Conair 150 User manual

Carousel Plus Dryer
W Series Models 150, 200, 300 and 400 with DC-2 Controls
Corporate Office: 412.312.6000 lInstant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861
USER GUIDE
UGD025-0407
www.conairnet.com
INTRODUCTION • Purpose of the User Guide • How the guide is organized • Your responsibilities as a user • ATTENTION:
Read this so no one gets hurt • How to use the lockout device • DESCRIPTION • What is the W Dryer? • Typical
applications • How it works • Specifications: W Dryer • INSTALLATION • Unpacking the boxes • Preparing for instal-
lation • Mounting the dryer and hopper on a Processing Machine • Positioning the dryer on the floor; Mounting the hop-
per on the throat • Mounting the dryer on the floor stand; Hopper on the throat • Mounting the dryer and hopper on the
mobile floor stand • Connecting the main power • Checking for proper air flow • Connecting the air hose • Connecting
air hose adapters • Connecting water hoses • Connecting the RTD probe • Connecting the setback RTD • Mounting a
loader on the hopper • OPERATION • How it works • The W dryer control panel • W dryer control functions • Control
Function Description • To start drying • To stop drying • Using the auto start timer

Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.
It’s a good idea to record the model and serial number(s) of your equipment and
the date you received it in the User Guide. Our service department uses this infor-
mation, 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: UGD025-0407
Serial Number(s):
Model Number(s):
See Screens 31 and 32 for Software Version
*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: The Conair Group, Inc., shall not be liable for errors contained in this User Guide or
for incidental, consequential damages in connection with the furnishing, performance or use of
this information. Conair makes no warranty of any kind with regard to this information, including,
but not limited to the implied warranties of merchantability and fitness for a particular purpose.
Copyright 2007 l The Conair Group l All rights reserved
✐

Table of Contents
1-1 Introduction
Purpose of the user guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Using the Carousel Plus W Series as a central dryer . . . . . . . . . . . . 1-3
Your responsibilities as a user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
ATTENTION: Read this so no one gets hurt . . . . . . . . . . . . . . . . . . . 1-4
How to use the lockout device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2-1 Description
What is the Carousel Plus W Series Dryer? . . . . . . . . . . . . . . . . . . .2-2
Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Specifications: Carousel Plus W Series Dryer. . . . . . . . . . . . . . . . . . 2-6
Carousel Plus W Series Dryer options . . . . . . . . . . . . . . . . . . . . . . . 2-7
3-1 Installation
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Positioning the dryer on the floor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Removing the cable tie from the desiccant wheel . . . . . . . . . . . . . . 3-5
Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Connecting the RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Connecting the setback RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Connecting the air hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Connecting the dryer to the hopper . . . . . . . . . . . . . . . . . . . . . . . 3-11
Connecting air hose adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Table of Contents l i

Connecting the aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Mounting a loader on the hopper . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Using communications (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
4-1 Operation
The W Series Dryer: control panel DC-2 . . . . . . . . . . . . . . . . . . . . . 4-2
W Series Dryer control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control function flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
How to navigate the menu tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control function descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
To start drying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
To stop drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
How to use the supervisor’s password . . . . . . . . . . . . . . . . . . . . . 4-39
Using the auto start timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Setting high setpoint limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Using dewpoint control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Using the setback function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Setback feature guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
5-1 Maintenance
Preventative maintenance checklist . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Checking dewpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleaning the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cleaning the process filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Cleaning the regeneration filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cleaning the aftercooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Cleaning the volatile trap on the demister . . . . . . . . . . . . . . . . . . . 5-12
Inspecting hoses and gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
ii l Table of Contents

6-1 Troubleshooting
Before beginning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
DIAGNOSTICS
How to identify the cause of a problem . . . . . . . . . . . . . . . . . . . . . 6-4
Shut down alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Passive alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Dewpoint troubleshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Poor material drying troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 6-24
REPAIR
Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Checking heater solid state relays. . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Checking or replacing temperature sensors . . . . . . . . . . . . . . . . . 6-31
Replacing the heaters
Regeneration heater tube . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Process heater tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Replacing the desiccant wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Replacing the desiccant wheel motor . . . . . . . . . . . . . . . . . . . . . . 6-37
AAppendix
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
BAppendix
Installing a precooler (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Table of Contents l iii

CAppendix
Cleaning the aftercooler and precooler coils . . . . . . . . . . . . . . . . . . C-1
DAppendix
Cleaning the Volatile Trap on the Demister . . . . . . . . . D-1
Addendum
Communication protocols for common controls - DC-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 W Series
as a central dryer . . . . . . . . . . . . . . . . 1-3
Your responsibilities as a user. . . . . . . . . . . 1-3
ATTENTION:
Read this so no one gets hurt . . . . . . . . 1-4
How to use the lockout device. . . . . . . . . . . 1-6
SECTION
1
Introduction l 1-1
1
Introduction

✐
Purpose of the User Guide
This User Guide describes the Conair Carousel Plus W Series Dryers and
explains step-by-step how to install, operate, maintain, and repair this
equipment.
Before installing this product, please take a few moments to read the User
Guide and review the diagrams and safety information in the instruction
packet. You also should review manuals covering associated equipment in
your system. This review won’t take long, and it could save you valuable
installation and operating time later.
How the Guide is Organized
Symbols have been used to help organize the User Guide and call your
attention to important information regarding safe installation and operation.
Symbols within triangles warn of conditions that could be hazardous to users or
could damage equipment. Read and take precautions before proceeding.
Numbers indicate tasks or steps to be performed by the user.
A diamond indicates the equipment’s response to an action performed by the user.
An open box marks items in a checklist.
A circle marks items in a list.
Indicates a tip. A tip is used to provide you with a suggestion that will help you with
the maintenance and the operation of this equipment.
Indicates a note. A note is used to provide additional information about the steps
you are following throughout the manual.
1
◆
❒
•
✒
1-2 l Introduction

Introduction l 1-3
Using the Carousel Plus W Series
as a Central Dryer
This manual incorporates the information necessary to use the Conair 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.
Your Responsibility as a User
You must be familiar with all safety procedures concerning installation, opera-
tion and maintenance of this equipment. Responsible safety procedures include:
•Thorough review of this User Guide, paying particular attention
to hazard warnings, appendices and related diagrams.
•Thorough review of the equipment itself, with careful attention
to voltage sources, intended use and warning labels.
•Thorough review of instruction manuals for associated equipment.
•Step-by-step adherence to instructions outlined in this User Guide.
This box will contain information or highlight system differ-
ences particular to the application of the W series dryer as a
central dryer.
1
Introduction

ATTENTION:
Read this so no one gets hurt
We design equipment with the user’s safety in mind. You can avoid the potential
hazards identified on this machine by following the procedures outlined below and
elsewhere in the User Guide.
WARNING: Improper installation, operation, or
servicing may result in equipment damage or
personal injury.
This equipment should be installed, adjusted, and serviced by qualified
technical personnel who are familiar with the construction, operation,
and potential hazards of this type of machine.
All wiring, disconnects, and fuses should be installed by qualified elec-
trical technicians in accordance with electrical codes in your region.
Always maintain a safe ground. Do not operate the equipment at power
levels other than what is specified on the machine serial tag and data
plate.
WARNING: Voltage hazard
This equipment is powered by three-phase alternating current,
as specified on the machine serial tag and data plate.
A properly sized conductive ground wire from the incoming power
supply must be connected to the chassis ground terminal inside the
electrical enclosure. Improper grounding can result in severe personal
injury and erratic machine operation.
Always disconnect and lock out the incoming main power source before
opening the electrical enclosure or performing non-standard operating
procedures, such as routine maintenance. Only qualified personnel
should perform troubleshooting procedures that require access to the
electrical enclosure while power is on.
1-4 l Introduction (continued)

1
Introduction
Introduction l 1-5
ATTENTION:
Read this so no one gets hurt (continued)
We design equipment with the user’s safety in mind. You can avoid the potential
hazards identified on this machine by following the procedures outlined below and
elsewhere in the User Guide.
CAUTION: Hot Surfaces.
Always protect yourself from hot surfaces inside the dryer and hopper.
Also exercise caution around exterior surfaces that may become hot
during use. These include the hopper door frame, the exterior of an
uninsulated hopper, the return air hose and the dryer’s process filter
housing and moisture exhaust outlet.
WARNING: Do not place aerosol, compressed
gas or flammable materials on or near this
equipment.
The hot temperatures associated with the drying process may cause
aerosols or other flammable materials placed on the dryer or hopper to
explode.

1-6 l Introduction
How to Use the Lockout Device
CAUTION: Before performing maintenance or repairs on this product, you
should disconnect and lockout electrical power sources to prevent injury
from unexpected energization or start-up. A lockable device has been
provided to isolate this product from potentially hazardous electricity.
Lockout is the preferred method of isolating machines or equipment from energy
sources. Your Conair product is equipped with the lockout device pictured below.
To use the lockout device:
11Stop or turn off the equipment.
22Isolate the equipment from the electric power. Turn the rotary
disconnect switch to the OFF, or “O” position.
33Secure the device with an assigned lock or tag. Insert a lock or tag
in the holes to prevent movement.
44The 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:
11Remove the lock or tag.
22Turn the rotary disconnect switch to the ON or “I” position.

Description l 2-1
Description
What is the Carousel Plus W Series Dryer? . . 2-2
Typical applications . . . . . . . . . . . . . . . . . . 2-2
How it works . . . . . . . . . . . . . . . . . . . . . . 2-4
Specifications: Carousel Plus W Series
Dryer . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Carousel Plus W Series Dryer options . . . . . . 2-7
SECTION
2
2
Description
Description l 2-1

What is the Carousel Plus W Series
Dryer?
The Carousel Plus W Series dehumidifying dryer produces hot, low-dewpoint air
that removes moisture from hygroscopic plastics. The dryer pulls warm, moist air
from a drying hopper and circulates it through a dehumidifying desiccant wheel.
The dryer then heats the air to the drying temperature you selected and circulates it
through the material in the hopper.
The dryer’s closed-loop design ensures a continuous supply of hot, dehumidified
air while preventing contamination from moisture in the plant.
Typical Applications
1Dryer on the floor; hopper on the throat.
2Hopper on a floor stand; the dryer next to it.
3Dryer and hopper on a mobile floor stand (MDC version 150 and 200 only).
4Central dryer, with ResinWorks system.
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:
2-2 l Description
(continued)

Description l 2-3
2
Description
Typical Applications (continued)
Model Drying Temperature Range
Low temperature (with precooler)* 100° - 150°F {38° - 66°C}
Standard 150° - 240°F {66° - 116°C}
High heat (with aftercooler)* 150° - 375°F {66° - 191°C}
Low-high (with aftercooler & precooler)* 100° - 375°F {38° - 191°C}
* See page 3-13 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
MDC Options (models 150 & 200 only)
•Non dry air conveying
•Machine loading only
•Self loading (machine and hopper loading)
When supplied for
central drying appli-
cations, the W series
dryer is not equipped
with a process heater.
Therefore, as a cen-
tral dryer, the W
dryer will only sup-
ply dry air to the hop-
pers.

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.
How It Works
The W dryer achieves continuous, closed loop drying by passing air simultaneous-
ly 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 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.
The Regeneration Cycle
The regeneration blower pulls air through the regeneration filter into the dryer’s
regeneration heater. The air is heated to 350° F {177° C} before it is pushed into
the “wet” section of the wheel. The hot air purges moisture from the desiccant. The
moist air is blown out the exhaust at the back of the dryer.
2-4 l Description

REGENERATION
AIR FILTER
DESICCANT
WHEEL
REGENERATION
BLOWER
REGENERATION
HEATER
HIGH TEMP
SHUTOFF
REGENERATION
RTD
HOPPER
PROCESS
BLOWER
RETURN
AIR
FILTER
4 PROCESS FILTER STATUS
RETURN
AIR
RTD
PROCESS
RTD
2 SETBACK TEMPERATURE
*
HIGH TEMP
SHUTOFF
PROCESS
HEATER BOX
7 PRECOOLER
7
DRYER OPTIONS
3 DEWPOINT MONITOR / CONTROL *
PROCESS
COOLING
REGENERATION
2
3
4
PROCESS
PROTECTION
RTD
REGENERATION
OUTLET
RTD
6
6 PHASE ROTATION PROTECTION
* Standard on DC-2
AFTERCOOLER
ALARM LIGHT
ALARM BELL
5 CURRENT METER
5
5
1 PROCESS CFM MONITOR
1
2
Description
How It Works (continued)
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.
Description l 2-5

2-6 l Description
Specifications: Carousel Plus W
Series Dryers
MODEL W150 W200 W300 W400
Performance characteristics (with full hopper)
Air flow {SCFM}
* 75 100 150 200
Air flow {ACFM @ 250 °F } * 101 134 201 268
Drying temperature All models 100 - 375
° F {38 - 191 ° C} with options
dewpoint All models -40 ° F {-40 ° C}
Dimensions inches {cm}
A - Height 70.4 {178.8}
B - Overall width 29 {73.7}
C - Control width 24 {61.0}
D - Depth 51.5 {130.8}
Control depth 8 {20.3}
Outlet/inlet tube size OD 2.5 5 5 5
Weight lbs {kg}
Standard Dryer Installed 600 {272} 660 {300} 710 {322} 760 {345}
Voltage - Total Amps
230 V/3 phase/60 Hz 47.1 61.4 67 N/A
400 V/3 phase/50 Hz 25.8 34 38.5 63.6
460 V/3 phase/60 Hz 23.6 30.7 33.5 55.3
575 V/3 phase/60 Hz 18.9 24.7 26.8 44.3
Total kilowatts kW {BTU/min} 6.2 {353} 8 {455} 11 {625} 14 {800}
Water requirements {for optional aftercooler or precooler}
Recommended temperature* 45 ° - 85 ° F
Water flow gal./min. {liters/min.} 3 {11.4}
Water connections NPT 3/4 in. NPT
SPECIFICATION NOTES:
* The term SCFM stands for Standard Cubic Feet Per Minute, referenced to a pre-specified pressure, tempera-
ture and relative humidity. In most cases, SCFM is referenced to 14.7 PSIA 68° F and 36% relative humidity.
ACFM stands for Actual Cubic Feet Per Minute, and must be supplied with a temperature reference, due to the
change in air density with temperature. Because dryers operate at a relatively low pressure the effects on air den-
sity are negligible.
† Dryers running at 50 HZ will have 17% less airflow, and a 17% reduction in material throughput.
Specifications may change without notice. Consult a Conair representative for the most current information.
D
A
C
B
TPDS018-0705-REV

Carousel Plus W Series Dryer
Options
•Volatile trap (only in conjunction with aftercooler) - The volatile trap is
recommended if drying materials that produce 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 flow after the desic-
cant 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-deter-
mined power consumption values for the blowers and the control.
•CFM monitor - The CFM monitor measures the cubic feet per minute of air
flow across the inlet/outlet of the process blower.
•DeviceNet or SPI communications - Allows the dryer to be networked to
industrial control systems. DeviceNet communications are standard. Alternate
communications are available.
2
Description
Description l 2-7

2-8 l Description