www.conairgroup.com USER GUIDE UGD035-0311 Carousel Plus Dryer W Series Models 600 through 5000 with DC-1 Controls Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.
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 record your equipment’s model and serial number(s) and the date you received it in the spaces provided. Please keep this User Guide and all manuals, engineering prints and parts lists together for documentation of your equipment.
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 . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . .
A Appendix We’re here to help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 How to contact customer service . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Before you call... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Equipment guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Performance warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Warranty limitations . . . . .
SECTION 1 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 Yo u r r e s p o n s i b i l i t i e s a s a u s e r . . . . . . . . . . . 1 - 3 AT T E N T I O N : Read this so no one gets hurt . . . . . . . . 1-4 How to use the lockout device . . . . . . . . . . .
Purpose of the User Guide 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.
Using the Carousel Plus W Series as a Central Dryer 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.
AT T E N T I O N : Read this so no one gets hurt We design equipment with the user’s safety in mind. You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide. WA R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n , o r servicing may result in equipment damage or p e r s o n a l i n j u r y.
AT T E N T I O N : Read this so no one gets hurt (continued) CA U T I O N : H o t S u r fa 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.
How to Use the Lockout Device CAUTION: Before performing maintenance or repairs on this product, you should disconnect and lockout electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity. Lockout is the preferred method of isolating machines or equipment from energy sources. Your Conair product is equipped with the lockout device pictured below.
SECTION 2 What is the Carousel Plus W Series Dryer? . . 2-2 Ty p i c a l a p p l i c a t i o n s . . . . . . . . . . . . . . . . . . 2 - 2 How it works . . . . . . . . . . . . . . . . . . . . . . 2-4 Specifications: Carousel Plus W Series Dehumidifying Dryer. . . . . . . . . . . . . . . 2-7 Carousel Plus W Series Dehumidifying Dryer options . . . . . . . . . . . . . . . . . . .
What is the Carousel Plus W Series Dryer? 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.
Ty p i c a l A p p l i c a t i o n s (continued) Model Drying Temperature Range 100° - 150°F {38° - 66°C} Standard 150° - 240°F {66° - 116°C} High heat (with aftercooler/intercooler)* 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}.
H o w I t Wo 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).
H o w I t Wo r k s (continued) (W600 - 1600 and 3200) NOTE: Earlier W1600-5000 dryers will have their intercoolers in the W6001000 location. ****** ****** ********************** W-series 1600-5000 intercooler location only. ********************** ✐ 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.
H o w I t Wo r k s (continued) (W2400 and 5000) 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. 2-6 l Description Protected under United States Patent No. 7,101,414 and other US and Foreign Patents Pending. .
Specifications: Carousel Plus W Series Dehumidifying Dryers A 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 1300 {590} Shipping 1495 {678} Voltage - Full load amps 400 V/3 phase/50 Hz† 37.2 460 V/3 phase/60 Hz 32.0 575 V/3 phase/60 Hz 25.
Carousel Plus W Series Dehumidifying Dryer Options • 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.
SECTION Installation Unpacking the boxes . . . . . . . . . . . . . . . . . 3-2 3 Preparing for installation . . . . . . . . . . . . . . 3-3 Po 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 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) . . . . . . . . . . . .
Unpacking the Boxes 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.
Unpacking the Boxes (continued) 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.
Po 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.
Installing the Return Air Adapter (W600 - 1000) 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.
Installing the Return Air Inlet and A i r O u t l e t A d a p t e r s (W1600 - 5000) 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.
Installing the Overhead Process Air D u c t (W3200 - 5000) 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 shipping 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.
C o n n e c t i n g t h e M a i n Po 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.
Opening the Dryer Doors (W1600 - 5000) 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 Dryer Door Locking Bolts (2) (W1600-5000) to resecure the dryer doors.
Checking for Proper Air Flow ✐ (continued) NOTE: Models W600-1000 dryer aftercooler and dry air delivery configuration shown. Location on larger Dry Delivery Air 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. 3 Visually verify the blower motor is moving in the correct direction indicated by the arrow on the blower housing.
Checking for Proper Air Flow (continued) 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.
Connecting the Air Hoses to a S i n g l e H o p p e r (W600 - 1000) 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 Return Air Inlet flexible hoses to kink or crimp.
Connecting the Air Hoses to a S i n g l e H o p p e r (W1600 - 5000) 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. Return Air Inlet crimp.
Connecting the Air Hoses to a R e s i n Wo 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.
Connecting the Dryer to the Hopper 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. ✐ Connecting the Dryer to 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).
Connecting Air Hose Adapters 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.
Connecting the Aftercooler and O p t i o n a l P r e c o o l e r (W600 - 1000) 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.
✒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. Connecting the Intercooler and O p t i o n a l P r e c o o l e r (W1600 - 5000) 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.
Mounting a Loader on the Hopper 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 2 Turn on the main power to the dryer.
Te s t i n g t h e I n s t a l l a t i o n 4 Press the STOP button. (continued) Stop If everything is installed correctly: • 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.
SECTION 4 Operation Carousel Plus W Series Dryer: control panel DC-1. . . . . . . . . . . . . . . . 4-2 Carousel Plus W Series Dryer DC-1 control functions . . . . . . . . . . . . . . . . . 4-3 Control function descriptions . . . . . . . . . . . 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 Using the auto start countdown function . . . 4-17 How to disable the auto start on the DC-1 control . . . . . . .
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 Pa n e l D C - 1 Increment/Decrement Buttons Used to increase and/or decrease the setpoint of a control function. Setpoint Display Actual Display Menu Number Display Shows the setpoint value. Shows the actual temperature value. Displays the menu number corresponding to what is shown in the setpoint and actual displays. Can also display letters for alarms and setup.
Carousel Plus W Series Dryer DC-1 Control Functions 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. Control Function Flow Chart The following flow chart provides a quick summary of the control functions.
Setpoint Display Display Menu Number Actual Display POWER ON ✐ NOTE: Screens 1-4 are only displayed during initialization. screen # 1 Pr 2 up 5 sec CP 600 5 sec - Model Disignator 3 C v2.0 3.00 1 sec - Control Software Version 4 d v2.0 3.
Control Function Descriptions Screen Function SCREEN 1 Once power is turned on, this screen is displayed for 5 seconds while the control goes through self-checking. Pr up SCREEN 2 CP 600 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. SCREEN 5 (Default Screen) Indicates configuration as a central dryer. v2.0 SCREEN 4 d 1 v2.
Control Function Descriptions Screen Function SCREEN 7 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.
Control Function Descriptions (continued) Screen Function SCREEN 13 (Dewpoint Monitor/ Dewpoint Control Option) 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}.
Control Function Descriptions Function Screen ✐ Screens 18-24 require access code 754. SCREEN 18 (Set up Screen) C (continued) 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. SCREEN 19 (Set up Screen) C off C05 SCREEN 21 (Set up Screen) Regeneration Differential Temperature C 4-8 l Operation 20 C07 This is the regeneration heater autotune screen.
Control Function Descriptions Screen ✐ Function Screens 18-24 require access code 754. SCREEN 22 (Set up Screen) Regeneration Air Temperature C 200 off This screen shows the actual temperature of the regeneration air at the outlet of the desiccant wheel. C08 SCREEN 24 Aftercooler/ Intercooler Flow Control Enable (Option) C (continued) C10 Screen 28-43 require access code 755. SCREEN 28 (Test Mode Screen) H off 1 This is the Test Mode screen for the process blower.
Control Function Descriptions (continued) S✐c r e e n Function SCREEN 30 (Test Mode Screen) 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. Screen 28-43 require access code 755. H off 3 SCREEN 31 (Test Mode Screen) H off 4 This is the Test Mode screen for the regeneration heater.
Control Function Descriptions Function S✐c r e e n (continued) Screen 28-43 require access code 755. SCREEN 34 (Test Mode Screen) H off 7 SCREEN 35 (Test Mode Screen) H off 8 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. This is the Test Mode screen for the alarm output (horn and/or red light).
Control Function Descriptions (continued) Screen ✐ Function SCREEN 40 (Test Mode Screen) This screen is not used in the current program. Screen 28-43 require access code 755. H off 13 SCREEN 41 (Test Mode Screen) H off 14 SCREEN 42 (Test Mode Screen) H off 15 This screen is not used in the current program. This is the Test Mode screen for the alarm output (yellow light). By pressing the (+) or (-) keys, the setting can be changed.
Control Function Descriptions (continued) Screen ✐ Function SCREEN 44 (Alarm Screen) 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. Access code 756 required.
Control Function Descriptions (continued) Screen ✐ Function SCREEN 47 (Degree F/Degree C) 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. Screen 47 require access code 754.
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. If everything is installed correctly: • 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.
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 Stop to cool the heaters. 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.
Using the Auto Start Countdown Function 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.
Using Dewpoint Control 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.
SECTION 5 Maintenance Preventative maintenance checklist . . . . . . . 5-2 Checking the dewpoint . . . . . . . . . . . . . . . . 5-3 Cleaning the hopper. . . . . . . . . . . . . . . . . . 5-5 Cleaning the process filter . . . . . . . . . . . . . 5-6 Cleaning the regeneration filter . . . . . . . . . . 5-8 Cleaning the aftercooler/intercooler coils . . . 5-9 Cleaning the precooler coils . . . . . . . . . . . 5-11 Inspecting hoses and gaskets . . . . . . . . . .
Preventative Maintenance Checklist Routine maintenance will ensure optimum operation and performance of the W Series Carousel Plus Dryer. We recommend the following maintenance schedule and tasks. • Whenever you change materials ❒ Drain and clean the hopper. • We 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.
Checking the Dewpoint 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.
Checking the Dewpoint (continued) 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.
Cleaning the Hopper 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.
Cleaning the Process Filter 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. ✐ CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the dryer and drying hopper. NOTE: Larger dryer models (W1600 - 5000) do not have covers.
Cleaning the Process Filter (continued) 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. 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.
Cleaning the Regeneration Filter ✐ Clogged filters reduce air flow and dryer efficiency. Cleaning frequency depends on the condition of your dryer’s ambient air. NOTE: Dirty or clogged 1 Push in on the sides to release the tabs on the front cover. Remove the cover. regeneration filters are the leading contributor of dryers not reaching desired dewpoints. CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the dryer and drying hopper.
Cleaning the Aftercooler/ Intercooler Coils 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.
Cleaning the Aftercooler/ I n t e r c o o l e r C o i l s (continued) 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.
Cleaning the Precooler Coils 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 Vo l a t i l e Tr a p o n the Demister If you have the optional volatile trap, you need to clean the trap to keep it working efficiently. See Appendix C for details. Inspecting Hoses and Gaskets Loose or damaged hoses and gaskets can allow moisture to seep into the closed-loop drying system.
5-12 l Maintenance
SECTION 6 Tr o u b l e s h o o t i n g Before beginning . . . . . . . . . . . . . . . . . . . . 6-2 A few words of caution . . . . . . . . . . . . . . 6-3 DIAGNOSTICS How to identify the cause of a problem . . . . 6-4 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Dewpoint troubleshooting . . . . . . . . . . . . . 6-17 Po 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 Replacing fuses . . . . . . . . . . . . . . . . . . . .
Before Beginning You can avoid most problems by following the recommended installation and maintenance procedures outlined in this User Guide. If you do have a problem, this section will help you determine what caused it and how to fix it. Before you 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.
Before Beginning (continued) ❏ 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 Fe w Wo r d s o f C a u t i o n The Carousel Plus W Series Dryer is equipped with numerous safety devices.
✐ How to Identify the Cause of a Problem NOTE: Pushing the Acknowledge Alarm button when there is no active alarm will display 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. the most recent alarm A problem can trigger two types of alarms: code.
Alarms A problem can trigger two types of alarms: ✐ NOTE: Shutdown alarms will cause the dryer to go through the normal shut down procedure to cool the heaters, then it will stop running. • 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.
Alarms • 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.
Alarms • 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. Solution A25 & P5 - Return Air MidHigh Temperature – If the return air temperature is between 150 and 180°F {66 and 82°C}.
Alarms • 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 A28 & P9 - Process Dewpoint – The dewpoint has not fallen below the setpoint.
Alarms • 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. Solution A34 & P28 - Return Air Temperature RTD Integrity – The dryer continues to run with a passive alarm.
Alarms • 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 A38 - Phase Error (Option al) - One of the three power wires is connected wrong.
Alarms • 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.
Alarms • 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 A55 & P31 - Wheel Rotation Failure - The regeneration temperature differential has been reached.
Alarms • 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.
Alarms • 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.
Additional Alarms Along with the alarm indicators, you may encounter additional messages that indicate a problem within the control. Problem Possible cause Solution CoS Er.4 or Co5 Er. 4 Displayed when the “Start” button is pushed during any active alarm. (Passive or Shutdown) The dryer will continue to run if there is a passive alarm, however it will not start if there is a active alarm. Push the alarm acknowledgement button to identify the alarm, and address it as necessary. CoS Er.0 or Co5 Er.
Additional Alarms Along with the alarm indicators, you may encounter additional messages that indicate a problem within the control. Problem Possible cause Solution Er. H - There is a problem in the analog input section of the control. RTD is not connected properly or is defective. Check RTD connections, replace defective RTD Connector to all RTDs is removed. 6 - 1 6 l Tr o u b l e s h o o t i n g The ribbon cable between an analog option board and the main control board is not connected properly.
D e w p o i n t Tr o u b l e s h o o t i n g 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. Problem Possible cause Solution Dryer not producing desired dewpoint. Low regeneration air flow. Check regeneration filter and clean and/or replace as necessary. Return air temperature exceeds 125°F {52°C}.
Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t 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.
✐ NOTE: Concerns with drying temperature may require review of HTC or ResinWorks controls. Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( 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.
Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( 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. Problem Possible cause Solution Material residence time is too long or short. Material level in hopper is too low. Make sure there is an adequate supply of material to feed the loader on top of the drying hopper.
Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) 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.
Replacement dewpoint monitors are available from Conair. Contact Conair Parts (800) 458 1960 From outside of the United States, call: (814) 437 6861 Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) 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.
Replacing Fuses 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.
Checking Heater Solid State Relays ON O OFF 1 CAUTION: Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by qualified personnel. Disconnect and lockout the main power supply. 2 Open the electrical enclosure. 3 Locate the regeneration solid state relays. Refer to the wiring diagrams that came with your dryer.
C h e c k i n g o r R e p l a c i n g Te m p e r a t u r e Sensors The 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: 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.
Replacing the Regeneration Heater (W600 - 1000) 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.
Replacing the Regeneration Heater (W600 - 1000) (continued) 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.
Replacing the Regeneration Heater (W1600 - 2400) 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 IMPORTANT: Always refer to the wiring diagrams that came with your dryer to locate specific electrical components.
Replacing the Regeneration Heater (W1600 - 2400) (continued) 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.
Replacing the Regeneration Heater (W3200 - 5000) 1 Stop the dryer, disconnect and lockout the main power. 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).
Replacing the Regeneration Heater (W3200 - 5000) (continued) 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.
Replacing the Desiccant Wheel A s s e m b l y (W600 - 1000) When desiccant becomes clogged or contaminated, you should replace the desiccant wheel to ensure optimum performance. 1 Stop the dryer, disconnect and lockout the main power. 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.
Replacing the Desiccant Wheel A s s e m b l y (W600 - 1000) (continued) 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.
Replacing the Desiccant Wheel M o t o r (W600 - 1000) 1 Stop the dryer, disconnect and lockout the main power. 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.
Replacing the Desiccant Wheel M o t o r (W 1600 - 5000) 1 Stop the dryer, disconnect and lockout the main power. 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.
Replacing the Desiccant Wheel M o t o r (W1600 - 5000) (continued) 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.
We ’ r e H e r e t o H e l p Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have installing and operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use.
Equipment Guarantee Conair guarantees the machinery and equipment on this order, for a period as defined in the quotation from date of shipment, against defects in material and workmanship under the normal use and service for which it was recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination.
Cleaning the Precooler Coils You need to clean the precooler 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 precooler, remove the compression fitting from the precooler inlet.
C l e a n i n g t h e Vo l a t i l e Tr a p o n t h e D e m i s t e r (W600 - 1000) 1 Stop the dryer and lockout the main power. 2 Remove the thumbscrews then remove the volatile demister cover. 3 Remove the demister by pulling it out from the housing. 4 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.
C l e a n i n g t h e Vo l a t i l e Tr a p o n t h e D e m i s t e r (W1600 -5000) 1 Stop the dryer and lockout the main power. 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. 4 Clean the assembly using a mild soap and water. Let the assembly dry ✐ thoroughly before installation.
