Conair W Series User manual

Carousel Plus Dryer
W Series odels 15, 25, 50, 75 and 100 with DC-2 Controls
U S E R U I D E
U D030-0407
www.conairgroup.com
Corporate Office: 724.584.5500 lInstant 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 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: UGD030-0407
Serial Number(s):
Model Number(s):
See Screens 31 and 32 for Software Version
*Display irmware Version:
*Display Menu Version:
*Control irmware Version:
* NOTE: Displayed upon initialization, during power up, or on a data tag
inside the door.
DISCLAI ER: Conair shall not be liable for errors contained in this User uide 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 Conai r l All rights res er ved
✐

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 Dehumidifying Dryer . . . . . . 2-6
Carousel Plus W Series Dehumidifying Dryer options . . . . . . . . . . . 2-7
3-1 Installation
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Positioning the dryer on the floor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Connecting the Process RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Connecting the setback RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Connecting the air hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Connecting the dryer to the hopper. . . . . . . . . . . . . . . . . . . . . . . . 3-10
Table of Contents l i

Connecting air hose adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Connecting the aftercooler and optional precooler. . . . . . . . . . . . . 3-12
Mounting a loader on the hopper . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Using communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
4-1 Operation
Carousel Plus W Series Dryer: control panel DC-2. . . . . . . . . . . . . . 4-2
Carousel Plus 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
To stop drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
How to use the supervisor’s password . . . . . . . . . . . . . . . . . . . . . 4-37
Using the auto start timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Setting the high setpoint limits . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Using the dewpoint monitor and dewpoint control. . . . . . . . . . . . . 4-41
Using the setback feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Setback feature guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
5-1 Maintenance
Preventative maintenance checklist . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Checking the dewpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleaning the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cleaning the process filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Cleaning the regeneration filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Cleaning the aftercooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Inspecting hoses and gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
ii l Table of Contents

6-1 Troubleshooting
Before beginning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
DIA NOSTICS
How to identify the cause of a problem . . . . . . . . . . . . . . . . . . . . . 6-4
Shutdown alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Passive alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Dewpoint troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Poor material drying troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 6-21
REPAIR
Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Checking heater solid state relays. . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Checking or replacing temperature sensors . . . . . . . . . . . . . . . . . 6-28
Replacing the heaters
Regeneration heater tube . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Process heater tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Replacing the desiccant wheel assembly . . . . . . . . . . . . . . . . . . . 6-33
Replacing the desiccant wheel motor . . . . . . . . . . . . . . . . . . . . . . 6-34
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
Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Table of Contents l iii

iv l Table of Contents
Addendum
Communication protocols for common controls - DC-2

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
S E C T I O N
1
Introductio n 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

Introductio n 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.
Central
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
Introductio n 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:
1Stop or turn off the equipment.
2Isolate the equipment from the electric power. Turn the rotary
disconnect switch to the O , 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 to the dryer, 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.

Description l 2-1
Description
What is the Carousel Plus W Series Dryer? . . 2-2
Typical applica tions . . . . . . . . . . . . . . . . . . 2-2
How it works . . . . . . . . . . . . . . . . . . . . . . 2-4
Specifications: Carousel Plus W Series
Dehumidifying Dr yer . . . . . . . . . . . . . . . 2-6
Carousel Plus W Series Dryer options . . . . . . 2-7
S E C T I O N
2
2
Description

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 (15 - 100).
2Hopper on a floor stand; the dryer next to it.
3Central dryer with ResinWorks.
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 Descript ion
(continued)

Typical Applications (continued)
odel 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 3-12 and Appendix B.
•Throughput rates of 15 to 100 lbs {6.8 to 37.3} per hour (some materials
can be ran at a higher rate).
•Dewpoints of -40° {-40°C}.
Use the aftercooler when:
•You are drying at temperatures over 240° {116°C}.
•Throughput rates are less than 50% of the dryer’s rated capacity.
•You are pre-drying material at temperatures over 150° {66°C}.
Dryer Standard Features:
•Audible and visual alarm
•Temperature setback
• Dewpoint monitor/dewpoint control
•DeviceNet communications (Alternate communications are
available: Modbus, SPI and Ethernet)
Description l 2-3
2
Description
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.
Central

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.
2-4 l Descript ion
Central
How It Works
The Carousel Plus W Series 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, then 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 select-
ed 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° {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.

REGENERAT I O N
AIR FILTER
DESICCANT
WHEEL
REGENERAT I O N
BLOWER
REGENERAT I O N
HEATER
HIGH TEMP
SHUTOFF
REGENERAT I O N
RTD
HOPPER
PROCESS
BLOWER
RETURN
AIR
FILTER
1 PROCESS FILTER STATUS
RETURN
AIR
RTD
PROCESS
RTD
HIGH TEMP
SHUTOFF
PROCESS
HEATER BOX
4 PRECOOLER
4
DRYER OPTIONS
PROCESS
COOLING
REGENERAT I O N
1
PROCESS
PROTECTION
RTD
REGENERAT I O N
OUTLET
RTD
3
3 PHASE ROTATION PROTECTION
AFTERCOOLER
ALARM LIGHT
ALARM BELL
2 CURRENT METER
2
2
SETBACK
TEMPERATURE
DEWPOINT
MONITOR/CONTROL
2
Description
How It Works (continued)
Description l 2-5
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.
Central

Specifications: Carousel Plus W
Series Dehumidifying Dryer
2-6 l Descript ion
C
A
B
MODEL W15 W25 W50 W75 W100
Perfor ance characteristics (with full hopper)
Drying temperature All models150 - 375 ° F {66 - 191 ° C} with options
Dewpoint All models -40 ° F {-40 ° C}
Di ensions inches {cm}
A - Height 36.0 {91.5} 43.5 {110.5}
B - Overall width 18.0 {45.7} 29.0 {73.7}
C - Depth 21.0 {53.3} 28.5 {72.4}
Outlet/inlet tube size OD 2.5
Weight lbs {kg}
Standard Dryer Installed 180 {82} 180 {82} 220 {91} 220 {91} 220 {91}
Voltage - Total Amps
208 V/3 phase/60 Hz 14.7 14.7 19.7 20.6 NA
230 V/3 phase/60 Hz 13.3 13.3 17.8 18.6 24.9
400 V/3 phase/50 Hz* 7.7 7.7 10.2 10.7 14.3
460 V/3 phase/60 Hz 6.7 6.7 8.9 9.3 12.4
575 V/3 phase/60 Hz 5.3 5.3 7.1 7.5 10.0
Total kilowatts
†
kw {BTU/min} 2.1 {120} 2.1 {120} 3.3 {188} 4.1 {233} 4.4 {250}
Water require ents {for optional aftercooler or precooler}
‡
Recommended temperature
§
45
°
- 85
°
F (7.2 - 29.4
°
C)
Water flow gal./min. {liters/min.} 1 {4.6} 2 {7.6}
Water connections N T 3/8 in. N T
T DS017-0305-REV
SPECIFICATION NOTES:
* Dryers running at 50 Hz will have 17% less airflow, and a 17% reduction in material throughput.
† Total kW listed at a process setpoint of 250°F {121°C} and a regeneration temperature of 350°F {177°C}.
‡ 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.

Carousel Plus W Series
Dehumidifying Dryer Options
•Volatile trap - 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. (Used only in conjunction with the standard
aftercooler.)
•Precooler - The precooler reduces the temperature of air flow after the
desiccant wheel and before the process heater, enables the dryer to control
temperatures at low setpoints (100º - 150º {38º - 66ºC}).
•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 C M monitor measures the cubic feet per minute of air
flow across the inlet/outlet of the process blower.
•Communications - Allows the dryer to be networked to industrial control
systems. DeviceNet is standard. Modbus, SPI and Ethernet are available.
Description l 2-7
2
Description

2-8 l Descript ion