Conair Carousel Plus D Series User manual

Carousel Plus Dryer
D Series Models 600 through 5000 with DC-C TouchViewTM Technology
Corporate Office: 724.584.5500 lInstant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861
USER GUIDE
UGD071-0919
www.conairgroup.com

Conair recommends recording 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: UGD071-0919
Serial Number(s):
Model Number(s):
Software Version(s):
Firmware Version Number:
Application File Name:
Programmable Logic Controller:
Firmware Version Number:
Application File Name:
Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.
DISCLAIMER: Conair nor its employees shall be liable for errors contained in this User Guide or for inciden-
tal, 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.
NOTE: The software,
firmware and application
file information for your
specific Carousel Plus
Dryer System is contained
on a serial tag that was
attached to the inside of
the Carousel Plus Dryer’s
control panel during as-
sembly.
0
Copyright 2019 l Conair l All rights reserved

Table of Contents l i
Table of Contents
1-1 Introduction
Purpose of the user guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Using the Carousel Plus Dryer with your system . . . . . . . . . . . . . . . . . . . . . . . 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 Dryer System? . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Typical applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
How the Carousel Plus Dryer System works . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Specifications: Carousel Plus D Series
Dehumidifying Dryers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3-1 Installation
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 models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installing the regeneration exhaust cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Connecting the Process RTD probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Connecting the Setback RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Installing the return air inlet and air outlet adapters . . . . . . . . . . . . . . . . . . . . 3-6
Connecting main power to the dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Opening the dryer doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Checking for proper airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Connecting the air hoses to a single hopper . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Connecting the air hoses to ResinWorks. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Connecting the drying to the hopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Connecting the Dryer to ResinWorks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Connecting air hose adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Connecting the aftercooler/intercooler and optional precooler
(W600-1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Connecting the aftercooler/aftercooler and optional precooler

(W1300-5000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Mounting a loader on the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Testing the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
4-1 Operation
The Dryer System control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
How to navigate the control screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
DC-C Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Operation - ResinWorks Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Control function flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Control function descriptions - ResinWorks configuration. . . . . . . . . . 4-15
Operation - Stand Alone Dryer Configuration . . . . . . . . . . . . . . . . . . . . . 4-31
Control functions flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Control function descriptions - Stand Alone configuration . . . . . . . . . 4-38
General Operation - Stand Alone and
ResinWorks Dryer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
DC-C System Security Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Starting the Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Adjusting the temperature setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Stopping the Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Stopping the Dryer in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
5-1 Maintenance
Preventative maintenance checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Checking the dewpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Cleaning the hopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cleaning the process filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Cleaning the regeneration filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cleaning the aftercooler/aftercooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Inspecting hoses and gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Cleaning the precooler coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Cleaning the volatile trap on the
demister (W600-W1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Cleaning the volatile trap on the
demister (W1300-W5000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Cleaning the DC-T HMI screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
ii l Table of Contents

Table of Contents l iii
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
Shutdown alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Passive alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Additional alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Dewpoint troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Poor material drying troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
REPAIR
Replacing fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Checking heater solid state relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Checking or replacing temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Replacing the regeneration heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Replacing the desiccant wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Replacing the desiccant wheel motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
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

iv l Table of Contents

Introduction
Purpose of the user guide . . . . . . . . . . . . . . . . . 1-2
How the guide is organized . . . . . . . . . . . . . . . . 1-2
Using the Carousel Plus Dryer
with your system . . . . . . . . . . . . . . . . . . . . 1-3
Your responsibilities as a user . . . . . . . . . . . . . . 1-3
ATTENTION:
Read this so no one gets hurt . . . . . . . . . . . . 1-4
How to use the lockout device . . . . . . . . . . . . . . 1-6
SECTION
1
1
Introduction
Introduction l 1-1

0
Purpose of the User Guide
This User Guide describes the Conair Carousel Plus Dryer with TouchViewTM Technology
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 manu-
als 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 equip-
ment. 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
u
r
•
2
1-2 l Introduction

Using the Carousel Plus Dryer with
Your System
The Conair Carousel Plus Dryer with TouchViewTM Technology used within your system is
factory configured to be used as a central dryer or in conjunction with ResinWorks or a
dedicated hopper using a Heater Pack or GasTrac. Therefore, this manual incorporates
the information necessary to use these dryers for central drying applications.
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.
1
Introduction
1-3 l 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 within this system by following the procedures outlined below and elsewhere in
the User Guide.
WARNING: Improper installation, operation or serv-
icing may result in equipment damage or personal
injury.
This equipment should be installed, adjusted and serviced by qualified techni-
cians who are familiar with the construction, operation and potential hazards of
this type of machinery.
All wiring, disconnects and fuses should be installed by qualified electrical tech-
nicians 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 equipment’s serial tags and data plates. Reference supple-
mental equipment’s manuals for their power requirements.
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 open-
ing the electrical enclosure or performing non-standard operating procedures,
such as routine maintenance. Only qualified personnel should perform trou-
bleshooting procedures that require access to the electrical enclosure while
power is on.
(continued)
1-4 l 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 within this system 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 ex-
ercise 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 exhaust outlet and the Hop-
per Temperature Controller (HTC) GasTrac Heater (CGT), or Heater Pack.
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
Introduction

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.
To use the lockout device:
1Stop or turn off the equipment.
2Isolate the equipment from the electric power. Turn the rotary
disconnect switch to the OFF, or “O” position.
3Secure the device with an assigned lock or tag. Insert a lock or tag
in the holes to prevent movement.
4The 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, turn the rotary disconnect back to the ON position:
1Remove the lock or tag.
2Turn the rotary disconnect switch to the ON or “I” position.
OFF
O
ON
I
OFF
O
ON
I
OFF
O
ON
I

Description
What is the Carousel Plus Dryer?. . . . . . . . . . . . . 2-2
Typical applications . . . . . . . . . . . . . . . . . . . . . 2-2
How the dryer System works. . . . . . . . . . . . . . . . 2-4
Specifications: Carousel Plus
D Series Dehumidifying Dryers . . . . . . . . . . . 2-6
SECTION
2
2
Description
Description l 2-1

2-2 l Description
What is the Carousel Plus D Series
Dryer?
The Carousel Plus D Series Dehumidifying Dryer produces low-dewpoint air that removes
moisture from hygroscopic plastics. The dryer pulls moist air from a drying hopper and cir-
culates 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 pre-
venting contamination from moisture in the plant.
Typical Applications
1Dryer on the floor, single hopper (with delivery air heat
Heater Pack on the hopper or a HTC on a floor stand).
2Dryer on the floor, multiple hoppers in central
configuration (ResinWorks) with separate heat
source for each hopper.
3Dryer on the floor, hopper(s) connected to Conair
GasTrac delivery air heater.
The Carousel Plus D Series Dryer can be used successfully in applications that require:
•A contamination-free drying environment.
•A constant flow of dehumidified air.
NOTE: The D600 - 5000 pro-
vides no heat to the delivery
air. A separate heat source is
required at the hopper(s) inlet
to heat the air to the desired
drying temperature.
0
(continued)

Typical Applications (continued)
Model Drying Temperature Range
Low temperature (with precooler)* 100° - 150°F {38° - 66°C}
High heat (with aftercooler)* 150° - 375°F {66° - 191°C}
Low-high (with aftercooler & precooler)* 100° - 375°F {38° - 191°C}
* See Installation: Connecting the Aftercooler and Precooler of this User Guide for more
information.
•Throughput rates of 600 to 5000 lbs {271 to 2267 kg} per hour (some
materials can be run at a higher rate).
•Dewpoints of -40°F {-40°C}.
Use the aftercooler when:
•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.
NOTE: The aftercooler reduces the temperature of air returning from the drying hopper, improving
the efficiency of the desiccant.
0
NOTE: All Carousel Plus D Series 600+ Dryers use an aftercooler located after the process blower.
0
2
Description
Description l 2-3

How It Works
The Process (Drying) Cycle
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 delivery air heat source (Heater Pack,
HTC, or GasTrac). After the air exits the delivery air 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 D2400, D4000 and D5000)
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.
2-4 l Description

2
Description
Description l 2-5
How It Works (continued)
Protected under United
States Patent No.
7,101,414 and other
US and Foreign
Patents Pending. .
Power Purge
D2400, 4000 and 5000 models have a Power Purge (cooling
fan) feature integral to the desiccant wheel assembly.

Specifications: Carousel Plus D Series
Dehumidifying Dryers
(continued)
See the next page for illustrations
2-6 l Description

2
Description
Description l 2-7
Specifications: Carousel Plus D Series
Dehumidifying Dryers (continued)
B
A
C

2-8 l Description