Conair Carousel Plus W Series User Manual Download

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Carousel Plus Dryer

W Series Models 150, 200, 300 and 400 with DC-T Controls

Corporate Office: 724.584.5500

Instant Access 24/7 (Parts and Service): 800.458.1960

Parts and Service: 814.437.6861

U S E R G U I D E

U G D 0 5 1 - 0 4 1 4

www.conairgroup.com

Summary of Contents for Carousel Plus W Series

Page 1: ...W Series Models 150 200 300 and 400 with DC T Controls Corporate Office 724 584 5500 l Instant Access 24 7 Parts and Service 800 458 1960 l Parts and Service 814 437 6861 U S E R G U I D E UGD051 0414...

Page 2: ...entation of your equipment Date Manual Number UGD051 0414 Serial Number s Model Number s Display firmware Version Display Menu Version Control Firmware Version NOTE Displayed upon initialization durin...

Page 3: ...l Plus W Series Dryer Options 2 7 3 1 Installation Unpacking the Boxes 3 2 Preparing for Installation 3 3 Positioning the Dryer on the Floor 3 3 Removing the Cable Tie from the Desiccant Wheel 3 3 Con...

Page 4: ...Control LED Lights 4 86 Alarm Email and Text Notification 4 87 Ethernet TCP IP Adress Setup to Enable Email Text Notification 4 87 Email Alarm Activation and Address Setup 4 88 Configuring the Email a...

Page 5: ...id State Relays 6 31 Checking or Replacing Temperature Sensors 6 32 Replacing the Heaters Regeneration Heater Tube 6 33 Process Heater Tube 6 34 Replacing the Desiccant Wheel 6 36 Replacing the Desicc...

Page 6: ...iv l Table of Contents...

Page 7: ...uide Is Organized 1 2 Using the Carousel Plus W Series as a Central Dryer 1 2 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...

Page 8: ...nt 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 m...

Page 9: ...ponsible 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 carefu...

Page 10: ...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 equip...

Page 11: ...e 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 t...

Page 12: ...ictured below To use the lockout device 1 Stop or turn off the equipment 2 Isolate the equipment from the electric power Turn the rotary disconnect switch to the OFF or O position 3 Secure the device...

Page 13: ...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 S E C T I O N 2 Description l 2 1 2...

Page 14: ...e hop per The dryer s closed loop design ensures a continuous supply of hot dehumidified air while preventing contamination from moisture in the plant Typical Applications 1 Dryer on the floor hopper...

Page 15: ...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 Dew...

Page 16: ...e 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 T...

Page 17: ...EMPERATURE 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 ROTAT...

Page 18: ...formance Tower chiller or municipal water sources can be used Specifications may change without notice Consult a Conair representative for the most current information C B A APPLICATION NOTES All drye...

Page 19: ...ter 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...

Page 20: ...2 8 l Description...

Page 21: ...n Power 3 4 Connecting the Process RTD Probe 3 5 Connecting the Setback RTD Probe 3 5 Checking for Proper Air Flow 3 6 Connecting the Air Hoses 3 9 Connecting the Dryer to the Hopper 3 9 Connecting Ai...

Page 22: ...e paper tape and plastic 3 Open the side panel and remove the cable tie securing the desiccant wheel See Installation section entitled Removing the cable tie from the desiccant wheel 4 Carefully inspe...

Page 23: ...tower city or chiller water at temperatures of 45 to 85 F 7 to 29 C Pipe should be run to the planned dryer location Use flexible hose to connect the water pipes to the aftercooler and or optional pre...

Page 24: ...nclosure Turn the discon nect dial on the dryer door to the Off or O position Lock out the main power see Page 1 6 for complete lock out information Turn the captive screw and swing the door open 2 In...

Page 25: ...ghten the connector Coil any excess cable and secure it with a wire tie Connecting the Setback RTD 1 Insert the probe in the hopper outlet at the top of the hopper The end of the probe must not touch...

Page 26: ...this equipment 1 Turn on the main power to the dryer Make sure the dryer s disconnect dial is in the ON position This powers up the control and the display will illuminate 2 From the Home Screen press...

Page 27: ...d your hand near the delivery air outlet You should feel air blowing out of the outlet 7 If air flow is incorrect disconnect power follow proper lockout proce dures and swap any 2 of the 3 main power...

Page 28: ...allation If the air flow is reversed the process blower is turning in the wrong direction Turn off and lock out the main power source Open the electrical enclosure and reverse any two leads connecting...

Page 29: ...air outlet from the top of the hopper 2 Attach one hose from the delivery air outlet of the dryer to the delivery air inlet of the hopper 3 Secure hoses with clamps The hose clamp should be secured at...

Page 30: ...r to con nect the hopper to your dryer To connect the air hose adapter 1 Place high temperature gasket half way down over the dryer outlet to the hopper 2 Place hose adapter inside high temperature ga...

Page 31: ...er housing using the six screws 2 Connect the water supply line to the aftercool er inlet If a manual shut off valve is used it should be mounted on the inlet line 3 Connect the water discharge or ret...

Page 32: ...vacuum receiver on the hopper disconnect the material inlet hose at the source or turn the loader off 2 Turn on the main power to the dryer Make sure the dryer s disconnect dial is in the ON position...

Page 33: ...ctly The blowers will continue running as needed to cool the heaters Until regeneration heaters are less than 150 F 66 C 7 The test is over If the dryer performed the normal operating sequences as out...

Page 34: ...3 14 l Installation...

Page 35: ...yer Configuration 4 81 DC T Security Levels 4 82 Starting the Dryer 4 83 Adjusting the Temperature Setpoint 4 84 Stopping the Dryer 4 85 Stopping the Dryer in An Emergency 4 86 Understanding the Contr...

Page 36: ...ResinWorks dryer with multiple hoppers a central dryer with separate heat source to multiple hoppers or as a stand alone dryer with a single hopper Once this factory configu ration is set based upon y...

Page 37: ...fying glass icons Magnifying Glass Icons Touching the magnifying glass icons will take the user to screens that contain detailed information about the system com ponent selected continued Navigation B...

Page 38: ...ed within fields with a heavy black boundaries Values shown within colored boxes are actual values and can not be changed Set point Field User Changeable Actual Values Non Changeable continued 350 NOT...

Page 39: ...reens continued All beveled grey buttons on the DC T control screen are selectable and will direct you to another screen At any point pressing the Home button will return you to the home screen 4 O p...

Page 40: ...hile in operation This screen is shown as a sample of functionality of a typical DC T screen See the functional descriptions below The follow ing pages are helpful in understanding how to use the DC T...

Page 41: ...en flow charts screen descriptions and basic operation describe the operation of the dryer when factory configured as a ResinWorks dryer attached to multi ple hoppers or as a central dryer attached to...

Page 42: ...Control Function Flow Charts From the Home screen Home ResinWorks Overview Trend Selection Login Logout Help Overview Active Alarms Setup 4 8 l Operation...

Page 43: ...nction Flow Charts From the Overview screen System Overview Hopper Selection Dryer Detail Individual hopper screen Individual hopper DM3 e if equipped settings screen Individual hopper settings screen...

Page 44: ...4 10 l Operation Control Function Flow Charts From the Alarm screen Home Alarms...

Page 45: ...ction Flow Charts From the Trend Selection screen Trend Selection Air Temp Trending Hopper Heater Trend Selection Dewpoint Trending Individual Hopper Air Temp Trend DM3 e Hopper Trend Selection DM3 e...

Page 46: ...4 12 l Operation Continued Control Function Flow Charts From the Setup screen Setup ResinWorks Setup Autostart Setup RW Dryer Options Hopper Setup or Hopper Names Hopper Comms...

Page 47: ...Flow Charts From the Setup screen continued Setup Regen Setup PID Values Reset To Default Regen PID Auto Tune I O Setup Dewpoint Setup Digital I O Status Set Time and Date Temp Sensor Setup Digital Ou...

Page 48: ...ion Control Function Flow Charts From the Setup screen continued Setup Alarm Setup Shutdown Alarm Setup 1 Shutdown Alarm Setup 2 Passive Alarm Setup 1 Passive Alarm Setup 2 User Manager Clean Screen E...

Page 49: ...4 O p e r a t i o n Control Function Flow Charts From the Login Logout screen Home Security Manager 3 Operation l 4 15...

Page 50: ...ct the dryer detail informa tion or the hopper s detail information NOTE On this Overview screen live data is displayed Data is displayed as colored text inside a solid black box Set points boxes are...

Page 51: ...n be made to Regeneration Temperature Setpoint Conair recommends not changing this setting Dewpoint Setpoint optional This screen also allows the user to start or stop the dryer The user can also view...

Page 52: ...user with the list of enabled hoppers If the list is empty or does not show the proper number of hoppers Setup has not been completed yet See Operation section entitled Hopper Setup NOTE Depending on...

Page 53: ...n near the tempeature zones to access DM3 e Settings and the Magnifying Glass zoom button near the bottom of the hopper to access the hopper setpoint settings The user can also view the other system p...

Page 54: ...which options your dryer has been configured with and whether or not you have the DM3 e Drying Monitor enabled your screens and icons may appear different For example if your ResinWorks system is DM3...

Page 55: ...rovides the user with the current alarm location zone and the Alarm Setpoint as well as a button to enable or disable DM3 e for this hopper These settings can be adjusted for each hopper in your DM3 e...

Page 56: ...ystem This screen allows you to change Hopper and hopper heater count Units selection Fahrenheit and Celsius Drying Monitor DM3 e enabling Dryer model Clock display 12 hour and 24 hour Voltage selecti...

Page 57: ...tings button from the Home screen 2 Press the ResinWorks Dryer Options button The ResinWorks Dryer Options screen provides the user with the ability to enable or dis able options This screen allows yo...

Page 58: ...tup Auto Start and Auto Stop 1 Press the Enable button to enable Dryer Auto Start 2 Press the Enable button next to each day of the week you would like to set the Auto Start time 3 Set the Auto Start...

Page 59: ...up button The ResinWorks Hopper Setup screen provides the user with the ability to move to a screen where you can Customize hopper names Enable hopper heater communication Enable DM3 e communication i...

Page 60: ...user entered hopper name up to 16 characters 2 Use the keypad to enter your new hop per name Hopper names can be up to 16 characters in total length 3 Press the enter button when complete 4 Use steps...

Page 61: ...r 1 Press the Enable button beside the hopper heater you would like to enable The button will illuminate green If communications are successful the LED beside the button will change from grey to green...

Page 62: ...ss the Regen Setup button NOTE Proper login is required to change these settings NOTE It is not typically necessary to use the Regen PID Auto Tune or the Reset PID Values to Factory button Contact the...

Page 63: ...ss the Settings button from the Home screen 2 Press the I O Setup button The Dryer I O Setup screen provides the user with the ability to open the Dewpoint Sensor Setup the Temp Sensor Setup the Digit...

Page 64: ...ir dewpoint sample rate sample averages and offset Return air dewpoint sample rate sample averages and offset To change a setpoint 1 Press the text inside white box with thick black outline of the set...

Page 65: ...etupbutton 3 Press the I O Status button The I O Status screen allows for a visual display of active outputs attached to the DC T control Inputs or outputs that are active will turn green Inactive inp...

Page 66: ...change from grey to green indicating that test mode is enabled 2 Press the power button beside the output you would like to test The button should illuminate and the LED beside the button should chan...

Page 67: ...et the setpoints for the Temperature Sensors Regen Temperature Sensor To change a setting 1 Press the white outlined setpoint box A pop up number pad will appear 2 Enter the desired setting Press ente...

Page 68: ...hernet settings load factory default Ethernet settings or to change and apply new Ethernet set tings To load the factory default Ethernet settings 1 Press the Load Factory Default Ethernet Settings bu...

Page 69: ...d will appear 2 Use the number pad to enter the new setting Press the enter button on the number pad to enter the new setting 3 Repeat steps 1 and 2 for each address setting 4 Press the Apply NEW Ethe...

Page 70: ...e Settings button from the Home screen 2 Press the Alarm Setup button The Alarm Setup screen provides the user with the ability to enable disable and adjust set points for alarms in the ResinWorks sys...

Page 71: ...r login is required to modify alarm settings Depending on your dryer configuration your alarm choices and screen configurations may vary from what is shown in this User Guide NOTE Some alarms require...

Page 72: ...n Alarm Setup button for the Shutdown alarms you would like to con figure screen 1 or screen 2 if applicable 4 Enter the desired setpoint and delay for each shutdown alarm NOTE Proper login is require...

Page 73: ...ard to the present time or jump immediately to live data The user can also touch any point on the trend line and the display will show the data reading date and time for that spot in the trend Scroll...

Page 74: ...Return Air Dryer Inlet Temperature Purple Wheel Outlet Temperature The Dryer Air Temperature Trending screen shows a snap shot of the last two 2 hours of operation and records and saves trending data...

Page 75: ...tion and records and saves trending data for the last seven 7 day period The scroll buttons near the bottom of the screen allow the user to scroll back to an earlier time or forward to the pres ent ti...

Page 76: ...Delivery Air Temperature Blue Hopper Outlet Temperature if equipped with setback The Hopper Heater Temperature Trending screen shows a snap shot of the last two 2 hours of operation and records and s...

Page 77: ...rs of operation and records and saves trending data for the last seven 7 day period The scroll buttons near the bottom of the screen allow the user to scroll back to an earlier time or forward to the...

Page 78: ...rms or clear individual alarms The following buttons are available from the Alarms log screen Previous The previous button is used to select the previous alarm when multiple alarms are displayed Next...

Page 79: ...harts screen descriptions and basic operation describe the operation of the dryer when factory configured as a stand alone dryer providing internal delivery air heat attached to a single hopper Operat...

Page 80: ...Control Function Flow Charts From the Home screen Home Dryer Overview Trend Selection Login Logout Help Overview Alarms Setup 4 46 l Operation...

Page 81: ...p e r a t i o n Control Function Flow Charts From the Overview screen Dryer Overview Dryer Delivery Air Heater Dryer DM II Drying Monitor Dryer Detail DM II Low Alarm Settings 280 250 350 Operation l...

Page 82: ...4 48 l Operation Control Function Flow Charts From the Alarm screen Home Alarms Alarm Banner Pop up...

Page 83: ...O p e r a t i o n Continued Control Function Flow Charts From the Trend Selection screen Trend Selection Air Temp Trending Material Temperature Trending if installed Dewpoint Trending Operation l 4 4...

Page 84: ...4 50 l Operation Continued Control Function Flow Charts From the Setup screen Setup Dryer System Setup Autostart Setup Dryer Options Ethernet Setup or Apply Settings Default Settings...

Page 85: ...Function Flow Charts From the Setup screen continued Setup Regen Setup PID Values Reset To Default Regen PID Auto Tune I O Setup Dewpoint Setup Digital I O Status Set Time and Date Temp Sensor Setup...

Page 86: ...ation Continued Control Function Flow Charts From the Setup screen continued Setup Alarm Setup Shutdown Alarm Setup 1 Shutdown Alarm Setup 2 Passive Alarm Setup 1 Passive Alarm Setup 2 User Manager Cl...

Page 87: ...4 O p e r a t i o n Control Function Flow Charts From the Setup screen continued Setup Delivery Air Heater Setup PID Values Reset To Default Delivery Air PID Autotune Continued Operation l 4 53...

Page 88: ...4 54 l Operation continued Control Function Flow Charts From the Setup screen continued Setup Delivery Air SP Setup...

Page 89: ...4 O p e r a t i o n Control Function Flow Charts From the Login Logout screen Home Security Manager 6 Operation l 4 55...

Page 90: ...et points boxes are white with heavy black bor ders Set points can be changed if the user has logged in at the proper security level by pressing the set point boxes This will launch a pop up keypad wi...

Page 91: ...art Autostop Setback Dewpoint Control are enabled If the user is logged in at the proper security level setpoint changes can be made to Regeneration Temperature Setpoint Dewpoint Setpoint The user can...

Page 92: ...oint for setback if equipped Hopper Setback activation This screen also allows the user to view the other system parameters view alarms view trending return to the Dryer Overview screen or return to t...

Page 93: ...M II Drying Monitor screen provides the user with the current alarm location zone and the Alarm Setpoint as well as a button to zoom to DM II settings These settings can be adjusted NOTE On these scre...

Page 94: ...ity to change the system set tings of this Dryer This screen allows you to change Units selection Fahrenheit and Celsius Dryer model Clock display 12 hour and 24 hour Voltage selection NOTE Your DC T...

Page 95: ...to enable or disable options This screen allows you to change the status of Filter Check Monitor Drying Monitor Setback Dewpoint Monitor Dewpoint Control Process Heater Current Regen Heater Current P...

Page 96: ...p Auto Start and Auto Stop 1 Press the Enable button to enable Dryer Auto Start 2 Press the Enable button next to each day of the week you would like to set the Auto Start time 3 Set the Auto Start ti...

Page 97: ...s the Settings button from the Home screen 2 Press the Alarm Setup button The Alarm Setup screen provides the user with the ability to enable disable and adjust set points for alarms in the Drying sys...

Page 98: ...for each alarm NOTE Proper login is required to modify alarm settings Depending on your dryer configuration you may have different alarm settings or different screen configurations NOTE Some alarms r...

Page 99: ...down Alarm Setup button for the Shutdown alarms you would like to configure screen 1 or screen 2 if applicable 4 Enter the desired setpoint and delay for each shutdown alarm NOTE Proper login is requi...

Page 100: ...een 2 Press the Regen Setup button NOTE Proper login is required to change these settings NOTE It is not typically necessary to use the Regen PID Auto Tune or the Reset PID Values to Factory button Co...

Page 101: ...reen To access the I O Setup screen 1 Press the Settings button from the Home screen 2 Press the I O Setup button The Dryer I O Setup screen provides the user with the ability open to the Dewpoint Set...

Page 102: ...nsor minimum and maximum Delivery air dewpoint sample rate sample averages and offset Return air dewpoint sample rate sample averages and offset To change a setpoint 1 Press the text inside white box...

Page 103: ...the I O Setupbutton 3 Press the I O Status button The I O Status screen allows for a visual display of active outputs attached to the DC T control Inputs or outputs that are active will turn green Ina...

Page 104: ...rey to green indicating that test mode is enabled 2 Press the power button beside the output you would like to test The button should illuminate and the LED beside the button should change from grey t...

Page 105: ...rature Sensors Delivery Air Temperature Sensor Regen Temperature Sensor Drying Monitor Temperature Sensors if equipped To change a setting 1 Press the white outlined setpoint box A pop up number pad w...

Page 106: ...e Home screen 2 Press the Delivery Air Heater Setup button NOTE Proper login is required to change these settings NOTE It is not typically necessary to use the PID Auto Tune or the Reset PID Values to...

Page 107: ...The Delivery Air Setpoint Setup screen provides the user with the ability change the set point for the Hopper Heater or other delivery air heat device To change the setpoint 1 Press the text inside wh...

Page 108: ...tton if you want to exit without loading the default factory settings To apply new Ethernet settings 1 Enter the new settings in the white boxes with thick black borders When you touch the setting ins...

Page 109: ...allow the user to scroll back to an earlier time or forward to the present time or jump immediately to live data The user can also touch any point on the trend line and the display will show the data...

Page 110: ...Dryer Inlet Pink Regeneration Temperature within the dryer Light Blue Wheel Outlet Temperature Green Delivery Air Heater Output Percentage Orange Hopper Outlet Temperature The Dry Air Temperature Tren...

Page 111: ...en shows a snap shot of the last two 2 hours of operation and records and saves trending data for the last seven 7 day period The scroll buttons near the bottom of the screen allow the user to scroll...

Page 112: ...ows a snap shot of the last two 2 hours of opera tion and records and saves trending data for the last seven 7 day period The scroll but tons near the bottom of the screen allow the user to scroll bac...

Page 113: ...or clear individual alarms The following buttons are available from the Alarms log screen Previous The previous button is used to select the previous alarm when multiple alarms are displayed Next The...

Page 114: ...4 80 l Operation...

Page 115: ...4 O p e r a t i o n General Operation Stand Alone and ResinWorks Dryer Configuration Operation l 4 81...

Page 116: ...ottom of the home page will have a number in it representing your current secu rity level Pressing the Login but ton again will log the user out of the system Also innactivity for 10 minutes will log...

Page 117: ...ressing the zoom button beside the hopper heater 5 Press the green start button beside the dryer graphic to start the dryer system OFF O ON I ResinWorks configuration Stand alone configuration 125 40...

Page 118: ...profile and the hopper outlet temperature Increasing the hopper outlet temperature will increase the pressure drop in filters due to the velocity of the air increas ing Increasing air temperature decr...

Page 119: ...t 2 Observe the dryer status changing to Stopping or Shutdown 3 Wait until the dryer status changes to Standby which will alert you that the cooldown setpoint has been reached Depending on your proces...

Page 120: ...osi tion Failure to do so will not allow the dryer to progress through the cooldown proce dure and could result in dam age to your equipment Understanding the Control LED Lights Your DC T control has...

Page 121: ...nction resides in the HMI so the HMI must be on for this feature to work This also means that multiple HMIs could be setup to email different addresses based on different types of alarms After activat...

Page 122: ...ticular dryer system The dryer name is set on the Dryer System Setup screen and appears in the subject line on the alarm messages Email Addresses This section lists all the email addresses and text ad...

Page 123: ...s per shift If no addresses are listed for a specific shift including the weekend shifts the email addresses from the previous shift will be used for notification messaging Once the email text address...

Page 124: ...etup screen the following configuration screens can be opened On each screen the individual alarms are listed followed by the enable disable but ton and then the Email Enabled indicator light When the...

Page 125: ...ty Shut Down Alarm Emails screen This screen shows the enable disable buttons for all of the possible RTD integrity dryer shut down alarms Depending on the dryer configuration some of these alarms may...

Page 126: ...n shows the enable disable buttons for all of the possible Dryer Passive alarms Depending on the dryer configuration some of these alarms may be hidden This screen is available on every DC T system wi...

Page 127: ...h one or more hoppers Depending on the hopper configurations some of these alarms may be hidden The arrows at the top of the navigation bar allow the operator to scroll through the configured hopper s...

Page 128: ...DC T screens If the user wants to make any changes the correct logon will still need to be pro vided for the DC T screens The default settings for the Web Server logon are User Name conair case sensi...

Page 129: ...th of the User Name or Password is 16 characters That includes spaces numbers and special characters If more than 16 characters are entered into the NEW fields once the changes are applied the string...

Page 130: ...4 96 l Operation...

Page 131: ...leaning the Process Filter 5 5 Cleaning the Regeneration Filter 5 7 Cleaning the Aftercooler Coils 5 8 Cleaning the Precooler Coils 5 9 Cleaning the Volatile Trap on the Demister 5 10 Inspecting Hoses...

Page 132: ...e connections Check for damage kinks or loose hose clamps Replace any hoses that show signs of damage or wear Reposition and tighten loose hose clamps Monthly Clean the optional aftercooler and precoo...

Page 133: ...ing it Some dewpoint monitors require a substantial amount of time for residual moisture to be purged from the sensor 4 In the event the dewpoint in not satisfactory refer to the Troubleshooting secti...

Page 134: ...e a con tainer beneath the hopper s drain port to catch the material 2 Remove the spreader cone Open the hopper door Reach into the hopper Grasp the spreader cone tube lift up slightly twist and then...

Page 135: ...r flow and dryer efficiency Cleaning frequency depends on how much material you process and how dusty or full of fines it is 1 Push in on the sides to release the tabs on the front cover Remove the co...

Page 136: ...the procedure to reinstall the process filter Ensure that the gasket on filter cap is in place and in good condition CAUTION Wear eye protection If you use compressed air to clean the equipment you m...

Page 137: ...ilter air dry 3 Loosen the hose clamp holding the regeneration filter onto the regenera tion inlet and remove the filter 4 Clean dust fines and dirt from the filter or replace it with a new filter Cle...

Page 138: ...ol was installed using the recommended 24 inch 61 cm of flexible hoses there is no need to disconnect the hoses from the aftercooler inlet and outlet 4 Remove the aftercooler assembly from the afterco...

Page 139: ...ntrol was installed using the recommended 24 inch 61 cm of flexible hoses there is no need to disconnect the hoses from the precooler inlet and outlet 4 Remove the precooler assembly from the precoole...

Page 140: ...thoroughly before installation Note In cases of heavy volitales steam cleaning or the use of solvents such as acetone may be neces sary Be sure to test a small area with the solvent you have selected...

Page 141: ...loop dry ing system 1 Stop the dryer and lockout the main power Allow the dryer to cool before touching any possible hot surfaces 2 Follow the hose routing of all the hoses in the dryer and inspect a...

Page 142: ...Clean HMI Screen button The touch functionality of the screen will be disabled for 30 seconds allowing for cleaning of the screen without accidently changing settings or pushing buttons 3 Using a clea...

Page 143: ...6 24 Poor material drying troubleshooting 6 25 REPAIR Replacing fuses 6 30 Checking heater solid state relays 6 31 Checking or replacing temperature sensors 6 32 Replacing the heaters Regeneration hea...

Page 144: ...ix the problem Refer to the alarm descriptions later in this section 3 Press the Alarm History button to view a history of alarms or press the Silence and Ack All Alarms button to acknowledge the alar...

Page 145: ...e or disable them Improper corrective action can lead to haz ardous conditions and should never be attempted to sustain production WARNING Only qualified service personnel should examine and correct p...

Page 146: ...larms for the Carousel Plus Dryer System or its components Shutdown alarms for the components within the Carousel Plus Dryer System A problem can trigger two types of alarms Shutdown The dryer has aut...

Page 147: ...1 Press the Silence and Ack Alarms button when the alarm banner appears at the top of the screen 2 Find the error message in the diagnostics table of the following troubleshooting sec tion of this ma...

Page 148: ...the main screen to access the alarm history and note the newest alarm s 4 Press the Silence Ack All Alarms button 5 After correcting the problem take note of the problem If the problem was not solved...

Page 149: ...ccant wheel Possible cause The regeneration exhaust is blocked or the air hoses are loose The regeneration blower is not running or running in the wrong direction The isolation contactor failed in the...

Page 150: ...he air lines are restricted or loose The delivery blower is not running or is running in the wrong direction The delivery heater output on the board has failed or the output fuse has failed Delivery s...

Page 151: ...board has failed Solution Locate and remove any airflow restric tions Tighten any loose hoses Correct the cause of the non running blower blown fuse etc or reverse the rotation of the blower Replace t...

Page 152: ...The process protection RTD has failed The control board has failed Solution Make sure the RTD temperature probe tip is in the center of the hopper inlet tube Correct the cause of the non functioning b...

Page 153: ...lution Check for air flow blockages or loose hoses between the outlet of the dryer and the inlet of the hopper Straighten any crimps in the hoses Tighten any loose hoses The dryer and the hopper shoul...

Page 154: ...cations boards have failed One of the three power wires are out of phase A fuse has blown Phase detection board has failed Internal control board problem Solution Check the RTD plug connection and mak...

Page 155: ...blower for mechanical failure and free rotation Replace if necessary Allow the over load to reset then try to restart the dryer Disconnect and lock out main power Check the delivery air blower for el...

Page 156: ...eck the regeneration blower for mechanical failure and free rotation Replace if necessary Allow the over load to reset then try to restart the dryer Disconnect and lock out main power Check the regene...

Page 157: ...ition The output on the board has failed The regeneration heater has failed The regeneration RTD is loose or has fallen out The regeneration blower is not running The output on the control board has f...

Page 158: ...ive regeneration heater The hopper does not contain enough material You are drying at a high drying tempera ture above 120 F 49 C or running at low throughputs The aftercooler does not have enough wat...

Page 159: ...ng and hose connections to the sensor resecure if needed Remove the air flow restrictions dirty filters etc Check the desiccant for contamination replace if needed Install plasticizer volatile trap fo...

Page 160: ...failed The control board has failed The wheel motor is not turning The belt tensioner is loose or the belt is slipping The regeneration heater is not working Solution Remove and clean or replace the p...

Page 161: ...n out Delivery air heater has failed Solution Replace the failed solid state relays SSRs Check the heater fuses and resistance across each leg of the delivery air heater Replace the board Check the pr...

Page 162: ...on and tighten if needed Replace the setback RTD Replace the control board Passive Alarms If an alarm occurs a red dialog box is displayed on the dryer s touch screen control The dryer continues to op...

Page 163: ...g connection and make any necessary repairs Check the plug connection and tighten if needed Replace the regeneration outlet RTD Replace the control board See Troubleshooting section entitled Passive a...

Page 164: ...trol board A sensor is disconnected or malfunction ing The dryer is currently in a stage where stopping or starting the dryer is not available Loose connection or wiring is not cor rect Dryer board fa...

Page 165: ...Solution Check that all jumpers are in their proper place Check to see if the dewpoint sensor and other sensors are connected properly Disconnect the ribbon cable connect ing any analog option boards...

Page 166: ...Parts at 800 458 1960 for the addition of a volatile trap Verify dryer dewpoint readings with a calibrated portable dewpoint meter Replace analog option board or sensor Dewpoint Troubleshooting Under...

Page 167: ...your Conair dryer is equipped with the Setback feature you should familiarize yourself with it and make use of it If not you may want to contact Conair to determine if it can be added to your dryer A...

Page 168: ...failure Solution Refer to the drying specifications for your material and adjust the setpoint to the recommended setpoint If your dryer has the Setback option make sure it is not active unless you ha...

Page 169: ...ion Make sure there is an adequate supply of material to feed the loader on top of the drying hopper Correct any problems with the convey ing system that may be preventing your loader from filling the...

Page 170: ...ubleshooting continued Airflow The airflow in the process drying circuit must be adequate to carry and distribute the heat throughout the entire bed of material inside the hopper If the airflow is too...

Page 171: ...rn air temperature is measured at the inlet to the process blower Poor desiccant performance Solution Replace or check defective heaters fuses etc Clean or replace the regeneration filter Ensure the r...

Page 172: ...se out and replace it with a fuse of the same type and rating Fuse Blocks To locate the appropriate fuse and replacement part refer to the wiring diagrams that came with your dryer IMPORTANT Always re...

Page 173: ...dia grams that came with your dryer 4 Check continuity using an ohmmeter IMPORTANT Always refer to the wiring diagrams that came with your dryer to locate specific electrical components Illustrations...

Page 174: ...correct if the sensors are touching the wall of an air hose or pipe or if the sensor or wiring is dam aged The tip of the sensor should be centered within the air hose or pipe Sensor wires should be a...

Page 175: ...er tube from the dryer 7 Compare the markings on the outside of the regeneration heater tube to ensure the new one has the same voltage and kW ratings as the original heater tube This information is o...

Page 176: ...d state relays Once disconnected pull the wires out of the control cabinet and separate them from the wiring harness along the dryer frame The high tem perature switch wires can be discon nected at th...

Page 177: ...clamp at the bottom of the heater tube 12 Put the original insulation back on the heater tube Apply duct tape to the seam that was cut during removal 13 W 200 400 models Route the heater wires with th...

Page 178: ...the dryer 5 Remove 4 bolts securing the wheel assembly sup port bracket to the dryer frame Using a crane or forklift lift the entire wheel assembly out of the dryer frame 6 Remove the wheel support b...

Page 179: ...e the belt from the motor pulley then remove the pulley from the motor 6 Remove the screws securing the motor to the upper and lower bracket and remove the motor 7 Secure the new motor to the bracket...

Page 180: ...rol type from the serial tag and parts list numbers for your particular equipment Service personnel will need this information to assist you Make sure power is supplied to the equipment Make sure that...

Page 181: ...ptions Inspect the equipment and perform alterations or adjustments to satisfy performance claims Charges for such inspections and corrections will be waived unless failure to meet warranty is due to...

Page 182: ...ckout the main power 2 Remove the side panels 3 Remove the knockout for the precooler housing on the dryer 4 Install the precooler housing Bolt the precooler housing in place with the hose connection...

Page 183: ...er discharge or return line with the pressure relief valve to the precooler outlet Use the bracket supplied to secure the pressure relief valve to the back of the dryer IMPORTANT Turn the water off wh...

Page 184: ...B 3 l Appendix...

Page 185: ...www conairgroup com Addendum DC T Modbus TCP IP Read Only Data V02 2 3 2014 S E C T I O N C C T C P I P D a t a Appendix C l C 1...

Page 186: ...iation Bit Read Only Bit 1 Dryer Process Low Temperature Bit Read Only Bit 2 Dryer Regen Temperature Deviation Bit Read Only Bit 3 Dryer Regen Temperature Low Bit Read Only Bit 4 Dryer Regen Temperatu...

Page 187: ...egister Actual Value Read Only 10 Test Mode Register Actual Value Read Only Dryer Running Status Integer Read Only Bit 0 Ready to Run Bit Read Only Bit 1 Hopper Setback Active Bit Read Only Bit 4 Alar...

Page 188: ...nly Return Air Temp Dryer Inlet Real Read Only Control Panel Temp Real Read Only Dryer Total Run Hours Real Read Only Passive Alarm Status 1 Integer Read Only Bit 2 Dryer Regen Temperature Deviation B...

Page 189: ...Blower Overload Bit Read Only Bit 3 Regen High Temperature Switch Bit Read Only Bit 6 Delivery Air Blower Overload Switch Bit Read Only Dryer Digital Input Status 2 Integer Read Only Bit 3 Return Air...

Page 190: ...Read Only Bit 8 RTD Integrity Bit Read Only Bit 9 Eeprom Error Bit Read Only Bit 10 Process Protection High Temperature Bit Read Only Bit 13 Air Flow Low Alarm Bit Read Only Bit 15 Process Temperatur...

Page 191: ...ly Drying Monitor 2 DM3e 43500 43599 Drying Monitor 3 DM3e 43600 43699 Drying Monitor 4 DM3e 43700 43799 Drying Monitor 5 DM3e 43800 43899 Drying Monitor 6 DM3e 43900 43999 Drying Monitor 7 DM3e 44000...

Page 192: ...Monitor 2 DM3e 43500 43599 Drying Monitor 3 DM3e 43600 43699 Drying Monitor 4 DM3e 43700 43799 Drying Monitor 5 DM3e 43800 43899 Drying Monitor 6 DM3e 43900 43999 Drying Monitor 7 DM3e 44000 44099 Dry...

Page 193: ...gen Heater KWH Real Read Only Delivery Air Heater Current L1 Real Read Only Delivery Air Heater Current L2 Real Read Only Delivery Air Heater Current L3 Real Read Only Total Dryer KWH Calculated Real...

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Conair Carousel Plus W Series, User Manual

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Summary of Contents for Carousel Plus W Series

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