Conair W600 User manual

Carousel Plus Dryer
W Series Models 600 through 5000 with DC-1 Controls
Corporate Office: 724.584.5500 lInstant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861
USER GUIDE
UGD035-1216
www.conairgroup.com

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: 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.
Copyright 2016 l Conair l All rights reserved
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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 . . . . . . 2-7
Carousel Plus W Series Dehumidifying Dryer options . . . . . . . . . . . 2-8
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) . . . 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
Table of Contents 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 Operation
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 Maintenance
Preventative maintenance checklist . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Checking the dewpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleaning the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cleaning the process filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
ii l Table of Contents

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 Troubleshooting
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
Table of Contents l iii

iv l Table of Contents
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
B Appendix
Cleaning the precooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
C Appendix
Cleaning the volatile trap on the demister (W600-1000) . . . . . . . . C-1
Cleaning the volatile trap on the demister (W1600-3200) . . . . . . . C-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
SECTION
1
Intro duction l 1-1
1
Introduction

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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 valu-
able 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 Introduction

Introduction l 1-3
Using the Carousel Plus W Series
as a Central Dryer
The Conair Carousel Plus W600-5000 Series Dryers are factory configured to
be used as central dryers only. Therefore, this manual incorporates the informa-
tion necessary to use these dryers for central drying applications.
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.
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)