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1. o D 5 2 E L4 Carousel Plus W Series Dryer Control Panel DC 1 Increment Decrement Buttons Used to increase and or decrease the set point of a control function Alarm Codes 1 Process Temp 2 Regen Temp See 3 Return Air Temp H 4 Auto Start Troubleshooting 5 Load Time MDC 6 Activate Setback Temp 7 Setback Temp Process Section for a more 8 Dewpoint complete listing of alarms Menu List Numbers 1 2 3 and 4 are standard items that will always be present Numbers 6 7 and 8 are screens associated with options If the option is not installed the screens will not be displayed Menu List l Numbers 2 3 and 4 are standard items that will i ed with an option If the option is not installed the screens will not be displayed Li Central 4 2 Operation i always be present Number 8 is a screen associat Setpoint Display Shows the setpoint value Start and Stop Buttons Press Start to start the dryer Press Stop to stop the dryer Actual Display Shows the actual temperature value Acknowledge Alarm Button Press once to silence the option al audible alarm and display alarm messages Press again to clear the alarm If pushed when there is no active alarm the most recent alarm code is displayed Menu Number Display Displays the menu number corresponding to what is shown in the setpoint and actual displays Can al
2. Refund the invoiced cost to the customer Credit is subject to prior notice by the customer at which time a Return Goods Authorization Number RGA will be issued by Conair s Service Department Returned equipment must be well crated and in proper operating condition including all parts Returns must be prepaid Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is being made Warranty Limitations Except for the Equipment Guarantee and Performance Warranty stated above Conair disclaims all other warranties with respect to the equipment express or implied arising by operation of law course of dealing usage of trade or otherwise including but not limited to the implied warranties of merchantability and fitness for a particular purpose Appendix A 2 Cleaning the Precooler Coils If you have the optional precooler you need to clean the coils to keep them work ing efficiently Cleaning frequency depends on the type and amount of material you process 1 Stop the dryer and lockout the main power A 2 Turn off the water flow to the water supply line Disconnect supply and return lines amp NOTE If an optional flow control was added with the precooler remove the compres sion fitting from the precooler inlet Loosen the fitting on the flow control then swing the copper water supply tube out and away from the precooler inlet 3 Remove the two 2 nuts sec
3. which can negatively impact residence time Airflow restrictions Process blower running backwards or performing poorly Material level in the hopper too low Solution Clean or replace the process filter Replace any worn or damaged hoses Tighten all hose clamps to eliminate leaks Remove any obstructions in the process air circuit Verify the process blower is running in the correct direction If backwards reverse direction by switching any 2 legs of high voltage to the motor IN WARNING Any electrical checks should be performed by a qualified electrician Repair or replace motor Other than running out of material to complete a job the material level inside the hopper must be a minimum of 50 full If the hopper is not at least half full the material in the cone section will not get adequate airflow to dry properly Troubleshooting 6 25 Poor Material Drying Troubleshooting continued Replacement dewpoint monitors are available from Conair Dewpoint The process air must be at a low dewpoint so it can efficiently collect the Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 moisture as it is released from the heated material and carry it to the dryer to be removed in the desiccant In most cases the dryer will dry your material satisfactory if the dewpoint of the air is 20 to 40 F 29 to 40 C If your dryer does not have dewpoint readout
4. Hose adapters are available from Conair The W 15 100 dryers have 2 1 2 inch inlet and outlet hose connections Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 Q NOTE If your dryer hose connection and your hopper hose connection are not the same size you will need a hose adapter Contact Conair Parts 1 800 458 1960 3 10 Installation Connecting Air Hose Adapters Depending on the hopper you purchased you may need to install an air hose adapter to connect the hopper to your dryer To connect the air hose adapter 1 Place a high temperature gasket approximately half way down from the end of the dry air delivery outlet Dryer Inlet Outlet p Connection 2 Place hose adapter inside high temperature gasket flush to the dryer outlet secure with pressure clamp Pressure Clamp 3 Attach the hopper inlet hose over the adapter secure with clamp Installation 3 11 47 ev D 2 IMPORTANT Do not move the Carousel Plus W series 15 100 dryer with the aftercooler and or optional precooler water hoses attached You must detach the water inlet outlet hoses and move the dryer to its new location and then reattach the water inlet outlet hoses Failure to do so will harm your equipment IMPORTANT When a precooler is purchased instead of an aftercooler the precooler will be mounted in the aftercooler s location ec TIP Make the water su
5. Replace the desiccant wheel See Troubleshooting section entitled Replacing the desiccant wheel Install plasticizer volatile trap for severe situations See A55 amp P3I Check for worn or lose hoses Replace as needed Remove and clean or replace the process air filter Troubleshooting 6 11 Alarms Shutdown A The dryer has automatically shut down because it has detect ed a serious problem that could damage your material or dryer Problem A33 amp P26 Regeneration RTD Integrity If the regen eration RTD is faulty it shuts down the dryer A34 amp P28 Return Air Temperature RTD Integrity The dryer continues to run with a passive alarm A35 amp P8 Regeneration Temperature Loop Break The regeneration temperature is outside of the operator entered deviation alarm band see Regeneration Temperature Deviation passive alarm and the regen eration temperature is not moving towards the setpoint at a rate greater than specified Default values are 2 F 1 C over 40 seconds Troubleshooting Passive P The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer Possible cause There is a loose connection in the wiring leading to the RTD The connection of the RTD plug on the control board is loose The regeneration RTD has failed The c
6. 145 250 Setback Temp Process Option Access Code Alarm Access Code Test Mode 755 History 756 2e n 44 4 32 H sfa sH A Am Hm A sH m A 73 E ES D sA sH Es i se er 2 Hl 39 m NN NH Hh per Be sH per 36 Control Function Descriptions Screen SCREEN 1 L SCREEN 2 E SCREEN 3 SCREEN 4 SCREEN 5 Default Screen SCREEN 6 Function Once the power is turned on this screen is displayed for 5 seconds while the control goes through self checking Once the power is turned on and screen 1 has been displayed for 5 seconds this screen is displayed for another 3 seconds It shows the dryer model number for which the control is configured After the model number is displayed this screen flashes for 1 second and displays the control board software version After the control versions is shown the screen flashes again for 1 second and dis plays the display board software version This is the DEFAULT screen It shows thei process air temperature setpoint and actual temperature measured at the inlet to the drying hopper The 4 or buttons can be used to change the setpoint Holding the or buttons in will cause the number to ramp up faster the longer the button is held The display will return to the default screen from anyplace in the menu structure if nothing is done after 10 minutes Indicates configuration as a central dryer This screen will be displaye
7. 3 Press the START button Hold your hand near the delivery air outlet You should feel air blowing out of the outlet amp NOTE If the dryer is running for more than 20 to 30 sec onds the Process Loop Break T EEA Mai i 4 Press the STOP button because the Process RTD is not seeing the expected tem perature rise A CAUTION Hot surface Do not place your hand directly on the delivery air outlet The outlet and the air can get hot enough to burn your hand Return Air Inlet Dry Delivery Air Moisture Exhaust 5 If air flow is incorrect disconnect power follow proper lockout procedures and swap any 2 of the 3 main power wires see photo page 3 9 N WARNING All wiring disconnects and fuses should be installed by quali fied electrical 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 the machine serial tag and data plate continued 3 8 Installation Checking for Proper Air FIOW continued Q amp Q INSTALLATION NOTE Models 50 75 and 100 use a three phase process blower If the dryer shuts down and a Process Loop Break shutdown alarm is indicated within the first few minutes of operation check for proper air flow 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
8. or button u Le 4 Scroll to screen 16 This is your current high setpoint limit Press or keys to set a new high setpoint limit ec Tip We recommend that you set your high setpoint limit 10 higher than your maximum high temperature setpoint To lock in your new high setpoint limit and exit the password protected screens scroll back to screen 14 then enter 500 and press scroll or cycle the power off and on 2 254 B Using Dewpoint Control Dewpoint control is a feature that can help you to reduce energy consumption It does this by varying the temperature of the regeneration air from its default set point of 350 F 177 C to maintain a setpoint that you have entered on the process dewpoint screen Screen 11 Example If your material is not difficult to dry it may dry adequately with 20 F 29 C dewpoint air When 20 F 29 C is entered as the setpoint Screen 11 the dryer will gradually lower the regeneration air temperature to a point where the dryer s delivery air is controlled at 20 F 29 C dewpoint The dewpoint control is active with setpoint values of 39 F 39 4 C and higher When the setpoint is 40 F 40 C or lower the regeneration tempera ture will be maintained at the default temperature of 350 F 177 C and the dewpoint control is inactive SE NOTE For more information concerning specific dewpoint control screens see Control Function Descriptions
9. D o D Maintenance 5 1 Preventative Maintenance Checklist Routine maintenance will ensure optimum operation and performance of the Carousel Plus W Series Dryer We recommend the following maintenance sched ule and tasks e Whenever you change materials CJ Drain and clean the hopper e Weekly or as often as needed O Clean or replace the process and regeneration filters You may need to clean filters more often than weekly Frequency depends on how much material you process and how dusty or full of fines it is O Inspect hoses and hose 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 e Monthly O Clean the aftercooler and or optional precooler coils You may need to clean the coils more often than monthly Frequency will depend on the type and volume of material you process e Every six months O Inspect gaskets for damage or wear Damaged gaskets can allow moisture to seep into the closed loop drying system Replace any gasket that is torn or cracked CJ Verify dewpoint readout and performance with calibrated portable instrument CJ Measure current draw on all 3 legs of heater wires This is to ensure that the heater is working properly 5 2 Maintenance Checking the Dewpoint It is a good idea to monitor the dewpoint performance of your dryer periodically with a calibrated portable dewpoint monitor
10. limit for the specified time Default values are 400 F 204 C for 20 seconds A27 amp P7 Regeneration Low Temperature The regeneration temperature is less than the low temperature setpoint for the specified time Defaults are 200 F 93 C for 20 seconds Troubleshooting larms Shutdown A The dryer has automatically shut down because it has detect ed a serious problem that could damage your material or dryer Passive P The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer Possible cause The hopper does not contain enough material You are drying at a high drying tempera ture above 240 F 116 C or running at low throughputs The aftercooler does not have enough water The aftercooler coils are dirty One of the solid state relays SSRs failed in the closed position The output on the board has failed The regeneration heater has failed The output on the control board has failed or the fuse has blown The regeneration RTD is loose or has fallen out Solution Make sure your material supply system is working properly Ensure water flow to the aftercooler Turn on the water supply or fix any leaks or blockages Clean the aftercooler coils See Maintenance section entitled Cleaning the aftercooler coils Replace the failed solid s
11. you can check the dewpoint with a portable dewpoint instru ment Conair sells a variety of portable dewpoint meters Contact Conair Parts Possible cause Low regeneration temperature Problem Dryer dewpoint is not reaching proper setpoint Poor regeneration airflow High dewpoint ambient air leaking into the closed loop drying circuit Return air temperature to the dryer is too high Poor desiccant performance 6 26 Troubleshooting Solution Replace or check defective heaters fuses etc Clean or replace the regeneration filter Ensure the regeneration blower is oper ating properly and rotating in the correct direction See Installation section enti tled Checking for proper air flow Remove obstructions in the air stream such as crimped hoses etc Replace damaged hoses and seal any leaks in the process air circuit If using a vacuum loader on the hopper ensure that the loader shroud is installed in the hopper and that the hopper is completely filled with material If partially filling your hopper ensure that the hopper loader is sealed against ambient air Install a gasket between the loader and the top of the hopper Clean the aftercooler coils See Maintenance section entitled Cleaning the aftercooler coils See Troubleshooting section entitled Replacing the desiccant wheel assembly Replacing Fuses 1 Disconnect and lockout the main power supply 2 Open the electrical enclosu
12. 97 C for longer than 180 seconds it shuts down the dryer A51 amp P29 Process Protection RTD Integrity If the process protection RTD is faulty it shuts down the dryer Possible cause The air lines between dryer and hopper are restricted or loose The dryer is located too far away from the hopper The process RTD is loose or has fallen out The process blower is not running The process hose is not insulated There is a loose connection in the wiring leading to the RTD The connection of the RTD plug on the control board is loose The process protection RTD has failed The control board has failed Shutdown Af The dryer has automatically shut down because it has detect ed a serious problem that could damage your material or dryer Solution 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 should not be located more than 10 feet 3 05 m apart Check the process RTD and tighten if needed Correct the cause of the non functioning blower Insulated hose is required for high dry ing temperatures Check the RTD plug connections make necessary repairs Check the plug connection and tighten if needed Replace the process protection RTD Replace the control board Passive Pf The dryer continues to operate but warns of a problem that c
13. Function Descriptions icontinueo Screen Screen 28 43 require access code 755 SCREEN 34 Test Mode Screen Lom 7 SCREEN 35 Test Mode Screen Ss SCREEN 36 Test Mode Screen EE ES oo SCREEN 37 Test Mode Screen SCREEN 38 Test Mode Screen E ce co Function This is the Test Mode screen for the isola tion contactor By pressing the or keys the setting can be changed When set to On the isolation contactor output will be turned on for 3 seconds and then shut off automatically This is the Test Mode screen for the alarm output horn and or red light By pressing the or keys the setting can be changed When set to On the alarm output will be turned on for 3 seconds and then shut off automatically 8 NOTE The alarm light on the membrane Switch will not come on If the optional alarm horn or red light is not installed nothing will happen This is the Test Mode screen for the pre cooler flow control valve By pressing the or keys the setting can be changed When set to On the precooler flow con trol valve output will be turned on for 3 seconds and then shut off automatically Q NOTE If the optional precooler flow control valve is not installed nothing will happen This is the Test Mode screen for the after cooler flow control valve By pressing the or keys the setting can be changed When set to On the aftercooler flow control valve output wil
14. Possible cause The dryer will continue to run if there is a passive alarm however it will not start if there is a active alarm Loose or improperly connected wire Improper dip switch setup on control board Defective display board or control board The software revision of the display board and control board are not compati ble Problem in the analog input section of the control Solution Push the alarm acknowledge button to identify the alarm and address it as nec essary Check wiring between control board and display board Check dip switch setup on control board Replace boards in sets to maintain soft ware compatibility In most cases both display and control boards will need to be replace as a set Check that all jumpers are in their prop er place Check to see if the dewpoint sensor is connected properly Disconnect the ribbon cable connecting any analog option boards to the main control board If the display returns to normal for all values except those that are generated through the analog options boards replace the option board Troubleshooting 6 19 6 20 Additional Alarms Along with the alarm indicators you may encounter additional messages that indicate a problem within the control Problem Er H There is a problem in the analog input section of the control Troubleshooting Possible cause Defect in the main control board RTD is not connected properly o
15. Series Dryer 05 2 2 Typical applications 0 0 0 ccc eee eee ee 2 2 HOW TEWOEKS isis uei ee d ert ret raed eei vwd geri qs 2 4 Specifications Carousel Plus W Series Dehumidifying Dryers 2 6 Carousel Plus W Series Dehumidifying Dryer options 2 7 3 1 Installation Unpacking the boxes 0 00 eee eee IIR 3 2 Preparing for installation lisse 3 4 Positioning the dryer on the floor 02 0005 3 4 Connecting the main power 22 0 cee ee eee eee 3 5 Connecting the process RTD probe 00 eee eee 3 6 Connecting the setback RTD probe Optional 3 6 Checking for proper air floW 0 0 cece eee eee ees 3 7 Connecting the air hoses 0 0 e cece eee 3 10 Connecting the dryer to the hopper 0 0000 3 10 Connecting the air hose adapters 000000 e ee 3 11 Table of Contents i ii Table of Contents Connecting the aftercooler and optional precooler 3 12 Mounting a loader on the hopper 000e eee 3 13 Testing the installation 0c cece eee eee eee 3 13 4 1 Operation Carousel Plus W Series Dryer control panel DC 1 4 2 Carousel Plus W Series Dryer control functions 4 3 Control function flow chart sse 4 3 Control function descriptions llle 4 5 To start drying ei i eee 4 17 TO StoD rylrig s c weve e
16. Visual alarms The audible and visual alarms are a combination of a blinking red alarm light and a horn that alerts the operator to a shutdown alarm Filter check The filter check sensor will activate a passive P10 alarm or a shutdown A29 alarm when the process filter is clogged or needs to be replaced Description 2 7 2 8 Description SECTION Installation Unpacking the boxes 3 2 Preparing for installation 3 4 Positioning the dryer on the floor 3 4 a Connecting the main power 3 5 Connecting the process RTD probe 3 6 S 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 Connecting air hose adapters 3 11 Connecting the aftercooler and optional precooler 3 12 Mounting a loader on the hopper 3 13 Testing the installations 3 ue Ron xs 3 13 Installation 3 1 3 2 Installation Unpacking the Boxes The Carousel Plus W Series Dryer comes in one to four boxes depending on the model and options ordered The boxes could include depending on the options selected Carousel Plus W Series Dryer Delivery air hose 10 ft 3 05 m Insulated with High Heat option Return air hose 10 ft 3 05 m Process RTD Setback RTD optional User manual 1 Carefully remove the dryer and components
17. best setpoints for their application based on experience Normal Setback Return Temp Setback Temp Drying Temp Screen 10 Process Screen 11 160 F 71 C 120 F 49 C 150 F 66 C 240 F 116 C 135 F 57 C 180 F 82 C 300 F 149 C 160 F 71 C 200 F 93 C 40 F 171 C 180 F 82 C 220 F 104 C To turn off the setback option 1 Enter the access code 754 see Screen 14 Then using the scroll buttons scroll to menu Screen 45 2 Turn the setback function for temperature option to Off by pressing the key 3 Push the scroll button to return to access code 754 then change the code to 500 Once the number has been entered push the scroll button or cycle the power to clear the access code Operation 4 23 4 24 Operation Setback Feature Guidelines optionan continued A recommended way to determine the Setback Return Temperature setpoint is to monitor the actual temperature of this function during pre drying of your material at start up and while running at your normal maximum material throughput The Setback Return Temperature setpoint should be set 10 to 20 above maximum temperature noted in these situations The Setback Temperature Process setpoint you select should be adequate to reduce the temperature significantly enough to prevent over drying of your materi al However keep in mind that the cooler the temperature selected the lon
18. clamps fittings and gaskets 2 Tighten any loose hose clamps or fittings 3 Replace worn or damaged hoses and gaskets Maintenance 5 9 5 10 Maintenance SECTION Troubleshooting BeIore beginning a v u2 4 lt ees oak Be EXE SH d 6 2 A few words of caution 22x horum 6 3 DIAGNOSTICS How to identify the cause of a problem 6 4 neis rr ooo Poe ad bw as ed i 6 5 Dewpoint troubleshooting 6 21 Poor material drying troubleshooting 6 22 REPAIR Replacing f Se8 ss SV eae e oos 6 27 Checking heater solid state relays 6 28 Checking or replacing temperature sensors 6 29 Replacing the heaters E cu Ss 22 a gt 72 20 e 9 imm gt io Regeneration heater tube 6 30 Process heater tUDG oon ceed nn 6 32 Replacing the desiccant wheel assembly 6 34 Replacing the desiccant wheel motor 6 35 Troubleshooting 6 1 Before Beginning You can avoid most problems by following the recommended installation and maintenance procedures outlined in this User Guide If you do have a problem this section will help you determine what caused it and how to fix it t NOTE Use of test Before you remove the cover from the dryer be sure to mode screens 28 43 may assist with the determining of possi ble cause of an alarm Access code 756 21 Diagnose causes from the control panel 1 Press Kc once to silence the optional audible alarm and display t
19. control box is loose and tighten if needed RTD is faulty it shuts down the dryer The connection in the electrical enclo Check the RTD plug connection and sure for the process RTD is loose tighten if needed The connection of the RTD plug on the Check the plug connection and tighten control board is loose if needed The process RTD has failed Replace the process RTD The control board has failed Replace the control board A21 amp P1 Process One of the solid state relays SSRs Replace the failed solid state relays Temperature Deviation failed SSRs The process temperature exceeds the deviation band as Process heater has failed Check heater fuses and resistance across entered for the specified time each leg of heater Default values are 10 F 6 C for 5 seconds The output on the board has failed Replace the board The process RTD is loose or has fallen Check the process RTD and tighten if out needed The air hose connections are loose Tighten all air hose connections 6 8 Troubleshooting Alarms Shutdown Af The dryer has automatically shut down because it has detect ed a serious problem that could damage your material or dryer Passive P The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer A22 amp P2 Process Low Precooler water is too cold or the wa
20. eee e Meds xu Veda ees 4 18 Using the auto start countdown function 4 19 How to disable the auto start on the DC 1 control 4 19 Setting the high setpoint limit 2 00000 4 20 Using dewpoint control 000 eee eee 4 21 Using the setback feature Optional 4 22 Setback feature guidelines Optional 4 23 Maintenance Preventative maintenance checklist 0 0 cece eee 5 2 Checking the dewpoint ss es reuses es eesse seeno eaaaa 5 3 Cleaning the hopper llssesseeenn RII 5 5 Cleaning the process filter lllillsieeseesesssese 5 6 Cleaning the regeneration filter 00 ccc eee eee 5 7 Cleaning the aftercooler coils 00 cece eee eee 5 8 Cleaning the precooler coils 00 0 cece eee eee 5 9 Inspecting hoses and gasketS 00c cece ee eee 5 9 6 1 Troubleshooting Before beginning 0 cee mmn 6 2 A few words of caution 0 eee eee eee 6 3 DIAGNOSTICS How to identify the cause of aproblem 005 6 4 AIMS nininini CECENE over ee cwevcvevevewcwdwenedss 6 5 Dewpoint troubleshooting 0000 cece eee eee 6 21 Poor material drying troubleshooting 6 22 REPAIR Replacing the fuses 0 00 cee ee eee 6 27 Checking the heater solid state relays 005 6 28 Checking or replacing temperature se
21. line from end to end then remove it from the old heater tube Insulation i central dryer there is no process heater in the sys item Therefore replac ing the process heater is 1 6 Compare the markings on the outside of the process heater tube to ensure the new one has the same voltage and kW rat ings as the original heater tube 7 Put the insulation on the new heater tube Use duct tape to hold the seam together 8 Secure the new heater tube using the hose clamp removed in Step 4 9 Connect the hoses to the top and the bottom of the process heater tube continued 6 32 Troubleshooting Replacing the Heaters Process Heater Tube continued 10 Connect the wiring harnesses from the process heater tube to the existing harnesses from the control box 11 Replace the plastic cover 12 Make sure the process heater fuses are not blown before applying power to the new heater Central i central dryer there is no process heater in the sys item Therefore replac ing the process heater is uum i i i mi mma mica nnl Eu Es mi Em Em cun ps id ES Bui Ex pn M Du Ed a n Troubleshooting 6 33 E 3 D wn a o s 9 A CAUTION Always disconnect and lock out the main power sources before making electri cal connections Electrical con nections should be made only by qualified personnel 6 34 Troubleshooting Replacing the Desiccant Wheel
22. not working There is a loose connection in the wiring leading to the RTD The connection of the RTD plug on the control board is loose The regeneration outlet RTD has failed The control board has failed Solution Check the motor plugs and fuses Change the tensioner spring or replace the belt Check the heater fuses and heater Check the RTD plug connection make necessary repairs Check the plug connection and tighten if needed Replace the regeneration outlet RTD Replace the control board Troubleshooting 6 17 Alarms Shutdown A The dryer has automatically shut down because it has detect ed a serious problem that could damage your material or dryer Passive P The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer Problem P34 Dewpoint Deviation High Displayed when the actual dewpoint goes above the setpoint by a specified amount of time and degrees Defaults are set for 5 F 3 C for 30 seconds P35 Dewpoint Deviation Low Displayed when the actual dewpoint goes below the setpoint by a specified amount of time and degrees Defaults are set for 5 F 3 C for 30 seconds Troubleshooting Possible cause The hose or wiring connections to the sensor block are loose or have fallen off Poor regeneration air flow Desi
23. of the W series dryer as a central dryer i Central 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 Introduction 1 3 1 4 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 N 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
24. page 4 5 Operation 4 21 4 22 itral drying applications ithe W series dryer is not equipped with a process theater Therefore the set tback function is not applicable NOTE Screen 5 will still show normal dry ing temperature as setpoint when setback is active Operation Using the Setback Feature optionay The setback function available on the Carousel Plus W Series Dryer with DC 1 control is designed to save you money on energy costs and keep you from over drying your material The optional setback feature if installed from the factory is disabled and will need to be enabled in access code 754 Screen 45 This is how setback operates when installed and turned on The control monitors the temperature of the air exiting the drying hopper If that temperature reaches a customer entered setpoint Screen 10 the delivery process air temperature will automatically setback to a customer entered setpoint Screen 11 Then if the air exiting the drying hopper drops below the customer entered temperature on Screen 10 by an amount greater than what is shown on Screen 23 the process temperature will automatically reset back to the original process temperature Screen 5 To turn on and setup the setback option 1 Enter the access code 754 see Screen 14 Then using the scroll buttons scroll to menu Screen 45 2 Turn the setback function for temperature option to On by pressing the key 3
25. problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer Note that once the Acknowledge Alarm button is pressed once the blinking amber LED becomes solid Possible cause The process high temperature setpoint is not at least 10 F 6 C above the drying setpoint One of the process solid state relays has failed The air lines are restricted or loose The process setpoint is too low The process heater output on the control board has failed Solution Reset the process high temperature set point at least 10 F 6 C above the drying setpoint Replace the solid state relay Straighten any crimps in the hoses Tighten any loose hoses Set the process setpoint higher or install an optional precooler Replace the control board Troubleshooting 6 5 6 6 Alarms Shutdown Af The dryer has automatically shut down because it has detect ed a serious problem that could damage your material or dryer A2 Process Temperature Loop Break If the process temperature is outside of the operator entered deviation alarm band see Process High Temperature Deviation passive alarm and the process tem perature is not moving towards the setpoint at a rate greater than specified it shuts down the dryer Defaults are set at 3 F 2 C over 20 seconds A3 Process Heater High Temperature The snap switch in the proces
26. 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 UGD032 0407 Serial Number s Model Number s Display Firmware 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 All rights reserved Table of Contents 1 1 Introduction Purpose of the user QUIde 1 esses 1 2 How the guide is organized 0 sce e eee eee 1 2 Using the Carousel Plus W Series as a central dryer 1 3 Your responsibilities as a USEF 1 sees 1 3 ATTENTION Read this so no one gets hurt 1 4 How to use the lockout device rsrsrsrerrrsroreosrats 1 6 2 1 Description What is the Carousel Plus W
27. regeneration and process protection and setback at the outlet heater of the hopper N IMPORTANT Always refer to the wiring diagrams that came with your dryer to locate specific electri cal components Illustrations in the User Guide are intended to be Location of representative only the Process RTD at the Hopper inlet To check or replace RTD sensors 1 2 Disconnect and lockout the main power supply A Remove dryer cover as necessary Locate the RTD sensors Check the sensor positions and conditions Temperature readings will be incorrect if the sensors are touching the wall of an air hose or pipe or if the sensor or wiring is damaged The tip of the sensor should be centered within the air hose or pipe Sensor wires should be attached to the appropriate connec tion points on the dryer s electrical enclosure or microprocessor board E ie D N o e E ea To check with ohm meter measure the resistance across the RTDs The resistance should be approximately 110 ohm at room temperature Replace the sensor if necessary Troubleshooting 6 29 6 30 Troubleshooting Replacing the Heaters Regeneration Heater Tube 1 Stop the dryer disconnect the power and follow proper lockout AN procedures 2 Remove the plastic cover Regeneration Heater Insulation Wires 7 Put the insulation on the new heater tube together Disconnect the wiring har nesses of th
28. to ensure it is performing at maxi mum capacity Even if your dryer has a dewpoint readout comparing it to a portable instrument periodically will confirm that the dewpoint sensor and readout is performing properly To check dewpoint 1 Connect your portable dewpoint meter to the dewpoint check port of the dryer Turn on the portable instrument and ensure there is positive airflow through the sensor Monitor the readout and allow ample time for it to stabilize before disconnecting the dewpoint monitor Some dewpoint monitors require a substantial amount of time for residual moisture to be purged from the sensor In the event the dewpoint in not satisfactory refer to the Troubleshooting section of the manual under A28 and P9 alarm for DC1 Alternate Procedure for dryers with no dewpoint check port 1 2 Stop dryer and allow it to cool Remove the plastic cover of the dryer and locate the process heater tube Connect a portable dewpoint instrument to the 1 8 inch NPT port at the process air outlet of the desiccant wheel assembly If there are existing con nections for the dryer s dewpoint sensor locate a 2nd 1 8 inch NPT port or connect your dewpoint sensor in series with the dryer sensor Do not install a tee to split the air between the dryer s sensor and your portable instrument This may cause one of them to be starved for adequate sample air Turn on the dryer NOTE Portable dewpoint moni tors p
29. Assembly When desiccant becomes clogged or contaminated you should replace the desiccant wheel assembly to ensure optimum performance 1 10 11 12 13 14 Stop the dryer disconnect the power and follow proper lockout procedures Remove the plastic cover from the dryer A Unbolt the control panel user interface from the wheel assembly discon nect wires and set the interface aside Disconnect all the hoses and RTD s from the wheel assembly Be sure to note the position of all hoses and RTDs for re assembly Disconnect the wires to the wheel motor Loosen the hose clamps on the wheel assembly then remove hoses Unbolt the wheel assembly and remove it from the dryer Bolt the new wheel assembly into place Return the heater tubes to their original location and secure the hoses with the original hose clamps Connect the wheel motor to the wiring harness Connect all hoses and RTDs to the wheel assembly Connect the wires to the control panel user interface and bolt it to the wheel assembly Reconnect power and start the dryer Verify that the wheel rotates smoothly and in the correct direction Replace the plastic cover Replacing the Desiccant Wheel Motor 1 Stop the dryer disconnect and lockout the main power N 2 Remove the plastic cover from the dryer A 3 Disconnect wires to the desiccant wheel motor CAUTION Always disconnect and lock out the main power sources before mak ing electrical conne
30. CONAIR www conairnet com USER GUIDE UGD032 0407 Carousel Plus Dryer W Series Models 15 25 50 75 and 100 with DC 1 Controls INTRODUCTION e Purpose of the User Guide How the guide is organized Using the Carousel Plus W series dryer as a central dryer e Your responsibilities as a user e ATTENTION Read this so no one gets hurt How to use the lockout device e DESCRIPTION What is the Carousel Plus W series dryer Typical applications e How it works Specifications Carousel Plus W series dehumidifying dryer INSTALLATION e Unpacking the boxes Preparing for installation e Positioning the dryer on the floor e Connecting the main power Connecting the process RTD probe e Connecting the setback RTD probe Checking for proper air flow Connecting the air hoses Connecting the dryer to the hopper eConnecting the water hoses e Mounting a loader on the hopper e Testing the installation e OPERATION e The W series dryer control panel DC 1 W dryer DC 1 control functions e Control function flow chart e Control function descriptions e To start drying To stop drying Using the auto start countdown function e How to disable the auto start Corporate Office 412 312 6000 Instant Access 24 7 Parts and Service 800 458 1960 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 Copyright 2007 The Conair Group It s a good idea to
31. COOLING DRYER OPTIONS ll REGENERATION 1 SETBACK TEMPERATURE 4 PHASE ROTATION PROTECTION 7 ALARM LIGHT 2 DEWPOINT MONITOR CONTROL 5 PRECOOLER 3 PROCESS FILTER STATUS 6 ALARM BELL Standard some DC 1 models depending on the package ordered The components identified by this type of box in the drawing are not supplied with the W dryer when it is configured as a central dryer Central Description 2 5 2 6 Description Specifications Carousel Plus W Series Dehumidifying Dryers Performance characteristics with full hopper Drying temperature Dewpoint Dimensions inches cm A Height B Overall width C Depth Outlet inlet tube size OD All models150 375 F 66 191 C with options All models 40 F 40 C 36 0 91 5 18 0 45 7 21 0 53 3 43 5 110 5 29 0 73 7 28 5 72 4 Weight Ibs kg Standard Dryer Installed 180 82 180 82 220 91 220 91 220 91 208 V 3 phase 60 Hz 20 6 230 V 3 phase 60 Hz 18 6 400 V 3 phase 50 Hz 77 77 10 7 460 V 3 phase 60 Hz 6 7 6 7 j 93 575 V 3 phase 60 Hz 5 3 5 3 7 5 Total kilowattst kw BTU min 2 1 120 2 1 120 3 3 188 4 1 233 Water requirements for optional aftercooler or precooler t Recommended temperature 45 85 F 7 2 29 4 C Water flow gal min liters min 1 4 6 2 7 6 Water connections NPT 3 8 in NPT 4 4 250 SPECIFICATION NOTES Dryers running at 50 Hz will have 17 less ai
32. IMPORTANT Always refer to the wiring diagrams that came with your dryer before making electrical connections 3 Connect the power wires to the three terminals at the top of the power disconnect 4 Connect the ground wire to the ground lug Ground Lug Installation 3 5 When configured as 1a central dryer there is no process heater ror process RTD in 1 the system 1 Therefore installa 1 tion and connection of the RTD probe 1 and or setback probe is not applicable 3 6 Installation Connecting the Process RTD Probe The process RTD probe monitors the temperature of the drying air as it enters the hopper If the probe is not installed correctly temperature readings will be inaccurate 1 Insert the probe at the inlet to the hopper The end of the probe must not touch the walls of the tube The tip of the probe should be approximately in the cen 1V ter of the tube Tighten the compression fit g ting to lock the probe in place 2 Plug the probe s cable into the receptacle labeled process on the left side of the electrical enclo sure Hand tight en the connector Coil any excess cable and secure it with a wire tie Connecting the Setback RTD Probe optional 1 Insert the probe in the hopper outlet at the top of the hopper The end of the probe must not touch the walls of the tube The tip of the probe should be approximately in the center of the tube Tighten the
33. M ao SCREEN 31 Test Mode Screen B ot 4 SCREEN 32 Test Mode Screen EE GM SCREEN 33 Test Mode Screen E Es 4 12 Operation Function This is the Test Mode screen for the process heater By pressing the or keys the setting can be changed When set to On the process heater output will be turned on for 3 seconds and then shut off automatically NOTE The isolation contactor will not be engaged therefore no electricity will go the heater The solid state relay contacts should close This is the Test Mode screen for the regen eration blower By pressing the or keys the setting can be changed When set to On the regeneration blower output will be turned on for 3 seconds and then shut off automatically This is the Test Mode screen for the regen eration heater By pressing the 4 or keys the setting can be changed When set to On the regeneration heater output will be turned on for 3 seconds and then shut off automatically Q NOTE The isolation contactor will not be engaged therefore no electricity will go the heater The solid state relay contacts should close This is the Test Mode screen for the wheel motor By pressing the or keys the setting can be changed When set to On the wheel motor output will be turned on for three seconds and then shut off automati cally This Test Mode screen is not used in the current program continued Control
34. Push the scroll button to return to access code 754 then change the code to 500 Once the number has been entered push the scroll button or cycle the power to clear the access code Go to Screen 10 This is where you will set the temperature setpoint for the air at the outlet of the drying hopper 5 On Screen 11 set the temperature setpoint to which the process air will revert to once the air at the outlet of the drying hopper has reached its setpoint continued Using the Setback Feature ioptionan continued 6 Use the setback temperature band screen Screen 23 to set the amount the return air temperature has to drop below the setpoint on Screen 10 before the original process temperature is restored For example if the activate setback temperature was 180 F 82 C and the value on Screen 23 is set to 20 once the dryer moves into setback the actual temperature measured at the outlet of the hopper would have to drop below 160 F 71 C to restore the original process set point 7 When the Setback Feature is active the Setback LED will be lit and the actual temperature on screen 5 will eventually approach the setpoint entered in screen 11 Setback Feature Guidelines optionay Careful selection of setpoint values in these functions is necessary for the setback to operate properly The following table is only a guideline of recommended settings for these setpoints It will be necessary for each customer to determine the
35. Troubleshooting 6 13 Alarms Shutdown Af The dryer has automatically shut down because it has detect ed a serious problem that could damage your material or dryer Passive P The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer shorten the hoses The process hose is not insulated Insulated hose is required for high drying temperatures A49 Process Protection The process RTD temperature probe is Make sure the RTD temperature probe High Temperature If the not installed correctly tip is in the center of the hopper inlet process protection temperature tube exceeds the process protection high temperature setpoint it The process blower is not running Correct the cause of the non functioning shuts down the dryer Defaults blower are set to 600 F 316 C for 10 seconds The air lines between dryer and hopper Straighten any crimps in the hoses are restricted or loose Tighten any loose hoses I i The dryer is too far from the hopper Move the dryer closer to the hopper and I l n I 1 1 l I l i 6 14 Troubleshooting Alarms Problem A50 Process Protection Differential If the difference between the process tempera ture exiting the process heater and the temperature of the air entering the hopper is greater than 175 F
36. a qualified personnel to the planned location for the dryer All electrical wiring should comply with your region s electrical codes CJ A source of water for the aftercooler and or the optional precooler The Carousel Plus W Series dryer s aftercooler and optional precooler can use 2 gals min 7 6 liters min tower city or chiller water at temperatures of 45 to 85 F 7 to 29 C Pipe should be ran to the planned dryer location Use flexible hose to connect the water pipes to the aftercooler and or precooler O Minimum clearance for safe operation and maintenance You should maintain 24 in 61 cm clearance on all sides of the dryer Positioning the Dryer on the Floor 1 Lift the dryer from the shipping container using a fork truck 2 Position the dryer on the floor near the processing machine Make sure the location allows for the connection of all hoses Connecting the Main Power AN CAUTION Always disconnect and lock out the main power sources before mak ing electrical connections Electrical connections should be made only by qualified personnel 1 Open the dryer s electrical enclosure 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 Insert the main power wire through the knockout in the side of the enclosure Secure the wire with an appro priate strain relief
37. a serious problem that could damage your material or dryer Passive P The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer Possible cause Plugs on wire harness between the display and control boards are loose or not wired correctly Display board or control board has failed One of the three power wires are out of phase A fuse has blown Phase detection board has failed Loose wire connection between phase board and control board Internal control board problem The connection in the electrical enclo sure for the hopper RTD is loose The connection of the RTD plug on the control board is loose The setback RTD has failed The control board has failed The setback RTD connection to the con trol box is loose Solution Make sure plugs are tight on board connections and match the wiring diagram Replace the defective boards Switch the position of two of the incom ing lead power wires at the dryer Check and or replace the fuse Replace the phase detection board Make sure wires are correct and secure Replace the control board Check the RTD plug connection and tighten if needed Check the plug connection and tighten if needed Replace the setback RTD Replace the control board Check the connection to the receptacle and tighten if needed
38. any two leads connecting the main power supply to the dryer amp NOTE If the dryer is running for more than 20 to 30 sec onds the Process Loop Break alarm A2 may occur because the Process RTD is not seeing the expected tem perature rise N WARNING All wiring disconnects and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region Always maintain a safe ground Do not operate the equip ment at power levels other than what is specified on the the machine serial tag and data plate Installation 3 9 Connecting the Air Hoses Using the two flexible hoses provided connect the inlets and outlets of the dry ing hopper to the dryer Make sure the dryer is located as close as possible to the hopper to reduce heat loss 10 ft 3 05 m of hose supplied If you have ordered an insulated hose it should be installed between the dryer outlet and the hopper inlet Return Air 1 Attach one hose from the return air Inlet inlet of the dryer to the return air out let from the top of the hopper Delivery Air Outlet 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 least 1 4 in 0 64 cm from the end of the inlet or outlet tube 9E NOTE Do not allow the flexible hoses to kink or crimp Connecting the Dryer to the Hopper
39. ations Equipment Guarantee Conair guarantees the machinery and equipment on this order for a period as defined in the quotation from date of shipment against defects in material and workmanship under the normal use and service for which it was recommended except for parts that are typically replaced after normal usage such as filters liner plates etc Conair s guarantee is limited to replacing at our option the part or parts determined by us to be defective after examination The customer assumes the cost of transportation of the part or parts to and from the factory Performance Warranty Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the equipment or as detailed in engineering specifica tions provided the equipment is applied installed operated and maintained in the recommended manner as outlined in our quotation or specifications Should performance not meet warranted levels Conair at its discretion will exercise one of the following options 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 misapplication improper installation poor maintenance practices or improper operation Replace the original equipment with other Conair equipment that will meet original performance claims at no extra cost to the customer
40. be set from 0 1 to 150 0 hours To set the countdown time 1 Use the Scroll button to access the function Menu 4 Screen 8 4 ON auto Start 2 Use the Setpoint Adjust keys to set the desired countdown time in hours 3 Press the Start button The Auto Start LED will blink to indicate that Auto Start is armed How to Disable the Auto Start on the DC 1 Control To disable auto start once armed cycle the power off and on Operation 4 19 central dryer the high setpoint limits can not be set since there is no process heater in the 1 l L I 1 l 1 l i 1 1 system Si NOTE Conair is not responsi 4 20 ble for damage caused by excessively high drying setpoints that are not in accordance with your drying material recommendations NOTE Software may allow the process temperature setpoint limit up to 450 F 232 C however Conair does not recommend a set point limit over 375 F 191 C due to nuisance alarms Operation Setting the High Setpoint Limit Using the high setpoint limit can protect your drying process from accidental or unauthorized settings above an acceptable level for the material you are drying 1 Turn on the main power to the dryer 2 While at the default screen Screen 5 press the scroll button and the set point minus button simultaneously to get to Screen 14 Py L ID jJ 3 On screen 14 enter the password for set up screens 754 using the setpoint
41. ccant wheel not turning The desiccant wheel may be contaminated Leaks in the process air stream The dewpoint can not control to the desired setpoint The dewpoint sensor has failed Solution Check wiring and hose connections to the sensor resecure if needed Remove the air flow restrictions clean or replace dirty filters etc See A55 amp P31 Check the desiccant for contamina tion replace if needed Replace the desiccant wheel See Troubleshooting section entitled Replacing the desiccant wheel Install plasticizer volatile trap for severe situations Check for worn or loose hoses Material and or ambient condition may be too dry to increase the actual dewpoint Please wait several hours to determine if the setpoint can be reached Increase the dewpoint low deviation value Replace the dewpoint sensor Additional Alarms Along with the alarm indicators you may encounter additional messages that indicate a problem within the control Problem CoS Er 4 or Co5 Er 4 Displayed when the Start button is pushed during any active alarm Passive or Shutdown CoS Er 0 or Co5 Er 0 Indicates there is a problem in the communication between the control board and the display board Err 004 Indicates a mis match of software between the display board and the control board Er L There is a problem in the sensor connection RTD dewpoint sensor etc for the affected function
42. cess DRYING CYCLE The process blower pulls moist air from the top of the drying hopper The air passes through the process filter and aftercooler ithen into the desiccant wheel where moisture is removed The dry air is delivered to the hopper after it passes through the optional i precooler if installed where a spreader cone evenly distributes the air through the material Central Bl 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 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 2 4 Description How It Works continued I I p s d REGENERATION Sansen 3 BLOWER HIGH TEMP SHUTOFF L Li REGENERATION 1 AIR FILTER HIGH TEMP SHUTOFF oO 4 77 EN V S E len e REGENERATION HEATER REGENERATION RTD DESICCANT WHEEL RETURN AIR FILTER AFTERCOOLER l PROCESS Mi PROCESS BLOWER d
43. ch of the four requirements that is not being satisfied refer to the following list and possible causes and solutions Temperature The temperature of the air entering the hopper must be at the proper drying temperature for your material as specified by your supplier Possible cause Incorrect setpoint entering the hopper is not at proper drying temperature Not able to achieve setpoint Inaccurate process temperature readout 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 have specifically activated it If neces sary refer to the Operation section of this manual for assistance in using the Setback function Replace any defective process heater contactors fuses etc Ensure the selected drying temperature is within the design specifications of your dryer Ensure the Process RTD is properly positioned in the air stream Determine if there is a problem in the temperature control circuit and repair or replace any defective components such as RTD temperature control circuit boards etc Troubleshooting 6 23 6 24 Problem Material residence time is too long or short Troubleshooting Poor Material Drying Troubleshooting continued Residence Time The time your material supplier has determined that the material in use must be heated to its drying te
44. compression fitting to lock the probe in place 2 Plug the probe s cable into the receptacle labeled setback on the left side of the electrical enclosure Hand tighten the connector Coil any excess cable and secure it with a wire tie Checking for Proper Air Flow This procedure is needed on W 50 through 100 models if the phase detection option was not ordered with the dryer AN CAUTION This procedure must be performed before the dryer s air hoses are con nected to the hopper Performing this step after the air hoses are connected could cause damage to the dryer if the air flow direction is incorrect due to improper phase connection Material from the hopper can be pulled into the process heater causing permanent damage 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 lights will illuminate 2 Set the drying temperature Press Setpoint Adjust or buttons to set the drying temperature to a low setpoint of 150 F 66 C n S gt lg oO Si Central CONAIR Actual 1 Process Temp 2 Regen Temp Process Blower Regen Blower Auto Start 3 Return Air Temp 4 Auto Start i ProcessHeater YT n MEE Dreier 5 Load Time MDC Conveying Blower Set Back Temp 6 Activate Setback Temp 7 Setback Temp Process Dewpoint Setpoint Adjust Buttons Installation 3 7 Checking for Proper Air FIOW continued
45. creen In this section the last 10 alarms that have occurred are saved starting with the most recent alarm The number in the setpoint screen shows the list of alarms 1 10 The alarm code shows up in the actual screen Some of the alarm codes are shown on the display label Please refer to the alarm section of this manual for all alarm code definitions These are the additional alarm screens See the explanation above Operation 4 15 4 16 Control Function Descriptions continued Screen Function Screen 45 49 require access code 754 SCREEN 45 Setback This screen shows the setting of the set back option It can be set to Off or On Off turns the setback mode off and the dryer will not change the process setpoint On tells the control the dryer should go into setback when the hopper outlet temperature reaches its setpoint Menu number 6 Screen 10 Temperature Enable Option When supplied for i central drying appli cations these func tions are not available 1 i 1 l 1 L 1 LI l 1 i Li 1 L 1 L 1 1 1 1 1 L l 1 I L l 1 l l l l 1 L i I I I I I I I 1 I I 1 I 1 I 1 I l l t a flow control option must be installed for H off this screen to appear If this screen is set I I I I 1 I 1 r I I I I I I I I 1 I I I 1 I 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 SCREEN 46 Precooler Flow This screen s
46. ctions Electrical connections should be made only by quali fied personnel 4 Remove the two 2 screws then remove the motor and motor bracket from the wheel manifold 5 Loosen the set screw then remove the coupling from the motor shaft 6 Remove the four 4 screws then remove the motor from the motor bracket 7 Align the new motor with the holes in the original bracket Secure the new motor to the bracket using the original four 4 screws 8 Position the coupling on the motor shaft and tighten the set screw against the flat side of the motor shaft 9 Position the motor and bracket on the desiccant wheel manifold Secure the assembly using the original two 2 screws amp NOTE It may be necessary to apply power to the motor to position the coupling Do not turn the motor shaft by hand This will damage the gears 10 Connect the wires to the motor 11 Replace the plastic cover Troubleshooting 6 35 Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Department for a nominal fee Most manuals can be downloading free of charge from the product section of the Conair website www conairnet com A 1 Appendix We re Here to Help Conair has made the largest investment in customer support in the plastics indus try Our service experts are available to help with any problem you might have installing and operating your equipment Your Conair sales representa
47. d when the dryer has been configured as central Shows the regeneration air setpoint and actual temperature The setpoint can not be changed from this screen it is shown only as a reference When supplied for central drying appli cations this function is not available Operation 4 5 4 6 Operation Control Function Descriptions continued Screen SCREEN 7 SCREEN 8 BE LI Function This screen shows the actual return air temperature measured at the inlet to the process blower If the optional aftercooler flow control is installed a setpoint will be displayed on this screen The or buttons can be used to change the set point Holding the or buttons in will cause the number to ramp up faster the longer the button is held This screen is used to set the dryer to auto start The dryer must be on but not run ning to set auto start The value shown is the countdown time setpoint It is adjustable from 0 1 hours to 150 hours Once the countdown time is set press the Start button The display will show ON to tell the operator that the auto start is ON and counting The auto start LED on the display also flashes green when the auto start is armed and counting down The LED will turn solid green when the dryer starts The dryer will begin operating when the control has finished counting down Control Function Descriptions continued Screen SCREEN 10 Setback Temperature Option
48. d with the aftercooler remove the compres sion fitting from the aftercooler inlet Loosen the fitting on the flow control then swing the copper water supply tube out and away from the aftercooler inlet 3 Remove the two 2 nuts securing the aftercooler in the housing ec TIP If the aftercooler without a flow control 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 aftercooler housing 5 Clean the assembly using a mild soap and water Let the assembly dry thoroughly before installation 6 Inspect the condition of the gasket If it is damaged replace the gasket 7 Reassemble by repeating the steps in reverse order 8 Connect the water supply line to the inlet If a manual shut off valve is used it should be mounted on the inlet line as well 9 Connect the outlet of the aftercooler to the inlet of the flow control valve using the pre shaped copper tubing and compression fittings provided 5 8 Maintenance Cleaning the Precooler Coils If you have the optional precooler you need to clean the cooling coils to keep them working efficiently See Appendix B for details Inspecting Hoses and Gaskets Loose or damaged hoses and gaskets can allow moisture to seep into the closed loop drying system 1 Follow the hose routing of all the hoses within the dryer and inspect all hoses
49. 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 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 This box will contain information or highlight system differ rences particular to the application
50. e Acknowledge Alarm button once to silence the optional audible alarm and display the alarm message Pressing the Acknowledge Alarm but ton once also changes the alarm LED from blinking to solid 2 Find the error message in the diagnostics table of this Troubleshooting section Use information provided to diagnose and resolve the cause of the alarm 3 Note that after correcting the problem pressing the Acknowledge Alarm button a second time will clear the alarm If the alarm reappears the cause has not been resolved By NOTE When the dryer detects abnormally high temperature in the process heater the dryer immediately shuts down and an error message appears in the display window drying applications these shutdown alarms are not available A1 Process High Temperature If the process temperature exceeds the process high temperature set point it shuts down the dryer Defaults are set to 385 F 196 C for 20 seconds Alarms A problem can trigger two types of alarms Shutdown A If the red Acknowledge Alarm LED is blinking the alarm is a shutdown alarm The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer Note that once the Acknowledge Alarm button is pressed once the blinking red LED becomes solid Passive P If the amber Acknowledge Alarm LED is blinking the alarm is a passive alarm The dryer continues to operate but warns of a
51. e defective regen eration heater Then discon nect the hoses from the top and bottom of the heater tube Remove the clamp securing the heater tube in place then remove the heater tube from the dryer Cut the insulation in a straight line from end to end then remove it from the old heater tube 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 Use duct tape to hold the seam 8 Secure the new heater tube using the hose clamp removed in Step 4 9 Connect the hoses to the top and the bottom of the regeneration heater tube continued Replacing the Heaters Regeneration Heater Tube continued 10 Connect the wiring harnesses from the regeneration heater tube to the existing harnesses from the control box 11 Replace the plastic cover 12 Make sure the regeneration heater fuses are not blown before applying power to the new heater Troubleshooting 6 31 Replacing the Heaters Process Heater Tube 1 Stop the dryer disconnect the power and follow proper lockout AX procedures 2 Remove the plastic cover 3 Disconnect the wiring harnesses of the defective process heater Then discon nect the hoses from the top and bottom of the heater tube Process Heater 4 Remove the clamp securing the heater tube in place then remove the heater tube from the dryer 5 Cut the insulation in a straight
52. ecessary N WARNING Any electrical checks should be performed by a qualified electrician Check regeneration filter and clean and or replace as necessary Check all hoses gaskets doors loaders or other potential areas where leakage may occur Replace any defective hoses or gaskets Verify proper drying temperatures and residence times If off gassing is a con dition of the material being processed contact Conair 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 Troubleshooting 6 22 Troubleshooting Poor Material Drying Troubleshooting Occasionally processing problems that are suspected of being caused by poor dry ing are eventually determined to be the result of other issues in the process setup The intent of the information provided here is to assist you in determining if your drying system is performing properly However the only way to know definitely if your material is properly dried is to perform moisture analysis of small samples as it leaves the bottom of the hopper or just as it enters the process Conair does not sell moisture analyzing equipment but there are many brands of this equipment available on the market You should also be aware that some processing problems may actually be the result of over drying material Most materials will degrade to some extent if they are expo
53. from their shipping containers Note that the dryer is secured to its shipping container with two bands and blocking 2 Remove all packing material protective paper tape and plastic 3 Carefully inspect all components to make sure no damage occurred during shipping and that you have all the necessary hardware continued Unpacking the Boxes continued 4 Take a moment to record serial numbers and electrical power specifica tions in the blanks provided on the back of the User Guide s title page The information will be helpful if you ever need service or parts 5 You are now ready to begin installation Follow the preparation steps on the next page then choose one of the three mounting options Dryer on the floor hopper on a floor stand Dryer on the floor hopper machine mounted Central dryer with ResinWorks system Installation 3 3 eC TIP If you plan to use vacu um or compressed air loaders to fill the hopper install con veying lines to the drying hopper location 3 4 Installation Preparing for Installation The Carousel Plus W Series Dryer is easy to install if you plan the location and prepare the mounting area properly 1 Make sure the mounting area provides CJ A grounded power source supplying the voltage and correct current for your dryer model Check the dryer s serial tag on the side of your control box for the correct amps voltage phase and cycles Field wiring should be completed by
54. ger it will take for the material to heat back up to its proper drying temperature once the dryer comes out of Setback mode When drying at low temperatures for example 160 180 F 71 82 C you are able to setback the temperature only a small amount The Setback Temperature Process should not be set lower than 150 F 66 C even if the control will allow it It is very likely the dryer will not be able to achieve low temperatures without adding additional cooling to the process air circuit The maximum achiev able setpoint is dependent on the temperature of the return air coming back to the dryer As the return air temperature climbs the temperature that the dryer is capa ble of controlling at climbs For example if the return air to the dryer is 110 F 43 C the dryer may not be able to control at a Setback Temperature Process setpoint below 150 155 F 66 68 C Q NOTE Selecting too low of a setpoint for Screen 26 may result in nuisance A2 Process Loop Break alarms if the dryer is not able to achieve this setpoint SECTION Maintenance Preventative maintenance checklist 5 2 Checking the dewpoint 5 3 Cleaning the DopDBE i aer S exe Rm 3e a 5 5 Cleaning the process filter 5 6 Cleaning the regeneration filter 5 7 Cleaning the aftercooler coils 5 8 Cleaning ihe precooler coils cu 5 9 Inspecting hoses and gaskets 5 9 z 2 E e D 2 0
55. he alarm message 2 Address the alarm message and fix the problem Refer to the alarm descriptions later in this section 3 Press again to clear the alarm If the alarm reappears the problem was not fixed CONAIR Actual 1 Process Temp 2 Regen Temp IM Regen Blower Auto Start 3 Return Air Temp 4 Auto Start ProcessHeater GRegen Heater Dewpoint Control 5 Load Time MDC M 6 Activate Setback Temp B corneaplomo e Tore Acknowledge 7 Setback Temp Process Alarm Button 8 Dewpoint C5 6 2 Troubleshooting Before Beginning continued 1 Find the wiring and equipment diagrams that were shipped with your dryer These diagrams are the best reference for correct ing a problem The diagrams also will note any custom features such as special wiring or alarm capabilities not covered in this User Guide See warnings below Open the electrical enclosure to check fuses and heater contactors A Few Words of Caution The Carousel Plus W Series Dryer is equipped with numerous safety devices Do not remove or disable them Improper corrective action can lead to haz ardous conditions and should never be attempted to sustain production N WARNING Only qualified service personnel should examine and correct problems that require opening the dryer s electrical enclosure or using electrical wires to diagnose the cause WARNING High voltage Always stop the Carousel Plus dryer disconnect and
56. he dryer A3 Process Heater High Temperature cont The snap switch in the process heater tube opens due to exces sive temperature A4 Regeneration Heater High Temperature The snap switch in the regeneration heater tube activated due to excessive temperature A7 Return Air High Temperature If the return air temperature at the inlet to the blower is greater than 180 F 82 C it shuts down the dryer Alarms Shutdown Af The dryer has automatically shut down because it has detect ed a serious problem that could damage your material or dryer Passive P The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer The isolation contactor failed in the closed position The process heater output on the board has failed The heater solid state relays SSRs failed The regeneration exhaust is blocked or the air hoses are loose The regeneration blower is not running or is running in the wrong direction The isolation contactor failed in the closed position The heater solid state relays SSRs failed The regeneration heater output on the board has failed The hopper does not contain enough material You are drying at a high drying tempera ture above 240 F 116 C or you are running at low throughputs Replace the isolation contactor Replace the b
57. hows how the precooler flow Control Enable Option control is set to operate The precooler to On the control will assume the pre cooler is installed in the process line and will only allow setpoints from 100 150 F 38 66 C It will also assume the water flow solenoid valve is piped in the water line and the dryer control will regulate water flow to control temperature amp NOTE If this function is set to off make sure the water to the precooler is turned off SCREEN 47 Degree F Degree C This is the temperature units screen It is used to change the temperature display from F to C or C to F Use the or keys to toggle between C and F Operation continued To Start Drying 1 Make sure there is material in the hopper 2 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 lights will illuminate 3 Set the drying temperature Use the Scroll button to get to the process temperature function Press the Adjust Setpoint or buttons to select a drying temperature Central ao D S A imr 2 E 1 Process Temp 2 Regen Temp ProcessBlower Regen Blower Auto Start 3 Return Air Temp 4 Auto Start p Pj cess Heater Regen Heater Dewpoint Control 5 Load Time MDC Conveying Blower Set Back Temp 6 Activate Setback Temp Scroll Button Setpoint Adjustment c
58. itor option installed there will only be an actual display no set point value Although the dryer is capable of producing dewpoints much lower than 40 F 40 C the minimum sensor range is 40 F 40 C This is the password entry screen that gives the user access to the Set Up Test Mode and Alarm History screens The user can get to the password protected control functions through this screen by pressing the scroll button and the adjust setpoint button at the same time This works only if you are on menu 1 default screen The access codes are as follows Set Up Screens 754 Test Mode Screens 755 Alarm History Screens 756 To exit the password section enter 500 and press scroll or cycle the power This is the process deviation temperature screen The range is 5 to 20 F 3 to 11 C This is the deviation temperature band around the set point If the dryer goes outside this band the dryer will display a passive alarm P1 SCREEN 15 Set up Screen Control Function Descriptions continuea Screen Function Screens 15 27 require access code 754 SCREEN 16 Set up Screen This is the process high temperature screen This is the high temperature limit If the process temperature reaches this setpoint the dryer will shutdown on alarm Al The range is 100 450 F 38 232 C actual temperature When supplied for SCREEN 17 Set up Screen This is the process heater autotune screen central drying a
59. l be turned on for 3 seconds and then shut off automatically t NOTE If the optional aftercooler flow control valve is not installed nothing will happen This screen is not used in the current program Operation 4 13 Control Function Screen Screen 28 43 require access code 755 SCREEN 39 Test Mode Screen SCREEN 40 Test Mode Screen SCREEN 41 Test Mode Screen SCREEN 42 Test Mode Screen SCREEN 43 Test Mode Screen 4 14 Operation Descriptions continued Function This screen is not used in the current program This screen is not used in the current program This screen is not used in the current program This is the Test Mode screen for the alarm output yellow light By pressing the or keys the setting can be changed When set to On the alarm output will be turned on for 3 seconds and then shut off automatically D NOTE If the optional tricolor light is not installed nothing will happen This is the Test Mode screen for the alarm output green light By pressing the or keys the setting can be changed When set to On the alarm output will be turned on for 3 seconds and then shut off automatically x NOTE If the optional tricolor light is not installed nothing will happen Control Function Descriptions continued Screen Access code 756 required SCREEN 44 Alarm Screen g ue N E N g Function This is the first Alarm History s
60. lock out the main power source before troubleshooting or performing repairs A CAUTION Hot surfaces Always protect yourself from hot surfaces inside and outside of the dryer and hopper Troubleshooting 6 3 NOTE Pushing the Acknowledge Alarm button when there is no active alarm will display the most recent alarm code SE NOTE The dryer cannot be started if a passive alarm is present on power up 6 4 Troubleshooting How to Identify the Cause of a Problem Dryer alarms are indicated by an illuminated Acknowledge Alarm light on the Carousel Plus W Series Dryer control panel Shutdown alarms will energize optional audible and visual alarm indicators A problem can trigger two types of alarms Shutdown The dryer has automatically shut down because it has detected a serious problem that could damage your material or dryer Passive The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer Actual 1 Process Temp 2 Regen Temp 3 Return Air Temp 4 Auto Start 5 Load Time MDC 6 Activate Setback Temp 7 Setback Temp Process 8 Dewpoint C Process Blower Regen Biower Auto Start ProcessHeater GRegen Heater Dewpoint Control Conveying Blower Set Back Temp Acknowledge Alarm LED and Button When the alarm light is displayed 1 Press th
61. lockwise direction to remove 2 Remove the filter cartridge from the filter housing 3 Clean or replace the filter CAUTION Wear eye protection If you use compressed air to clean the equipment you must wear eye protection and observe all OSHA and other safety regulations pertaining to the use of compressed air 4 Wipe the inside of the filter housing clean then replace the filter cartridge into the housing 5 Line up the slots in the top of the filter housing push down and turn counterclockwise until locked into place 5 6 Maintenance Cleaning the Regeneration Filter Clogged filters reduce air flow and dryer efficiency Cleaning frequency depends on how much material you process and how dusty it is 1 To access the regeneration filter use a small flat screwdriver to gently pry down on the slot in the lower right hand corner of the filter grill while pulling out on the bottom 2 Remove the filter from inside the grill and clean with soap and water 3 Replace the filter in the grill and snap the grill into place Maintenance 5 7 Cleaning the Aftercooler Coils The aftercooler coils will need to be kept clean to keep the aftercooler working efficiently Cleaning frequency depends on the type and amount of material you process 1 Stop the dryer and lockout the main power 2 Turn off the water flow to the water supply line Disconnect supply and return lines BR NOTE If an optional flow control was adde
62. machine serial tag and data plate N 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 continued ATTENTION Read this so no one gets hurt continuea 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 p 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 6 WARNING Do not place aerosol compressed gas or flammable materials on or near this equipment The hot temperature
63. mperature to achieve proper drying Possible cause Material level in hopper is too low Material throughput is too high Solution 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 hopper If your hopper has a level sensor for maintaining a material level less than completely full be sure this sensor is adjusted properly Take any necessary steps such as slow ing down the process to ensure the material usage is within design specifi cations of the dryer and hopper Problem Too much or too little air flow Q NOTE If there is too Poor Material Drying Troubleshooting 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 low the material in the center of the hopper may get heated fully to the drying temperature but the material against the sidewalls will not In most cases the material 2 3 to 3 4 of the way toward the top of the hopper should be heated to the proper drying temperature Possible cause Dirty process air filter Collapsed hoses or holes leaks in the hoses and hose connections much airflow the material may fluidize inside the hopper resulting in inconsistent material flow through the hopper
64. nd outside the dryer and drying hopper The hopper spreader cone and discharge assembly should be cleaned thoroughly between material changes to prevent resin contamination 1 Close the hopper slide gate 2 Disconnect the hoses and remove the distribution box under the hopper and drain the remaining material into a bucket 3 Remove the spreader cone Open the hopper door Reach into the hopper Grasp the spreader cone tube lift up slightly twist and then push down to release it Tilt the cone assembly and pull it out through the hopper door 4 Clean the spreader cone and the inside of the hopper Make sure you also clean the return air screen at the return air outlet of the hopper 5 Repeat the steps in reverse order to reassemble the hopper before adding material Maintenance 5 5 E D pde D o z E fas S Cleaning the Process Filter Clogged filters reduce air flow and dryer efficiency Cleaning frequency depends on how much material you process and how dusty or full of fines it is 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 1 To access the filter push down and turn the top of the filter housing in a c
65. nsors 6 29 Replacing the heaters Regeneration heater tube 2 000 00s 6 30 Process heater tube xs secar Rr rere rRr err Rr RFT 6 32 Replacing the desiccant wheel assembly 6 34 Replacing the desiccant wheel motor 0 6 35 A Appendix We re hereto help lessen RII A 1 How to contact customer service a se A 1 Before you Call lsslseeeeeee IRR A 1 Equipment guarantee 0 0 cece cece ene A 2 Performance warranty 0 00 cc cece cece eens A 2 Warranty limitations 0 0c cece cece eee eee A 2 B Appendix Cleaning the precooler COIS 12 0 eee eee B 1 Table of Contents iii iv Table of Contents SECTION E 2 25 c zl 2 E Introduction Purpose of The user guld amp 45 os Be we 3 1 2 How the guide is organized 1 2 Using the Carousel Plus W series as a central Over uius beo eee 1 3 Your responsibilities as user ss 1 3 ATTENTION Read this so no one gets hurt 1 4 How to use the lockout device 1 6 Introduction 1 1 1 2 Introduction ue 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
66. oard Replace the failed heater solid state relays SSRs Locate and remove any airflow restric tions Tighten hoses Correct the cause of the non running blower blown fuses etc or reverse the rotation of the blower See Installation section entitled Checking for proper air flow Replace the isolation contactor Replace the failed heater solid state relays SSRs Replace the board Make sure your material supply system is working properly Ensure water flow to the aftercooler Troubleshooting 6 7 Alarms Shutdown Af The dryer has automatically shut down because it has detect ed a serious problem that could damage your material or dryer Passive P The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer Central Problem Possible cause Solution A7 Return Air High The aftercooler does not have enough Turn on the water supply or fix any Temperature cont If the water leaks or blockages return air temperature at the inlet to the blower is greater The aftercooler coils are dirty Clean the aftercooler coils See than 180 F 82 C it will Maintenance section entitled Cleaning shut the dryer down the aftercooler coils A10 amp P26 Process RTD The process RTD connection to the Check the connection to the receptacle Integrity If the process
67. ocess and regeneration blowers turn on and the display LEDs will illuminate The process and regeneration heaters turn on and the display LEDs will illuminate The desiccant wheel starts turning The green light on the start button will illuminate he process and regeneration blowers turn on and the display LEDs will illuminate The regeneration heater turns on and the display LED will illuminate The desiccant wheel starts turning Central 5 Press the STOP button If everything is installed correctly The blowers will continue running as needed to cool the heaters until both heaters are less than 150 F 66 C 6 The test is over If the dryer performed the normal operating sequences as outlined you can load the hopper and begin operation If it did not refer to the Troubleshooting section of the User Guide Operation Carousel Plus W Series Dryer control panel DC 1 Carousel Plus W Series Dryer DC 1 control functions sasaaa e bo ed Control function flow chart sse zs Control function descriptions TO start drying e ue x ex Ron ES a Rn To stop GIVING uo uo eoo ceux Using the auto start countdown function How to disable the auto start on the DC 1 CONTrOl a s a ado sa oe e Setting the high setpoint limit Using dewpoint control Using the setback feature Setback feature guidelines SECTION Operation 4 1
68. on You have completed the installation Now it s time to make sure everything works 1 Make sure there is no material in the hopper If you have mounted a loader or vacuum receiver on the hopper disconnect the material inlet hose at the source or turn the loader off 2 s gt oO 2 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 lights will illuminate 3 Set the drying temperature Press Setpoint Adjust or buttons to set the drying temperature to a low setpoint of 150 F 66 C Actual Process Temp When configured as a 1 2 Regen Temp BProcess Blower Regen Blower Auto Start 3 Retum Air Temp I I 4 Auto Stat pcc Orts n i central dryer the dry i 6 Activate Setback Temp S oru Boe e etc ee l I 7 Setback Temp Process 1 ing temper ature can i 8 Dewpoint not be set since there is i no process heater in i I I the system 1 I I I Setpoint Adjust Buttons continued Installation 3 13 3 14 NOTE If the dryer is running for more than 20 to 30 sec onds the Process Loop Break alarm A2 may occur because the Process RTD is not seeing the expected tem perature rise Installation Testing the Installation inen 4 Press the START button If everything is installed correctly The green light on the start button will illuminate The pr
69. ontinued Operation 4 17 4 18 Operation To Start Drying continued 4 Press the START button If everything is installed correctly The green light on the start button will illuminate The process and regeneration blowers turn on and the display LEDs will illuminate The process and regeneration heaters turn on and the display LEDs will illuminate The desiccant wheel starts turning The green light on the start button will illuminate The process and regeneration blowers turn on and the display LEDs will illuminate The regeneration heater turns on and the display LED will illuminate The desiccant wheel starts turning Central i To Stop Drying 1 Press the STOP button The Stop LED blinks red The blowers continue running for a few minute to cool the heaters 2 Be sure to disconnect and lockout the main power if you have stopped the dryer to perform maintenance or repair IMPORTANT Do not use the main power switch to stop the dryer Turning off power to the control and dryer during normal operation prevents the necessary cool down period and can trigger the shutdown high temperature alarm during your next drying cycle A CAUTION Improper shut down can cause damage to your dryer Using the Auto Start Countdown Function The countdown function allows the user to set the Carousel Plus W Series Dryer to automatically start at a predetermined time The countdown time can
70. ontrol board has failed There is a loose connection in the wiring leading to the RTD The connection of the RTD plug on the control board is loose The return air RTD has failed The control 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 failed or the fuse is blown Solution Check the RTD plug connections make necessary repairs Check the plug connection and tighten if needed Replace the regeneration RTD Replace the control board Check the RTD plug connections make necessary repairs Check the plug connection and tighten if needed Replace the return air RTD Replace the control board Check the heater fuses and resistance across each leg of the process heater Check the regeneration RTD and tighten if needed Correct the cause of the non functioning blower See Installation section entitled Checking for proper air flow Replace the control board or fuse Problem A36 Control Communications Watchdog The display board has lost communications with the control board A38 Phase Error Phase Option One of the three power wires is connected wrong or one or more phases of power is missing A39 EEProm Write Error A41 amp P30 Setback RTD Integrity Alarms Shutdown Af The dryer has automatically shut down because it has detect ed
71. ould prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer Troubleshooting 6 15 6 16 A Problem A53 Process Blower Overload If the process blower exceeds its full load amp rating or the overload has tripped due to a mechani cal or electrical problem the dryer will shut down NOTE Once the overload has tripped you must wait 2 15 minutes with power on for it to auto matically reset Troubleshooting larms Shutdown A The dryer has automatically shut down because it has detect ed a serious problem that could damage your material or dryer Passive P The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer Possible cause The process blower current draw has exceeded the full load amps rating of the motor The process blower has mechanically failed or is unable to rotate freely The process blower has failed electri cally Loss of phase of power to the motor starter The overload is set incorrectly Overload is defective Solution Press alarm acknowledge and allow overload to automatically reset then try to restart the dry If the alarm con dition occurs again have a qualified electrician check the current draw to the motor Disconnect and lock out main power Check
72. ow high with aftercooler amp precooler 100 375 F 38 191 C See page 3 12 and Appendix B Throughput rates of 15 to 100 Ibs 6 8 to 37 3 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 Dryer Options Dewpoint monitor dewpoint control Audible and visual alarm Temperature setback I I I L applications the W series dryer 1i is not equipped with a process heater Therefore as a central dryer the W dryer will only sup ply dry air to the hoppers Description 2 3 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 desic cant wheel X THe Process DnviNc 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 Pro
73. ppli I i I The autotune function can be turned on by ications these func I pressing the key Once the key is tions are not available pressed the screen will show On and then 777777 777 7 7 7 7 7 7 7 start the autotune process This may take a NOTE Software may i i I l I I i minute or so to complete When finished allow the Process tem the display will read don The new PID perature setpoint limit up values are automatically saved An auto to 450 F 232 C howev tune should be performed on a cold dryer Before beginning autotune be certain your normal drying temperature has been entered on Screen 5 Menu number 1 er Conair does not rec ommend a setpoint limit over 375 F 191 C due to nuisance alarms SCREEN 18 Set up Screen This is a regeneration temperature screen Q NOTE There is normally no need to change this temperature SCREEN 19 Set up Screen This is the regeneration heater autotune screen The autotune function can be turned on by pressing the key Once the key is pressed the screen will show On and then start the autotune process This may take a minute or so to complete When finished the display will read don The new PID values are automatically saved An autotune should be performed on a cold dryer It will autotune to the value entered on Screen 18 Operation 4 9 4 10 When supplied for i central drying appli cations the
74. pply and discharge return connections with flexible hoses at least 24 in 61 cmj long This allows you to easily remove the aftercooler or optional precooler assembly for cleaning ec TIP If an optional flow control is also being installed with the after cooler or optional precooler the manual shut off valve should be installed on the inlet line for the flow control 3 12 Installation Connecting the Aftercooler and Optional Precooler optionan The aftercooler and optional precooler require 2 gals min 7 6 liters min tower city or chiller water and a discharge or return line 1 Remove the two 2 screws that secure the dryer s plastic cover then remove cover SE NOTE 50 100 models have four 4 screws that secure the plastic cover to the dryer 2 Connect water fittings to the 90 degree tubing bend of the aftercooler or optional precooler Seal the threads with silicon tape 3 Connect water supply inlet Secure with hose clamp 4 Connect water supply outlet Secure with hose clamp 5 Replace plastic cover resecure screws IMPORTANT Turn the water off when the dryer is not in use to prevent condensation Mounting a Loader on the Hopper If you have a Conair loader or vacuum receiver you can use the flange and mounting clips provided on the top of the hopper Refer to the manuals that came with your receiver or loader for detailed installation instructions Testing the Installati
75. r is defective Connector to all RTDs is removed The ribbon cable between an analog option board and the main control board is not connected properly Problem in the analog input section of the control Defect in the main control board Solution Replace main control board Check RTD connections replace defective RTD Check connections between analog option board and the main control board Disconnect the ribbon cable connect ing any analog option boards to the main control board If the display returns to normal for all values except those that are generated through the analog options boards replace the option board Replace main control board Dewpoint Troubleshooting Under normal operating conditions the dryer will produce dewpoints in the range of 40 to 20 F 40 to 29 C However you may experience situations that pro duce undesirable results Problem Dryer not producing desired dewpoint Possible cause Return air temperature exceeds 125 F 52 C Regeneration temperature is below normal setting Low regeneration air flow Leaks in process lines Contaminated desiccant due to off gassing too long of a residence time or drying temperature is too high for the grade of material being processed Analog option board sensor malfunction Solution Reduce the temperature of the cooling water or increase the flow Check amperage of regeneration heaters Replace heaters if n
76. re door 3 Check the fuse If necessary pull the fuse 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 A IMPORTANT Always refer to the wiring diagrams that ig came with your dryer to 9 W z Y locate specific electrical caw vn ons components Illustrations in the User Guide are intended to be representative only a 9 ons en 3 Cc e O 3 ie 20 o E ES e Troubleshooting 6 27 Checking Heater Solid State Relays 1 Disconnect and lockout the main power supply 2 Open the electrical enclosure 3 Locate the process or regeneration relays Refer to the wiring diagrams that came with your dryer 4 Check continuity using an ohmmeter A IMPORTANT Always refer to the wiring diagrams that came with your dryer to locate specific electrical components Illustrations in the User Guide are intended to be representative only Regeneration heater solid state relays If ohms equal zero or infinity replace the relays Process heater solid state relays If ohms equal zero or infinity replace the relays 6 28 Troubleshooting Checking or Replacing Temperature Sensors The Carousel Plus W Series Dryer uses RTD sensors to monitor the temperatures of the drying air the return air the regeneration outlet and the
77. rflow and a 17 reduction in material throughput T 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 TPDS017 0305 REV 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 desic cant wheel and before the process heater enables the dryer to control tempera tures at low setpoints 100 150 F 38 66 C Dewpoint monitor dewpoint control The dewpoint monitor dewpoint con trol allows the operator to monitor and control the performance of the dryer s dewpoint level making energy savings possible by reducing the regeneration temperature Temperature setback The temperature setback automatically reduces the drying temperature to a lower standby mode when the machine throughput is reduced or stopped helping to minimize over drying material Audible
78. s m m SCREEN 11 Setback Options Function If the dryer has the setback on temperature option installed this is the temperature set point for the air at the outlet of the drying hopper When this setpoint is reached the dryer will automatically change the process setpoint to the setpoint shown on Menu number 7 Screen 11 When the temperature at the outlet of the hopper drops below the setpoint entered on this screen in this example 150 by the value shown under C09 Screen 23 the dryer will return to the normal drying setpoint If the dryer has the setback on temperature option installed this is the temperature setpoint to which the process air will revert once the air at the outlet of the hopper has reached its setpoint Screen 10 Menu number 6 When supplied for i central drying applica tions these functions are not available Q NOTE See informa tion on page 4 22 for activating and using the setback option Operation 4 7 Control Function Descriptions continued Screen SCREEN 13 Dewpoint Monitor Option SCREEN 14 U dio code 754 When supplied for i central drying appli cations these func tions are not available 4 8 Operation Screens 15 27 require access Function If the dryer has the dewpoint monitor option installed this screen will show the actual dewpoint of the process delivery air measured after the desiccant wheel With the dewpoint mon
79. s Dryer 2 2 Typical applications 2 1 kom e b dem bie 2 2 BOW TI WOIRS gc aw ee eee ek See d 2 4 Specifications Carousel Plus W Series Dehumidifying Dryers a na X 34S 2 6 Carousel Plus W Series Dehumidifying Dryer options oes ecceri e eae HAS 2 7 Description 2 1 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 1 Dryer on the floor hopper on the throat 15 100 2 Hopper on a floor stand the dryer next to it 3 Central dryer with ResinWorks The Carousel Plus 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 continued 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 L
80. s associated with the drying process may cause aerosols or other flammable materials placed on the dryer or hopper to explode Introduction 1 5 How to Use the Lockout Device AN 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 prod uct 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 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 with an assigned lock or tag Insert a lock or tag in the holes to prevent movement 4 The 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 1 Remove the lock or tag 2 Turn the rotary disconnect switch to the ON or I position 1 6 Introduction SECTION Description Ma 4 4 ET V S ke m e E What is the Carousel Plus W Serie
81. s heater tube opens due to excessive temperature Troubleshooting Process RTD is loose or has fallen out The process heater has failed The air lines are restricted or loose The process blower is not running or is running in the wrong direction The process heater output on the board has failed or the output fuse has failed Process setpoint is set too low Setback setpoint is set too low There is an air flow blockage or loose hoses The process blower is not running or running in the wrong direction Check the process RTD and tighten if needed Check the heater fuses and resistance across each leg of the process heater Straighten any crimps in the hoses Tighten any loose hoses Correct the cause of the non running blower or reverse the rotation of the blower See Installation section entitled Checking for proper air flow Replace the board or the fuse for the output Adjust to higher setting or add a precooler Adjust to higher setting or add a precooler 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 See Installation section entitled Checking for proper air flow Passive P The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down t
82. se func tions are not available Operation Control Function Descriptions continued Screen Function Screens 15 27 require access code 754 SCREEN 21 Set up Screen This screen shows the differential tempera Regeneration Differential ture at the regeneration inlet and the outlet Temperature at the desiccant wheel If the actual temperature is under the set value the dryer will alarm P31 but will still run SCREEN 22 Set up Screen This screen is the actual temperature Regeneration Outlet temperature measured at the regeneration outlet on the wheel This screen is the Setback Temperature Band screen This temperature is the amount the return air out of the hopper has to drop below the activate setback temperature before the original process temperature is restored For example if the activate setback temperature was 180 F 82 C and the dryer was in setback The actual temperature measured at the outlet to the hopper would have to drop below SCREEN 23 Set up Screen 160 F 71 C to restore the original Setback Temperature Band Option process setpoint This screen is the Aftercooler Flow Control Enable screen By pressing the pon or keys the setting can be changed BL D win this off or disabled the dryer will not open the flow control valve and try and control the return air temperature There will also be no set point value on Menu number 3 Screen 7 SCREEN 24 Set up Screen Con
83. sed to their specified drying temperature for a time significantly longer than the residence time specified by the supplier If you want to maintain its dry ness it is recommended that you reduce the process air temperature If 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 majority of customer questions to Conair are related to dewpoint It is important to realize that dewpoint is one of four requirements that need to be satisfied There are four requirements listed in order of importance necessary to properly dry hygroscopic plastic resins Drying temperature of the air entering the hopper must be at the proper drying temperature for your material as specified by your material supplier Residence time is the time determined by your material supplier that the material in use must be heated to achieve proper drying temperature e Airflow during the process drying circuit must be adequate to carry and distribute the heat throughout the entire bed of material inside the hopper Dewpoint of the process air must be low so it can efficiently collect the moisture as it is released from the heated material and carry it to the dryer to be removed in the desiccant Problem The temperature of the air Poor Material Drying Troubleshooting continued Once it is determined whi
84. so display letters for alarms and setup Scroll Button Press to scroll through the closed loop menu list Pressing the Scroll button moves you down the list Carousel Plus W Series Dryer Control Functions Dryer functions are values that you can set or monitor Press the Scroll button to access the function within a Menu list until the function you want to set or monitor appears in the LED display 8 NOTE Grey shaded screens denote optional functions If the options were not purchased with the dryer those screens will not appear Control Function Flow Chart The following flow chart provides a quick summary of the control functions For an explanation of each control function see Control Function Descriptions Screen numbers correspond with numbers beside each block in the flow chart Operation 4 3 4 4 Display Menu Number t NOTE Screens 1 4 are only displayed during initialization i drying applications these l control functions are not available Setup 754 o o fee e Q o N a c s A A 9 Ol a Operation Setpoint Actual Display Display POWER ON screen 1 lup 5sec 2 C 5 sec Model Designator a c 1 sec Control Software Version 4 s 1 sec Display Software Version 5G Process Temp Default Screen 6 2 Regen Temp 7 3 Return Air Temp 8 4 Auto Start i 10 6 450 120 Activate Setback Temp Option I 11 7
85. tate relays SSRs Replace the board Check the heater fuses and resistance across each leg of the process heater Replace the control board or the fuse Check the regeneration RTD and tighten if needed Problem A28 amp P9 Process dew point The dewpoint has not fallen below the setpoint If the dewpoint goes below the setpoint for 180 seconds the alarm should go away NOTE The alarm is not active for the first 5 minutes A29 amp P10 Process Filter Clogged Option The process filter differential pres sure switch is tripped Alarms Shutdown A The dryer has automatically shut down because it has detect ed a serious problem that could damage your material or dryer Passive P The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer Possible cause Defective sensor The hose or wiring connections to the sensor block are loose or have fallen off Poor regeneration air flow The desiccant wheel may be contaminated Desiccant wheel not turning Leaks in the process air stream The process air filter is clogged Solution Replace the sensor Check wiring and hose connections to the sensor resecure if needed Remove any air flow restrictions dirty filters kinked hoses etc Check the desiccant for contamination replace if needed
86. ter Check water temperature and flow Temperature The process flow rate is too high settings Adjust as necessary temperature is less than the H low temperature setpoint for The output on the board has failed Replace the board i the specified time Default i values are 70 F 21 C for 20 Flow control solenoid is stuck open Replace the valve seconds The process RTD is loose or has fallen Check the process RTD and tighten if i out needed I Process heater has failed Check the heater fuses and resistance i Li l across each leg of the process heater A23 amp P3 Regeneration One of the solid state relays SSRs Replace the failed solid state relays Temperature Deviation failed SSRs The regeneration temperature exceeds the deviation band for The regeneration RTD is loose or has Check the regeneration RTD and tighten the specified time Default fallen out if needed values are 10 F 6 C for 5 seconds The air hose connections are loose Tighten all air hose connections The output on the board has failed Replace the board Defective heater Check the heater fuses and resistance across each leg of the regeneration heater Troubleshooting 6 9 6 10 A Problem A25 amp P5 Return Air Mid High Temperature If the return air temperature is between 150 and 180 F 66 and 82 C A26 amp P6 Regeneration High Temperature If the regeneration temperature exceeds the high temperature
87. the process blower for mechani cal failure and free rotation Replace if necessary Allow overload to automati cally reset then try to restart the dryer Disconnect and lock out main power Check the process blower for electrical shorts or open circuits Replace if nec essary Allow overload to automatical ly reset then try to restart the dryer Check for a blown fuse in the dryer or main power supply Allow overload to automatically reset then try to restart the dryer Disconnect and lock out main power Check the overload settings and con firm that the settings match the full load amps listed on the process blower motor Allow overload to automatical ly reset then try to restart the dryer Replace the overload A Problem A55 amp P31 Wheel Rotation Failure The regeneration tem perature differential has been reached A56 amp P32 Regeneration Outlet RTD Integrity The control can not sense the regeneration outlet RTD larms Shutdown A The dryer has automatically shut down because it has detect ed a serious problem that could damage your material or dryer Passive P The dryer continues to operate but warns of a problem that could prevent correct drying of your material If ignored this problem could lead to a condition that will shut down the dryer Possible cause The wheel motor is not turning The belt tensioner is loose or the belt is slipping The regeneration heater is
88. tive also can help analyze the nature of your problem assuring that it did not result from misapplication or improper use How to Contact Customer Service To contact Customer Service personnel call PARTS amp SERVICE 800 458 1960 UOT cotar 24 HOURS A DAY 7 DAYS A WEEK NOTE Normal operating hours are 8 00 AM 5 00 PM After hours emer gency service is available at the same phone number From outside the United States call 814 437 6861 You can commission Conair service personnel to provide on site service by contacting the Customer Service Department Before You Call If you do have a problem please complete the following checklist before calling Conair CJ Make sure you have all model control type and serial numbers from the serial tag and parts list numbers for your particular equipment Service personnel will need this information to assist you g Make sure power is supplied to the equipment CJ Make sure that all connectors and wires within and between control systems and related components have been installed correctly Check the troubleshooting guide of this manual for a solution Thoroughly examine the instruction manual s for associated equipment especial ly controls Each manual may have its own troubleshooting guide to help you Check that the equipment has been operated as described in this manual Check accompanying schematic drawings for information on special consider
89. trol Function Descriptions continued Screen Function Screens 15 27 require access code 754 SCREEN 26 Set up Screen Reserved function this should always be off SCREEN 27 Set up Screen This screen shows how the precooler is Precooler Option set to operate If itis set to Off the con trol assumes the precooler is not installed in the process line and will not control well below 150 F 66 C If the screen is set to On the control will assume the precooler is connected in the process line When supplied for and will only allow setpoints from 100 to i central drying appli 150 F 38 to 66 C The control will also cations these func assume that the water flow rate is set tions are not available manually with a ball valve and make no attempt to control water flow The pre cooler option must be installed for this screen to appear Y NOTE If this function is set to off make sure the water to the precooler is turned off Screen 28 43 require access code 755 SCREEN 28 Test Mode Screen This is the Test Mode screen for the process blower By pressing the or H keys the setting can be changed When set to On the process blower output will be turned on for 3 seconds and then shut off automatically Operation 4 11 Control Function Descriptions continued Screen Screen 28 43 require access code 755 SCREEN 29 Test Mode Screen M ca a SCREEN 30 Test Mode Screen
90. urchased from Conair are provided with a male connector that plugs into the dewpoint check port If you purchased your portable instrument else where the male connector is available through the Conair parts department NOTE The dewpoint check port was not included on the initial release of the Carousel Plus Dryers It can be added easily Contact the Conair parts department or follow the alternate procedure Replacement dewpoint moni tors male connectors and dewpoint check ports are available from Conair Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 Maintenance 5 3 5 4 Maintenance Checking the Dewpoint continues 5 Turn on the portable instrument and ensure there is positive airflow through the sensor 6 Monitor the readout and allow ample time for it to stabilize before discon necting the portable instrument Some dewpoint monitors require a substan tial amount of time for residual moisture to be purged from the sensor 7 In the event the dewpoint is not satisfactory refer to the Troubleshooting section of the manual under A28 and P9 alarm for DC1 8 Stop the dryer and allow it to cool down After the dryer has cooled disconnect the portable instrument and replace any pipe plugs that may have been removed 9 Replace the plastic cover and start the dryer Cleaning the Hopper A CAUTION Hot surfaces Always protect yourself from hot surfaces inside a
91. uring the precooler in the housing e TIP If the precooler without a flow control 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 precooler housing 5 Clean the assembly using a mild soap and water Let the assembly dry thoroughly before installation imi veta 6 Inspect the condition of the gasket If it is damaged replace the gasket 7 Reassemble by repeating the steps in reverse order 8 Connect the water supply line to the inlet If a manual shut off valve is used it should be mounted on the inlet line as well 9 Connect the outlet of the precooler to the inlet of the flow control valve using the pre shaped copper tubing and compression fittings provided B 1 Appendix Appendix B 2

with DC-1 Control

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