Conair 5000 User guide

U S E R G U I D E

U G D 0 3 5 - 0 3 1 1

Carousel Plus Dryer

W Series Models 600 through 5000 with DC-1 Controls www.conairgroup.com

Corporate Office: 724.584.5500 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: UGD035-0311

Serial Number(s):

Model Number(s):

See Screens 3 and 4 for Software Version

*Display Firmware Version:

✐ *Control Firmware Version:

* NOTE: Displayed upon initialization, during power up, or on a data tag inside the door.

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.

C o p y r i g h t 2 0 1 1 l T h e C o n a i r G r o u p l A l l r i g h t s r e s e r v e d

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

Using the Carousel Plus W Series as a central dryer . . . . . . . . . . . . 1-3

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

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

How to use the lockout device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2-1 D e s c r i p t i o n

What is the Carousel Plus W Series Dryer? . . . . . . . . . . . . . . . . . . .2-2

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

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

Specifications: Carousel Plus W Series Dehumidifying Dryer . . . . . . 2-7

Carousel Plus W Series Dehumidifying Dryer options . . . . . . . . . . . 2-8

3-1 I n s t a l l a t i o n

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

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

Positioning the dryer on the floor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Removing the cable tie from the desiccant wheel (W600-1000) . . . 3-4

Installing the regeneration exhaust cover . . . . . . . . . . . . . . . . . . . . 3-4

Installing the return air adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Installing the return air inlet and air outlet adapters (W1600-5000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Installing the overhead process air duct (W3200-5000) . . . . . . . . . 3-7

Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Ta b l e o f C o n t e n t s l i

Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Connecting the air hoses to a single hopper (W600-1000) . . . . . . 3-12

Connecting the air hoses to a single hopper (W1600-5000) . . . . . 3-13

Connecting the air hoses to a ResinWorks. . . . . . . . . . . . . . . . . . . 3-14

Connecting the dryer to the hopper . . . . . . . . . . . . . . . . . . . . . . . 3-15

Connecting the dryer to ResinWorks . . . . . . . . . . . . . . . . . . . . . . . 3-15

Connecting air hose adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Connecting the aftercooler and optional precooler (W600-1000) . . 3-17

Connecting the intercooler and optional precooler (W1600-5000) . 3-18

Mounting a loader on the hopper . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

4-1 O p e r a t i o n

Carousel Plus W Series Dryer: control panel DC-1 . . . . . . . . . . . . . . 4-2

Carousel Plus W Series Dryer DC-1 control functions . . . . . . . . . . . 4-3

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

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

To start drying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

To stop drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Using the auto start countdown function . . . . . . . . . . . . . . . . . . . . 4-17

How to disable the auto start on the DC-1 control. . . . . . . . . . . . . 4-17

Using the dewpoint monitor and dewpoint control. . . . . . . . . . . . . 4-18

5-1 M a i n t e n a n c e

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

Checking the dewpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

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

Cleaning the process filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 i i l Ta b l e o f C o n t e n t s

Cleaning the regeneration filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Cleaning the aftercooler/intercooler coils. . . . . . . . . . . . . . . . . . . . . 5-9

Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Cleaning the volatile trap on the demister . . . . . . . . . . . . . . . . . . . 5-11

Inspecting hoses and gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

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

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Dewpoint troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Poor material drying troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 6-18

REPAIR

Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Checking heater solid state relays. . . . . . . . . . . . . . . . . . . . . . . . . 6-24

Checking or replacing temperature sensors . . . . . . . . . . . . . . . . . 6-25

Replacing the regeneration heater (W600-1000) . . . . . . . . . . . . . . 6-26

Replacing the regeneration heater (W1600-2400) . . . . . . . . . . . . . 6-28

Replacing the regeneration heater (W3200-5000) . . . . . . . . . . . . . 6-30

Replacing the desiccant wheel assembly (W600-1000). . . . . . . . . 6-32

Replacing the desiccant wheel motor (W600-1000) . . . . . . . . . . . 6-34

Replacing the desiccant wheel motor (W1600-5000) . . . . . . . . . . 6-35

Ta b l e o f C o n t e n t s l i i i

A A p p e n d i x

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 A p p e n d i x

Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

C A p p e n d i x

Cleaning the volatile trap on the demister (W600-1000) . . . . . . . . C-1

Cleaning the volatile trap on the demister (W1600-3200) . . . . . . . C-2 i v l Ta b l e o f C o n t e n t s

I n t r o d u c t i o n

P u r p o s e o f t h e u s e r g u i d e . . . . . . . . . . . . . . 1 - 2

H o w t h e g u i d e i s o r g a n i z e d . . . . . . . . . . . . . 1 - 2

U s i n g t h e C a r o u s e l P l u s W S e r i e s a s a c e n t r a l d r y e r . . . . . . . . . . . . . . . . 1 - 3

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 :

R e a d t h i s s o n o o n e g e t s h u r t . . . . . . . . 1 - 4

H o w t o u s e t h e l o c k o u t d e v i c e . . . . . . . . . . . 1 - 6

S E C T I O N

1

I n t r o d u c t i o n l 1 - 1

1 - 2 l I n t r o d u c t i o n

P u r p o s e o f t h e U s e r G u i d e

This User Guide describes the Conair Carousel Plus W Series Dryer 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.

H o w t h e G u i d e i s O r g a n i z e d

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.

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.

U s i n g t h e C a r o u s e l P l u s W S e r i e s a s a C e n t r a l D r y e r

The Conair Carousel Plus W600-5000 Series Dryers are factory configured to be used as central dryers only. Therefore, this manual incorporates the information necessary to use these dryers for central drying applications.

Yo u r R e s p o n s i b i l i t y a s a U s e r

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

•

Thorough review of this User Guide, paying particular attention to hazard warnings, appendices and related diagrams.

•

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

•

Thorough review of instruction manuals for associated equipment.

•

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

I n t r o d u c t i o n l 1 - 3


AT T E N T I O N :

R e a d t h i s s o n o o n e g e t s h u r t

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.

W A 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 s e r v i c i n g m a y r e s u l t i n e q u i p m e n t d a m a g e o r 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.

W A R N I N G : V o 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. Improper grounding can result in severe personal injury and erratic machine operation.

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

(continued)

AT T E N T I O N :

R e a d t h i s s o n o o n e g e t s h u r t

( c o n t i n u e d )

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.

C A U T I O N : H o t S u r f a c e s .

Always protect yourself from hot surfaces inside the dryer and hopper.

Also exercise caution around exterior surfaces that may become hot during use. These include the hopper door frame, the exterior of an uninsulated hopper, the return air hose and the dryer’s process filter housing and moisture exhaust outlet.

W A R N I N G : D o n o t p l a c e a e r o s o l , c o m p r e s s e d g a s o r f l a m m a b l e m a t e r i a l s o n o r n e a r t h i s e q u i p m e n t .

The hot temperatures associated with the drying process may cause aerosols or other flammable materials placed on the dryer or hopper to explode.

I n t r o d u c t i o n l 1 - 5


H o w t o U s e t h e L o c k o u t D e v i c e

CAUTION: Before performing maintenance or repairs on this product, you should disconnect and lockout electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity.

Lockout is the preferred method of isolating machines or equipment from energy sources. Your Conair product is equipped with the lockout device pictured below.

To use the lockout device:

1 Stop or turn off the equipment.

2 Isolate the equipment from the electric power. Turn the rotary 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.

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 dryer, turn the rotary disconnect back to the ON position:

1 Remove the lock or tag.

2 Turn the rotary disconnect switch to the ON or “ I” position.

D e s c r i p t i o n

W h a t i s t h e C a r o u s e l P l u s W S e r i e s D r y e r ? . . 2 - 2

Ty p i c a l a p p l i c a t i o n s . . . . . . . . . . . . . . . . . . 2 - 2

H o w i t w o r k s . . . . . . . . . . . . . . . . . . . . . . 2 - 4

S p e c i f i c a t i o n s : C a r o u s e l P l u s W S e r i e s

D e h u m i d i f y i n g D r y e r . . . . . . . . . . . . . . . 2 - 7

C a r o u s e l P l u s W S e r i e s D e h u m i d i f y i n g

D r y e r o p t i o n s . . . . . . . . . . . . . . . . . . . 2 - 8

S E C T I O N

2

D e s c r i p t i o n l 2 - 1

W h a t i s t h e C a r o u s e l P l u s W S e r i e s

D r y e r ?

The Carousel Plus W Series dehumidifying dryer produces low-dewpoint air that removes moisture from hygroscopic plastics. The dryer pulls moist air from a drying hopper and circulates it through a dehumidifying desiccant wheel. The dryer then circulates the air through the material in the hopper.

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

✐

NOTE: The W600 - 5000 provides no heat to the process air. A separate heat source is required at the hopper(s) inlet to heat the air to the desired drying temperature.

Ty p i c a l A p p l i c a t i o n s

1 Dryer on the floor, single hopper (with HTC Hopper Temperature Control package) on a floor stand.

2 Dryer on the floor, multiple hoppers in central configuration (ResinWorks) with separate heat source for each hopper.

The Carousel Plus W Series Dryer can be used successfully in applications that require:

• A contamination-free drying environment.

• A constant flow of dehumidified air.

(continued)

2 - 2 l D e s c r i p t i o n

Ty p i c a l A p p l i c a t i o n s

( c o n t i n u e d )

Model

Low temperature (with precooler)*

Standard

High heat (with aftercooler/intercooler)*

Drying Temperature Range

100° - 150°F {38° - 66°C}

150° - 240°F {66° - 116°C}

150° - 375°F {66° - 191°C}

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

* See page 3-17, 3-18 and Appendix B

• Throughput rates of 600 to 5000 lbs {271 to 454 kg} per hour (some materials can be ran at a higher rate).

• Dewpoints of -40°F {-40°C}.

Use the aftercooler/intercooler when:

• You are drying at temperatures over 240°F {116°C}.

• Throughput rates are less than 50% of the dryer’s rated capacity.

• You are pre-drying material at temperatures over 150°F {66°C}

• The return air is 120°F {49°C} or above.

✐

NOTE: The aftercooler/intercooler reduces the temperature of air returning from the drying hopper, improving the efficiency of the desiccant.

Dryer Options

• Dewpoint monitor/dewpoint control

• Audible and visual alarm

✐

NOTE: Temperature setback is only available in conjunction with the Hopper Temperature

Controller (HTC) or ResinWorks systems.

✐

NOTE: Carousel Plus W Series 600-1000 Dryers use an aftercooler located before the the process blower. Carousel Plus W Series 1600-5000 uses an intercooler located after the process blower.

D e s c r i p t i o n l 2 - 3


H o w I t W o r k s

The Process (Drying) Cycle

(W600 - 1000)

Process air from the hopper is pulled into the dryer, through the process filter and then into the process blower inlet. Air exits the process blower and then enters the aftercooler, then passes through the desiccant wheel, where moisture is removed.

The air exits the dryer and passes through the precooler (if installed), then into the process heat source (HTC or CGT Gas Unit). After the air exits the process heat source it then goes into the hopper inlet, then to the spreader cone, which evenly distributes the air through the material.

The Process (Drying) Cycle

(W1600 - 5000)

Process air from the hopper is pulled into the dryer, through the process filter and then into the process blower inlet. Air exits the process blower and then enters the intercooler, then passes through the desiccant wheel, where moisture is removed.

The air exits the dryer and passes through the precooler (if installed), then into the process heat source (HTC or CGT Gas Unit). After the air exits the process heat source it then goes into the hopper inlet through internal piping, then to the spreader cone, which evenly distributes the air through the material.

The Regeneration Cycle

The regeneration blower pulls air through the regeneration filter into the dryer’s regeneration heater. The air is heated to 350°F {177°C} before it is pushed into the

“wet” section of the desiccant wheel. The hot air purges moisture from the desiccant. The moist air is blown out the moisture exhaust at the top of the dryer.

The Cooling Cycle

(All models except W2400 and 5000)

Regenerated desiccant must be cooled before it rotates back into the process cycle.

The process blower pushes the process air through the desiccant wheel. A small amount of the process air is diverted through a small section of the desiccant wheel to cool the air. The cooling air then returns back to the process air stream at the start of the process cycle.


( c o n t i n u e d )

( W 6 0 0 - 1 6 0 0 a n d 3 2 0 0 )

W-series 600-1000 aftercooler location.

**********************

W-series 1600-5000 intercooler location only.

**********************

✐

NOTE: Earlier W1600-5000 dryers will have their intercoolers in the W600-

1000 location.

✐

NOTE: Carousel Plus W Series 600-1000 Dryers use an aftercooler located before the the process blower. Carousel Plus W Series 1600-5000 dryers use an intercooler located after the process blower.

D e s c r i p t i o n l 2 - 5


( c o n t i n u e d )

( W 2 4 0 0 a n d 5 0 0 0 )

Power Purge

W 2400 and 5000 models have a Power Purge (cooling fan) feature integral to the desiccant wheel assembly.

✐

NOTE: Carousel Plus W Series 600-1000 Dryers use an aftercooler located before the the process blower. Carousel

Plus W Series 1600-5000 dryers use an intercooler located after the process blower.

Protected under

United States Patent

No. 7,101,414 and other US and Foreign

Patents Pending.


.

S p e c i f i c a t i o n s : C a r o u s e l P l u s W

S e r i e s D e h u m i d i f y i n g D r y e r s

A

B

MODELS W600 *

Performance characteristics (with full hopper)

Drying temperature

Dewpoint

Dimensions inches {cm}

A - Height

B - Width

C - Depth

Outlet/inlet hose diameter

Approximate weight lbs {kg}

Installed

Shipping

Voltage - Full load amps

400 V/3 phase/50 Hz †

460 V/3 phase/60 Hz

575 V/3 phase/60 Hz

1300 {590}

1495 {678}

37.2

32.0

25.6

W800 *

92.6 {235.2}

43.3 {109.9}

57.6 {146.3}

8 {20.3}

1300 {590}

1515 {687}

37.2

32.0

25.6

W1000 *

C

W1600 * †† W2400 * †† W3200 * †† W5000 * ††

All models 100 - 375°F {38 - 191°C} with options

All models -40°F {-40°C}

1400 {636}

1515 {687}

37.5

32.2

25.7

Water requirements {for aftercooler/intercooler or optional precooler} §

Recommended temperature

**

Water flow gal./min. {liters/min.} 6-25 {22.7-94.6}

Water connections NPT

64.7

56.3

45.0

95.5 {242.6}

48.3 {122.7}

86.2 {218.9}

12 {30.5}

1600 {726}

2100 {953}

45° - 85°F {7- 29}

12-40 {45.4-151.4}

1 1/2 in. NPT

1600 {726} 2000 {907} 2000 {907}

2620 {1188} 3385 {1535} 3385 {1535}

73.7

63.1

50.5

122.3

106.6

85.3

102.8 {261.1}

48.9 {124.2}

112.0 {284.5}

12 {30.5}

128.0

111.0

89.1

15-50 {56.8-189.3}

SPECIFICATION NOTES:

* Dryers W600-W5000 are central dryers and do not have process heaters. Hopper Temperature Controllers (HTC’s) or ResinWorks systems are used at the hopper for heating the process air. See the Hopper Temperature Controller (HTC) specification sheet for additional information.

†

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

‡ Total kW listed at a regeneration temperature of 350°F {177°C}.

§ When drying below 150 °F {66°C} a precooler is required. When drying above 180°F {82°C} an aftercooler/intercooler and insulated drying hose is required.

** Temperatures above or below the recommended levels may affect dryer performance. Tower, chiller or municipal water sources can be used.

††

Models W1600-5000 do not have casters.

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

TPDS019-0311-REV

D e s c r i p t i o n l 2 - 7


C a r o u s e l P l u s W S e r i e s

D e h u m i d i f y i n g D r y e r O p t i o n s

• Volatile trap (only in conjunction with aftercooler/intercooler) - The volatile trap is recommended if drying materials that produce volitales that condense into a waxy or oily residue and/or if the material contains excessive fines.

• Precooler - The precooler reduces the temperature of air after the desiccant wheel and before the process heater, which enables the dryer to control temperatures at low setpoints, (100º - 150ºF {38º - 66ºC})

• Filter check - The filter check sensor will activate a passive alarm when the process filter is clogged or needs to be replaced.

✐

NOTE: Temperature setback is only available in conjunction with the Hopper Temperature

Controller (HTC) or the ResinWorks system.

I n s t a l l a t i o n

U n p a c k i n g t h e b o x e s . . . . . . . . . . . . . . . . . 3 - 2

P r e p a r i n g f o r i n s t a l l a t i o n . . . . . . . . . . . . . . 3 - 3

P o s i t i o n i n g t h e d r y e r o n t h e f l o o r . . . . . . . . . 3 - 4

R e m o v i n g t h e c a b l e t i e f r o m t h e d e s i c c a n t w h e e l ( W 6 0 0 - 1 0 0 0 ) . . . . . . . . 3 - 4

I n s t a l l i n g t h e r e g e n e r a t i o n e x h a u s t c o v e r . . . 3 - 4

I n s t a l l i n g t h e r e t u r n a i r a d a p t e r . . . . . . . . . . 3 - 5

I n s t a l l i n g t h e r e t u r n a i r i n l e t a n d a i r o u t l e t a d a p t e r s ( W 1 6 0 0 - 5 0 0 0 ) . . . . . . . . . . . . 3 - 6

I n s t a l l i n g t h e O v e r h e a d P r o c e s s A i r D u c t

( W 3 2 0 0 - 5 0 0 0 ) . . . . . . . . . . . . . . . . . . . 3 - 7

C o n n e c t i n g t h e m a i n p o w e r . . . . . . . . . . . . . 3 - 8

C h e c k i n g f o r p r o p e r a i r f l o w . . . . . . . . . . . . 3 - 9

C o n n e c t i n g t h e a i r h o s e s t o a s i n g l e h o p p e r ( W 6 0 0 - 1 0 0 0 ) . . . . . . . . . . . . . . 3 - 1 2

C o n n e c t i n g t h e a i r h o s e s t o a s i n g l e h o p p e r ( W 1 6 0 0 - 5 0 0 0 ) . . . . . . . . . . . . . 3 - 1 3

C o n n e c t i n g t h e a i r h o s e s t o a

R e s i n W o r k s . . . . . . . . . . . . . . . . . . . . 3 - 1 4

C o n n e c t i n g t h e d r y e r t o t h e h o p p e r . . . . . . 3 - 1 5

C o n n e c t i n g t h e d r y e r t o R e s i n W o r k s . . . . . . 3 - 1 5

C o n n e c t i n g a i r h o s e a d a p t e r s . . . . . . . . . . 3 - 1 6

C o n n e c t i n g t h e a f t e r c o o l e r a n d o p t i o n a l p r e c o o l e r ( W 6 0 0 - 1 0 0 0 ) . . . . . . . . . . . . 3 - 1 7

C o n n e c t i n g t h e i n t e r c o o l e r a n d o p t i o n a l p r e c o o l e r ( W 1 6 0 0 - 5 0 0 0 ) . . . . . . . . . . . 3 - 1 8

M o u n t i n g a l o a d e r o n t h e h o p p e r . . . . . . . . 3 - 1 9

Te s t i n g t h e i n s t a l l a t i o n . . . . . . . . . . . . . . . 3 - 1 9

S E C T I O N

3

I n s t a l l a t i o n l 3 - 1

3 - 2 l I n s t a l l a t i o n

U n p a c k i n g t h e B o x e s

The Carousel Plus W Series Dryer comes in one to four boxes, depending on the model and options ordered. The box(es) could include (depending on the options selected):

• Carousel Plus W Series Dryer

• Delivery air hose

• Return air hose

• User Guide

1 Carefully remove the dryer and components from their shipping container(s). Note that the dryer is secured to its shipping container with metal bands that pass through the bottom of the dryer frame.

2 Unbolt any additional items secured to the shipping pallet, such as the regeneration exhaust cover and return air adapter. (Carousel Plus W Series

1600-2400 Dryers will have a dry air delivery adapter. Carousel Plus W Series

3200-5000 Dryers will have a dry air delivery adapter and an overhead process air duct.)

3 Remove all packing material, protective paper, tape, and plastic.

4 Cut and remove the desiccant wheel tie securing the wheel assembly.

(W600-1000)

5 Carefully inspect all components to make sure no damage occurred during shipping, and that you have all the necessary hardware.

U n p a c k i n g t h e B o x e s

( c o n t i n u e d )

6 Take a moment to record serial numbers and electrical power specifications in the blanks provided on the back of the User Guide’s title page. The information will be helpful if you ever need service or parts.

7 You are now ready to begin installation.

Follow the preparation steps on the next page, then choose one of the two

✐ mounting options:

• Dryer on the floor, single hopper (with HTC Hopper Temperature Control package) on a floor stand.

• Dryer on the floor, multiple hoppers in central configuration (ResinWorks) with separate heat source for each hopper.

NOTE: The W600 - 5000 provides no heat to the process air. A separate heat source is required at the hopper(s) inlet to heat the air to the desired drying temperature .

P r e p a r i n g f o r I n s t a l l a t i o n

The Carousel Plus W Series Dryer is easy to install if you plan the location and prepare the mounting area properly.

✒

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

1 Make sure the mounting area provides:

❒ A grounded power source supplying the voltage and correct current for your dryer model. Check the dryer’s serial tag (on the control box) for the correct amps, voltage, phase, and cycles. Field wiring should be completed by a qualified personnel to the planned location for the dryer. All electrical wiring should comply with your region’s electrical codes.

❒ A source of water, when using the aftercooler/intercooler and/or pre-

cooler. The W Dryer’s aftercooler/intercooler and precooler require tower, city, or chiller water at temperatures of 45° to 85°F {7° to 29°C}.

Refer to the Specifications Sheet (page 2-7) for flow rate for your unit.

Piping should be ran to the planned dryer location. Use flexible hose to connect the water pipes to the aftercooler/intercooler and/or optional precooler.

❒ Minimum clearance for safe operation and maintenance. You should maintain 24 in. {61 cm} clearance on all sides of the dryer.

✐

NOTE: The aftercooler/intercooler reduces the temperature of air returning from the drying hopper, improving the efficiency of the desiccant.

I n s t a l l a t i o n l 3 - 3

Desiccant Cable Tie

Regeneration

Exhaust Cover

P o s i t i o n i n g t h e D r y e r o n t h e F l o o r

1 Lift the dryer from the shipping container using a fork truck.

2 Position the dryer on the floor near the hopper or ResinWorks sled. Make sure the location allows for the connection of all hoses, keeping hose lengths as short as possible.

R e m o v i n g t h e C a b l e T i e f r o m t h e

D e s i c c a n t W h e e l

( W 6 0 0 - 1 0 0 0 )

1 Open the dryer side panels and remove the cable tie securing the desiccant

wheel, if it was not done while unpacking the dryer.

I n s t a l l i n g t h e R e g e n e r a t i o n

E x h a u s t C o v e r

The Carousel Plus W Series Dryer’s regeneration exhaust cover must be installed.

To install the regeneration exhaust cover:

1 Remove the exhaust cover that is attached to the dryer’s shipping pallet.

2 Locate the bolt pattern at the top of the dryer, on top of the regeneration exhaust outlet.

3 Position the regeneration exhaust cover on top of the regeneration exhaust

outlet, aligning both bolt patterns.

4 Secure the regeneration exhaust cover with supplied hardware, using an appropriately sized wrench.


I n s t a l l i n g t h e R e t u r n A i r A d a p t e r

( W 6 0 0 - 1 0 0 0 )

The Carousel Plus W Series Dryer’s return air adapter must be installed.

To install the return air adapter:

1 Remove the return air adapter that is attached to the dryer’s shipping pallet.

2 Locate the bolt pattern on the top of the dryer, on top of the return air inlet.

3 Position the return air adapter on top of the return air inlet, aligning both bolt patterns.

4 Secure the return air adapter with supplied hardware, using an appropriately sized wrench.

Return Air

Inlet Adapter

I n s t a l l a t i o n l 3 - 5


I n s t a l l i n g t h e R e t u r n A i r I n l e t a n d

A i r O u t l e t A d a p t e r s

( W 1 6 0 0 - 5 0 0 0 )

The Carousel Plus W Series Dryer’s return air inlet and air outlet adapters will be removed when the dryer is shipped

To install the return air inlet and air outlet adapters:

1 Remove the return air inlet and air outlet adapters that are attached to the dryer’s shipping pallet.

2 Locate the bolt patterns on the top of the dryer, on top of the return air inlet and air out outlet.

3 Position the return air adapter on top of the return air inlet, aligning both bolt patterns.

4 Secure the return air adapter with supplied hardware, using an appropriately sized wrench.

5 Position the air inlet adapter on top of the inlet air inlet, aligning both bolt patterns.

6 Secure the air inlet adapter with supplied hardware, using an appropriately sized wrench.

Return Air

Inlet Adapter

Dry Air

Outlet

Adapter

I n s t a l l i n g t h e O v e r h e a d P r o c e s s A i r

D u c t

( W 3 2 0 0 - 5 0 0 0 )

The Carousel Plus W Series Dryer’s overhead process air duct will be removed when the dryer is shipped.

To install the overhead process air duct:

1 Remove the overhead process air duct that is attached to the dryer’s ship-

ping pallet. The piping will be shipped as one unit with included gaskets (2).

2 Locate the bolt patterns on the top of the dryer, over top of the overhead process air duct inlet and outlet.

3 Position the overhead process air duct on top of the overhead process air duct inlet and outlet making sure to place supplied gaskets between the

overhead process air duct and the inlet and outlet of the dryer, align all bolt patterns.

4 Secure the piping with supplied hardware, using an appropriately sized wrench.

Overhead Process Air

Duct

Gaskets (2)

I n s t a l l a t i o n l 3 - 7


C o n n e c t i n g t h e M a i n P o w e r

CAUTION: Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by qualified personnel.

1 Open the dryer’s electrical enclosure. Turn the disconnect dial on the dryer door to the Off or

“O” position. Lock out the main power (see

Page 1-6 for complete lock out information).

Turn the captive screw, and swing the door open.

2 Insert the main power wire through the knockout in the side of the enclosure or the rear of the dryer. (the dryer’s electrical wire connection location was a factory option and may be connected through the front or the rear of the dryer.)

Secure the wire with an appropriate compression fitting or strain relief.

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

3 Connect the power wires to the three terminals at the top of the power disconnect holder.

4 Connect the ground wire to the ground lug as shown in the photo.

O p e n i n g t h e D r y e r D o o r s

( W 1 6 0 0 - 5 0 0 0 )

Carousel Plus W Series 1600-5000 Dryers designed after August 2007 will have locking side panel door bolts.

To unlock the side panel door bolts:

1 Rotate the two (2) locking door bolts on the dryer door counterclockwise with a regular screw driver.

2 Close the dryer doors and rotate the two (2) locking door bolts clockwise to resecure the dryer doors.

C h e c k i n g f o r P r o p e r A i r F l o w

This procedure is needed on W600-5000 models if the phase detection option was not ordered with the dryer.

IMPORTANT: This procedure must be performed before the dryer’s air hoses are connected to the hopper or before loading material into the hopper.

CAUTION: If the air flow direction is incorrect due to improper phase connection, material from the hopper can be pulled back into the dryer, causing permanent damage to this equipment.

1 Turn on the main power to the dryer. Make sure the dryer’s disconnect dial is in the ON position. This powers up the control and the display lights will illuminate.

Stop

Start

2 Press the START button then the STOP button.

Set Point Actual

Shutdown Alarms

A1 Process High Temp

A2

A3

Process Loop Break

Process Heater High Temp

A7 Return Temp

A49 Process Protection High Temp

1 Process Temp.

2 Regen. Temp.

3 Return Air Temp.

4 Auto Start

5 Load Time (MDC)

6 Activate Setback Temp.

7 Setback Temp.(Process)

8 Dewpoint Passive Alarms

P1 Process Temp Deviation

P5

P17

Return Air Mid High Temp

MDC Conveying Demand

1000

Process Blower Regen. Blower

Regen. Heater

Auto Start

Dryer Status

Start and Stop Buttons

(continued)

Dryer Door

Locking Bolts (2)

(W1600-5000)

I n s t a l l a t i o n l 3 - 9


( c o n t i n u e d )

✐

NOTE: Models W600-1000 dryer aftercooler and dry air delivery configuration shown.

Location on larger models are different.

Refer to the labeling on your dryer. See

Installation section entitled, Installing the

Return/Delivery Air

Adapters, for proper air line connections.

Dry Delivery

Air

3 Visually verify the blower motor is moving in the correct direction indicated by the arrow on the blower

housing. The W series 600-5000 dryers are equipped with centrifugal process blowers.

Direction

Indication

Arrow

3 - 1 0 l I n s t a l l a t i o n


( c o n t i n u e d )

4 If air flow is incorrect disconnect power, follow proper lockout procedures and swap any 2 of the 3 main power wires.

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

If the air flow is reversed, the process blower is turning in the wrong direction. Turn off and lock out the main power source. Open the electrical enclosure and reverse any two leads connecting the main power supply to the dryer.

LEADS

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

I n s t a l l a t i o n l 3 - 1 1

C o n n e c t i n g t h e A i r H o s e s t o a

S i n g l e H o p p e r

( W 6 0 0 - 1 0 0 0 )

Using the two flexible hoses provided, connect the inlet of the HTC and outlet of the drying hopper to the dryer. Make sure the dryer is located as close as possible to the hopper (10 ft {3.05 m} of hose supplied).

1 Attach one hose from the return air inlet, located on top of the

dryer, to the outlet of the hopper.

✐

✐

NOTE: Do not allow the flexible hoses to kink or crimp.


Location on larger models are different.

Refer to the labeling on your dryer.

2 Attach one hose from the delivery

air outlet to the inlet of the HTC.

Return

Air Inlet

✐

NOTE: All air hose connections will be appropriately labeled.

3 Secure hoses with clamps. The hose clamp should be secured at least 1/4 in.

{0.64 cm} from the end of the inlet or outlet tube.

Dry Delivery Air

3 - 1 2 l I n s t a l l a t i o n


S i n g l e H o p p e r

( W 1 6 0 0 - 5 0 0 0 )

Using the two flexible hoses provided, connect the inlet of the HTC and outlet of the drying hopper to the dryer. Make sure the dryer is located as close as possible to the hopper (10 ft {3.05 m} of hose supplied).

1 Attach one hose from the return air inlet, located on top of the

dryer, to the outlet of the hopper.

✐


2 Attach one hose from the delivery air outlet, located on top of the

dryer, to the inlet of the HTC.

Return Air

Inlet

Delivery Air

Outlet

3 Secure hoses with clamps. The hose clamp should be secured at least 1/4 in. {0.64 cm} from the end of the inlet or outlet tube.

I n s t a l l a t i o n l 3 - 1 3

✐



R e s i n W o r k s

Using the two flexible hoses provided, connect the delivery air and return air manifolds of the ResinWorks to the dryer. Make sure the dryer is located as close as possible to the sleds (10 ft {3.05 m} of hose supplied).

1 Attach one hose from the

return air inlet of the dryer to the return air manifold of the

ResinWorks.

Dry

Delivery

Air

2 Attach one hose from the

delivery air outlet of the dryer to the delivery air manifold of the ResinWorks.

3 Secure hoses with clamps. The hose clamp should be secured at least 1/4 in. {0.64 cm} from the end of the inlet or outlet tube.

Return

Air

Insulated hose shown not standard.

Dry

Delivery

Air

Return

Air

3 - 1 4 l I n s t a l l a t i o n

C o n n e c t i n g t h e D r y e r t o t h e H o p p e r

If your dryer hose connection and your hopper HTC hose connection are not the same size, you will need a hose adapter. Contact Conair Parts 1 800-458-1960.

✐ C o n n e c t i n g t h e D r y e r t o

NOTE: Because the W600 - 5000 models require a separate heat source for the delivery air, all references to this heat source will be identified as “HTC” (Hopper

Temperature Controller). When using this dryer with a HTC, reference the User

Guide supplied with the HTC for installation instructions.

R e s i n W o r k s

If your dryer hose connection and the connection on your ResinWorks sled are not the same size, you will need to use a hose adapter. Contact Conair Parts

1 800-458-1960.

✐

NOTE: Because the W600 - 5000 models require a separate heat source for the delivery air, all references to this heat source will be identified as ResinWorks.

When using this dryer with a ResinWorks sled reference the User Guide supplied with the ResinWorks sled for installation instructions.

I n s t a l l a t i o n l 3 - 1 5

3 - 1 6 l I n s t a l l a t i o n

C o n n e c t i n g A i r H o s e A d a p t e r s

Depending on the hopper you purchased you may need to install an air hose adapter to connect the hopper to your dryer.

To connect the air hose adapter:

1 Place high temperature gasket half way down over the dry air delivery outlet.

Dryer

Inlet/Outlet

Connection

2 Place hose adapter inside high temperature gasket flush to the dryer outlet, secure with pressure clamp.

Pressure Clamp

3 Attach the hopper inlet hose over the adapter, secure with clamp.

C o n n e c t i n g t h e A f t e r c o o l e r a n d

O p t i o n a l P r e c o o l e r

( W 6 0 0 - 1 0 0 0 )

The aftercooler and/or optional precooler require a source of city, tower, or chiller water and a discharge or return line. You can use water at temperatures of 45 to

85°F {7 to 29°C}. But the water flow should be at least 3 gal/min {11.4

liters/min}.

✒

TIP: Make the water supply and discharge / return connections with flexible hoses at least 24 in.

(61 cm) long. This allows you to easily remove the aftercooler

1 Connect the water supply line to the aftercooler or precooler inlet.

If a manual shut off valve is used, it should be mounted on the inlet line.

assembly for cleaning.

✒

TIP: If an optional flow control is also being installed with the aftercooler, the manual shut off valve should be installed on the inlet line for the flow control.

Aftercooler Inlet

2 Connect the water discharge or return line with the pressure relief valve to the aftercooler or

precooler outlet. Use the bracket supplied to secure the pressure relief valve to the back of the dryer.

✐


Location on larger models are different. Refer to the labeling on your dryer.

Aftercooler Outlet

IMPORTANT: Turn the water off when the dryer is not in use to prevent condensation.

I n s t a l l a t i o n l 3 - 1 7

✒

TIP: Make the water supply and discharge / return connections with flexible hoses at least 24 in.

(61 cm) long. This allows you to easily remove the intercooler assembly for cleaning.

C o n n e c t i n g t h e I n t e r c o o l e r a n d

O p t i o n a l P r e c o o l e r

( W 1 6 0 0 - 5 0 0 0 )

The intercooler and/or optional precooler require a source of city, tower, or chiller water and a discharge or return line. You can use water at temperatures of 45 to

85°F {7 to 29°C}. But the water flow should be at least 3 gal/min {11.4

liters/min}.

✒

TIP: If an optional flow control is also being installed with the intercooler, the manual shut off valve should be installed on the inlet line for the flow control.

1 Connect the water supply line to the intercooler or precooler inlet.

If a manual shut off valve is used, it should be mounted on the inlet line.

Intercooler Inlet

2 Connect the water discharge or return line with the pressure relief valve to the intercooler

or precooler outlet. Use the bracket supplied to secure the pressure relief valve to the back of the dryer.

Intercooler Outlet

IMPORTANT: Turn the water off when the dryer is not in use to prevent condensation.

3 - 1 8 l I n s t a l l a t i o n

M o u n t i n g a L o a d e r o n t h e H o p p e r

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

Te s t i n g t h e I n s t a l l a t i o n

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

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

2 Turn on the main power to the dryer. Make sure the dryer’s disconnect dial is in the ON position. This powers up the control and the display lights will illuminate.

IMPORTANT: Be sure the cable tie has been removed from the desiccant wheel. (W600-1000 models)


Shutdown Alarms

A1

A2

A3

Process High Temp



A4

A7

Regen Heater High Temp

Return Air High Temp


A53 Process Blower Overload

Passive Alarms


P5 Return Air Mid High Temp

P17 MDC Conveying Demand

1 Process Temp.

2 Regen. Temp.


4 Auto Start




8 Dewpoint

1000


Regen. Heater

Auto Start

Dryer Status

3 Press the START button.

Start

If everything is installed correctly:

• The green light on the start button will illuminate.

• The regeneration and process blowers and LEDs will turn on.

• The regeneration heater and LED will turn on.

• The LEDs will illuminate.

• The desiccant wheel starts turning.

(continued)

I n s t a l l a t i o n l 3 - 1 9

3 - 2 0 l I n s t a l l a t i o n

Te s t i n g t h e I n s t a l l a t i o n

( c o n t i n u e d )

4 Press the STOP button.


Stop

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

(until regeneration heaters are less than 150°F {66°C})

5 The test is over. If the dryer performed the normal operating sequences as outlined, you can load the hopper and begin operation. If it did not, refer to the Troubleshooting section of the User Guide.

O p e r a t i o n

C a r o u s e l P l u s W S e r i e s D r y e r : c o n t r o l p a n e l D C - 1 . . . . . . . . . . . . . . . . 4 - 2

C a r o u s e l P l u s W S e r i e s D r y e r D C - 1 c o n t r o l f u n c t i o n s . . . . . . . . . . . . . . . . . 4 - 3

C o n t r o l f u n c t i o n f l o w c h a r t . . . . . . . . . . . . . 4 - 3

C o n t r o l f u n c t i o n d e s c r i p t i o n s . . . . . . . . . . . 4 - 5

To s t a r t d r y i n g . . . . . . . . . . . . . . . . . . . . 4 - 1 5

To s t o p d r y i n g . . . . . . . . . . . . . . . . . . . . . 4 - 1 6

U s i n g t h e a u t o s t a r t c o u n t d o w n f u n c t i o n . . . 4 - 1 7

H o w t o d i s a b l e t h e a u t o s t a r t o n t h e

D C - 1 c o n t r o l . . . . . . . . . . . . . . . . . . . 4 - 1 7

U s i n g d e w p o i n t c o n t r o l . . . . . . . . . . . . . . . 4 - 1 8

S E C T I O N

4

O p e r a t i o n l 4 - 1

C a r o u s e l P l u s W S e r i e s D r y e r : C o n t r o l P a n e l D C - 1

A l a r m C o d e s

See Troubleshoot-

ing section for a more complete list-

NOTE:

Process related alarms are not applicable when the unit is configured as a central dryer.

I n c r e m e n t / D e c r e m e n t

B u t t o n s

Used to increase and/or decrease the setpoint of a control function.

Shutdown Alarms


A2

A3

A4

A7







Passive Alarms




1 Process Temp.

2 Regen. Temp.


4 Auto Start




8 Dewpoint

M e n u L i s t

Numbers 2, 3, and 4 are standard items that will always be present. Number 8 is a screen associated with options. If the option is not installed, the

NOTE: #1 Process is not displayed when the unit is configured as a central dryer.

1000

S e t p o i n t

D i s p l a y

Shows the setpoint value.

Set Point


Regen. Heater

S t a r t a n d S t o p

B u t t o n s

Press “Start” to start the dryer.

Press “Stop” to stop the dryer.

A c t u a l

D i s p l a y

Shows the actual temperature value.

Actual

Auto Start

Dryer Status

A c k n o w l e d g e

A l a r m B u t t o n

Press once to silence the optional audible alarm and display alarm messages. Press again to clear the alarm. If pushed when no active alarm is present, the most recent alarm will be displayed.

M e n u

N u m b e r

D i s p l a y

Displays the menu number corresponding to what is shown in the setpoint and actual displays.

Can also display letters for alarms and setup.

S c r o l l

B u t t o n

Press to scroll through the closed loop menu list.

Pressing the

Scroll button moves you down the list.

4 - 2 l O p e r a t i o n

C a r o u s e l P l u s W S e r i e s D r y e r D C - 1

C o n t r o l F u n c t i o n s

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

✐

NOTE: Grey shaded screens denote optional functions. If the options were not purchased with the dryer, those screens will not appear.

C o n t r o l F u n c t i o n F l o w C h a r t

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

4-5).

The Main Menu functions can be accessed by pressing the Scroll button when on

Screen 5. To access the Setup, Test Mode, and Alarm History Menus, the appropriate access code must be entered. Refer to the instructions for Screen 14

(page 4-7).

O p e r a t i o n l 4 - 3

✐

NOTE: Screens 1-4 are only displayed during initialization.

Display Menu

Number

Setpoint

Display

Actual

Display

POWER ON screen #

1 Pr up 5 sec

2

3 C

4 d

CP v2.0

v2.0

MAIN MENU

600 5 sec - Model Disignator

3.00

1 sec - Control Software Version

3.00

1 sec - Display Software Version

5 1

6 2

7 3

8 4

13 9

14 0

CNT

350

100

16

-30

DRY Configured as a Central Dryer

350 Regen Temp

100 Return Air Temp

On Auto Start

-40

0

Dewpoint Monitor or Dewpoint Control

Password Screen

Setup Menu

18 C

Access Code

754

350 C04

19 C off C05

21 C

22 C

24 C

47 C

20

200 off

F

C07

C08

C10

C15

Test Mode Menu

28 H

Access Code

755 off 1

30 H off 3

31 H

32 H

33 H

34 H

35 H

37 H

38 H

40 H

41 H off off off off off off off off off

8

10

11

13

14

6

7

4

5

44 A

44 A

44 A

44 A

44 A

Alarm History Menu

44 A

Access Code

756

1 P3

44 A 2 A1

44 A 3 A5

4 A4 44 A

44 A 5 P1

8

9

6

7

10

P5

A1

A7

A2

A6

42 H off 15

43

H off 16 ✐

NOTE: In the event new control boards are installed, screens showing Process and MDC may be present. The boards will need to be configured for a central dryer. If this is not done, alarms will occur.


C o n t r o l F u n c t i o n D e s c r i p t i o n s

S c r e e n F u n c t i o n

SCREEN 1

Pr up

Once power is turned on, this screen is displayed for 5 seconds while the control goes through self-checking.

SCREEN 2

CP 600

SCREEN 3

C v2.0

3.00

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

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

SCREEN 4 d v2.0

3.00

SCREEN 5 (Default Screen)

1 CNT DRY

SCREEN 6

2 350 350

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

Indicates configuration as a central dryer.

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

O p e r a t i o n l 4 - 5



( c o n t i n u e d )

S c r e e n

SCREEN 7

3 100 100

SCREEN 8

4 16 On

F u n c t i o n

This screen shows the actual return air temperature measured at the inlet to the process blower. (The return air temperature on W1600-5000 dryers is measured at the inlet to the desiccant wheel. W1600-5000

dryers designed prior to August 2007, the return air temperature is measured at the inlet to the process blower.) If the optional aftercooler/intercooler flow control is installed, a setpoint will be displayed on this screen as well. The (+) or (-) buttons can be used to change the set point.

Holding the (+) or (-) buttons in will allow the number to ramp up faster the longer the button is held.

This screen is used to set the dryer to auto start. The dryer must be on but not running to set auto start. The value shown is the countdown time setpoint. It is adjustable from 0.1 hours to 150 hours.

Once the countdown time is set, press the

“START” button. The display will show

ON to tell the operator that the auto start is

ON and counting. The auto start LED on the display also flashes green when the auto start is armed and counting down.

The LED will turn solid green when the dryer starts. The dryer will begin operating when the control has finished counting down.


( c o n t i n u e d )

S c r e e n

SCREEN 13 (Dewpoint Monitor/

Dewpoint Control Option)

8 -30 -40

F u n c t i o n

If the dryer has the dewpoint monitor option installed, this screen will show the actual dewpoint of the process delivery air.

With the dewpoint monitor option installed, there will only be an actual display (no setpoint value). Although the dryer is capable of producing dewpoints much lower than -40 ° F {-40 °C} , the minimum sensor range is -40 ° F {-40 °C} .

Dewpoint control will automatically adjust the regeneration temperature to maintain dewpoint setpoint. Dewpoint control is not active with -40 ° F {-40°C} setpoint.

SCREEN 14

0 0

This is the password entry screen that gives the user access to the Set Up, Test

Mode, and Alarm History screens. The user can get to the password protected control functions through this screen by pressing the Scroll button and the adjust setpoint button (-) at the same time. This works only if you are on menu #1 (Screen

5). The access codes are as follows:

Set Up Screens 754

Test Mode Screens

Alarm History Screens

755

756

To exit the password section, enter 500 and press scroll or cycle the power.

(continued)

O p e r a t i o n l 4 - 7



( c o n t i n u e d )

S c r e e n

✐

Screens 18-24 require access code 754.

F u n c t i o n

SCREEN 18 (Set up Screen)

C 350 C04

This is the regeneration setpoint screen.

✐

NOTE: There is normally no need to change this temperature. Consult Conair prior to changing this setting.


C off C05


Regeneration Differential

Temperature

C 20 C07

This is the regeneration heater autotune screen. The autotune function can be turned on by pressing the (+) key. Once the (+) key is pressed, the screen will show

“On” and then start the autotune process.

This may take a minute or so to complete.

When finished the display will read "don".

The new PID values are automatically saved. An autotune should be performed on a cold dryer. It will autotune to the setpoint value entered on Screen 18.

This screen shows the minimum differential temperature between the regeneration inlet and the outlet at the desiccant wheel.

If the actual temperature differential is under the set value, the dryer will alarm

(P31), but will still run. The temperature range is 5 to 100°F {-15 to 38°C}. The default temperature is 20°F {-7°C}.


( c o n t i n u e d )

S c r e e n

✐

Screens 18-24 require access code 754.

F u n c t i o n


Regeneration Air Temperature

C 200 C08

This screen shows the actual temperature of the regeneration air at the outlet of the desiccant wheel.

SCREEN 24 Aftercooler/

Intercooler Flow Control Enable

(Option)

C off C10

✐

Screen 28-43 require access code 755.

SCREEN 28 (Test Mode Screen)

H off 1

This screen is the Aftercooler/Intercooler

Flow Control Enable screen. By pressing the (+) or (-) keys, this function can be turned on or off. When off, the dryer will not open the optional flow control valve to control the return air temperature. There will also be no setpoint value on Menu #3,

Screen 7. This screen is not visible if the aftercooler/intercooler flow control option is not installed on the dryer.

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

(continued)

O p e r a t i o n l 4 - 9

4 - 1 0 l O p e r a t i o n


( c o n t i n u e d )

F u n c t i o n



H off 3


H off 4

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

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


H off 5


H off 6

NOTE: The isolation contactor will not be engaged so no electricity will go the heater.

The solid state relay contacts should close.

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

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


( c o n t i n u e d )

F u n c t i o n



H off 7

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


H off 8

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


H off 10

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

This is the Test Mode screen for the aftercooler/intercooler flow control valve. By pressing the (+) or (-) keys, the setting can be changed. When set to "On", the aftercooler/intercooler flow control valve output will be turned on for


H off 11

NOTE: If the optional aftercooler/intercooler flow control valve is not installed nothing will happen.

This screen is not used in the current program.

(continued)

O p e r a t i o n l 4 - 1 1

4 - 1 2 l O p e r a t i o n


( c o n t i n u e d )

F u n c t i o n



H off 13



H off 14



H off 15


H off 16

This is the Test Mode screen for the alarm output (yellow light). By pressing the (+) or (-) keys, the setting can be changed.

When set to "On", the alarm output will be turned on for 3 seconds and then shut off

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

This is the Test Mode screen for the alarm output (green light). By pressing the (+) or (-) keys, the setting can be changed.

When set to "On", the alarm output will be turned on for 3 seconds and then shut off

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

A

A

A

A


( c o n t i n u e d )

F u n c t i o n

Access code 756 required.

SCREEN 44 (Alarm Screen)

A 1 P3

A 2 A1

This is the first Alarm History screen. In this section, the last 10 alarms that have occurred are saved, starting with the most recent alarm. The number in the setpoint screen shows the list of alarms

1-10. The alarm code shows up in the actual screen. Some of the alarm codes are shown on the display label. Please refer to the alarm section of this manual for all alarm code definitions.

These are the additional alarm screens.

See the explanation above.

A 3 A5

A

A

4 A4

5 P1

A 6 P5

7 A7

8 A2

9 A6

10 P2

O p e r a t i o n l 4 - 1 3

4 - 1 4 l O p e r a t i o n


( c o n t i n u e d )

F u n c t i o n

Screen 47 require access code 754.

SCREEN 47 (Degree F/Degree C)

C F C15

This is the temperature units screen. It is used to change the temperature display from ° F to ° C or ° C to ° F. Use the (+) or

(-) keys to toggle between ° C and ° F.

To S t a r t D r y i n g

1 Make sure there is material in the hopper.

2 Turn on the main power to the dryer. Make sure the dryer’s disconnect dial is in the ON position. This powers up the control and the display lights will illuminate.

Start

3 Press the START button.


• The green light on the start button will illuminate.

• The process and regeneration blowers turn on and the LEDs will illuminate.

• The regeneration heater turns on and the LED will illuminate.

• The desiccant wheel starts turning.


Shutdown Alarms


A2

A3



A4

A7





Passive Alarms




1 Process Temp.

2 Regen. Temp.


4 Auto Start




8 Dewpoint


Regen. Heater

Auto Start

Dryer Status

1000

✐

NOTE: Once the dryer has been started, go to the ResinWorks or HTC and set the setpoint, then turn on the unit.

O p e r a t i o n l 4 - 1 5

4 - 1 6 l O p e r a t i o n

To S t o p D r y i n g

✐

NOTE: Turn off the ResinWorks or HTC and allow the heaters to cool (3 to 5 minutes) before turning off the dryer.

1 Press the STOP button. The Stop LED blinks red.

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

Stop

2 Be sure to disconnect and lockout the main power if you have stopped the dryer to perform maintenance or repair.

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

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

U s i n g t h e A u t o S t a r t C o u n t d o w n

F u n c t i o n

The countdown function allows the user to set the Carousel Plus W Series

Dryer to automatically start at a predetermined time. The countdown time can be set from 0.1 to 150.0 hours.

To set the countdown time:

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

4 16 ON

Auto Start

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

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

H o w t o D i s a b l e t h e A u t o S t a r t o n t h e D C - 1 C o n t r o l

To disable auto start once armed cycle the power off and on.

O p e r a t i o n l 4 - 1 7

4 - 1 8 l O p e r a t i o n

U s i n g D e w p o i n t C o n t r o l

Dewpoint control is a feature that can help you to reduce energy consumption. It does this by varying the temperature of the regeneration air from its default setpoint of 350 ° F {177 ° C}, to maintain a setpoint that you have entered on the process dewpoint screen (Screen 11).

Example:

If your material is not difficult to dry, it may dry adequately with -20 ° F

{-29 ° C} dewpoint air. When -20 ° F {-29 ° C} is entered as the setpoint (Screen

11), the dryer will gradually lower the regeneration air temperature to a point where the dryer’s delivery air is controlled at -20 ° F {-29 ° C} dewpoint.

The dewpoint control is active with setpoint values of -39 ° F {-39.4

° C} and higher. When the setpoint is -40 ° F {-40 ° C} or lower, the regeneration temperature will be maintained at the default temperature of 350 ° F {177 ° C} and the dewpoint control is inactive.

✐

NOTE: For more information concerning specific dewpoint control screens, see Control

Function Descriptions, page 4-5.

M a i n t e n a n c e

P r e v e n t a t i v e m a i n t e n a n c e c h e c k l i s t . . . . . . . 5 - 2

C h e c k i n g t h e d e w p o i n t . . . . . . . . . . . . . . . . 5 - 3

C l e a n i n g t h e h o p p e r . . . . . . . . . . . . . . . . . . 5 - 5

C l e a n i n g t h e p r o c e s s f i l t e r . . . . . . . . . . . . . 5 - 6

C l e a n i n g t h e r e g e n e r a t i o n f i l t e r . . . . . . . . . . 5 - 8

C l e a n i n g t h e a f t e r c o o l e r / i n t e r c o o l e r c o i l s . . . 5 - 9

C l e a n i n g t h e p r e c o o l e r c o i l s . . . . . . . . . . . 5 - 1 1

C l e a n i n g t h e v o l a t i l e t r a p o n t h e d e m i s t e r . . 5 - 1 1

I n s p e c t i n g h o s e s a n d g a s k e t s . . . . . . . . . . 5 - 1 1

S E C T I O N

5

M a i n t e n a n c e l 5 - 1

5 - 2 l M a i n t e n a n c e

P r e v e n t a t i v e M a i n t e n a n c e

C h e c k l i s t

Routine maintenance will ensure optimum operation and performance of the

W Series Carousel Plus Dryer. We recommend the following maintenance schedule and tasks.

• W h e n e v e r y o u c h a n g e m a t e r i a l s

❒ Drain and clean the hopper.

• W e e k l y, o r a s o f t e n a s n e e d e d

❒ Clean or replace the process and regeneration filters.

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

❒ Inspect hoses and hose connections.

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

• M o n t h l y

❒ Clean the aftercooler/intercooler and optional precooler coils.

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

• E v e r y s i x m o n t h s

❒ Inspect gaskets for damage or wear.

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

❒ Inspect the overhead process air duct connections.

(W3200-5000) Ensure that all connections are tighten properly and have . no air leaks.

❒ Verify dewpoint readout and performance with calibrated portable instrument.

❒ Measure current draw on all 3 legs of heater wires. This is to ensure that the heater is working properly.

C h e c k i n g t h e D e w p o i n t

It is a good idea to monitor the dewpoint performance of your dryer periodically with a calibrated portable dewpoint monitor, to ensure it is performing at maximum capacity. Even if your dryer has a dewpoint readout, comparing it to a portable instrument periodically will confirm that the dewpoint sensor and readout is performing properly.

To check dewpoint:

1 Connect your portable dewpoint meter to the dewpoint check port of the dryer.

2 Turn on the portable instrument, and ensure there is positive airflow through the sensor.

3 Monitor the readout and allow ample time for it to stabilize before discon-

necting the portable dewpoint monitor. Some dewpoint monitors require a substantial amount of time for residual moisture to be purged from the sensor.

✐

4 In the event the dewpoint in not satisfactory, refer to the Troubleshooting

section of the manual, under A28 and P9 alarm for DC1.

✐

NOTE: Portable dewpoint monitors purchased from Conair are provided with a male connector that plugs into the dewpoint check port. If you purchased your portable instrument elsewhere, the male connector is available through the Conair parts department.

NOTE: The dewpoint check port was not included on early dryers. It can be added easily.

Contact the Conair parts department or follow the alternate procedure.

Alternate Procedure: (for dryers with no dewpoint check port)

1 Stop dryer and allow it to cool.

2 Swing open or remove the left side panel. See Installation section entitled,

Opening the dryer doors (W1600-5000).

3 Remove the 1/8 inch NPT pipe plug at the process air outlet on the bottom manifold of the desiccant wheel assembly.

4 Connect a portable dewpoint meter to the hole from which the plug was just removed.

Replacement dewpoint monitors, male connectors and dewpoint check ports are available from Conair.

Contact Conair Parts

(800) 458 1960

From outside of the

United States, call:

(814) 437 6861

M a i n t e n a n c e l 5 - 3


C h e c k i n g t h e D e w p o i n t

( c o n t i n u e d )

5 Turn on the portable instrument, and ensure there is positive airflow through the sensor.

6 Monitor the readout and allow ample time for it to stabilize before

disconnecting the portable instrument. Some dewpoint monitors require a substantial amount of time for residual moisture to be purged from the sensor.

7 In the event the dewpoint is not satisfactory, refer to the Troubleshooting

section of the manual, under A28 and P9 alarms for DC1.

8 Stop the dryer, and allow it to cool down. Then disconnect your portable instrument and replace any pipe plugs that may have been removed.

9 Close or replace the side panel.

1/8 inch NPT Hole Plug

C l e a n i n g t h e H o p p e r

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 Close the hopper slide gate.

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

3 Open the drain port and allow the material to drain.

4 Open the hopper door and wipe out the inside of the hopper.

5 Clean the return air screen at the return air outlet of the hopper.

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

6 Remove the container from beneath the hopper and replace the drain

port cover before filling the hopper with material.

M a i n t e n a n c e l 5 - 5

CAUTION: Hot surfaces.

Always protect yourself from hot surfaces inside and outside the dryer and drying hopper.

C l e a n i n g t h e P r o c e s s F i l t e r

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

C a r o u s e l P l u s W- s e r i e s D r y e r s 6 0 0 - 1 0 0 0

1 Push in on the sides to release the tabs on the front cover. Remove the cover.

✐

NOTE: Larger dryer models

(W1600 - 5000) do not have covers.

2 Remove the cover wing nut, then pull the filter cap off.

C a r o u s e l P l u s W- s e r i e s D r y e r s 1 6 0 0 - 5 0 0 0

2a Remove the four (4) filter cap cover

latches, then pull the filter cap off.

Process Fitter Cap Latch (4)


C l e a n i n g t h e P r o c e s s F i l t e r

( c o n t i n u e d )

C a r o u s e l P l u s W- s e r i e s D r y e r s 6 0 0 - 5 0 0 0

3 Remove the filter wing nut, then remove the filter.

4 Remove outer filter and clean it with soapy

✐ water. Let air dry.

NOTE: On models W1600-5000 the process filter will not have an outer filter.

5 Clean the filter by laying it on its side and gently tapping it on the floor. Replace damaged, worn, or clogged filters.

6 Reverse the procedure to reinstall the process filter. Ensure that the gasket on filter cap is in place and in good condition.

CAUTION: Wear eye protection. If you use compressed air to clean the equipment, you must

wear eye protection and observe all OSHA and other safety regulations pertaining to the use of compressed air.

✒

TIP: If gasket on the process filter cap becomes loose or detached from the filter cap, resecure with high temperature silicone adhesive.

M a i n t e n a n c e l 5 - 7

✐

NOTE: Dirty or clogged regeneration filters are the leading contributor of dryers not reaching desired dewpoints.

CAUTION: Hot sur-

faces. Always protect yourself from hot surfaces inside and outside the dryer and drying hopper.

C l e a n i n g t h e R e g e n e r a t i o n F i l t e r

Clogged filters reduce air flow and dryer efficiency. Cleaning frequency depends on the condition of your dryer’s ambient air.

1 Push in on the sides to release the tabs on the front cover. Remove the cover.

✐

NOTE: Larger dryer models (W1600 - 5000) do not have covers.

2 Remove the filter wing nut, then remove the filter.


3 Remove outer filter and clean it with soapy water. Let air dry.

4 Clean the filter by laying it on its side and gently tapping it on the floor.

Replace damaged, worn or clogged filters.

5 Reverse the procedure to reinstall the regeneration filter.

CAUTION: Wear eye protection. If you use compressed air to clean the equipment, you must

wear eye protection and observe all OSHA and other safety regulations pertaining to the use of compressed air.

C l e a n i n g t h e A f t e r c o o l e r /

I n t e r c o o l e r C o i l s

You need to clean the aftercooler/intercooler coils to keep them working efficiently. Cleaning frequency depends on the type and amount of material you process.

1 Stop the dryer and lockout the main power.

2 Turn off the water flow to the water supply line. Disconnect

✐ supply and return lines.

NOTE: If an optional flow control was added with the aftercooler/intercooler, remove the compression fitting from the aftercooler/intercooler inlet. Loosen the fitting on the flow control, then swing the copper water supply tube out and away from the aftercooler/intercooler inlet.

W600 - 1000

Models

W1600 - 5000

Models

3 Remove the bolts securing the aftercooler/intercooler cover. Remove the cover.

4 Remove the aftercooler/intercooler by pulling it out of the aftercooler/intercooler housing.

(continued)

M a i n t e n a n c e l 5 - 9

5 - 1 0 l M a i n t e n a n c e

C l e a n i n g t h e A f t e r c o o l e r /

I n t e r c o o l e r C o i l s

( c o n t i n u e d )

5 Clean the assembly using a mild soap and water. Let the assembly

✐ dry thoroughly before installation.

NOTE: In cases of heavy volatiles, steam cleaning or the use of solvents, such as acetone, may be necessary. Be sure to test a small area with the solvent you have selected to be sure there is no adverse reaction.

6 Inspect the condition of the gasket. If it is damaged, replace the gasket.

7 Reassemble by repeating the steps in reverse order.

8 Connect the water supply line to the inlet. If a manual shut off valve is used, it should be mounted on the inlet line as well.

9 Connect the outlet of the aftercooler/intercooler to the inlet of the

flow control valve using the pre-shaped copper tubing and compression fittings provided.

C l e a n i n g t h e P r e c o o l e r C o i l s

You need to clean the precooler cooling coils to keep them working efficiently. See

Appendix B for details.

C l e a n i n g t h e V o l a t i l e Tr a p o n t h e D e m i s t e r

If you have the optional volatile trap, you need to clean the trap to keep it working efficiently. See Appendix C for details.

I n s p e c t i n g H o s e s a n d G a s k e t s

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

1 Follow the hose routing of all the hoses within the dryer and inspect all hoses, clamps, fittings, and gaskets.

2 Tighten any loose hose clamps or fittings.

3 Replace worn or damaged hoses and gaskets.

M a i n t e n a n c e l 5 - 1 1

5 - 1 2 l M a i n t e n a n c e

S E C T I O N

6

Tr o u b l e s h o o t i n g

B e f o r e b e g i n n i n g . . . . . . . . . . . . . . . . . . . . 6 - 2

A f e w w o r d s o f c a u t i o n . . . . . . . . . . . . . . 6 - 3

D I A G N O S T I C S

H o w t o i d e n t i f y t h e c a u s e o f a p r o b l e m . . . . 6 - 4

A l a r m s . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5

D e w p o i n t t r o u b l e s h o o t i n g . . . . . . . . . . . . . 6 - 1 7

P o o r m a t e r i a l d r y i n g t r o u b l e s h o o t i n g . . . . . 6 - 1 8

R E PA I R

R e p l a c i n g f u s e s . . . . . . . . . . . . . . . . . . . . 6 - 2 3

C h e c k i n g h e a t e r s o l i d s t a t e r e l a y s . . . . . . . 6 - 2 4

C h e c k i n g o r r e p l a c i n g t e m p e r a t u r e s e n s o r s . 6 - 2 5

R e p l a c i n g t h e r e g e n e r a t i o n h e a t e r

( W 6 0 0 - 1 0 0 0 ) . . . . . . . . . . . . . . . . . . 6 - 2 6


( W 1 6 0 0 - 2 4 0 0 ) . . . . . . . . . . . . . . . . . 6 - 2 8


( W 3 2 0 0 - 5 0 0 0 ) . . . . . . . . . . . . . . . . . 6 - 3 0

R e p l a c i n g t h e d e s i c c a n t w h e e l a s s e m b l y

( W 6 0 0 - 1 0 0 0 ) . . . . . . . . . . . . . . . . . . 6 - 3 2

R e p l a c i n g t h e d e s i c c a n t w h e e l m o t o r

( W 6 0 0 - 1 0 0 0 ) . . . . . . . . . . . . . . . . . . 6 - 3 4

R e p l a c i n g t h e d e s i c c a n t w h e e l m o t o r

( W 1 6 0 0 - 5 0 0 0 ) . . . . . . . . . . . . . . . . . 6 - 3 5 Tr o u b l e s h o o t i n g l 6 - 1

6 - 2 l Tr o u b l e s h o o t i n g

B e f o r e B e g i n n i n g

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 open the side panels of the dryer be sure to:

❏ Diagnose causes from the control panel.

1

Press once to silence the optional audible alarm and display the alarm message.

2

Address the alarm message and fix the problem. (Refer to the alarm descriptions later in this section.)

3

Press again to clear the alarm. If the alarm reappears the problem was not fixed.


Shutdown Alarms

A1

A2

A3

Process High Temp



A4 Regen Heater High Temp

A7 Return Temp

1 Process Temp.

2 Regen. Temp.


4 Auto Start




8 Dewpoint Passive Alarms




1000


Regen. Heater

Auto Start

Dryer Status

Acknowledge

Alarm Button

Scroll

Button

B e f o r e B e g i n n i n g

( c o n t i n u e d )

❏ Find the wiring and equipment diagrams that were shipped

with your dryer. 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 electrical enclosure to check fuses and heater contactors.

A F e w W o r d s o f C a u t i o n

The Carousel Plus W Series Dryer is equipped with numerous safety devices.

Do not remove or disable them. Improper corrective action can lead to hazardous conditions and should never be attempted to sustain production.

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

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

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

Tr o u b l e s h o o t i n g l 6 - 3

✐

NOTE: Pushing the

Acknowledge Alarm button when there is no active alarm will display the most recent alarm code.

✐

NOTE: The dryer cannot be started if a passive alarm is present on power-up.

H o w t o I d e n t i f y t h e C a u s e o f a

P r o b l e m

Dryer alarms are indicated by an illuminated Acknowledge Alarm light on the W

Series Dryer control panel. Shutdown alarms will energize optional audible and visual alarm indicators.

A problem can trigger two types of alarms:

• Shutdown: The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer.

• Passive: The dryer continues to operate, but warns of a problem that could prevent correct drying of your material. If ignored, this problem could lead to a condition that will shut down the dryer.


Shutdown Alarms


A2

A3



A7 Return Air High Temp



Passive Alarms




1 Process Temp.

2 Regen. Temp.


4 Auto Start




8 Dewpoint


Regen. Heater

Auto Start

Dryer Status

1000

When the alarm light is displayed:

Acknowledge

Alarm LED and

Button

1 Press the Acknowledge Alarm button once to silence the optional audible

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

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

section. Use information provided to diagnose and resolve the cause of the alarm.

3 Note that, after correcting the problem, pressing the Acknowledge Alarm

button a second time will clear the alarm. If the alarm reappears,

✐ the cause has not been resolved.

NOTE: When the dryer detects abnormally high temperature in the process heater, the dryer immediately shuts down and an error message appears in the display window.


✐

NOTE: Shutdown alarms will cause the dryer to go through the normal shut down procedure to cool the heaters, then it will stop running.

A l a r m s

A problem can trigger two types of alarms:

• Shutdown (A#): If the red Acknowledge Alarm LED is blinking, the alarm is a shutdown alarm. The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. Note that once the

Acknowledge Alarm button is pressed once, the blinking red LED becomes solid.

• Passive (P#): If the amber Acknowledge Alarm LED is blinking, the alarm is a passive alarm. The dryer continues to operate, but warns of a problem that could prevent correct drying of your material. If ignored, this problem could lead to a condition that will shut down the dryer. Note that once the Acknowledge Alarm button is pressed once, the blinking amber LED becomes solid.

Problem Possible cause Solution

A4 - Regeneration Heater

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

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

Locate and remove any airflow restrictions.

The isolation contactor failed in the closed position.

Tighten any loose hoses.

The regeneration blower is not running or running in the wrong direction.

Correct the cause of the non-running blower or reverse the rotation of the blower.

Replace the isolation contactor.

The heater solid state relays (SSRs) failed.

Replace the failed heater solid state relays (SSRs).

The regeneration heater output on the board has failed.

Replace the board.


A l a r m s

• Shutdown (A#): The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer.

• Passive (P#): The dryer continues to operate, but warns of a problem that could prevent correct drying of your material. If ignored, this problem could lead to a condition that will shut down the dryer.

Problem Possible cause Solution

A7 - Return Air High

Temperature – If the return air temperature at the inlet to the blower is greater than

180°F {82°C}, it shuts down the dryer. (The return air temperature on W1600-5000 dryers is measured at the inlet to the desiccant wheel. W1600-

5000 dryers designed prior to

August 2007, the return air temperature is measured at the inlet to the process blower.)

The hopper does not contain enough material.

You are drying at a high drying temperature above 120°F {49°C} or you are running at low throughputs.

The aftercooler/intercooler does not have enough water.

The aftercooler/intercooler coils are dirty.

Make sure your material supply system is working properly.

Ensure water flow to the aftercooler/ intercooler.

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

Clean the aftercooler coils. See

Maintenance section entitled, Cleaning the aftercooler/intercooler coils.

A23 & P3 - Regeneration

Temperature Deviation – The regeneration temperature exceeds the deviation band for the specified time. Default values are 10°F {6°C} for 5 seconds.

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

Replace the failed solid state relays

(SSRs).

The heater has become defective.

Check the heater fuses and resistance across each leg of the regeneration heater

The regeneration RTD is loose or has fallen out.

Check the regeneration RTD and tighten if needed.

The air hose connections are loose.

Tighten all air hose connections.

The output on the board has failed.

Replace the board.


A l a r m s



Problem

A25 & P5 - Return Air Mid-

High Temperature – If the return air temperature is between 150 and 180°F

{66 and 82°C}. (The return air temperature on W1600-

5000 dryers is measured at the inlet to the desiccant wheel. W1600-5000 dryers designed prior to August

2007, the return air temperature is measured at the inlet to the process blower.)

Possible cause

The hopper does not contain enough material.

Solution

Make sure your material supply system is working properly.

You are drying at a high drying temperature above 120°F {49°C} or running at low throughputs.

Ensure water flow to the aftercooler/ intercooler.

The aftercooler/intercooler does not have enough water.

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

The aftercooler/intercooler coils are dirty.

Clean the aftercooler/intercooler coils.

See Maintenance section entitled,

Cleaning the aftercooler/intercooler coils.

Replace the failed solid state relays

(SSRs).

Replace the board.


High Temperature – If the regeneration temperature exceeds the high temperature limit for the specified time.

Default values are 400°F

{204°C} for 20 seconds


Low Temperature – The regeneration temperature is less than the low temperature for the specified time (200°F

{93°C} for 20 seconds).

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

The output on the board has failed.

The regeneration heater has failed.

The output on the control board has failed or the fuse has blown.


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

Replace the control board or the fuse.



A l a r m s



Problem

A28 & P9 - Process

Dewpoint – The dewpoint has not fallen below the setpoint.

If the dewpoint goes below the setpoint for 180 seconds the

Possible cause

Defective sensor.

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

Poor regeneration air flow.

NOTE: The alarm is not active for the first 5 minutes.

Desiccant wheel not turning.

The desiccant wheel may be contaminated.

Leaks in the process air stream.

Power Purge blower not running.

(Models 2400 and 5000)

The process air filter is clogged.

Solution

Replace the sensor.

Check wiring and hose connections to the sensor, resecure if needed.

Remove the air flow restrictions, dirty filters, etc.

See A55 & P31

Check the desiccant for contamination, replace if needed. See Troubleshooting section, entitled Replacing the desiccant wheel assembly.

Install plasticizer/volatile trap for severe situations.

Check for worn or loose hoses.

Check fuse, wiring or replace blower.

Remove and clean or replace the process air filter.

A29 & P10 - Process Filter

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


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

There is a loose connection in the wiring leading to the RTD.

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

The regeneration RTD has failed.

The control board has failed.

Check the RTD plug connections, make necessary repairs.

Check the plug connection and tighten if needed.

Replace the regeneration RTD.

Replace the control board.


A l a r m s



Problem Possible cause

A34 & P28 - Return Air

Temperature RTD Integrity

– The dryer continues to run with a passive alarm. (The return air temperature on

W1600-5000 dryers is measured at the inlet to the desiccant wheel. W1600-5000 dry- ers designed prior to August




The return air RTD has failed.



Temperature Loop Break –

The regeneration temperature is outside of the operator entered deviation alarm band

(see Regeneration

Temperature Deviation passive alarm) and the regeneration temperature is not moving towards the setpoint at a rate greater than specified. Default values are 2°F {1°C} over 40 seconds.

The regeneration heater has failed.


The regeneration blower is not running.

The output on the control board has failed or the fuse is blown.

A36 - Control

Communications Watchdog

- The display board has lost communications with the control board.

Plugs on wire harness between the display and control boards are loose or not wired correctly.

Display board or communications boards have failed.

Solution



Replace the return air RTD.


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


Correct the cause of the non-functioning blower.

Replace the control board or fuse.

Make sure plugs are tight on board connections and match the wiring diagram.

Replace the defective boards.


Problem

A38 - Phase Error (Option

al) - One of the three power wires is connected wrong.

A l a r m s



Possible cause

One of the three power wires are out of phase.

A fuse has blown.

Phase detection board has failed.

There is loose wiring between the phase board and the control board.

Solution

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

Check and replace the fuse.

Replace the phase detection board.

Make sure wires are correct and secure.

A39 - EEProm Write Error Internal control board problem.


A48 & P22 -

Aftercooler/Intercooler Loop

Break (Optional) - Indicates return air temperature is not moving towards the setpoint when flow control option is installed.

No water to aftercooler/intercooler.

Turn on water supply.

Ensure flow control valve is functioning properly.

6 - 1 0 l Tr o u b l e s h o o t i n g

A l a r m s



Possible cause Solution Problem

A53 - Process Blower

Overload - If the process blower exceeds its full load amp rating or the overload has tripped due to a mechanical or electrical problem the dryer will shut down.

✐

NOTE: Once the overload has tripped you must wait

2 - 15 minutes with power on for it to reset automatically.

The process blower current draw has exceeded the full load amps rating of the motor.

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

The process blower has failed electrically.

Loss of phase of power to the motor starter.

The overload is set incorrectly.

Overload is defective.

Press alarm acknowledge and allow overload to automatically reset, then try to restart the dry. If the alarm condition occurs again have a qualified electrician check the current draw to the motor.

Disconnect and lock out main power.

Check the process blower for mechanical failure and free rotation. Replace if necessary. Allow overload to automatically reset, then try to restart the dryer.


Check the process blower for electrical shorts or open circuits. Replace if necessary. Allow overload to automatically reset, then try to restart the dryer.

Check for a blown fuse in the dryer or main power supply. Allow overload to automatically reset, then try to restart the dryer.


Check the overload settings and confirm that the settings match the full load amps listed on the process blower motor. Allow overload to automatically reset, then try to restart the dryer.

Replace the overload.

Tr o u b l e s h o o t i n g l 6 - 1 1

A l a r m s



Problem Possible cause

A55 & P31 - Wheel Rotation

Failure - The regeneration temperature differential has been reached.

The wheel motor is not turning.

The belt tensioner is loose or the belt is slipping.

The regeneration heater is not working.

Solution

Check the motor, plugs, and fuses.

Change or adjust the tensioner spring or replace the belt.

Check the heater fuses and heater.


Outlet RTD Integrity - The control can not sense the regeneration outlet RTD.





The regeneration outlet RTD has failed.

Replace the regeneration outlet RTD.




A l a r m s



Possible cause Solution Problem

A57 - Regeneration Blower

Overload - If the regeneration blower exceeds its full load amp rating or the overload has tripped due to a mechanical or electrical problem the dryer will shut down.

✐

NOTE: Once the overload has tripped you must wait

2 - 15 minutes with power on for it to reset automatically.

The regeneration blower current draw has exceeded the full load amps rating of the motor.

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

The regeneration blower has failed electrically.

Press alarm acknowledge and allow overload to reset automatically, then try to restart the dryer. If the alarm condition occurs again have a qualified electrician check the current draw to the motor.


Check the regeneration blower for mechanical failure and free rotation.

Replace if necessary. Allow overload to reset automatically, then try to restart the dryer.


Check the regeneration blower for electrical shorts or open circuits. Replace if necessary. Allow overload to reset automatically, then try to restart the dryer.

Loss of phase of power to the motor starter.

The overload is set incorrectly.

Overload is defective.

Check for a blown fuse in the dryer or main power supply.


Check the overload settings and confirm that the settings match the full load amps listed on the process blower motor. Allow overload to reset automatically, then try to restart the dryer

Replace the overload.


Problem

A58 & P34 - Dewpoint

Deviation High (Option) -

Displayed when the actual dewpoint goes above the setpoint by a specified amount of time and degrees. Defaults are set for 5°F {3°C} for 30 seconds.

A l a r m s



Possible cause

Desiccant wheel not turning.

Solution

See A55 & P31

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

Check wiring and hose connections to the sensor, resecure if needed.

Poor regeneration air flow.

Remove the air flow restrictions, dirty filters, etc.

The desiccant wheel may be contaminated.

Install plasticizer/volatile trap for severe situations.

Replace the desiccant wheel. See

Troubleshooting section, entitled

Replacing the desiccant wheel assembly.

A 59 & P35 - Dewpoint

Deviation Low (Option) -

Displayed when the actual dewpoint goes below the setpoint by a specified amount of time and degrees. Defaults are set for 5°F {3°C} for 30 seconds.

Leaks in the process air stream.

The dewpoint can not control to the desired setpoint.

The dewpoint sensor has failed.

Check for worn or loose hoses.

Material and/or ambient condition may be too dry to increase the actual dewpoint. Please wait several hours to determine if the setpoint can be reached.

Increase the dewpoint low deviation value.

Replace the dewpoint sensor.


A d d i t i o n a l A l a r m s

Along with the alarm indicators, you may encounter additional messages that indicate a problem within the control.

Problem

CoS Er.4 or Co5 Er. 4 -

Displayed when the “Start” button is pushed during any active alarm. (Passive or

Shutdown)

Possible cause

The dryer will continue to run if there is a passive alarm, however it will not start if there is a active alarm.

Solution

Push the alarm acknowledgement button to identify the alarm, and address it as necessary.

CoS Er.0 or Co5 Er.0 -

Indicates there is a problem in the communication between the control board and the display board.

Loose or improperly connected wire. Check wiring between control board and display board.

Check dip switch setup on control board.

Improper dip switch setup on control board.

Defective display board or control board.

Replace boards in sets to maintain software compatibility.

Err 004 - Indicates a mismatch of software between the display board and the control board.

Er. L - There is a problem in the sensor connection (RTD, dewpoint sensor, etc.) for the effected function.

The software revision of the display board and control board are not compatible.

In most cases, both display and control boards will need to be replace as a set.

Problem in the analog input section of the control.

Check that all jumpers are in their proper place.

Check to see if the dewpoint sensor is connected properly.

Defect in the main control board.

Disconnect the ribbon cable connecting any analog option boards to the main control board. If the display returns to normal for all values except those that are generated through the analog options boards, replace the option board.

Replace main control board.


A d d i t i o n a l A l a r m s

Along with the alarm indicators, you may encounter additional messages that indicate a problem within the control.

Problem

Er. H - There is a problem in the analog input section of the control.

Possible cause

RTD is not connected properly or is defective.

Solution

Check RTD connections, replace defective RTD

Connector to all RTDs is removed.

The ribbon cable between an analog option board and the main control board is not connected properly.

Problem in the analog input section of the control.

Defect in the main control board.

Check connections between analog option board and the main control board.

Disconnect the ribbon cable connecting any analog option boards to the main control board. If the display returns to normal for all values except those that are generated through the analog options boards, replace the option board.

Replace main control board.


D e w p o i n t Tr o u b l e s h o o t i n g

Problem

Dryer not producing desired dewpoint.

Under normal operating conditions, the dryer will produce dewpoints in the range of -40 to -20° F {-40 to -29° C}. However, you may experience situations that produce undesirable results.

Possible cause

Low regeneration air flow.

Solution

Check regeneration filter and clean and/or replace as necessary.

Return air temperature exceeds 125°F

{52°C}. (The return air temperature on

W1600-5000 dryers is measured at the inlet to the desiccant wheel. On W1600-

5000 dryers designed prior to August

2007, the return air temperature will be measured at the inlet to the process blower.)

Regeneration temperature is below normal setting.

Reduce the temperature of the cooling water or increase the flow.

Connect water to the aftercooler/intercooler if not already connected.

Check for adequate water temperature.

Water temperature should be approximately 85°F {29°C}.

Check amperage of regeneration heaters.

Replace heaters if necessary.

WARNING: Any electrical checks should be performed by a qualified electrician.

Leaks in process lines.

Contaminated desiccant due to offgassing, too long of a residence time or drying temperature is too high for the grade of material being processed.

Check all hoses, gaskets, doors, loaders or other potential areas where leakage may occur. Replace any defective hoses or gaskets.

Verify proper drying temperatures and residence times. If off-gassing is a condition of the material being processed, contact Conair Parts at (800) 458 1960 for the addition of a volatile trap.

Analog option board/sensor malfunction Verify dryer dewpoint readings with a calibrated portable dewpoint meter.

Replace analog option board or sensor.


✐

NOTE: Concerns with drying temperature may require review of HTC or

ResinWorks controls.

P o o r M a t e r i a l D r y i n g


Occasionally, processing problems that are suspected of being caused by poor drying are eventually determined to be the result of other issues in the process setup.

The information can assist you in determining if your drying system is performing properly. However, the only way to know definitely if your material is properly dried is to perform moisture analysis of small samples as it leaves the bottom of the hopper or just as it enters the process. Conair does not sell moisture-analyzing equipment, but there are many brands of this equipment available on the market.

You should also be aware that some processing problems may actually be the result of over-drying material. Most materials will degrade to some extent if they are exposed to their specified drying temperature for a time significantly longer than the residence time specified by the supplier. If you want to maintain its dryness, it is recommended that you reduce the process air temperature. If your Conair dryer is equipped with the Setback feature, you should familiarize yourself with it, and make use of it. If not, you may want to contact Conair to determine if it can be added to your dryer.

A majority of customer questions to Conair are related to dewpoint. It is important to realize that dewpoint is one of four requirements that need to be satisfied.

There are four requirements, listed in order of importance, necessary to properly dry hygroscopic plastic resins:

1 Drying temperature of the air entering the hopper must be at the proper drying temperature for your material, as specified by your material supplier.

2 Residence time is the time, determined by your material supplier, that the material in use must be heated to achieve proper drying temperature.

3 Airflow during the process drying circuit must be adequate to carry and distribute the heat throughout the entire bed of material inside the hopper.

4 Dewpoint of the process air must be low so it can efficiently collect the moisture as it is released from the heated material and carry it to the dryer to be removed in the desiccant.


✐

NOTE: Concerns with drying temperature may require review of HTC or Resin-

Works controls.



( c o n t i n u e d )

Once it is determined which of the four requirements that is not being satisfied, refer to the following list of possible causes and solutions.

Temperature - The temperature of the air entering the hopper must be at the proper drying temperature for your material, as specified by your supplier.

Problem

The temperature of the air entering the hopper is not at proper drying temperature.

Possible cause

Incorrect setpoint

Not able to achieve setpoint.

Inaccurate process temperature readout.

Solution

Refer to the drying specifications for your material and adjust the setpoint to the recommended setpoint.

If your dryer has the Setback option, make sure it is not active unless you have specifically activated it. If necessary, refer to the Operation section of this manual for assistance in using the

Setback function.

Replace any defective process heater, contactors, fuses, etc.

Ensure the selected drying temperature is within the design specifications of your dryer.

Ensure the Process RTD is properly positioned in the air stream.

Determine if there is a problem in the temperature control circuit and repair or replace any defective components such as RTD, temperature control, circuit boards, etc.


Problem

Material residence time is too long or short.



( c o n t i n u e d )

Residence Time - The time your material supplier has determined that the material in use must be heated to its drying temperature to achieve proper drying.

Possible cause

Material level in hopper is too low.

Material throughput is too high.

Solution

Make sure there is an adequate supply of material to feed the loader on top of the drying hopper.

Correct any problems with the conveying system that may be preventing your loader from filling the hopper.

If your hopper has a level sensor for maintaining a material level less than completely full, be sure this sensor is adjusted properly.

Take any necessary steps, such as slowing down the process, to ensure the material usage is within design specifications of the dryer and hopper.




( c o n t i n u e d )

Problem

Airflow - The airflow in the process drying circuit must be adequate to carry and distribute the heat throughout the entire bed of material inside the hopper. If the airflow is too low, the material in the center of the hopper may get heated fully to the drying temperature, but the material against the sidewalls will not. In most cases, the material 2/3 to 3/4 of the way toward the top of the hopper should be heated to the proper drying temperature.

Possible cause

Too much or too little airflow.

✐

NOTE: If there is too much airflow, the material may fluidize inside the hopper, resulting in inconsistent material flow through the hopper, which can negatively impact residence time.

Dirty process air filter.

Collapsed hoses or holes/leaks in the hoses and hose connection.

Airflow restrictions.

Process blower running backwards or performing poorly.

Solution

Clean or replace the process filter.

Replace any worn or damaged hoses.

Tighten all hose clamps to eliminate leaks.

Remove any obstructions in the process air circuit.

Verify the process blower is running in the correct direction. If backwards, reverse direction by switching any 2 legs of high voltage to the motor.

Material level in the hopper too low.

WARNING: Any electrical checks should be performed by a qualified electrician.

Repair or replace motor.

Other than running out of material to complete a job, the material level inside the hopper must be a minimum of 50% full. If the hopper is not at least half full, the material in the cone section will not get adequate airflow to dry properly.


Replacement dewpoint monitors are available from Conair.



( c o n t i n u e d )

Contact Conair Parts

(800) 458 1960

From outside of the

United States, call:

(814) 437 6861

Problem

Dryer dewpoint is not reaching proper setpoint.

Dewpoint - The process air must be at a low dewpoint so it can efficiently collect the moisture as it is released from the heated material and carry it to the dryer to be removed in the desiccant. In most cases, the dryer will dry your material satisfactory if the dewpoint of the air is -20 to -40° F {-29 to -40° C}. If your dryer does not have a dewpoint readout, you can check the dewpoint with a portable dewpoint instrument. Conair sells a variety of portable dewpoint meters. Contact Conair Parts.

Possible cause Solution

Low regeneration temperature.

Replace or check defective heaters, fuses etc.

Poor regeneration airflow.

Clean or replace the regeneration filter.

High dewpoint, ambient air leaking into the closed loop drying circuit.

Return air temperature to the dryer is too high. (The return air temperature on

W1600-5000 dryers is measured at the inlet to the desiccant wheel. W1600-

5000 dryers designed prior to August


Poor desiccant performance.

Ensure the regeneration blower is operating properly and rotating in the correct direction. See Installation section entitled, Checking for proper airflow.

Remove obstructions in the air stream, such as crimped hoses, etc.

Replace damaged hoses and seal any leaks in the process air circuit.

If using a vacuum loader on the hopper, ensure that the loader shroud is installed in the hopper and that the hopper is completely filled with material.

If partially filling your hopper, ensure that the hopper loader is sealed against ambient air.

Install a gasket between the loader and the top of the hopper.

Clean the aftercooler/intercooler coils.

See Maintenance section entitled,

Cleaning the aftercooler/intercooler coils.

See Troubleshooting section entitled,

Replacing the desiccant wheel assembly.


R e p l a c i n g F u s e s

1 Disconnect and lockout the main power supply.

2 Open the electrical enclosure door.

3 Check the fuse with an ohmmeter. If necessary, pull the fuse out and replace it with a fuse of the same type and rating.

Fuse Blocks

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

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


ON

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

C h e c k i n g H e a t e r S o l i d S t a t e R e l a y s

CAUTION: Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by qualified personnel.


2 Open the electrical enclosure.

3 Locate the regeneration solid state relays. Refer to the wiring diagrams that came with your dryer.

✐ NOTE: Measure voltage using a voltmeter across the two high voltage connections of each relay. (Shown here circled in red.)

Regeneration heater solid state relays

4 Turn power on to the machine.

5 Start the dryer.

6 Measure voltage across the high voltage connections using a voltmeter.

When relay is energized, as indicated by the LED (green) voltage should be read 0 (zero). When relay is de-energized, LED off, full voltage should be measured across the relay. When relay is off, if voltage reads zero, relay is bad and needs replaced. Repeat this procedure for each relay.


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

S e n s o r s

The Carousel Plus W Series Dryer uses RTD sensors to monitor the temperatures of the return air, air into the desiccant, the regeneration outlet, and the regeneration inlet.

To check or replace an RTD sensors:


2 Remove dryer panels, as necessary. See Installation section entitled, Opening the dryer doors (W1600-5000).

3 Locate the RTD sensors.

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

5 To check with ohm meter, measure the resistance across the RTDs. The resistance should be approximately 110 ohm at room temperature.

6 Replace the sensor, if necessary.

IMPORTANT: Always refer to the wiring diagrams that came with your dryer to locate specific electrical components.

Illustrations in the User

Guide are intended to be representative only.





Clamp

Regeneration

Heater

Clamp

R e p l a c i n g t h e R e g e n e r a t i o n H e a t e r

( W 6 0 0 - 1 0 0 0 )

1 Stop the dryer, disconnect the power, and follow proper lockout procedures.

2 Remove the right side panel of the dryer, as viewed from the front of the dryer, to gain access to the regeneration heater.

3 Disconnect the regeneration heater power wires from the terminal

block in the control cabinet. Feed the regeneration power cable out of the control cabinet.

4 Unplug the quick disconnect for the

high temperature switch cable at the switch.

5 Loosen the hose clamps then remove

the hoses from the top and bottom of the regeneration heater tube. Remove and check the bottom heater hose for loose debris or fragments, these fragments can damage the newly installed heater if not removed.

Clamp

Insulation

6 While supporting the heater tube, loosen the hose clamp supporting the regeneration tube to the mounting

bracket, then remove the heater tube from the dryer.

7 Slide the insulation off the heater

tube, or make a cut the entire length of the insulation sleeve to aid removal.



( W 6 0 0 - 1 0 0 0 ) ( c o n t i n u e d )

8 Compare the markings on the outside of the regeneration heater tube to ensure the new one has the same voltage and kW ratings as the original heater tube. This information is on the end nearest the wires.

9 Slide the original insulation over the new heater or, if the insulation was cut for removal, wrap the cut insulation sleeve around the new heater tube and secure it with duct tape.

10 Make sure the cable end of the heater tube is to the bottom then secure the new heater tube to the mounting bracket with a hose clamp.

11 Connect the hoses to the top and bottom of the heater tube and secure them with hose clamps.

12 Connect the high temperature switch wires to the quick disconnects near the heater tube.

13 Route the heater power cable into the control cabinet and connect the

leads to the original locations on the terminal block. Refer to the wiring diagram for specific connection information.

14 Replace the side panel of the dryer.

15 Measure the resistance from each leg of the heater tube to the others and

from each leg to ground. There should be +/- 5% resistance variation between all 3 legs, and high resistance from each leg to ground.

16 Connect the dryer to power and turn it on. Verify that the regeneration temperature achieves the setpoint.



( W 1 6 0 0 - 2 4 0 0 )

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

2 Locate the heater. Open the side panels of the dryer locating the heater which is secured to the inlet of the desiccant wheel assembly by hard piping, brackets and clamps. See Installation section entitled, Opening the dryer doors (W1600-5000).

Clamp

Gasket

Clamp

Gasket

Heater

Tube

Bracket





3 Disconnect the main power leads at the junction box inside the frame of the dryer.

4 Disconnect the high temperature switch cable at the quick disconnect.

5 To remove the defective regeneration heater tube, loosen the pressure clamps at the top and bottom of the heater tube connection and slide the clamp and its silicon gasket back away from the heater tube. W1600-

2400 model dryers lower clamp is attached to a bracket that is mounted to the desiccant wheel assembly, loosen clamp to remove it from the

bracket. Remove and check the bottom heater hose for loose debris or fragments, these fragments can damage the newly installed heater if not removed.

6 Slide the insulation off the heater tube, or make a cut down the entire length of the insulation sleeve to aid removal.

7 Compare the markings on the outside of the regeneration heater tube to ensure the new one has the same voltage and kW ratings as the original

heater tube. This information is on the end nearest the wires.

(continued)


( W 1 6 0 0 - 2 4 0 0 )

( c o n t i n u e d )

8 Slide the original insulation over the new heater, or if the insulation was cut for removal, wrap the cut insulation sleeve around the new heater tube and secure it with heat tape.

9 Make sure the cable end of the new heater tube is to the bottom, then

connect the hoses to the top and bottom of the heater tube and resecure with pressure clamps and the lower heater tube bracket that was removed in

Step 5.

10 Connect the high temperature switch cable to the quick disconnect.

11 Route the heater power wires into the junction box, and connect them to

the supply leads from the control box. Refer to the wiring diagram for specific connection information.

12 To ensure all connections are correct, measure the resistance as in Step 3.

You should measure the readings as noted for a good heater.

13 Close the side panel of the dryer.

14 Connect the dryer to power and turn it on. Verify the regeneration temperature achieves the setpoint.



( W 3 2 0 0 - 5 0 0 0 )


2 Locate the heater(s). Open the side panels of the dryer locating the heaters which are secured to the inlet of the desiccant wheel assembly by hard piping, a heater tube manifold, brackets and clamps. See

Installation section entitled, Opening the dryer doors (W1600-5000).

Clamps and

Gaskets




Heater

Tubes

Manifold

3 Disconnect the main power leads at the junction box inside the frame

of the dryer. In units with two heaters (W3200 and W5000), it may be necessary to measure resistance across the power leads of each heater tube to determine which heater needs to be replaced. In a good element, the resistance across all three legs should be +/- 5% resistance variation when measured leg-to-leg, and high resistance from each leg to ground. Readings other than this indicate a defective heater.

4 Disconnect the high temperature switch cables at the quick disconnects.

5 Loosen the pressure clamps at the top and bottom of the heater tube connection and slide the clamp and its silicon gasket back and away from the heater tube to remove the defective regeneration heater tube(s).

W3200-5000 model dryers lower heater clamp(s) are attached to a manifold that is secured to the desiccant wheel assembly with a bracket, loosen the clamp that secures the heater tube to the manifold to remove it from the dryer.

(continued)



( W 3 2 0 0 - 5 0 0 0 ) ( c o n t i n u e d )

6 Loosen the two (2) lower clamps that secure the regeneration manifold

and tubing to the desiccant wheel bracket. Remove the regeneration manifold and the tubing that is attached to the bottom of the manifold. Then remove the tubing from the regeneration blower outlet and check for loose particles within the tubing, clean as necessary. Reverse this procedure to reinstall the regeneration manifold and tubing.

7 Slide the insulation off the heater tube(s), or make a cut down the entire length of the insulation sleeve to aid removal.

8 Compare the markings on the outside of the regeneration heater tube to ensure the new one has the same voltage and kW ratings as the original

heater tube. This information is on the end nearest the wires.

9 Slide the original insulation over the new heater, or if the insulation was cut for removal, wrap the cut insulation sleeve around the new heater tube and secure it with heat tape.

10 Make sure the cable end of the new heater tube is to the bottom, then

reconnect the hoses to the top and bottom of the heater tube and resecure with pressure clamps that were removed in Step 5.

11 Connect the high temperature switch cable to the quick disconnect.

12 Route the heater power wires into the junction box and connect them to

the supply leads from the control box. Refer to the wiring diagram for specific connection information.

13 To ensure all connections are correct, measure the resistance as in Step 3.

You should measure the readings as noted for a good heater.

14 Close the side panel of the dryer.

15 Connect the dryer to power and turn it on. Verify the regeneration temperature achieves the setpoint.



R e p l a c i n g t h e D e s i c c a n t W h e e l

A s s e m b l y

( W 6 0 0 - 1 0 0 0 )

When desiccant becomes clogged or contaminated, you should replace the desiccant wheel to ensure optimum performance.


2 Remove the upper and lower side panels from both sides of the

dryer.

3 Remove the top cover from the dryer by removing the securing bolts.

4 Note the position of all the hoses, RTDs, and wiring connections then

remove or disconnect these from the desiccant wheel assembly.

5 If the dryer aftercooler is being used, turn off the water supply to the

aftercooler and disconnect the water lines from the aftercooler.

6 Remove the bolts securing the aftercooler assembly to the desiccant wheel assembly.

7 Remove the bolts securing the desiccant wheel assembly in the dryer frame.

8 If the dryer aftercooler is being used, slide the desiccant wheel assembly towards the front of the dryer, being careful not to let it fall off the dryer

frame. Unbolt the aftercooler assembly from the back panel of the dryer and remove it.

9 Note the orientation of the desiccant wheel assembly. Using an overhead crane or similar device, use the lifting rings provided and lift the desiccant wheel assembly out of the dryer.

(continued)


A s s e m b l y

( W 6 0 0 - 1 0 0 0 )

( c o n t i n u e d )

10 Lift the new desiccant wheel into the dryer frame, being sure it is oriented properly.

To verify the correct orientation, ensure that the regeneration air inlet is positioned closest to the regeneration heater tube. DO NOT bolt into place at this time.

11 If the dryer aftercooler is being used, slide the desiccant wheel assembly towards the front of the dryer, being careful to not let it slip off one side of the dryer frame.

Position the aftercooler assembly into the dryer frame and bolt it to the rear panel.

12 Position the desiccant wheel assembly and bolt it in place.

13 Bolt the aftercooler to the desiccant wheel assembly.

14 If the aftercooler is being used, reconnect the water lines.

15 Reconnect or reinstall all hoses, RTDs, and wiring connections.

16 Bolt the top cover in place.

17 Connect the power to the dryer and start it. Ensure that the desiccant wheel assembly rotates in the correct direction.

18 Replace all upper and lower side panels.




M o t o r

( W 6 0 0 - 1 0 0 0 )


2 Remove both side panels.

3 Disconnect wiring to the motor.

4 Remove the pivot bolt securing the belt tensioner to the motor bracket.

Be sure to retain the flat washers located between the tensioner and bracket.

Disconnect the spring and remove the tensioner.

5 Remove the belt from the motor pulley, then remove the pulley from the motor.

6 Remove the screws securing the motor to the upper and lower bracket, and remove the motor.

7 Secure the new motor to the bracket.

8 Install the pulley on the new motor, and position the belt on the pulley.

9 Connect the spring to the tensioner, then secure the tensioner to the

motor bracket. Be sure to install flat washers between the motor bracket and the tensioner.

10 Connect the wires to the motor.

11 Connect the power to the dryer. Turn the dryer on and ensure that the desiccant wheel is rotating in the correct direction.

12 Replace the side panels.


M o t o r

( W 1 6 0 0 - 5 0 0 0 )


2 Open the right side panel(s), as viewed from the front of the dryer.

See Installation section entitled, Opening the dryer doors (W1600-5000).

3 Unbolt and remove the access panel on the side of the desiccant wheel assembly.

4 Disconnect the wiring connection to the motor.

5 While noting the number of turns, relieve the tension on the drive bolt by loosening the nut above the tension spring until the belt can be slipped off the motor sprocket.

6 Unbolt the motor and remove it from its mounting bracket.

7 Remove the sprocket from the old motor, and install it onto the new motor.

8 Bolt the new motor in place. Be sure to remove the plastic plug in the vent hole of the gearbox.

(continued)




M o t o r

( W 1 6 0 0 - 5 0 0 0 ) ( c o n t i n u e d )

9 Slip the belt onto the sprocket, and adjust the tension spring nut to its original position.

10 Connect the wires to the new motor.

11 With the access panel still removed, connect the power to the dryer and

start it. Ensure the wheel turns in the correct direction. If the belt appears to be slipping, it may be necessary to increase the tension on the drive belt slightly. Do not increase this tension any more than necessary to allow the wheel to rotate without slipping.

12 Bolt the access panel in place and close the side panel(s) on the dryer.

W e ’ 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.

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.conairgroup.com

H o w t o C o n t a c t C u s t o m e r S e r v i c e

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.

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, control type and serial numbers from the serial tag, 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.

A p p e n d i x l A - 1

A - 2 l A p p e n d i x

E q u i p m e n t G u a r a n t e e

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.

P e r f o r m a n c e W a 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.

W a 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.

C l e a n i n g t h e P r e c o o l e r C o i l s

You need to clean the precooler coils to keep them working efficiently. Cleaning frequency depends on the type and amount of material you process.


2 Turn off the water flow to the water supply line. Disconnect supply and return lines.

✐

NOTE: If an optional flow control was added with the precooler, remove the compression fitting from the precooler inlet. Loosen the fitting on the flow control, then swing the copper water supply tube out and away from the precooler inlet.

3 Remove the bolts securing the precooler cover. Remove the cover.

4 Remove the precooler by pulling it out of the precooler housing.

5 Clean the assembly using a mild soap and water. Let the assembly dry

✐ thoroughly before installation.



7 Reassemble by repeating the steps in reverse order.

8 Connect the water supply line to the inlet. If a manual shut off valve is used, it should be mounted on the inlet line as well.

9 Connect the outlet of the precooler to the inlet of the flow control valve using the pre-shaped copper tubing and compression fittings provided.

A p p e n d i x l B - 1

C l e a n i n g t h e V o l a t i l e Tr a p o n t h e

D e m i s t e r

( W 6 0 0 - 1 0 0 0 )


2 Remove the thumbscrews then remove the volatile demister cover.

3 Remove the demister by pulling it out from the housing.

C - 1 l A p p e n d i x




5 Insert the demister carefully back into the housing, making sure to completely push it towards the back of its housing.


7 Secure the cover in place using the original thumbscrews.

C l e a n i n g t h e V o l a t i l e Tr a p o n t h e

D e m i s t e r

( W 1 6 0 0 - 5 0 0 0 )


2 Remove the thumbscrews then remove the volatile demister carriage and demister from its housing.

3 Remove the demister from the demister carriage by pushing it out towards the right side of the carriage.




5 Insert the demister carefully back into the demister carriage and then replace the entire assembly back into the demister housing.


7 Secure the cover in place using the original thumbscrews.

A p p e n d i x l C - 2

Conair 5000 User guide

Carousel Plus Dryer

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