Conair Carousel Plus W Series, Carousel Plus W300, Carousel Plus W200, Carousel Plus W150, Carousel Plus W400 User Manual
U S E R G U I D E
UG D 05 1-0 4 14
Carousel Plus Dryer
W Series Models 150, 200, 300 and 400 with DC-T Controls
www.conairgroup.com
Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861
Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.
It’s a good idea to record the model and serial number(s) of your equipment and the date
you received it in the User Guide. Our service department uses this information, along with
the manual number, to provide help for the specific equipment you installed.
Please keep this User Guide and all manuals, engineering prints and parts lists together for
documentation of your equipment.
Date:
Manual Number: UGD051-0414
Serial Number(s):
Model Number(s):
*Display firmware Version:
*Display Menu Version:
* Control Firmware Version:
✐
NOTE: Displayed upon initialization, during power up, or on a data tag inside the door.
DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential damages in connection with the furnishing, performance or use of this information. Conair makes no
warranty of any kind with regard to this information, including, but not limited to the implied warranties of
merchantability and fitness for a particular purpose.
C o p y ri g ht 20 14 l Co n ai r l A l l ri gh t s re se rv ed
Ta b l e o f C o ntents
1-1 I ntr o d uct i o n
Purpose of the User Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How the Guide Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Using the Carousel Plus W Series as a Central Dryer. . . . . . . . . . . . . . . . . . . 1-2
Your Responsibility as a User. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
ATTENTION: Read this so no one gets hurt . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
How to Use the Lockout Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2-1 D esc r i pti o n
What is the Carousel Plus W Series Dryer?. . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
How the Carousel Plus W Series Dryer Works . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Specifications: Carousel Plus W Series Dryer . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Carousel Plus W Series Dryer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3-1 I nst a l lat i o n
Unpacking the Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Positioning the Dryer on the Floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removing the Cable Tie from the Desiccant Wheel . . . . . . . . . . . . . . . . . . . . 3-3
Connecting the Main Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Connecting the RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Connecting the Setback RTD Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Checking for Proper Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Connecting the Air Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Connecting the Dryer to the Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Connecting Air Hose Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Connecting the Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Mounting a Loader on the Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Using Communications (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
4-1 O per a t ion
The Dryer System control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
How to navigate the control screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
DC-T Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Ta b le o f Co nt en ts l i
Operation - ResinWorks Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Control Function Flow Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Control Function Descriptions - ResinWorks Configuration. . . . . . . . . 4-16
Operation - Stand Alone Dryer Configuration . . . . . . . . . . . . . . . . . . . . . 4-45
Control Functions Flow Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Control Function Descriptions - Stand Alone Configuration . . . . . . . . 4-56
General Operation - Stand Alone and
ResinWorks Dryer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
DC-T Security Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Starting the Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
Adjusting the temperature setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
Stopping the Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
Stopping the Dryer in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Understanding the Control LED Lights . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Alarm Email and Text Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
Ethernet TCP/IP Adress Setup to Enable Email/Text Notification . . . . . 4-87
Email Alarm Activation and Address Setup. . . . . . . . . . . . . . . . . . . . . 4-88
Configuring the Email and Text Addresses . . . . . . . . . . . . . . . . . . . . . 4-89
Text Messaging Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
Enabling and Disabling Notification for Individual Alarms . . . . . . . . . . 4-90
DC-T Web Access Logon and Security . . . . . . . . . . . . . . . . . . . . . . . . 4-94
Web Server Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95
5-1 Ma inten an ce
Preventative Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Checking Dewpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleaning the Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Cleaning the Process Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cleaning the Regeneration Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Cleaning the Aftercooler Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cleaning the Precooler Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Cleaning the Volatile Trap on the Demister. . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Inspecting Hoses and Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Cleaning the DC-T HMI Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
i i
l Tab l e of C on te nt s
6-1 Tr ou bl eshoo ti ng
Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Diagnostics
How to Identify the Cause of a Problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Shutdown Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Passive Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Additional Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Replacing the Desiccant Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Replacing the Desiccant Wheel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
A A ppe n d ix
We’re Here to Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
How to Contact Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Before You Call... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Equipment Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Performance Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Warranty Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
B A ppe n d ix
Installing a Precooler (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
C A d den d u m
DC-T Modbus TCP/IP Read Only Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Ta b le o f Co nt en ts l ii i
i v l Ta b l e of C on te nt s
I n troduc t i o n
P u r p o s e of t he U se r Gui de . . . . . . . . . . . . . . . . . 1 - 2
H o w t he Gu id e Is Or ga ni ze d . . . . . . . . . . . . . . . . 1 - 2
U s i n g the Ca ro us el P l u s W S er ie s
a s a C e n t r a l Dr ye r . . . . . . . . . . . . . . . . . . . . 1- 2
S E C T I O N
1
I n tro d uc ti o n
1
Yo ur Re sp on si bi li ti es a s a U se r . . . . . . . . . . . . . . 1 -3
A t t e n t i o n : R ea d Th is s o No One Ge ts H ur t . . . . . . . 1- 4
H o w t o U se t he Lo ck ou t De vi ce . . . . . . . . . . . . . . 1- 6
I n t r od u ct i on l 1 - 1
P u r p o s e o f t h e U ser Gu i d e
This User Guide describes the Conair Carousel Plus W Series Dryers and explains step-bystep how to install and operate, maintain, and repair this equipment.
Before installing this product, please take a few moments to read the User Guide and review
the diagrams and safety information in the instruction packet. You also should review manuals covering associated equipment in your system. This review won’t take long, and it could
save you valuable installation and operating time later.
H o w t h e G u i d e i s O r g an i z e d
Symbols have been used to help organize the User Guide and call your attention to important
information regarding safe installation and operation.
Symbols within triangles warn of conditions that could be hazardous to users or could damage equipment. Read and take precautions before proceeding.
Numbers indicate tasks or steps to be performed by the user.
1
A diamond indicates the equipment’s response to an action performed by the user.
◆
An open box marks items in a checklist.
❒
A circle marks items in a list.
•
Indicates a tip. A tip is used to provide you with a suggestion that will help you with the maintenance and
✒
the operation of this equipment.
✐
Indicates a note. A note is used to provide additional information about the steps you are following
throughout the manual.
U s i n g t h e C a r ou s e l P l u s W S e r i es a s a
C e n t r a l D r y e r
This manual incorporates the information necessary to use the Conair Carousel Plus 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.
This box will contain information or highlight system differences particular to the application of the W series dryer as a central dryer.
1 - 2 l In tr o du ct i on
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I n tro d uc ti o n
1
I n t r od u ct i on l 1 - 3
AT T E N TI O N :
R e a d T h i s S o N o O n e G e t s H urt
We design equipment with the user’s safety in mind. You can avoid the potential hazards
identified on this machine by following the procedures outlined below and elsewhere in the
User Guide.
WA RN IN G: I mp ro pe r i ns ta ll at io n, o p e r a t i o n , o r s er vi c i n g may re su lt i n equ ip me nt da ma ge o r per so na l
i n j u r y.
This equipment should be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential
hazards of this type of machine.
All wiring, disconnects, and fuses should be installed by qualified electrical
technicians in accordance with electrical codes in your region. Always maintain
a safe ground. Do not operate the equipment at power levels other than what is
specified on the machine serial tag and data plate.
WA RN IN G: V ol ta ge h az ar d
This equipment is powered by three-phase alternating current, as specified on
the machine serial tag and data plate.
A properly sized conductive ground wire from the incoming power supply must
be connected to the chassis ground terminal inside the electrical enclosure.
Improper grounding can result in severe personal injury and erratic machine
operation.
Always disconnect and lock out the incoming main power source before opening the electrical enclosure or performing non-standard operating procedures,
such as routine maintenance. Only qualified personnel should perform troubleshooting procedures that require access to the electrical enclosure while
power is on.
1 - 4 l In tr o du ct i on
AT T E N TI O N :
R e a d T h i s S o N o O n e G e t s H urt
We design equipment with the user’s safety in mind. You can avoid the potential hazards
identified on this machine by following the procedures outlined below and elsewhere in the
User Guide.
( c o nt i nu ed )
CA UT IO N: H ot Su rfa ce s.
Always protect yourself from hot surfaces inside the dryer and hopper. Also
exercise caution around exterior surfaces that may become hot during use.
These include the hopper door frame, the exterior of an uninsulated hopper, the
return air hose and the dryer’s process filter housing and moisture exhaust outlet.
WA RN IN G: D o n ot p la ce ae ro so l, c o m p r e s s e d ga s o r
f l a m m a b l e mat er ia l s on o r nea r t hi s eq u i p m e n t .
The hot temperatures associated with the drying process may cause aerosols or
other flammable materials placed on the dryer or hopper to explode.
I n tro d uc ti o n
1
I n t r od u ct i on l 1 - 5
H o w t o U s e t h e L o c k o ut De v i c e
CAUTION: Before performing maintenance or repairs on this product, you should discon-
nect and lockout electrical power sources to prevent injury from unexpected energization or
start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity.
Lockout is the preferred method of isolating machines or equipment from energy sources.
Your Conair product is equipped with the lockout device pictured below. To use the lockout
device:
1
Stop or turn off the equipment.
2
Isolate the equipment from the electric power. Turn the rotary
disconnect switch to the OFF, or “O” position.
3
Secure the device with an assigned lock or tag. Insert a lock or tag
in the holes to prevent movement.
4
The equipment is now locked out.
WARNING: Before removing lockout devices and returning switches to the ON position, make sure that all personnel are clear of the machine, tools have been
removed, and all safety guards reinstalled.
To restore power to the dryer, turn the rotary disconnect back to the ON position:
1
Remove the lock or tag.
2
Turn the rotary disconnect switch to the ON or “I” position.
1 - 6 l In tr o du ct i on
S E C T I O N
2
D e script i o n
W h a t is th e Ca ro us el Pl us W Ser i e s Dr ye r? . . . . . . . 2- 2
Typ ic al A pp li ca t i o n s . . . . . . . . . . . . . . . . . . . . . . 2- 2
H o w I t Wo r k s . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -4
S p e c i f i c a ti on s: C a r o u s e l Pl us W S er ie s
D r y er . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 6
C a r o u s e l Pl us W S er ie s D ry er Op ti on s . . . . . . . . . . 2- 7
D e scr i pt io n
2
D e s c ri p ti o n l 2 - 1
W h a t i s t h e C a r o use l P l u s W S e r i e s
D r y er?
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.
Ty p i c al Ap p l i c a ti o n s
1 Dryer on the floor; hopper on the throat.
2 Hopper on a floor stand; the dryer next to it.
3 Dryer on the floor, multiple hoppers in central configuration (ResinWorks) with separate
heat source for each hopper.
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.
2 - 2 l De sc r ip ti o n
( C o nt i nu ed )
Ty p i c al Ap p l i c a ti o n s ( co n ti nu ed )
The W Series Dryer can be used successfully in applications that require:
• A contamination-free drying environment.
• Drying temperatures within the ranges shown in the following table:
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 and Appendix B and C.
• Throughput rates of 150 to 400 lbs {68.1 to 149.2 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}
Standard Dryer Features
• Dewpoint monitor / dewpoint control
• Audible and visual alarm
• Temperature setback
D e scr i pt io n
2
D e s c ri p ti o n l 2 - 3
H o w I t Work s
The W dryer achieves continuous, closed loop drying by passing air simultaneously through
two heaters and a continuously rotating desiccant wheel.
THE PROCESS (DRYING) CYCLE
The process blower pulls moist air from the top of the drying hopper. The air passes
through the process filter and aftercooler 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 PROCESS (DRYING) CYCLE
The process blower pulls moist air from the top of the drying hopper. The air
passes through the process filter and aftercooler, then into the desiccant
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.
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.
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 aftercooler and repeats the circuit.
2 - 4 l De sc r ip ti o n
R
EGENERATION
AIR FILTER
DESICCANT
WHEEL
REGENERATION
BLOWER
REGENERATION
H
EATER
HIGH TEMP
SHUTOFF
REGENERATION
RTD
HOPPER
PROCESS
BLOWER
RETURN
AIR
FILTER
4 PROCESS FILTER STATUS
RETURN
AIR
RTD
P
ROCESS
R
TD
2 SETBACK TEMPERATURE
H
IGH TEMP
SHUTOFF
PROCESS
HEATER BOX
7 PRECOOLER
7
DRYER OPTIONS
3 DEWPOINT MONITOR / CONTROL
PROCESS
COOLING
REGENERATION
2
3
4
P
ROCESS
P
ROTECTION
R
TD
REGENERATION
OUTLET
RTD
6
6 PHASE ROTATION PROTECTION
AFTERCOOLER
A
LARM LIGHT
A
LARM BELL
5 CURRENT METER
5
5
1 PROCESS CFM MONITOR
1
H o w I t Work s ( c o nt i nu ed )
D e scr i pt io n
2
The components identified by this type of box in the drawing are not supplied with the
W series dryer when it is configured as a central dryer.
D e s c ri p ti o n l 2 - 5
S p e c i f ic a t i o n s: C ar o u s e l P l us W S e ri e s
D r y ers
A
B
C
MODEL W150 W200 W300 W400
Performance characteristics (with full hopper)
Drying temperature
†
All models 100°- 375°F {38°- 191°C} with options
Dew point All models -40°F {-40°C}
Dimensions inches {cm}
A - Height 64.3 {163.3}
B - Overall width 29 {73.7}
C - Depth 51.5 {130.8}
Outlet/inlet tube size OD 2.5 {63.5} 5.0 {127.0} 5.0 {127.0} 5.0 {127.0}
Weight lbs {kg}
Standard dryer installed 600 {272} 660 {300} 710 {322} 760 {345}
Voltage - Full load amps Standard/Central drying
230 V/3 phase/60 Hz 47.1 / 16.7 57.6 / 19.9 67.7 / 30.0 N/A
400 V/3 phase/50 Hz
*
23.4 / 8.9 32.1 / 10.4 37.9 / 16.2 64.5 / 21.1
460 V/3 phase/60 Hz 21.0 / 8.4 28.9 / 10.0 34.0 / 15.1 56.3 / 18.6
575 V/3 phase/60 Hz 16.8 / 6.7 23.7 / 8.6 27.3 / 12.2 43.2 / 13.0
Water requirements {for aftercooler or optional precooler}
Recommended temperature
Water flow
Water connections NPT 3/4 inch NPT
SPECIFICATION NOTES:
gal./min.{liters/min.}
‡
45°- 85°F
3 {11.4}
†
* Dryers running at 50 Hz will have 17% less airflow, and a 17% reduction in material throughput.
†
When drying below 150°F {66°C} a precooler is required.
‡
Temperatures above or below the recommended levels may affect dryer performance.
Tower, chiller or municipal water sources can be used.
Specifications may change without notice. Consult a Conair representative for the most current information.
APPLICATION NOTES:
All dryers are supplied with an aftercooler
as standard. The aftercooler reduces the
temperature of the return air from the drying hopper, improving the efficiency of the
desiccant. The aftercooler must be connected with the proper water flow rate and temperature to attain the rated throughput.
When to use central models
Central dryers do not have process
heaters. These models should be used
when drying multiple materials that
require different drying temperatures.
Central models dehumidify the process
air, which is then heated to the correct
setpoint by a Heater Pack mounted on the
hopper and controlled from the dryer.
When to use additional filtration
The standard return air cartridge filter is
sized for the airflow of each dryer model
and is suited for most applications. You
should consider adding an optional dust
collector and/or volatile trap if:
●
The material contains excessive fines. An
additional dust collector or cyclone will
extend time between filter cleaning.
●
The material produces volatiles during
drying which condense into a waxy or
oily residue. A volatile trap will help to
protect the desiccant.
2 - 6 l De sc r ip ti o n
TPDX018-0113
C a r o u s el P lu s W Ser i e s D r y e r O p t i o n s
• 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 desiccant wheel
and before the process heater.
• Filter check - The Filter check sensor will activate a passive alarm when the process
filter is clogged or needs to be replaced.
• Heater current monitor - The heater current monitor measures the total amperage
across both the process and regeneration heaters and the pre-determined power consumption values for the blowers and the control.
• CFM monitor - The CFM monitor measures the cubic feet per minute of airflow across
the inlet/outlet of the process blower.
• DeviceNet or SPI communications - Allows the dryer to be networked to industrial con-
trol systems. DeviceNet communications are standard. Alternate communications are
available.
D e scr i pt io n
2
( C o nt i nu ed )
D e s c ri p ti o n l 2 - 7
2 - 8 l De sc r ip ti o n
I n stalla t i o n
U n p a c k i n g the Bo xe s . . . . . . . . . . . . . . . . . . . . . 3- 2
P r e p a r i n g for In st al la ti on . . . . . . . . . . . . . . . . . . 3- 3
Po si ti on in g t he D r y e r on t h e Fl oo r . . . . . . . . . . . . 3 -3
R e m o v i n g th e C a b l e Ti e fr om th e D e s i c c a n t Wh ee l . . 3 - 3
S E C T I O N
3
I n sta l la ti on
3
C o n n e c t i n g th e M a i n Po we r . . . . . . . . . . . . . . . . . 3- 4
C o n n e c t i n g th e P r o c e s s RT D Pro be . . . . . . . . . . . . 3 -5
C o n n e c t i n g th e S e t b a c k RT D Pro be . . . . . . . . . . . . 3 -5
C h e c k i n g fo r P r o p e r A ir Fl ow . . . . . . . . . . . . . . . . 3 -6
C o n n e c t i n g th e Ai r Ho se s . . . . . . . . . . . . . . . . . . 3 - 9
C o n n e c t i n g th e D r y er t o the Ho pp er . . . . . . . . . . . 3 -9
C o n n e c t i n g A ir Ho se A d a pt er s . . . . . . . . . . . . . . 3 -1 0
C o n n e c t i n g th e Af te rc oo le r . . . . . . . . . . . . . . . . 3- 11
M o u n t i n g a L o a d e r on t h e Ho pp er . . . . . . . . . . . . 3- 12
Te st in g t he I ns ta ll a t i o n . . . . . . . . . . . . . . . . . . . 3 -1 2
U s i n g Com mu ni ca t io ns ( Op ti on al ) . . . . . . . . . . . . 3 - 1 3
I n s t al l at io n l 3 - 1
U n p a c k in g th e B o x e s
The Carousel Plus W series dryer comes in one to four boxes, depending on the model and
options ordered. The 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
• 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.
5 Take a moment to record serial numbers and electrical power specifications in the
blanks provided on the back of the User Guide’s title page. The information will be helpful if you ever need service or parts.
6 You are now ready to begin installation.
Follow the preparation steps on the next page, then choose one of the four mounting
options:
• Dryer on the floor; hopper on a floor stand (see page 3-5).
• Dryer on the floor; hopper machine mounted
• Central dryer, with ResinWorks system.
3 - 2 l In st a ll at io n
P r e p a r in g fo r I n s t a l la t i o n
The Carousel Plus W Series Dryer is easy to install if you plan the location and prepare the
mounting area properly.
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.
Posit i o n i n g t he Dr y e r o n t h e F l oo r
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.
I n sta l la ti on
3
1 Lift the dryer from the shipping container using a fork truck.
2 Position the dryer on the floor near the processing machine. Make sure the
location allows for the connection of all hoses.
R e m o v in g t h e C a b l e T i e f r o m t h e
D e s i c c an t Wh e e l
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
I n s t al l at io n l 3 - 3
C o n n e c ti n g t h e M a i n Po w e r
CAUTION: Always disconnect and lock out the main power sources before making electrical con-
nections. Electrical connections should be made only by qualified personnel.
1 Open the dryer’s electrical enclosure. Turn the discon-
nect dial on the dryer door to the Off or “O” position.
Lock out the main power (see Page 1-6 for complete
lock out information). Turn the captive screw, and swing
the door open.
2
Insert the main power
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.
wire through the knockout in the
IMPORTANT: Always refer to the
wiring diagrams that came with
your dryer before making electrical
connections.
3 - 4 l In st al la ti on
Connect the power wires
3
to the three terminals at the top of the power disconnect.
4 Connect the ground wire to the ground lug as shown in the photo.
C o n n e c ti n g t h e P r o c e ss RTD P r obe
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 fitting to lock the probe in place.
Setback RTD
Process RTD
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.
C o n n e c ti n g t h e S e t b a ck RTD
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 fitting to lock the probe in place.
2 Plug the probe’s cable into the receptacle labeled setback on the left side of the elec-
trical enclosure. Hand tighten the connector. Coil any excess cable and secure it with a
wire tie.
I n sta l la ti on
3
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.
I n s t al l at io n l 3 - 5
O
FF
O
O
N
I
✐
NOTE: Users must be
logged in as Maint 1
(user level 3) in order to
perform this operational
test.
C h e c k i ng for Pr o p e r A i r F l o w
IMPORTANT: This procedure must be performed before loading material into the hopper.
CAUTION: If the airflow direction is incorrect due to improper phase connection, material from
the hopper can be pulled back into the dryer, causing permanent damage to this equipment.
1 Turn on the main power to the dryer. Make sure the dryer’s disconnect dial is in the ON
position. This powers up the control and the display will illuminate.
When configured as a
central dryer, the drying temperature can
not be set since there
is no process heater in
the system.
2 From the Home Screen , press the “Setup” button.
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.
3 - 6 l In st a ll at io n
C h e
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3 Pr
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4 Pr
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5 Pr
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button to star
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button agai
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I n sta l la ti on
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✐
NOTE: On initial test (first time
in Dryer I/O Test Mode) the
process blower will automati-
cally start. Press the button
beside “Delivery Air Blower” to
stop the blower.
ear the
n
d
n
a
h
your
ld
6 Ho
feel
ld
u
sho
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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.
If air flow is incorrect disconnect
7
power, follow proper lockout proce
dures and swap any 2 of the 3 main
power wires.
delivery
lowin
air b
Return
g
-
Air Inlet
Dry Delivery
Air
Moisture
Exhaust
( C o nt i nu ed )
I n s t al l at io n l 3 - 7
C h e c k i ng for Pr o p e r A i r F l o w ( co nt i nu ed )
✐
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 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 blo wer is turning in the wrong direction. Turn
off and lock out the main power source. Open the electrical enclosure and reverse
any two leads connecting the main power supply to the dryer.
LEADS
3 - 8 l In st a ll at io n
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.
C o n n e c ti n g t h e A i r H o s e s
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 dr yer 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.
Return
Air Inlet
Dry
2 Attach one hose from the delivery
air outlet of the dryer to the delivery
air inlet of the hopper.
Delivery
Air
I n sta l la ti on
3
3 Secure hoses with clamps.
The hose clamp should be secured at
least 1/4 in. {0.64 cm} from the end of
the inlet or outlet tube.
C o n n e c ti n g t h e D r ye r to th e Ho p p e r
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.
✐
NOTE: Water to cooler
should be turned off
when the dryer is not
running to prevent
condensation
.
I n s t al l at io n l 3 - 9
C o n n e c ti n g A i r H o s e A d a pte r s
Depending on the hopper you purchased you may need to install an air hose adapter to connect the hopper to your dryer.
To connect the air hose adapter:
1 Place high temperature gasket half way down over the dryer outlet to the
hopper.
2 Place hose adapter inside high temperature gasket flush to the dryer outlet, secure
with pressure clamp.
Pressure clamp
3 Attach the hopper inlet hose over the adapter, secure with clamp.
3 - 1 0 l In st al la ti o n
( C o nt i nu ed )
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