Conair 200, 300, 400, 150, Carousel Plus 200 User Manual

Carousel Plus Dryer

Models 150, 200, 300, and 400 with DC-1 Controls

Corporate Office: 412.312.6000 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861

USER GUIDE

UGD028-0107

www.conairnet.com

INTRODUCTION • Purpose of the User Guide • How the guide is organized • Your responsibilities as a user • ATTENTION:

Read this so no one gets hurt • How to use the lockout device • DESCRIPTION • What is the W Dryer? • Typical

applications • How it works • Specifications: W Dryer • INSTALLATION • Unpacking the boxes • Preparing for instal-

-lation • Mounting the dryer and hopper on a Processing Machine • Positioning the dryer on the floor; Mounting the hop-

per on the throat • Mounting the dryer on the floor stand; Hopper on the throat • Mounting the dryer and hopper on the

mobile floor stand • Connecting the main power • Checking for proper air flow • Connecting the air hoses • Connect-

ing water hoses • Connecting air hose adapters • Connecting the RTD probe • Connecting the setback RTD • Mounting

a loader on the hopper • OPERATION • How it works • The W dryer control panel • W dryer control functions • Control

Function Description • To start drying • To stop drying • Using the auto start timer

Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.

It’s a good idea to record the model and serial number(s) of your equipment and
the date you received it in the User Guide. Our service department uses this infor­mation, along with the manual number, to provide help for the specific equipment
you installed.

Please keep this User Guide and all manuals, engineering prints and parts lists
together for documentation of your equipment.

Date:

Manual Number: UGD028-0107

Serial Number(s):

Model Number(s):

* Display Firmware Version:

* Control Firmware Version:

* NOTE: Displayed upon initialization, during power up, or on a data tag

inside the door.

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

Copyright 2007 l The Conair Group l All rights reserved

✐

Table of Contents

1-1 Introduction

Purpose of the user guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

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

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

2-1 Description

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

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

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

Specifications: Carousel Plus W Series Dryer. . . . . . . . . . . . . . . . . . 2-6

Carousel Plus W Series Dryer options . . . . . . . . . . . . . . . . . . . . . . . 2-7

3-1 Installation

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

Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Positioning the dryer on the floor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Removing the cable tie from the desiccant wheel . . . . . . . . . . . . . . 3-5

Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Connecting the process RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Connecting the setback RTD probe (Optional) . . . . . . . . . . . . . . . . . 3-7

Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Connecting the air hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Connecting the dryer to the hopper . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Table of Contents l i

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 Operation

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

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

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

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

To start drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

To stop drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Using the auto start countdown function . . . . . . . . . . . . . . . . . . . . 4-21

How to disable the auto start on the DC-1 control . . . . . . . . . . . . . 4-21

Setting high setpoint limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Using dewpoint control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Using the setback feature (Optional) . . . . . . . . . . . . . . . . . . . . . . . 4-24

Setback feature guidelines (Optional) . . . . . . . . . . . . . . . . . . . . . . 4-25

5-1 Maintenance

Preventative maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . 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

Cleaning the volatile trap on the demister . . . . . . . . . . . . . . . . . . . 5-12

Inspecting hoses and gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

ii l Table of Contents

6-1 Troubleshooting

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

Poor material drying troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 6-25

REPAIR

Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Checking heater solid state relays. . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Checking or replacing temperature sensors . . . . . . . . . . . . . . . . . 6-32

Replacing the heaters

Regeneration heater tube . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Process heater tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

Replacing the desiccant wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Replacing the desiccant wheel motor . . . . . . . . . . . . . . . . . . . . . . 6-38

A Appendix

We’re here to help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

How to contact customer service . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Before you call... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Equipment guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Performance warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Warranty limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

B Appendix

Installing a precooler (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Table of Contents l iii

C Appendix

Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

D Appendix

Cleaning the volatile trap on the demister (Optional) . . . . . . . . . . . D-1

iv l Table of Contents

Introduction

Purpose of the user guide. . . . . . . . . . . . . . 1-2

How the guide is organized . . . . . . . . . . . . . 1-2

Using the Carousel Plus W Series as

a central dryer . . . . . . . . . . . . . . . . . . 1-3

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

ATTENTION:

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

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

SECTION

1

Introduction l 1-1

1

Introduction

✐

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.

How the Guide is Organized

Symbols have been used to help organize the User Guide and call your
attention to important information regarding safe installation and operation.

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

Numbers indicate tasks or steps to be performed by the user.

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

An open box marks items in a checklist.

A circle marks items in a list.

Indicates a tip. A tip is used to provide you with a suggestion that will help you with
the maintenance and the operation of this equipment.

Indicates a note. A note is used to provide additional information about the steps
you are following throughout the manual.

1

◆

❒

•

✒

1-2 l Introduction

Introduction l 1-3

Using the Carousel Plus W Series
as a Central Dryer

This manual incorporates the information necessary to use the Conair W Series
Dryer as a central dryer. Throughout this manual, information particular to cen­tral dyer application of the W series dryer is called out by the following treat­ment.

Your Responsibility as a User

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

•

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

• Thorough review of the equipment itself, with careful attention

to voltage sources, intended use and warning labels.

• Thorough review of instruction manuals for associated equipment.

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

This box will contain information or highlight system differ­ences particular to the application of the W series dryer as a
central dryer.

1

Introduction

ATTENTION:
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.

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

This equipment should be installed, adjusted, and serviced by qualified
technical personnel who are familiar with the construction, operation,
and potential hazards of this type of machine.

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

WARNING: Voltage hazard

This equipment is powered by three-phase alternating current,
as specified on the machine serial tag and data plate.

A properly sized conductive ground wire from the incoming power
supply must be connected to the chassis ground terminal inside the
electrical enclosure. Improper grounding can result in severe personal
injury and erratic machine operation.

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

1-4 l Introduction

(continued)

1

Introduction

Introduction l 1-5

ATTENTION:
Read this so no one gets hurt

(continued)

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.

CAUTION: Hot Surfaces.

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.

WARNING: Do not place aerosol, compressed
gas or flammable materials on or near this
equipment.

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

1-6 l Introduction

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.
To use the lockout device:

11

Stop or turn off the equipment.

22

Isolate the equipment from the electric power. Turn the rotary

disconnect switch to the OFF, or “O” position.

33

Secure the device with an assigned lock or tag. Insert a lock or tag

in the holes to prevent movement.

44

The equipment is now locked out.

WARNING: Before removing lockout devices and returning switches to the ON
position, make sure that all personnel are clear of the machine, tools have been
removed, and all safety guards reinstalled.

To restore power to the dryer, turn the rotary disconnect back to the ON position:

11

Remove the lock or tag.

22

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

Description l 2-1

Description

What is the Carousel Plus W series dryer?. . . 2-2

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

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

Specifications: Carousel Plus W Series

Dryer . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Carousel Plus W Series Dryer options . . . . . . 2-7

SECTION

2

2

Description

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.

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

Typical Applications

1 Dryer on the floor; hopper on the throat.

2 Hopper on a floor stand; the dryer next to it.

3 Dryer and hopper on a mobile floor stand (MDC version 150 and 200 only).

4 Central dryer with ResinWorks system.

The W dryer can be used successfully in applications that require:

• A contamination-free drying environment.

• Drying temperatures within the ranges shown in the following table:

2-2 l Description

(continued)

Typical Applications (continued)

Model Drying Temperature Range

Low temperature (with precooler)* 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

• Throughput rates of 150 to 400 lbs {68 to 149 kg} per hour

(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}.

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

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

Dryer Options

• Dewpoint monitor / dewpoint control

• Audible and visual alarm

• Temperature setback

MDC Options (Models 150 & 200 only)

• Non dry air conveying

• Machine loading only

• Self-loading (machine and hopper loading)

Description l 2-3

2

Description

When supplied for central drying
applications, the W series dryer
is not equipped with a process
heater. Therefore, as a central
dryer, the W dryer will only sup­ply dry air to the hoppers.

THE

PROCESS (D

RYING) C

YCLE

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 wheel, where moisture is removed. The dry
air is delivered to the hopper (after it passes through the optional
precooler, if installed) where a spreader cone evenly distributes the
air through the material.

How It Works

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. The now dry air moves through the
optional precooler (if installed) and process heater, where it is heated to the drying
temperature selected by the operator. The hot, dry air is delivered to the hopper
where a spreader cone evenly distributes the air through the material.

The Cooling Cycle

Regenerated desiccant must be cooled before it rotates back into the process cycle.
The process blower pushes a small amount of air through the cooling section of the
desiccant wheel. The cooling air then passes through the optional aftercooler, if
installed, and repeats the circuit.

The Regeneration Cycle

The regeneration blower pulls air through the regeneration filter into the dryer’s
regeneration heater. The air is heated to 350° F {177° C} before it is pushed into
the “wet” section of the wheel. The hot air purges moisture from the desiccant. The
moist air is blown out the exhaust at the back of the dryer.

2-4 l Description

How It Works (continued)

2

Description

Description l 2-5

The components identified by this type of box in the drawing are not supplied with the
W dryer when it is configured as a central dryer.

REGENERATION

AIR FILTER

DESICCANT

WHEEL

REGENERATION

BLOWER

REGENERATION

HEATER

HIGH TEMP

SHUTOFF

REGENERATION

RTD

HOPPER

PROCESS

BLOWER

RETURN

AIR

FILTER

3 PROCESS FILTER STATUS

RETURN

AIR

RTD

PROCESS

RTD

1 SET BACK TEMPERATURE

HIGH TEMP

SHUTOFF

PROCESS

HEATER BOX

6 ALARM BELL

†

6

7

5 PRECOOLER

7 ALARM LIGHT

†

5

DRYER OPTIONS

2 DEWPOINT MONITOR / CONTROL

PROCESS

COOLING

REGENERATION

1

2

3

PROCESS

PROTECTION

RTD

REGENERATION

OUTLET

RTD

4

4 PHASE ROTATION PROTECTION

*

AFTERCOOLER

*

Standard on MDC only

†

Standard on some DC-1 models

Specifications: Carousel Plus W
Series Dryers

2-6 l Description

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 2.5 5 5 5

Weight lbs {kg}

Standard Dryer Installed 600 {272} 660 {300} 710 {322} 760 {345}

Voltage - Total Amps

230 V/3 phase/60 Hz 47.1 61.4 67 N/A
400 V/3 phase/50 Hz 25.8 34 38.5 63.6
460 V/3 phase/60 Hz 23.6 30.7 33.5 55.3
575 V/3 phase/60 Hz 18.9 24.7 26.8 44.3

Total kilowatts kW {BTU/min} 6.2 {353} 8 {455} 11 {625} 14 {800}
Water requirements {for optional aftercooler or precooler}

Recommended temperature* 45

°

- 85°F

Water flow gal./min. {liters/min.} 3 {11.4}
Water connections NPT 3/4 in. NPT

SPECIFICATION NOTES:

* The term SCFM stands for Standard Cubic Feet Per Minute, referenced to a pre-specified pressure, temperature

and relative humidity. In most cases, SCFM is referenced to 14.7 PSIA 68° F and 36% relative humidity. ACFM
stands for Actual Cubic Feet Per Minute, and must be supplied with a temperature reference, due to the change
in air density with temperature. Because dryers operate at a relatively low pressure the effects on air density are
negligible.

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

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

D

A

C
B

TPDS018-0705-REV

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.

• Precooler - The precooler reduces the temperature of air flow after the desic-

cant wheel and before the process heater, enables the dryer to control tempera­tures at low setpoints, (100º - 150ºF {38º - 66ºC})

• Dewpoint monitor/dewpoint control - The dewpoint monitor/dewpoint con-

trol allows the operator to monitor and control the performance of the dryer’s

dewpoint level, making energy savings possible by reducing the regeneration

temperature.

• Temperature setback - The temperature setback automatically reduces the

drying temperature to a lower standby mode when the machine throughput is

reduced or stopped, helping to minimize over drying material

• Audible/Visual alarms - The audible and visual alarms are a combination of a

blinking red alarm light and a horn that alerts the operator to a shutdown alarm.

• Filter check - The filter check sensor will activate a passive P10 alarm or a

shutdown A29 alarm when the process filter is clogged or needs to be replaced.

Description l 2-7

2

Description

2-8 l Description

Installation l 3-1

Installation

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

Preparing for installation . . . . . . . . . . . . . . 3-4

Positioning the dryer on the floor. . . . . . . . . 3-5

Removing the cable tie from the

desiccant wheel . . . . . . . . . . . . . . . . . 3-5

Connecting the main power . . . . . . . . . . . . . 3-6

Connecting the process RTD probe . . . . . . . . 3-7

Connecting the setback RTD probe (Optional). 3-7

Checking for proper air flow . . . . . . . . . . . . 3-8

Connecting the air hoses . . . . . . . . . . . . . 3-11

Connecting the dryer to the hopper . . . . . . 3-11

Connecting air hose adapters . . . . . . . . . . 3-12

Connecting the aftercooler . . . . . . . . . . . . 3-13

Mounting a loader on the hopper . . . . . . . . 3-14

Testing the installation . . . . . . . . . . . . . . . 3-14

SECTION

3

3

Installation

3-2 l Installation

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.

Note that the dryer is secured to its shipping container with
straps that pass through the bottom of the dryer frame.

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

3 Open the side panel and remove the cable tie securing the desiccant wheel.

See Installation section entitled, Removing the cable tie from the desiccant
wheel.

4 Carefully inspect all components to make sure no damage occurred during

shipping, and that you have all the necessary hardware.

Installation l 3-3

Unpacking the Boxes (continued)

5 Take a moment to record serial numbers and electrical power specifica-

tions 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.

• Dryer and hopper on a mobile floor stand.

• Central dryer, with ResinWorks system.

3

Installation

✐

NOTE: Conair also sells an MDC (dryer and hopper on a mobile floor stand with convey-

ing capabilities) version of this dryer in the 150 and 200 Models. Contact Conair Sales

for additional information.

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. All electrical wiring should comply
with your region’s electrical codes.

❒❒

A source of water, if you have an aftercooler and/or optional

precooler. The W dryer’s aftercooler and optional precooler require 3

gals./min. {11.4 liters/min.} tower, city, or chiller water at temperatures of
45° to 85°F {7° to 29°C}. Pipe should be run to the planned dryer location.
Use flexible hose to connect the water pipes to the aftercooler and/or optional
precooler.

❒❒

Minimum clearance for safe operation and maintenance.

You should maintain 24 in. {61 cm} clearance on all sides of the dryer.

3-4 l Installation

Material and conveying lines

installed. If you plan to use

vacuum or compressed air

loaders to fill the hopper,

install conveying lines to the

drying hopper location.

✒

3

Installation

Installation l 3-5

Positioning the Dryer on the Floor

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.

Removing the Cable Tie from the
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.

Desiccant cable tie

3

Connect the power wires

to the three terminals at the top of the power disconnect holder.

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

3-6 l Installation

Connecting the Main Power

CAUTION: Always disconnect and lock out the main power sources before making electri-

cal connections. Electrical connections should be made only by qualified personnel.

1 Open the dryer’s electrical enclosure. Turn the discon-

nect dial on the dryer door to the Off or “O” position.
Lock out the main power (see Page 1-6 for complete
lock out information). Turn the captive screw, and
swing the door open.

2

Insert the main power

wire through the knockout in the

side of the enclosure or the rear of the dryer. (The
dryer’s electrical wire connection location was a factory
option and may be connected through the front or the
rear of the dryer.) Secure the wire with an appropriate
strain relief.

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

3

Installation

Installation l 3-7

Connecting the Process RTD Probe

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.

2 Plug the probe’s

cable into the
receptacle
labeled process
on the left side of
the electrical
enclosure. Hand

tighten the con­nector. Coil any
excess cable and
secure it with a
wire tie.

Connecting the Setback RTD Probe

(Optional)

1 Insert the probe in the hopper outlet at the top of 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.

2 Plug the probe’s cable into the receptacle labeled setback on the left side of

the electrical enclosure. Hand tighten the connector. Coil any excess cable
and secure it with a wire tie.

Process RTD

Setback RTD

When configured as
a central dryer, moni­toring the drying air
temperature is not
necessary since there
is no process heater
in the system.
Therefore, installa­tion and connection
of the RTD probe
and/or setback probe
is not applicable.

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.

CAUTION: This procedure must be performed before the dryer’s air hoses are con-

nected to the hopper. Performing this step after the air hoses are connected could
cause damage to the dryer if the air flow direction is incorrect due to improper
phase connection. Material from the hopper can be pulled into the process

heater, causing permanent damage.

1 Turn on the main power to the dryer. Make sure the dryer’s disconnect dial is

in the ON position. This powers up the control and the display lights will
illuminate.

2 Set the drying temperature. Press Setpoint Adjust (+) or (-) buttons to set the

drying temperature to a low setpoint of 150ºF {66ºC}.

Shutdown Alarms
A1 Process High Temp
A2 Process Loop Break
A3 Process Heater High Temp
A4 Regen Heater High Temp
A7 Return Air High Temp
A49 Process Protection High Temp
A53 Process Blower Overload
A55 Wheel Rotation Failure

Passive Alarms
P1 Process Temp Deviation
P3 Regen Temp Deviation
P5 Return Air Mid High Temp
P17 MDC Conveying Demand

1 Process Temp.
2 Regen. Temp.
3 Return Air Temp.
4 Auto Start
5 Load Time (MDC)
6 Activate Setback Temp.
7 Setback Temp.(Process)
8 Dewpoint

Auto Start

Dewpoint Control

Set-Back Temp.

Regen. Blower

Regen. Heater

Conveying Blower

Process Blower

Process Heater

3-8 l Installation

When configured as a central dryer, the drying temperature can
not be set since there is no process heater in the system.

Setpoint Adjust
Buttons

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

Installation l 3-9

3

Installation

(continued)

Checking for Proper Air Flow (continued)

3 Press the START button. Hold your hand near the delivery air

outlet. You should feel air blowing out of the outlet.

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.

4 Press the STOP button.

5 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 machine serial tag and
data plate.

Start

Stop

Moisture
Exhaust

Return
Air Inlet

Dry Delivery
Air

✐

NOTE: If the dryer is running for

more than 20 to 30 seconds, the

Process Loop Break alarm may

occur because the Process RTD is

not seeing the expected tempera-

ture rise.

3-10 l Installation

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 direc-

tion. Turn off and lock out the main power source. Open the electrical

enclosure and reverse any two leads connecting the main power supply to

the dryer.

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 machine serial
tag and data plate.

✐

LEADS