Standard Models CM100, 150, 200, 300 and 400 CM Carousel Dryer · Sop Drye CM -1 0 TYPICAL...

CM Carousel Dryer

The Conair Group, Inc.One Conair DrivePittsburgh, PA 15202Phone: (412) 312-6000Fax: (412)-312-6227

Standard Models CM100, 150, 200, 300 and 400

CM Carousel Dryer

Set Temperature Dryer Status

Power

Running

Alarm/Fault

Start Dryer

Stop Dryer

CM-100

UGD018/0101

Installation

Maintenance

Operation

Troubleshooting

dmontini

Archive Stamp

It’s a good idea to record the model and serial number(s) ofyour equipment and the date you received it in the UserGuide. Our service department uses this information, alongwith the manual number, to provide help for the specificequipment you installed.

Please keep this User Guide and all manuals, engineeringprints and parts lists together for documentation of yourequipment.

Date:

Manual number: UGD018/0101

Serial number(s):

Model number(s):

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

Copyright 2001 THE CONAIR GROUP, INC. All rights reserved

Please record yourequipment’s model

and serial number(s)and the date you

receive it in thespaces provided.

INTRODUCTION .........................................1-1Purpose of the user guide ......................................................1-2How the guide is organized ...................................................1-2Your responsibilities as a user .............................................. 1-2ATTENTION: Read this so no one gets hurt ........................1-3How to use the lockout device...............................................1-5

DESCRIPTION .......................................... 2-1What is the CM Carousel dryer? ...........................................2-2Typical applications ...............................................................2-2How it works..........................................................................2-3Specifications: CM dryer.......................................................2-4

INSTALLATION......................................... 3–1Unpacking the boxes..............................................................3-2Preparing for installation .......................................................3-3Mounting the hopper on a processing machine.....................3-4Installing the hopper ..............................................................3-5Connecting air and water hoses.............................................3-6Connecting the RTD probe ....................................................3-7Connecting the main power...................................................3-7Testing the installation...........................................................3-8 .Initial setup ..........................................................................3-10

OPERATION............................................ 4–1The dryer control panel .........................................................4-2CM dryer functions................................................................4-3To start drying........................................................................4-4To stop drying ........................................................................4-5

MAINTENANCE........................................ 5–1Preventative maintenance checklist .......................................5-2Cleaning the hopper...............................................................5-3Cleaning the process filter .....................................................5-4Cleaning the regeneration filter .............................................5-4Cleaning the aftercooler coils ................................................5-5Inspect hoses and gaskets ......................................................5-5Performing an autotune .........................................................5-6

TROUBLESHOOTING................................. 6–1Before beginning....................................................................6-2A few words of caution .........................................................6-2

TABLE OF

CONTENTS

UGD018/0101 CM Carousel Dehumidifying Dryer i

TROUBLESHOOTING (continued) .................. 6–1DIAGNOSTICSHow to identify the cause of a problem ................................6-3Removing the dryer side panels ............................................6-3Shut down alarms ..................................................................6-4Controller alarms ...................................................................6-8Dryer will not power up ......................................................6-10

REPAIRReplacing fuses....................................................................6-11Checking heater contactors..................................................6-11Checking motor overloads ...................................................6-12Replacing the temperature controller ..................................6-13Checking or replacing temperature sensors.........................6-14Replacing heater elements ...................................................6-15Removing desiccant tanks ...................................................6-16Refilling desiccant tanks (CM100)......................................6-17Refilling desiccant tanks (CM150,200,300,400).................6-18Adjusting the limit switch ...................................................6-20

APPENDIXService/Warranty information...............................................A-1Default Parameters ................................................................B-1Series 16 Temperature Controller Instruction ManualMaterial Safety Data Sheets..................................................C-1

PARTS/DIAGRAMSThis section has been provided for you tostore spare parts lists and diagrams.

CM Carousel Dehumidifying Dryer UGD018/0101ii

TABLE OF

CONTENTS

�� Purpose of the User Guide .........1-2�� How the guide is organized ........1-2�� Your responsibilities as a user ...1-2�� ATTENTION: Read this so

no one gets hurt .....................1-3�� How to use the lockout device ..1-4

INTRODUCTION

UGD018/0101 CM Carousel Dehumidifying Dryer 1-1

1-2 INTRODUCTION CM Carousel Dehumidifying Dryer UGD018/0101

This User Guide describes the Conair CM carousel dehumidi-fying dryer and explains step-by-step how to install, operate,maintain and repair this equipment.

Before installing this product, please take a few moments toread the User Guide and review the diagrams and safety infor-mation in the instruction packet. You also should review man-uals covering associated equipment in your system. Thisreview won’t take long, and it could save you valuable instal-lation and operating time later.

Symbols have been used to help organize the User Guide andcall your attention to important information regarding safeinstallation and operation.

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

Numbers within shaded squares indicate tasks or stepsto be performed by the user.

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

An open box marks items in a checklist.

A shaded circle marks items in a list.

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

� Thorough review of this User Guide, paying particularattention to hazard warnings, appendices and related dia-grams.

� Thorough review of the equipment itself, with carefulattention to voltage sources, intended use and warninglabels.

� Thorough review of instruction manuals for associatedequipment.

� Step-by-step adherence to instructions outlined in thisUser Guide.

PURPOSE OFTHE USERGUIDE

HOW THEGUIDE ISORGANIZED

1

�

❒

�

YOURRESPONSIBILITYAS A USER

1-3UGD018/0101 CM Carousel Dehumidifying Dryer

We design equipment with the user’s safety in mind. You canavoid the potential hazards identified on this machine by fol-lowing the procedures outlined below and elsewhere in theUser Guide.

INTRODUCTION

ATTENTION:READ THIS SO NO

ONE GETS HURT

WARNING: Electrical shock hazard

This equipment is powered by three-phasemain voltage, as specified on the machine seri-al tag and data plate.

Always disconnect and lock out the incomingmain power source before opening the electri-cal enclosure or performing non-standard oper-ating procedures, such as troubleshooting ormaintenance. Only qualified personnel shouldperform procedures that require access to theelectrical enclosure while power is on.

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

This equipment should be installed, adjusted,and serviced by qualified technical personnelwho are familiar with the construction, opera-tion and potential hazards of this type of equip-ment.

All wiring, disconnects and fuses should beinstalled by qualified electrical technicians inaccordance with electrical codes in your region.

Always maintain a safe ground. A properlysized conductive ground wire from the incomingpower supply must be connected to the chassisground terminal inside the electrical enclosure.Improper grounding can result in personalinjury and erratic machine operation.

Do not operate the equipment at power levelsother than what is specified on the the equip-ment serial tag and data plate.

continued on next page

CM Series Carousel Dehumidifying Dryer UGD0018/0101

CAUTION: Hot surfaces

Always protect yourself from hot surfacesinside the dryer and hopper. Also exercise cau-tion around certain exterior surfaces that canreach temperatures of 180° to 200° F (82° to93° C). These include the hopper door frame,the exterior of an uninsulated hopper, the delivery and return air hose and the dryer’sprocess filter housing and moisture exhaustoutlet.

WARNING: Hazardous substanceThe electrical contactors in this dryer containmercury, which is considered a hazardous sub-stance and must be dealt with accordingly.Material Safety Data Sheet (#7439-97) hasbeen included in your instruction packet. Thissheet explains the potential hazards, how toavoid them and how to clean up and dispose ofthe mercury if it ever spills.

WARNING: Do not place aerosol, com-pressed gas or flammable materials onor near this equipment.The hot temperatures associated with the dryingprocess may cause aerosols or other flammablematerials placed on the dryer or hopper toexplode.

ATTENTION:READ THIS SO NO

ONE GETS HURT

1-4 INTRODUCTION

UGD018/0101 CM Series Carousel Dehumidifying Dryer

HOW TO USETHE LOCKOUTDEVICE

1-5INTRODUCTION

Lockout is the preferred method of isolating machines orequipment from energy sources. Your Conair product may beequipped with the lockout device pictured below. To use thelockout device:

Stop or turn off the equipment.

Isolate the equipment from electrical power. Turn the rotarydisconnect switch to the Off, or Oposition, by pressing down on thespring tab and turning the switchcounter-clockwise.

Secure the device with anassigned lock or tag. Pull out thecenter tab of the rotary handle.Insert a lock or tag in the holes toprevent movement.

The equipment is now locked out.

To rotate the disconnect back to the On position:

Remove the lock or tag and push in the center tab of therotary handle.

Slide the spring tab down.

Turn the rotary disconnect switchclockwise to the ON or I position.

WARNING: Before performing maintenanceor repairs on this product, you should disconnect andlock out electrical power sources to prevent injury fromunexpected energization or start-up. A lockable devicehas been provided to isolate this product from potential-ly hazardous electricity.

TRIP+ON

Reset

OOFF

TRIP+ON

Reset

OOFF

WARNING: Before removing lockout devicesand returning switches to the ON position, make surethat all personnel are clear of the machine, tools havebeen removed and all safety guards reinstalled.

1

2

3

4

TRIP+ON I

Reset

OOFF

Spring tab

1

23

Spring tab

�� What is the CM Carousel Dryer? .. 2-2�� Typical applications ...................... 2-2�� How it works .................................. 2-3�� Specifications: CM Dryer............... 2-4

DESCRIPTION


The CM 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 andpumps it through dehumidifying desiccant. The dryer thenheats the air to the drying temperature you selected and circu-lates it through the material in the hopper.

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

The CM dryer can be used successfully in applications thatrequire:

� A contamination-free drying environment.� Drying temperatures of 150° to 375°F (66° to 191°C).� Throughput rates of 90 to 400 lbs (41 to 181 kg) per hour

for models CM100, 150 and 200. Throughput rates of 90 to745 lbs (41 to 338 kg) per hour for models CM300 andCM400.

� 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 anaftercooler and insulated delivery hose.

The CM dryer also can be used for central drying applications.Central dryers do not have process heaters. These modelsshould not be used when drying multiple materials that requiredifferent drying temperatures. Central models dehumidify theprocess air, which is then heated to the correct setpoint by heatboosters or pre-heaters mounted on the hoppers.

2-2 CM Carousel Dehumidifying Dryer UGD018/0101

WHAT IS THECM CAROUSELDRYER?

CM Carousel Dryer


Power

Running

Alarm/Fault

Start Dryer

Stop Dryer

CM-100

TYPICALAPPLICATIONS

The CM dryer isequipped with castersand can be installedbeside or near theprocessing machine.

DESCRIPTION

CM Carousel Dryer

CM-100

The CM Carousel Dryer achieves continuous, closed loop drying by passing air simultaneously through two heaters andthree tanks of molecular sieve desiccant.

DESCRIPTION 2-3UGD018/0101 CM Carousel Dehumidifying Dryer

HOW IT WORKS

The Process(Drying) CycleThe process blowerpulls moist air from thetop of the drying hop-per. The air passesthrough the process fil-ter and aftercoolerthrough the processblower and into thedryer’s desiccant tank,where moisture isremoved. The now-dryair moves through theprocess heater, where itis heated to the dryingtemperature selected bythe operator. The hot,dry air is delivered tothe hopper, where aspreader cone evenlydistributes the airthrough the material.

The Regeneration CycleThe regeneration blower pulls airthrough the regeneration filter into thedryer’s regeneration heater. The air isheated to 425°F (218°C) before it ispushed into the “wet” desiccant tank.The hot air purges moisture from thedesiccant. The moist air is blown outthe exhaust at the back of the dryer.

The Cooling CycleA regenerated desiccant tankmust be cooled before it ismoved back into the processcycle. The process blower pushes a small amount of airthrough the regenerated desic-cant tank. The cooling air thengoes back to the inlet of theprocess blower. The cycleremains closed loop.

The CarouselThe carousel indexesevery 30 minutes onthe CM100 movinga desiccant tankthrough three cyclesin 90 minutes. Thecarousel indexesevery 15 minutes onCM150, 200, 300and 400 models,moving a desiccanttank through threecycles in 45 minutes.

NOTE: Normalcarousel rotation forCM100, 150 and200 models is clock-wise. Normalcarousel rotation forfor CM300 and 400models is counter-clockwise.

2-4

SPECIFICATIONS: CM CAROUSEL DRYERS

CM Carousel Dehumidifying Dryer UGD018/0101DESCRIPTION

CM Carousel DryerCM Carousel Dryer

MODEL CM100 CM150 CM200 CM300 CM400Performance characteristics

Air flow ft3/min {m3/min} 90 {2.6} 120 {3.4} 150 {4.3} 200 {5.6} 300 {8.5}Drying temperature STANDARD MODELS (A) 160° -250° F {71°-121° C} HIGH HEAT MODELS (H) 160° -375° F {71°-191° C}Dew point ALL MODELS -40° F {-40° C}Blower type Peripheral Peripheral Peripheral Peripheral PeripheralNumber of desiccant cartridges 3 3 3 4 4

Dimensions inches {cm}A - Height 69.7 {177.0} 69.7 {177.0} 69.7 {177.0} 74 {188.0} 86 {218.4}B - Width 25.5 {64.8} 25.5 {64.8} 25.5 {64.8} 32 {81.3} 36 {91.4}C - Depth 36.0 {91.4} 36.0 {91.4} 36.0 {91.4} 46 {116.8} 53 {134.6}

Delivery and return air line size, OD 2.5 {6.4} 2.5 {6.4} 2.5 {6.4} 3 {7.6} 3 {7.6}*Weight lb {kg}

A = standard / H = high heat † A H A H A H A H A HShipping 660 {299} 710 {322} 720 {327} 770 {349} 850 {386} 900 {408} 1080 {490} 1150 {522} 1430 {649} 1530 {694}Installed 600 {272} 650 {295} 660 {299} 710 {322} 745 {338} 795 {361} 1010 (458} 1080 {490} 1350 {612} 1450 {658}

Voltage Total Amps - Connected LoadA = standard / H = high heat / C = central † A H C A H C A H C A H C A H C

240 V/3 phase/60 Hz 22.0 28.8 14.2 31.6 35.2 16.6 40.5 56.3 24.0 45.7 63.4 29 79.7 — 46.1380 V/3 phase/50 Hz 12.1 15.0 7.4 16.6 18.6 9.8 21.0 29.5 — 28.8 41.0 15.4 40.0 56.4 24.0415 V/3 phase/50 Hz 13.1 16.2 7.9 18.0 20.1 9.7 22.8 32.0 — 26.4 36.7 15.2 43.7 62.0 22.0480 V/3 phase/60 Hz 11.0 14.2 7.0 15.8 17.6 8.3 20.4 28.3 11.8 22.1 31.7 14.2 39.6 55.7 22.6575 V/3 phase/60 Hz 10.4 13.0 5.7 13.0 14.5 7.0 16.5 22.8 10.1 19.2 26.2 12.1 31.1 43.8 18.4

Total Kilowatts kw 8.5 10.8 5.9 12.0 13.5 7.0 16.5 23.1 10.1 18.2 26.4 12.4 33.4 44.2 19.5Water requirements for aftercooler

Recommended temperature‡ 55°-70°F {13°-21°C}Water flow / connections 4 - 6 GPM {18 - 27 liters/min.} / Water connections: 1/2 in. NPT

SPECIFICATION NOTES:* The delivery and return air line size for Central models of the CM400 is 4 inches {10.2 cm}.† CM dryer models are designated A, H or C to indicate whether the process circuit has been designed for standard (A), high-heat (H) or central (C)

applications. C models do not have process heaters, and are designed for central drying applications that require drying multiple materials atdifferent setpoint temperatures. Central models dehumidify the process air, which is then heated to the correct setpoint by Heat Boosters orpre-heaters mounted on the hopper. A or H models, which are equipped with process heaters, may be used when drying a single material at acentral location for distribution to multiple processing machines.

‡ Water temperatures outside this range may affect dryer performance. If you have the optional high-efficiency aftercooler, you can use water at temperatures of 85°-90°F {29°-32°C}. Aftercooler water may be supplied by a tower, chiller or municipal source.

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

A

B C

�� Unpacking the boxes ................... 3-2�� Preparing for installation ............ 3-3�� Mounting the hopper

on a processing machine ....... 3-4�� Installing the hopper ..................... 3-5�� Connecting air and water hoses.. 3-6�� Connecting the RTD probe ......... 3-7�� Connecting the main power ....... 3-7�� Testing the installation ............... 3-8�� Initial set up.................................. 3-10�� Changing temperature units........3-11�� Setting the security level.............3-12

INSTALLATION


The CM carousel dryer comes in one to four boxes, dependingon the models and options ordered. The boxes should include:

Carefully remove the dryer and componentsfrom their shipping containers, and set upright.

Remove all packing material, protective paper, tapeand plastic.

Carefully inspect all components to make sure nodamage occurred during shipping, and that you have allthe necessary hardware.

Take a moment to record serial numbers andelectrical power specifications in the blanks provided onthe back of the the User Guide’s title page. The informa-tion will be helpful if you ever need service or parts.

You are now ready to begin installation.Follow the preparation steps on the next page.

INSTALLATION3-2 CM Carousel Dehumidifying Dryer UGD018/0101

CM Carousel Dryer


Power

Running

Alarm/Fault

Start Dryer

Stop Dryer

CM-100

1

2

3

4

Two lengths of flexible hose(high heat dryer models includeone length of insulated hose)

CM Dryer

5

RTD probe

UNPACKING

THE BOXES

Four hoseclamps

The CM Dryer is easy to install, if you plan the locationand prepare the area properly.

Make sure the location provides:❒❒ A grounded power source supplying the correct

current for your dryer model. Check the dryer’s serialtag for the correct amps, voltage, phase and cycles.Wiring should be completed by qualified personnel tothe planned location for the dryer. All electrical wiringshould comply with your region’s electrical codes.

❒❒ A source of water, if you have an aftercooler.The CM dryer’s optional aftercooler can use tower,city or chiller water at temperatures of 55° to 70°F(21° to 32°C). Pipe should be run to the planned dryerlocation. Use flexible hose to connect the water pipesto the aftercooler.

❒❒ Minimum clearance for safe operationand maintenance.We recommend at least 12 inches (30.5 cm)clearance above the dryer for removing filters. You should maintain 36 inches (91 cm) clearance at the front and at eachside of the dryer for opening the electricalenclosure or removing side panels for main-tenance.

❒❒ Material and conveying lines installed. If you plan to use vacuum or compressed air loaders tofill the hopper, install conveying lines to the dryinghopper location.

❒❒ Minimal distance between dryer and hopper.To prevent excessive heat loss, locate the dryer nomore than10 feet (3 meters) from the hopper.

Drill and tap mounting holes or make adapter.Available drying hopper discharge assemblies and slidegates fit mounting surfaces with these bolt patterns anddiameters.

INSTALLATION 3-3UGD018/0101 CM Carousel Dehumidifying Dryer

1

PREPARING FORINSTALLATION

Control

Top

36 inches(91 cm)

36 inches

(91 cm)

36 inches(91 cm)

36 inches

(91 cm)

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

If your mounting sur-face does not matchthe standard bolt pat-terns available, youwill need an adapter.You can make anadapter using thedimensions providedor purchase one fromConair.

2

The hopper bolts to the throat of the processing machine. Thedryer should be placed within 10 feet (3 meters) of the dryinghopper unless Heat Boosters are used on the drying hoppers.

3-4 INSTALLATION CM Carousel Dehumidifying Dryer UGD018/0101

MOUNTING THEHOPPER TO THEPROCESSINGMACHINE

WARNING: You are responsible for thestructural integrity of this installation.

We recommend that you use bolts no smaller than3/8 inch (M 10) when mounting the hopper to thethroat of a processing machine.

Tools for installation:❒ 5/32” Allen wrench❒ 3/8” and 9/16” wrench❒ Phillips screwdriver❒ Flathead screwdriver❒ Hoist and strap

CM Carousel Dryer

Set Temperature

Dryer Status

Power

Running

Alarm/Fault

Start Dryer

Stop DryerCM-100

Hopper

Slide gate

Drain port

Mountingadapter (optional)

Lift the hopper onto the throat.Lift the hopper with a hoist, using the lifting lugs provid-ed. Make sure you align the bolt holes in the throat withthe bolt holes on the discharge assembly.

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


INSTALLINGTHE HOPPER

2

1

2

CAUTION: To prevent accident and injury,lift the empty hopper onto the throat of theprocessing machine using a hoist and thelifting lugs provided.

IMPORTANT: Before mounting the drying hopper,check inside for parts that may have been placed therefor shipping. You should also clean all internal surfacesof the drying hopper with a solvent to remove the rust prevention coating that was applied for shipping.

The optional aftercooler requires a source of cooling water anda discharge or return line. The water source should provide 4to 6 gpm (15 to 23 lpm) at temperatures from 55° to 70°F (13°to 21°C).

Connect the cooler inlet tothe water source.

Connect the cooler outlet to adischarge or return line.

Using the two flexible hoses provided, connect the inlet andoutlet of the drying hopper to the dryer.

Attach the length ofinsulated hose to the delivery air outlet of the dryerand to the hopper’s deliveryair inlet. If you do not have ahigh heat dryer, attach eitherof the lengths of flexible hoseto the delivery air outlet andinlet.

Attach the other lengthof flexible hose to thereturn air inlet of the dryerand to the return air outlet atthe top of the hopper.

Secure hoses with clamps.The hose clamp should be securedat least 1/4 inch (.64 cm) from theend of the inlet or outlet tube.

INSTALLATION3-6 CM Carousel Dehumidifying Dryer UGD018/0101

CONNECTINGAIR HOSES

CONNECTINGWATER HOSES

1

2

3NOTE: Do not allowthe flexible hoses tokink or crimp.

TIP: Make the connections withflexible hose at least 14 inches(35.5 cm) long. This allows you toeasily remove the cooler coils forcleaning.

1/2 inch NPT femalecouplings. If a manualshut off valve is used, itshould be mounted onthe inlet line.

Return airoutlet

Deliveryair inlet

Deliveryair outlet

Return airinlet

1

2

NOTE: If the aftercooler is used as a volatile trap, usewater chilled at 45° to 55°F (7° to 13°C)

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

Insert the probe inthe delivery air inlet atthe side of the hopper. Theend of the probe must becentered on the airstream.Tighten the nuts to lock theprobe in place.

Plug the probe’s cable into thereceptacle on top of the dryerelectrical enclosure. Hand tight-en the connector. Coil excess cableand secure with a wire tie.

Open the dryer’s electrical enclosure.Disconnect and lock out the main power source.If the dryer is fitted with the optional lockoutdevice turn the disconnect dial on the dryerdoor to the Off position. Turn the captive screw, and swing the door open.

Insert the main power wirethrough the knockout in the side of theenclosure. Secure the wire with a rub-ber compression fitting or strain relief.

Connect the powerwires as shown in yourwiring diagram.

Connect the groundwire to the groundingpoint shown in the wiringdiagram.


WARNING: Always disconnectand lock out the main power sourcesbefore making electrical connections.Electrical connections should bemade only by qualified personnel.

CONNECTING THERTD PROBE

CONNECTING THEMAIN POWER

CM Carousel Dryer

Power

1

2

1

2

3

4

IMPORTANT: Alwaysrefer to the wiring diagramsthat came with your dryerbefore making electricalconnections. The diagramsshow the minimum sizemain power cable requiredfor your dryer, and themost accurate electricalcomponent information.

TRIP+ON

Reset

OOFF

1L1

3L2

5L3

10E

T12

T24

T36

N.O.14

R

AB C

D

A

M

9 82-T1

4-T2

6-T3

CM Carousel Dehumidifying Dryer UGD018/0101

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

Make sure there is no material in the hopper.If you have mounted a loader or vacuum receiver on thehopper, disconnect the material inlet hose at the source.

Turn on main power to the dryer.If the dryer is equipped with the optionaldisconnect turn it to the ON position.

� The power light on the control panel will illuminate.

Turn the control power switch to the ON position.If everything is installed correctly:� The control power switch will light.� The temperature controller activates.

Set the drying temperature.Press Adjust Setpoint � or � arrow until the setpoint tem-perature you want appears in the setpoint display.

Continued on next page.

3-8 INSTALLATION

1

2

3

TESTING THEINSTALLATION

TRIP+ON I

Reset

OOFF

4

CM Carousel Dryer


Power

Running

Alarm/Fault

Start Dryer

Stop Dryer

CM-100

ONOFF

3

45

7

NOTE: If you do not intend to start the dryer within a few minutes, place the temperature controller in Standbymode to prevent a “false” loop break or process low temperature alarm. These alarms, which will prevent thedryer from running, can be removed by turning the controlpower switch OFF and then ON.

To enter the Standby mode, press and hold forthree seconds. Press � or � until “StbY” appears in thelower display.

Press again. The upper display will alternate between“StbY” and the process value.

UGD018/0101 CM Carousel Dehumidifying Dryer

Press the Start Dryer button.If everything is installed correctly:� The green running light turns on.� 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 and stop in the correct position.

The dryer will display an alarm/fault light if the temperature deviates +/- 20 degrees from the setpoint.

Check for proper air flow. Remove the delivery air hose on the dryer. Hold yourhand near, but not on, the outlet. When the dryer ison, you should feel air blowing out of the outlet. Ifyou do not feel air, the blower is rotating in the wrongdirection. See the Installation Note below.

Press the Stop Dryer button.If everything is installed correctly:� The green running light turns off, but the blowers

continue running as needed to cool the heaters.

The test is over. If the dryer performed the normal operating sequencesas outlined, you can begin operation. If it did not, refer tothe TROUBLESHOOTING section of the User Guide.

INSTALLATION 3-9

7

Deliveryair outlet

6

8

CAUTION: Hot surfaceDo not place your hand on the delivery airoutlet. The outlet and the air can get hotenough to burn your hand.

TESTING THEINSTALLATION

5

Regenerationexhaust

INSTALLATION NOTE:CM dryers use a three-phase process blower. If the dryershuts down within the first few minutes of operation,check for proper air flow.

If air flow is reversed, the processblower is turning in the wrongdirection. Turn off and lock outthe main power source. Openthe control enclosure andreverse any two leads connect-ing the main power supply tothe dryer.

1L1

3L2

5L3

10E

T12

T24

T36

N.O.14

R

AB C

D

A

M

9 82-T1

4-T2

6-T3

IMPORTANT: Make sure thedryer is phased properly beforeconnecting it to a hopper con-taining material to ensure thatmaterial will not be pulled fromthe hopper or air inlet into thedryer.

3-10 INSTALLATION CM Series Carousel Dehumidifying Dryer UGD0018/0101

INITIAL SETUP The CM dryer has been configured at the factory to satisfymost applications. But you can change some settings as need-ed, including:❒ The temperature units.❒ The security level allowing operator access to settings and

parameters.

CAUTION: The dryer will not operate correctly if cer-tain factory-set parameters are changed. Parametersshould be changed only by qualified technical personnel who are familiar with the operation of thistype of equipment. If the dryer does not appear to beworking correctly, verify the parameters against the listof factory settings in the Appendix.

For a complete list of the factory-set parameters See DEFAULTPARAMETERS in the Appendix. For more detailed informationabout these parameters and instructions on returning the para-meters to the initial factory setup, See the SERIES 16CINSTRUCTION MANUAL included with the instruction packet.

All parameters can be changedusing the keypad and the menusystem within the temperaturecontroller.

Mode/Enter KeyUsed to access operating modes,index through menu items andenter parameter settings.

Lower KeyUsed to decrease values or togglebetween setting choices.(Hold for fast-step progression)

Raise KeyUsed to increase values or togglebetween setting choices.(Hold for fast-step progression)

Menu Access KeyUsed to enter or exit the menu system, index to the next menuand enter the Security Level menu.

INSTALLATION 3-11UGD018/0101 CM Series Carousel Dehumidifying Dryer

CHANGINGTEMPERATUREUNITS

The dryers are factory-set as degrees Celsius, Kelvin orFahrenheit, as specified when the unit was ordered.

To change this setting:

Place the controller in Standby mode.a. Press and hold for

three seconds until theoperating mode appears inthe lower display.

b. Press or until the Standby mode appearsin the lower display.

c. Press again. The upper display will alternate between Standbyand the process value. You are now in Standby mode.

Press and hold for three seconds to accessthe menu system.

Press until the dSPL (Display) menu appears.

Press until Unit appearsin the lower display.

Press or to select thetemperature unit.F = FahrenheitC = CelsiusCAY = Kelvin

Press to index to the next menu withparameter settings you want to change.

If you do not want to change other parameter settings,press and hold for three seconds to return to the normal operating mode.

1

2

3

4

a

b c

5

6

3-12 INSTALLATION CM Series Carousel Dehumidifying Dryer UGD0018/0101

The CM Dryers provide the ability to protect system parameters from accidental or unauthorized changes. Six security levels are available, allowing various degrees ofaccess to the menus, setpoint and operating mode selections.

We recommend selecting the most restrictive security levelthat suits your application. The security levels are:

Key Lockout. Highest security level. No access to anycontroller functions.

Setpoint. Allows setpoint value or output percentage(manual mode) to be changed. No access to menus.

Setpoint Plus Mode. Allows changes to setpoint value,output percentage (manual mode) or the operatingmode. No access to menus.

User. Allows access to all Setpoint Level privileges, aswell as access to Operating Mode, Autotune andControl menus.

Configuration. Allows access and changes to all para-meters and menus except the Calibration menu. Accessrecommended only for trained service personnel.

Factory. Lowest security level. Allows access to allparameters, menus and calibration settings. Access rec-ommended only for factory personnel.

To change or view a Security Level:

Press and hold for about 10 seconds.The controller will display AcLv inthe upper display and the access levelcode in the lower display. (Ignore themenu label that appears in the upperdisplay after three seconds.)

Press or to indexthrough the security levels,stopping on the level that you want.

Press once to select the level and exit to the process value display.

SETTING THESECURITYLEVEL

Loc.O

SP

SP.PL

FACt

USEr

CnFg

1

2

3

�� The dryer control panel .............. 4-2�� CM dryer functions ...................... 4-3�� To start drying ............................. 4-4�� To stop drying ............................. 4-5

OPERATION


4-2 OPERATION CM Carousel Dehumidifying Dryer UGD018/0101

THE DRYERCONTROL PANEL

CM Carousel Dryer


Power

Running

Alarm/Fault

Start Dryer

Stop Dryer

CM-100

ONOFF

Start Dryer ButtonPress Start Dryer button tostart drying.

Control Power On/Off Turn switch clockwise to turn onpower to the control. Turn theswitch the counter clockwise toturn power off. The switch willlight when power is on.

Alarm/Fault LightOn when the dryerdetects a problem.

Adjust SetpointPress � or � to set the drying tem-perature. Press � to increase avalue. Press � to decrease a value.TIP: Press and hold the button forfaster scrolling speed.

Power LightOn when the main poweris on.

Stop DryerButtonPress Stop Dryerbutton to stop drying.

Display WindowsThe upper window displays the actualtemperature of drying air entering thehopper. The lower window displayssetpoint values. When there is analarm, the windows display error codes.

RunningLightOn when thedryer is running.

OPERATION 4-3UGD018/0101 CM Carousel Dehumidifying Dryer

CM DRYERFUNCTIONS

The CM dryer control uses a menu system to access differentoperating modes or change system parameters. Please see theAPPENDIX for default parameter settings and detailed informa-tion on each of these modes and parameters

Operating ModesNormal. The unit operates with normal automatic control based on the parameters entered during initialsetup. The setpoint temperature can be changed in thismode as long as the Security Level allows changes.

Standby. Use to disable control outputs. You must firstbe in Standby mode to initiate an Autotune. Standbymode also is recommended when you initially configurethe controller.

Autotune. Use to ensure that the control continues toobtain good approximations of the PID constants. AnAutotune should be performed after the first two hoursof operation and whenever process variables change.See PERFORMING AN AUTOTUNE in the MAINTENANCE sec-tion.

Parameter Menus

Input. Use to select sensor-related parameters, such asinput type.

Display. Use to set or change display units or decimalposition.

Output. Use to specify output usage, control methodsand alarms.

Control. Use to select parameters associated with con-trol methods.

Alarm. Use to select alarm parameters.

Tune. Use to set autotune damping parameter.

StbY

nor

dSPL

Atun

InP

CtrL

OutP

tunE

ALr

Press and hold forthree seconds toaccess the menus

Press to indexthrough the menus.

Press to indexthrough parametersunder each menu item.

Press and hold forthree seconds toaccess operatingmodes.

NOTE: You must be inStandby mode toaccess Autotune.

NOTE: You may need to change the security level toaccess these menus. See SETTING THE SECURITY LEVELat the end of the INSTALLATION section.

Make sure there is material in the hopper.

Turn on the main power to the dryer.Make sure the main power or rotary disconnectswitch on the dryer is in the ON position.

� The white power light will illuminate.

Turn the Control Power switch to ON.� Temperature controller is activated.

Set the drying temperature.Press Setpoint Adjust � or � arrow until the setpoint temperature you want appears in the setpoint display.

Press the start dryer button.� The green running light turns on.� Process and regeneration blowers and heaters turn on.� If the desiccant tanks are not in the correct position, the

carousel will turn and stop in the correct position.� The dryer will alarm if the actual temperature deviates

+/- 20 degree from the setpoint temperature.

4-4 OPERATION CM Carousel Dehumidifying Dryer UGD018/0101

TO STARTDRYING

5

12

3

TRIP+ON I

Reset

OOFF

4

CM Carousel Dryer


Power

Running

Alarm/Fault

Start Dryer

Stop Dryer

CM-100

ONOFF

34 5

NOTE: If you decide to runthe dryer with the hopper empty make sure that theprocess temperature doesnot exceed 150°F (65°C).

NOTE: If you do not intend to start the dryer within a few minutes, place the temperature controller in Standbymode to prevent a “false” loop break or process low temperature alarm. These alarms, which will prevent thedryer from running, can be removed by turning the ControlPower switch OFF and then ON.

To enter the Standby mode: press and hold for threeseconds. Press � or � until “StbY” appears in the lowerdisplay. Press again. The upper display will alternatebetween “StbY” and the process value.

To resume normal operation: Press and hold forthree seconds to enter Normal (“nor”) operating mode.

OPERATION 4-5UGD018/0101 CM Carousel Dehumidifying Dryer

TO STOP DRYINGLower the process temperature setpoint toroom temperature.Allow the dryer to run for a few minutes to cool off.

Press the Stop Dryer button.� The running light turns off.

Turn the ON/OFF dryer switch to OFFafter the blowers stop running.Be sure to disconnect and lockout the mainpower if you have stopped the dryer to performmaintenance or repair.

IMPORTANT: Always use the Stop Dryer buttonto stop drying. Do not use the main power switchor the Control Power ON/OFF switch to stop thedryer. Turning off main power to the control ordryer during normal operation prevents the necessary cool-down period, and can trigger theshut down/high temperature alarm during yournext drying cycle.

1

2

3

�� Maintenance schedule.................. 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�� Inspect hoses and gaskets .......... .5-5�� Performing an autotune.................5-6

MAINTENANCE


Routine maintenance will ensure optimum operation andperformance of the CM Carousel Dryer. We recommend thefollowing 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 thanweekly. Frequency depends on how much materialyou process and how dusty or full of fines it is.

❒❒ Clean the return air screen in the hopper.Cleaning frequency depends on how much materialyou 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 orwear. Reposition and tighten loose hose clamps.

�� Monthly❒❒ Clean the aftercooler coils.

High-heat dryer models have an aftercooler. Youmay need to clean the coils more often than month-ly. Frequency will depend on the type and volumeof material you process.

�� Every six months❒❒ Inspect gaskets for damage or wear.

Damaged gaskets can allow moisture to seep intothe closed-loop drying system. Replace any gasketthat is torn or cracked.

5-2 MAINTENANCE CM Carousel Dehumidifying Dryer UGD0180101

PREVENTATIVEMAINTENANCESCHEDULE

The hopper, spreader cone and discharge assembly should becleaned thoroughly before operation and between materialchanges to prevent resin contamination.

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

. Close the hopper slide gate.

Remove the drain-port plug.Pull the pin and allow the plug to drop.

After draining material, open the hopper door.

Remove the spreader cone. Reachinto the hopper. Grasp the spreader conetube, lift up slightly, twist and then pushdown to release it. Tilt the cone assemblyand pull it out through the hopper door.

Clean the spreader cone and theinside of the hopper. Make sure youalso clean the return air screen at thereturn air outlet of the hopper.

Repeat the steps in reverse orderto reassemble the hopper before addingmaterial.

MAINTENANCE 5-3UGD018/0101 CM Carousel Dehumidifying Dryer

CLEANINGTHE HOPPER

CAUTION: Hot surfaces.Always protect yourself from hot sur-faces inside and outside the dryer anddrying hopper.

2

3

5

4

1

6

1

2

Clogged filters reduce air flow and dryer efficiency. Cleaningfrequency depends on how much material you process and howdusty it is.

Remove process hose.Use a flat head screw-driver or a 5/16-inch nutdriver to remove thehose from the back ofthe process filter.

Remove the lid on theprocess filter byremoving the wing nutand washer.

Remove the filterby removing the nut andwasher that hold theprocess filter in the canister.

Clean the filter. Replace the filter if it is worn, damaged or hopelesslyclogged with dirt, fines or dust.

Inspect gasket for wear.

Reassemble by repeating the steps in reverse order.

Remove the regeneration filter by removing the wingnut and washer.

Clean the filter.Replace the filter if it isworn, damaged or hope-lessly clogged with dirt,fines or dust.

Inspect gasket forwear.

Reassemble byrepeating the steps inreverse order.

5-4 MAINTENANCE CM Carousel Dehumidifying Dryer UGD018/0101

CLEANING THEREGENERATIONFILTER

CM Carousel Dryer

Set Temperature

Dryer Status

Power

Running

Alarm/Fault

Start Dryer

Stop DryerCM-100

CM Carousel Dryer

Set Temperature

Dryer Status

Power

Running

Alarm/Fault

Start Dryer

Stop DryerCM-100

2

3

1

4

2

3

1

CLEANING THEPROCESSFILTER

6

4

5

NOTE: Dryer must bestopped prior to cleaningthe filters.

If you have the optional aftercooler,you need to clean the cooling coils tokeep them working efficiently.Cleaning frequency depends on thetype and amount of material youprocess.

Remove water hoses on topof the aftercooler.

Release the latches at the topof the aftercooler.

Pull the coils out of the after-cooler housing.

Clean the coils with high-pressure steam.

Inspect gasket for wear.

Reassemble by repeating steps in the reverse order.

Loose or damaged hoses and gaskets can allow moisture to seepinto the closed-loop drying system.

Tighten any loose hose clamps.

Replace worn or damaged hoses and gaskets.

UGD018/0101 CM Carousel Dehumidifying Dryer MAINTENANCE 5-5

CLEANING THEAFTERCOOLERCOILS

2

1

3

INSPECT HOSESAND GASKETS

21

CM Carousel Dryer

CM-100

Hose clamps

Hose clamps

Filter gaskets

Hopperdoor gasket

Hose clamps

45

6

CM Series Carousel Dehumidifying Dryer UGD0018/01015-6 MAINTENANCE

You should perform an Autotune only if the process tempera-tures is unstable (oscillates) to ensure that the control contin-ues to obtain good approximations of the PID constants.

To ensure a successful Autotune, verify that:

❒ The dryer has been stopped and the process value is sta-ble. A fluctuating process value will fool the software intomaking inaccurate tuning decisions. If the process value isnot stable, the Autotune terminates and the control displaysan error.

❒ The setpoint/process deviation is at least 25°F. Tuningaccuracy increases as the spread between the process andsetpoint values increases. If the absolute value of setpointminus the process temperature is not at least 25°F, theAutotune terminates and the control displays an error.

To perform an Autotune:

Press the Stop Dryer button.

Place the controller in Standby mode.a. Press and hold for three

seconds until the operatingmode appears in the lower dis-play.

b. Press or until the Standby mode appears inthe lower display.

c. Press again. The upper display will alternate between Standby andthe process value. You are now in Standby mode.

Enter a setpoint value, if one has not been set.Press or until increase or decrease the setpoint.

continued on next page

PERFORMING ANAUTOTUNE

1

2

3

a

b c

NOTE: The autotune should take up to 30 minutes if ittakes longer than that contact the service department.

UGD018/0101 CM Series Carousel Dehumidifying Dryer MAINTENANCE 5-7

Initiate the Autotune.a. Press and hold again

for three seconds until CtrLand the operating mode aredisplayed.

b. Press or until the Autotune mode appearsin the lower display.

c. Press again. The upper display will alternate between “tunE”and the process value whilethe Autotune is underway.

If Autotune is successful, the controller automaticallystarts controlling using the new PID parameters.

If a fault occurs during the Autotune, the control entersStandby mode and displays the appropriate error message.

PERFORMING ANAUTOTUNE

ERROR CODE ERROR DESCRIPTION

No PID device configured.Verify that Output 1 Type and Output 2 Type are configured as PID outputs.

Incorrect output action.Verify that the outputs are set up and wired correctly.Output 2 should be reverse acting for heating.

Insufficient setpoint/process deviation.If the absolute value of setpoint minus process valueis less than 25° F. The Autotune cannot be starteduntil the temperature difference is at least 25° F.

Tune timed out. Autotune will time out if a stableprocess value cannot be obtained. If this erroroccurs, verify that you followed every requirementunder “To ensure a successful Auto Tune” and perform a second tune.

Invalid tune results.The most likely causes of this error is a tune startedinappropriately or an external element (i.e., loosethermocouple) that upset the process while tuningwas in progress. Verify that you followed everyrequirement under “To ensure a successful AutoTune” and perform a second tune.

a

c

02

05

03

09

08

4

�� Before beginning .......................... 6-2�� A few words of caution ................6-2

DIAGNOSTICS�� How to identify the cause

of a problem ...............................6-3�� Shut down alarms ........................ 6-4�� Controller alarms .........................6-7�� Dryer will not power up ...............6-10

REPAIR�� Replacing fuses ........................... 6-11�� Checking heater contactors ........6-11�� Checking motor overloads ..........6-12�� Replacing the temperature

controller....................................6-13�� Checking or replacing

temperature sensors ................6-14�� Replacing heater elements ......... 6-15�� Removing desiccant tanks ..........6-16�� Refilling desiccant tanks ............ ..6-17�� Adjusting the limit switch ........... 6-20

TROUBLESHOOTING


CM Carousel Dehumidifying Dryer UGD018/0101

You can avoid most problems by following the recommendedinstallation and maintenance procedures outlined in this UserGuide. If you do have a problem, this section will help youdetermine what caused it and how to fix it.

Before you begin troubleshooting:

❏ Find the wiring diagrams that were shippedwith your equipment. These diagrams are the best ref-erence for correcting a problem. The diagrams also willnote any custom features, such as special wiring, control orplumbing options, not covered in this User Guide.

❏ Verify that you have manuals for other equip-ment in the process line. Solving problems mayrequire troubleshooting malfunctions or incorrect operatingprocedures on other pieces of equipment.

❏ If an alarm is present, note any indicator lightsand messages shown on the control panel. Theseindicators will help you discover the cause of the problemmore quickly.

The CM Carousel Dryer is equipped with numerous safetydevices. Do not remove or disable them. Improper correctiveaction can lead to hazardous conditions and should never beattempted to sustain production

6-2 TROUBLESHOOTING

A FEW WORDSOF CAUTION

BEFOREBEGINNING

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

DANGER: Voltage hazard.Troubleshooting the electrical system of thisequipment requires use of precision electronicmeasuring equipment, and may require accessto the electrical enclosure while power is on.Exposure to potentially fatal voltage levels maybe unavoidable. These troubleshooting proce-dures should be performed only by qualifiedelectrical technicians who know how to usethis precision electronic equipment and whounderstand the hazards involved.

WARNING: This machines should beadjusted and serviced only by qualified techni-cal personnel who are familiar with construc-tion and operation of this type of equipment.

Most dryer malfunctions are indicated by an illuminated alarmlight and error codes displayed on the CM dryer control panel.

A problem can cause the dryer to shut down andthe Alarm/Fault light to glow red.Shut Down: The dryer has automatically shut down becauseit detected a serious problem that could damage your materialor facility.

When the alarm/fault light is displayed and/or the dryer unexpectedly shuts down:

Note any indicator lights or error messages tohelp determine the cause of the problem.

Find the alarm or error code in the diagnosticstables in this section of the User Guide. Causes are listedin the order of most likely to least likely problem.

Determine and fix the cause of the alarm.

Lift off the side panels.Use the black handles to liftthem up and off.

Replace side panels. Guide the mounting tabs onthe side panel into the knotch-es on the side of the dryer.

UGD018/0101 CM Carousel Dehumidifying Dryer TROUBLESHOOTING 6-3

HOW TO IDENTIFYTHE CAUSE OF APROBLEM

CM Carousel Dryer


Power

Running

Alarm/Fault

Start Dryer

Stop Dryer

CM-100

ONOFF

1

2

3

1 REMOVING THESIDE PANELSFROM THEDRYER

2

When a shut down alarm lights, the dryer has detected a prob-lem or combination of problems that could damage your dryeror materials. When a shut down alarm occurs:

� The dryer automatically shuts off.� The alarm/fault light turns on.� The power light remains on.

6-4 TROUBLESHOOTING CM Carousel Dehumidifying Dryer UGD018/0101

Alarm

A loop break orprocess low tempera-ture alarm occurredwhen the dryer waspowered up but notstarted.

The dryer detectedexcessive heat in theprocess or regenera-tion heater boxesbecause the blowerswere shut off beforethe cool-down modehad completed.

SHUT DOWNALARMS

Possible cause

Was the dryer poweredup but not started formore than 10 minutes ?

Was there a loss of poweror improper shut downusing the power ON/OFFswitch or the main powerdisconnect?

SolutionIf the dryer is not started with-in 10 minutes of activating thetemperature controller, thedryer may indicate a “false”loop break or process low tem-perature alarm. These alarmswill prevent the dryer frombeing started. The alarm canbe removed by cycling thepower switch again. If youknow the dryer will sit for anextended period of time with-out running, this alarm can beavoided by putting the temper-ature controllers into standbymode. See STARTING THEDRYER.

Turn the power to the dryer offand then on. Allow the dryer tocool, then press RUN torestart. The power interruptionprevented the heaters fromcooling down after normaloperation. This may have trig-gered a high temperaturealarm.

Alarm/Fault

Alarm/Fault

TROUBLESHOOTING 6-5UGD018/0101 CM Carousel Dehumidifying Dryer

Alarm

The RTD probe atthe drying hopperinlet sensed that theactual drying tem-perature is more than20°F (7°C) higher orlower than setpoint.

WARNING:Only qualified electri-cal service personnelshould examine andcorrect problems thatrequire opening thedryer’s electrical enclosure or checkingelectrical current todiagnose the cause ofa problem.

Possible cause

Are process air linesrestricted?

Is the dryer too far fromthe hopper to maintainsetpoint temperature ofthe drying air?

Is the RTD temperatureprobe installed correctly?

Is the process blowerrotating in the wrongdirection?

Did a process heaterelement fail?

Did a process heatercontactor fail?

Solution

Check the delivery air hoseand process filter. Removeblockage. Straighten crimps inhoses. Attach any loose hoses.

The dryer should be no morethan 10 feet (3 m) from thehopper. Move the dryer closerto the hopper, or insulate theair delivery hoses.

Verify that the tip of the RTDprobe is inserted into the cen-ter of the delivery air inlet ofthe hopper. Temperature read-ings will be incorrect, if thesensor touches the walls of theinlet pipe.

If the process blower is turningopposite the arrow stamped onits housing, reverse any twoleads connecting main powerto the dryer.

Using an ampmeter, check thecurrent in the heater elementwires. If the current is lowerthan indicated on the wiringdiagrams, replace the heaterelement. See REPLACINGHEATER ELEMENTS.

Disconnect power. Check thecontinuity of the contactor out-puts. If the ohm reading is zeroor near zero, replace the con-tactor. See CHECKING HEATERCONTACTORS.

SHUT DOWNALARMS



Alarm/Fault

Possible causeIs the correct voltagesupplied to the dryer?

Is the blower overload setcorrectly?

Is the blower damaged?

Is the correct voltage supplied to the dryer?

Is the blower overload setcorrectly?

Is the blower damaged?


Alarm

Process blower over-load has tripped. Theblower is drawingexcessive current.

Regeneration bloweroverload has tripped.The blower is draw-ing excessive cur-rent.

SolutionCheck the voltage rating on thedryer nameplate. If it does notmatch the supplied voltage,supply power from a correctvoltage source.

Disconnect the power andopen the electrical enclosure.Adjust the blower overload set-ting, if necessary. Press theoverload reset button toresume operation. SeeCHECKING MOTOR OVERLOADS.

Replace the blower, if the sup-ply voltage and overload set-tings are correct but the blowercontinues to draw excessivecurrent.

Check the voltage rating on thedryer nameplate. If it does notmatch the supplied voltage,supply power from a correctvoltage source.

Disconnect the power andopen the electrical enclosure.Adjust the blower overload set-ting, if necessary. Press theoverload reset button toresume operation. SeeCHECKING MOTOR OVERLOADS.

Replace the blower, if supplyvoltage and overload settingsare correct but the blower con-tinues to draw excessive cur-rent.



SHUT DOWNALARMS

Alarm/Fault

Alarm/Fault


CONTROLLERALARMS

The dryer has detected a problem that could lead to equipmentdamage or personal injury if it is not corrected.

� The controller displays a red alarm LED and/or an error codeindicating the cause of the problem.

Alarm

OpenSensor

The RTD in theprocess supply lineis not working cor-rectly.

WARNING:The Dryer should betested and repaired onlyby qualified techniciansequipped with the cor-rect tools and trained inthe maintenance andrepair of electrical sys-tems and industrialappliances.

CauseIs the RTD wired correctly,or is the wire loose?

Is the input parameter inthe controller set correctly?

Has the RTD failed?

Solution

Check the wiring and connec-tions between the RTD and con-troller. Refer to the wiring dia-grams that came with your unit.

Verify that the Input SensorType in the controller’s Inputmenu is set to RTD. Verifyother input settings against theDEFAULT PARAMETERS table inthe Appendix.

Check the RTD and replace ifnecessary. See CHECKING AND

REPLACING THE RTD.

Err.H

6-8 TROUBLESHOOTING CM Series Carousel Dehumidifying Dryer UGD0018/0101

CONTROLLERALARMS

Alarm

LoopBreak

The input is notchanging or respond-ing properly to theoutput action. Thiscan be caused by aRTD, input, heateror load failure.

WARNING:The Dryer should betested and repaired onlyby qualified techniciansequipped with the cor-rect tools and trained inthe maintenance andrepair of electrical sys-tems and industrialappliances.

Possible causeIs the RTD wired correct-ly, or is the wire loose?

Is the input parameter inthe controller set correct-ly?

Has the thermocouplefailed?

Did a heater element fail?

Did a heater contactorfail?

Solution

Check the wiring and wiringconnections between the RTDand controller. Refer to thewiring diagrams that camewith your unit.

Verify that the Input SensorType in the controller’s Inputmenu is set to RTD. Verifyother input settings against theDEFAULT PARAMETERS table inthe Appendix.

Check the RTD and replace ifnecessary. See CHECKING AND

REPLACING THE RTD.

With the unit powered down:Check for loose connections.Check resistance between thephase legs on the output sideof the heater contactor.Readings should be within0.25 ohms of each other.Replace the heater, if neces-sary. See REPLACING HEATER

ELEMENTS.

With power on and theHeater LED lit: Check theamp draw on each of the threephase legs to the heater. Allshould match the FLA listedfor the heater on the wiringdiagram. Replace the heatercontactor if there is a voltageimbalance greater than 10%.See REPLACING THE HEATER

CONTACTOR.

LPbr

The dryer has detected a problem that could lead to equipmentdamage or personal injury if it is not corrected.

� The controller displays a red alarm LED and/or an error codeindicating the cause of the problem.

TROUBLESHOOTING 6-9UGD018/0101 CM Series Carousel Dehumidifying Dryer

CONTROLLERALARMS

Alarm

ChecksumError

RAMError

DefaultsLoaded

EEPROMWriteFailure

InvalidInterrupt

“36” will be followedby a 2-digit code.

Possible causeElectrical noise or amicroprocessor problemcaused a failure duringpower up or operation.

Electrical noise or amicroprocessor problemcaused a failure duringpower up or operation.



Power fail resume featuredisabled.

Electrical noise, CPU fail-ure or software bug causedan internal software error.

Solution

Press any key to perform a softreset and reinitialize the con-troller. If the error persists,contact Conair service.




No further resume actionsavailable.


0100

The Dryer has detected a non-recoverable error involving themicroprocessor control.

� The controller displays an error code indicating the cause of theproblem.

0101

0202

0303

38CS

36_ _


Symptom

Turning the PowerON/OFF switchdoes not turn onthe dryer control.

Possible cause

Is the main power supplyto the dryer on?

Has the dryer blown afuse?

Is the temperature controller damaged ?

Solution

Verify that the main powersupply is on and that thedryer’s main power disconnectdial is in the ON position.

Disconnect power. Open thedryer’s electrical enclosure andcheck the main power fuses.See REPLACING FUSES.

Contact Conair service. SeeREPLACING THE TEMPERATURE

CONTROLLER.

DRYER WILLNOT POWER UP

You have a problem with the main power circuit or the dryer’smicroprocessor board, if the dryer control panel does not lightwhen the Power ON/OFF switch is turned to the ON position.


Disconnect and lock out the main power.

Open the electrical enclosure door.

Check the fuse.If necessary, pull the fuse out and replace it with a fuse ofthe same type and rating.

Disconnect and lock out the main power.

Open the electrical enclosure.

Locate the process or regeneration contactors.Refer to the wiring diagrams that came with your dryer.

Check continuity using an ohmmeter.

1L1

3L2

5L3

10E

T12

T24

T36

N.O.14

R

AB C

D

A

M

9 82-T1

4-T2

6-T3

2

3

1

23

1

4

Fuse BlockTo locate the appropriatefuse and replacementpart, refer to the wiringdiagrams that came withyour dryer.

1L1

3L2

5L3

10E

T12

T24

T36

N.O.14

R

AB C

D

A

M

9 82-T1

4-T2

6-T3

Process heater contactorsIf ohms equal zero or infinity,replace the contactor.

Regenerationheater contactorsIf ohms equal zero or infinity,replace the contactor.

IMPORTANT:Always refer to the wiringdiagrams that came withyour dryer to locate spe-cific electrical compo-nents. Illustrations in theUser Guide are intendedto be representative only.

REPLACINGFUSES

CHECKINGHEATERCONTACTORS

IMPORTANT:Always refer to the wiringdiagrams that came withyour dryer to locate spe-cific electrical compo-nents. Illustrations in theUser Guide are intendedto be representative only.


Disconnect and lockout the main power.

Open the electricalenclosure door.

Check the overload.If the blue reset button isout, the overload hastripped. Press the buttonto reset the overload andresume normal operation.

If the overload continuesto trip, check the overloadsettings. The factory set-ting for the overload is theblower’s amp rating plus0.1 amp.This rating isnoted on the wiring dia-gram.

2

1CHECKINGMOTOROVERLOADS

IMPORTANT: Always refer to the wiring diagramsthat came with your dryer to locate specific electricalcomponents. Illustrations in the User Guide areintended to be representative only.

3

1L1

3L2

5L3

10E

T12

T24

T36

N.O.14

R

AB C

D

A

M

9 82-T1

4-T2

6-T3

R

AB C

D

A

M

9 82-T1

4-T2

6-T3


REPLACING THETEMPERATURECONTROLLER

The temperature controller used in the CM dryer slides in andout of its casing for easy replacement.

Disconnect and lockout the main power supply.

Press the grips on each side of the front panelbezel until the tabs release.

Pull the controller chassis out of its casing.

To reinstall or replace the controller:

Press the grips on each side of the bezel.

Carefully push the controller back into the casinguntil the tabs snap into place.

Program the new controller.Use the DEFAULT PARAMETER settings found in theAppendix. For additional information on all the parameters,see the SERIES 16C INSTRUCTION MANUAL in the Appendix.

IMPORTANT: Alwaysrefer to the wiring dia-grams that came withyour Dryer to locate spe-cific electrical compo-nents. Illustrations in theUser Guide are intendedto be representative only.

1

2

3

4

5

6

Bezel Case Clip

Control PanelGasket

Grips

Controllerchassis


CHECKING ORREPLACINGTEMPERATURESENSORS

The CM dryer uses RTD sensors to monitorthe temperature of the drying air.

To check or replace an RTD sensor:

Disconnect and lockout the main power supply.

Remove dryer panels, as necessary.

Locate the temperature sensor.

Check the sensor position and condition.Temperature readings will be incorrect, if the sensor istouching the wall of an air hose or pipe or if the sensor orwiring is damaged. The tip of the sensor should be cen-tered within the air hose or pipe. Sensor wires should beattached to the appropriate connection points on the dryer’selectrical enclosure or the temperature controller.

Replace the sensor, if necessary.

IMPORTANT:Always refer to thewiring diagrams thatcame with your dryer tolocate specific electricalcomponents.Illustrations in the UserGuide are intended tobe representative only.

CM Carousel Dryer

CM-100

Process (drying air)temperature probe

(RTD)

Regenerationtemperature control sensor

Process hightemperature switch

Regeneration hightemperature switch

23

1

4

5


Disconnect power andremove the dryer’s sidepanel.

Locate the appropriateheater box.

Remove the heater cover.

Detach the heater elementwires from the terminal stripabove the heater box. Eachelement has two wires.

Check continuity of theheater element wires.Replace any element thatshows an ohm reading of zeroor infinity.

Remove the heaterelement assembly.Loosen the screws and pull theassembly out of the box.

Replace the faulty heaterelement(s). Remove the nutholding the element to theassembly plate. Pull the ele-ment out of the plate. Insertthe wires of a new elementthrough the plate. Secure theelement with the nut.

Reassemble. Follow steps inreverse order

REPLACINGHEATERELEMENTS2

3

1

36

4

5

6

8

7

Nut

Gasket

Heater mounting plate

Washer

Heater element

4

Process

Regeneration

TIP: For faster repairs,keep a spare heaterassembly that can beswapped for theassembly containing afaulty element.

Number of heating elementsA Series

Process Regeneration

CM100 3 (1250w) 3 (1250w)

CM150 3 (2000w) 3 (1250w)

CM200 3 (2500w) 3 (2500w)

Number of heating elementsH Series (high heat)

Process Regeneration

CM100 3 (2000w) 3 (1250w)

CM150 3 (2500w) 3 (1250w)

CM200 6 (2500w) 3 (2500w)

Depending on the model CM dryer you have refillable solidcore or hollow core desiccant tanks. When desiccant becomesclogged or contaminated, you should replace the desiccant inall tanks to ensure optimum performance.

Stop the dryer anddisconnect power.

Remove the sidepanel.

Disconnect the hosefrom the desiccanttank.Loosen the hose clampwith a screw driver.

Lift the tank off thecarousel assembly.

Refill the tank withfresh desiccant.See REFILLINGDESICCANT TANKS.

Check the O-rings inthe carousel coupling.Replace any O-rings thatare cracked, worn ordamaged. Apply petrole-um jelly on the inside ofthe coupling around theO-ring.

Place the refilledtank on the carouselassembly. Make sure theinlet/outlet tube of thetank seats fully into theO-rings on the carouselpipe.

Connect the hose to the top of the tank.Secure with the hoseclamp.

Reinstall the sidepanel.

REMOVINGDESICCANTTANKS

2

3

1

4

5

6

O-ring

7

8

9

TIP: It’s important thatthe new tanks are con-nected to the correcthoses. Mark the hosesas they are disconnect-ed, or replace one tankat a time, to ensurethat you install the newtanks in the correctpositions.


WARNING:Hot Surfaces.

The metal surfaces ofthe desiccant tankscan become very hot.Always allow the dryerto cool before remov-ing the tanks. Weargloves to protect your-self from hot surfacesthe correct positions.


REFILLINGDESICCANTTANKS(SOLID-CORE TANKS

ON CM100 MODELS)

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

Remove the desiccant tank from the carousel.See REMOVING DESICCANT TANKS.

Remove the screws on the tank end plate.

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

Remove the old desiccant.

Replace the gasket on the flange, if necessary.

Fill the tank with fresh desiccant.Fill the tank to the top of the band. Vibrate the tank for15 minutes, then add more desiccant until the desiccant islevel with the top of the band.

Reinstall the screen cap.Place the cap on the band. Install one of the 1/4-20 nutson the center post and tighten. Do not over-tighten.Install the second 1/4-20 nut and tighten.

Reinstall the tank end plate.Place the end plat on the tank and tighten the screws.

Reinstall the desiccant tank on the carousel.See REPLACING DESICCANT TANKS.

IMPORTANT: After fillingwith fresh desiccant,vibrate the tank for at least15 minutes. Add desiccantas needed until level withthe top of the band.

456

1

23

Strip and stick gasket

Fill to the top of the band

1/4-20 bolts

Screen cap

7

8

9

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

Remove the desiccant tankfrom the carousel. SeeREMOVING DESICCANT TANKS.

Remove the screws on thetank end plate.

Pull out the desiccant core and flip the coreupside down.

Remove the core cap. Remove the two bolts and a washer from the center postand pull the cap out.

Continued on next page.


2

3

1

REFILLING THEDESICCANTTANKS(HOLLOW-CORE TANKS ON

CM150-CM400 MODELS)

324

4

Desiccant core

Tank end plate

Desiccant tank

Core cap

Tank end plate

Remove and dispose of the old desiccant.

Check for gasket and o-ring wear. Replace the gasket on the flange and/or the o-ring ifit is cracked or worn

Fill the tank with fresh desiccant. Use 13X desiccant, 8 X 12 bead size (Conair part#18907302) Fill the tank to the top of the band. Vibratethe tank for 1 hour, topping off occasionally as settlingoccurs. When finished vibrating, the desiccant levelshould be level with the top.

Reinstall the cap.Place the cap on the core andtighten bolts and washer onthe center post.

Check for adequate desiccant packing. The desiccant beads shouldnot move when the core isturned end-to-end.

Upright the core andplace it back inside thetank.

Replace the screws onthe tank end plate.

Reinstall the desiccanttank on the carousel.See REMOVING DESICCANTTANKS.


REFILLING THEDESICCANTTANKS(HOLLOW-CORE TANKS ON

CM150-CM400 MODELS)

5

6

7

8

9

IMPORTANT:Before installing the cap,make sure there are nodesiccant beads betweenthe cap and the rim of thecore, or between centerpost and the nuts. Thereshould be gap betweenthe cap and the rim.

10

11

Core cap

Core

Tank end plate

8

10

11

Core cap

Core

Tank end plate

Tank12


Stop the dryer.Disconnect and lockoutthe main power.

Remove the side panel.

Loosen the screw on thelimit switch bracket.

Slide the bracket left or right toposition the limit switch so that its smallroller drops into the valley on the bedplate. The roller should not hit the sta-tionary bottom plate.

Test for correct indexing of the carousel.Restore main power to the dryer. Hold the limit switch outof the valley on the carousel bed plate while you press thethe START. button 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.

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

ADJUSTING THELIMIT SWITCH

3

4

1

2

SidePanel

5

6

SERVICE INFORMATION APPENDIX A-1IMS0002/0296

Conair has made the largest investment in customer support inthe plastics industry. Our service experts are available to helpwith any problem you might have installing and operatingyour equipment. Your Conair sales representative also can helpanalyze the nature of your problem, assuring that it did notresult from misapplication or improper use.

To contact Customer Service personnel, call:

From outside the United States, call: 814-437-6861

You can commission Conair service personnel to provide on-site service by contacting the Customer Service Department.Standard rates include an on-site hourly rate, with a one-dayminimum plus expenses.

If you do have a problem, please complete thefollowing checklist before calling Conair:

❒ Make sure you have all model, serial and parts listnumbers for your particular equipment. Servicepersonnel will need this information to assist you.

❒ Make sure power is supplied to the equipment.

❒ Make sure that all connectors and wires withinand between control systems and related components have been installed correctly.

❒ Check the troubleshooting guide of this manualfor a solution.

❒ Thoroughly examine the instruction manual(s)for associated equipment, especially controls.Each manual may have its own troubleshootingguide to help you.

❒ Check that the equipment has been operated asdescribed in this manual.

❒ Check accompanying schematic drawings for information on special considerations.

BEFORE YOU

CALL ...

HOW TO CONTACT

CUSTOMER

SERVICE

Additional manuals andprints for your Conairequipment may beordered through theCustomer Service orParts Departments fora nominal fee.

WE’RE HERETO HELP

APPENDIX A-2 WARRANTY INFORMATION IMS0003/0795

EQUIPMENTGUARANTEE

PERFORMANCEWARRANTY

WARRANTY

LIMITATIONS

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 normaluse and service for which it was recommended (except forparts that are typically replaced after normal usage, such as fil-ters, liner plates, etc.). Conair’s guarantee is limited to replac-ing, at our option, the part or parts determined by us to bedefective after examination. The customer assumes the cost oftransportation of the part or parts to and from the factory.

Conair warrants that this equipment will perform at or abovethe ratings stated in specific quotations covering the equipmentor as detailed in engineering specifications, provided theequipment is applied, installed, operated and maintained in therecommended manner as outlined in our quotation or specifi-cations.

Should performance not meet warranted levels, Conair at itsdiscretion will exercise one of the following options:

� Inspect the equipment and perform alterations oradjustments to satisfy performance claims. (Chargesfor such inspections and corrections will be waivedunless failure to meet warranty is due to misapplica-tion, improper installation, poor maintenance practicesor improper operation.)

� Replace the original equipment with other Conairequipment that will meet original performance claimsat no extra cost to the customer.

� Refund the invoiced cost to the customer. Credit issubject to prior notice by the customer at which time aReturn Goods Authorization Number (RGA) will beissued by Conair’s Service Department. Returnedequipment must be well crated and in proper operatingcondition, including all parts. Returns must be prepaid.

Purchaser must notify Conair in writing of any claim and pro-vide a customer receipt and other evidence that a claim isbeing made.

Except for the Equipment Guarantee and PerformanceWarranty stated above, Conair disclaims all other warrantieswith respect to the equipment, express or implied, arising byoperation of law, course of dealing, usage of trade or other-wise, including but not limited to the implied warranties ofmerchantability and fitness for a particular purpose.

DEFAULTPARAMETERS

Menu Parameter Description Setting UnitsInP TyPE Input sensor type rtd 100 ohm platinum RTD

Bias Bias 0SP.LL Lower setpoint limit 100 °FSP.HL Upper setpoint limit 400 °FI.FIL Filtering 0.5 Seconds

DSPL Dec.p Decimal position 0d.FIL Display filter 0.1 SecondsUnit Temperature units F FahrenheitBLAn Blanking OFF

OutP O1.tY Output 1 type ALrO1.AA Output 1 alarm action nor NormalO1.A0 Output 1 alarm operation norb Normal bandO1.dL Output 1 alarm delay 600 SecondsO1.1H Output 1 alarm inhibit 60 SecondsO1.SP Output 1 alarm setpoint ± 20° FahrenheitO2.tY Output 2 type PidO2.Ac Output 2 action rE Reverse actingO2.cY Output 2 cycle type 20 SecondsO2.LL Output 2 low power limit 0%O2.HL Output 2 high power limit 100%CtrL db.1 Deadband 1Pb2 Proportional band 2 22° FahrenheitdEr Derivative action - rate 22 SecondsOFFS Manual reset OFFInt Integral action (Auto Reset) 85 Seconds

aLr a1.aa Alarm 1 alarm action OFFa1.ao Alarm 1 alarm operation a1.dL Alarm 1 delaya1.IH Alarm 1 inhibita1.SP Alarm 1 setpointa2.aa Alarm 2 alarm action OFFa2.ao Alarm 2 alarm operation a2.dL Alarm 2 delaya2.IH Alarm 2 inhibita2.SP Alarm 2 setpoint

TunE dPnG Damping for autotuningr-s r.OPt Ramp to setpoint menu

The dryer will not operate correctly if certain factory-set parameters are changed. Parameters should be changed only by qualified technicalpersonnel who are familiar with the operation of this type of equipment.

If the dryer does not appear to be working correctly, verify the parame-ters against the list of factory settings.

For more detailed information about these parameters and returningparameters to the initial factory setup, See the SERIES 16CINSTRUCTION MANUAL included with this instruction package.

UGD018/0101 DEFAULT PARAMETERS APPENDIX B-1

DEFAULTPARAMETERS(CONTINUED)

Menu Parameter Description Setting UnitsSUPr F.S.01 Output 1 failsafe state

F.S.02 Output 2 failsafe stateL.br.t Loop Break time 240 SecondsHI.rd Highest ReadingLO.rd Lowest ReadingLd.dp Load default parameters

CAL CALo Low calibration operationCAHi High calibration operation

OPtn CArd Installed option card(s)

DEFAULT PARAMETERS UGD018/0101APPENDIX B-2

Standard Models CM100, 150, 200, 300 and 400 CM Carousel Dryer · Sop Drye CM -1 0 TYPICAL...

Documents

Transcript of Standard Models CM100, 150, 200, 300 and 400 CM Carousel Dryer · Sop Drye CM -1 0 TYPICAL...