WARNING - Reliance on this Manual Could Result in Severe...

WARNING - Reliance on this Manual Could Result in Severe...
WARNING - Reliance on this Manual Could Result in Severe Bodily Injury or Death!
This manual is out-of-date and is provided only for its technical information, data and capacities. Portions of this manual
detailing procedures or precautions in the operation, inspection, maintenance and repair of the product forming the subject
matter of this manual may be inadequate, inaccurate, and/or incomplete and cannot be used, followed, or relied upon.
Contact Conair at [email protected] or 1-800-654-6661 for more current information, warnings, and materials about
more recent product manuals containing warnings, information, precautions, and procedures that may be more adequate
than those contained in this out-of-date manual.
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USER GUIDE
UGD040-1006
ResinWorks
Central Drying and Conveying System
INTRODUCTION • Purpose of the User Guide • How the guide is organized • Your responsibilities as a user • ATTENTION:
Read this so no one gets hurt • How to use the lockout device • DESCRIPTION • What is the ResinWorks central
drying and conveying system? • Typical applications • How it works • Specifications: ResinWorks system •
INSTALLATION • Unpacking the boxes • Preparing for installation • Installation of the ResinWorks system • Connecting
the main power • Connecting the dryer to the ResinWorks • Connecting the conditioned air (if applicable) • Connecting
additional ResinWorks sleds • Connecting the ResinWorks distributions system to the plant-wide material distribution system • Connecting the loading system to the ResinWorks • Installing the optional setback RTD • Testing the installation
OPERATION • The ResinWorks system: DC control panel • ResinWorks DC control functions • Control function flow
charts • Control function descriptions • ResinWorks DC control alarms • Initial operation • Autotuning • Normal operation
Corporate Office: 412.312.6000 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861
Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.
It’s a good idea to record the model and serial number(s) of your equipment and
the date you received it in the User Guide. Our service department uses this information, along with the manual number, to provide help for the specific equipment
you installed.
Please keep this User Guide and all manuals, engineering prints and parts lists
together for documentation of your equipment.
Date:
Manual Number: UGD040-1006
Serial Number(s):
Model Number(s):
DISCLAIMER: The Conair Group, Inc., shall not be liable for errors contained in this User Guide or
for incidental, consequential damages in connection with the furnishing, performance or use of
this information. Conair makes no warranty of any kind with regard to this information, including,
but not limited to the implied warranties of merchantability and fitness for a particular purpose.
Copyright 2006 l The Conair Group l All rights reserved
Ta b l e o f C o n t e n t s
1-1 I n t r o d u c t i o n
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2-1 D e s c r i p t i o n
What is the ResinWorks central drying and conveying system? . . . .2-2
Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Specifications: ResinWorks system . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3-1 I n s t a l l a t i o n
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installation of the ResinWorks system . . . . . . . . . . . . . . . . . . . . . . . 3-4
Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Connecting the dryer to the ResinWorks . . . . . . . . . . . . . . . . . . . . . 3-6
Connecting the conditioned air (if applicable) . . . . . . . . . . . . . . . . . 3-8
Connecting additional ResinWorks sleds . . . . . . . . . . . . . . . . . . . . . 3-9
Connecting the ResinWorks central drying system to the
plant-wide material distribution system . . . . . . . . . . . . . . . 3-11
Connecting the loading system to the ResinWorks . . . . . . . . . . . . 3-12
Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Ta b l e o f C o n t e n t s l i
4-1 O p e r a t i o n
The ResinWorks system: DC control panel . . . . . . . . . . . . . . . . . . . 4-2
ResinWorks DC control functions. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control function flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control function descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
ResinWorks DC control alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Autotuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Normal operation to start processing . . . . . . . . . . . . . . . . . . . . . . 4-24
Normal operation to stop processing. . . . . . . . . . . . . . . . . . . . . . . 4-25
5-1 M a i n t e n a n c e
Preventative maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Cleaning the hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
6-1 Tr o u b l e s h o o t i n g
Before beginning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
DIAGNOSTICS
How to identify the cause of a problem . . . . . . . . . . . . . . . . . . . . . 6-4
Shut down alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Passive alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
REPAIR
Opening the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Checking process solid state relays . . . . . . . . . . . . . . . . . . . . . . . 6-11
Checking or replacing temperature sensors . . . . . . . . . . . . . . . . . 6-12
Replacing the process heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Replacing the air flow static pressure switch . . . . . . . . . . . . . . . . 6-14
i i l Ta b l e o f C o n t e n t s
A
Appendix
We’re here to help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
How to contact customer service . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Before you call... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Equipment guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Performance warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Warranty limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
B
Appendix
Installing the Optional Setback RTD . . . . . . . . . . . . . . . . . . . . . . . . B-1
Ta b l e o f C o n t e n t s l i i i
i v l Ta b l e o f C o n t e n t s
SECTION
1
Purpose of the user guide . . . . . . . . . . . . . . 1-2
How the guide is organized . . . . . . . . . . . . . 1-2
Yo u r r e s p o n s i b i l i t i e s a s a u s e r . . . . . . . . . . . 1 - 3
AT T E N T I O N :
Read this so no one gets hurt . . . . . . . . 1-4
How to use the lockout device . . . . . . . . . . . 1-5
Introduction l 1-1
1
Introduction
Introduction
Purpose of the User Guide
This User Guide describes the Conair ResinWorks conveying and preconditioning system 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.
1
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.
✒
✐
1-2 l Introduction
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.
Yo u r R e s p o n s i b i l i t y a s a U s e r
• Thorough review of this User Guide, paying particular attention
•
•
•
to hazard warnings, appendices, and related diagrams.
Thorough review of the equipment itself, with careful attention
to voltage sources, intended use, and warning labels.
Thorough review of instruction manuals for associated equipment.
Step-by-step adherence to instructions outlined in this User Guide.
Introduction l 1-3
1
Introduction
You must be familiar with all safety procedures concerning installation, operation and maintenance of this equipment. Responsible safety procedures include:
AT T E N T I O N :
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.
WA R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n , o r
servicing may result in equipment damage or
p e r s o n a l i n j u r y.
This equipment should be installed, adjusted, and serviced by qualified
technical personnel who are familiar with the construction, operation,
and potential hazards of this type of machine.
All wiring, disconnects, and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region.
Always maintain a safe ground. Do not operate the equipment at
power levels other than what is specified on the machine serial tag and
data plate.
WA R N I N G : Vo l t a g e h a z a r d
This equipment is powered by three-phase alternating current,
as specified on the machine serial tag and data plate.
A properly sized conductive ground wire from the incoming power
supply must be connected to the chassis ground terminal inside the
electrical enclosure (control center). 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 control center or performing non-standard operating procedures, such as routine maintenance. Only qualified personnel should
perform troubleshooting procedures that require access to the control
center while power is on.
1-4 l Introduction
How to Use the Lockout Device
ON
2 Isolate the equipment from the electric power. Turn the rotary
O OFF
1 Stop or turn off the equipment.
disconnect switch to the OFF, or “O” position.
3 Secure the device with an assigned lock or tag. Insert a lock or tag
in the holes to prevent movement.
ON
O OFF
4 The equipment is now locked out.
WARNING: Before removing lockout devices and returning switches to the
ON position, make sure that all personnel are clear of the machine, tools
have been removed, and all safety guards reinstalled.
To restore power to the heater, turn the rotary disconnect back to the ON position:
1 Remove the lock or tag.
O OFF
2 Turn the rotary disconnect switch to the ON or “ I ” position.
ON
Introduction l 1-5
1
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:
Introduction
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.
1-6 l Introduction
SECTION
2
W h a t i s t h e R e s i n Wo r k s c e n t r a l d r y i n g a n d
conveying system? . . . . . . . . . . . . . . . . 2-2
Ty p i c a l a p p l i c a t i o n s . . . . . . . . . . . . . . . . . . 2 - 3
How it works . . . . . . . . . . . . . . . . . . . . . . 2-4
S p e c i f i c a t i o n s : R e s i n Wo r k s s y s t e m . . . . . . . . 2 - 6
Description l 2-1
2
Description
Description
W h a t i s t h e R e s i n Wo r k s C e n t r a l
Drying and Conveying System?
ResinWorks is a central drying and conveying system for providing materials to
processing machines from a central area. The materials may be in a raw material state (straight from a silo, bin, or box) or they may be blended, dried, ground,
reclassified, etc. (preconditioned) before they are pneumatically transported to
the end use location; usually a processing machine throat.
Due to the wide variation in the ways that these systems can be configured, different instruction manuals must be referred to for a full understanding of all the
ResinWorks components.
2-2 l Description
Ty p i c a l A p p l i c a t i o n s
The ResinWorks central drying and conveying system is designed for applications requiring drying temperatures from 180 - 375°F (82.2 - 190.6°C).
Description l 2-3
2
Description
The ResinWorks can be used successfully in applications that require:
• The ability to dry multiple materials requiring different drying temperature
setpoints in a central drying system.
• The ability to easily take a hopper “off-line” for cleaning without shutting
down the entire central drying system.
• The ability to move the equipment to a central location for safety, energy
efficiency, and ease of maintenance.
H o w i t Wo r k s
The ResinWorks central drying and conveying system is comprised of multiple
components working together to deliver dry, multiple materials to meet various
production needs.
Dryer
The ResinWorks utilizes a central dryer to provide dessicated air to each hopper. The heaters at each hopper elevate the temperature for drying the specific
material in each hopper.
ResinWorks Sled
The ResinWorks sled serves as the support structure for all hoppers in the system. The supply and return air, as well as the dry air conveying manifolds are
integrated into the sled.
A control panel and air flow lever are located at each hopper station on the
ResinWorks sled . This allows each hopper to be controlled individually based
on the material in the hopper. The Enable/Standby switch and air flow lever
(On/Off control) allows each hopper to be isolated from the rest of the system
for cleaning without shutting down the entire system.
Hopper
The hoppers available with the ResinWorks system are insulated and made of
stainless steel. They have large, easy to open doors that allow for easy cleaning.
Automatic Bypass Valve
The automatic bypass valve allows each hopper to be taken “off line” without
having to manually adjust the air flow on any of the other hoppers.
Adjustable Purge Valve
The adjustable purge valve meters the materials entering the conveying air
stream for delivery to the destination. It also purges the line after delivery to
prevent cross-contamination of materials.
2-4 l Description
H o w i t Wo r k s
(continued)
Resin Selection Station
The resin selection station (material distribution center) allows the user to direct
the material from each hopper to any processing machine connected to the system. For example, the material from a specific hopper may need to be directed
to six separate processing machines. Each row in the material distribution center is fed by one of the specific hoppers.
How the ResinWorks Works
Central Dryer
ResinWorks Sled
Hopper
Automatic Bypass Valve
Adjustable Purge Valve
Resin Selection Station
3
4
1
2
6
5
Description l 2-5
2
Description
1
2
3
4
5
6
S p e c i f i c a t i o n s : R e s i n Wo r k s S y s t e m
R E S I N D RY I N G H O P P E R S A N D S TA N D S
MODEL
FIGURE NUMBER
RWH14-3
RWH18-6
RWH24-12
RWH24-18
RWH33-21
RWH33-28
RWH39-35
RWH39-42
RWH44-58
Fig. 1
Fig. 1
Fig. 1
Fig. 1
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 2
Performance characteristics
3 {85}
6 {170}
12 {340}
18 {509}
21 {595}
28 {793}
35 {991}
42 {1189}
58 {1643}
Capacity @ 35 lb/ft3 lb {kg}
Volume ft3 {liter}
105 {48}
210 {95}
420 {191}
630 {286}
735 {333}
980 {445}
1225 {556}
1470 {667}
2030 {921}
Capacity @ 52 lb/ft3 lb {kg}
156 {71}
312 {142}
624 {283}
936 {425}
1092 {495}
1456 {660}
1820 {826}
2184 {991} 3016 {1368}
Air inlet/outlet OD {mm}
2.5 {64}
2.5 {64}
2.5 {64}
2.5 {64}
5 {127}
5 {127}
5 {127}
5 {127}
5 {127}
Inside diameter OD {mm}
14 {356}
18 {457}
24 {610}
24 {610}
33 {838}
33 {838}
39 {991}
39 {991}
44 {991}
Material inlet
IT06
IT07
IT07
IT07
IT07
IT07
IT07
IT07
IT07
Material outlet ID {mm}
2 {51}
2 {51}
2 {51}
2 {51}
3 {76}
3 {76}
3 {76}
3 {76}
3 {76}
Material discharge (bottom)
IB02
IB02
IB02
IB02
IB02
IB02
IB03
IB03
IB03
Dimensions
inches {cm}
Standard sled
A - Overall height *
78.7 {200}
86.5 {219.7} 92.6 {235.2} 116.3 {295.4} 93.6 {237.8} 107.5 {273.1} 121.5 {308}
B - Height below mounting flange
29.3 {74.4}
25.6 {65.0}
C - Panel height
20.6 {52.3}
20.6 {52.3}
24 {61.0}
24 {61.0}
19.5 {50}
41.25 {104.8} 41.25 {104.8} 41.25 {104.8} 41.25 {104.8} 41.25 {104.8} 41.25 {104.8} 41.75 {106}
D - Sled width
25 {63.5}
E - Depth
25 {63.5}
36 {91.4}
36 {91.4}
45 {114.3}
45 {114.3}
51.25 {130.3} 51.25 {130.3} 51.25 {130.3} 51.25 {130.3} 51.25 {130.3} 51.25 {130.3}
132.5 {337} 138.5 {352}
19.5 {50}
14.5 {37}
41.75 {106} 41.75 {106}
69 {175.3}
69 {175.3}
74 {187.9}
59 {150}
59 {150}
64 {162}
SPECIFICATION NOTES:
*For multi-hopper sled, be sure to use the largest hopper as the reference for the height dimension.
Specifications can change without notice. Contact a Conair representative for the most current information.
Depending upon hopper requirements, ResinWorks drying systems may be configured with single-hopper sleds,
multiple-hopper sleds or a combination of both.
Multi-Hopper Sled
Figure 1
A
C
B
E
2-6 l Description
D
Hoppers that are 33 inches in diameter and
smaller may be joined together onto a single
sled and shipped as unit, installed as a unit
and connected into your drying system as a
single unit (see Figure 1). This consolidation
greatly saves time and expense and once connected to the proper central drying unit, provides an optimum dehumidification system
for all of your resins. Hoppers 39 inches and
over in diameter are provided on their own
individual floor stands (sleds) and each is
equipped with air connections, heater, control,
etc. (see Figure 2).
TPDS016-0606
S p e c i f i c a t i o n s : R e s i n Wo r k s S y s t e m
(continued)
R E S I N D RY I N G H O P P E R S A N D S TA N D S
Single-Hopper Sled
Figure 2
*A minimum
clearance of
42 inches
{107 cm} is
required.
C
B
E
D
Available Hopper Combinations
RWH Hopper Models
possible sled combinations
Figure 3
Sled Total Length
in. {mm}
ft. {cm}
45 {1143}
33
3.8 {116}
33
33
90 {2286}
7.5 {229}
33
33
24
126 {3200}
10.5 {320}
33
33
14/18
115 {2921}
9.6 {293}
33
24
70 {1778}
5.8 {177}
33
24
24
95 {2413}
7.9 {241}
33
24
14/18
14/18
131 {3327}
10.9 {332}
33
14/18
14/18
14/18
120 {3048}
10.0 {305}
24
24
24
36 {914}
3.0 {91}
72 {1829}
6.0 {183}
24
24
24
108 {2743}
9.0 {274}
24
24
14/18
97 {2464}
8.1 {247}
Use Figure 3 to identify the available hopper combinations that would be right for your operation, and
determine the overall width of each multi-hopper sled.
More specific dimensions for hoppers can be found
on the previous page, in the specifications table.
✐
24
24
14/18
14/18
122 {3099}
10.2 {311}
24
14/18
14/18
14/18
111 {2814}
9.3 {283}
NOTE: Conair 39 and 44 inch hoppers are mounted
25 {635}
2.1 {64}
on their own individual sleds. (see Fig.2).
50 {1270}
4.2 {128}
75 {1905}
6.3 {192}
100 {2540}
8.3 {253}
14/18
14/18
14/18
14/18
14/18
14/18
14/18
14/18
14/18
14/18
TPDS016-0606
Description l 2-7
2
Description
A
R e s i n Wo r k s S y s t e m O p t i o n s
Multiple Sled Connection Kit
This option allows the connection between multiple sleds for the integral supply, return and conveying manifolds. For each junction between sleds, a kit is
required.
Adjustable Purge Valve
New design! This valve controls material flow from material source to destination. This easy to clean and install valve has a discharge that rotates 360
degrees to allow complete purge of material lines.
Hopper Discharge Drain Port
Facilitates hopper draining and cleanout.
Precision Slidegate
Use the precision slidegate to prevent material leakage when no purge valve or
distribution box is specified on the hopper.
Communications
Options include: Modbus and DeviceNet.
Temperature Setback RTD
Automatically reduces the drying temperature to a lower standby mode when
the machine throughput is reduced or stopped to prevent overdrying of material.
2-8 l Description
SECTION
3
Installation
Unpacking the boxes . . . . . . . . . . . . . . . . . 3-2
Preparing for installation . . . . . . . . . . . . . . 3-3
I n s t a l l a t i o n o f t h e R e s i n Wo r k s s y s t e m . . . . . . 3 - 4
Connecting the main power . . . . . . . . . . . . . 3-5
C o n n e c t i n g t h e d r y e r t o t h e R e s i n Wo r k s . . . . 3 - 6
applicable) . . . . . . . . . . . . . . . . . . . . . . . . 3-8
C o n n e c t i n g a d d i t i o n a l R e s i n Wo r k s s l e d s . . . . 3 - 9
C o n n e c t i n g t h e R e s i n Wo r k s c e n t r a l d r y i n g
system to the plant-wide material
distribution system . . . . . . . . . . . . . . 3-11
Connecting the loading system to the
R e s i n Wo r k s . . . . . . . . . . . . . . . . . . . . 3 - 1 2
Te s t i n g t h e i n s t a l l a t i o n . . . . . . . . . . . . . . . 3 - 1 3
Installation l 3-1
3
Installation
Connecting the conditioned air (if
Unpacking the Boxes
The ResinWorks central drying and conveying system, depending on the model
and options ordered, could include:
✐
*Exception: For large hoppers
(24-18; 33-28), the “high hat”
will not be bolted in place due
to shipping constraints.
•
•
•
•
•
•
•
ResinWorks sled;
Hoppers (installed)*;
Purge valve(s);
Sled connection kit;
Dry air conveying connection kit;
2 hoses to connect the central dryer to the sled (supply and return air hoses);
Hose adapters (if required).
Other Equipment
•
•
•
•
•
Resin selection station;
Loaders/receivers;
Vacuum pump;
Dust collector;
Central loading control.
1 Carefully remove all components from their shipping containers.
2 Remove all packing material, protective paper, tape, and plastic.
3 Carefully inspect all components to make sure no damage occurred during
shipping, and that you have all the necessary hardware.
4 Take a moment to record serial numbers and electrical power specifications
in the blanks provided on the back of the the User Guide’s title page. The information will be helpful if you ever need service or parts.
5 You are now ready to begin installation. Follow the preparation steps on the
next page.
3-2 l Installation
Preparing for Installation
The ResinWorks system is easy to install if you select and prepare the installation area properly.
1 Make sure the mounting area provides:
❒ A grounded power source supplying the correct current for your
ResinWorks system. All ResinWorks systems require three-phase
power. Check the ResinWorks' serial tag for the correct amps, voltage,
and cycles. Field wiring should be completed by qualified personnel at
the planned location for the ResinWorks. All electrical wiring should
comply with your region's electrical codes.
systems will require separate
power drops for each sled.
✐
NOTE: If compressed air will be
used for the conveying air used
in conjunction with the
ResinWorks system, the compressed air system and hoses
are the responsibility of the
❒ Access to the plant's material and feed and delivery systems.
customer. No compressed air
hoses are supplied with the
ResinWorks system.
Installation l 3-3
3
❒ If applicable, close proximity to the Cargo Caire dry air generator
to be used with the ResinWorks system. Conair recommends using
the 3.0 inch flex hose supplied to make the connections between the
Cargo Caire conveying air system and the ResinWorks conveying air
manifolds.
NOTE: Multi-sled ResinWorks
Installation
❒ Close proximity to the central dryer to be used with the
ResinWorks system. Conair recommends using the hoses supplied
with the dryer to make the connections between the dryer's delivery
outlet and return air inlet and the ResinWorks delivery and return air
manifolds.
✐
I n s t a l l a t i o n o f t h e R e s i n Wo r k s
System
✐
CAUTION: You are responsible for the structural integrity of this installation.
NOTE: The ResinWorks is shipped with wooden supports bolted between the legs of the
unit to keep them from being damaged during shipping and to aid in moving the unit to
the installation location.
1 The bottom plates on the legs of the ResinWorks are bolted to the shipping
skid. Remove and discard the mounting bolts then remove all packing
materials from the ResinWorks and its components. DO NOT remove the
wooden supports bolted between the legs at this time. The wooden supports
stabilize the legs for transit and should be used to move the ResinWorks into its
installation location.
CAUTION: Do not remove the wooded supports until the sled has been installed in
its final location. Attempting to move the ResinWorks after the wooden supports
have been removed from the legs of the unit could allow damage to the legs during
movement.
2 Once the ResinWorks is in its installation location and properly positioned,
WARNING: Make sure the
unit has been properly
secured. The integrity of the
installation is the responsibility of the customer.
unbolt the wooden supports from the legs on the unit. Discard the wooden
supports and mounting hardware.
✐
NOTE: Conair recommends that you bolt the ResinWorks sled to the concrete
✐
floor.
NOTE: The bottom plates on the legs of the ResinWorks are designed to accept
either adjustable footpads for leveling or lag bolts for securing the unit to the factory floor. The footpads and/or mounting hardware are the responsibility of the
installer.
3-4 l Installation
C o n n e c t i n g t h e M a i n Po w e r
✐
IMPORTANT: Always refer
to the wiring diagrams that
came with your ResinWorks
before making electrical
connections.
NOTE: All components of the ResinWorks are pre-wired. The only electrical connection
that must be made is the main power connection. This does not include optional accessories such as valves and loaders.
1 Remove the two (2) screws securing the power connection cover on the
rear left corner of the ResinWorks.
✐
NOTE: Each sled will have a
main power connection.
2 Feed the main power cable into
the hole above the power connection cover. Secure the power
cable to the frame with an appropriate cord grip (customer supplied).
3 Connect the ground wire and
three main wires to the proper
terminals on the distribution
plate.
Cord Grip
Ground
Wire
4 Reinstall the power connection
cover using the original hardware.
Main
Wires
Installation l 3-5
3
Installation
2 Screws
IMPORTANT: Always refer
to the wiring diagrams that
came with your ResinWorks
before making electrical
connections.
Connecting the Dryer to the
R e s i n Wo r k s
CAUTION: Before connecting a dryer to the ResinWorks, make sure the dryer
is "phase corrected" and that the dryer's blower is turning in the correct direction. Refer to the manual supplied with your dryer for additional information.
✐
NOTE: The ResinWorks drying air delivery and return ports are 5 in. (127 mm) in diameter. If the
ports on the dryer are smaller or larger, install the necessary adapters (included if needed) on the
✐
ResinWorks so the hoses supplied with the dryer can be connected.
NOTE: An insulated
hose is not standard.
1 Connect one (1) of the supplied hoses to the drying air delivery inlet port of
the ResinWorks using the clamp supplied. If you have an insulated hose, it
should be installed on the delivery port.
✐
NOTE: The hoses supplied with the dryer can be cut if necessary for the installation.
2 Route the ResinWorks dryer air delivery
hose from Step 1 to the ResinWorks dry
air delivery inlet. Secure the hose to the
dryer outlet port using the hose clamp supplied.
✐
NOTE: Do not allow the
flexible hoses to kink or
Dryer Air
Delivery
Outlet
Dryer Return
Air Inlet
Dryer Return
Air Inlet
crimp.
ResinWorks
Dry Air Delivery
Inlet
ResinWorks
Return Air
Outlet
3-6 l Installation
Dryer Air
Delivery
Outlet
Typical Dryer
Connecting the Dryer to the
R e s i n Wo r k s ( c o n t i n u e d )
3 Connect the other supplied hose to the return air outlet of the ResinWorks
using the hose clamp supplied.
4 Route the ResinWorks return air hose from Step 3 to the dryer return air
inlet. Secure the hose to the dryer inlet port using the hose clamp supplied.
3
Installation
Installation l 3-7
Connecting the Conditioned Air (If
Applicable)
This section only applies if you have purchased the Cargo Caire dry air generator
option.
1 Connect the supplied 3 in. (76.2 mm)
hose to the conveying air inlet port of
the ResinWorks using the hose clamp
supplied.
✐
NOTE: Do not allow the
flexible hoses to kink or
crimp.
2 Route the ResinWorks conveying air hose to the conveying air source or an
optional Cargo Caire unit or central dryer. Secure the hose to the conveying
air source using the clamp hose supplied.
Conveying Air
Inlet Port
3-8 l Installation
C o n n e c t i n g A d d i t i o n a l R e s i n Wo r k s
Sleds
The ResinWorks can consist of as many as 20 hoppers, depending on the specifications of the customers order. This is accomplished by means of multiple
ResinWorks sleds. Follow the instructions below to connect additional
ResinWorks sleds.
✒
✐
It is best to have the larger hoppers close to the dryer. If you are adding a sled(s) to your system with large hoppers, and your current sled(s) has only smaller hoppers, the new sled should
be situated as the first sled in the system. Contact your Conair Sales Representative for additional information.
NOTE: The following instructions assume that the
main ResinWorks sled
has been set in the
installation location, the
main power connected,
the dryer connected,
and the conveying air
(if applicable) connected to the unit.
1 Remove the hardware securing
Drying Air
Manifold Cap
2 Align the drying air adapter manifold
adapter kit with the drying air manifold.
Secure the drying air adapter manifold to the
ResinWorks frame using the hardware
removed in Step 1 and the hardware supplied
with the adapter kit.
✐
NOTE: Apply a bead of high temperature silicone to one of the mating surfaces.
3 Remove the hardware securing the conveying air manifold cap to the right or
left side (based on your specific installation) of the ResinWorks frame. Remove
and discard the conveying air manifold cap.
Return Air
Outlet Port
✐
NOTE: Steps 3 and 4 are only
applicable if conveying
air is used in the system. If conveying air is
not used in the system,
proceed to Step 5.
(continued)
Installation l 3-9
3
Installation
the drying air manifold cap to the
right or left side (based on your
specific installation) of the
ResinWorks frame. Remove the
drying air manifold cap.
C o n n e c t i n g A d d i t i o n a l R e s i n Wo r k s
S l e d s (continued)
4 Align the conveying air adapter manifold with the conveying air manifold.
Secure the conveying air adapter manifold to the ResinWorks frame using the
hardware removed in Step 3 and the hardware supplied with the adapter kit.
✐
NOTE: Apply a bead of high temperature silicone to one of the mating surfaces.
5 Install additional ResinWorks sled(s) so that the side of the additional sled(s)
is approximately 1 to 2 ft (0.31 to 0.61 m) (minimum of 8 in. [203.2 mm]) from
the side of the main ResinWorks sled.
6 Using the hose and clamps supplied, connect the outlet of the drying air adapter
manifold on the main ResinWorks sled
to the drying air inlet on the second
ResinWorks sled.
7 Using the hose and clamps supplied, con-
✐
nect the outlet of the return air adapter manifold on the main ResinWorks
sled to the return air inlet on the second ResinWorks sled.
NOTE: Step 8 is only applicable if conveying air is
used in the system. If
conveying air is not
used in the system,
proceed to Step 9.
8 Using the hose and clamps supplied, connect the outlet of the conveying air
adapter manifold on the main ResinWorks sled to the conveying air inlet
on the second ResinWorks sled.
9 Follow the instructions given in Section 3.6 to connect the main power to
the second ResinWorks sled.
✐
NOTE: If additional sleds are to
be used, follow the
instructions in this section for each additional
sled.
3-10 l Installation
C o n n e c t i n g t h e R e s i n Wo r k s C e n t r a l
Drying System to the Plant-wide
Material Distribution System
Material Conveying Lines (from the Drying Hoppers)
Materials dried in the hoppers of your ResinWorks system need to be directed to the
final end use location. A wide variety of methods may be used for this transfer.
✐
NOTE: Do not allow the
flexible hoses to kink or
crimp.
The path of the material transfer lines from the drying hopper sled to the end use
location will vary depending upon the actual configuration of your system, but all
lines should be adequately supported against vibration, coupled with leak proof connectors, and routed with minimal bends.
Refer to both your system flow schematic and the appropriate additional instruction
manuals for more information regarding the material transfer system.
Installation l 3-11
3
Flex hose should be used for the connection at the base of the hopper to allow flexibility if/when removed. If supplied with your system, connection to the dry air manifold will have already been made. If not, then a flex hose connection to the dry air
manifold will also be required. All flex hose
connections should be as straight as possible and
secured with hose clamps. Double check that all
under-hopper components may be easily
removed for service before finalizing your installation.
Installation
The Resin Works Drying System is ideal for providing this transfer utilizing conveying air that is itself dry (with optional Cargo Caire), to assure that moisture will not
be regained in the transfer process. If your plan includes this dry air conveying
process, then the appropriate equipment for combining material from the drying hopper, mixing it with dry conveying air and then directing this air/material mix into the
conveying line is provided with your system. It may include a simple take-off box or
an adjustable purge valve (APV). Each module has its own operating characteristics,
but each mounts below the hopper and must be plumbed from its location towards
the material distribution system.
Connecting the Loading System to
t h e R e s i n Wo r k s
IMPORTANT: Always refer to
the wiring diagrams that
came with your heater before
making electrical connections.
The hoppers available with the ResinWorks system are designed to accept a variety
of loading systems. The lids supplied with the hoppers are designed to accept
either a 12-in. (304.8-mm) loader (all hoppers) and/or an 8-in. (203.2-mm) loader
(smaller hoppers only).
It is the responsibility of the installer to mount the loading system to the hoppers
on the ResinWorks and make all necessary power and control connections.
3-12 l Installation
✐
Te s t i n g t h e I n s t a l l a t i o n
NOTE: The installation can be
tested hopper by hopper, or all
You have completed the ResinWorks installation. Now it is time to make sure
everything works.
the hoppers at once. The decision is up to the installer.
1 Fill each hopper to at least the 50% level
ON
2 Turn on the main power.
50%
Level
O OFF
(green area of the site glass).
3 Turn on the dryer used with the
ResinWorks system.
the hopper to the "On" position.
5 Make sure the airflow valve is in the "Open" position (all the way up).
(continued)
Installation l 3-13
3
Installation
4 Turn the main power disconnect for
Te s t i n g t h e I n s t a l l a t i o n
(continued)
6 Set the set point temperature to 150°F (65.6°C). "Stand By" will appear in
the "Actual Temperature" window.
Actual Temperature
Window
7 Depress the Enable/Disable switch to
the "Enable" position.
8 Verify that the heaters turn on and
the actual temperature begins to rise
towards the set point temperature.
9 If you are testing each hopper separately, repeat Steps 4 through 8 for each
hopper in the ResinWorks system.
3-14 l Installation
SECTION
4
Operation
T h e R e s i n Wo r k s s y s t e m : D C c o n t r o l p a n e l . . . 4 - 2
R e s i n Wo r k s D C c o n t r o l f u n c t i o n s . . . . . . . . . 4 - 3
Control function flow charts . . . . . . . . . . . . 4-3
Control function descriptions . . . . . . . . . . . 4-7
Initial operation . . . . . . . . . . . . . . . . . . . 4-21
Autotuning . . . . . . . . . . . . . . . . . . . . . . . 4-22
Normal operation to start processing . . . . . 4-24
Normal operation to stop processing . . . . . . 4-25
Operation l 4-1
4
Operation
R e s i n Wo r k s D C c o n t r o l a l a r m s . . . . . . . . . . 4 - 2 0
T h e R e s i n Wo r k s S y s t e m : D C C o n t r o l Pa n e l
Increment/Decrement
Buttons
Used to increase or decrease values.
Setpoint
Display
Actual
Display
Shows the setpoint value.
Shows the actual
temperature value.
Heater
Enable/Standby
Scroll Button
Also is used to reset shut
down alarms (see
Troubleshooting”
Section 6) and to
“Autotune” the controller
(see “Autotuning”
Section 4).
Press to scroll
through the
closed loop menu
list. Pressing the
Scroll button
moves you down
the list.
Acknowledge Alarm Button
Under an alarm condition, push the
Acknowledge button once to display the
alarm message. Pushing the
Acknowledge button a second time
turns off the alarm LED.
4-2
l Operation
R e s i n Wo r k s D C C o n t r o l F u n c t i o n s
ResinWorks functions are values that you can set or monitor. Press the Scroll button until the function you want to set or monitor appears in the LED display.
Control Function Flow Charts
The following flow charts provide a quick summary of the control functions. For
an explanation of each control function, see Control Function Descriptions.
4
Operation
Operation l 4-3
POWER ON
(Default Screen)
1
888
888
2
v1.0
1.02 2 sec Software Version
3
rE
4
250
2 sec All LEDs On
Sin
250
Process Setpoint and Actual Temp (Default Screen)
Press + or - to change setpoint.
Press Scroll Button for Process Deviation Alarm Setpoint (Dev)
5
5
dEv
+ or - Deviation Band
Press + or - to change setpoint.
Press Scroll to enter the value
(The Following Shows Only If the Mode Is Set to Resin.)
Press Scroll Button again for Setback
Return Temperature Setpoint
(Optional)
6
180
Srt
Press + or - to change setpoint.
Press Scroll to enter the value
Press Scroll Button again for Process
Setback Temperature Setpoint
(Optional)
7
140
PSt
Press + or - to change setpoint.
Press Scroll to enter the value
Process Screens
Press Scroll Button and + key at the
same time for 2 sec to get in.
To get out at any time Press Scroll
button and - ket at the same time
2 min timer then return to the default screen.
8
PrO
cES
Press Scroll again to view next screen
9
250
Hi.L Process High Limit
Press Scroll again to view next screen
10
3
Lbb Process Loop Break Band
Press Scroll again to view next screen
11
10
Lbt
Process Loop Break Time
Press Scroll again to view next screen
12
250
H.AL Process High Alarm Setpoint
Press Scroll again to view next screen
13
50
Pb
Process Proportional Band
Press Scroll again to view next screen
14
16
int
Process Integral
Press Scroll again to view next screen
15
2
dEr
Process Derivative
Press Scroll again to view next screen
16
tun
OFF Process Autotune
Press + Key to Start Autotune
Press Scroll again to view next screen
17
F
unt
Units degrees F or degrees C
Press + Key to toggle between F and C
Press Scroll again to view the first screen
4-4
l Operation
Note:
To go from the Process
Screens directly to the
Setup Screens, press the
Scroll Button and the
+ key at the same time
for 10 sec.
Setback Screens
Gateway Communications Screens
Press Scroll Button and + key at the
same time again for 2 sec to get in.
Press Scroll Button and + key at the
same time for 10 sec to get in.
To get out at any time Press Scroll
button and - key at the same time.
To get out at any time Press Scroll
button and - key at the same time.
18
25
SEt
bAc
Add
rES
Press Scroll again to view next screen
Press Scroll again to view next screen
19
26
rEt
250
Return Temperature
0
500
Param. # for RTA Addr. 500
Press Scroll again to view next screen
20
10
bAn
Setback Return Band
Press Scroll again to view next screen
21
10
SLS
Setback Loadrate Setpoint
Press Scroll again to view next screen
22
Ldr
0
Loadrate Reading
Press Scroll again to view next screen
23
2
P.dL
Process Hi Switch Alarm Delay
Press Scroll again to view next screen
24
10
A.dL
Airflow Alarm Delay
Press Scroll again to view next screen
Operation l 4-5
4
(The following shows only if DC
Resin is installed.)
Operation
(The following shows only if DC
Resin is installed.)
Setup Screens
Test Mode Screens
(The following shows only if the
control is in Standby.)
Press Scroll Button and + key at the
same time for 10 sec to get in.
To get out at any time Press Scroll
button and - key at the same time.
27
SEt
uP
28
tyP
rES
Controller Type
Press Scroll again to view next screen
29
Prt
OFF Process Protection Install
Press Scroll again to view next screen
30
Stb
OFF Setback Install
Press Scroll again to view next screen
31
id
1
Communication ID
Press Scroll again to view next screen
32
tSt
OFF Goto Test Mode
Press Scroll again to view next screen
33
Ld.d
* The test mode screens become
visable if tSt (screen 40) is turned on.
To get out at any time Press Scroll
button and - key at the same time.
34
Press Scroll again to view next screen
Note:
Screen 29 (Process Protection Install)
MUST BE left in the OFF position since
it is not an option on ResinWorks
systems.
(The following shows only if the
control is in Test mode.)
OFF Load Default
Press + Key to Load Default
Press Scroll again to view the first screen
tE
St
Press Scroll again to view next screen
35
in.1
OFF Digital Input 1 Status
Press Scroll again to view next screen
36
in.2
OFF Digital Input 2 Status
Press Scroll again to view next screen
37
in.3
OFF Digital Input 3 Status
Press Scroll again to view next screen
38
in.4
OFF Digital Input 4 Status
Press Scroll again to view next screen
39
Ou.1
OFF Press + Key to Jog Output 1
Press Scroll again to view next screen
40
Ou.2
OFF Press + Key to Jog Output 2
Press Scroll again to view next screen
41
Ou.3
OFF Press + Key to Jog Output 3
Press Scroll again to view next screen
42
Ou.4
OFF Press + Key to Jog Output 4
Press Scroll again to view next screen
43
Ou.5
OFF Press + Key to Jog Output 5
Press Scroll again to view next screen
44
Ou.6
OFF Press + Key to Jog Output 6
Press Scroll again to view the first screen
4-6
l Operation
Control Function Descriptions
General Screens
Function
SCREEN 1
Once the power is turned on, this screen is
displayed for 2 seconds while the control
performs its self-checking process. All
LEDs are illuminated during this 2-second
interval.
888
888
SCREEN 2
v1.0
1.02
SCREEN 3
rE
Sin
250
SCREEN 5
5
dEv
This is the default screen. It shows the
process air temperature setpoint and the
actual temperature measured at the inlet to
the drying hopper. The “+/-” buttons can
be used to change the setpoint. Holding the
“+/-” buttons in will cause the number to
ramp up or down faster the longer the button is held. The display will return to the
default screen from anyplace in the menu
structure if nothing is done for 10 minutes.
This is the process deviation temperature
alarm setpoint screen. It is used to set the
deviation temperature band around the
process temperature setpoint. The range is
5 - 20°F (2.8 - 11.1°C). The “+/-” buttons
can be used to change the setpoint. If the
temperature goes outside the band, the
control will display a passive alarm (P1).
(continued)
Operation l 4-7
4
250
After the software version is displayed,
this screen appears for 2 seconds and identifies that the control is setup for a
ResinWorks system.
Operation
SCREEN 4
Setpoint
Actual
After the self-checking process is complete, this screen flashes for 2 seconds and
displays the software version.
Control Function Descriptions
✐
NOTE: Setback is optional.
General Screens
Function
SCREEN 6 (Optional)
First Setback screen (Setback Setpoint).
When setback is enabled, this is the hopper
outlet temperature at which the setback
becomes active.
180
Srt
SCREEN 7 (Optional)
140
4-8
l Operation
(continued)
PSt
Second Setback screen (Process Setpoint).
The process setpoint is the temperature the
control tries to maintain when functioning
in the setback mode.
Control Function Descriptions
Process Screens
(continued)
Function
To access the Process Screens, press the
“Scroll” and “+” buttons at the same time
and hold for two seconds . To get out of
the Process Screens at any time, press the
Scroll and “-” buttons at the same time.
After two minutes, you will be returned to
the Default screen.
SCREEN 8
PrO
cES
SCREEN 9
250
Hi.L
Lbb
Process Screens directly to
the Setup Screens (skipping over the Setback and
Gateway Communications
Screens), press the
"Scroll" and "+" buttons
at the same time and hold
for 10 seconds.
This is the process high limit screen. It is
used to set the high limit for the process
temperature setpoint. The “+/-” buttons
can be used to change this value. If set at
150 to 375°F (65.6 to 190.6°C), the operator cannot set the process setpoint above
250°F (121.1°C).
This is the process loop break band screen.
It is used to set the temperature band for
the loop break alarm. The “+/-” buttons
can be used to change the setpoint. If outside the deviation band, if the actual temperature does not move toward the setpoint
by this value in the time value in Screen
11, a loop break alarm will occur.
(continued)
Operation l 4-9
4
3
NOTE: To go from the
Operation
SCREEN 10
This is the process header screen. It indicates that all items below it pertain to the
process temperature control.
✐
Control Function Descriptions
Process Screens
Function
SCREEN 11
This is the process loop break time screen.
It is used to set the temperature band time
for the loop break alarm. The “+/-” buttons can be used to change the temperature
band time. If the actual temperature is
outside the deviation band and if the temperature is not moving toward the setpoint
at a rate greater than or equal to the value
in Screen 10 for the amount of time selected in this screen (sec.), then the heater will
alarm on loop break. Once the actual temperature is within the deviation band, the
loop break is ignored.
10
Lbt
SCREEN 12
250 H.AL
* These parameters will be
automatically adjusted
by the autotune procedures. Conair does not
recommend they be
adjusted individually.
SCREEN 13 *
50
Pb
SCREEN14 *
16
int
SCREEN 15 *
2
4-10 l Operation
(continued)
dEr
This is the process alarm high temperature
setpoint screen. It is used to set the temperature at which the process high temperature shutdown alarm (A1) will shutdown
the heater and display the alarm. The “+/-”
buttons can be used to change the setpoint.
This is the process proportional band
screen. It is used to change the proportional band value for the process control
loop. The “+/-” buttons can be used to
change the proportional band setpoint.
This is the process integral screen. It is
used to change the integral value for the
process control loop. The “+/-” buttons
can be used to change the integral value
setpoint.
This is the process derivative screen. It is
used change the derivative value for the
process control loop. The “+/-” buttons
can be used to change the derivative value
setpoint.
Control Function Descriptions
(continued)
Process Screens
Function
SCREEN 16
This is the process heater autotune screen.
(See page 4-22 for detailed information on
the autotune function.) The autotune procedure should be performed when setting
up the system the first time or if the control is inconsistent. Autotuning may take a
minute or so to complete. When finished,
the display will read “don”. The new PID
values are automatically saved (to screens
13, 14, and 15).
tun
OFF
SCREEN 17
F
unt
This is the temperature units screen. It is
used to change the ResinWorks controller
(temperature display) from °F to °C or °C
to °F.
Operation l 4-11
4
Operation
(continued)
Control Function Descriptions
Setback
Screens
SCREEN 18
SEt
bAc
SCREEN 19
rEt
250
(continued)
Function
To access the ResinWorks’ in setback
screens, press the Scroll and “+” buttons at
the same time and hold for two seconds
from the Process Screens (Screen 8). To
get out of the ResinWorks’ setback screens
at any time, press the Scroll and “-“ buttons at the same time.
This is the setback option setup screen. It
indicates that all items below it pertain to
the setback option.
This shows the actual return air temperature measured underneath the hopper in the
return air elbow.
SCREEN 20
10
bAn
SCREEN 21
10
4-12
l Operation
SLS
This shows the setback return band setting.
The value is used to determine when the
setback mode is disabled, once the dryer
has gone into the setback mode. This
example indicates a 10° band width, which
means when your hopper outlet temperature is 10° below your setpoint, the
ResinWorks will come out of setback
mode.
This is the setback load rate setpoint. (Not
available at this time.)
Control Function Descriptions
(continued)
Setback
Screens
Function
SCREEN 22
This is the load rate reading. (Not available
at this time.)
Ldr
0
SCREEN 23
2
P.dL
SCREEN 24
10
A.dL
This is the process heater alarm delay. It
is used to delay the process heater alarm.
This number is the delay time in seconds
that an alarm will occur on loss of process
heat.
This is the airflow alarm delay. It is used
to delay the airflow alarm. This number is
the delay time in seconds that an alarm
will occur on loss of airflow. (Not available at this time.)
Operation l 4-13
4
Operation
(continued)
Control Function Descriptions
(continued)
Function
Gateway
Communication
To access the ResinWorks' gateway comScreens
munications screens, press the Scroll and
"+" buttons at the same time and hold for
two seconds from the setback screens
(Screen 18). To get out of the ResinWorks'
gateway communications screens at any
time, press the Scroll and "-" buttons at the
same time.
SCREEN 25
Add
rES
SCREEN 26
10
A.dL
This is the gateway communications header screen. It indicates that all items below
it pertain to address registers for the communications gateway.
This screen and all the following address
screens show which internal parameters
are mapped to the customer communications area. Conair does not recommend
using this function unless instructed to by
a Conair Service Technician.
CAUTION: The setting on Screen 26
should not be changed without the
direction of Conair Service Personnel.
4-14
l Operation
Control Function Descriptions
Setup Screens
(continued)
Function
To access the setup screens, press the
Scroll and “+” buttons at the same time
and hold for ten seconds from the Gateway
Communications Screens. To get out of
the setup screens at any time, press the
Scroll and “-“ buttons at the same time.
SCREEN 27
SEt
uP
SCREEN 28
tyP
rES
OFF
Screen 30 (Optional)
Stb
OFF
Screen 31
id
1
Process Screens directly to
the Setup Screens (skipping over the Setback and
Gateway Communications
Screens), press the
"Scroll" and "+" buttons
This is the initial setup screen. It indicates
that all items below it pertain to the
ResinWorks setup.
at the same time and hold
for 15 seconds.
This screen indicates the hardware to the
controller. This controller can be setup to
control a dryer or a ResinWorks. This
should always be set to “rES” for a
Resinworks system.
This screen turns the process protection off
and on. This should always be set to OFF
for a ResinWorks system since process
protection is not an option with the
ResinWorks system.
This screen turns the setback “On” or
“Off”. The ResinWorks system is shipped
with function set to “On” if the setback
option is installed.
✐
NOTE: Screen 29 (Process
Protection) MUST BE left in
the OFF position since it is
not an option on
ResinWorks systems.
This screen allows the user to modify the
default device address. If multiple controllers are connected to a gateway or other
external device, the address may need to
be changed so that multiple controllers do
not have the same address.
(continued)
Operation l 4-15
4
Prt
NOTE: To go from the
Operation
SCREEN 29
✐
Control Function Descriptions
Setup Screens
Function
Screen 32
This screen lets you access the Test Mode.
To access the Test Mode screens, press "+"
button when you are in the test screen. To
get out of the test mode screens at any
time, press the Scroll and "-" buttons at the
same time.
tSt
CAUTION: The setting on
screen 33 should not be
changed without the direction of Conair Service
Personnel.
4-16
l Operation
(continued)
OFF
Screen 33
Ld.d
OFF
This screen returns the control board to the
factory default settings (not necessarily for
a specific model). Conair does not recommend using this function unless instructed
to by a Conair Service Technician.
Control Function Descriptions
Te s t M o d e
Screens
(continued)
Function
To access the Test Mode screens, press "+"
button when you are in the “Go To Test
Mode” screen (Screen 32). To get out of the
Test Mode screens at any time, press the
Scroll and "-" buttons at the same time.
SCREEN 34
tE
St
SCREEN 35 *
in.1
OFF
in.2
OFF
SCREEN 37
in.3
OFF
This screen shows the state of digital input 2.
If the input is open, "OFF" will be displayed.
If the input is closed, "ON" will be displayed. Digital input 2 on a ResinWorks
system is the heat on/off limit switch on the
valve handle. This switch is closed when the
handle in the "Heat" on position and open
when in the "Heat Off" position.
This screen shows the state of digital input 3.
If the input is open, "OFF" will be displayed.
If the input is closed, "ON" will be displayed. Digital input 3 on a ResinWorks
system is the optional load rate relay. The
relay is closed when the loader on top of the
drying hopper is loading and open when it is
(continued)
not loading.
Operation l 4-17
4
SCREEN 36
This screen shows the state of digital input 1.
If the input is open, "OFF" will be displayed.
If the input is closed, "ON" will be displayed. Digital input 1 on a ResinWorks
system is the process high temperature
switch. This switch is closed during normal
operation. It opens when it detects a high
temperature inside the process heater tube.
Operation
* See the supplied electrical drawings to associate instruments to
inputs.
This is the Test Mode screen. While in the
test mode, you can see the status of the
inputs and outputs and you can toggle the
outputs on or off by pressing the up and
down arrow keys on the control.
Control Function Descriptions
(continued)
Te s t M o d e
Screens
Function
SCREEN 38
This screen shows the state of digital input 4.
If the input is open, "OFF" will be displayed.
If the input is closed, "ON" will be displayed. Digital input 4 on a ResinWorks
system is not used.
in.4
OFF
* Outputs 1, 2, and 4 are not used
in the ResinWorks system.
SCREEN 39 *
Ou.1
OFF
SCREEN 40 *
Ou.2
OFF
SCREEN 41
Ou.3
OFF
SCREEN 41 *
Ou.4
4-18
l Operation
OFF
This screen shows the state of digital output
1. Press the + key to jog output 1. Output 1
on a ResinWorks system is not used.
This screen shows the state of digital output
2. Press the + key to jog output 2. Output 2
on a ResinWorks system is not used.
This screen shows the state of digital output
3. Press the + key to jog output 3. Output 3
on a ResinWorks system is the process
heater solid-state relay signal. Pressing the +
key will cause the process solid-state relays
to fire. Observe the solid-state relay LED to
check this output. Since the isolation contactor is open, the heater does not come on
because it does not have power.
This screen shows the state of digital output
4. Press the + key to jog output 4. Output 4
on a ResinWorks system is not used.
Control Function Descriptions
(continued)
Te s t M o d e
Screens
Function
SCREEN 42
This screen shows the state of digital output 5. Press the + key to jog output 5.
Output 5 on a ResinWorks system is the
process heater power isolation contactor
signal. Pressing the + key will cause the
isolation contactor to close. Watch the isolation contactor pull in to check this output. Since the solid-state relays are not on,
the heaters do not come on because they
do not have power.
ou.5
OFF
SCREEN 43
ou.6
OFF
Operation l 4-19
4
Operation
This screen shows the state of digital output 6. Press the + key to jog output 6.
Output 6 on a ResinWorks system is the
general alarm relay. Pressing the + key
will cause the relay to close. Observe the
relay LED to check this output.
R e s i n Wo r k s D C C o n t r o l A l a r m s
PASSIVE ALARMS
Passive alarms flash the alarm code and display process temperature until the
alarm condition goes away, or it becomes a shutdown alarm.
Code
P1
Description
Process Temperature Deviation
Alarm LED
Blinking Red
SHUTDOWN ALARMS
Shutdown alarms flash the alarm code and display process temperature. The
ResinWorks process air heaters should stop when the process temperature is below
150°F (65.6°C) but should still flash the alarm code until the Acknowledge Alarm
button is pressed. If the alarm condition is still active, the ResinWorks cannot
start. It will flash the alarm code again. If the alarm condition is not active, the
display should return to the normal default screen display and the ResinWorks is
ready to run.
Alarms place the control in “standby” mode. After the alarm is corrected and
acknowledged, cycle the heater Standby/Enable switch to “Standby” then back to
“Enable” to restart the process control.
Code
A1
A2
A3
A10
A39
4-20
l Operation
Description
Process High Temperature
Process Temperature Loop Break
Process Heater Tube High Temperature
RTD Integrity
EEProm Write Error-Internal Control
Alarm LED
Solid Red
Solid Red
Solid Red
Solid Red
Solid Red
Initial Operation
1 Hopper material: Fill the hopper with the material to be heated.
WARNING: Fire potential - The electric heating elements are exposed to the air
going into the hopper. It is important that there is no debris in this air stream. Under
no circumstances should the tube heater be run in a dirty air stream as material passing through the heater could ignite embers and shoot sparks into the hopper, which
could catch fire.
2 Auto tuning: When the unit is fully assembled and ready for operation, it
should be tuned to the actual system that it is connected to with material in the
hopper. Follow the auto tuning procedure detailed on page 4-22 of this manual.
3 Hopper residence time: The material throughput rate must be determined by
the size of the hopper, the drying time required, and the extent of drying desired
for the product (see page 4-20).
4
Operation
Operation l 4-21
Autotuning
✒ Tip: Conair recommends
that the autotune should
be run from a cold start.
The minimum temperature
difference between the
start temperature and the
autotune and setpoint temperature you will be running should be 50ºC
(122ºF).
Follow the procedure below to “Autotune” the ResinWorks system.
1 Use the selector switch and put the ResinWorks control into “Standby”.
2 Adjust the setpoint to a “Normal” setting.
3 Establish the normal operating air flow.
4 Access the Process menu by pressing and holding the Scroll and Plus
keys for 2 seconds until “Process” is displayed.
PrO
cES
5 Press the Scroll key until “Tune Off” is displayed.
tun
OFF
6 Press the Plus key and “Tune Set” is displayed. If the control remains on
Screen 8, the difference between the setpoint and the actual temperature is not
at least the required minimum.
tun
SEt
7 Enable the heater after the system stabilizes. The following will display
when autotuning starts.
tun
H.ru
8 When autotune is complete, “Tune Done” is displayed and the heater is
placed in the Standby mode.
tun
don
9 Note the “Pb”, “int”, and “dEr” values (Screens 13, 14, and 15).
4-22
l Operation
Autotuning
(continued)
10 To return to the normal control, cycle the heater to Standby and then
back to Enable.
11 If “Tune Error 1” is displayed, the autotune was not successful and the
process must be repeated. The most likely reason for this error is that the
difference between the starting temperature and the autotune temperature was not at least 50ºC (122ºF).
tun
Er.1
4
Operation
Operation l 4-23
N o r m a l O p e r a t i o n To S t a r t P r o c e s s i n g
1 Determine what the ResinWorks’ setpoint must be for your process and materials. Consult your material supplier.
2 Make sure there is material in the hoppers.
ON
3 Start the dryer connected to the ResinWorks system.
O OFF
4 Ensure the flow of conveying air (optional Cargo Caire) to the ResinWorks, if
supplied.
5 Turn on the main power to the ResinWorks. Make sure the ResinWorks disconnect dial is in the ON position. This powers up the control and the display lights will
illuminate.
6 Make sure the air flow valve is in the “Open” position (all the way up).
7 Set the processing temperature. Press the Adjust Setpoint ▲ or
the temperature.
Setpoint Adjust
Buttons
8 Move the heater switch to “Enable” to start heating.
4-24
l Operation
buttons to select
N o r m a l O p e r a t i o n To S t o p P r o c e s s i n g
1 Move the heater switch to “Standby”.
IMPORTANT: Always turn off the ResinWorks BEFORE the dryer.
Standby
Position
2 Allow the ResinWorks to cool to below 110°F (43.3°C).
3 Turn the air flow valve “Off” (all the way down).
4 Turn off the dryer and conveying air (Cargo Caire), if applicable.
5 Be sure to disconnect and lockout the main power if you have stopped the
IMPORTANT: Lockout the main power. It is also important to note that each hopper is
equipped with a lockout device.
CAUTION: Improper shut down can cause damage to your ResinWorks system.
Operation l 4-25
4
Operation
ResinWorks to perform maintenance or repair.
4-26
l Operation
SECTION
5
Maintenance
Preventative maintenance checklist . . . . . . . 5-2
Cleaning the hoppers . . . . . . . . . . . . . . . . . 5-3
5
Maintenance
Maintenance l 5-1
Preventative Maintenance
Checklist
The ResinWorks conveying and preconditioning system requires little maintenance. We recommend the following maintenance schedule and tasks.
• Whenever you change material or process
❒ Change the ResinWorks setpoint if it must be changed.
• Daily or weekly as needed
❒ Inspect the inlet and outlet hoses.
Tighten the hose clamps if loose. Replace the hose if worn or damaged.
❒ Inspect the filters on the central dryer (process and regeneration).
Clean or replace the filter as necessary.
• Monthly or as often as needed
❒ Inspect the main power wires, heater wires and conduit, and RTD
probe wires for damage and wear.
Replace any damaged or worn wire or conduit.
❒ Check for any damage to the control panel.
Replace if damaged.
❒ Check for damage to the heater.
Replace if damaged.
❒ Clean dirt from exterior surfaces with a cloth dampened with water.
5-2 l Maintenance
Cleaning the Hoppers
CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the dryer and drying hopper.
The hopper, spreader cone, and discharge assembly should be cleaned thoroughly
between material changes to prevent resin contamination.
1 Place a container beneath the hopper’s drain port to catch the material.
2 Close the hopper slide gate.
3 Disconnect the hoses and remove
the distribution box or adjustable
purge valve (APV) under the
hopper. Allow the remaining
material to drain into a bucket.
4 Remove the spreader cone. Open the hopper door.
(continued)
Maintenance l 5-3
5
Maintenance
Reach into the hopper. Grasp the spreader cone tube,
lift up slightly, twist and then push down to release it.
Tilt the cone assembly and pull it out through the hopper door.
C l e a n i n g t h e H o p p e r s (continued)
5 Clean the spreader cone and the inside
of the hopper. Make sure you also clean
the return air screen at the return air outlet
of the hopper.
6 Repeat the steps in reverse order to
reassemble the hopper before adding material.
5-4 l Maintenance
SECTION
6
Tr o u b l e s h o o t i n g
Before beginning . . . . . . . . . . . . . . . . . . . . 6-2
A few words of caution
. . . . . . . . . . . . . . 6-3
DIAGNOSTICS
How to identify the cause of a problem . . . . 6-4
Shut down alarms . . . . . . . . . . . . . . . . . . 6-5
Pa s s i v e a l a r m s
. . . . . . . . . . . . . . . . . . . . 6-7
R E PA I R
Opening the control panel . . . . . . . . . . . . . . 6-8
Replacing fuses . . . . . . . . . . . . . . . . . . . . 6-10
Checking process solid state relays . . . . . . 6-11
Checking or replacing temperature
Replacing the process heater . . . . . . . . . . 6-13
Replacing the air flow static pressure
switch . . . . . . . . . . . . . . . . . . . . . . . 6-14
Tr o u b l e s h o o t i n g l 6 - 1
6
Troubleshooting
sensors . . . . . . . . . . . . . . . . . . . . . . 6-12
Before Beginning
You can avoid most problems by following the recommended installation and
maintenance procedures outlined in this User Guide. If you do have a problem,
this section will help you determine what caused it and how to fix it.
Before you start disassembling the components of the ResinWorks conveying
and preconditioning system be sure to:
❏ Diagnose causes from the control panel.
1
Press the Acknowledge Alarm button to acknowledge the alarm.
2
3
4
Address the alarm message and fix the problem.
Move the heater switch from Enable to Standby.
Cycle the heater switch from Standby to Enable to restart normal control. If the alarm reappears the problem was not fixed.
If the alarm is a passive alarm you will see P in the screen title display.
If the alarm is a shut down alarm you will see A in the screen title
display.
Scroll
Button
6 - 2 l Tr o u b l e s h o o t i n g
Acknowledge
Alarm Button
Before Beginning
(continued)
❏ Find the wiring and equipment diagrams that were shipped with your ResinWorks. These
diagrams are the best reference for correcting a problem. The diagrams also will note any custom features, such as special wiring or alarm capabilities, not covered in this User Guide.
See warnings
below. Open the
control panel to
check fuses and
heater contactors.
A Fe w Wo r d s o f C a u t i o n
The ResinWorks conveying and preconditioning system is equipped with numerous safety devices.
Do not remove or disable them. Improper corrective action can lead to hazardous conditions and
should never be attempted to sustain production.
WARNING: Only qualified service personnel should examine and correct problems that require
opening the ResinWorks’ control panel or using electrical wires to diagnose the cause.
Tr o u b l e s h o o t i n g l 6 - 3
6
CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside of the
ResinWorks.
Troubleshooting
WARNING: High voltage. Always stop the ResinWorks, disconnect and lock out the main power
source before troubleshooting or performing repairs.
How to Identify the Cause of a
Problem
Most process malfunctions are indicated by an illuminated Alarm light on the
ResinWorks conveying and preconditioning system control panel.
A problem can trigger two types of alarms:
• Shut Down: The ResinWorks has automatically shut down because it detected a
serious problem that could damage your material or dryer.
• Passive: The ResinWorks continues to operate, but warns of a problem that
could prevent correct conveying and preconditioning of your material. If
ignored, this problem could lead to a condition that will shut down the system.
Alarm Light
Acknowledge Alarm
Button
When the alarm light is displayed:
1 Press the Acknowledge Alarm button to acknowledge the alarm.
2 Find the error message in the diagnostics table of this Troubleshooting
section.
3 Cycle the heater switch from Enable to Standby and then back to
Enable to clear and restart normal control. If the alarm reappears, the
problem was not fixed.
6 - 4 l Tr o u b l e s h o o t i n g
Shut Down Alarms
If the red Acknowledge Alarm LED is solid, the alarm is a shutdown alarm.
The ResinWorks will shutdown automatically to prevent damage to the
equipment or personnel.
Problem
Possible cause
Solution
A1 Process High
Temperature – If the process
temperature exceeds the
process high temperature setpoint, it shuts down the
ResinWorks. Defaults are set
to 385°F (196.1°C) for 20 sec.
The RTD temperature probe is not
installed correctly.
Make sure the RTD temperature probe
tip is in the center of the hopper inlet
tube.
The air lines are restricted or loose.
Straighten any crimps in the hoses.
Tighten any loose hoses.
SSR has failed.
Replace the SSR.
Output on the board has failed.
Replace the board.
Process RTD is loose or has fallen out.
Check the process RTD and tighten if
needed.
The process heater has failed.
Check the heater fuses, and resistance
across each leg of the process heater.
The air lines are restricted or loose.
Straighten any crimps in the hoses.
Tighten any loose hoses.
Output on the board failed “Open”.
Replace the board.
Drying or setback setpoint is too low.
Adjust the setpoint.
A2
Process Temperature
Loop Break – If the process
temperature is outside of the
operator entered deviation,
alarm band (see Process High
Temperature Deviation passive
alarm) and the process temperature is not moving
towards the setpoint at a rate
greater than specified. It shuts
down the dryer. Defaults are
set at 3°F (1.7°C) over 20 sec.
Tr o u b l e s h o o t i n g l 6 - 5
6
Troubleshooting
(continued)
Shut Down Alarms
(continued)
Problem
Possible cause
Solution
A3
There is an air flow blockage or loose
hoses.
Remove the blockage.
Process Heater High
Temperature – The snap switch
in the process heater tube
opens due to excessive temperature.
Tighten any loose hoses.
The isolation contactor failed in the
closed position.
Replace the isolation contactor.
The heater solid state relays (SSRs)
failed.
Replace the failed heater solid state
relays (SSRs).
No air flow or the airflow is reversed.
Turn on the blower.
Reverse the connection points of the
hoses.
Check the operation of the differential
pressure switch.
A10
RTD Integrity – If a
RTD is faulty.
A39
EEProm Write Error.
6 - 6 l Tr o u b l e s h o o t i n g
The connection for the RTD is loose.
Check the RTD plug connection and
tighten if needed.
The connection of the RTD plug on the
control board is loose.
Check the plug connection and tighten if
needed.
One of the RTDs has failed.
Replace the RTD.
The RTD is enabled but wired incorrectly.
Move the wires to the proper terminals
(see the wiring diagrams supplied with
the unit).
Internal control board problem.
Replace the control board.
Pa s s i v e A l a r m s
If the red Alarm LED is blinking, the alarm is a passive alarm. The heater continues to operate, but this problem could prevent correct heating of your material.
Note that once the Acknowledge Alarm button is pressed once, the blinking red
LED becomes solid. A passive alarm will go away when the alarm condition is
cleared.
Problem
Possible cause
Solution
P1
One of the solid state relays (SSRs) has
failed.
Replace the failed solid state relays
(SSR).
The process RTD is loose or has fallen
out.
Check the process RTD and tighten if
needed.
The air hose connections are loose.
Tighten all air hose connections.
The heater has failed.
Replace the failed heating element (see
page 6-13).
Process Temperature
Deviation – The process temperature exceeds the deviation
band as entered for the specified time. Default values are
10°F (6°C) for 5 sec.
6
Troubleshooting
Tr o u b l e s h o o t i n g l 6 - 7
IMPORTANT: Always refer
to the wiring diagrams that
came with your ResinWorks
to locate specific electrical
components. Illustrations in
the User Guide are intended
to be representative only.
ON
O p e n i n g t h e C o n t r o l Pa n e l
1 Lock-out the power with the main power disconnect switch.
✐
NOTE: If the main power disconnect switch is in the "On" position, the control panel
CANNOT be opened.
Locking
Screws
2 Turn the two locking screws 1/2
O OFF
turn counter clock-wise.
3 Pull the top of the control panel
away from the sled. The panel is
hinged on the bottom and opens out
towards the technician.
4 This gives access to all control circuit components including the:
• power disconnect;
• SSRs for the process heater;
• isolation contactor;
• fuses;
• high voltage transformer going from 460 V to 110 V;
• low voltage transformer (24 V) to power the control panel;
• relays;
• communications board (optional); and
• control panel.
6 - 8 l Tr o u b l e s h o o t i n g
O p e n i n g t h e C o n t r o l Pa n e l
High Voltage
Transformer
Low Voltage
Transformer
(continued)
Fuses
Isolation
Contactor
Solid State
Relays
Power
Disconnect
Control
Panel
6
Troubleshooting
Tr o u b l e s h o o t i n g l 6 - 9
ON
Replacing Fuses
O OFF
1 Disconnect and lockout the main power supply.
2 Open the control panel.
Fuse Blocks
To locate the appropriate fuse
and replacement part, refer to
the wiring diagrams that
came with your ResinWorks.
IMPORTANT: Always refer
to the wiring diagrams that
came with your ResinWorks
to locate specific electrical
components. Illustrations in
the User Guide are intended
to be representative only.
3 Check the fuse. If necessary, pull the fuse out and replace it with a fuse of the
same type and rating.
6 - 1 0 l Tr o u b l e s h o o t i n g
Checking Process Solid State
Relays
O OFF
1 Disconnect and lockout the main power supply.
ON
2 Open the control panel.
3 Locate the process solid state relays (SSRs). Refer to the wiring diagrams that
came with your ResinWorks.
4 Check the resistance using an ohmmeter.
Solid state relays
Check the resistance between
the terminal screws. If ohms
equal zero, replace the relays.
IMPORTANT: Always refer
to the wiring diagrams that
came with your ResinWorks
to locate specific electrical
components. Illustrations in
the User Guide are intended
to be representative only.
Terminal Screws
6
Troubleshooting
Tr o u b l e s h o o t i n g l 6 - 1 1
C h e c k i n g o r R e p l a c i n g Te m p e r a t u r e
Sensors
The ResinWorks process air heater uses RTD sensors to monitor the process temperature in the hoppers and the setback temperature (optional) in the return air
elbow.
IMPORTANT: Always refer
to the wiring diagrams
that came with your
ResinWorks to locate specific electrical components. Illustrations in the
User Guide are intended
to be representative only.
Typical location
of the Process
RTD at the
hopper inlet.
To check or replace an RTD sensor:
1 Disconnect and lockout the main power supply.
O OFF
ON
2 Locate the RTD sensors.
3 Check the sensor positions and conditions. Temperature readings will be
incorrect if the sensors are touching the wall of a component or if the sensor or
wiring is damaged. The tip of the sensor should be centered within its receptacle. Sensor wires should be attached to the appropriate connectors in the
ResinWorks’ wiring.
4 To check with an ohm meter, measure the resistance across the RTDs. The
resistance should be approximately 110 ohm at room temperature.
5 If an RTD sensor is found to be defective, replace the sensor. To replace the
sensor, locate the RTD wiring harness connector and disconnect the RTD harness
from the connector. Remove the RTD sensor from its mounting location.
6 Install the new RTD sensor by installing the RTD in its mounting location.
Route the RTD harness to its connector and plug the harness into the connector.
6 - 1 2 l Tr o u b l e s h o o t i n g
Replacing the Process Heater
ON
O OFF
1 Disconnect and lockout the main power.
2 Locate the heater wiring harness connector and disconnect the harness.
Heater Wiring Harness
IMPORTANT: Always refer
to the wiring diagrams
that came with your
ResinWorks to locate specific electrical components. Illustrations in the
User Guide are intended
to be representative only.
3 Note the orientation of the “hot”
and “cold” ends of the heater. The
new heater MUST be installed in
the same orientation. The heater
wires are on the “cold” end of the
heater.
Hot End
Cold End
4 Remove the hose clamps at both ends of the process heater. Pull the hoses
of both ends of the process heater. The process heater is now free.
5 Remove the hose clamps securing the insulation to the heater. Carefully
remove the insulation from the heater.
original hose clamps.
7 To install the new process heater, align the heater then slide the hoses
onto the heater. Secure the hoses to the heater using the original hose
clamps.
8 Route the process heater harness to its connection point and plug the harness into its connector.
Tr o u b l e s h o o t i n g l 6 - 1 3
6
Troubleshooting
6 Slide the insulation onto the new process heater and secure it using the
Replacing the Air Flow Static
Pressure Switch
ON
If the air flow static pressure switch fails to detect the pressure drop between the
heater inlet and ambient, it should be replaced.
O OFF
1 Stop the ResinWorks, disconnect and lockout the main
power.
2 The air flow static pressure switch is mounted to the inside of
the sled frame. Locate the pressure switch and trace the wiring harness to
its connection point. Unplug the pressure switch harness from its connector.
IMPORTANT: Always refer
to the wiring diagrams
that came with your
heater to locate specific
electrical components.
Illustrations in the User
Guide are intended to be
representative only.
3 After noting the correct connection point, disconnect the hose from the
high side port of the pressure switch. The low side port has no hose connected to it.
4 Remove and retain the screws
securing the pressure switch to the
sled frame. Remove the pressure
switch.
5 Align the new pressure switch with the mounting holes. Secure the new
pressure switch to the sled frame using the original mounting hardware.
6 Connect the hose to the same port from which it was removed.
7 Route the pressure switch wiring harness to the connection point. Connect
the harness to the pressure switch connector.
8 Test the system to insure that the new air flow static switch is detecting the
pressure drop between the heater inlet and ambient.
6 - 1 4 l Tr o u b l e s h o o t i n g
We ’ r e H e r e t o H e l p
Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have
installing and operating your equipment. Your Conair sales representative also
can help analyze the nature of your problem, assuring that it did not result from
misapplication or improper use.
How to Contact Customer Service
Additional manuals and prints for
your Conair equipment may be
ordered through the Customer
Service or Parts Department for a
nominal fee. Most manuals can
be downloaded free of charge
from the product section of the
Conair website.
www.conairnet.com.
To contact Customer Service personnel, call:
✐
NOTE: Normal operating hours are 8:00 AM - 5:00 PM. After hours emergency
service is available at the same phone number.
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.
B e f o r e Yo u C a l l . . .
If you do have a problem, please complete the following checklist before
calling Conair:
❒ Make sure you have all model, serial, and parts list numbers for your particular
equipment. Service personnel will need this information to assist you.
❒ Make sure power is supplied to the equipment.
❒ Make sure that all connectors and wires within and between control systems
and related components have been installed correctly.
❒ Check the troubleshooting guide of this manual for a solution.
❒ Thoroughly examine the instruction manual(s) for associated equipment, especially controls. Each manual may have its own troubleshooting guide to help you.
❒ Check that the equipment has been operated as described in this manual.
❒ Check accompanying schematic drawings for information on special considerations.
Appendix l A-1
Equipment Guarantee
Conair guarantees the machinery and equipment on this order, for a period as
defined in the quotation from date of shipment, against defects in material and
workmanship under the normal use and service for which it was recommended
(except for parts that are typically replaced after normal usage, such as filters,
liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part
or parts determined by us to be defective after examination. The customer assumes
the cost of transportation of the part or parts to and from the factory.
Pe r f o r m a n c e Wa r r a n t y
Conair warrants that this equipment will perform at or above the ratings stated in
specific quotations covering the equipment or as detailed in engineering specifications, provided the equipment is applied, installed, operated and maintained in the
recommended manner as outlined in our quotation or specifications.
Should performance not meet warranted levels, Conair at its discretion will
exercise one of the following options:
• Inspect the equipment and perform alterations or adjustments to satisfy
performance claims. (Charges for such inspections and corrections will be
waived unless failure to meet warranty is due to misapplication, improper
installation, poor maintenance practices or improper operation.)
• Replace the original equipment with other Conair equipment that will meet
original performance claims at no extra cost to the customer.
• Refund the invoiced cost to the customer. Credit is subject to prior notice by the
customer at which time a Return Goods Authorization Number (RGA) will be
issued by Conair’s Service Department. Returned equipment must be well crated
and in proper operating condition, including all parts. Returns must be prepaid.
Purchaser must notify Conair in writing of any claim and provide a customer receipt
and other evidence that a claim is being made.
Wa r r a n t y L i m i t a t i o n s
Except for the Equipment Guarantee and Performance Warranty stated
above, Conair disclaims all other warranties with respect to the equipment,
express or implied, arising by operation of law, course of dealing, usage of
trade or otherwise, including but not limited to the implied warranties of
merchantability and fitness for a particular purpose.
A-2 l Appendix
Installing the Optional Setback
RT D
ON
CAUTION: Always disconnect and lock out the main power sources before
making electrical connections. Electrical connections should be made only by
qualified personnel.
✐
O OFF
IMPORTANT: Always refer to the proper wiring diagram supplied with your
equipment before making electrical connections.
NOTE: The wiring for the optional setback RTD is pre-installed at the factory before
the ResinWorks system is shipped. It is located under the surface of the
ResinWorks sled at the left rear corner near the delivery air manifold.
1 Locate the existing wiring and connector for the setback RTD. It is located
under the surface of the ResinWorks sled at the left rear corner near the delivery
air manifold.
IMPORTANT: Always refer to the wiring diagrams that came with your
ResinWorks system to locate specific electrical components. Illustrations in the
User Guide are intended to be representative only.
2 Remove pipe plug from the return air elbow.
3 Insert the setback RTD probe into the
return air elbow. Center the end of the
probe so that the tip does not touch the
elbow walls. Tighten the nut to lock the
RTD in place.
(continued)
Appendix l B-1
Installing the Optional Setback
RT D ( c o n t i n u e d )
4 Plug the connector on the setback RTD wiring into the RTD connector.
5 Refer to page 4-7, ResinWorks Control Function Descriptions, and follow
the directions to "activate" the setback RTD on the control.
B-2 l Appendix
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