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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 . . . . . . . . . . . . . . . . . . .
Connecting air hose adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Connecting the aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Mounting a loader on the hopper . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 4-1 O p e r a t i o n Carousel Plus W Series Dryer: control panel DC-1. . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C Appendix Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 D Appendix Cleaning the volatile trap on the demister (Optional) . . . . . . . . . . .
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 Dryers and explains step-by-step how to install, operate, maintain, and repair this equipment. Before installing this product, please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet. You also should review manuals covering associated equipment in your system. This review won’t take long, and it could save you valuable installation and operating time later.
Using the Carousel Plus W Series as a Central Dryer This box will contain information or highlight system differences particular to the application of the W series dryer 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.
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 Dryer . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Carousel Plus W Series Dryer options . . . . . .
What is the Carousel Plus W Series Dryer? The Carousel Plus W Series Dehumidifying Dryer produces hot, low-dewpoint air that removes moisture from hygroscopic plastics. The dryer pulls warm, moist air from a drying hopper and circulates it through a dehumidifying desiccant wheel. The dryer then heats the air to the drying temperature you selected and circulates it through the material in the hopper.
Ty p i c a l A p p l i c a t i o n s Model (continued) Drying Temperature Range 100° - 150°F {38° - 66°C} Standard 150° - 240°F {66° - 116°C} High heat (with aftercooler)* 150° - 375°F {66° - 191°C} Low-high (with aftercooler & precooler)* 100° - 375°F {38° - 191°C} * See page 3-13, Appendix B (some materials can be run at a higher rate). • Dewpoints of -40°F {-40°C}. Use the aftercooler when: • You are drying at temperatures over 240°F {116°C}.
H o w I t Wo r k s The W dryer achieves continuous, closed loop drying by passing air simultaneously through two heaters and a continuously rotating desiccant wheel. THE PROCESS (DRYING) CYCLE The process blower pulls moist air from the top of the drying hopper. The air passes through the process filter (and optional aftercooler, if installed) into the desiccant wheel, where moisture is removed.
H o w I t Wo r k s (continued) 4 1 PROCESS PROCESS PROTECTION RTD RTD PROCESS HEATER BOX 7 6 REGENERATION BLOWER HIGH TEMP SHUTOFF REGENERATION HEATER 5 REGENERATION RTD HOPPER DESICCANT WHEEL 2 3 REGENERATION OUTLET RTD RETURN AIR FILTER AFTERCOOLER RETURN AIR RTD PROCESS PROCESS BLOWER COOLING DRYER OPTIONS 1 SET BACK TEMPERATURE 4 PHASE ROTATION PROTECTION 2 DEWPOINT MONITOR / CONTROL 3 PROCESS FILTER STATUS 5 PRECOOLER 6 ALARM BELL† * 7 ALARM LIGHT † REGENERATION *† Standard on MD
Specifications: Carousel Plus W Series Dryers A D MODEL W150 W200 W300 W400 Performance characteristics (with full hopper) Air flow {SCFM}* 75 100 150 200 Air flow {ACFM @ 250°F}* 101 134 201 268 Drying temperature All models 100 - 375°F {38 - 191°C} with options dewpoint All models -40°F {-40°C} Dimensions inches {cm} A - Height 70.4 {178.8} B - Overall width 29 {73.7} C - Control width 24 {61.0} D - Depth 51.5 {130.8} Control depth 8 {20.3} Outlet/inlet tube size OD 2.
Carousel Plus W Series Dryer Options • Volatile trap (only in conjunction with aftercooler) - The volatile trap is recommended if drying materials that produce volatile that condense into a waxy or oily residue and/or if the material contains excessive fines.
2-8 l Description
SECTION 3 Installation Unpacking the boxes . . . . . . . . . . . . . . . . . 3-2 Preparing for installation . . . . . . . . . . . . . . 3-4 Removing the cable tie from the desiccant wheel . . . . . . . . . . . . . . . . . 3-5 Connecting the main power . . . . . . . . . . . . . 3-6 C o n n e c t i n g t h e p r o c e s s RT D p r o b e . . . . . . . . 3 - 7 C o n n e c t i n g t h e s e t b a c k RT D p r o b e ( O p t i o n a l ) . 3 - 7 Checking for proper air flow . . . . . . . . . . . .
Unpacking the Boxes The Carousel Plus W Series Dryer comes in one to four boxes, depending on the model and options ordered. The boxes could include (depending on the options selected): • Carousel Plus W Series Dryer • Delivery air hose - 10 ft {3.05 m} - Insulated with High Heat option. • Return air hose - 10 ft {3.05 m} • Process RTD • Setback RTD (optional) • User manual 1 Carefully remove the dryer and components from their shipping containers.
Unpacking the Boxes (continued) 5 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. 6 You are now ready to begin installation. Follow the preparation steps on the next page, then choose one of the four mounting options: • Dryer on the floor; hopper on a floor stand (see page 3-5). • Dryer on the floor; hopper mounted to the machine stand.
Preparing for Installation The Carousel Plus W Series Dryer is easy to install if you plan the location and prepare the mounting area properly. 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 for the correct amps, voltage, phase, and cycles. Field wiring should be completed by qualified personnel to the planned location for the dryer.
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 processing machine. Make sure the location allows for the connection of all hoses. R e m o v i n g t h e C a b l e Ti e f r o m t h e Desiccant Wheel 1 Open the dryer side panels and remove the cable tie securing the desiccant wheel, if it was not done while unpacking the dryer.
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.
C o n n e c t i n g t h e P r o c e s s RT D P r o b e The process RTD probe monitors the temperature of the drying air as it enters the hopper. If the probe is not installed correctly, temperature readings will be inaccurate. 1 Insert the probe at the inlet to the hopper. The end of the probe must not touch the walls of the inlet. The tip of the probe should be approximately in the center of the tube. Tighten the compression fittings to lock the probe in place.
Checking for Proper Air Flow This procedure is needed on W-50 through 100 models if the phase detection option was not ordered with the dryer. IMPORTANT: This step must be performed before the dryer’s air hoses are connected to the hopper or before loading material into the hopper. CAUTION: This procedure must be performed before the dryer’s air hoses are connected to the hopper.
Checking for Proper Air Flow (continued) 3 Press the START button. Hold your hand near the delivery air Start outlet. You should feel air blowing out of the outlet. ✐ NOTE: If the dryer is running for more than 20 to 30 seconds, the Process Loop Break alarm may CAUTION: Hot surface Do not place your hand directly on the delivery air outlet. The outlet and the air can get hot enough to burn your hand. occur because the Process RTD is not seeing the expected temperature rise. 4 Press the STOP button.
Checking for Proper Air Flow ✐ (continued) INSTALLATION NOTE: Models 150, 200, 300, and 400 These models use a three-phase process blower. If the dryer shuts down and a Process Loop Break shutdown alarm (A2) is indicated within the first few minutes of operation, check for proper air flow or check the Process RTD for proper installation. If the air flow is reversed, the process blower is turning in the wrong direction. Turn off and lock out the main power source.
Connecting the Air Hoses Using the two flexible hoses provided, connect the inlets and outlets of the drying hopper to the dryer. If you have positioned the dryer on the floor or mounted it to an optional floor stand, make sure the dryer is located as close as possible to the hopper to reduce heat loss. (10 ft {3.05 m} of hose supplied) ✐ NOTE: If you have ordered an insulated hose, it should be installed between the dryer outlet and the hopper inlet, see step 2.
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 dryer outlet to the hopper. 2 Attach the hopper inlet hose over the adapter, secure with clamp. Dryer inlet/outlet connection 3 Place hose adapter inside high temperature gasket flush to the dryer outlet, secure with pressure clamp.
Connecting the Aftercooler (Optional) The aftercooler and 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}. See Appendix B for installation and water connection instructions for the optional precooler. 1 Secure the aftercooler assembly in the aftercooler housing using the six screws.
✐ NOTE: Check to make sure cable tie has been removed from desic- ✐ cant wheel. NOTE: If A2 (Process 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 manuals that came with your receiver or loader for detailed installation instructions. Loop Break) alarm occurs, blower rotation may be incorrect or Te s t i n g t h e I n s t a l l a t i o n Process RTD is installed incorrectly.
Te s t i n g t h e I n s t a l l a t i o n 4 Press the START button. (continued) Start If everything is installed correctly: • The green light on the start button will illuminate. • The process and regeneration blowers and LEDS will turn on. • The process and regeneration heaters and LEDS will turn on. • The desiccant wheel starts turning. 5 Press the STOP button. Stop • The green light on the start button will illuminate.
3-16 l Installation
SECTION 4 Operation Carousel Plus W Series Dryer: control panel DC-1 . . . . . . . . . . . . . . . . . . 4-2 Carousel Plus W Series Dryer control functions . . . . . . . . . . . . . . . . . 4-3 Control function descriptions . . . . . . . . . . . 4-5 To s t a r t d r y i n g . . . . . . . . . . . . . . . . . . . . 4 - 1 9 To s t o p d r y i n g . . . . . . . . . . . . . . . . . . . . . 4 - 2 0 Using the auto start countdown function . . . 4-21 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. Alarm Codes See Troubleshooting section for a more complete listing of alarms.
Carousel Plus W Series Dryer Control Functions Dryer functions are values that you can set or monitor. Press the Scroll button until the function you want to set or monitor appears in the LED display. ✐ 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.
✐ Display Menu Number NOTE: Screens 1-4 are only displayed during initialization. 5 1 When supplied for central drying applications, these control functions are not available. Control function only available for MDC only. ✐ NOTE: Gray areas designate parameters associated with options.
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 150 v2.0 d v2.0 SCREEN 5 (Default Screen) 1 250 250 SCREEN 5 (Default Screen) 1 CNT 350 Indicates configuration as a central dryer. DRY SCREEN 6 2 This is the DEFAULT screen. It shows the process air temperature setpoint and actual temperature measured at the inlet to the drying hopper.
Control Function Descriptions Screen Function SCREEN 7 This screen shows the actual return air temperature measured at the inlet to the process blower. If the optional aftercooler 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.
Control Function Descriptions (continued) Screen Function SCREEN 10 (Setback Temperature Option) If the dryer has the setback on temperature option installed, this is the temperature setpoint for the air at the outlet of the drying hopper. When this setpoint is reached, the dryer will automatically change the process setpoint to the setpoint shown on Menu number 7, Screen 11.
Control Function Descriptions 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 measured after the desiccant wheel in the process position but before the process heater. With the dewpoint monitor option installed, there will only be an actual display (no setpoint value).
Control Function Descriptions (continued) Function Screen Screens 15-27 require access code 754. SCREEN 16 (Set up Screen) C 375 C02 SCREEN 17 (Set up Screen) C off C03 350 C04 SCREEN 19 (Set up Screen) C off C05 When supplied for central drying applications, this function is not available. This is a regeneration temperature screen. ✐ NOTE: There is normally no need to change this temperature. This is the regeneration heater autotune screen.
Control Function Descriptions (continued) Function Screen Screens 15-27 require access code 754. Control function only available for MDC only. SCREEN 20 (Set up Screen) MDC Option (Models 150 & 200 only) C 10 C06 SCREEN 21 (Set up Screen) Regeneration Differential Temperature C 20 C07 SCREEN 22 (Set up Screen) Regeneration Outlet temperature C 4-10 l Operation 200 C08 This screen shows the time delay setting for the conveying blower on the MDC.
Control Function Descriptions (continued) Function Screen Screens 15-27 require access code 754. SCREEN 23 (Set up Screen) Setback Temperature Band Option C 20 C09 off C10 This screen is the Aftercooler Flow Control Enable screen. By pressing the (+) or (-) keys, the setting can be changed. With this off or disabled, the dryer will not open the flow control valve and try to control the return air temperature. There will also be no set point value on Menu number 3, Screen 7.
Control Function Descriptions (continued) Function Screen Screens 15-27 require access code 754. SCREEN 26 (Set up Screen) C off C12 SCREEN 27 (Set up Screen) Precooler Option C off C13 When supplied for central drying applications, these functions are not available. Reserved function. This should always be off. This screen shows how the precooler is set to operate.
Control Function Descriptions (continued) Function Screen Screen 28-43 require access code 755. SCREEN 29 (Test Mode Screen) H off 2 This is the Test Mode screen for the process heater. By pressing the (+) or (-) keys, the setting can be changed. When set to "On", the process heater output will be turned on for 3 seconds and then shut off automatically. ✐ SCREEN 30 (Test Mode Screen) H off 3 off 4 This is the Test Mode screen for the regeneration heater.
Control Function Descriptions Function Screen (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) Function Screen Screen 28-43 require access code 755. SCREEN 39 (Test Mode Screen) H off 12 This is the Test Mode screen for the MDC conveying blower. By pressing the (+) or (-) keys, the setting can be changed. When set to "On", the conveying blower output will be turned on for 3 seconds and then shut off automatically.
Control Function Descriptions (continued) Function Screen Access code 756 required. SCREEN 44 (Alarm Screen) 4-16 l Operation A 1 P3 A 2 A1 A 3 A5 A 4 A4 A 5 P1 A 6 P5 A 7 A7 A 8 A2 A 9 A6 A 10 P2 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.
Control Function Descriptions (continued) Function Screen Screen 45-49 require access code 754. SCREEN 45 (Setback Temperature Enable Option) C off C11 off C14 SCREEN 47 (Degree F/Degree C) C F C15 This screen shows how the precooler flow control is set to operate. The precooler flow control option must be installed for this screen to appear. It will also assume the water flow solenoid valve is piped in the water line and the dryer control will regulate water flow to control temperature.
Control Function Descriptions Screen 45-49 require access code 754. Control function only available for MDC only. SCREEN 48 (MDC Conveying Option Shutdown on Alarm Option) C off C16 SCREEN 49 (MDC Shutdown Delay Option) H 4-18 l Operation off C17 (continued) Function This screen can be used to determine if the MDC conveying on function will shutdown or continue to operate upon any dryer alarm. When turned off, the MDC blower will continue to cycle indefinitely.
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. 3 Set the drying temperature. Use the Scroll button to get to the process temperature function. Press the Adjust Setpoint (+) or (-) buttons to select the temperature.
To S t a r t D r y i n g (continued) Start 4 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 display LEDS will illuminate. • The process and regeneration heaters turn on and the display LEDs will illuminate. • The desiccant wheel starts turning. When configured as a central dryer, the high setpoint limits can not be set since there is no process heater in the system.
Using the Auto Start Countdown Function The countdown function allows the user to set the W Wheel 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.
Setting the High Setpoint Limit Using the high setpoint limit can protect your drying process from accidental or unauthorized settings above an acceptable level for the material you are drying. Start 1 Turn on the main power to the dryer. 2 While at the default screen (Screen 5) press the scroll button and the setpoint (-) minus button simultaneously to get to Screen 14. 0 0 3 On screen 14 enter the password for set up screens (754) using the setpoint (+) or (-) button.
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.
U s i n g t h e S e t b a c k Fe a t u r e (Optional) The setback function available on the Carousel Plus W series dryer with DC-1 control is designed to save you money on energy costs and keep you from over drying your material. When supplied for central drying applications, the W series dryer is not equipped with a process heater. Therefore the setback function is not applicable.
U s i n g t h e S e t b a c k Fe a t u r e (Optional) (continued) 6 Use the setback temperature band screen (Screen 23) to set the amount the return air temperature has to drop below the setpoint on Screen 10 before the original process temperature is restored.
S e t b a c k Fe a t u r e G u i d e l i n e s (Optional) (continued) A recommended way to determine the “Setback Return Temperature” setpoint is to monitor the actual temperature of this function during pre-drying of your material at start-up, and while running at your normal maximum material throughput. The “Setback Return Temperature” setpoint should be set 10 to 20° above maximum temperature noted in these situations.
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 coils . . . . . . . . . . 5-10 Cleaning the precooler coils . . . . . . . . . . . 5-12 Inspecting hoses and gaskets . . . . . . . . . .
Preventative Maintenance Checklist Routine maintenance will ensure optimum operation and performance of the W Series 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, alarm P9. 8 Stop the dryer, and allow it to cool down.
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 Drain the hopper. Place a container beneath the hopper’s drain port to catch the material. 2 Remove the spreader cone. Open the 3 Clean the spreader cone and 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. 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. 2 Remove the cover wing nut, then pull the cap off. 3 Remove the filter wing nut, then remove the filter.
Cleaning the Process Filter (continued) 4 Remove outer filter and clean it with soapy water. Let air dry. 5 Clean the filter by laying it on its side and gently tapping it on the floor. Replace damaged, worn, or clogged filters. 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. place and in good condition.
Cleaning the Regeneration 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. 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. 2 Remove outer filter and clean it with soapy water. Let the outer filter air dry.
Cleaning the Regeneration Filter (continued) 4 Clean dust, fines, and dirt from the filter, or replace it with a new filter. Clean the filter by laying it on its side and gently tapping it on the floor. Replace damaged, worn, or clogged filters. 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. 5 Reverse the procedure to reinstall the regeneration filter.
Cleaning the Aftercooler Coils The aftercooler coils will need to be kept clean to keep the aftercooler 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, remove the compression fitting from the aftercooler inlet.
Cleaning the Aftercooler Coils 5 Clean the assembly using a mild soap and water. Let the assembly dry thoroughly before installation. In severe situations, steam cleaning or use of solvents maybe necessary. CAUTION: During the cleaning process, DO NOT cut or remove the stainless steel wire that holds the assembly together. 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.
Cleaning the Precooler Coils If you have the optional precooler, you need to clean the cooling coils to keep them working efficiently. See Appendix C 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 D for details. Inspecting Hoses and Gaskets Loose or damaged hoses and gaskets can allow moisture to seep into the closedloop drying system.
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 . . . . . . . . . . . . . 6-24 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 - 2 5 R E PA I R Replacing fuses . . . . . . . . . . . . . . . . . . . .
✐ Before Beginning NOTE: Use of test mode screens 28-43 may assist with the 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. determining of possible cause of an alarm. Access code 756. Before you open the side panels of the dryer be sure to: ❏ Diagnose causes from the control panel.
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 the most recent alarm code. ✐ 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.
Alarms A problem can trigger two types of alarms: • Shutdown (A#): If the red Acknowledge Alarm LED is blinking, the alarm is a When supplied for central drying applications, these shutdown alarms are not available. 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. When supplied for central drying applications, these shutdown alarms are not available.
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. When supplied for central drying applications, these shutdown alarms are not available.
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. When supplied for central drying applications, these shutdown alarms are not available.
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. When supplied for central drying applications, these shutdown alarms are not available.
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 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. Problem Possible cause . A33 & P26 - Regeneration RTD Integrity – If the regeneration RTD is faulty, it shuts 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 A36 -Control Communications Watchdog - The display board has lost communications with the control board.
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. When supplied for central drying applications, these shutdown alarms are not available.
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. When supplied for central drying applications, these shutdown alarms are not available.
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 A54 & P23 - Conveying Blower Overload – The conveying blower overload has tripped due to a mechanical or electrical problem.
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. Defect in the main control board. Replace main control board. RTD is not connected properly or is defective. Check RTD connections, replace defective RTD(s) Connector to all RTDs are removed.
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. Return air temperature exceeds 125°F {52°C}. Reduce the temperature of the cooling water or increase the flow. Regeneration temperature is below normal setting. Check amperage of regeneration heaters.
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 intent of the information provided here is to assist you in determining if your drying system is performing properly.
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 and 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 Possible cause Solution The temperature of the air entering the hopper is not at proper drying temperature.
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. If necessary, pull the fuse out and replace it with a fuse of the same type and rating. 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.
Checking Heater Solid State Relays 1 Disconnect and lockout the main power supply. 2 Open the electrical enclosure. 3 Locate the process or regeneration relays. Refer to the wiring diagrams that came with your dryer. 4 Check continuity using an ohmmeter. Regeneration heater solid state relays If ohms equal zero or infinity, replace the relays. IMPORTANT: Always refer to the wiring diagrams that came with your dryer to locate specific electrical components.
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 drying air, the return air, the regeneration outlet, the regeneration inlet, process protection and setback at the outlet heater of the hopper if the option is installed. 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 Heaters R e g e n e r a t i o n H e a t e r Tu b e 1 Stop the dryer, disconnect the power, and follow proper lockout procedures. 2 Open or remove the right side panel of the dryer, as viewed from the control panel, to gain access to the regeneration heater. 3 Disconnect the regeneration heater wires and high temperature switch wires at the quick disconnects near the heater tube.
Replacing the Heaters R e g e n e r a t i o n H e a t e r Tu b e (continued) 9 Connect the hose and clamp to the bottom of the new regeneration heater tube. 10 Put the original insulation back on the regeneration heater tube. Apply duct tape to the seam that was cut during removal. 11 Connect the heater wires and high temperature switch wires to the quick disconnects near the heater tube. 12 Replace the side panel of the dryer.
Replacing the Heaters P r o c e s s H e a t e r Tu b e 1 Stop the dryer, disconnect the power, and follow proper lockout procedures. 2 Open or remove the right side panel of the dryer, as viewed from the control panel, to gain access to the process heater. Process Heater the electrical enclosure. Refer to the wiring diagram of the dryer to identify the process heater wires and/or trace the wires from the process heater tube into the control box.
Replacing the Heaters P r o c e s s H e a t e r Tu b e (continued) 6 While supporting the heater tube, Clamp remove the hose and clamp at the top of the heater tube. 7 Loosen the clamp holding the bottom of the heater tube to the support bracket, and remove the heater tube from the dryer. Insulation 8 Compare the markings on the out- When configured as a central dryer, there is no process heater in the system. Therefore, replacing the process heater is not applicable.
Replacing the Desiccant Wheel When desiccant becomes clogged or contaminated, you should replace the desiccant wheel to ensure optimum performance. 1 Stop the dryer, disconnect the power, and follow proper lockout procedures. 2 Remove the side panels of the dryer. 3 Note the position of all the hoses and RTDs. Disconnect the hoses and RTDs from both manifolds and the wires from wheel assembly motor. 4 Remove the plastic roof panel from the dryer.
Replacing the Desiccant Wheel Motor 1 Stop the dryer, disconnect and lockout the main power. 2 Open 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 under the tensioner. 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.
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.
Installing a Precooler (Optional) You can add a precooler to the Carousel Plus W Series Dryer by ordering the optional precooler assembly. Installation is easy. The optional precooler requires a source of city, tower, or chiller water and a discharge or return line. You can use water at temperatures up to 85°F {30°C}. But the water flow should be at least 3 gal/min {11.4 liters/min} for W dryer models 150 - 400. 1 Stop the dryer and lockout the main power.
Installing a Precooler (Optional) (continued) 7 Prepare the precooler for installation. Make sure the gasket is put in place. ✒ TIP: Make the water supply and Apply the gasket material to the inside of the precooler flange. discharge / return connections with flexible hoses at least 24 inch {61 cm} long. This allows you to easily remove the precooler assembly for cleaning. ✒ TIP: If an optional flow control is also Precooler Installed 8 Install the coils in the housing.
Cleaning the Precooler Coils The optional precooler coils will need to be kept clean to keep the precooler 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.
Cleaning the Precooler Coils 5 Clean the assembly using a mild soap and water. Let the assembly dry thoroughly before installation. In severe situations, steam cleaning or use of solvents maybe necessary. CAUTION: During the cleaning process, DO NOT cut or remove the stainless steel wire that holds the assembly together. 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.
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 Demister 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 volatile, steam cleaning or the use of solvents, such as acetone, may be necessary.
