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.

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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

Introduction l 1-1

Introduction

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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.

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•

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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.

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)

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:

Stop or turn off the equipment.

Isolate the equipment from the electric power. Turn the rotary

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

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

in the holes to prevent movement.

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:

Remove the lock or tag.

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

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

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)

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

†

5 PRECOOLER

7 ALARM LIGHT

†

DRYER OPTIONS

2 DEWPOINT MONITOR / CONTROL

PROCESS

COOLING

REGENERATION

PROCESS

PROTECTION

RTD

REGENERATION

OUTLET

RTD

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.

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

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

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.

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.

✒

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

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.

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.

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

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.

✐

LEADS

Installation

Installation l 3-11

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.

1 Attach one hose from the return

air inlet of the dryer to the return air outlet from the top of the hopper.

2 Attach one hose from the deliv-

ery air outlet of the dryer to the delivery air inlet of the hopper.

3 Secure hoses with clamps.

The hose clamp should be secured at least 1/4 in. {6.35 mm} from the end of the inlet or outlet tube.

Connecting the Dryer to the Hopper

W 150 has a 2 1/2 inch {63.5 mm} inlet and outlet hose connections. W 200, W 300 and W 400 have a 5 inch {127 mm} inlet and outlet hose connections.

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

NOTE: Do not allow the

flexible hoses to kink or

crimp.

✐

Return Air Inlet

Dry Delivery Air

✐

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.

3 Place hose adapter inside high temperature gasket flush to the dryer outlet,

secure with pressure clamp.

3-12 l Installation

Dryer inlet/outlet connection

Pressure clamp

Installation

Installation l 3-13

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.

2 Connect the water supply line to the

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

3 Connect the water discharge or return

line to the aftercooler outlet.

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

✒

TIP: Make the water supply and dis-

charge / return connections with

flexible hoses at least 24 in.

{61 cm} long. This allows you to

easily remove the aftercooler

assembly for cleaning.

✒

TIP: If an optional flow control is also

being installed with the aftercooler,

the manual shut off valve should be

installed on the inlet line for the flow

control.

Aftercooler

3-14 l Installation

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.

Testing the Installation

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

1 Make sure there is no material in the hopper. If you have mounted a

loader or vacuum receiver on the hopper, disconnect the material inlet hose at the source or turn the loader off.

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. Press Setpoint Adjust (+) or (-) buttons to set

the drying temperature to a low setpoint (150ºF {66ºC}).

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

Setpoint adjustment buttons

NOTE: Check to make

sure cable tie has been

removed from desic-

cant wheel

✐

NOTE: If A2 (Process

Loop Break) alarm

occurs, blower rotation

may be incorrect or

Process RTD is

installed incorrectly.

✐

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

Testing the Installation

(continued)

4 Press the START button.

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.

If everything is installed correctly:

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

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

6 The test is over. If the dryer performed the normal operating sequences as out-

lined, you can load the hopper and begin operation. If it did not, refer to the Troubleshooting section of the User Guide.

Stop

• The green light on the start button will illuminate.

• The process and regeneration blowers turn on and the display

LEDS will illuminate.

• The regeneration heater turns on and the display LED will

illuminate.

• The desiccant wheel starts turning.

Start

Installation l 3-15

Installation

3-16 l Installation

SECTION

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 limit. . . . . . . . . . . . . 4-22

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

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

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

Operation l 4-1

4-2 l Operation

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

Carousel Plus W Series Dryer

: Control Panel DC-1

Scroll Button

Press to scroll through the closed loop menu list. Pressing the Scroll button moves you down the list.

Alarm Codes

See Troubleshooting section for a more

complete listing of alarms.

Setpoint Display

Shows the setpoint value.

Menu List

Numbers 1, 2, 3, and 4 are standard items that will always be present. Numbers 5, 6, 7, 8 are screens associated with options. If the option is not installed, the screens will not be displayed.

Increment/Decrement Buttons

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

Acknowledge Alarm Button

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

Actual Display

Shows the actual temperature value.

Menu Number Display

Displays the menu number corresponding to what is shown in the setpoint and actual displays. Can also display letters for alarms and setup.

Start and Stop Buttons

Press Start to start the dryer. Press Stop to stop the dryer.

Menu List

Numbers 2, 3, and 4 are standard items that will always be present. If the option is not installed, the screens will not be displayed.

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. For an explanation of each control function, see Control Function Descriptions. Screen numbers correspond with numbers beside each block in the flow chart.

Operation l 4-3

Operation

✐

4-4 l Operation

CNT

DRY

When supplied for central drying applications, these control functions are not available.

Display Menu Number

Setpoint Display

Actual Display

NOTE: Screens 1-4 are

only displayed during

initialization.

✐

Control function only available for MDC only.

NOTE: Gray areas designate

parameters associated with

options.

✐

Operation

Operation l 4-5

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

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

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

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

This is the DEFAULT screen. It shows the process air temperature setpoint and actual temperature measured at the inlet to the drying hopper. The (+) or (-) buttons can be used to change the setpoint. Holding the (+) or (-) buttons in will allow the number to ramp up faster the longer the button is held. The display will return to the default screen from anyplace in the menu structure if nothing is done after 10 minutes.

Indicates configuration as a central dryer.

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

Screen

SCREEN 1

SCREEN 2

SCREEN 3

SCREEN 4

SCREEN 5 (Default Screen)

SCREEN 6

Function

Control Function Descriptions

150

v2.0

5.01

v2.0

5.02

250

350

CNT

DRY

When supplied for central drying applications, this function is not available.

4-6 l Operation

Screen

SCREEN 7

SCREEN 8

SCREEN 9 (MDC Option 150 & 200 only)

100

Function

Control Function Descriptions

(continued)

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.

This screen is used to set the dryer to auto start. The dryer must be on but not running to set auto start. The value shown is the countdown time setpoint. It is adjustable from 0.1 hours to 150 hours. Once the countdown time is set, press the “START” button. The display will show ON to tell the operator that the auto start is ON and counting. The auto start LED on the display also flashes green when the auto start is armed and counting down. The LED will turn solid green when the dryer starts. The dryer will begin operating when the control has finished counting down.

This screen shows the amount of time the conveying blower will run. Based on the position of the demand sensor in the material receiver, this time may need adjusted. The time should be set for the time it takes to satisfy the demand sensor + 1 second. If the MDC tries to load three consecutive times without satisfying the demand signal the dryer will display a passive alarm. The range for this time setting is 5 to 20 seconds.

100

-----

Control function only available for MDC only.

Operation l 4-7

Operation

Screen

SCREEN 10 (Setback Temperature Option)

SCREEN 11 (Setback Options)

Function

Control Function Descriptions

(continued)

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. When the temperature at the outlet of the hopper drops below the setpoint (entered on this screen, in this example 150) by the value shown under C09, Screen 23, the dryer will return to the normal drying setpoint.

If the dryer has the setback on temperature option installed, this is the temperature setpoint to which the process air will revert once the air at the outlet of the hopper has reached its setpoint (Screen 10, Menu number 6).

150

120

145

250

When supplied for central drying applications, these functions are not available.

NOTE: See informa-

tion on page 4-24 for

use of Setback.

✐

4-8 l Operation

Screen

SCREEN 13 (Dewpoint Monitor/Dewpoint Control Option)

SCREEN 14

Screens 15-27 require access code 754.

SCREEN 15 (Set up Screen)

Function

Control Function Descriptions

(continued)

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). Although the dryer is capable of producing dewpoints much lower than -40

°F {-40

°C}, the mini-

mum sensor range is -40

°F {-40°C}

. dewpoint control will automatically adjust the regeneration temperature to maintain dewpoint setpoint. Dewpoint control is not active with -40

°F {-40°C} setpoint.

This is the password entry screen that gives the user access to the Set Up, Test Mode, and Alarm History screens. The user can get to the non-password protected control functions through this screen by pressing the scroll button and the adjust setpoint button at the same time. This works only if you are on menu #1 (default screen). The access codes are as follows:

Set Up Screens 754 Test Mode Screens 755

Alarm History Screens 756 To exit the password section, enter 500 and press scroll or cycle the power.

This is the process deviation temperature screen. The range is 5 to 20

°F {3 to

11°C}. This is the deviation temperature band around the set point. If the dryer goes outside this band, the dryer will display a passive alarm (P1).

-30

-40

C01

When supplied for central drying applications, this function is not available.

Operation

Operation l 4-9

Screen

Screens 15-27 require access code 754.

SCREEN 16 (Set up Screen)

SCREEN 17 (Set up Screen)

SCREEN 18 (Set up Screen)

SCREEN 19 (Set up Screen)

Function

Control Function Descriptions

(continued)

This is the process high temperature limit screen. It limits how high the process temperature setpoint can be adjusted. (Screen 5) The range is 100 - 450

°F

{38 - 232°C}.

This is the process heater autotune screen. The autotune function can be turned on by pressing the (+) key. Once the (+) key is pressed, the screen will show On and then start the autotune process. This may take a minute or so to complete. When finished, the display will read "don". The new PID values are automatically saved. An autotune should be performed on a cold dryer. Before beginning autotune, be certain your normal drying temperature has been entered on Screen 5, Menu number 1.

This is a regeneration temperature screen.

NOTE: There is normally no need to change

this temperature.

This is the regeneration heater autotune screen. The autotune function can be turned on by pressing the (+) key. Once the (+) key is pressed, the screen will show On and then start the autotune process. This may take a minute or so to complete. When finished the display will read "don". The new PID values are automatically saved. An autotune should be performed on a cold dryer. It will autotune to the value entered on Screen 18.

375

C02

off

C03

350

C04

off

C05

✐

When supplied for central drying applications, this function is not available.

NOTE: Software may allow the Process temperature setpoint limit up to 450

°F {232°C}, howev-

er Conair does not recommend a setpoint limit over 375

°F {191°C} due

to nuisance alarms.

✐

4-10 l Operation

Screen

Screens 15-27 require access code 754.

SCREEN 20 (Set up Screen) MDC Option (Models 150 & 200 only)

SCREEN 21 (Set up Screen) Regeneration Differential Temperature

SCREEN 22 (Set up Screen) Regeneration Outlet temperature

Function

Control Function Descriptions

(continued)

This screen shows the time delay setting for the conveying blower on the MDC. This is the minimum time the MDC will wait before starting another load cycle.

This screen shows the differential temperature at the regeneration inlet and the outlet at the desiccant wheel. If the actual temperature is under the set value, the dryer will alarm (P31), but will still run.

This screen is the actual temperature measured at the regeneration outlet on the wheel.

C07

200

C08

C06

Control function only available for MDC only.

Operation

Operation l 4-11

Screen

Screens 15-27 require access code 754.

SCREEN 23 (Set up Screen) Setback Temperature Band Option

SCREEN 24 (Set up Screen) Aftercooler Flow Control Enable Option

Function

Control Function Descriptions

(continued)

This screen is the Setback Temperature Band screen. This temperature is the amount the return air out of the hopper has to drop below the activate setback temperature (Screen 10) before the original process temperature is restored. For example, if the activate setback temperature was 180°F {82°C} and the dryer was in setback. The actual temperature measured at the outlet to the hopper which has a 20° Setpoint (Screen 23) would have to drop below 160°F {71°C} to restore the original process setpoint.

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.

C09

off

C10

When supplied for central drying applications, these functions are not available.

4-12 l Operation

Screen

Screens 15-27 require access code 754.

SCREEN 26 (Set up Screen)

SCREEN 27 (Set up Screen) Precooler Option

Screen 28-43 require access code 755.

SCREEN 28 (Test Mode Screen)

Function

Control Function Descriptions

(continued)

Reserved function. This should always be off.

This screen shows how the precooler is set to operate. If it is set to "Off" the control assumes the precooler is not installed in the process line and will not control well below 150

°F {66°C}. If the screen is set to

"On" the control will assume the precooler is connected in the process line and will only allow setpoints from 100 to 150°F {38 to 66

°C}. The control will also

assume that the water flow rate is set manually with a ball valve and make no attempt to control water flow. The precooler option must be installed for this screen to appear.

NOTE: If this function is set to Off, make

sure the water to the precooler is turned off.

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

off

C13

off

C12

When supplied for central drying applications, these functions are not available.

✐

Operation l 4-13

Operation

Screen

Screen 28-43 require access code 755.

SCREEN 29 (Test Mode Screen)

SCREEN 30 (Test Mode Screen)

SCREEN 31 (Test Mode Screen)

SCREEN 32 (Test Mode Screen)

SCREEN 33 (Test Mode Screen)

Function

Control Function Descriptions

(continued)

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.

NOTE: The isolation contactor will not be engaged so no electricity will go the heater. The solid state relay contacts should close.

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

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

NOTE: The isolation contactor will not be engaged so no electricity will go the heater. The solid state relay contacts should close.

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

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

(continued)

off

✐

off

✐

off

4-14 l Operation

Screen

Screen 28-43 require access code 755.

SCREEN 34 (Test Mode Screen)

SCREEN 35 (Test Mode Screen)

SCREEN 36 (Test Mode Screen)

SCREEN 37 (Test Mode Screen)

SCREEN 38 (Test Mode Screen)

Function

Control Function Descriptions

(continued)

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

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

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

NOTE: If the optional precooler flow control

valve is not installed nothing will happen.

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

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

This screen is not used in the current program.

off

✐

off

Operation l 4-15

Operation

Screen

Screen 28-43 require access code 755.

SCREEN 39 (Test Mode Screen)

SCREEN 40 (Test Mode Screen)

SCREEN 41 (Test Mode Screen)

SCREEN 42 (Test Mode Screen)

SCREEN 43 (Test Mode Screen)

Function

Control Function Descriptions

(continued)

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.

NOTE: If the dryer is not an MDC nothing will happen.

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

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

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

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

off

✐

off

✐

(continued)

4-16 l Operation

Screen

Access code 756 required.

SCREEN 44 (Alarm Screen)

Function

Control Function Descriptions

(continued)

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 Troubleshooting section of this manual for all alarm code definitions.

These are the additional alarm screens. See the explanation above.

Operation l 4-17

Screen

Screen 45-49 require access code 754.

SCREEN 45 (Setback Temperature Enable Option)

SCREEN 46 (Precooler Flow Control Enable Option) (not available at this time)

SCREEN 47 (Degree F/Degree C)

Function

Control Function Descriptions

(continued)

This screen shows the setting of the setback option. It can be set to “Off” or “On”. “Off” turns the setback mode off, and the dryer will not change the process setpoint. “On” tells the control the dryer should go into setback when the hopper outlet temperature reaches its setpoint (Menu number 6, Screen 10). If setback option was ordered, it is turned “Off” when shipped and must be turned on to use the option.

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.

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.

off

C11

C15

When supplied for central drying applications, these functions are not available.

Operation

off

C14

4-18 l Operation

Function

Control Function Descriptions

(continued)

Screen 45-49 require access code 754.

SCREEN 48 (MDC Conveying Option Shutdown on Alarm Option)

SCREEN 49 (MDC Shutdown Delay Option)

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.

Use this screen in the event Screen 48 is enabled to set the amount of time the conveying function will continue to operate once the dryer has alarmed. If Screen 48 is disabled, the conveying functions will continue indefinitely.

off

C16

off

C17

Control function only available for MDC only.

To Start Drying

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.

(continued)

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

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

Operation

Operation l 4-19

Acknowledge Alarm Button

Setpoint Adjust Buttons

Scroll Button

4-20 l Operation

To Start Drying (continued)

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.

To Stop Drying

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

• The blowers continue running for a few minutes

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. Turning off power to the

control and dryer during normal operation prevents the necessary cool-down period, and can

trigger the shut down/high temperature alarm during your next drying cycle.

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

• The green light on the start button will illuminate.

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

• The regeneration heater and LEDs will turn on.

• The desiccant wheel starts turning.

Stop

Start

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

Operation

Operation l 4-21

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).

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.

How to Disable the Auto Start on the DC-1 Control

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

4-22 l Operation

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.

1 Turn on the main power to the dryer.

2 While at the default screen (Screen 5) press the scroll button and the set-

point (-) minus button simultaneously to get to Screen 14.

3 On screen 14 enter the password for set up screens (754) using the setpoint

(+) or (-) button.

4 Scroll to screen 16.

This is your current high setpoint limit. Press (+) or (-) keys to set a new high setpoint limit.

Tip: We recommend that you set your high setpoint limit 10° higher than your maxi-

mum high temperature setpoint.

5 To lock in your new high setpoint limit and exit the password protected

screens, scroll back to screen 14, then enter 500 and press scroll or cycle the power off and on.

754

385

C02

754

✒

Start

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

NOTE: Software may allow

the Process temperature

setpoint limit up to 450

°F

{232

°C}, however Conair

does not recommend a set-

point limit over 375

°F

{191

°C} due to nuisance

alarms.

✐

NOTE: Conair is not responsi-

ble for damage caused by

excessively high drying

setpoints that are not in

accordance with your drying

material recommendations.

✐

Operation l 4-23

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

11), the dryer will gradually lower the regeneration air temperature to a point where the dryer’s delivery air is controlled at -20

° F {-29° C} dewpoint.

The dewpoint control is active with setpoint values of -39

° F {-39.4° C} and

higher. When the setpoint is -40

° F {-40

° C} or lower, the regeneration tempera-

ture will be maintained at the default temperature of 350

° F {177° C} and the

dewpoint control is inactive.

Operation

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

Function Descriptions, page 4-5.

✐

When supplied for central drying applications, the W series dryer is not equipped with a process heater. Therefore the setback function is not applicable.

Using the Setback Feature (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.

The optional setback feature, if installed from the factory, is disabled and will need to be enabled in access code 754 (Screen 45).

This is how setback operates when installed and turned on:

The control monitors the temperature of the air exiting the drying hopper. If that temperature reaches a customer entered setpoint (Screen 10), the delivery process air temperature will automatically setback to a customer-entered setpoint (Screen 11). Then, if the air exiting the drying hopper drops below the customerentered temperature on Screen 10 by an amount greater than what is shown on Screen 23, the process temperature will automatically reset back to the original process temperature (Screen 5).

To turn on and setup the setback option:

1 Enter the access code 754 (see Screen 14). Then using the scroll buttons,

scroll to menu Screen 45.

2 Turn the setback function for temperature option to "On" by pressing the

(+) key.

3 Push the scroll button to return to access code 754, then change the code to

500. Once the number has been entered push the scroll button or cycle the power to clear the access code.

4 Go to Screen 10. This is where you will set the temperature setpoint for the air

at the outlet of the drying hopper.

5 On Screen 11 set the temperature setpoint to which the process air will revert

to once the air at the outlet of the drying hopper has reached its setpoint.

(continued)

4-24 l Operation

NOTE: Screen 5 will

still show normal dry-

ing temperature as

setpoint when setback

is active.

✐

Using the Setback Feature (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. For example, if the activate setback temperature was 180ºF {82ºC} and the value on Screen 23 is set to 20, once the dryer moves into setback, the actual temperature measured at the outlet of the hopper would have to drop below 160ºF {71ºC} to restore the original process set point.

7 When the “Setback” Feature is active, the Setback LED will be lit, and the

actual temperature on screen 5 will eventually approach the setpoint entered in screen 11.

Setback Feature Guidelines

(Optional)

Careful selection of setpoint values in these functions is necessary for the setback to operate properly. The following table is only a guideline of recommended settings for these setpoints. It will be necessary for each customer to determine the best setpoints for their application based on experience.

To turn off the setback option:

1 Enter the access code 754 (see Screen 14). Then using the scroll buttons,

scroll to menu Screen 45.

2 Turn the setback function for temperature option to "Off" by pressing the

(-) key.

3 Push the scroll button to return to access code 754, then change the code to

500. Once the number has been entered push the scroll button or cycle the power to clear the access code.

Operation

Operation l 4-25

Normal Setback Return Temp Setback Temp

Drying Temp Screen #10 (Process) Screen #11

160° F {71° C} 120° F {49° C} 150° F {66° C}

240° F {116° C} 135° F {57° C} 180° F {82° C}

300° F {149° C} 160° F {71° C} 200° F {93° C}

340° F {171° C} 180° F {82° C} 220° F {104° C}

4-26 l Operation

Setback Feature Guidelines (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.

The “Setback Temperature (Process)” setpoint you select should be adequate to reduce the temperature significantly enough to prevent over-drying of your material. However, keep in mind that the cooler the temperature selected, the longer it will take for the material to heat back up to its proper drying temperature once the dryer comes out of Setback mode.

When drying at low temperatures (for example 160 - 180° F {71 - 82° C}), you are able to setback the temperature only a small amount. The “Setback Temperature (Process)” should not be set lower than 150° F {66° C}, even if the control will allow it. It is very likely the dryer will not be able to achieve low temperatures without adding additional cooling to the process air circuit. The maximum achievable setpoint is dependent on the temperature of the return air coming back to the dryer. As the return air temperature climbs, the temperature that the dryer is capable of controlling at climbs. For example, if the return air to the dryer is 110° F {43° C}, the dryer may not be able to control at a “Setback Temperature (Process)” setpoint below 150 - 155° F {66 - 68°C}.

NOTE: Selecting too low of a setpoint for Screen 26 may result in nuisance A2 Process

Loop Break alarms if the dryer is not able to achieve this setpoint.

✐

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

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

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

SECTION

Maintenance

Maintenance l 5-1

5-2 l Maintenance

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.

• Weekly, or as often as needed

❒❒

Clean or replace the process and regeneration filters.

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

❒❒

Inspect hoses and hose connections.

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

• Monthly

❒❒

Clean the optional aftercooler and precooler coils.

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

• Every six months

❒❒

Inspect gaskets for damage or wear.

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

❒❒

Verify dewpoint readout and performance with calibrated portable

instrument.

❒❒

Measure current draw on all 3 legs of heater wires. This is to ensure

the heater is working properly.

Maintenance l 5-3

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.

To check dewpoint:

1 Connect your portable dewpoint meter to the

dewpoint check port of the dryer.

2 Turn on the portable instrument, and ensure

there is positive airflow through the sensor.

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

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

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

section of the manual, alarm P9.

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

1 Stop dryer and allow it to cool.

2 Open the right side panel of the dryer, and locate the process heater tube.

3 At the bottom end (cool air inlet) of the process heater tube, remove

1/8 inch NPT pipe plug and connect your portable dewpoint monitor at this location. If there are existing connections for the dryer’s dewpoint sensor,

locate a 2nd 1/8 inch NPT port, or connect your dewpoint sensor in series with the dryer sensor. Do not install a tee to split the air between the dryer’s sensor and your portable instrument. This may cause one of them to be starved for adequate sample air.

4 Turn on the dryer.

Maintenance

✐

NOTE: Portable dewpoint moni-

tors purchased from Conair are

provided with a male connector

that plugs into the dewpoint

Check port. If you purchased

your portable instrument else-

where, the male connector is

available through the Conair

parts department.

NOTE: The dewpoint check port

was not included on early dry-

ers. It can be added easily.

Contact the Conair parts depart-

ment or follow the alternate

procedure.

✐

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

Contact Conair Parts (800) 458 1960 From outside of the United States, call: (814) 437 6861

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 discon-

necting 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. Then disconnect your portable

instrument and replace any pipe plugs that may have been removed.

9 Close side panels and start the dryer.

5-4 l Maintenance

Cleaning the Hopper

CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and out-

side 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

hopper door. Reach into the hopper. Grasp the spreader cone tube, lift up slightly, twist and then push down to release it. Tilt the cone assembly and pull it out through the hopper door.

3 Clean the spreader cone and the inside of the hopper. Make sure you also

clean the return air screen at the return air outlet of the hopper.

4 Repeat the steps in reverse order to reassemble the hopper before adding

material.

Maintenance l 5-5

Maintenance

5-6 l Maintenance

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.

2 Remove the cover wing nut,

then pull the cap off.

3 Remove the filter wing nut,

then remove the filter.

CAUTION: Hot surfaces.

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

Maintenance

Maintenance l 5-7

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.

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

place and in good condition.

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

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

✒

5-8 l Maintenance

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.

2 Remove outer filter and clean it

with soapy water. Let the outer filter air dry.

3 Loosen the hose clamp holding

the regeneration filter onto the regeneration inlet and remove the filter.

CAUTION: Hot surfaces.

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

Maintenance l 5-9

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.

5 Reverse the procedure to reinstall the regeneration filter.

Maintenance

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.

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 compres-

sion fitting from the aftercooler inlet. Loosen the fitting on the flow control, then swing

the copper water supply tube out and away from the aftercooler inlet.

3 Remove the screws securing the aftercooler in the aftercooler housing.

✒

TIP: If the aftercooler (without a flow control) was installed using the recommended

24 inch {61 cm} of flexible hoses, there is no need to disconnect the hoses from the

aftercooler inlet and outlet.

4 Remove the aftercooler assembly from the aftercooler housing.

✐

(continued)

5-10 l Maintenance

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. If a manual shut off

valve is used, it should be mounted on the inlet line as well.

9 Connect the outlet of the aftercooler to the inlet of the flow control

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

Maintenance l 5-11

Maintenance

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.

Cleaning the Volatile Trap on 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.

1 Follow the hose routing of all the hoses within the dryer and inspect all

hoses, clamps, fittings, and gaskets.

2 Tighten any loose hose clamps or fittings.

3 Replace worn or damaged hoses and gaskets.

5-12 l Maintenance

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

REP

AIR

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

SECTION

Troubleshooting

Troubleshooting l 6-1

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. (Refer to the alarm

descriptions later in this section.)

3 Press again to clear the alarm. If the alarm reappears the problem

was not fixed.

❏ Diagnose causes from the front of the dryer.

You can locate any problem from the front of the dryer.

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

Acknowledge Alarm Button

6-2 l Troubleshooting

NOTE: Use of test

mode screens 28-43

may assist with the

determining of possi-

ble cause of an alarm.

Access code 756.

✐

Troubleshooting l 6-3

Before Beginning (continued)

❏ Find the wiring and equipment diagrams that were shipped

with your dryer. These diagrams are the best reference for correct-

ing a problem. The diagrams also will note any custom features, such as special wiring or alarm capabilities, not covered in this User Guide.

Troubleshooting

A Few Words of Caution

The Carousel Plus W Series Dryer is equipped with numerous safety devices. Do not remove or disable them. Improper corrective action can lead to hazardous conditions and should never be attempted to sustain production.

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

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

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

See warnings below. Open the electrical enclosure to check fuses and heater contactors.

How to Identify the Cause of a Problem

Dryer alarms are indicated by an illuminated Acknowledge Alarm light on the W Series Dryer control panel. Shutdown alarms will energize optional audible and

visual alarm indicators.

A problem can trigger two types of alarms:

• Shutdown: The dryer has automatically shut down because it detected a

serious problem that could damage your material or dryer.

• Passive: The dryer continues to operate, but warns of a problem that could

prevent correct drying of your material. If ignored, this problem could lead to a condition that will shut down the dryer.

When the alarm light is displayed:

1 Press the Acknowledge Alarm button once to silence the

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

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

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

alarm.

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

button a second time will clear the alarm. If the alarm reappears, the cause has not been resolved.

NOTE: When the dryer detects abnormally high temperature in the process heater, the

dryer immediately shuts down and an error message appears in the display window.

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

Acknowledge Alarm LED and Button

✐

6-4 l Troubleshooting

NOTE: Pushing the

Acknowledge Alarm button

when there is no active alarm

will display the most recent

alarm code.

✐

NOTE: The dryer cannot be

started if a passive alarm is

present on power-up.

✐

Troubleshooting l 6-5

Alarms

A problem can trigger two types of alarms:

• Shutdown (A#): If the red Acknowledge Alarm LED is blinking, the alarm is a

shutdown alarm. The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer. Note that once the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid.

• Passive (P#): If the amber Acknowledge Alarm LED is blinking, the alarm is a

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

When supplied for central drying applications, these shutdown alarms are not available.

Problem

A1 - Process High Temperature – If the process

temperature exceeds the process high temperature setpoint, it shuts down the dryer. Defaults are set to 385°F {196°C} for 20 seconds.

Possible cause

The process high temperature setpoint is not at least 10°F {6°C} above the drying setpoint.

One of the process solid state relays has failed.

The air lines are restricted or loose.

The process setpoint is too low.

The process heater output on the control board has failed.

Solution

Reset the process high temperature setpoint at least 10°F {6°C} above the drying setpoint.

Replace the solid state relay.

Straighten any crimps in the hoses. Tighten any loose hoses.

Set the process setpoint higher or install an optional precooler.

Replace the control board.

Troubleshooting

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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

A2 - Process Temperature Loop Break – If the process

temperature is outside of the operator entered deviation, alarm band (see Process High Temperature Deviation passive alarm) and the process temperature is not moving towards the setpoint at a rate greater than specified, it shuts down the dryer. Defaults are set at 3°F {2°C} over 20 seconds.

A3 - Process Heater High Temperature – The snap

switch in the process heater tube opens due to excessive temperature.

Possible cause

Process RTD is loose or has fallen out.

The process heater has failed.

The air lines are restricted or loose.

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

The process heater output on the board has failed or the output fuse has failed.

Process setpoint is set too low.

Setback setpoint is set too low.

There is an air flow blockage or loose hoses.

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

Solution

Check the process RTD and tighten if needed.

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

Straighten any crimps in the hoses. Tighten any loose hoses.

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

Replace the board or the fuse for the output.

Adjust to higher setting or add a precooler.

Locate and remove any airflow restrictions.

Tighten any loose hoses.

Correct the cause of the non-running blower (blown fuse, etc.) or reverse the rotation of the blower. See Installation

section entitled, Checking for proper air flow.

6-6 l Troubleshooting

When supplied for central drying applications, these shutdown alarms are not available.

(continued)

Troubleshooting l 6-7

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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

A3 - Process Heater High Temperature (cont.)– The

snap switch in the process heater tube opens due to excessive temperature.

A4 - Regeneration Heater High Temperature – The

snap switch in the regeneration heater tube activated due to excessive temperature.

A7 - Return Air High Temperature – If the return

air temperature at the inlet to the blower is greater than 180°F {82°C}, it shuts down the dryer.

Possible cause

The isolation contactor failed in the closed position.

The process heater output on the board has failed.

The heater solid state relays (SSRs) failed.

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

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

The isolation contactor failed in the closed position.

The heater solid state relays (SSRs) failed.

The regeneration heater output on the board has failed.

The hopper does not contain enough material.

You are drying at a high drying temperature (above 240°F {116°C}) or you are running at low throughputs.

Solution

Replace the isolation contactor.

Replace the board.

Replace the failed heater solid state relays (SSRs).

Locate and remove any airflow restrictions.

Tighten hoses.

Correct the cause of the non-running blower (blown fuses, etc.) or reverse the rotation of the blower.

Replace the isolation contactor.

Replace the failed heater solid state relays (SSRs).

Replace the board.

Make sure your material supply system is working properly.

Ensure water flow to the aftercooler.

Troubleshooting

When supplied for central drying applications, these shutdown alarms are not available.

(continued)

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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.

6-8 l Troubleshooting

Problem

A7 - Return Air High Temperature (cont.) – If the

return air temperature at the inlet to the blower is greater than 180°F {82°C}, it shuts down the dryer.

A10 & P26 - Process RTD Integrity – If the process

RTD is faulty, it shuts down the dryer.

A21 & P1 - Process Temperature Deviation –

The process temperature exceeds the deviation band as entered for the specified time. Default values are 10°F {6°C} for 5 seconds.

Possible cause

The aftercooler does not have enough water.

The aftercooler coils are dirty.

The process RTD connection to the control box is loose.

The connection in the electrical enclosure for the process RTD is loose.

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

The process RTD has failed.

The control board has failed.

One of the solid state relays (SSRs) failed.

Process heater has failed.

The output on the board has failed.

The process RTD is loose or has fallen out.

The air hose connections are loose.

Solution

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

Clean the aftercooler coils. See

Maintenance section entitled, Cleaning the aftercooler coils.

Check the connection to the receptacle and tighten if needed.

Check the RTD plug connection and tighten if needed.

Check the plug connection and tighten if needed.

Replace the process RTD.

Replace the control board.

Replace the failed solid state relays (SSRs).

Check heater fuses and resistance across each leg of heater.

Replace the board.

Check the process RTD and tighten if needed.

Tighten all air hose connections.

When supplied for central drying applications, these shutdown alarms are not available.

Troubleshooting l 6-9

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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

A22 & P2 - Process Low Temperature – The process

temperature is less than the low temperature setpoint for the specified time. Default values are 70°F {21°C} for 20 seconds.

A23 & P3 - Regeneration Temperature Deviation –

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

Possible cause

Precooler water is too cold, or the water flow rate is too high.

The output on the board has failed.

Flow control solenoid is stuck open.

The process RTD is loose or has fallen out.

Process heater has failed.

One of the solid state relays (SSRs) failed.

The regeneration RTD is loose or has fallen out.

The air hose connections are loose.

The output on the board has failed.

Defective heater.

Solution

Check water temperature and flow settings. Adjust as necessary.

Replace the board.

Replace the valve.

Check the process RTD and tighten if needed.

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

Replace the failed solid state relays (SSRs).

Check the regeneration RTD and tighten if needed.

Tighten all air hose connections.

Replace the board.

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

Troubleshooting

When supplied for central drying applications, these shutdown alarms are not available.

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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

A25 & P5 - Return Air MidHigh Temperature – If the

return air temperature is between 150 and 180°F {66 and 82°C}.

A26 & P6 - Regeneration High Temperature – If the

regeneration temperature exceeds the high temperature limit for the specified time. Default values are 400°F {204°C} for 20 seconds.

A27 & P7 - Regeneration Low Temperature – The

regeneration temperature is less than the low temperature setpoint for the specified time. Defaults are 200°F {93°C} for 20 seconds.

Possible cause

The hopper does not contain enough material.

You are drying at a high drying temperature (above 240°F {116°C}) or running at low throughputs.

The aftercooler does not have enough water.

The aftercooler coils are dirty.

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

The output on the board has failed.

The regeneration heater has failed.

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

The regeneration RTD is loose or has fallen out.

Solution

Make sure your material supply system is working properly.

Ensure water flow to the aftercooler.

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

Clean the aftercooler coils. See

Maintenance section entitled, Cleaning the aftercooler coils.

Replace the failed solid state relays (SSRs).

Replace the board.

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

Replace the control board or the fuse.

Check the regeneration RTD and tighten if needed.

6-10 l Troubleshooting

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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

A28 & P9 - Process dewpoint – The dewpoint has not

fallen below the setpoint. If the dewpoint goes below the setpoint for 180 seconds the alarm should go away.

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

A29 & P10 - Process Filter Clogged (Option) – The

process filter differential pressure switch is tripped.

Possible cause

Defective sensor.

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

Poor regeneration air flow.

The desiccant wheel may be contaminated.

Desiccant wheel not turning.

Leaks in the process air stream.

The process air filter is clogged.

Solution

Replace the sensor.

Check wiring and hose connections to the sensor, re-secure if needed.

Remove any air flow restrictions, dirty filters, kinked hoses, etc.

Check the desiccant for contamination, replace if needed.

Replace the desiccant wheel. See

Troubleshooting section, entitled Replacing the desiccant wheel.

Install plasticizer/volatile trap for severe situations.

See A55 & P31

Check for worn or lose hoses. Replace as needed.

Remove and clean or replace the process air filter.

Troubleshooting

Troubleshooting l 6-11

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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.

6-12 l Troubleshooting

Problem

A33 & P26 - Regeneration RTD Integrity – If the regen-

eration RTD is faulty, it shuts down the dryer.

A34 & P28 - Return Air Temperature RTD Integrity

– The dryer continues to run with a passive alarm.

A35 & P8 - Regeneration Temperature Loop Break –

The regeneration temperature is outside of the operator entered deviation alarm band (see Regeneration Temperature Deviation passive alarm) and the regeneration temperature is not moving towards the setpoint at a rate greater than specified. Default values are 2°F {1°C} over 40 seconds.

Possible cause

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

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

The regeneration RTD has failed.

The control board has failed.

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

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

The return air RTD has failed.

The control board has failed.

The regeneration heater has failed.

The regeneration RTD is loose or has fallen out.

The regeneration blower is not running.

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

Solution

Check the RTD plug connections, make necessary repairs.

Check the plug connection and tighten if needed.

Replace the regeneration RTD.

Replace the control board.

Check the RTD plug connections, make necessary repairs.

Check the plug connection and tighten if needed.

Replace the return air RTD.

Replace the control board.

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

Check the regeneration RTD and tighten if needed.

Correct the cause of the non-functioning blower.

Replace the control board or fuse.

Troubleshooting l 6-13

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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.

Troubleshooting

Problem

A36 -Control Communications Watchdog

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

A38 - Phase Error (Phase Option, STD on MDC's) -

One of the three power wires is connected wrong, or one or more phases of power is missing.

A39 - EEProm Write Error

A41 & P30 - Setback RTD Integrity - The control can

not sense the regeneration outlet RTD.

Possible cause

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

Display board or control board has failed.

One of the three power wires are out of phase.

A fuse has blown.

Phase detection board has failed.

Loose wire connection between phase board and control board.

Internal control board problem.

The connection in the electrical enclosure for the hopper RTD is loose.

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

The setback RTD has failed.

The control board has failed.

The setback RTD connection to the control box is loose.

Solution

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

Replace the defective boards.

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

Check and/or replace the fuse.

Replace the phase detection board.

Make sure wires are correct and secure.

Replace the control board.

Check the RTD plug connection and tighten if needed.

Check the plug connection and tighten if needed.

Replace the setback RTD.

Replace the control board.

Check the connection to the receptacle and tighten if needed.

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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.

6-14 l Troubleshooting

Problem

A43 & P17 - Machine Loader Conveying Demand (MDC Option) - The demand sensor

located at the material receiver has not been satisfied after three consecutive attempts.

Possible cause

Sensor is out of position.

The sensor is not adjusted properly.

No material is being conveyed.

The conveying load time is too short or the delay time is too long.

Conveying blower is not coming on.

The conveying filter is clogged.

Hoses have come off or are loose in the conveying loop.

Solution

Raise the sensor to a higher / lower position on the bracket.

Adjust the sensitivity of the sensor.

Check for material in the hopper, or that the slide gate is open.

Increase the load time setpoint or shorten the delay time.

Check the blower fuses in the control and the overload settings.

Clean or replace the conveying filter.

Check for loose hoses and make sure all hose clamps are secure.

Troubleshooting l 6-15

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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.

Troubleshooting

Problem

A49 - Process Protection High Temperature – If the

process protection temperature exceeds the process protection high temperature setpoint, it shuts down the dryer. Defaults are set to 600°F {316°C} for 10 seconds.

Possible cause

The process RTD temperature probe is not installed correctly.

The process blower is not running.

The air lines between dryer and hopper are restricted or loose.

The dryer is too far from the hopper.

The process hose is not insulated.

Solution

Make sure the RTD temperature probe tip is in the center of the hopper inlet tube.

Correct the cause of the non-functioning blower.

Straighten any crimps in the hoses. Tighten any loose hoses.

Move the dryer closer to the hopper and shorten the hoses.

Insulated hose is required for high drying temperatures.

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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.

6-16 l Troubleshooting

Problem

A50 - Process Protection Differential - If the difference

between the process temperature exiting the process heater and the temperature of the air entering the hopper is greater than 175°F {97°C} for longer than 180 seconds it shuts down the dryer.

A51 & P29 - Process Protection RTD Integrity –

If the process protection RTD is faulty, it shuts down the dryer.

Possible cause

The air lines between dryer and hopper are restricted or loose.

The dryer is located too far away from the hopper.

The process RTD is loose or has fallen out.

The process blower is not running.

The process hose is not insulated.

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

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

The process protection RTD has failed.

The control board has failed.

Solution

Check for air flow blockages or loose hoses between the outlet of the dryer and the inlet of the hopper. Straighten any crimps in the hoses. Tighten any loose hoses.

The dryer and the hopper should not be located more than 10 ft

{3.05 m} apart.

Check the process RTD and tighten if needed.

Correct the cause of the non-functioning blower.

Insulated hose is required for high drying temperatures.

Check the RTD plug connections, make necessary repairs.

Check the plug connection and tighten if needed.

Replace the process protection RTD.

Replace the control board.

When supplied for central drying applications, these shutdown alarms are not available.

Troubleshooting l 6-17

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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.

Troubleshooting

Problem

A53 - Process Blower Overload - If the process

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

Possible cause

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

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

The process blower has failed electrically.

Loss of phase of power to the motor starter.

The overload is set incorrectly.

Overload is defective.

Solution

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

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

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

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

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

Replace the overload.

NOTE: Once the overload

has tripped you must wait

2 - 15 minutes with

power on for it to reset

automatically.

✐

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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.

6-18 l Troubleshooting

Problem

A54 & P23 - Conveying Blower Overload – The con-

veying blower overload has tripped due to a mechanical or electrical problem.

Possible cause

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

The conveying blower has failed electrically.

The overload is set incorrectly.

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

Overload is defective.

Solution

Disconnect and lock out main power. Check the conveying blower for mechanical failure and free rotation. Replace if necessary. Allow overload to automatically reset, then try to restart the dryer.

Disconnect and lock out main power. Check the conveying blower for electrical shorts or open circuits. Replace if necessary. Allow overload to automatically reset, then try to restart the dryer.

Disconnect and lock out main power. Check the overload settings and confirm that the settings match the full load amps listed on the conveying blower motor. Allow overload to automatically reset, then try to restart the dryer.

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

Replace the overload.

NOTE: Once the overload

has tripped you must wait

2 - 15 minutes with

power on for it to reset

automatically.

✐

Troubleshooting l 6-19

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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.

Troubleshooting

Problem

A55 & P31 - Wheel Rotation Failure - The regeneration tem-

perature differential has been reached.

A56 & P32 - Regeneration Outlet RTD Integrity - The

control can not sense the regeneration outlet RTD.

Possible cause

The wheel motor is not turning.

The belt tensioner is loose or the belt is slipping.

The regeneration heater is not working.

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

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

The regeneration outlet RTD has failed.

The control board has failed.

Solution

Check the motor, plugs and fuses.

Change the tensioner spring or replace the belt.

Check the heater fuses and heater.

Check the RTD plug connection, make necessary repairs.

Check the plug connection and tighten if needed.

Replace the regeneration outlet RTD.

Replace the control board.

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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.

6-20 l Troubleshooting

Problem

A57 - Regeneration Blower Overload - If the regenera-

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

Possible cause

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

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

The regeneration blower has failed electrically.

Loss of phase of power to the motor starter.

The overload is set incorrectly.

Overload is defective.

Solution

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

Disconnect and lock out main power. Check the regeneration blower for mechanical failure and free rotation. Replace if necessary. Allow overload to reset automatically, then try to restart the dryer.

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

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

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

Replace the overload.

NOTE: Once the overload

has tripped you must wait

2 - 15 minutes with

power on for it to reset

automatically.

✐

Alarms

• Shutdown (A#): The dryer has automatically shut down because it has detect-

ed 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.

Troubleshooting l 6-21

Troubleshooting

Problem

P34 - Dewpoint Deviation High – Displayed when the

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

P35 - Dewpoint Deviation Low – Displayed when the

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

Possible cause

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

Poor regeneration air flow.

Desiccant wheel not turning.

The desiccant wheel may be contaminated.

Leaks in the process air stream.

The dewpoint can not control to the desired setpoint.

The dewpoint sensor has failed.

Solution

Check wiring and hose connections to the sensor, re-secure if needed.

Remove the air flow restrictions, dirty filters, etc.

See A55 & P31

Check the desiccant for contamination, replace if needed.

Replace the desiccant wheel. See

Troubleshooting section, entitled Replacing the desiccant wheel.

Install plasticizer/volatile trap for severe situations.

Check for worn or loose hoses.

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

Replace the dewpoint sensor.

Additional Alarms

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

6-22 l Troubleshooting

Problem

CoS Er.4 or Co5 Er. 4 Displayed when the “Start” button is pushed during any active alarm. (Passive or Shutdown)

CoS Er.0 or Co5 Er.0 Indicates there is a problem in the communication between the control board and the display board.

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

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

Possible cause

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

Loose or improperly connected wire.

Improper dip switch setup on control board.

Defective display board or control board.

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

Problem in the analog input section of the control.

Solution

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

Check wiring between control board and display board.

Check dip switch setup on control board.

Replace boards in sets to maintain software compatibility.

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

Check that all jumpers are in their proper place.

Check to see if the dewpoint sensor is connected properly.

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

Additional Alarms

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

Troubleshooting l 6-23

Troubleshooting

Problem

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

Possible cause

Defect in the main control board.

RTD is not connected properly or is defective.

Connector to all RTDs are removed.

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

Problem in the analog input section of the control.

Defect in the main control board.

Solution

Replace main control board.

Check RTD connections, replace defective RTD(s)

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

Replace main control board.

Dewpoint Troubleshooting

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.

6-24 l Troubleshooting

Problem

Dryer not producing desired dewpoint.

Possible cause

Return air temperature exceeds 125°F {52°C}.

Regeneration temperature is below normal setting.

Low regeneration air flow.

Leaks in process lines.

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

Analog option board/sensor malfunction

Solution

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

Check amperage of regeneration heaters. Replace heaters if necessary.

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

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

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

Verify dryer dewpoint readings with a calibrated portable dewpoint meter.

Replace analog option board or sensor.

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

Troubleshooting l 6-25

Troubleshooting

Poor Material Drying Troubleshooting

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

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

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

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

1 Drying temperature of the air entering the hopper must be at the proper

drying temperature for your material, as specified by your material supplier.

2 Residence time is the time, determined by your material supplier, that the

material in use must be heated to achieve proper drying temperature.

3 Airflow during the process drying circuit must be adequate to carry and

distribute the heat throughout the entire bed of material inside the hopper.

4 Dewpoint of the process air must be low so it can efficiently collect the

moisture as it is released from the heated material and carry it to the dryer to be removed in the desiccant.

Poor Material Drying Troubleshooting (continued)

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.

6-26 l Troubleshooting

Problem

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

Possible cause

Incorrect setpoint

Not able to achieve setpoint.

Inaccurate process temperature readout.

Solution

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

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

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

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

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

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

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

Specifications and Main Features

Frequently Asked Questions

User Manual