Conair W600, W1000, W1600, W5000, W2400 User Manual
...
Carousel Plus Dryer
W Series Models 600 through 5000 with DC-1 Controls
Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861
U S E R G U I D E
UGD035-1216
www.conairgroup.com
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Please keep this User Guide and all manuals, engineering prints and parts lists
together for documentation of your equipment.
Date:
Manual Number: UGD035-1216
Serial Number(s):
Model Number(s):
See Screens 3 and 4 for Software Version
*Display Firmware 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.
Co p yr ig ht 2 01 6 l Co na ir l A ll r ig ht s re se rv ed
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Table of Contents
1-1 I ntr odu cti on
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 D esc rip tio n
What is the Carousel Plus W Series Dryer? . . . . . . . . . . . . . . . . . . .2-2
Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Specifications: Carousel Plus W Series Dehumidifying Dryer . . . . . . 2-7
Carousel Plus W Series Dehumidifying Dryer options . . . . . . . . . . . 2-8
3-1 I nst all ati on
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Positioning the dryer on the floor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Removing the cable tie from the desiccant wheel (W600-1000) . . . 3-4
Installing the regeneration exhaust cover . . . . . . . . . . . . . . . . . . . . 3-4
Installing the return air adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Installing the return air inlet and air outlet
adapters (W1600-5000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Installing the overhead process air duct (W3200-5000) . . . . . . . . . 3-7
Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Ta bl e of C on te nt s l i
Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Connecting the air hoses to a single hopper (W600-1000) . . . . . . 3-12
Connecting the air hoses to a single hopper (W1600-5000) . . . . . 3-13
Connecting the air hoses to a ResinWorks. . . . . . . . . . . . . . . . . . . 3-14
Connecting the dryer to the hopper . . . . . . . . . . . . . . . . . . . . . . . 3-15
Connecting the dryer to ResinWorks . . . . . . . . . . . . . . . . . . . . . . . 3-15
Connecting air hose adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Connecting the aftercooler and optional precooler (W600-1000). . 3-17
Connecting the intercooler and optional precooler (W1600-5000) . 3-18
Mounting a loader on the hopper . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
4-1 O per ati on
Carousel Plus W Series Dryer: control panel DC-1. . . . . . . . . . . . . . 4-2
Carousel Plus W Series Dryer DC-1 control functions . . . . . . . . . . . 4-3
Control function flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control function descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
To start drying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
To stop drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Using the auto start countdown function. . . . . . . . . . . . . . . . . . . . 4-17
How to disable the auto start on the DC-1 control. . . . . . . . . . . . . 4-17
Using the dewpoint monitor and dewpoint control. . . . . . . . . . . . . 4-18
5-1 M ain ten anc e
Preventative maintenance checklist . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Checking the dewpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleaning the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cleaning the process filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
ii l Tab l e of Co nt en t s
Cleaning the regeneration filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cleaning the aftercooler/intercooler coils . . . . . . . . . . . . . . . . . . . . 5-9
Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Cleaning the volatile trap on the demister . . . . . . . . . . . . . . . . . . . 5-11
Inspecting hoses and gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
6-1 Troubleshoo tin g
Before beginning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
DIAGNOSTICS
How to identify the cause of a problem . . . . . . . . . . . . . . . . . . . . . 6-4
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Dewpoint troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Poor material drying troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 6-18
REPAIR
Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Checking heater solid state relays. . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Checking or replacing temperature sensors . . . . . . . . . . . . . . . . . 6-25
Replacing the regeneration heater (W600-1000). . . . . . . . . . . . . . 6-26
Replacing the regeneration heater (W1600-2400). . . . . . . . . . . . . 6-28
Replacing the regeneration heater (W3200-5000). . . . . . . . . . . . . 6-30
Replacing the desiccant wheel assembly (W600-1000). . . . . . . . . 6-32
Replacing the desiccant wheel motor (W600-1000) . . . . . . . . . . . 6-34
Replacing the desiccant wheel motor (W1600-5000) . . . . . . . . . . 6-35
Ta bl e of C on te nt s l i ii
iv l Tab l e of Co nt en t s
A App endix
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
Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
C A p pen dix
Cleaning the volatile trap on the demister (W600-1000) . . . . . . . . C-1
Cleaning the volatile trap on the demister (W1600-3200) . . . . . . . C-2
Introduction
Purp o se o f t he u ser guid e . . . . . . . . . . . . . . 1-2
How the gu i de i s o rgani z ed . . . . . . . . . . . . . 1-2
Usin g th e C a rouse l P l us W Serie s
as a c entra l d r yer . . . . . . . . . . . . . . . . 1-3
Yo ur r espo n s ibil i ties as a u ser. . . . . . . . . . . 1 -3
ATTE N T ION:
Read th i s s o n o on e g e ts h urt . . . . . . . . 1-4
How to use th e lo c kout dev i ce . . . . . . . . . . . 1- 6
S E C T I O N
1
In t ro du ct io n l 1 -1
1
In t r odu c t ion
✐
Purpose of the User Guide
This User Guide describes the Conair Carousel Plus W Series Dryer and
explains step-by-step how to install, operate, maintain, and repair this
equipment.
Before installing this product, please take a few moments to read the User
Guide and review the diagrams and safety information in the instruction
packet. You also should review manuals covering associated equipment
in your system. This review won’t take long, and it could save you valuable installation and operating time later.
How the Guide is Organized
Symbols have been used to help organize the User Guide and call your
attention to important information regarding safe installation and operation.
Symbols within triangles warn of conditions that could be hazardous to users or
could damage equipment. Read and take precautions before proceeding.
Numbers indicate tasks or steps to be performed by the user.
A diamond indicates the equipment’s response to an action performed by the user.
An open box marks items in a checklist.
A circle marks items in a list.
Indicates a tip. A tip is used to provide you with a suggestion that will help you with
the maintenance and the operation of this equipment.
Indicates a note. A note is used to provide additional information about the steps
you are following throughout the manual.
1
◆
❒
•
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1- 2 l I n tr od uc ti o n
In t ro du ct io n l 1 -3
Using the Carousel Plus W Seri es
as a Central Dr yer
The Conair Carousel Plus W600-5000 Series Dryers are factory configured to
be used as central dryers only. Therefore, this manual incorporates the information necessary to use these dryers for central drying applications.
Your Responsibility a s 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.
1
In t r odu c t ion
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.
WA RNING : Impr o per inst a llati o n, oper ation , or
ser v icing ma y re sult in equi p ment dam a ge o r
perso n al injur 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 RNING : Vo ltage ha z ard
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 I n tr od uc ti o n
(continued)
1
In t r odu c t ion
In t ro du ct io n l 1 -5
ATTENTION:
Read this so no one gets hurt
(c on ti nue d)
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.
CA UTION : Hot Sur fa c es.
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 RNING : Do not plac e a e rosol , compr e ssed
gas or flamm able mate r ials on or near th i s
equip m ent.
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 I n tr od uc ti o n
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:
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.
De s cr ip ti on l 2- 1
Description
Wha t is th e C a r ouse l Pl u s W S erie s D r yer ? . . 2-2
Typi c a l a ppli c ati o n s . . . . . . . . . . . . . . . . . . 2- 2
How it wor k s . . . . . . . . . . . . . . . . . . . . . . 2-4
Spec i fica t ions: C arous e l P l us W Seri e s
Dehu m idify i ng Dry e r. . . . . . . . . . . . . . . 2- 7
Caro u sel Plus W Se r ies Dehu m idify i ng
Dr y er o ptio n s . . . . . . . . . . . . . . . . . . . 2-8
S E C T I O N
2
2
De s c rip t i on
What is the Carousel Plus W Series
Dryer?
The Carousel Plus W Series dehumidifying dryer produces low-dewpoint air that
removes moisture from hygroscopic plastics. The dryer pulls moist air from a
drying hopper and circulates it through a dehumidifying desiccant wheel. The
dryer then circulates the air through the material in the hopper.
The dryer’s closed-loop design ensures a continuous supply of dehumidified air
while preventing contamination from moisture in the plant.
Typical Applications
1 Dryer on the floor, single hopper (with HTC Hopper Temperature Control
package) on a floor stand.
2 Dryer on the floor, multiple hoppers in central configuration (ResinWorks) with
separate heat source for each hopper.
The Carousel Plus W Series Dryer can be used successfully in applications that
require:
• A contamination-free drying environment.
• A constant flow of dehumidified air.
2- 2 l D e sc ri pt io n
NOTE: The W600 - 5000 pro-
vides no heat to the process
air. A separate heat source is
required at the hopper(s) inlet
to heat the air to the desired
drying temperature.
✐
(continued)
De s cr ip ti on l 2- 3
2
De s c rip t i on
Typical Applications ( co nt inu ed )
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/intercooler)* 150° - 375°F {66° - 191°C}
Low-high (with aftercooler/intercooler & precooler)* 100° - 375°F {38° - 191°C}
* See page 3-17, 3-18 and Appendix B
• Throughput rates of 600 to 5000 lbs {271 to 454 kg} per hour (some
materials can be ran at a higher rate).
• Dewpoints of -40°F {-40°C}.
Use the aftercooler/intercooler 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}
• The return air is 120°F {49°C} or above.
Dryer Options
• Dewpoint monitor/dewpoint control
• Audible and visual alarm
NOTE: Temperature setback is only available in conjunction with the Hopper Temperature
Controller (HTC) or ResinWorks systems.
✐
NOTE: The aftercooler/intercooler reduces the temperature of air returning from the drying hopper, improving the efficiency of the desiccant.
✐
NOTE: Carousel Plus W Series 600-1000 Dryers use an aftercooler located before the the process
blower. Carousel Plus W Series 1600-5000 uses an intercooler located after the process blower.
✐
How It Works
2- 4 l D e sc ri pt io n
The Process (Drying) Cycle (W1600 - 5000)
Process air from the hopper is pulled into the dryer, through the process filter and
then into the process blower inlet. Air exits the process blower and then enters the
intercooler, then passes through the desiccant wheel, where moisture is removed.
The air exits the dryer and passes through the precooler (if installed), then into the
process heat source (HTC or CGT Gas Unit). After the air exits the process heat
source it then goes into the hopper inlet through internal piping, then to the spreader cone, which evenly distributes the air through the material.
The Cooling Cycle (All models except W2400 and 5000)
Regenerated desiccant must be cooled before it rotates back into the process cycle.
The process blower pushes the process air through the desiccant wheel. A small
amount of the process air is diverted through a small section of the desiccant wheel
to cool the air. The cooling air then returns back to the process air stream at the
start of the process cycle.
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 desiccant wheel. The hot air purges moisture from the
desiccant. The moist air is blown out the moisture exhaust at the top of the dryer.
The Process (Drying) Cycle (W600 - 1000)
Process air from the hopper is pulled into the dryer, through the process filter and
then into the process blower inlet. Air exits the process blower and then enters the
aftercooler, then passes through the desiccant wheel, where moisture is removed.
The air exits the dryer and passes through the precooler (if installed), then into the
process heat source (HTC or CGT Gas Unit). After the air exits the process heat
source it then goes into the hopper inlet, then to the spreader cone, which evenly
distributes the air through the material.
2
De s c rip t i on
How It Works (c on tin ued )
(W600 - 1 6 0 0 and 3 2 0 0 )
De s cr ip ti on l 2- 5
W-series 1600-5000
intercooler location only.
W-series 600-1000
aftercooler location.
NOTE: Earlier W1600-5000 dryers will have their intercoolers in the W6001000 location.
✐
NOTE: Carousel Plus W Series 600-1000 Dryers use an aftercooler located
before the the process blower. Carousel Plus W Series 1600-5000 dryers
use an intercooler located after the process blower.
✐
**********************
**********************
******
******
2- 6 l D e sc ri pt io n
How It Works (c on tin ued )
(W2400 and 5 0 0 0 )
Protected under
United States Patent
No. 7,101,414 and
other US and Foreign
Patents Pending.
.
NOTE: Carousel Plus W Series 600-1000 Dryers use an
aftercooler located before the the process blower. Carousel
Plus W Series 1600-5000 dryers use an intercooler located
after the process blower.
✐
Power Purge
W 2400 and 5000 models have a Power Purge (cooling fan)
feature integral to the desiccant wheel assembly.
Specifications: Carousel Plus W
Series Dehumidifying Dryers
C
A
B
De s cr ip ti on l 2- 7
2
De s c rip t i on
TPDS019-0311-REV
MODELS W600* W800* W1000
*
W1600
*††
W2400
*††
W3200
*††
W5000
*
††
Performance characteristics (with full hopper)
Drying temperature All models 100 - 375°F {38 - 191°C} with options
Dewpoint All models -40°F {-40°C}
Dimensions inches {cm}
A - Height 92.6 {235.2} 95.5 {242.6} 102.8 {261.1}
B - Width 43.3 {109.9} 48.3 {122.7} 48.9 {124.2}
C - Depth 57.6 {146.3} 86.2 {218.9} 112.0 {284.5}
Outlet/inlet hose diameter 8 {20.3} 12 {30.5} 12 {30.5}
Approximate weight lbs {kg}
Installed 1300 {590} 1300 {590} 1400 {636} 1600 {726} 1600 {726} 2000 {907} 2000 {907}
Shipping 1495 {678} 1515 {687} 1515 {687} 2100 {953} 2620 {1188} 3385 {1535} 3385 {1535}
Voltage - Full load amps
400 V/3 phase/50 Hz† 37.2 37.2 37.5 64.7 73.7 122.3 128.0
460 V/3 phase/60 Hz 32.0 32.0 32.2 56.3 63.1 106.6 111.0
575 V/3 phase/60 Hz 25.6 25.6 25.7 45.0 50.5 85.3 89.1
Water requirements {for aftercooler/intercooler or optional precooler}
§
Recommended temperature
**
45°- 85°F {7- 29}
Water flow gal./min. {liters/min.} 6-25 {22.7-94.6} 12-40 {45.4-151.4} 15-50 {56.8-189.3}
Water connections NPT 1 1/2 in. NPT
SPECIFICATION NOTES:
* Dryers W600-W5000 are central dryers and do not have process heaters. Hopper Temperature Controllers (HTC’s) or ResinWorks systems are used at the
hopper for heating the process air. See the Hopper Temperature Controller (HTC) specification sheet for additional information.
†
Dryers running at 50 Hz will have 17% less airflow, and a 17% reduction in material throughput.
‡ Total kW listed at a regeneration temperature of 350°F {177°C}.
§ When drying below 150 °F {66°C} a precooler is required. When drying above 180°F {82°C} an aftercooler/intercooler and insulated drying hose is
required.
** Temperatures above or below the recommended levels may affect dryer performance. Tower, chiller or municipal water sources can be used.
††
Models W1600-5000 do not have casters.
Specifications may change without notice. Consult a Conair representative for the most current information
.
2- 8 l D e sc ri pt io n
Carousel Plus W Series
Dehumidifying Dr yer Options
• Volatile trap (only in conjunction with aftercooler/intercooler) - The volatile
trap is recommended if drying materials that produce volitales that condense
into a waxy or oily residue and/or if the material contains excessive fines.
• Precooler - The precooler reduces the temperature of air after the desiccant
wheel and before the process heater, which enables the dryer to control
temperatures at low setpoints, (100º - 150ºF {38º - 66ºC})
• Filter check - The filter check sensor will activate a passive alarm when the
process filter is clogged or needs to be replaced.
NOTE: Temperature setback is only available in conjunction with the Hopper Temperature
Controller (HTC) or the ResinWorks system.
✐
In s ta ll at io n l 3 -1
Installation
Unpa c king the box e s . . . . . . . . . . . . . . . . . 3-2
Prep a ring for ins t alla t ion . . . . . . . . . . . . . . 3-3
Po siti o n ing the dr y er on the floo r . . . . . . . . . 3-4
Remo v ing the cabl e t i e f r om the
desi c cant whe e l ( W 600- 1 0 00) . . . . . . . . 3-4
Inst a lling th e re g enera tion exh a ust cove r . . . 3 -4
Inst a lling th e re t urn air ada p ter . . . . . . . . . . 3-5
Inst a lling th e re t urn air inl e t a n d a ir o utle t
ada p ters (W1 6 00-50 0 0) . . . . . . . . . . . . 3-6
Inst a lling th e Ov e rhead Pr o cess A i r D u ct
(W32 0 0-500 0 ) . . . . . . . . . . . . . . . . . . . 3-7
Conn e cting th e ma i n p ower . . . . . . . . . . . . . 3-8
Chec k ing for prop e r a ir f low . . . . . . . . . . . . 3 -9
Conn e cting th e ai r h o ses to a s i ngle
hopp e r ( W 600- 1 000) . . . . . . . . . . . . . . 3-12
Conn e cting th e ai r h o ses to a s i ngle
hopp e r ( W 1600 - 5000) . . . . . . . . . . . . . 3-13
Conn e cting th e ai r h o ses to a
Resi n Wo r ks . . . . . . . . . . . . . . . . . . . . 3-14
Conn e cting th e dr yer to the hop p er . . . . . . 3 -15
Conn e cting th e dr yer to Resi n Wo rks . . . . . . 3-15
Conn e cting ai r ho s e a dapt e rs . . . . . . . . . . 3 -16
Conn e cting th e af t erco o l er and opti o nal
prec o oler (W6 0 0-100 0 ) . . . . . . . . . . . . 3 - 17
Conn e cting th e in t erco o l er and opti o nal
prec o oler (W1 6 00-50 0 0) . . . . . . . . . . . 3 - 1 8
Moun t ing a l oader on th e ho p per . . . . . . . . 3- 1 9
Te sting th e in s tall a tion . . . . . . . . . . . . . . . 3- 1 9
S E C T I O N
3
3
In s t all a t i on
3- 2 l I n st al la ti on
Unpacking the Boxes
The Carousel Plus W Series Dryer comes in one to four boxes, depending on the
model and options ordered. The box(es) could include (depending on the options
selected):
• Carousel Plus W Series Dryer
• Delivery air hose
• Return air hose
• User Guide
1 Carefully remove the dryer and components from their shipping
container(s). Note that the dryer is secured to its shipping container with metal
bands that pass through the bottom of the dryer frame.
2 Unbolt any additional items secured to the shipping pallet, such as the
regeneration exhaust cover and return air adapter. (Carousel Plus W Series
1600-2400 Dryers will have a dry air delivery adapter. Carousel Plus W Series
3200-5000 Dryers will have a dry air delivery adapter and an overhead process
air duct.)
3 Remove all packing material, protective paper, tape, and plastic.
4 Cut and remove the desiccant wheel tie securing the wheel assembly.
(W600-1000)✎
5 Carefully inspect all components to make sure no damage occurred during
shipping, and that you have all the necessary hardware.
In s ta ll at io n l 3 -3
Unpacking the Boxes ( co nti nue d)
6 Take a moment to record serial numbers and electrical power specifications
in the blanks provided on the back of the User Guide’s title page. The
information will be helpful if you ever need service or parts.
7 You are now ready to begin installation.
Follow the preparation steps on the next page, then choose one of the two
mounting options:
• Dryer on the floor, single hopper (with HTC Hopper Temperature Control
package) on a floor stand.
• Dryer on the floor, multiple hoppers in central configuration (ResinWorks)
with separate heat source for each hopper.
3
In s t all a t i on
NOTE: The W600 - 5000 provides no heat to the process air. A separate heat source is
required at the hopper(s) inlet to heat the air to the desired drying temperature.
✐
Preparing for Instal lation
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 (on the control box) for
the correct amps, voltage, phase, and cycles. Field wiring should be completed by a qualified personnel to the planned location for the dryer. All
electrical wiring should comply with your region’s electrical codes.
❒
A source of water, when using the aftercooler/intercooler and/or pre-
cooler. The W Dryer’s aftercooler/intercooler and precooler require
tower, city, or chiller water at temperatures of 45° to 85°F {7° to 29°C}.
Refer to the Specifications Sheet (page 2-7) for flow rate for your unit.
Piping should be ran to the planned dryer location. Use flexible hose to
connect the water pipes to the aftercooler/intercooler 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.
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.
✒
NOTE: The aftercooler/intercooler reduces the temperature
of air returning from the drying
hopper, improving the efficiency of the desiccant.
✐
3- 4 l I n st al la ti on
Posit ioning the Dr yer on the Floor
1 Lift the dryer from the shipping container using a fork truck.
2 Position the dryer on the floor near the hopper or ResinWorks sled. Make
sure the location allows for the connection of all hoses, keeping hose lengths as
short as possible.
Removing the Cable Tie from the
Desiccant Wheel (W600-1000)
1 Open the dryer side panels and remove the cable tie securing the desiccant
wheel, if it was not done while unpacking the dryer.
Installing the Regen eration
Exhaust Cover
The Carousel Plus W Series Dryer’s regeneration exhaust cover must be installed.
To install the regeneration exhaust cover:
1 Remove the exhaust cover that is attached to the dryer’s shipping pallet.
2 Locate the bolt pattern at the top of the dryer, on top of the regeneration
exhaust outlet.
3 Position the regeneration exhaust cover on top of the regeneration exhaust
outlet, aligning both bolt patterns.
4 Secure the regeneration exhaust cover with supplied hardware, using an
appropriately sized wrench.
Desiccant Cable Tie
Regeneration
Exhaust Cover
3
In s t all a t i on
In s ta ll at io n l 3 -5
Installing the Retur n Air Adapter
(W600 - 1 0 0 0 )
The Carousel Plus W Series Dryer’s return air adapter must be installed.
To install the return air adapter:
1 Remove the return air adapter that is attached to the dryer’s shipping
pallet.
2 Locate the bolt pattern on the top of the dryer, on top of the return air inlet.
3 Position the return air adapter on top of the return air inlet, aligning both
bolt patterns.
4 Secure the return air adapter with supplied hardware, using an appropriate-
ly sized wrench.
Return Air
Inlet Adapter
Installing the Retur n Air Inlet and
Air Outlet Adapters (W1600 - 5000)
The Carousel Plus W Series Dryer’s return air inlet and air outlet adapters will be
removed when the dryer is shipped
To install the return air inlet and air outlet adapters:
1 Remove the return air inlet and air outlet adapters that are attached to the
dryer’s shipping pallet.
2 Locate the bolt patterns on the top of the dryer, on top of the return air inlet
and air out outlet.
3 Position the return air adapter on top of the return air inlet, aligning both
bolt patterns.
4 Secure the return air adapter with supplied hardware, using an appropriate-
ly sized wrench.
5 Position the air inlet adapter on top of the inlet air inlet, aligning both bolt
patterns.
6 Secure the air inlet adapter with supplied hardware, using an appropriately
sized wrench.
3- 6 l I n st al la ti on
Dry Air
Outlet
Adapter
Return Air
Inlet Adapter
Installing the Overh ead Process Air
Duct (W3200 - 5000)
The Carousel Plus W Series Dryer’s overhead process air duct will be removed
when the dryer is shipped.
To install the overhead process air duct:
1 Remove the overhead process air duct that is attached to the dryer’s ship-
ping pallet. The piping will be shipped as one unit with included gaskets (2).
2 Locate the bolt patterns on the top of the dryer, over top of the overhead
process air duct inlet and outlet.
3 Position the overhead process air duct on top of the overhead process air
duct inlet and outlet making sure to place supplied gaskets between the
overhead process air duct and the inlet and outlet of the dryer, align all bolt
patterns.
4 Secure the piping with supplied hardware, using an appropriately sized
wrench.
In s ta ll at io n l 3 -7
Overhead Process Air
Duct
Gaskets (2)
Connecting the Main Power
CAUTION: Always disconnect and lock out the main power sources before mak-
ing electrical connections. Electrical connections should be made only by qualified
personnel.
1 Open the dryer’s electrical enclosure. Turn
the disconnect dial on the dryer door to the Off
or “O” position. Lock out the main power (see
Page 1-6 for complete lock out information).
Turn the captive screw, and swing the door
open.
2
Insert the main power
wire through the knock-
out 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 compression fitting or strain relief.
3- 8 l I n st al la ti on
IMPORTANT: Always refer to the
wiring diagrams that came with
your dryer before making electrical
connections.
3
Connect the power wires
to the three terminals at the top of the power
disconnect holder.
4 Connect the ground wire to the ground lug as shown in the photo.
Auto Start
Dryer Status
Process Blower Regen. Blower
Regen. Heater
Set Point Actual
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
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
1000
Opening the Dryer Doors
(W1600 - 5 0 0 0 )
Carousel Plus W Series 1600-5000 Dryers designed after August 2007 will
have locking side panel door bolts.
To unlock the side panel door bolts:
1 Rotate the two (2) locking door bolts on the dryer door counterclockwise
with a regular screw driver.
2 Close the dryer doors and rotate the two (2) locking door bolts clockwise
to resecure the dryer doors.
Checking for Proper Air Flow
This procedure is needed on W600-5000 models if the phase detection option
was not ordered with the dryer.
CAUTION: If the air flow 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 discon-
nect dial is in the ON position. This powers up the control and the display
lights will illuminate.
2 Press the START button then the STOP button.
(continued)
Start and Stop Buttons
Stop
Start
In s ta ll at io n l 3 -9
3
In s t all a t i on
IMPORTANT: This procedure must be performed before the dryer’s air hoses are
connected to the hopper or before loading material into the hopper.
Dryer Door
Locking Bolts (2)
(W1600-5000)
3- 1 0 l I ns ta ll at io n
Checking for Proper Air Flow ( co nti nue d)
3 Visually verify the blower motor is
moving in the correct direction indicated by the arrow on the blower
housing. The W series 600-5000 dryers
are equipped with centrifugal process
blowers.
Dry Delivery
Air
Direction
Indication
Arrow
✐
NOTE: Models W600-1000
dryer aftercooler and dry
air delivery configuration
shown. Location on larger
models are different.
Refer to the labeling on
your dryer. See
Installation section entitled, Installing the
Return/Delivery Air
Adapters, for proper air
line connections.
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