Conair Carousel Plus UGD043-1216 User manual

Carousel Plus Dryer
W Series Models 600 through 5000 with TouchViewTM Technology (Siemens)
Corporate Office: 724.584.5500 lInstant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861
USER GUIDE
UGD043-
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 equip-
ment you installed.
Please keep this User Guide and all manuals, engineering prints and parts lists
together for documentation of your equipment.
Date:
Manual Number: UGD0043-126
Serial Number(s):
Model Number(s):
Software Version(s):
Multi Panel Operator Interface Terminal
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 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 201l Conair l All rights reserved
NOTE: The software,
firmware and application
file information for your
specific Dryer System is
contained on a serial tag
that was attached to the
inside of the Dryer’s con-
trol panel during assem-
bly.
✐

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 W Series
Dehumidifying Dryers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Dryer control options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
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 dessicant wheel . . . . . . . . . . . . . 3-4
Installing the regeneration exhaust cover . . . . . . . . . . . . . . . . . . . . 3-4
Connecting the delivery air RTD probe . . . . . . . . . . . . . . . . . . . . . . 3-5
Connecting the process protection RTD . . . . . . . . . . . . . . . . . . . . . 3-5
Installing the return air inlet and air outlet adapters . . . . . . . . . . . . 3-6
Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Table of Contents l i

Opening the dryer doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Connecting the air hoses to a single hopper . . . . . . . . . . . . . . . . . . 3-9
Connecting the air hoses to ResinWorks . . . . . . . . . . . . . . . . . . . 3-10
Connecting the dryer to the hopper . . . . . . . . . . . . . . . . . . . . . . . 3-11
Connecting the dryer to ResinWorks . . . . . . . . . . . . . . . . . . . . . . 3-11
Mounting a loader on the hopper . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Connecting the air hose adapters . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Connecting the aftercooler/intercooler and
optional precooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Testing the primary receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Testing the secondary receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
4-1 Operation
The Carousel Plus Dryer control panel. . . . . . . . . . . . . . . . . . . . . . . 4-2
How to navigate the control screens . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control function flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Login flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Basic controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Operation flow chart 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Operation flow chart 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Dew point package controls . . . . . . . . . . . . . . . . . . . . . . 4-11
Operation flow chart 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Operation flow chart 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Drying monitor package controls . . . . . . . . . . . . . . . . . . 4-15
Operation flow chart 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Operation flow chart 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Operation flow chart 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
ii l Table of Contents

Example set point change . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Control function descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Carousel Plus Dryer System security levels . . . . . . . . . . . . . . . . . 4-44
Starting the Carousel Plus Dryer System . . . . . . . . . . . . . . . . . . . 4-45
Adjusting the temperature set point . . . . . . . . . . . . . . . . . . . . . . . 4-47
Using the auto start timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Stopping the Carousel Plus Dryer System . . . . . . . . . . . . . . . . . . 4-50
Control function descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Carousel Plus Dryer System security levels . . . . . . . . . . . . . . . . . 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 coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Draining the volatile drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Inspecting the hoses and gaskets . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Cleaning the volatile trap on the demister . . . . . . . . . . . . . . . . . . . 5-13
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
Table of Contents l iii

Passive alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Dew point troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Poor material drying troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 6-23
REPAIR
Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Checking heater solid state relays. . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Checking or replacing temperature sensors . . . . . . . . . . . . . . . . . 6-30
Replacing the regeneration heater . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Replacing the desiccant wheel assembly . . . . . . . . . . . . . . . . . . . 6-37
Replacing the desiccant wheel motor . . . . . . . . . . . . . . . . . . . . . . 6-43
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

Table of Contents l v

vi 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
Introduction l 1-1
1
Introduction

✐
Purpose of the User Guide
This User Guide describes the Conair Carousel Plus Dryer with
TouchViewTM Technology (Siemens) 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