Conair 100 manual

D Carousel Dr yer - 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 UGD02 4 /0 3 04 www .conairnet.com INTRODUCTION • Purpose of the User Guide • How the guide is organized • Y our responsibilities as a us[...]

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 receiv ed it in the User Guide. Our service department uses this infor- mation, along with the manual number , to provide help for the speci[...]

T able 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 Y our responsibilities as a user . . . . . . . . [...]

Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Connecting the air hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Connecting water hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Connecting the RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

6-1 T roubleshooting 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 . . . . . . . . . . . . . . . . .[...]

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) . . . . . . . [...]

T able of Contents l v The MDC control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12 MDC control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12 T o start dr ying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12 T o stop dr ying . . . . . . . . . . . . . . . . . .[...]

vi l T able 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 Y our responsibilities as a user . . . . . . . . . . 1-3 A TTENTION: Read this so no one gets hurt . . . . . . . . 1-4 How to use the lockout device . . . . . . . . . . 1-5[...]

✐ Purpose of the User Guide This User Guide describes the Conair D series of carousel dehumidifying dryers and explains step-by-step ho w to install, operate, maintain and repair this equipment. Before installing this product, please take a fe w moments to read the User Guide and re view the diagrams and safety information in the instruction pack[...]

Using the D Series as a Central Dr yer This manual incorporates the information necessary to use the Conair D series dryer as a central dryer . Throughout this manual, information particular to cen- tral dyer application of the D series dryer is called out by the following treat- ment. Y our Responsibility as a User Y ou must be familiar with all s[...]

1-4 l Introduction A TTENTION: Read this so no one gets hurt W e design equipment with the user’ s safety in mind. Y ou can avoid the potential hazards identified on this machine by follo wing the procedures outlined below and elsewhere in the User Guide. WARNING: Improper installation, operation, or servicing may result in equipment damage or pe[...]

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 injur y from unexpected energization or start-up. A lockable device has been provid- ed to isolate this product from potentially hazardous electricity . Lockout i[...]

1-6 l Introduction[...]

Description What is the D carousel dr yer? . . . . . . . . . . 2-2 T ypical a pplications . . . . . . . . . . . . . . . . . 2-2 How it works . . . . . . . . . . . . . . . . . . . . . . 2-4 Specifications: D dryer . . . . . . . . . . . . . . . 2-6 SECTION 2 2 Description Description l 2-1[...]

What is the D Carousel Dr yer? The D carousel dehumidifying dryer produces hot, low-de w point air that remov es moisture from hygroscopic plastics. The dryer pulls w arm, 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 mat[...]

Description l 2-3 2 Description Central 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 sup- ply dry air to the hoppers. T ypical Applications (continued) The D carousel dryer can be used successfully in applications that require:[...]

How It W orks The D carousel dryer achiev es continuous, closed loop drying by passing air simul- taneously through two heaters and three tanks of molecular sie ve desiccant. T HE P ROCESS (D RYING ) C YCLE The process blower pulls moist air from the top of the drying hopper . The air pass- es through the process filter (and optional aftercooler , [...]

2 Description How It W orks (continued) REGENERA TION AIR FIL TER DESICCANT T ANKS BEDPLA TE REGENERA TION BLOWER REGENERA TION HEA TER HIGH TEMP SHUT OFF REGENERA TION RTD HOPPER 4 CURRENT METER PROCESS BLOWER RETURN AIR FIL TER 8 AFTERCOOLER 5 PROCESS FIL TER ST A TUS RETURN AIR RTD PROCESS RTD 1 SET BACK TEMPERA TURE 2 PROCESS CFM MONIT OR HIGH [...]

2-6 l Description Specifications: D Carousel DEHUMIDIFYING DR YERS D Small Series Car ousel Dr yer s MODEL D15 D25 D50 D75 D100 Perf ormance characteristics (with full hopper) Air flow {SCFM} * 12 20 35 50 80 Air flow {A CFM @ 250 ° } * 16 27 47 67 107 Drying temperature All models 100 - 375 ° F {38 - 191 ° C} with options Dew point All models -[...]

Description l 2-7 2 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 [...]

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 . . . . . . . . . . . . . . . [...]

3-2 l Installation Unpacking the Boxes The D carousel dryer comes in one to four boxes, depending on the model and options ordered. The box es could include (depends on options selected): 1 Carefully r emove the dryer and components from their shipping containers, and set upright. Note that the dryer is secured to its shipping container with four b[...]

Installation l 3-3 Unpacking the Boxes (continued) 4 T ake a moment to r ecord serial numbers and electrical po wer specifications in the blanks provided on the back of the the User Guide’ s title page. The infor- mation will be helpful if you ev er need service or parts. 5 Y ou are now r eady to begin installation. Follo w the preparation steps [...]

12 in. (30.48 cm) needed to remove optional aftercooler coil for cleaning 3 in. (7.62 cm) 3 in. (7.62 cm) Regeneration exhaust high temperature 6 in. (15.24 cm) 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) 3 in. [...]

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 pat- terns available, you will need an adapte[...]

Mounting the Dr yer and Hopper on a Processing Machine WARNING : Y ou are responsible for the structural integrity of this installation. W e 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 pl[...]

3 Description Mounting the Dr yer and Hopper on a Processing Machine (continued) The drying hopper , slide gate, support frame, and discharge assembly may hav e been shipped fully assembled. Y ou 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[...]

P ositioning the Dr yer on the Floor; Mounting the Hopper on the Throat WARNING: Y ou are responsible for the structural integrity of this installa tion. W e 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 picture[...]

Installation l 3-9 3 Description Mounting the Hopper CAUTION: T o 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 dr yer from the shipping container using a hoist and the lifting lugs provided. 1 Lift the hopper onto the throat. Lift the hopper [...]

3-10 l Installation Mounting the Dr yer 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 Dr yer and Hopper on the Mobile Floor Stand For information about mounting the dryer and hopper on the mobile floor stand, refer to Appendix B. C[...]

Installation l 3-11 3 Description IMPORT ANT : Always refer to the wiring diagrams that came with your dryer before making electri- cal connections. 3 Connect the power wir es to the three terminals at the top of the power discon- nect holder . 4 Connect the ground wir e to either grounding point as shown in the photo. Connecting the Main P ower (c[...]

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 dr yer if the air flow dir[...]

Checking for Proper Air Flow (continued) 3 Press the ST AR T button. Hold your hand near the deliv ery air outlet. Y ou should feel air blowing out of the outlet. 4 Press the ST OP b utton. Start Installation l 3-13 Stop Moisture e xhaust Delivery air outlet (15, 25, and 50 models) Retur n Air Inlet Delivery air outlet (75 and 100 models) Retur n A[...]

Checking for Proper Air Flow (continued) INST ALLA TION NOTE: Models 50, 75, and 100 These models use a three-phase process blower . If the dr yer 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 wro[...]

3 Description Installation l 3-15 Connecting the Air Hoses Using the two flexible hoses pro vided, connect the inlets and outlets of the dry- ing hopper to the dryer . If you hav e positioned the dryer on the floor or mount- ed 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 l[...]

Connecting the R TD Probe The R TD 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 t[...]

3 Description Installation l 3-17 Mounting a Loader on the Hopper If you hav e a Conair loader or vacuum recei ver , you can use the flange and mounting clips provided on the top of the hopper . Refer to the manuals that came with your receiv er or loader for detailed installation instructions. T esting The Installation Y ou have completed the inst[...]

T esting The Installation (continued) 4 Press the ST AR T button. If ev erything is installed correctly: • The green light on the start button will illuminate. • The process and regeneration blo wers turn on. • The process and regeneration heaters turn on. • If the desiccant tanks are not in their correct position, the carousel will turn cl[...]

SECTION 4 4 Operation 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 T o start drying . . . . . . . . . . . . . . . . . . . . 4-17 T o stop drying . . . . . . . . .[...]

The DC-1 Dr yer Control P anel 4-2 l Operation Set Point Actual 1 Process Temp. 2 Regen. T emp. 3 Return Air T emp. 4 Auto Start 5 Load Time (MDC) 6 Activate Setback T emp. 7 Setback Temp.(Pr ocess) 8 Setback Load Rate 9 PM1 Dewpoint Shutdown Alarms A1 Process High Temp. A2 Process Loop Break A3 Process Heater High Temp. A4 Regen. Heater High T emp[...]

D Dr yer 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 purchas[...]

4-4 l Operation POWER ON screen # 1 Pr up 5 sec 2 d2 5 5 sec 3 C v00 09.5 1 sec 4 d v00 01.0 1 sec 5 1 250 250 Proces s Tem p Default Screen 6 2 425 425 Regen Tem p 7 3 100 100 Return Air Temp 8 41 6 O n Auto Start 9 5 10 ----- Load Time ( MDC) 10 6 150 120 Activate Setback Tem p (Option) 11 7 145 250 Setback Tem p Process (O ption) 12 85 7 Setback[...]

Once power is turned on, this screen is dis- played 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 dis- played 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.[...]

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 dis- played on this screen as well. The + / - buttons can be used to change the set[...]

Screen SCREEN 10 (Setback T emperature 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 dry- ing hopper . When this setpoint is reached, the dryer [...]

Screen SCREEN 13 (PM1 and/or DEW- POINT 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 deli very air measured after the desiccant tank in the process position but before the process heater . If the Po wer M[...]

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 de viation temp[...]

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 T emperature Option Function Control Function Descriptions (continued) This screen shows the time delay setting for the con veying blo wer on the MDC. This is the minimum time the MDC will wait before starti[...]

Screen Screens 15-27 require access code 754. SCREEN 23 (Set up Screen) Aftercooler Flow Control Option SCREEN 24 (Set up Screen) Setback T emperature Option SCREEN 25 (Set up Screen) Setback Load Rate Option Function Control Function Descriptions (continued) This screen is the Aftercooler Flo w Control Enable screen. By pressing the + or - keys, t[...]

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 C[...]

Screen Screen 28-43 require access code 755. SCREEN 29 (T est Mode Screen) SCREEN 30 (T est Mode Screen) SCREEN 31 (T est Mode Screen) SCREEN 32 (T est Mode Screen) SCREEN 33 (T est Mode Screen) Function Control Function Descriptions (continued) This is the T est Mode screen for the process heater . By pressing the + or - keys, the setting can be c[...]

Screen Screen 28-43 require access code 755. SCREEN 34 (T est Mode Screen) SCREEN 35 (T est Mode Screen) SCREEN 36 (T est Mode Screen) SCREEN 37 (T est Mode Screen) SCREEN 38 (T est Mode Screen) Function Control Function Descriptions (continued) This is the T est Mode screen for the isola- tion contactor . By pressing the + or - ke ys, the setting [...]

Screen Screen 28-43 require access code 755. SCREEN 39 (T est Mode Screen) SCREEN 40 (T est Mode Screen) SCREEN 41 (T est Mode Screen) SCREEN 42 (T est Mode Screen) SCREEN 43 (T est Mode Screen) Function Control Function Descriptions (continued) This is the T est Mode screen for the MDC con veying blo wer . By pressing the + or - keys, the setting [...]

Screen Access code 756 required. SCREEN 44 (Alarm Screen) Function Control Function Descriptions (continued) 1 P3 A This is the first Alarm History screen. In this section, the last 10 alarms that hav e occurred are sav ed, starting with the most recent alarm. The number in the setpoint screen shows the list of alarms 1-10. The alarm code sho ws up[...]

T o Start Drying 1 Make sur e there is material in the hopper . 2 T urn on the main po wer to the dryer . Make sure the dryer’ s disconnect dial is in the ON position. This po wers up the con- trol and the display lights will illuminate. 3 Set the drying temperature. Use the Scroll button to get to the Process T emp function. Press the Adjust Set[...]

T o Start Drying (continued) 4 Press the ST AR T button. If ev erything is installed correctly: • The green light on the start button will illuminate. • The process and regeneration blo wers turn on. • The process and regeneration heaters turn on. • If the desiccant tanks are not in their correct position, the carousel will turn clockwise a[...]

Using the Auto Start Countdown Function The countdown function allo ws the user to set the D Carousel dryer to automat- ically start at a predetermined time. The countdo wn time can be set from 0.1 to 150.0 hours. T o set the countdown time: 1 Use the Scroll button to access the function (Menu 4, Screen 8). A uto Star t 2 Use the Setpoint Adjust ke[...]

4-20 l Operation Setting the High Setpoint Limits Y ou can protect your drying process by prev enting someone from entering process temperatures abov e an acceptable level for the material. Y ou can also set the high limit equal to the process temperature to prev ent accidental or unauthorized changes to the setting during operation. 1 T urn on the[...]

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 [...]

5-2 l Maintenance Preventative Maintenance Checklist Routine maintenance will ensure optimum operation and performance of the D Carousel Dryer . W e recommend the follo wing maintenance schedule and tasks. • Whenever you change materials ❒ ❒ Drain and clean the hopper . • W eekly , or as often as needed ❒ ❒ Clean the process and r egene[...]

5 Maintenance Maintenance l 5-3 Cleaning the Hopper CAUTION: Hot surf aces. Always protect yourself from hot surfaces inside and out- side the dryer and dr ying hopper . The hopper , spreader cone, and discharge assembly should be cleaned thoroughly between material changes to pre vent resin contamination. Place a container beneath the hopper’ s [...]

5-4 l Maintenance Cleaning the Process Filter Clogged filters reduce air flo w and dryer eff iciency . Cleaning frequency depends on how much material you process and ho w dusty it is. 1 Remove the pr ocess filter . Remov e the black plastic knob. Pull the cap off. Remo ve the wing nut. Remov e the filter cap and filter . 2 Clean the filter tube. 3[...]

5 Maintenance Maintenance l 5-5 Cleaning the Aftercooler Coils If you hav e the optional aftercooler, you need to clean the cooling coils to k eep them working ef ficiently . See Appendix C for details. Cleaning the Precooler Coils If you hav e the optional precooler, you need to clean the cooling coils to k eep them working ef ficiently . See Appe[...]

5-6 l Maintenance[...]

T roubleshooting 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 . . . . . . . . . . . . . . . . . .[...]

6-2 l T roubleshooting Before Beginning Y ou can av oid most problems by following the recommended installation and maintenance procedures outlined in this User Guide. If you do hav e a problem, this section will help you determine what caused it and how to f ix it. Befor e you tak e the side panels off of the dryer be sure to: ❏ Diagnose causes [...]

6 T roubleshooting T roubleshooting l 6-3 ❏ Find the wiring and equipment diagrams that were shipped with your dry er . These diagrams are the best reference for correcting a prob- lem. The diagrams also will note an y custom features, such as special wiring or alarm capabilities, not cov ered in this User Guide. A F ew Words of Caution The D Car[...]

6-4 l T roubleshooting How to Identify the Cause of a Problem Most dryer malfunctions are indicated by an illuminated Ackno wledge Alarm light on the D carousel dryer control panel. A problem can trigger tw o types of alarms: • Shut Down: The dryer has automatically shut do wn because it detected a serious problem that could damage your material [...]

T roubleshooting l 6-5 Shut Down Alarms If the red Ackno wledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer will shutdo wn automatically to prev ent damage to the equipment or personnel. Note that once the Ackno wledge Alarm button is pressed once, the blinking red LED becomes solid. P ossible cause The process high temperature [...]

6-6 l T roubleshooting Shut Down Alarms Problem A4 Regen Heater High T emperature – The snap switch in the regeneration heater tube activ ated due to excessi ve tem- perature. A5 Carousel Index T oo Long Alarm – If the carousel index was more than 1.5 times the normal index time, it shuts down the dryer . A6 Carousel Inde x Failure – If the c[...]

T roubleshooting l 6-7 Shut Down Alarms Problem A8 Process Blo wer Pressure – If the process blower pres- sure switch opens (loss of pressure), it shuts down the dryer . A24 Regen Blo wer Pressure – The re generation blower pressure switch opens (loss of pressure) and the regeneration heater shuts down. NOTE: The system may index one more time [...]

6-8 l T roubleshooting Shut Down Alarms Problem A49 Process Protection High T emperature – 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 T emperature – If the process protection differ[...]

T roubleshooting l 6-9 6 T roubleshooting P ossible cause The process blower has mechanically failed or is unable to rotate freely . The process blower has f ailed electrical- ly . The ov erload is set incorrectly . Solution W ith the power remov ed, check the process blower for mechanical f ailure and free rotation. Replace if necessary . W ait 3 [...]

6-10 l T roubleshooting P assive Alarms If the amber Ackno wledge Alarm LED is blinking, the alarm is a passive alarm. The dryer continues to operate, but this problem could pre vent correct drying of your material. Note that once the Ackno wledge Alarm button is pressed once, the blinking amber LED becomes solid. Problem P1 Process T emperature De[...]

6 T roubleshooting T roubleshooting l 6-11 P assive Alarms Problem P5 Return Air High T emperature – If the return air temperature is between 150 and 180°F (65.6 and 82.2°C). P6 Re gen High T emperature – If the regeneration tempera- ture exceeds the high tempera- ture limit for the specified time. Default v alues are 450°F (232.2°C) for 20[...]

6-12 l T roubleshooting P ossible cause The hose or wiring connections to the sensor block are loose or hav e fallen off. Desiccant lev el low . The desiccant may be contaminated. Leaks in the process air stream. The process air filter is clogged. Sensor is out of position. The con veying load time is too short. Con veying blo wer is not coming on.[...]

T roubleshooting l 6-13 6 T roubleshooting Problem P23 The MDC con veying blower e xceeded the full load amps rating for the blower motor . This is a passi ve alarm so the dryer will continue run- ning, but the material con ve y- ing function will stop. P25 R TD Integrity – If the process R TD is faulty . P ossible cause The MDC blower has mechan[...]

6-14 l T roubleshooting P assive Alarms Problem P26 Regen R TD Integrity – If the process R TD is faulty . P28 Return Air R TD Integrity Alarm– If the return air R TD is faulty . P30 Out of Hopper R TD Integrity – The dryer continues to run with a passiv e alarm. P ossible cause The connection in the electrical enclo- sure for the regen R TD [...]

T roubleshooting l 6-15 Setback The setback function av ailable on the DC-1 Dryer is designed to sav e you money on energy costs and k eep you from over drying your material. Setback is a vailable as separate options on both the temperature and load rate setting. This is how setback operates when the contr ol setback is set to "On" on &qu[...]

Setback (continued) 4 Use Screen 11 to set the temperatur e setpoint to which the process air will re vert to once the air at the outlet of the drying hopper has reached its setpoint. 5 Use the setback temperature band scr een (Screen 22) to set the amount the retur n air temperature has to drop belo w to activ ate setback temperature before the or[...]

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 T o loca te the appropriate fuse and replacement part, refer to the wiring diagrams that came with your dryer . IMPORT ANT : Al[...]

6-18 l T roubleshooting Checking Heater Solid State Relays 1 Disconnect and lockout the main power supply . 2 Open the electrical enclosure. 3 Locate the process or r egeneration contactors. Refer to the wiring diagrams that came with your dryer . 4 Check continuity using an ohmmeter . IMPORT ANT : Always refer to the wiring diagrams that came with[...]

T roubleshooting l 6-19 Checking or Replacing T emperature Sensors The D carousel dryer uses R TD sensors to monitor the temperatures of the drying air , the return air , the regeneration exhaust, and the regeneration and process heater boxes. T o check or replace an R TD sensors: 1 Disconnect and lockout the main power supply . 2 Remove dry er pan[...]

6-20 l T roubleshooting Adjusting the Limit Switch 1 Stop the dryer . Disconnect and lockout the main power . 2 Remove the right side panel fr om the dryer . IMPORT ANT : Note the position of the tanks. 3 Loosen the screws securing the limit switch to the car ousel. Note that the hole for the front scre w is slotted to allow for adjustment. 4 Slide[...]

T roubleshooting l 6-21 6 T roubleshooting Replacing the Heaters Regeneration Heater 1 Disconnect and lockout the main power . 2 Gain access to the regeneration heater by remo ving 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 fr om the h[...]

6-22 l T roubleshooting Replacing the Heaters Regeneration Heater (continued) 12 Put petroleum jelly on the tips of the new heater wir e 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 R TD fitting and R TD in t[...]

T roubleshooting l 6-23 ✐ 6 T roubleshooting Replacing the Heater Process Heater 1 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 Dr yers 4 Remove the hose and hose clamp at the bottom of the heater tube. 5 Remove the i[...]

12 Put petroleum jelly on the tips of the new heater wir e 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. Mak e sure to duct tape the seam that was cut during remov al. 14 Reattach the lower 2-1/2&[...]

T roubleshooting l 6-25 6 T roubleshooting Replacing the Desiccant T anks 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[...]

6-26 l T roubleshooting Refilling the Desiccant T anks When desiccant becomes clogged or contaminated, you should replace the des- iccant in all three tanks to ensure optimum performance. 1 Remove the desiccant tank fr om the carousel. See “Replacing Desiccant T anks. ” 2 Remove the the tank end plate. Remov e the six 10-32 self-tapping screws [...]

T roubleshooting l 6-27 6 T roubleshooting Refilling the Desiccant T ank (continued) 7 V ibrate 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 ov er-tighten. Install the second 1/4- 20 nut and tighten. [...]

6-28 l T roubleshooting[...]

W e’re Here to Help Conair has made the largest in vestment in customer support in the plastics indus- try . Our service experts are av ailable to help with any problem you might hav e installing and operating your equipment. Y our Conair sales representativ e also can help analyze the nature of your problem, assuring that it did not result from [...]

A-2 l Appendix Equipment Guarantee Conair guarantees the machinery and equipment on this order , for a period as defined in the quotation from date of shipment, against defects in material and workmanship under the normal use and service for which it was recommended (except for parts that are typically replaced after normal usage, such as f ilters,[...]

Appendix l B-1 Mounting the Dr yer on a Floor Stand Caution : to prevent accident and injury , lift the dryer onto the floor stand using a hoist and lifting lugs provided. 1 Lift the dryer onto the floor stand. Lift using a hoist and the lifting lugs pro- vided. 2 Align the four bolt holes on the bottom of the dry er with the four bolts holes on th[...]

B-2 l Appendix Mounting the Dr yer and Hopper on a Mobile Floor Stand CAUTION: T o prevent accident and injury , lift the empty hopper and the dryer onto the mobile floor stand using a hoist and the lifting lugs provided. 1 Lift the hopper onto the mobile floor stand using a hoist and the lifting lugs provided. Make sure you align the bolt holes in[...]

Appendix l B-3 3 Lift the dryer onto the mobile floor stand using a hoist and lifting lugs provided. 4 Align the four bolt holes on the bottom of the dryer with the four bolts holes in the mobile floor stand stand. 5 Bolt the dryer to the mobile floor stand using the four 5/16”-18 self-locking bolts provided. Mounting the Dr yer and Hopper on a M[...]

Installing an Aftercooler (Optional) Y ou can add an aftercooler to the D Carousel Dryer by ordering the optional after- cooler assembly . Installation is easy . The optional aftercooler requires a source of city , tower , or chiller water and a dis- charge or return line. Y ou can use water at temperatures up to 85°F (30°C). But the water flo w [...]

Appendix l C-2 Installing an Aftercooler (Optional) (continued) 5 Secure the after cooler assembly in the aftercooler housing using the fi ve scre ws. NOTE: If an optional flo w control was ordered with the aftercooler , see Appendix E "Optional Flow Control" for information on connecting the water supply . 6 Connect the water supply line[...]

✐ Cleaning the Aftercooler If you hav e the optional aftercooler, you need to clean the aftercooler coils to keep them working ef ficiently . Cleaning frequency depends on the type and amount of material you process. 1 Stop the dryer and lockout the main po wer . 2 T urn off the water flo w to the water supply line. Disconnect supply and return l[...]

Appendix l C-4 Cleaning the Aftercooler (continued) 5 Remove the after cooler assembly from the aftercooler housing. 6 Clean the aftercooler assembly using a mild soap and w ater . Let the after- cooler dry thoroughly before installation. CAUTION: During the cleaning process, DO NOT cut or remove the stainless steel wire that holds the aftercooler [...]

Cleaning the Aftercooler (continued) 9 Connect the water supply line to the aftercooler / precooler inlet. If a manual shut off v alve is used, it should be mounted on the inlet line as well. 10 Connect the outlet of the aftercooler / precooler to the inlet of the flow control valv e using the pre-shaped copper tubing and compression fittings provi[...]

Appendix l D-1 Installing the Flow Control (Optional) Y ou can add optional flow controls to the D Carousel Dryer for use with the optional aftercooler or precooler . Installation is easy . The optional flow control requires a source of city , tower , or chiller water . Y ou can use water at temperatures up to 85°F ( 30°C). But the water flo w sh[...]

E-1 l Appendix Installing a Precooler (Optional) Y ou can add a precooler to the D Carousel Dryer by ordering the optional precool- er assembly . Installation is easy . The optional precooler requires a source of city , tower , or chiller water and a dis- charge or return line. Y ou can use water at temperatures up to 85°F ( 30°C). But the water [...]

Appendix l E-2 Installing a Precooler (Optional) (continued) 7 Connect the water discharge or r eturn line with the pressur e relief valve to the precooler outlet. Use the brack et supplied to secure the pressure relief valv e and discharge line to the back of the dryer . 8 Install the plastic precooler cap o ver the water connections. Precooler in[...]

E-3 l Appendix Cleaning the Precooler If you hav e the optional precooler, you need to clean the precooler coils to k eep them working ef ficiently . Cleaning frequency depends on the type and amount of material you process. 1 Stop the dryer and lockout the main power . 2 T urn off the water flo w to the water supply line. Disconnect supply and ret[...]

Appendix l E-4 5 Remove the pr ecooler assembly from the precooler housing. 6 Clean the precooler assembly using a mild soap and w ater . Let the precooler dry thoroughly before installation. CAUTION: During the c leaning process, DO NOT cut or remove the stainless steel wire that holds the precooler assembly together . 7 I nspect the condition of [...]

F-1 l Appendix Installing the Dew P oint Sensor (Optional) The dew point sensor can be mounted to the inside bottom right corner of the dryer back panel. 1 Peal the tape fr om the dew point sensor block and place it in the bottom right side of the back panel as shown. 2 Route the hose near the top of the block to the fitting near the top of the pro[...]

Appendix l G-1 What is the MDC? The MDC is a self-contained, mobile unit designed to dry plastic resin and con vey it with dehumidified air directly to a processing machine. This mobile unit contains the: • Dehumidifying dryer • Drying hopper and material distribution box • Con veying blo wer and dust collector • Mobile drying cart • Dire[...]

G-2 l Appendix NOTE: Throughput rates will vary by MDC model and type of material. See the Specification pages for recommended throughputs. T ypical Applications The MDC was designed for drying and con ve ying beside the press. But it can also be used to pre-dry material in one location, and then transport the dried material to another location for[...]

How Conveying W orks When the con veying function is turned on, the MDC uses dry air to mo ve material from the drying hopper to the process machine as it is needed. 4 Material enters the vacuum recei ver and falls into the receiv er and viewing chamber . The blower pulls air through the vacuum recei ver f ilter into the return air conv eying line.[...]

G-4 l Appendix Central When configured as a central dryer , the MDC option is not av ailable. 6 in. (15.2 cm) 1.625 in. dia. (4.1 cm) through hole 6 in. (15.2 cm) 4 in. (10.2 mm) 1.625 in. dia. (4.1 cm) through hole 4 in. (10.2 cm) Outlet - 2 in. dia. {5.1 cm} Specifications: MDC MOBILE DRYING AND CONVEYING MDC Small Carousel Models A B C D TLR T u[...]

Specifications: MDC (continued) Central When config- ured as a central dryer , the MDC option is not av ailable. SPECIFICA TION NO TES: * Consult Conair about other available hopper selections. † SCFM stands for standard cubic feet per minute, referenced to a pre-specified pressure, temperature and relative humidity . In most cases, SCFM is refer[...]

G-6 l Appendix Unpacking the Boxes The MDC comes fully assembled on a mobile drying cart. Y ou should have receiv ed the following components: 1 Carefully r emove the dryer and components from the shipping container . The vacuum recei ver and material inserts will be on the b uilt-in holders on the drying cart. The R TD probe and extension cable ma[...]

Unpacking the Boxes (continued) 3 Carefully inspect all components to mak e sure no damage occurred during shipping, and that you hav e all the necessary hardware. 4 T ake a moment to r ecord 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 i[...]

G-8 l Appendix Preparing for Installation The MDC has been designed for use beside the processing machine. The mobile unit also can be used for pre-drying in a remote location. 1 Make sur e the location for the MDC pro vides: ❒ A grounded po wer source supplying the correct curr ent for your dryer model. Check the dryer’ s serial tag for the co[...]

Installing the MDC The MDC was designed to be mobile. So e very time you mov e the MDC, you will need to mount the vacuum recei ver , connect the main po wer source, and connect a water source for the optional aftercooler . Phasing of electric power should be consistant between locations. The first time you install the MDC: 1 1 Move the MDC to the [...]

G-10 l Appendix Connecting Conveying Lines The vertical con ve ying tubes and flexible con veying hoses may ha ve been remov ed for shipping. T o assemble: 1 Insert each vertical con veying tube into its quick disconnect fitting on the MDC. Push the tube down until you feel it seat snugly inside the disconnect fitting. Tighten the thumb screws on t[...]

Connecting the R TD Probe See “Connecting the RTD Pr obe” page 3-16 Connecting the Demand Sensor The capacitiv e demand sensor monitors the lev el of material in the viewing cham- ber of the vacuum recei ver when the MDC is con ve ying. The sensor signals the MDC control to start the con veying blo wer whenev er the level of material drops belo[...]

G-12 l Appendix Mounting a Loader on the Hopper See “Mounting a Loader on the Hopper” page 3-17 T esting the Installation See “T esting the Installation” page 3-17 The MDC Control P anel See “The DC-1 Dryer Contr ol P anel” page 4-2 MDC Control Functions See “D Dryer DC-1 Contr ol Functions” page 4-3 T o Start Drying See “T o Star[...]

T o Start Conveying 1 Move the MDC to the pr ocessing machine. Lock the wheels and connect the main power source. Connect the w ater source if you have an aftercooler . 2 Mount the vacuum r eceiver on the feed throat. Push the v acuum receiv er onto the mounting bracket. 3 Place the appropriate material insert inside the distribution box. 4 Make su[...]

G-14 l Appendix T o Stop Conveying 1 Set the load time to zero. Once the load time is set to zero, con ve ying will stop. See page 4-6, Scr een 9 T ransporting the MDC The MDC can be mov ed to another processing machine, to a pre-drying area, or to an area away from the processing machine for cleaning and maintenance. T o trans- port safely: 1 Disc[...]

Preventative Maintenance Schedule See “Pr eventative Maintenance Checklist” pa ge 5-2 Cleaning the Hopper See “Cleaning the Hopper” page 5-3 Cleaning the Conveying Lines This method should be used only after most of the material has been drained from the drying hopper . 1 Disconnect the material line from the loader . 2 Place the disconnect[...]

G-16 l Appendix Cleaning the V acuum Receiver The vacuum recei ver should be cleaned an ytime you change materials. Replace the screen mesh filter if it is torn, damaged, distorted, or so clogged with material that it cannot be cleaned. 1 T urn off the con veying system by setting the load time to zer o (See P age 4-6, Scr een 9) . Disconnect the a[...]

Cleaning the Dust Collector The dust collector filters dust and f ines from the air used to con vey material. The filter should be cleaned re gularly to maintain conv eying air flo w and optimum performance of the con veying blo wer . 1 T urn off the con veying system by setting the load time to zero (See P age 4-6, Scr een 9) . 2 Remove the dust c[...]

Cleaning the Process Filter See “Cleaning the Pr ocess F ilter” page 5-4 Cleaning the Regeneration Filter See “Cleaning the Re generation F ilter” pag e 5-4 Cleaning the Aftercooler Coils See “Cleaning the After cooler Coils” page 5-5 Cleaning the Precooler Coils See “Cleaning the Pr ecooler Coils” page 5-5 Inspect Hoses and Gaskets[...]