Conair MDCW Carousel Plus W15 User manual

MDCW Carousel Plus Dryer
MDCW Models 15, 25, 50, 75 and 100 with DC-2 Controls
Corporate Office: 724.584.5500 lInstant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861
U S E R G U I D E
UGD029-0311
www.conairgroup.com

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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: UGD029-0311
Serial Number(s):
Model Number(s):
See Screens 31 and 32 for Software Version
*Display Firmware Version:
*Display Menu Version:
*Control Firmware Version:
* NOTE: Displayed upon initialization, during power up, or on a data tag
inside the door.
DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental,
consequential damages in connection with the furnishing, performance or use of this information.
Conair makes no warranty of any kind with regard to this information, including, but not limited
to the implied warranties of merchantability and fitness for a particular purpose.
Copyright 2011 l Conair l All rig hts reser ved
✐

Table of Contents
1-1 Introduction
Purpose of the user guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Your responsibilities as a user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
ATTENTION: Read this so no one gets hurt . . . . . . . . . . . . . . . . . . . 1-4
How to use the lockout device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2-1 Description
What is the MDCW Carousel Plus Dryer? . . . . . . . . . . . . . . . . . . . . .2-2
Optional self-loading MDCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
How it works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
How conveying works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Specifications: MDCW Carousel Plus Dryers . . . . . . . . . . . . . . . . . . 2-8
MDCW Carousel Plus dryer options . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3-1 Installation
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installing the MDCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Connecting the conveying lines . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Connecting the demand sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Mounting a loader on the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Connecting material lines for self-loading (Optional) . . . . . . . . . . . . 3-8
Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Connecting compressed air for self-loading (Optional). . . . . . . . . . 3-11
Table of Conte nts l i

Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Connecting the aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Using communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
4-1 Operation
The MDCW dryer: control panel DC-2 . . . . . . . . . . . . . . . . . . . . . . . 4-2
MDCW Carousel Plus Dryer control functions . . . . . . . . . . . . . . . . . 4-3
Control function flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
How to navigate the menu tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control function descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
To start drying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
To stop drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Using the self-loading function on the hopper
loader (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Machine loader conveying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
How to use the supervisor’s password . . . . . . . . . . . . . . . . . . . . . 4-41
Using the auto start timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Setting high setpoint limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Using dewpoint control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Using the setback feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Setback feature guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
5-1 Maintenance
Preventative maintenance checklist . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Checking the dewpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Cleaning the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Cleaning the process filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Cleaning the regeneration filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Cleaning the conveying filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Cleaning the vacuum receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
ii l Table of Conte nts

Screen filter cleaning (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Cleaning the compressed air filter (Optional). . . . . . . . . . . . . . . . . 5-13
Cleaning the aftercooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Inspecting hoses and gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
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
Shutdown alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Passive alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Dewpoint troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Poor material drying troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 6-22
REPAIR
Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Checking heater solid state relays. . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Checking or replacing temperature sensors . . . . . . . . . . . . . . . . . 6-29
Replacing the heaters
Regeneration heater tube . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Process heater tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Replacing the desiccant wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
AAppendix
We’re here to help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
How to contact customer service . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Before you call... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Equipment guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Performance warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Warranty limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Table of Conte nts l iii

iv l Table of Conte nts
BAppendix
Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Addendum
Communication protocols for common controls - DC-2

Introduction
Purpose of the user guide . . . . . . . . . . . . . . 1-2
How the guide is organized . . . . . . . . . . . . . 1-2
Your responsibilities as a user. . . . . . . . . . . 1-3
ATTENTION:
Read this so no one gets hurt . . . . . . . . 1-4
How to use the lockout device . . . . . . . . . . . 1-6
S E C T I O N
1
Introduction l 1-1
1
Introduction

✐
Purpose of the User Guide
This User Guide describes the Conair MDCW Carousel Plus series dryers
and explains step-by-step how to install, operate, maintain, and repair this
equipment.
Before installing this product, please take a few moments to read the User
Guide and review the diagrams and safety information in the instruction
packet. You also should review manuals covering associated equipment in
your system. This review won’t take long, and it could save you valuable
installation and operating time later.
How the Guide is Organized
Symbols have been used to help organize the User Guide and call your
attention to important information regarding safe installation and operation.
Symbols within triangles warn of conditions that could be hazardous to users or
could damage equipment. Read and take precautions before proceeding.
Numbers indicate tasks or steps to be performed by the user.
A diamond indicates the equipment’s response to an action performed by the user.
An open box marks items in a checklist.
A circle marks items in a list.
Indicates a tip. A tip is used to provide you with a suggestion that will help you with
the maintenance and the operation of this equipment.
Indicates a note. A note is used to provide additional information about the steps
you are following throughout the manual.
1
◆
❒
•
✒
1-2 l Introduction

Introduction l 1-3
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.
1
Introduction

ATTENTION:
Read this so no one gets hurt
We design equipment with the user’s safety in mind. You can avoid the potential
hazards identified on this machine by following the procedures outlined below and
elsewhere in the User Guide.
WARNING: Improper installation, operation, or
ser vicing 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 elec-
trical technicians in accordance with electrical codes in your region.
Always maintain a safe ground. Do not operate the equipment at power
levels other than what is specified on the machine serial tag and data
plate.
WARNING: Voltage hazard
This equipment is powered by three-phase alternating current,
as specified on the machine serial tag and data plate.
A properly sized conductive ground wire from the incoming power
supply must be connected to the chassis ground terminal inside the
electrical enclosure. Improper grounding can result in severe personal
injury and erratic machine operation.
Always disconnect and lock out the incoming main power source before
opening the electrical enclosure or performing non-standard operating
procedures, such as routine maintenance. Only qualified personnel
should perform troubleshooting procedures that require access to the
electrical enclosure while power is on.
1-4 l Introduction (continued)

1
Introduction
Introduction l 1-5
ATTENTION:
Read this so no one gets hurt (continued)
We design equipment with the user’s safety in mind. You can avoid the potential
hazards identified on this machine by following the procedures outlined below and
elsewhere in the User Guide.
CAUTION: Hot Surfaces.
Always protect yourself from hot surfaces inside the dryer and hopper.
Also exercise caution around exterior surfaces that may become hot
during use. These include the hopper door frame, the exterior of an
uninsulated hopper, the return air hose and the dryer’s process filter
housing and moisture exhaust outlet.
WARNING: Do not place aerosol, compressed
gas or flammable materials on or near this
equipment.
The hot temperatures associated with the drying process may cause
aerosols or other flammable materials placed on the dryer or hopper to
explode.

1-6 l Introduction
How to Use the Lockout Device
CAUTION: Before performing maintenance or repairs on this product, you should
disconnect and lockout electrical power sources to prevent injury from unexpected
energization or start-up. A lockable device has been provided to isolate this
product from potentially hazardous electricity.
Lockout is the preferred method of isolating machines or equipment from energy
sources. Your Conair product is equipped with the lockout device pictured below.
To use the lockout device:
1Stop or turn off the equipment.
2Isolate the equipment from the electric power. Turn the rotary
disconnect switch to the OFF, or “O” position.
3Secure the device with an assigned lock or tag. Insert a lock or tag
in the holes to prevent movement.
4The equipment is now locked out.
WARNING: Before removing lockout devices and returning switches to the
ON position, make sure that all personnel are clear of the machine, tools
have been removed, and all safety guards reinstalled.
To restore power to the dryer, turn the rotary disconnect back to the ON position:
1Remove the lock or tag.
2Turn the rotary disconnect switch to the ON or “I” position.

Description l 2-1
Description
What is the MDCW Carousel Plus Dryer? . . . . 2-2
Optional self-loading MDCW . . . . . . . . . . . . 2-2
Typical applications . . . . . . . . . . . . . . . . . . 2-3
How it works . . . . . . . . . . . . . . . . . . . . . . 2-5
How conveying works . . . . . . . . . . . . . . . . . 2-7
Specifications: MDCW Carousel Plus Dryers . . 2-8
MDC W Ca rouse l Pl us Dr ye r opt io ns . . . . . . . 2-10
S E C T I O N
2
2
Description

2-2 l Description
What is the MDCW Carousel Plus
Dryer?
The MDCW Carousel Plus Dryer is a self-contained, mobile unit designed to dry
plastic resin and convey it with dehumidified air directly to a processing machine.
This mobile unit contains:
•A mobile dehumidifying dryer
•Drying hopper with a material distribution box
•Conveying blower and filter
•Direct feed machine loader with a demand sensor
•Hopper loader (with self-loading option)
•Quick disconnect conveying hoses
The dryer produces hot, low dewpoint air that removes moisture from hygroscopic
plastics. When the conveying function is turned on, the conveying blower conveys
the dried resin to the machine loader mounted on the processing machine. The
demand sensor on the machine loader viewing chamber allows you to convey just
enough material to satisfy the shot size required for your process.
Optional Self-Loading MDCW
The self-loading option on the MDCW Carousel Plus Dryer allows the conveying
blower to convey new material from the material source into the drying hopper on
the MDCW. This option is in addition to the standard conveying capability on an
MDCW, which is conveying material to the machine from the drying hopper. This
option allows the MDCW to be a totally self-contained system with a common
control.

Description l 2-3
NOTE: Throughput rates will vary
by MDCW model and type of
material. See the Specification
pages for recommended
throughputs.
Typical Applications
The MDCW Carousel Plus Dryer was designed for drying and conveying 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 conveying into the processing
machine.
The MDCW can be used successfully in applications that require:
•A contamination-free drying environment.
•Drying temperatures of 100° to 375°F {38° to 191°C}.
•Throughput rates of 15 to 100 lbs {6.8 to 45.4 kg} per hour (some materials can
be run at a higher rate).
•Dew points of -40°F {-40°C}.
•Conveying material at distances up to, but not more than, 8 feet {2.4 m}
vertically and 6 feet {1.8 m} horizontally. (The long haul option allows
conveying material at distances up to, but not more than, 15 feet {4.6 m}
vertically and 50 feet {15.2 m} horizontally.)
✐
(continued)
2
Description

Typical Applications (continued)
The MDCW Carousel Plus 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}
* See page 3-12 and Appendix B
•Throughput rates of 15 to 100 lbs {6.8 to 37.3} per hour (some materials can be ran at a
higher rate).
•Dewpoints of -40°F {-40°C}.
Use the aftercooler when:
•You are drying at temperatures over 240°F {116°C}.
•Throughput rates are less than 50% of the dryer’s rated capacity.
•You are pre-drying material at temperatures over 150°F {66°C}
2-4 l Description

2
Description
Description l 2-5
The Process (Drying) Cycle
The process blower pulls moist air from the top of the drying hopper. The air pass-
es through the process filter and aftercooler, then into the desiccant wheel, where
moisture is removed. The now dry air moves through the optional precooler (if
installed) and process heater, where it is heated to the drying temperature selected
by the operator. The hot, dry air is delivered to the hopper where a spreader cone
evenly distributes the air through the material.
The Cooling Cycle
Regenerated desiccant must be cooled before it rotates back into the process cycle.
The process blower pushes a small amount of air through the cooling section of the
desiccant wheel. The cooling air then passes through the aftercooler and repeats
the circuit.
The Regeneration Cycle
The regeneration blower pulls air through the regeneration filter into the dryer’s
regeneration heater. The air is heated to 350° F {177° C} before it is pushed into
the “wet” section of the wheel. The hot air purges moisture from the desiccant.
The moist air is blown out the exhaust at the back of the dryer.
How It Works

REGENERAT I O N
AIR FILT E R
DESICCANT
WHEEL
REGENERAT I O N
BLOWER
REGENERAT I O N
HEAT E R
HIGH TEMP
SHUTOFF
REGENERAT I O N
RTD
HOPPER
PROCESS
BLOWER
RETURN
AIR
FILT E R
5 PROCESS FILTER STATUS
RETURN
AIR
RTD
PROCESS
RTD
1 SETBACK TEMPERAT U R E *
2 PROCESS CFM MONITOR
HIGH TEMP
SHUTOFF
PROCESS
HEAT E R B O X
6 PRECOOLER
6
DRYER OPTIONS
3 DEWPOINT MONITOR / CONTROL*
PROCESS
COOLING
REGENERAT I O N
1
2
3
5
REGENERAT I O N
OUTLET
RTD
*Standard on DC-2 controls
AFTERCOOLER
PHASE ROTATION PROTECTION
ALARM BELL
ALARM LIGHT
4 CURRENT METER
44
How It Works (continued)
2-6 l Description

Description l 2-7
2
Description
How Conveying Works
When the conveying function is turned on, the MDCW uses dry air to move
material from the drying hopper to the process machine as it is needed.
4Material enters the vacuum receiver and falls into the
receiver and viewing chamber. The blower pulls air through
the vacuum receiver filter into the return air conveying line.
6The filter traps dust and
fines before the returning
air reaches the blower.
5The conveying blower runs until the
load time set at the MDCW control is
reached. When the material level drops
below the demand sensor, the sensor
signals for more material. The
conveying blower turns on again. 1Dry material drops into the
distribution box when the slide
gate on the drying hopper is
opened.
2When the conveying
function is turned on,
the conveying blower
starts.
3Positive and negative air
flow generated by the
blower moves the material
from the distribution box
beneath the drying hopper
to the vacuum receiver.

B
A
D
Specifications: MDCW Carousel
Plus Dryers
MODEL W15 W25 W50 W75 W100
Standard hopper models* RWH14-2 RWH14-3 RWH18-6 RWH24-9 RWH24-12
Performance characteristics (with full hopper)
Air flow {SCFM} ** 7.5 12.5 25 37.5 50
Air flow {ACFM @ 250 °F } ** 10 17 34 50 67
Drying temperature All models 150 - 375 ° F {66 - 191 ° C} with options
Dew point All models -40 ° F {-40 ° C}
Standard conveying dist. ft {m} 8 {2.44} vertical; 6 {1.83} horizontal
Long distance option ft {m} 15 {4.57} vertical; 50 {15.24} horizontal
Dimensions inches {cm}
A - Height top of convey pipe 78.5 {199.4} 78.5 {199.4} 87.5 {222.3} 87.5 {222.3} 87.5 {222.3}
B - Overall width 28.5 {72.4} 28.5 {72.4} 40.5 {102.9} 40.5 {102.9} 40.5 {102.9}
C - Height to top of hopper 60.5 {153.7} 73.5 {186.7} 90.5 {229.9} 82.5 {209.6} 93.5 {237.5}
D - Depth 46 {116.8} 46 {116.8} 58 {147.3} 58 {147.3} 58 {147.3}
Outlet/inlet tube OD in. {cm} 2.5 {6.35}
Weight lbs {kg}
Standard dryer installed 500 {226.8} 550 {249.5} 600 {272.2} 675 {306.2} 750 340.2}
Voltage - Total Amps {standard/long conveying distance}
208 V/3 phase/60 Hz 16.9/20.9 16.9/20.9 21.9/25.9 22.8/26.8 NA
230 V/3 phase/60 Hz 15.3/18.9 15.3/18.9 19.8/23.4 20.6/24.2 24.9/30.5
400 V/3 phase/50 Hz ‡ 8.5/9.6 8.5/9.6 11/12.1 11.5/12.6 15.1/16.2
460 V/3 phase/60 Hz 7.7/9.5 7.7/9.5 9.9/11.7 10.3/12.1 13.4/15.2
575 V/3 phase/60 Hz 6.0/7.8 6.0/7.8 7.8/9.4 8.2/9.8 10.7/12.5
Total kilowatts † kw {std./long} 1.5/2.7 1.5/2.7 1.9/3.0 4.0/5.1 4.6/5.7
Water requirements {for optional aftercooler}
Recommended temp. § 45 ° - 85 ° F {7.2 - 29.4 ° C}
Water flow gal/min {liters/min} 1 {4.6} 2 {9.1}
Water connections NPT 3/4 in. NPT
Compressed air requirements {self-loading option only}
Compressed air 0.5 SCFH @ 80 psi
SPECIFICATION NOTES:
* Other hopper sizes are available.
** The term 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 36% relative humidity. ACFM stands for Actual Cubic Feet
Per Minute, and must be supplied with a temperature reference, due to the change in air density with temperature. Because dry-
ers 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.
† TOTAL kW listed at a process setpoint of 250°F {121.1°C} and a regeneration temperature of 350°F {176.7°C}.
§
Temperatures above or below the recommended levels may affect dryer performance. Tower, chiller, or municipal water
sources can be used.
Specifications may change without notice. Consult a Conair representative for the most current information.
C
(continued)
2-8 l Description
TPDS020-0311-REV