C-1

Cleaning the aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

D Appendix

Installing the flow control (optional) . . . . . . . . . . . . . . . . . . . . . . . D-1

E Appendix

Installing a precooler (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Cleaning the precooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3

F Appendix

Installing the dew point sensor (optional) . . . . . . . . . . . . . . . . . . . F-1

G Appendix

What is the MDC? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

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

How conveying works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3

Specifications: MDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4

Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6

Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8

Installing the MDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9

Connecting conveying lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10

Connecting the RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11

Connecting the demand sensor . . . . . . . . . . . . . . . . . . . . . . . . . G-11

Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11

Connecting the water hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11

Mounting a loader on the hopper. . . . . . . . . . . . . . . . . . . . . . . . G-12

Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12

iv l Table of Contents

Table of Contents l v

The MDC control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12

MDC control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12

To start drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12

To stop drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12

Using the auto start countdown function . . . . . . . . . . . . . . . . . . G-12

Setting the high setpoint limits . . . . . . . . . . . . . . . . . . . . . . . . . G-12

To start conveying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-13

To stop conveying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-14

Transporting the MDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-14

Preventative maintenance schedule . . . . . . . . . . . . . . . . . . . . . . G-15

Cleaning the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-15

Cleaning the conveying lines . . . . . . . . . . . . . . . . . . . . . . . . . . . G-15

Cleaning the vacuum receiver . . . . . . . . . . . . . . . . . . . . . . . . . . G-16

Cleaning the dust collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-17

Cleaning the process filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-18

Cleaning the regeneration filter . . . . . . . . . . . . . . . . . . . . . . . . . G-18

Cleaning the aftercooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . G-18

Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . G-18

Inspect hoses and gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-18

vi l Table of Contents

Introduction

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

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

Using the D series as a central dryer . . . . . . 1-3

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

ATTENTION:

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

How to use the lockout device . . . . . . . . . . 1-5

SECTION

Introduction l 1-1

Introduction

✐

Purpose of the User Guide

This User Guide describes the Conair D series of carousel dehumidifying dryers and explains step-by-step how to install, operate, maintain and repair this equipment.

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

How the Guide is Organized

Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation.

Symbols within triangles warn of conditions that could be hazardous to users or could damage equipment. Read and take precautions before proceeding.

Numbers indicate tasks or steps to be performed by the user.

A diamond indicates the equipment’s response to an action performed by the user.

An open box marks items in a checklist.

A circle marks items in a list.

Indicates a tip. A tip is used to provide you with a suggestion that will help you with the maintenance and operation of this equipment.

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

◆ ❒

•

✒

1-2 l Introduction

Using the D Series as a Central Dryer

This manual incorporates the information necessary to use the Conair D series dryer as a central dryer. Throughout this manual, information particular to central dyer application of the D series dryer is called out by the following treatment.

Your Responsibility as a User

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

• Thorough review of this User Guide, paying particular attention

to hazard warnings, appendices and related diagrams.

•

Thorough review of the equipment itself, with careful attention to voltage sources, intended use and warning labels.

• Thorough review of instruction manuals for associated equipment.

•

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

Introduction l 1-3

Introduction

Central

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

1-4 l Introduction

ATTENTION: Read this so no one gets hurt

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

WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury.

This equipment should be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of machine.

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

WARNING: Voltage hazard

This equipment is powered by three-phase alternating current, as specified on the machine serial tag and data plate.

A properly sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical enclosure. Improper grounding can result in severe personal injury and erratic machine operation.

Always disconnect and lock out the incoming main power source before opening the electrical enclosure or performing non-standard operating procedures, such as routine maintenance. Only qualified personnel should perform troubleshooting procedures that require access to the electrical enclosure while power is on.

Introduction l 1-5

How to Use the Lockout Device

CAUTION: Before performing maintenance or repairs on this product, you should disconnect and lockout electri-

cal power sources to prevent injury from unexpected energization or start-up. A lockable device has been 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 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.

Introduction

1-6 l Introduction

Description

What is the D carousel dryer? . . . . . . . . . . 2-2

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

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

Specifications: D dryer . . . . . . . . . . . . . . . 2-6

SECTION

Description

Description l 2-1

What is the D Carousel Dryer?

The D carousel dehumidifying dryer produces hot, low-dew point air that removes moisture from hygroscopic plastics. The dryer pulls warm, moist air from a drying hopper and pumps it through dehumidifying desiccant. The dryer then heats the air to the drying temperature you selected and circulates it through the material in the hopper.

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

Typical Applications

2-2 l Description

The D dryer can be mounted beside the hopper on the throat of a processing machine using the optional diving board support frame, or positioned on the floor near the machine using the standard casters. Two mobile floor stand designs are also available.

Dryer on a floor stand; hopper on the throat.

Dryer and hopper on the processing machine throat using the optional support frame.

Dryer on the floor; hopper on the throat.

Dryer and hopper on a mobile floor stand (MDC version).

Description l 2-3

Description

Central

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

Typical Applications (continued)

The D carousel dryer can be used successfully in applications that require:

• A contamination-free drying environment.

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

Model Drying Temperature Range

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

Standard 150° - 250°F (66° - 121°C)

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

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

*Note: See instruction on page 4-12 for setpoints over 150°F (66°C).

• Throughput rates of 15 to 100 lbs (6.8 to 37.3 kg) per hour (some materials

can be run at a higher rate).

• Dew points of -40°F (-40°C).

If you are drying material at temperatures over 250°F (121°C), you will need the high-temperature package that includes an aftercooler. An aftercooler is standard equipment on the High heat and Low-high models.

How It Works

The D carousel dryer achieves continuous, closed loop drying by passing air simultaneously through two heaters and three tanks of molecular sieve desiccant.

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 optional aftercooler, if installed) into the dryer’s desiccant tank, where moisture is removed. The now dry air moves through the process heater, where it is heated to the drying temperature selected by the operator. The hot, dry air is delivered to the hopper (after it passes through the optional precooler, if installed) where a spreader cone evenly distributes the air through the material.

The Cooling Cycle

A regenerated desiccant tank must be cooled before it is moved back into the process cycle. The process blower pushes a small amount of air through the regenerated desiccant tank. The cooling air then passes through the optional aftercooler, if installed, and repeats the circuit.

The Regeneration Cycle

The regeneration blower pulls air through the regeneration filter into the dryer’s regeneration heater. The air is heated to 425°F (218°C) before it is pushed into the “wet” desiccant tank. The hot air purges moisture from the desiccant. The moist air is blown out the exhaust at the back of the dryer.

2-4 l Description

Central

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 optional aftercooler, if installed) into the dryer’s desiccant tank, where moisture is removed. The dry air is delivered to the hopper (after it passes through the optional precooler, if installed) where a spreader cone evenly distributes the air through the material.

Description

How It Works (continued)

REGENERATION

AIR FILTER

DESICCANT

TANKS

BEDPLATE

REGENERATION

BLOWER

REGENERATION

HEATER

HIGH TEMP

SHUTOFF

REGENERATION

RTD

HOPPER

4 CURRENT METER

PROCESS

BLOWER

RETURN

AIR

FILTER

8 AFTERCOOLER

5 PROCESS FILTER STATUS

RETURN AIR

RTD

PROCESS

RTD

1 SET BACK TEMPERATURE 2 PROCESS CFM MONITOR

HIGH TEMP

SHUTOFF

PROCESS

HEATER BOX

10 ALARM HORN

9 FLOW CONTROL VALVE

7 PRECOOLER

11 ALARM LIGHTS

DRYER OPTIONS

3 PM1 / DEW POINT MONITOR

6 PHASE ROTATION PROTECTION

PROCESS COOLING

REGENERATION

Description l 2-5

Central

The components identified by this type of box in the drawing are not supplied with the D dryer when it is configured as a central dryer.

2-6 l Description

Specifications: D Carousel

DEHUMIDIFYING DRYERS D Small Series Carousel Dryers

MODEL D15 D25 D50 D75 D100 Performance characteristics (with full hopper)

Air flow {SCFM}

12 20 35 50 80

Air flow {ACFM @ 250°}

16 27 47 67 107

Drying temperature All models 100 - 375

F {38 - 191° C} with options

Dew point All models -40° F {-40° C}

Dimensions inches {cm}

A - Height 35.5 {90.2} 35.5 {90.2} 35.5 {90.2} 42.1 {107} 42.1 {107} B - Overall width 17.3 {43.9} 17.3 {43.9} 17.3 {43.9} 22.0 {55.9} 22.0 {55.9} C - Control width 15.7 {39.9} 15.7 {39.9} 15.7 {39.9} 15.7 {39.9} 15.7 {39.9} D - Depth 24.8 {63.0} 24.8 {63.0} 24.8 {63.0} 30.3 {77.0} 30.3 {77.0} Control depth 7.3 {18.5} 7.3 {18.5} 7.3 {18.5} 7.3 {18.5} 7.3 {18.5} Outlet/inlet tube size OD 2.5 2.5 2.5 2.5 2.5

Weight lbs {kg}

Installed 225 {102} 225 {102} 240 {109} 310 {141} 340 {155}

Voltage†Total Amps

208 V/3 phase/60 Hz 6.6 7.5 10.1 18.2 NA 240 V/3 phase/60 Hz 5.7 6.5 8.8 15.8 25.3 400 V/3 phase/50 Hz 3.5 3.9 5.4 9.5 14 480 V/3 phase/60 Hz 2.8 3.2 4.4 7.9 11.7 575 V/3 phase/60 Hz 2.4 2.7 3.7 6.6 9.7

Total kilowatts kw {BTU/min} 2.2 {125} 2.5 {142} 3.4 {193} 6.1 {347} 9.0 {512} Water requirements {for optional aftercooler or precooler}

Recommended temperature* 45

- 85°F 45°- 85°F

Water flow gal./min.{liters/min.} 1 {3.8} 2 {7.6} Water connections NPT 1/2 inch NPT

SPECIFICATION NOTES:

SCFM stands for standard cubic feet per minute, referenced to a pre-specified pressure, temperature and relative humidity.In most cases, SCFM is referenced to 14.7 PSIA 68° F and 0% relative humidity.ACFM stands for actual cubic feet per minute, and must be supplied with a temperature reference, due to the change in air density with temperature.Because dryers operate at a relatively low pressure the effects on air density are negligible.

†

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

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

Description l 2-7

Description

Specifications: D Carousel (continued)

7/16 inches {1.1 cm}

diameter

4 inches {10.2 cm} square

1 inch {2.5 cm}

diameter

3 inches {7.6 cm} square

6 inches {15.2 cm} square

7/16 inches {1.1 cm}

diameter

5 inches {12.7 cm} square

2 inches {5.1 cm}

diameter

Standard Base Plate IB02

Optional Base Plate IB01

(for mounting CH10 and CH14 hoppers independent of dryer only)

▲

OPTIONAL HOPPERS AND MOUNTING BRACKET

MOUNTING PATTERNS

▲

HOPPER MODEL CH10-0.5 CH10-1 CH10-1.5 CH14-2 CH14-3 CH14-4 Hopper / Mounting Frame Dimensions inches {cm}

A - Insulated hopper diameter 12.5 {13.8} 12.5 {31.8} 12.5 {31.8} 17 {43.2} 17 {43.2} 17 {43.2} B - Overall height 32 {81.3} 43 {109.2} 54 {137.2} 45 {114.3} 56 {142.2} 67 {170.2} C - Base plate, square 7.5 {19} 7.5 {19} 7.5 {19} 6.5 {16.5} 6.5 {16.5} 6.5 {16.5} D - Width with insulated hopper 39 {99.1} 39 {99.1} 39 {99.1} 41 {104.1} 41 {104.1} 41 {104.1}

Volume ft3{liters} 0.5 {9.4} 1 {28.3} 1.5 {42.5} 2 {56.6} 3 {85} 4 {113.2} Capacity lb {kg} @40 lb/ft

20 {9.0} 40 {18.1} 60 {27.2} 80 {36.3} 120 {54.4} 160 {72.5}

Mounting Frame Weight lb {kg} 30 {13.6} 30 {13.6} 30 {13.6} 35 {15.9} 35 {15.9} 35 {15.9} Hopper Weight lb {kg}

Insulated 40 {18.1} 50 {22.7} 70 {31.7} 80 {36.32} 95 {43.1} 110 {48.9}

HOPPER MODEL CH18-4 CH18-6 CH24-8 CH24-12 CH24-15 Hopper / Mounting Frame Dimensions inches {cm}

A - Insulated hopper diameter 21 {53.3} 21 {53.3} 27 {68.58} 27 {68.58} 27 {68.58} B - Overall height 48 {121.9} 68 {172.7} 64 {162.6} 79 {200.7} 90 {228.6} C - Base plate, square 6.5 {16.5} 6.5 {16.5} 6.5 {16.5} 6.5 {16.5} 6.5 {16.5} D - Width 47.63 {121.0} 47.63 {121.0} 47.63 {121.0} 50.63 {128.6} 50.63 {128.6}

Volume ft3{liters} 4 {113.3} 6 {169.9} 8 {226.5} 12 {339.8} 15 {424.8} Capacity lb {kg} @40 lb/ft

160 {72.5} 240 {108.9} 320 {145.1} 480 {217.7} 600 {272.2}

Mounting Frame Weight lb {kg} 50 {22.7} 50 {22.7} 70 {31.7} 70 {31.7} 70 {31.7} Hopper Weight lb {kg}

Insulated 145 {66} 165 {75} 210 {95} 235 {107} 255 {116}

2-8 l Description

Installation

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

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

Mounting the dryer and hopper on a

processing machine . . . . . . . . . . . . . . 3-6

Positioning the dryer on the floor;

mounting the hopper on the throat . . . . . 3-8

Mounting the hopper. . . . . . . . . . . . . . . . . 3-9

Positioning the dryer on the floor . . . . . . . . 3-9

Mounting the dryer on the floor stand;

hopper on the throat . . . . . . . . . . . . . 3-10

Mounting the dryer and hopper on the mobile

floor stand . . . . . . . . . . . . . . . . . . . 3-10

Connecting the main power . . . . . . . . . . . 3-10

Checking for proper air flow . . . . . . . . . . . 3-12

Connecting the air hoses . . . . . . . . . . . . . 3-15

Connecting the water hoses . . . . . . . . . . . 3-15

Connecting the RTD probe . . . . . . . . . . . . 3-16

Connecting the Optional Setback RTD . . . . . 3-16

Mounting a loader on the hopper . . . . . . . . 3-17

Testing the installation . . . . . . . . . . . . . . 3-17

SECTION

Installation

Installation l 3-1

3-2 l Installation

Unpacking the Boxes

The D carousel dryer comes in one to four boxes, depending on the model and options ordered. The boxes could include (depends on options selected):

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

and set upright. Note that the dryer is secured to its shipping container with four bolts that pass through the bottom of the dryer frame. These bolts are accessed by removing the side panels of the dryer.

2 Remove all packing material, protective paper, tape, and plastic, including any

inserted in the top section of the dryer. Be sure to remove the side panels from the dryer and cut and remove three (3) tie wraps securing the bedplates. Also cut and remove the tie wrap on the bedplate limit switch.

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

shipping, and that you have all the necessary hardware.

Mounting Hardware:

Floor stand option:

❒four 5/16-18 self-locking

bolts

❒four hose clamps

Support frame option:

❒eight 3/8-16 self-locking

bolts

❒four 5/16-18 self-locking

bolts

❒four hose clamps

NOTE: You must posi-

tion the dryer on the

floor or mount it to a

floor stand if your pro-

cessing machine throat

opening is 1 inch (2.54

cm) diameter or small-

er and requires a 3x3

inch (7.6x7.6 cm) or

smaller bolt pattern.

✐

RTD Probe

Hoses

D Carousel Dryer

Hopper

Support Frame

Mobile Floor Stand

Frame with Casters

Slide Gate

Installation l 3-3

Unpacking the Boxes (continued)

4 Take a moment to record serial numbers and electrical power specifications

in the blanks provided on the back of the the User Guide’s title page. The information will be helpful if you ever need service or parts.

5 You are now ready to begin installation.

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

• Dryer and hopper on the processing machine throat using the optional

support frame (see page 3-6).

• Dryer on the floor; hopper on the throat (see page 3-8).

• Dryer and hopper on a mobile floor stand (MDC mounting, see

Appendix B).

• Dryer on a floor stand; hopper on the throat (see Appendix B).

Description

12 in. (30.48 cm) needed to remove optional aftercooler coil for cleaning

3 in. (7.62 cm)

Regeneration exhaust high temperature

6 in. (15.24 cm)

needed to change

filter

D-75 & D-100

Minimum

Clearance

6 in. (15.24 cm)

12 in. (30.48 cm) needed to remove optional aftercooler coil for cleaning

3 in. (7.62 cm)

Regeneration exhaust high temperature

6 in. (15.24 cm)

needed to change

filter

D-15, D-25 & D-100

Minimum Clearance

3-4 l Installation

Preparing for Installation

The D carousel 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 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 precooler.

The D dryer’s optional aftercooler and precooler can use 1-2 gals./min. (3.8-

7.6 liters/min.) tower, city, or chiller water at temperatures of 40° to 85°F (4° to 29°C). Pipe should be run to the planned dryer location. Use flexible hose to connect the water pipes to the aftercooler and precooler. If the dryer has an optional flow control, see Appendix D for connection information.

❒❒

Minimum clearance for safe operation and maintenance.

You should maintain 24 in. (61 cm) clearance on at least three sides of the dryer. If the dryer is mounted with a hopper on a processing machine throat, clearance between the dryer and hopper can be 4 in. (10.2 cm).

Installation l 3-5

6 inches (15.24 cm) square

5 inches

(12.7 cm)

square

7/16 inches

(1.11 cm)

diameter

2 inches

(5.08 cm)

diameter

4 inches (10.16 cm) square

3 inches

(7.62 cm)

square

7/16 inches

(1.11 cm)

diameter

1 inch

(2.54 cm)

diameter

NOTE: If your mounting surface does not match the standard bolt patterns available, you will need an adapter. You can make an adapter using the dimensions provided or purchase one from Conair.

❒❒

A mounting surface that will support the weight of the dryer, support

frame, and a fully-loaded hopper, or just the fully-loaded hopper. See the specifications tables for weights and volumes.

❒❒

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.

2 Drill and tap mounting holes or make adapter.

Available discharge assemblies and slide gates fit mounting surfaces with these bolt patterns and diameters.

Description

✐

Preparing for Installation (continued)

Mounting the Dryer and Hopper on a Processing Machine

WARNING: You are responsible for the structural integrity of this installation.

We recommend that you:

❒❒

Use bolts no smaller than 3/8 inch (M 10) when mounting the

hopper/dryer combination to the throat of a processing machine.

❒❒

Do not mount the hopper/dryer combination on a plate that swings away or slides away from the processing machine throat. Either remove the swing or slide plate, position the dryer on the floor, or

mount the dryer to an optional floor stand.

The dryer and hopper mount on a support frame / discharge assembly that bolts to the throat of the processing machine, as pictured above.

CAUTION: To prevent accident and injury, lift the empty hopper and support frame onto the throat of the processing machine using a hoist and the lifting lugs provided. After the hopper is mounted, then lift the dryer onto the support frame using a hoist and the lifting lugs provided.

Tools for installation:

❒ Flathead screwdriver ❒ 9/16” and 1/2” wrench ❒ Hoist

NOTE: You must position the

dryer on the floor or mount it to

an optional floor stand if your

processing machine throat

requires the small discharge

assembly or a mounting plate

with less than a 3 x 3 in.

(7.6 x 7.6 cm) bolt pattern and

1 in. (2.54 cm) diameter open-

ing.

✐

3-6 l Installation

Description

Mounting the Dryer and Hopper on a Processing Machine (continued)

The drying hopper, slide gate, support frame, and discharge assembly may have been shipped fully assembled. You can remove the hopper from the support frame, if you find it easier to lift and bolt the frame and then the hopper to the throat of the processing machine.

1 Lift the hopper, support frame, and discharge assembly onto the process-

ing machine throat. Use a hoist to lift the support frame and hopper. Position the frame and discharge assembly so that its bolt holes line up with the holes drilled in the throat. If hole patterns do not match, you can place a mounting adapter between the throat and the support frame.

2 Bolt the frame and discharge assembly to

the throat. Using four 3/8 in. -16 (M 10) self-locking bolts, fasten the support frame and discharge assembly to the throat. The bolts must be long enough to reach at least 1/2 in. (1.25 cm) into the processing machine throat or mounting adapter after passing through the discharge assembly and support frame.

NOTE: If you removed the hopper from the support frame, lift the hopper onto the frame using a hoist. Make sure the slide gate is positioned in the recess on the bottom of the hopper base plate. Align the bolt holes and fasten the base plate to the discharge assembly using the four 3/8 in. -16 (M 10) self-locking bolts provided.

3 Lift the dryer onto the support

frame using a hoist and the lifting lugs provided. Align the four bolt

holes on the bottom of the dryer with the four bolt holes on the top of the support frame. Fasten the dryer to the frame with 5/16 in. -18 bolts.

✐

Installation l 3-7

Positioning the Dryer on the Floor; Mounting the Hopper on the Throat

WARNING: You are responsible for the structural integrity of this installation.

We recommend that you:

• Use bolts no smaller than 3/8 in. (M 10) to mount the hopper on the throat of

a processing machine.

The hopper bolts to the throat of the processing machine, as pictured above. The dryer can be positioned on the floor near the processing machine.

3-8 l Installation

Tools for installation:

❒ 9/16” wrench ❒ Flathead screwdriver ❒ Hoist

Installation l 3-9

Description

Mounting the Hopper

CAUTION:

To prevent accident and injury, lift the empty hopper onto the throat of the processing machine using a hoist and the lifting lugs provided. Also lift the dryer from the shipping container using a hoist and the lifting lugs provided.

1 Lift the hopper onto the throat. Lift the hopper with a hoist, using the lifting

lugs provided. Make sure you align the bolt holes in the throat with the bolt holes on the discharge assembly.

2 Bolt the hopper to the throat of

the machine. Using four 3/8 in.-16 (M 10) self-locking bolts, fasten the support frame, discharge, and slide gate to the throat. The bolts must be long enough to reach at least 1/2 in. (1.25 cm) into the mounting adapter or processing machine throat, after passing through the discharge and slide gate.

Positioning the Dryer on the Floor

1 Lift the dryer from the shipping

container using a hoist and the lifting lugs provided.

2 Position the dryer on the floor near

the processing machine. Make sure the location allows for the connection of all hoses.

3-10 l Installation

Mounting the Dryer on the Floor Stand; Hopper on the Throat

For information about mounting the dryer on the floor stand and the hopper on the throat, refer to Appendix B.

Mounting the Dryer and Hopper on the Mobile Floor Stand

For information about mounting the dryer and hopper on the mobile floor stand, refer to Appendix B.

Connecting the Main Power

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

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

1 Open the dryer’s electrical enclo-

sure. Turn the disconnect dial on the dryer door to the Off or O position. Lock out the main power (see Page 1-4 for complete lock out information). Turn the captive screw, and swing the door open.

Insert the main power

wire

through the knockout in the side of the enclosure. Secure the wire with a rubber compression fitting or strain relief.

Installation l 3-11

Description

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

Connect the power wires

to the three terminals at the top of the power discon-

nect holder.

4 Connect the ground wire to either grounding point as shown in the photo.

Connecting the Main Power (continued)

Checking for Proper Air Flow

This step is only needed on 50, 75, and 100 models if the phase detection option was not ordered with the dryer.

CAUTION: This step must be performed before the dryer’s air hoses are connected to the hopper. Performing this step after the air hoses are connected could cause damage to the dryer if the air flow direction is incorrect due to improper phase connection. Material from the hopper can be pulled into the process heater, causing permanent damage.

1 Turn on the main power to the dryer. Make sure the dryer’s disconnect dial is

in the ON position. This powers up the control and the display lights will illuminate.

2 Set the drying temperature. Press Setpoint Adjust ▲or ▼ buttons to set the

temperature.

3-12 l Installation

Set Point Actual

1 Process T emp. 2 Regen. T emp. 3 Return Air T emp. 4 Auto Start 5 Load Time (MDC) 6 Activate Setback Temp. 7 Setback T emp.(Pr ocess) 8 Setback Load Rate 9 PM1 Dewpoint

Shutdown Alarms A1 Process High T emp. A2 Process Loop Break A3 Process Heater High T emp. A4 Regen. Heater High T emp. A5 Carousel Index Too Long A6 Carousel Index Failure A7 Return Air High T emp.

Passive Alarms P1 Process T emp. Deviation P3 Regen. T emp. De viation P5 Return Air High T emp.

Auto Start Desiccant Indexing Set-Back Temp.

Process Blower Process Pressure Process Heater

Regen. Blower Regen. Pressure Regen. Heater

Central

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

Checking for Proper Air Flow (continued)

3 Press the START button. Hold your hand near the delivery

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

4 Press the STOP button.

Start

Installation l 3-13

Stop

Moisture exhaust

Delivery air outlet (15, 25, and 50 models)

Return Air Inlet

Delivery air outlet (75 and 100 models)

Return Air Inlet

Moisture exhaust

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

Description

Checking for Proper Air Flow (continued)

INSTALLATION NOTE: Models 50, 75, and 100

These models use a three-phase process blower. If the dryer shuts down and a Process

Loop Break shutdown alarm is indicated within the first few minutes of operation, check

for proper air flow.

If the air flow is reversed, the process blower is turning in the wrong direction.

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

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

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

✐

3-14 l Installation

Description

Installation l 3-15

Connecting the Air Hoses

Using the two flexible hoses provided, connect the inlets and outlets of the drying hopper to the dryer. If you have positioned the dryer on the floor or mounted it to an optional floor stand, make sure the dryer is located no more than 5 feet (1.5 m) from the hopper to reduce heat loss.

If you ordered an insulated hose, it should be installed between the dryer outlet and the hopper inlet.

If you have ordered an optional aftercooler or precooler, see Appendices C and E.

1 Attach the hose to the return

air outlet at the top of the hopper labeled “From Hopper”.

2 Attach the hose to the hopper’s

delivery air inlet labeled “To Hopper”.

Secure hoses with clamps.

The hose clamp should be secured at least 1/4 in. (0.64 cm) from the end of the inlet or outlet tube.

Connecting the Water Hoses

The optional aftercooler, flow control, and precooler require a source of cooling water and a discharge or return line. See Appendix C for information on installing and connecting water hoses to the optional aftercooler. See Appendix D for information on installing and connecting water hoses to the optional flow control. See Appendix E for information on installing and connecting water hoses to the optional precooler.

NOTE: Do not allow the

flexible hoses to kink or

crimp.

✐

Delivery air outlet (75 and 100 models)

Return Air Inlet

Delivery air outlet (15, 25, and 50 models)

Return Air Inlet

Connecting the RTD Probe

The RTD probe monitors the temperature of the drying air as it enters the hopper. If the probe is not installed correctly, temperature readings will be inaccurate.

1 Insert the probe at the inlet to the

hopper. The end of the probe must not touch the walls of the inlet. The tip of the probe should be approximately in the center of the tube. Tighten the nuts to lock the probe in place.

2 Plug the probe’s

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

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

Connecting the Optional Setback RTD

1 Insert the probe in the hopper outlet at the top of the hopper. The end of the

probe must not touch the walls of the inlet. The tip of the probe should be approximately in the center of the tube. Tighten the nuts to lock the probe in place.

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

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

3-16 l Installation

Central

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 this RTD probe is not applicable.

Process RTD

Setback RTD (Optional)

Description

Installation l 3-17

Mounting a Loader on the Hopper

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

Testing The Installation

You have completed the installation. Now it’s time to make sure everything works.

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

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

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

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

3 Set the drying temperature. Press the Setpoint Adjust ▲or ▼ buttons to set

the temperature.

(continued)

Central

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

Set Point Actual

1 Process T emp. 2 Regen. T emp. 3 Return Air T emp. 4 Auto Start 5 Load Time (MDC) 6 Activate Setback Temp. 7 Setback T emp.(Pr ocess) 8 Setback Load Rate 9 PM1 Dewpoint

Shutdown Alarms A1 Process High T emp. A2 Process Loop Break A3 Process Heater High T emp. A4 Regen. Heater High T emp. A5 Carousel Index Too Long A6 Carousel Index Failure A7 Return Air High T emp.

Passive Alarms P1 Process T emp. Deviation P3 Regen. T emp. De viation P5 Return Air High T emp.

Auto Start Desiccant Indexing Set-Back Temp.

Process Blower Process Pressure Process Heater

Regen. Blower Regen. Pressure Regen. Heater

Testing The Installation(continued)

4 Press the START button.

If everything is installed correctly:

• The green light on the start button will illuminate.

• The process and regeneration blowers turn on.

• The process and regeneration heaters turn on.

• If the desiccant tanks are not in their correct position, the carousel will

turn clockwise and stop in the correct position.

5 Press the STOP button.

If everything is installed correctly:

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

6 The test is over. If the dryer performed the normal operating sequences as out-

lined, you can load the hopper and begin operation. If it did not, refer to the

ROUBLESHOOTING

section of the User Guide.

Stop

Start

3-18 l Installation

Central

• The regeneration heater turns on.

SECTION

Operation

T he DC-1 dryer control panel . . . . . . . . . . . 4-2

D dryer DC-1 control functions . . . . . . . . . . 4-3

Control function flow chart . . . . . . . . . . . . 4-3

Control function descriptions . . . . . . . . . . . 4-5

To start drying . . . . . . . . . . . . . . . . . . . . 4-17

To stop drying . . . . . . . . . . . . . . . . . . . . 4-18

Using the auto start countdown function . . . 4-19

How to enable the auto start on the DC-1

conrtol . . . . . . . . . . . . . . . . . . . . . . 4-19

How to disable the auto start on the DC-1

control . . . . . . . . . . . . . . . . . . . . . . 4-19

Setting high and low setpoint limits . . . . . . 4-20

Operation l 4-1

The DC-1 Dryer Control Panel

4-2 l Operation

Set Point Actual

1 Process T emp. 2 Regen. T emp. 3 Return Air T emp. 4 Auto Start 5 Load Time (MDC) 6 Activate Setback Temp. 7 Setback T emp.(Pr ocess) 8 Setback Load Rate 9 PM1 Dewpoint

Shutdown Alarms A1 Process High T emp. A2 Process Loop Break A3 Process Heater High T emp. A4 Regen. Heater High T emp. A5 Carousel Index Too Long A6 Carousel Index Failure A7 Return Air High T emp.

Passive Alarms P1 Process T emp. Deviation P3 Regen. T emp. De viation P5 Return Air High T emp.

Auto Start Desiccant Indexing Set-Back Temp.

Process Blower Process Pressure Process Heater

Regen. Blower Regen. Pressure Regen. Heater

Start and Stop Buttons

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

Increment/ Decrement Buttons

Used to increase or decrease values.

Acknowledge Alarm Button

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

Actual Display

Shows the actual temperature value.

Set Point Display

Shows the set point value.

Menu List

Numbers 1, 2, 3, and 4 are standard items that will always be present. Numbers 5, 6, 7, 8, and 9 are screens associated with options. If the option is not installed the screen will not be displayed.

Alarm Codes

See “Troubleshooting” Section 6 for a more complete listing of alarm codes.

Scroll Button

Press to scroll through the closed loop menu list. Pressing the scroll button moves you down the list.

Menu Number Display

Displays the menu number corresponding to what is shown in the set point and actual displays. Can also display letters for alarm and setup screens.

Central

Menu List

Numbers 2, 3, and 4 are standard items that will always be present. Number 9 is a screen associated with an option. If the option is not installed, the screen will not be displayed.

D Dryer DC-1 Control Functions

Dryer functions are values that you can set or monitor. Press the Scroll button until the function you want to set or monitor appears in the LED display.

Note: Grey shaded screens denote optional functions. If the options were not purchased with the dryer, those screens will not appear. All options can be purchased and installed in the field.

Control Function Flow Chart

The following flow chart provides a quick summary of the control functions. For an explanation of each control function, see Control Function Description.

Operation l 4-3

Operation

✐

4-4 l Operation

POWER ON

screen #

Pr up

5 sec

d25

5 sec

C v00 09.5

1 sec

d v00 01.0

1 sec

1 250 250

Process Temp Default Screen

2 425 425

Regen Temp

3 100 100

Return Air Temp

416On

Auto Start

5 10 -----

Load Time (MDC)

6 150 120

Activate Setback Temp (Option)

7 145 250

Setback Temp Process (Option)

857

Setback Load Rate (Option)

9-30-40

Dewpoint Monitor or PM1 (Options)

Password Screen

754 755 756

C10C01

Hoff 1

A1P3

C 400 C02

off 2

A1A1

CoffC03

Hoff 3

A1A5

C 425 C04

Hoff 4

A1A4

CoffC05

Hoff 5

A1P1

C10C06

Hoff 6

A1P5

CtimC07

Hoff 7

A1A1

C20C08

Hoff 8

A1A7

CoffC09

Hoff 9

A1A2

CoffC10

Hoff 10

A1A6

CoffC11

Hoff 11

CoffC12

Hoff 12

CoffC13

Hoff 13

Hoff 14

Hoff 15

Hoff 16

Setup

Access Code

Test Mode

Access Code

Alarm History

Access Code

Central

CNT

DRY

Central

When supplied for central drying applications, these control functions are not available.

Once power is turned on, this screen is displayed for 5 sec. while the control does some self-checking.

Once power is turned on and screen 1 is displayed for 5 sec., this screen is displayed for another 3 sec. It shows the dryer model number for which the control is configured.

After the model number is displayed, this screen flashes for 1 sec. and displays the control board software version.

After the control versions is shown, the screen flashes again for 1 sec. and displays the display board software version.

This is the DEFAULT screen. It shows the process air temperature setpoint and actual temperature measured at the inlet to the drying hopper. The + / - buttons can be used to change the setpoint. Holding the + / - buttons in will cause the number to ramp up faster the longer the button is held. The display will return to the default screen from anyplace in the menu structure if nothing is done after 10 min.

Indicates configuration as a central dryer.

Shows the regeneration air setpoint and actual temperature. The setpoint can not be changed from this screen; it is shown only as a reference.

Operation

Operation l 4-5

Screen

SCREEN 1

SCREEN 2

SCREEN 3

SCREEN 4

SCREEN 5 (Default Screen)

SCREEN 6

Function

Control Function Descriptions

v00

09.5

v00

01.0

250

425

CNT

DRY

Central

Screen

SCREEN 7

SCREEN 8

SCREEN 9 (MDC Option)

100

Function

Control Function Descriptions

(continued)

This screen shows the actual return air temp measured at the inlet to the process blower. If the optional aftercooler flow control is installed, a setpoint will be displayed on this screen as well. The + / buttons can be used to change the set point. Holding the + / - buttons in will cause the number to ramp up faster the longer the button is held.

This screen is used to set the dryer to auto start. The dryer must be on but not running to set auto start. The value shown is the countdown time setpoint. It is adjustable from 0.1 hrs. to 150 hrs. Once the countdown time is set, press the RUN button. The display will show ON to tell the operator that the auto start is ON and counting. The auto start LED on the display also flashes green when the auto start is armed and counting down. The LED will turn solid green when the dryer starts. The dryer will begin operating when the control has finished counting down.

This screen shows the amount of time the conveying blower will run. Based on the position of the demand sensor in the material receiver, this time may need adjusted. The time should be set for the time it takes to satisfy the demand sensor + 1 sec. If the MDC tries to load 3 times without satisfying the demand signal the dryer will display a passive alarm. The range for this time setting is 5 to 20 sec.

100

-----

4-6 l Operation

Central

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

Screen

SCREEN 10 (Setback Temperature Option)

SCREEN 11 (Setback Options)

SCREEN 12 (Setback Load Rate Option)

Function

Control Function Descriptions

(continued)

If the dryer has the setback on temperature option installed, this is the temperature setpoint for the air at the outlet of the drying hopper. When this setpoint is reached, the dryer will automatically change the process setpoint to the setpoint shown on Menu number 7, Screen 11. When the temperature at the outlet of the hopper drops below the setpoint (menu number 6) by the value shown under C07, screen 22, the dryer will return to the normal drying setpoint.

If the dryer has the setback on temperature option installed, this is the temperature setpoint to which the process air will revert once the air at the outlet of the hopper has reached its setpoint. (Menu number 6)

If the dryer has the optional setback on load rate option, this screen shows the number of load dumps per hour, setpoint and actual. When the actual drops below the setpoint the dryer will go into setback mode. When the actual goes above the setpoint, the dryer will return to the normal process temperature.

150

120

145

250

Operation l 4-7

Operation

Central

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

Screen

SCREEN 13 (PM1 and/or DEWPOINT MONITOR Options)

SCREEN 14

Function

Control Function Descriptions

(continued)

If the dryer has the dewpoint monitor option installed, this screen will show the actual dewpoint of the process delivery air measured after the desiccant tank in the process position but before the process heater. If the Power Miser 1 (PM1) option is installed, there will also be a setpoint shown on this screen. Although the dryer is capable of producing dewpoints much lower than -40

°F (-40°C), the minimum

sensor range is -40°F (-40°C). The PM1 option (when set to index on dewpoint) will monitor the dewpoint of the process air and not index a new tank into the process position until the dewpoint reaches the entered setpoint. After the normal regeneration cycle is complete, the regeneration heaters and regeneration blower will turn off and wait for the dewpoint to reach setpoint before turning on again. This saves energy by only regenerating when you need to if your material is not that wet. The maximum time it will wait to index is 2 hr.

This is the password entry screen that gives the user access to the Set Up, Test Mode, and Alarm History screens and also password protected control functions. The user can get to the non-password protected control functions through this screen by pressing the scroll button and the - button at the same time. This works only if you are on menu #1 . (default screen). The access codes are as follows:

Set Up Screens 754 Test Mode Screens 755

Alarm History Screens 756 To exit the password section, enter 500 and press scroll.

-30

-40

4-8 l Operation

Screen

Screens 15-27 require access code 754.

SCREEN 15 (Set up Screen)

SCREEN 16 (Set up Screen)

SCREEN 17 (Set up Screen)

SCREEN 18 (Set up Screen)

SCREEN 19 (Set up Screen)

Function

Control Function Descriptions

(continued)

This is the process deviation temperature screen. The range is 5 - 20°F (-15.0 -

-6.7°C). This is the deviation temperature band around the set point. If the dryer goes outside this band, the dryer will display a passive alarm (P1).

This is the process high temperature screen. This is the high temperature limit. If the process temperature reaches this setpoint, the dryer will shutdown on alarm A1.

This is the process heater autotune screen. The autotune function can be turned on by pressing the + key. Once the + key is pressed, the screen will show On and then start the autotune process. This may take a minute or so to complete. When finished, the display will read "don". The new PID values are automatically saved.

This is a regeneration temperature screen.

This is the regeneration heater autotune screen. The autotune function can be turned on by pressing the + key. Once the + key is pressed, the screen will show On and then start the autotune process. This may take a minute or so to complete. When finished the display will read "don". The new PID values are automatically saved.

400

C02

off

C03

425

C04

C01

off

C05

Operation l 4-9

Operation

Central

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

Screen

Screens 15-27 require access code 754.

SCREEN 20 (Set up Screen) MDC Option

SCREEN 21 (Set up Screen)

SCREEN 22 (Set up Screen) Setback Temperature Option

Function

Control Function Descriptions

(continued)

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

This screen shows how the dryer is set to index the bedplates, on Time "tim"or Dewpoint "dew". To have the selection for indexing on Dewpoint, the PM1 option must be installed. By pressing the + or keys, the setting can be changed. When the dryer is set to index on Dewpoint, it will index on time (20 min.) for the first 3 indexes so that the desiccant tanks have time to dry out. Then it will index on dewpoint. The regeneration cycle will still be 20 min. If at the end of the 20 min. regeneration cycle the process dewpoint is still below the setpoint the dryer will turn off the regeneration blower and heater and wait for the process dewpoint to reach its setpoint. If, however, the process dewpoint stays below setpoint for 2 hrs., the dryer will index automatically.

This screen is the Setback Temperature Band screen. This temperature is the amount the return air out of the hopper has to drop below the activate setback temperature before the original process temperature is restored. For example, if the activate setback temperature was 180

°F

(82.2°C) and the dryer was in setback. The actual temperature measured at the outlet to the hopper would have to drop below 160

°F (71°C)to restore the original process

setpoint.

tim

C07

C08

C06

4-10 l Operation

Central

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

Central

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

Screen

Screens 15-27 require access code 754.

SCREEN 23 (Set up Screen) Aftercooler Flow Control Option

SCREEN 24 (Set up Screen) Setback Temperature Option

SCREEN 25 (Set up Screen) Setback Load Rate Option

Function

Control Function Descriptions

(continued)

This screen is the Aftercooler Flow Control Enable screen. By pressing the + or - keys, the setting can be changed. With this off or disabled, the dryer will not open the flow control valve and try and control the return air temperature. There will also be no set point value on Menu number 3, Screen 7.

This screen shows the setting of the setback option. It can be set to Off or On. "Off" turns the setback mode off, and the dryer will not change the process set point. "On" tells the control the dryer should go into setback when the hopper outlet temperature reaches its set point. Menu 6 Screen 10.

This screen shows the setting of the setback load rate option. It can be set to Off or On. “Off” turns the setback load rate function off, and the dryer will not change the process set point. The "On" setting tells the dryer to go into setback when the load rate gets to its set number of loads per hour Menu 8, Screen 12. (continued next page)

off

C11

off

C09

off

C10

Operation l 4-11

Operation

Central

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

Screen

Screens 15-27 require access code 754.

SCREEN 26 (Set up Screen) Precooler Option

WARNING: The precooler must NOT be installed in the process line for temperature setpoints above 150°F (65.5°C). The precooler hosing will absorb too much heat and will result in poor process temperature control.

SCREEN 27 (Set up Screen) Precooler Flow Control Option

Screen 28-43 require access code 755.

SCREEN 28 (Test Mode Screen)

Function

Control Function Descriptions

(continued)

This screen shows how the precooler is set to operate. If it is set to "Off" the control assumes the precooler is not installed in the process line and will not control well below 150

°F (65.5°C). If the screen is set

to "On" the control will assume the precooler is connected in the process line and will only allow setpoints from 100 to 150

°F (37.8 to 65.5°C). The control will

also assume that the water flow rate is set manually with a ball valve and make no attempt to control water flow. The precooler option must be installed for this screen to appear.

This screen shows how the precooler flow control is set to operate. The precooler flow control option must be installed for this screen to appear. If the screen is set to "On", the control will assume the precooler is installed in the process line and will only allow setpoints from 100 to 150

°F

(37.8 to 65.5

°C). It will also assume the

water flow solenoid valve is piped in the water line and the dryer control will regulate water flow to control temperature.

This is the Test Mode screen for the process blower. By pressing the + or keys, the setting can be changed. When set to "On", the process blower output will be turned on for 3 sec. and then shut off automatically.

off

C13

off

C12

4-12 l Operation

Central

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

Screen

Screen 28-43 require access code 755.

SCREEN 29 (Test Mode Screen)

SCREEN 30 (Test Mode Screen)

SCREEN 31 (Test Mode Screen)

SCREEN 32 (Test Mode Screen)

SCREEN 33 (Test Mode Screen)

Function

Control Function Descriptions

(continued)

This is the Test Mode screen for the process heater. By pressing the + or keys, the setting can be changed. When set to "On", the process heater output will be turned on for 3 sec. and then shut off automatically.

Note: The isolation contactor will not be pulled in so no electricity will go the heater. The solid state relay contacts should close.

This is the Test Mode screen for the regeneration blower. By pressing the + or keys, the setting can be changed. When set to "On", the regeneration blower output will be turned on for 3 sec. and then shut off automatically.

This is the Test Mode screen for the regeneration heater. By pressing the + or - keys, the setting can be changed. When set to "On", the regeneration heater output will be turned on for 3 sec. and then shut off automatically.

Note: The isolation contactor will not be pulled in so no electricity will go the heater. The solid state relay contacts should close.

This is the Test Mode screen for the bed drive motor. By pressing the + or - keys, the setting can be changed. When set to "On", the bed drive motor output will be turned on until the limit switch makes the next valley, and then shut off automatically.

This Test Mode screen is not used in the current program.

(continued)

off

✐

off

✐

Operation l 4-13

Operation

off

Screen

Screen 28-43 require access code 755.

SCREEN 34 (Test Mode Screen)

SCREEN 35 (Test Mode Screen)

SCREEN 36 (Test Mode Screen)

SCREEN 37 (Test Mode Screen)

SCREEN 38 (Test Mode Screen)

Function

Control Function Descriptions

(continued)

This is the Test Mode screen for the isolation contactor. By pressing the + or - keys, the setting can be changed. When set to "On", the isolation contactor output will be turned on for 3 sec. and then shut off automatically.

This is the Test Mode screen for the alarm output (horn and or red light). By pressing the + or - keys, the setting can be changed. When set to "On", the alarm output will be turned on for 3 sec. and then shut off automatically.

Note: The alarm light on the membrane switch will not come on. If the optional alarm horn or red light is not installed, nothing will happen.

This is the Test Mode screen for the precooler flow control valve. By pressing the + or - keys the setting can be changed. When set to "On" the precooler flow control valve output will be turned on for 3 sec and then shut off automatically.

Note: If the optional precooler flow control valve is not installed, nothing will happen.

This is the Test Mode screen for the aftercooler flow control valve. By pressing the + or - keys, the setting can be changed. When set to "On", the aftercooler flow control valve output will be turned on for 3 sec. and then shut off automatically.

Note: If the optional aftercooler flow control valve is not installed, nothing will happen.

This screen is not used in the current program.

off

✐

4-14 l Operation

✐

off

Screen

Screen 28-43 require access code 755.

SCREEN 39 (Test Mode Screen)

SCREEN 40 (Test Mode Screen)

SCREEN 41 (Test Mode Screen)

SCREEN 42 (Test Mode Screen)

SCREEN 43 (Test Mode Screen)

Function

Control Function Descriptions

(continued)

This is the Test Mode screen for the MDC conveying blower. By pressing the + or keys, the setting can be changed. When set to "On", the conveying blower output will be turned on for 3 sec. and then shut off automatically.

Note: If the dryer is not an MDC, nothing will happen.

This screen is not used in the current program.

This is the Test Mode screen for the alarm output (yellow light). By pressing the + or - keys, the setting can be changed. When set to "On", the alarm output will be turned on for 3 sec. and then shut off automatically.

Note: If the optional tricolor light is not installed, nothing will happen.

This is the Test Mode screen for the alarm output (green light). By pressing the + or - keys, the setting can be changed. When set to "On", the alarm output will be turned on for 3 sec. and then shut off automatically.

Note: If the optional tricolor light is not installed, nothing will happen.

off

✐

off

Operation l 4-15

Operation

✐

(continued)

Screen

Access code 756 required.

SCREEN 44 (Alarm Screen)

Function

Control Function Descriptions

(continued)

This is the first Alarm History screen. In this section, the last 10 alarms that have occurred are saved, starting with the most recent alarm. The number in the setpoint screen shows the list of alarms 1-10. The alarm code shows up in the actual screen. Some of the alarm codes are shown on the display label. Please refer to the alarm section of this manual for all alarm code definitions.

These are the additional alarm screens. See the explanation above.

4-16 l Operation

To Start Drying

1 Make sure there is material in the hopper.

2 Turn on the main power to the dryer

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

3 Set the drying temperature. Use the Scroll

button to get to the Process Temp function. Press the Adjust Setpoint ▲ or Jbuttons to select the temperature.

(continued)

Set Point Actual

1 Process T emp. 2 Regen. T emp. 3 Return Air T emp. 4 Auto Start 5 Load Time (MDC) 6 Activate Setback Temp. 7 Setback T emp.(Pr ocess) 8 Setback Load Rate 9 PM1 Dewpoint

Shutdown Alarms A1 Process High T emp. A2 Process Loop Break A3 Process Heater High T emp. A4 Regen. Heater High T emp. A5 Carousel Index Too Long A6 Carousel Index Failure A7 Return Air High T emp.

Passive Alarms P1 Process T emp. Deviation P3 Regen. T emp. De viation P5 Return Air High T emp.

Auto Start Desiccant Indexing Set-Back Temp.

Process Blower Process Pressure Process Heater

Regen. Blower Regen. Pressure Regen. Heater

Operation

Central

When configured as a central dryer, the drying temperature can

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

Operation l 4-17

To Start Drying(continued)

4 Press the START button.

If everything is installed correctly:

• The green light on the start button will illuminate.

• The process and regeneration blowers turn on.

• The process and regeneration heaters turn on.

• If the desiccant tanks are not in their correct position, the carousel will

turn clockwise and stop in the correct position.

To Stop Drying

1 Press the STOP button. The drying light stays on.

• The blowers continue running for a few minutes to cool the heaters.

2 Be sure to disconnect and lockout the

main power if you have stopped the dryer to perform maintenance or repair.

IMPORTANT: Do not use the main power switch to stop the dryer. Turning off power to the control and dryer during normal operation prevents the necessary cool-down period, and can trigger the shut down/high temperature alarm during your next drying cycle.

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

Stop

4-18 l Operation

Start

Central

• The regeneration heater turns on.

Using the Auto Start Countdown Function

The countdown function allows the user to set the D Carousel dryer to automatically start at a predetermined time. The countdown time can be set from 0.1 to

150.0 hours.

To set the countdown time:

1 Use the Scroll button to access the function (Menu 4, Screen 8).

Auto Start

2 Use the Setpoint Adjust keys to set the desired countdown time.

How to Enable the Auto Start on the DC-1 Control

1 Scroll to the Auto Start screen.

2 Increment the Auto Atart Time with the plus key.

3 Press the Start button. The Auto Start LED will blink to indicate that Auto Start

is armed.

How to Disable the Auto Start on the DC-1 Control

1 The Auto Start LED will be blinking to indicate that Auto Start is armed.

2 Scroll to the Auto Start screen.

3 Press the Stop button. The Auto Start LED will quit blinking. Leave the Auto

Start screen by pressing the Scroll button.

Operation

Operation l 4-19

4-20 l Operation

Setting the High Setpoint Limits

You can protect your drying process by preventing someone from entering process temperatures above an acceptable level for the material. You can also set the high limit equal to the process temperature to prevent accidental or unauthorized changes to the setting during operation.

1 Turn on the main power to the dryer.

2 While at the default screen (screen 5) press the scroll button and the (-)

minus button simultaneously to get to screen 14

3 On screen 14 enter the password for set up screens (754).

4 Scroll to screen 16.

This is your current high setpoint limit. Press +/- keys to set a new high setpoint limit.

Tip: We recommend that you set your high setpoint limit 10° higher than your maxi- mum high temperature setpoint to avoid unwanted alarms.

5 To lock in your new high setpoint limit and exit the password protected

screens, scroll back to screen 14,

then enter 500 and hit scroll.

754

400

C02

754

✒

Central

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

Maintenance

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

Cleaning the hopper . . . . . . . . . . . . . . . . . 5-3

Cleaning the process filter. . . . . . . . . . . . . 5-4

Cleaning the regeneration filter . . . . . . . . . 5-4

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

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

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

SECTION

Maintenance

Maintenance l 5-1

5-2 l Maintenance

Preventative Maintenance Checklist

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

• Whenever you change materials

❒❒

Drain and clean the hopper.

• Weekly, or as often as needed

❒❒

Clean the process and regeneration filters.

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

❒❒

Clean the return air screen in the hopper.

Cleaning frequency depends on how much material you process and how dusty or full of fines it is.

❒❒

Inspect hoses and hose connections.

Check for damage, kinks, or loose hose clamps. Replace any hoses that show signs of damage or wear. Reposition and tighten loose hose clamps.

• Monthly

❒❒

Clean the optional aftercooler and precooler coils.

You may need to clean the coils more often than monthly. Frequency will depend on the type and volume of material you process.

• Every six months

❒❒

Inspect gaskets for damage or wear.

Damaged gaskets can allow moisture to seep into the closed-loop drying system. Replace any gasket that is torn or cracked.

Maintenance

Maintenance l 5-3

Cleaning the Hopper

CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and out-

side the dryer and drying hopper.

The hopper, spreader cone, and discharge assembly should be cleaned thoroughly between material changes to prevent resin contamination.

Place a container beneath the hopper’s drain port to catch the material.

1 Close the hopper slide gate.

2 Remove the drain-port plug. Pull

the pin and allow the plug to drop.

3 Remove the spreader cone. Open the hopper door. Reach into the hopper.

Grasp the spreader cone tube, lift up slightly, twist and then push down to release it. Tilt the cone assembly and pull it out through the hopper door.

4 Clean the spreader cone and the inside of the hopper.

Make sure you also clean the return air screen at the return air outlet of the hopper.

5 Repeat the steps in reverse order to reassemble the hopper

before adding material.

5-4 l Maintenance

Cleaning the Process Filter

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

1 Remove the process filter.

Remove the black plastic knob. Pull the cap off. Remove the wing nut. Remove the filter cap and filter.

2 Clean the filter tube.

3 Using compressed air, clean

the process filter by blowing air from the inside out. Replace damaged, worn, or clogged filters.

4 Reverse the procedure to reinstall the process filter.

Cleaning the Regeneration Filter

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

1 Remove the regeneration filter.

Remove the two bolts and the metal screen.

2 Clean the regeneration filter. Clean

dust, fines, and dirt from the filter, or replace it with a new filter.

3 Reverse the procedure to reinstall the regeneration filter.

CAUTION: Wear eye protection. If you use compressed air to clean the equipment, you must wear eye protection and observe all OSHA and other safety regulations pertaining

to the use of compressed air.

Maintenance

Maintenance l 5-5

Cleaning the Aftercooler Coils

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

Cleaning the Precooler Coils

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

Inspecting Hoses and Gaskets

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

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

hoses, clamps, fittings, and gaskets.

2 Tighten any loose hose clamps or fittings.

3 Replace worn or damaged hoses and gaskets.

5-6 l Maintenance

Troubleshooting

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

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

DIAGNOSTICS

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

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

Passive alarms . . . . . . . . . . . . . . . . . . . 6-10

Setback . . . . . . . . . . . . . . . . . . . . . . . . 6-15

REP

AIR

Replacing fuses . . . . . . . . . . . . . . . . . . . 6-17

Checking heater solid state relays . . . . . . . 6-18

Checking or replacing temperature sensors . 6-19

Adjusting the limit switch . . . . . . . . . . . . 6-20

Replacing the heaters . . . . . . . . . . . . . . . 6-21

Replacing the desiccant tanks. . . . . . . . . . 6-25

Refilling the desiccant tanks . . . . . . . . . . 6-26

SECTION

Troubleshooting

Troubleshooting l 6-1

6-2 l Troubleshooting

Before Beginning

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

Before you take the side panels off of the dryer be sure to:

❏ Diagnose causes from the control panel.

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

alarm message.

2 Address the alarm message and fix the problem.

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

was not fixed.

If the alarm is a passive alarm you will see P in the screen title display. If the alarm is a shut down alarm you will see A in the screen title

display.

❏ Diagnose causes from the front of the dryer.

You can locate any problem from the front of the dryer.

Set Point Actual

1 Process T emp. 2 Regen. T emp. 3 Return Air Temp. 4 Auto Start 5 Load Time (MDC) 6 Activate Setback T emp. 7 Setback T emp.(Process) 8 Setback Load Rate 9 PM1 Dewpoint

Shutdown Alarms A1 Process High T emp. A2 Process Loop Break A3 Process Heater High T emp. A4 Regen. Heater High T emp. A5 Carousel Index T oo Long A6 Carousel Index Failure A7 Return Air High Temp.

Passive Alarms P1 Process T emp. Deviation P3 Regen. T emp. Deviation P5 Return Air High Temp.

Auto Start Desiccant Indexing Set-Back Temp.

Process Blower Process Pressure Process Heater

Regen. Blower Regen. Pressure Regen. Heater

Acknowledge alarm button

Scroll button

Troubleshooting

Troubleshooting l 6-3

❏ Find the wiring and equipment diagrams that were shipped with your dryer. These diagrams are the best reference for correcting a prob-

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

A Few Words of Caution

The D Carousel dryer is equipped with numerous safety devices. Do not remove or disable them. Improper corrective action can lead to hazardous conditions and should never be attempted to sustain production.

WARNING: Only qualified service personnel should examine and correct problems that require opening the dryer’s electrical enclosure or using electrical wires to diagnose the cause.

WARNING: High voltage. Always stop the D Carousel dryer, disconnect and lock out the main power source before troubleshooting or performing repairs.

CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside of the dryer and hopper.

Open the electrical enclosure to check fuses and heater contactors.

6-4 l Troubleshooting

How to Identify the Cause of a Problem

Most dryer malfunctions are indicated by an illuminated Acknowledge Alarm light on the D carousel dryer control panel.

A problem can trigger two types of alarms:

• Shut Down: The dryer has automatically shut down because it detected a

serious problem that could damage your material or dryer.

• Passive: The dryer continues to operate, but warns of a problem that could

prevent correct drying of your material. If ignored, this problem could lead to a condition that will shut down the dryer.

When the alarm light is displayed:

1 Press the Acknowledge Alarm button once to silence the

optional audible alarm and display the alarm message.

Pressing the Acknowledge Alarm button once also changes the alarm LED from blinking to solid.

2 Find the error message in the diagnostics table of this troubleshooting

section.

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

the alarm.

NOTE: When the dryer detects abnormally high temperature in the process heater, the dryer immediately shuts down and an error message appears in the display window. The alarm light does not illuminate.

Set Point Actual

1 Process T emp. 2 Regen. T emp. 3 Return Air T emp. 4 Auto Start 5 Load Time (MDC) 6 Activate Setback T emp. 7 Setback T emp.(Process) 8 Setback Load Rate 9 PM1 Dewpoint

Shutdown Alarms A1 Process High T emp. A2 Process Loop Break A3 Process Heater High T emp. A4 Regen. Heater High T emp. A5 Carousel Index Too Long A6 Carousel Index Failure A7 Return Air High T emp.

Passive Alarms P1 Process T emp. Deviation P3 Regen. T emp. Deviation P5 Return Air High T emp.

Auto Start Desiccant Indexing Set-Back Temp.

Process Blower Process Pressure Process Heater

Regen. Blower Regen. Pressure Regen. Heater

Acknowledge Alarm LED and button

✐

Troubleshooting l 6-5

Shut Down Alarms

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

Possible cause

The process high temperature setpoint is not at least 37°F (3°C) above the drying setpoint.

The RTD temperature probe is not installed correctly.

The air lines are restricted or loose.

Process RTD is loose or has fallen out.

The process heater has failed.

The air lines are restricted or loose.

There is an air flow blockage or loose hoses.

The isolation contactor failed in the closed position.

The heater solid state relays (SSRs) failed.

Solution

Reset the process high temperature setpoint at least 37°F (3°C) above the drying setpoint.

Make sure the RTD temperature probe tip is in the center of the hopper inlet tube.

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

Check the process RTD and tighten if needed.

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

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

Check that the bed plates are in the proper position (lined up with the hoses).

Tighten any loose hoses.

Replace the isolation contactor.

Replace the failed heater solid state relays (SSRs).

Problem

A1 Process High

Temperature – If the process temperature exceeds the process high temperature setpoint, it shuts down the dryer. Defaults are set to 385°F (196.1°C) for 20 sec.

A2 Process Temperature

Loop Break – If the process temperature is outside of the operator entered deviation, alarm band (see Process High Temperature Deviation passive alarm) and the process temperature is not moving towards the setpoint at a rate greater than specified. It shuts down the dryer. Defaults are set at 37°F (3°C) over 10 sec.

A3 Process Heater High

Temperature – The snap switch in the process heater tube opens due to excessive temperature.

Troubleshooting

Central

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

6-6 l Troubleshooting

Shut Down Alarms

Problem

A4 Regen Heater High

Temperature – The snap switch in the regeneration heater tube activated due to excessive temperature.

A5 Carousel Index Too Long

Alarm – If the carousel index was more than 1.5 times the normal index time, it shuts down the dryer.

A6 Carousel Index Failure –

If the carousel index is requested but no contact transition from on to off is seen within 5 sec, it shuts down dryer.

A7 Return Air High

Temperature – If the return air temperature at the inlet to the blower is greater than 180°F (82.2°C), it shuts down the dryer.

Possible cause

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

The isolation contactor failed in the closed position.

The heater solid state relays (SSRs) failed.

The limit switch is not adjusted correctly.

The limit switch is not adjusted

correctly.

The bed drive motor is damaged.

The set screw on the bed drive motor shaft plate is loose.

The bed drive motor relay has failed.

The hopper does not contain enough material.

You are drying at a high drying temp (above 250°F [121.1°C]) or you are running at low throughputs.

If an optional aftercooler is installed, it does not have enough water.

The aftercooler coils are dirty.

Solution

Check that the bed plates are in the proper position (lined up with the hoses). See “Adjusting the limit switch”.

Tighten any loose hoses.

Replace the isolation contactor.

Replace the failed heater solid state relays (SSRs).

Adjust the limit switch so that it drops into the groove and stops the bed plates.

See “Adjusting the limit switch”.

Adjust the limit switch so that it drops into the groove and stops the bed plates.

Replace the bed drive motor.

Tighten the set screw. Make sure it is on the flat of the D shaped shaft.

Replace the bed drive motor relay.

Make sure your material supply system is working properly.

Add an optional aftercooler, if one is not currently installed.

Turn on the water supply, or fix any leaks or blockages.

Clean the aftercooler coils. See

“Cleaning the Aftercooler”.

Troubleshooting l 6-7

Shut Down Alarms

Problem

A8 Process Blower Pressure

– If the process blower pressure switch opens (loss of pressure), it shuts down the dryer.

A24 Regen Blower Pressure

– The regeneration blower pressure switch opens (loss of pressure) and the regeneration heater shuts down.

NOTE: The system may index one more time after the alarm, then stop indexing.

A36 Control

Communications Watchdog The display board has lost communications with the control board.

A38 Phase Error (Phase

Option, STD, on MDC's) One of the three power wires is connected wrong.

A39 EEProm Write Error

Possible cause

The tubing going to the pressure switch is cut or has come loose.

The process blower overload has tripped.

The blower motor starter has failed

The tubing going to the pressure switch is cut or has come loose.

The blower motor relay has failed.

Plugs on wire harness between the display and control boards are loose.

Display board or Communications boards have failed.

One of the three power wires are out of phase.

Phase Detector Board has failed.

Internal Control board problem.

Solution

Check the tubing for cracks and make sure it is secure on the fittings.

Check the process blower overload. If it is tripped, check the process blower to make sure its not locked. Make sure the overload is set slightly above the full load current shown on the motor nameplate. Refer to your wiring diagram for proper settings.

Check the process blower motor starter.

Check the tubing for cracks and make sure it is secure on the fittings.

Check the regeneration blower motor relay.

Make sure plugs are tight on board connections.

Replace the boards.

Switch the position of two of the incoming lead power wires at the dryer.

Replace the Phase Detection Board.

Replace the Control board.

✐

Troubleshooting

6-8 l Troubleshooting

Shut Down Alarms

Problem

A49 Process Protection

High Temperature – If the process protection temperature exceeds the process protection high temperature setpoint, it shuts down the dryer. Defaults are set to 600°F (315.6°C) for 10 sec.

A50 Process Protection

Differential Temperature – If the process protection differential temperature exceeds the process protection differential temperature setpoint, it shuts down the dryer. Defaults are set to 295°F (146.1°C) for 180 sec.

A51 Process Protection RTD

Integrity – If the process RTD is faulty, it shuts down the dryer.

Possible cause

The Process RTD temperature probe is not installed correctly.

The air lines are restricted or loose.

The process protection differential temperature setpoint is not at least 37°F (3°C) above the drying setpoint.

The Process RTD temperature probe is not installed correctly.

The air lines are restricted or loose.

The connection in the electrical enclosure for the process protection RTD is loose.

The connection of the RTD plug on the control board is loose.

The process protection RTD has failed.

Solution

Make sure the RTD temperature probe tip is in the center of the hopper inlet tube.

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

Reset the process protection differential temperature setpoint at least 37°F (3°C) above the drying setpoint.

Make sure the RTD temperature probe tip is in the center of the hopper inlet tube.

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

Check the RTD plug connection and tighten if needed.

Check the plug connection and tighten if needed.

Replace the process protection RTD.

Central

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

Troubleshooting l 6-9

Troubleshooting

Possible cause

The process blower has mechanically failed or is unable to rotate freely.

The process blower has failed electrically.

The overload is set incorrectly.

Solution

With the power removed, check the process blower for mechanical failure and free rotation. Replace if necessary. Wait 3 to 15 minutes with the power on until the dryer indicates the overload condition has cleared then try to restart the dryer.

With the power removed, check the process blower for electrical shorts or open circuits. Replace if necessary. Wait 3 to 15 minutes with the power on until the dryer indicates the overload condition has cleared then try to restart the dryer.

With the power removed, check the overload settings and confirm that the settings match the full load amps listed on the process blower motor. Wait 3 to 15 minutes with the power on until the dryer indicates the overload condition has cleared then try to restart the dryer.

Problem

A53 Process Blower

Overload – The process blower

overload has tripped due to a

mechanical or electrical prob-

lem.

Shut Down Alarms

6-10 l Troubleshooting

Passive Alarms

If the amber Acknowledge Alarm LED is blinking, the alarm is a passive alarm. The dryer continues to operate, but this problem could prevent correct drying of your material. Note that once the Acknowledge Alarm button is pressed once, the blinking amber LED becomes solid.

Problem

P1 Process Temperature

Deviation – The process temperature exceeds the deviation band as entered for the specified time. Default values are 43°F (6°C) for 5 sec.

P2 Process Low

Temperature – The process temperature is less than the low temperature setpoint for the specified time. Default values are 70°F (21.1°C) for 20 sec.

P3 Regen Temperature

Deviation – The regeneration temperature exceeds the deviation band for the specified time. Default values are 43°F (6°C) for 5 sec.

Possible cause

One of the solid state relays (SSRs) failed in the closed position.

The process RTD is loose or has fallen out.

The air hose connections are loose.

Precooler water is too cold, or the water flow rate is too high.

The process RTD is loose or has fallen out.

Process heater has failed.

One of the solid state relays (SSRs) failed in the closed position.

The regeneration RTD is loose or has fallen out.

The air hose connections are loose.

Solution

Replace the failed solid state relays (SSR).

Check the process RTD and tighten if needed.

Tighten all air hose connections.

Check water temperature and flow settings. Adjust as necessary.

Check the process RTD and tighten if needed.

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

Replace the failed solid state relays (SSRs).

Check the regeneration RTD and tighten if needed.

Tighten all air hose connections.

Central

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

Troubleshooting

Troubleshooting l 6-11

Passive Alarms

Problem

P5 Return Air High

Temperature – If the return air temperature is between 150 and 180°F (65.6 and 82.2°C).

P6 Regen High Temperature

– If the regeneration temperature exceeds the high temperature limit for the specified time. Default values are 450°F (232.2°C) for 20 sec.

P7 Regen Low Temperature

– The regeneration temperature is less than the low temperature setpoint for the specified time. Defaults are 350°F (176.7°C) for 20 sec.

P8 Regen Temperature Loop

Break – The regeneration temperature is outside of the operator entered deviation alarm band (see Regen Temperature Deviation passive alarm) and the regeneration temperature is not moving towards the setpoint at a rate greater than specified. Default values are 36°F (2°C) over 20 sec.

Possible cause

The hopper does not contain enough material.

You are drying at a high drying temperature (above 250°F [121.1°C]) or running at low throughputs.

If an optional aftercooler is installed, it does not have enough water.

The aftercooler coils are dirty.

The air hose connections are loose.

One of the solid state relays (SSRs) failed in the closed position.

The regeneration RTD is loose or has fallen out.

The regeneration heater has failed.

The regeneration RTD is loose or has fallen out.

The return air RTD has failed.

The regeneration heater has failed.

The regeneration RTD is loose or has fallen out.

Solution

Make sure your material supply system is working properly.

Add an optional aftercooler, if one is not currently installed.

Turn on the water supply, or fix any leaks or blockages.

Clean the aftercooler coils.

Tighten all air hose connections.

Replace the failed solid state relays (SSRs).

Check the regeneration RTD and tighten if needed.

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

Check the regeneration RTD and tighten if needed.

Replace the return air RTD.

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

Check the regeneration RTD and tighten if needed.

6-12 l Troubleshooting

Possible cause

The hose or wiring connections to the sensor block are loose or have fallen off.

Desiccant level low.

The desiccant may be contaminated.

Leaks in the process air stream.

The process air filter is clogged.

Sensor is out of position.

The conveying load time is too short.

Conveying blower is not coming on.

Hoses have come off or are loose in the conveying loop.

Solution

Check wiring and hose connections to the sensor, re-secure if needed.

Replace tanks or repack desiccant. See

“Replacing the Desiccant Tanks” Page 6-21 “Refilling the Desiccant Tanks” Page 6-22.

Check the desiccant for contamination, replace if needed.

Check for worn or loose hoses.

Remove and clean or replace the process air filter.

Raise the sensor to a higher/lower position on the bracket.

Increase the load time setpoint.

Check the blower fuses in the control and the overload settings.

Check for loose hoses and make sure all hose clamps are secure.

Passive Alarms

Problem

P9 Process Dew Point (PM1

Option) – The dew point has not fallen below the setpoint. If the dew point goes below the setpoint, the alarm should go away.

Note: The alarm is not active for the first 3 indexes

P10 Process Filter Clogged

(Option) – The process filter differential pressure switch is tripped.

P17 Conveying Demand

(MDC Option) - The demand sensor located at the material receiver has not been satisfied after 3 attempts.

✐

Troubleshooting l 6-13

Troubleshooting

Problem

P23 The MDC conveying

blower exceeded the full load amps rating for the blower motor. This is a passive alarm so the dryer will continue running, but the material conveying function will stop.

P25 RTD Integrity – If the

process RTD is faulty.

Possible cause

The MDC blower has mechanically failed or is unable to rotate freely.

The MDC blower has failed electrically.

The overload is set incorrectly.

The MDC conveying blower has exceeded the full load amps rating for the blower motor.

The connection in the electrical enclosure for the process RTD is loose.

The connection of the RTD plug on the control board is loose.

The process RTD has failed.

Solution

With the power removed, check the MDC blower for mechanical failure and free rotation. Replace if necessary. Wait 3 to 15 minutes with power on until the dryer indicates the overload condition has cleared then try to restart the dryer.

With the power removed, check the MDC blower for electrical shorts or open circuits. Replace if necessary. Wait 3 to 15 minutes with power on until the dryer indicates the overload condition has cleared then try to restart the dryer.

With the power removed, check the overload settings and confirm that the settings match the full load amps listed on the conveying blower motor. Wait 3 to 15 minutes with power on until the dryer indicates the overload condition has cleared then try to restart the dryer.

Press alarm acknowledge and wait 2 to 3 minutes for the overload to automatically reset. If the alarm condition occurs again, have a qualified electrician check the current draw to the motor.

Check the RTD plug connection and tighten if needed.

Check the plug connection and tighten if needed.

Replace the process RTD.

Passive Alarms

6-14 l Troubleshooting

Passive Alarms

Problem

P26 Regen RTD Integrity –

If the process RTD is faulty.

P28 Return Air RTD

Integrity Alarm– If the return air RTD is faulty.

P30 Out of Hopper RTD

Integrity – The dryer continues to run with a passive alarm.

Possible cause

The connection in the electrical enclosure for the regen RTD is loose.

The connection of the RTD plug on the control board is loose.

The regen RTD has failed.

The connection in the electrical enclosure for the return air RTD is loose.

The connection of the RTD plug on the control board is loose.

The return air RTD has failed.

Solution

Check the RTD plug connection and tighten if needed.

Check the plug connection and tighten if needed.

Replace the regen RTD.

Check the RTD plug connection and tighten if needed.

Check the plug connection and tighten if needed.

Replace the return air RTD.

Troubleshooting l 6-15

Setback

The setback function available on the DC-1 Dryer is designed to save you money on energy costs and keep you from over drying your material. Setback is available as separate options on both the temperature and load rate setting.

This is how setback operates when the control setback is set to "On" on "Temperature" (Screen 24) (optional on DC-1 controls).

The control monitors the temperature of the air exiting the drying hopper. If that temperature reaches a customer entered setpoint (Screen 10), the delivery process air temperature will automatically set back to a customer-entered set point (Screen 11). Then, if the air exiting the drying hopper drops below the customerentered temperature on Screen 10 by an amount greater than what is shown on Screen 22, the process temperature will automatically reset back to the original process temperature (Screen 5).

This is how setback operates when the control setback is set to "On" on the "Load Rate" option screen (Screen 25) (optional on DC-1 controls).

When operating the setback option on the load rate setting, the control counts how many times the loader attempts to load. The load rate setting tells the dryer to go into setback when the load rate reaches its set number of loads per hour (Screen 12). If the load rate drops below the customer-entered setpoint (Screen 12), the delivery process air temperature will automatically set back to the original process temperature (Screen 5).

To set-up setback on the temperature option

1 Reference the flow chart on Page 4-4 and follow the menu tree path to

access Screen 24.

2 Turn the setback function for the temperature option to "On" or "Off".

"Off" turns the setback mode off, and the dryer will not change the process setpoint. "On" tells the control the dryer should go into setback when the hopper outlet temperature reaches its setpoint (Menu 6, Screen 10).

3 If you have decided to turn the temperature setback to "On", go to Screen

10. This is where you will set the temperature setpoint for the air at the outlet of the drying hopper. When this setpoint is reached, the dryer will automatically change the process setpoint to the setpoint shown on Screen 11. When the temperature at the outlet of the hopper drops below the setpoint by the value shown on Screen 22, the dryer will return to the normal drying setpoint (Screen 5).

Central

When supplied for central drying applications, the D series dryer is not equipped with a process heater. Therefore the Setback function is not applicable.

Setback (continued)

4 Use Screen 11 to set the temperature setpoint to which the process air will

revert to once the air at the outlet of the drying hopper has reached its setpoint.

5 Use the setback temperature band screen (Screen 22) to set the amount the

return air temperature has to drop below to activate setback temperature before the original process temperature is restored. For example, if the activate setback temperature was 180ºF (82.2ºC) and the dryer was in setback, the actual temperature measured at the outlet to the hopper would have to drop below 160ºF (71ºC) to restore the original process set point.

To set-up setback on the load rate option

1 Reference the flow chart on Page 4-4 and follow the menu tree path to

access Screen 25.

2 Turn the setback function for the load rate option to "On" or "Off". "Off"

turns the setback load rate option off and the dryer will not change the process set point. The "On" setting tells the dryer to go into setback when the load rate gets to its set number of loads per hour (Menu 9, Screen 12).

3 If you have decided to turn the temperature setback to "On", go to Screen

12. This screen shows the number or load dumps per hour, set point and actual. When the actual drops below the setpoint, the dryer will go into setback mode. When the actual goes above the setpoint, the dryer will return to the normal process temperature (Screen 5).

6-16 l Troubleshooting

Replacing Fuses

1 Disconnect and lockout the main power supply.

2 Open the electrical enclosure door.

3 Check the fuse. If necessary, pull the fuse out and replace it with a fuse of the

same type and rating.

Fuse Blocks

To locate the appropriate fuse and replacement part, refer to the wiring diagrams that came with your dryer.

IMPORTANT: Always refer to the wiring diagrams that came with your dryer to locate specific electrical components. Illustrations in the User Guide are intended to be representative only.

Troubleshooting

Troubleshooting l 6-17

6-18 l Troubleshooting

Checking Heater Solid State Relays

1 Disconnect and lockout the main power supply.

2 Open the electrical enclosure.

3 Locate the process or regeneration contactors. Refer to the wiring diagrams

that came with your dryer.

4 Check continuity using an ohmmeter.

IMPORTANT: Always refer to the wiring diagrams that came with your dryer to locate specific electrical components. Illustrations in the User Guide are intended to be representative only.

Regeneration heater solid state relays

If ohms equal zero or infinity, replace the contactor.

Process heater solid state relays

If ohms equal zero or infinity, replace the contactor.

Troubleshooting l 6-19

Checking or Replacing Temperature Sensors

The D carousel dryer uses RTD sensors to monitor the temperatures of the drying air, the return air, the regeneration exhaust, and the regeneration and process heater boxes.

To check or replace an RTD sensors:

1 Disconnect and lockout the main power supply.

2 Remove dryer panels, as necessary.

3 Locate the RTD sensors.

4 Check the sensor positions and conditions. Temperature readings will be

incorrect, if the sensors are touching the wall of an air hose or pipe or if the sensor or wiring is damaged. The tip of the sensor should be centered within the air hose or pipe. Sensor wires should be attached to the appropriate connection points on the dryer’s electrical enclosure or microprocessor board.

5 To check with ohm meter - measure the resistance across the RTDs. The

resistance should be approx. 110 ohm.

6 Replace the sensor, if necessary.

IMPORTANT

: Always refer

to the wiring diagrams that came with your dryer to locate specific electrical components. Illustrations in the User Guide are intended to be representative only.

Location of the Process RTD at the Hopper

Troubleshooting

6-20 l Troubleshooting

Adjusting the Limit Switch

1 Stop the dryer. Disconnect and lockout the main power.

2 Remove the right side panel from the dryer.

IMPORTANT: Note the position of the tanks.

3 Loosen the screws securing the limit switch to the carousel. Note that the

hole for the front screw is slotted to allow for adjustment.

4 Slide the switch to the left or right to position the limit switch so that its small

roller drops into the valley on the bed plate. The roller on the switch should not hit the stationary bottom plate.

5 Test for correct indexing of the carousel. Restore main power to the dryer.

Hold the limit switch out of the valley on the carousel bed plate while you push START. It may not be necessary to push START. If not in run mode, the carousel will turn when the switch is out of the valley. Once the bed plate starts turning, release the switch.

If everything is adjusted correctly:

• The carousel bed turns.

• When the limit switch reaches the next valley in the bed plate, the carousel

should stop turning.

6 Reset the desiccant carousel.

Continue indexing until the desiccant tanks return to the positions they were in when the dryer shut down.

Troubleshooting l 6-21

Troubleshooting

Replacing the Heaters

Regeneration Heater

Disconnect and lockout the main power.

2 Gain access to the regeneration heater by removing the right

dryer side panel.

3 Open the electrical enclosure door.

4 Remove the hose and hose clamp at the bottom of the heater tube.

5 Remove the insulation from the heater tube by cutting the insulation in a

straight line from top to bottom.

6 Remove the small 1/8" (3.18 mm) plastic hose from the hose barb, and

remove the hose barb. Save the barb, it will need to be installed in the new heater tube.

7 Remove and save the regeneration RTD and fitting. They will be installed

in the new heater.

8 Reference the wiring diagram and / or trace the wires from the regenera-

tion heater tube into the control box. Remove the wires from the relays and terminal strips. Once disconnected, pull the wires from the control box into the dryer housing toward the heater tube.

Remove the heater tube by twisting the tube counterclockwise. The tube is threaded into the lower bed plate. You may need to use a pipe wrench or chain wrench to remove it.

10 Check the ID mark on the side of the heater tube for kW rating and volt-

age. The ID mark is on the outside of the tube near the end with the lead wires. Make sure the kW and voltage is the same as the replacement heater.

11 Thread the new heater into the lower bed plate. The RTD should be point-

ing directly toward the back of the dryer. Do not over tighten. Hand tighten, and use a wrench for no more than one turn to get RTD into the correct position.

Note: When installed the regeneration heater tube must be oriented so the RTD is directly toward the back of the dryer.

✐

6-22 l Troubleshooting

Replacing the Heaters

Regeneration Heater (continued)

12 Put petroleum jelly on the tips of the new heater wire leads to make it eas-

ier to go through the holes in the back of the control box. Reference the wiring diagram to re-attach the heater wires and the two snap switch wires.

13 Install the RTD fitting and RTD in the 1/8" (3.18 mm) NPT hole toward the

top of the heater tube.

14 Put the insulation back on. Make sure to duct tape the seam that was cut

during removal.

15 Put the hose barb back in the lower 1/8" (3.18 mm) NPT hole and connect

the plastic hose.

16 Reattach the lower 2-1/2" (63.5 mm) hose and hose clamp.

17 Make sure the heater fuses are not blown before trying the new heater.

2.5"

(63.5mm)

IMPORTANT: The distance the RTD extends into the heater is critical for proper functioning. The distance from the metal heater tube to the outside surface of the curve on the RTD must be 2.5

" (63.5 mm) (see photo). To take

the measurement, peel back (but do not remove) any existing insulation to access the metal heater tube.

Troubleshooting l 6-23

✐

Troubleshooting

Replacing the Heater

Process Heater

Disconnect and lockout the main power.

2 Gain access to the process heater by

removing the left dryer side panel.

3 Open the electrical enclosure door.

For D15, D25, and D50 Dryers

4 Remove the hose and hose clamp at the bottom of the heater tube.

5 Remove the insulation from the heater tube by cutting the insulation in a

straight line from top to bottom.

6 Reference the wiring diagram and / or trace the wires from the process

heater tube into the control box. Remove the wires from the relays and terminal strips. Once disconnected, pull the wires from the control box into the dryer housing toward the heater tube.

7 Remove the heater tube by twisting the tube counterclockwise. The

tube is threaded into the lower bed plate. You may need to use a pipe wrench or chain wrench to remove the heater.

8 Remove the plugs or hose fittings toward the top end of the heater. These

will need to be installed on the new heater.

9 Check the ID mark on the side of the heater tube for kW rating and volt-

age. The ID mark is on the outside of the tube near the end with the lead wires. Make sure the kW and voltage is the same as the replacement heater.

10 Reinstall the plugs or hose fittings into the 1/8" (3.18 mm) NPT holes

near the top end of the heater tube.

11 Thread the new heater into the lower bed plate. The lead wires should

be pointing toward the inside of the dryer. Do not over tighten. Hand tighten then use a wrench for no more than one turn to put the lead wires into the correct position.

✒

TIP: Depending on the model and

the mounting configuration selected

for the dryer installation, it may be

necessary to access the process

heater through the right side panel

or to remove the process blower to

create adequate access to use a

wrench to remove the process

heater. See Removing the Process

Blower.

Note: When installed, the process heater tube must be oriented so the power wires are toward the inside of the dryer.

Central

When configured as a central dryer, there is no process heater in the system. Therefore, replacing the process heater is not applicable.

12 Put petroleum jelly on the tips of the new heater wire leads to make it

easier to go through the holes in the back of the control box. Reference the wiring diagram to reattach the heater wires and the two snap switch wires.

13 Put the insulation back on. Make sure to duct tape the seam that was cut

during removal.

14 Reattach the lower 2-1/2" (63.5 mm) hose and hose clamp.

15 Make sure the heater fuses are not blown before trying the new heater.

For D75 and D100 Dryers

4 Remove the hose clamp holding the heater tube to the dryer frame.

5 Remove the insulation from the heater tube by cutting the insulation in a

straight line from top to bottom.

6 Remove the hose and clamps at the top and bottom of the heater tube.

7 Remove the plugs or hose fittings toward the top end of the heater. These

will need to be installed on the new heater.

8 Reference the wiring diagram and / or trace the wires from the process

heater tube into the control box. Remove the wires from the relays and terminal strips. Once disconnected pull the wires from the control box into the dry housing toward the heater tube.

9 Check the ID on the side of the heater tube for kW rating and voltage.

The ID mark on the outside of the tube near the end with the lead wires. Make sure the kW and voltage is the same as the replacement heater.

10 Reinstall the plugs or hose fittings toward the top of the heater tube.

11 Reattach the lower 2-1/2" (63.5 mm) hose and clamps to the top and

bottom.

12 Put the insulation back on. Make sure to duct tape the seam that was cut

during removal.

13 Install the hose clamp holding the heater tube to the dryer frame.

14 Put petroleum jelly on the tips of the new heater wire leads to make it

easier to go through the holes in the back of the control box. Reference the wiring diagram to reattach the heater wires and the two snap switch wires.

15 Make sure the heater fuses are not blown before trying the new heater.

6-24 l Troubleshooting

Replacing the Heater

Process Heater (continued)

Central

When configured as a central dryer, there is no process heater in the system. Therefore, replacing the process heater is not applicable.

Troubleshooting l 6-25

Troubleshooting

Replacing the Desiccant Tanks

The D Carousel Dryer has refillable desiccant tanks. When desiccant becomes clogged or contaminated, you should replace the desiccant in all three tanks to ensure optimum performance, or purchase new, prefilled tanks from Conair.

1 Stop the dryer then disconnect and lockout the main power.

2 Remove the right side panel from the

dryer.

3 Disconnect the hose from the desiccant

tank. Loosen the hose clamp with a screw driver.

4 Lift the tank off the carousel assembly.

5 Refill the tank with fresh desiccant.

See “Refilling the Desiccant Tank (Section 6).

6 Check the O-rings in the carousel coupling. Replace any O-rings that are

cracked, worn, or damaged. Apply petroleum jelly on the inside of the coupling around the O-ring.

7 Place the refilled tank on the carousel assembly. Make sure the inlet/outlet

tube of the tank seats fully into the O-rings on the carousel pipe.

8 Connect the hose to the top of the tank. Secure with the hose clamp.

9 Reinstall the side panel.

IMPORTANT: It’s important that the new tanks are connected to the correct hoses. Mark the hoses as they are disconnected, or replace one tank at a time, to ensure that you install the new tanks in the correct positions.

6-26 l Troubleshooting

Refilling the Desiccant Tanks

When desiccant becomes clogged or contaminated, you should replace the desiccant in all three tanks to ensure optimum performance.

1 Remove the desiccant tank from the carousel.

See “Replacing Desiccant Tanks.”

2 Remove the the tank end plate.

Remove the six 10-32 self-tapping screws from the end plate.

3 Remove the screen cap.

Remove the two 1/4-20 nuts from the center post and pull the screen cap out.

4 Remove the old desiccant.

5 Replace the gasket on the flange, if necessary.

6 Fill the tank with fresh desiccant.

Fill the tank with the weight of desiccant indicated in the following table.

Model Desiccant Weight

15 & 25 1 lb. (0.37 kg) 50 2 lb. (0.75 kg) 75 3 lb. (1.12 kg) 100 4 lb. (1.49 kg)

(continued)

Troubleshooting l 6-27

Troubleshooting

Refilling the Desiccant Tank (continued)

7 Vibrate the tank for 15 minutes. (Important, no further settling can

occur.)

8 Reinstall the screen cap. Place the cap on the band. Install one of the 1/4-20

nuts on the center post and tighten. Do not over-tighten. Install the second 1/420 nut and tighten.

9 Reinstall the tank end plate. Place the end plate on the tank and tighten the

six 10-32 screws.

10 Shake the tank beside your ear. If properly filled, you will not be able to

hear any desiccant rattling in the tank.

11 Reinstall the desiccant tank on the carousel. See “Replacing Desiccant

Tanks.”

IMPORTANT: After filling with fresh desiccant, vibrate the tank for at least 15 minutes.

6-28 l Troubleshooting

Conair 15, 50, 75, 25, D15 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual