Conair Carousel Plus W Series User Manual
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Conair Carousel Plus W Series User Manual

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www.conairgroup.com
U S E R G U I D E
UGD051-0414
Carousel Plus Dryer
W Series Models 150, 200, 300 and 400 with DC-T Controls
Corporate Office: 724.584.5500
l
Instant Access 24/7 (Parts and Service): 800.458.1960
l
Parts and Service: 814.437.6861

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  • Page 1 www.conairgroup.com U S E R G U I D E UGD051-0414 Carousel Plus Dryer W Series Models 150, 200, 300 and 400 with DC-T Controls Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861...
  • Page 2 NOTE: Displayed upon initialization, during power up, or on a data tag inside the door. DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequen- tial 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.

  • Page 3: Table Of Contents

    Specifications: Carousel Plus W Series Dryer ......2-6 Carousel Plus W Series Dryer Options......2-7 I n s t a l l a t i o n Unpacking the Boxes .
  • Page 4 Operation - ResinWorks Configuration ......4-7 Control Function Flow Charts....... . 4-8 Control Function Descriptions - ResinWorks Configuration.
  • Page 5 Troubleshooting Before Beginning ..........6-2 A Few Words of Caution .
  • Page 6 l Ta b l e o f C o n t e n t s...
  • Page 7 S E C T I O N I n t r o d u c t i o n P u r p o s e o f t h e U s e r G u i d e ....1 - 2 H o w t h e G u i d e I s O r g a n i z e d .

  • Page 8: I N T R O D U C T I O N

    P u r p o s e o f t h e U s e r G u i d e This User Guide describes the Conair Carousel Plus W Series Dryers and explains step-by- step how to install and operate, maintain, and repair this equipment.
  • Page 9 I n t r o d u c t i o n l 1 - 3...
  • Page 10 AT T E N T I O N : R e a d T h i s S o N o O n e G e t s H u r t 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.

  • Page 11: Attention: Read This So No One Gets Hurt

    AT T E N T I O N : R e a d T h i s S o N o O n e G e t s H u r t ( c o n t i n u e d ) We design equipment with the user’s safety in mind.

  • Page 12: How To Use The Lockout Device

    A lockable device has been provided to isolate this product from potentially haz- ardous 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: Stop or turn off the equipment.

  • Page 13: D E S C R I P T I O N

    S E C T I O N D e s c r i p t i o n W h a t i s t h e C a r o u s e l P l u s W S e r i e s D r y e r ? ..2 - 2 Ty p i c a l A p p l i c a t i o n s .

  • Page 14: Typical Applications

    W h a t i s t h e C a r o u s e l P l u s W S e r i e s D r y e r ? 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.
  • Page 15 Ty p i c a l A p p l i c a t i o n s ( c o n t i n u e d ) The W Series Dryer can be used successfully in applications that require: •...
  • Page 16 H o w I t Wo r k s The W dryer achieves continuous, closed loop drying by passing air simultaneously through two heaters and a continuously rotating desiccant wheel. ROCESS RYING YCLE 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.
  • Page 17 H o w I t Wo r k s ( c o n t i n u e d ) ALARM LIGHT PROCESS PROCESS PROTECTION ALARM BELL REGENERATION PROCESS BLOWER HEATER BOX HIGH TEMP SHUTOFF REGENERATION AIR FILTER HIGH TEMP SHUTOFF REGENERATION HEATER...

  • Page 18: Specifications: Carousel Plus W Series Dryer

    ‡ 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. TPDX018-0113 2 - 6 l D e s c r i p t i o n...

  • Page 19: Carousel Plus W Series Dryer Options

    C a r o u s e l P l u s W S e r i e s D r y e r O p t i o n s • Volatile trap (only in conjunction with aftercooler) - The volatile trap is recommended if drying materials that produce volatile that condense into a waxy or oily residue and/or if the material contains excessive fines.
  • Page 20 2 - 8 l D e s c r i p t i o n...

  • Page 21: I N S T A L L A T I O N

    S E C T I O N I n s t a l l a t i o n U n p a c k i n g t h e B o x e s ..... 3 - 2 P r e p a r i n g f o r I n s t a l l a t i o n .

  • Page 22: Unpacking The Boxes

    U n p a c k i n g t h e B o x e s 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): •...

  • Page 23: Preparing For Installation

    P r e p a r i n g f o r I n s t a l l a t i o n The Carousel Plus W Series Dryer is easy to install if you plan the location and prepare the mounting area properly.

  • Page 24: Connecting The Main Power

    C o n n e c t i n g t h e M a i n Po w e r CAUTION: Always disconnect and lock out the main power sources before making electrical con- nections. Electrical connections should be made only by qualified personnel. Open the dryer’s electrical enclosure.

  • Page 25: C O N N E C T I N G T H E P R O C E S S Rt D P R O B E

    C o n n e c t i n g t h e P r o c e s s RT D P r o b e 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.

  • Page 26: Checking For Proper Air Flow

    C h e c k i n g f o r P r o p e r A i r F l o w IMPORTANT: This procedure must be performed before loading material into the hopper. CAUTION: If the airflow direction is incorrect due to improper phase connection, material from the hopper can be pulled back into the dryer, causing permanent damage to this equipment.
  • Page 27 NOTE: On initial test (first time in Dryer I/O Test Mode) the process blower will automati- cally start. Press the button beside “Delivery Air Blower” to stop the blower. Return Air Inlet CAUTION: Hot surface Do not place Dry Delivery your hand directly on the delivery air outlet.
  • Page 28 C h e c k i n g f o r P r o p e r A i r F l o w ( c o n t i n u e d ) INSTALLATION NOTE: Models 150, 200, 300, and 400 These models use a three-phase process blower.

  • Page 29: Connecting The Air Hoses

    If your dryer hose connection and your hopper hose connection are not the same condensation size, you will need a hose adapter. Contact Conair Parts 1-800-458-1960. I n s t a l l a t i o n l 3 - 9...

  • Page 30: Connecting Air Hose Adapters

    C o n n e c t i n g A i r H o s e A d a p t e r s Depending on the hopper you purchased you may need to install an air hose adapter to con- nect the hopper to your dryer.

  • Page 31: Connecting The Aftercooler

    C o n n e c t i n g t h e A f t e r c o o l e r ( O p t i o n a l ) The aftercooler and optional precooler require a source of city, tower, or chiller water and a discharge or return line.

  • Page 32: Mounting A Loader On The Hopper

    M o u n t i n g a L o a d e r o n t h e H o p p e r If you have a Conair loader or vacuum receiver, you can use the flange and mounting clips provided on the top of the hopper.

  • Page 33: Te S T I N G T H E I N S T A L L A T I O

    Te s t i n g t h e I n s t a l l a t i o n ( c o n t i n u e d ) If everything is installed correctly: IMPORTANT: Be sure the cable tie •...
  • Page 34 3 - 1 4 l I n s t a l l a t i o n...

  • Page 35: O P E R A T I O N

    S E C T I O N O p e r a t i o n The Dryer System Control Panel ....... . . 4-2 How to navigate the Control Screens.
  • Page 36 HMI software version, the dryer board ver- sion, and Conair’s copyright. The software version and board version will be helpful for serv- ice and troubleshooting purpos- Dryer board version HMI software version At start-up, the system security level is "Default".

  • Page 37: How To Navigate The Control Screens

    H o w t o N a v i g a t e t h e C o n t r o l S c r e e n s Navigate through the DC-T control screens by touching any navigation "buttons" and/or magnifying glass icons.
  • Page 38 H o w t o N a v i g a t e t h e C o n t r o l S c r e e n s ( c o n t i n u e d ) The user name, password and other information can be entered using the pop-up keyboard window that appears when an appropriate field is touched.
  • Page 39 H o w t o N a v i g a t e t h e C o n t r o l S c r e e n s ( c o n t i n u e d ) All beveled grey buttons on the DC-T control screen are selectable and will direct you to another screen.

  • Page 40: Dc-T Control Panel

    T h e D C - T C o n t r o l Pa n e l Below is a screen from the DC-T while in operation. This screen is shown as a sample of functionality of a typical DC-T screen. See the functional descriptions below. The follow- ing pages are helpful in understanding how to use the DC-T Control.

  • Page 41: Operation - Resinworks Configuration

    O p e r a t i o n - R e s i n Wo r k s C o n f i g u r a t i o n The following pages (screen flow charts, screen descriptions, and basic operation) describe the operation of the dryer when factory configured as a ResinWorks dryer attached to multi- ple hoppers, or as a central dryer attached to one or multiple hoppers with delivery air heat at each hopper.

  • Page 42: Control Function Flow Charts

    C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e H o m e s c r e e n ResinWorks Help Overview...

  • Page 43: Control Functions Flow Chart

    C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e O v e r v i e w s c r e e n Hopper Selection System Overview...
  • Page 44 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e A l a r m s c r e e n Alarms Home 4 - 1 0...
  • Page 45 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e Tr e n d S e l e c t i o n s c r e e n Air Temp.
  • Page 46 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e S e t u p s c r e e n ResinWorks Setup Setup...
  • Page 47 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e S e t u p s c r e e n ( c o n t i n u e d ) Regen Setup...
  • Page 48 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e S e t u p s c r e e n ( c o n t i n u e d ) Alarm Setup...
  • Page 49 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e L o g i n / L o g o u t s c r e e n Security Manager Home O p e r a t i o n l...
  • Page 50 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n System Overview Screen NOTE: On this Overview screen, live data is displayed.
  • Page 51 If the user is logged-in at the proper security level, setpoint changes can be made to: See Operation section entitled, How to Navigate Control Screens. • Regeneration Temperature Setpoint - Conair recommends not changing this setting. After the new set point value has • Dewpoint Setpoint (optional) been entered, press the "Enter"...
  • Page 52 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Hopper Selection Screen To access the Hopper Selection screen:...
  • Page 53 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Individual Hopper Screen NOTE: Depending on...
  • Page 54 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Hopper Setpoint Settings screen NOTE: Depending on which options...
  • Page 55 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) DM3-e Hopper Settings Screen (if equipped) NOTE:...
  • Page 56 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) ResinWorks System Setup screen NOTE: Your DC-T control should...
  • Page 57 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) ResinWorks Dryer Options screen To access the ResinWorks Dryer Options screen:...
  • Page 58 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Autostart Setup screen NOTE: Proper login is required to...
  • Page 59 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) ResinWorks Hopper Setup screen To access the ResinWorks Hopper Setup screen:...
  • Page 60 NOTE: Hopper names can be per name. Hopper changed multipe times as neces- names can be up to 16 sary. Conair recommends naming characters in total the hopper using whatever system length. works for your application. Some...
  • Page 61 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Hopper Comms (Communications) screen To access the Hopper Comms screen:...
  • Page 62 NOTE: It is not typically necessary to use the Regen PID Auto Tune or the Reset PID Values to Factory button. Contact the Conair Service department if you have questions about these items. Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861.
  • Page 63 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) I/O Setup screen To access the I/O Setup screen:...
  • Page 64 Press the Settings button from the Home screen. NOTE: These are factory settings and should not need changed. Consult Press the I/O Setup button. with Conair before making any changes to these settings. Conair’s Press the Dewpoint Setup button. Instant Access 24/7 Parts and Service number is 800-458-1960.
  • Page 65 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Digital I/O Status screen To access the I/O Status screen:...
  • Page 66 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Digital Output Test screen NOTE: The dryer must be...
  • Page 67 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Temperature Sensor Setup screen To access the Temperature...
  • Page 68 Press the X button if you want to exit without loading the default factory settings. NOTE: The default IP address established by Conair is 10.1.12.1 4 - 3 4 l O p e r a t i o n (continued)
  • Page 69 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Ethernet Setup screen To apply new Ethernet settings:...
  • Page 70 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Alarm Setup screen NOTE: Proper login is required to...
  • Page 71 Conair. NOTE: Proper login is required to modify alarm settings. Depending on your dryer configuration, your alarm choices and screen configurations Conair’s Instant Access may vary from what is shown in this User Guide. 24/7 Parts and Service number is 800-458-1960.
  • Page 72 Enter the desired setpoint should not be changed and delay for each shutdown without first consulting alarm. with Conair. Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861. 4 - 3 8...
  • Page 73 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Trending NOTE: Depending on your DC-T...
  • Page 74 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Dry Air Temperature Trend To access the Dry Air Temperature...
  • Page 75 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Dryer Dewpoint Trend NOTE: Using the scroll...
  • Page 76 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Hopper Heater Temperature Trends NOTE: Using the scroll...
  • Page 77 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Hopper Drying Monitor Trends (if equipped) To access the Hopper...
  • Page 78 C o n t r o l F u n c t i o n D e s c r i p t i o n s - R W C o n f i g u r a t i o n ( c o n t i n u e d ) Alarms When an alarm occurs, an audible...
  • Page 79 O p e r a t i o n l 4 - 4 5...
  • Page 80 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e H o m e s c r e e n Dryer Help Overview...
  • Page 81 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e O v e r v i e w s c r e e n Dryer Delivery Air Heater Dryer Overview...
  • Page 82 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e A l a r m s c r e e n Alarms Home Alarm Banner Pop-up...
  • Page 83 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e Tr e n d S e l e c t i o n s c r e e n Air Temp.
  • Page 84 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e S e t u p s c r e e n Dryer System Setup Setup...
  • Page 85 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e S e t u p s c r e e n ( c o n t i n u e d ) Regen Setup...
  • Page 86 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e S e t u p s c r e e n ( c o n t i n u e d ) Alarm Setup...
  • Page 87 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e S e t u p s c r e e n ( c o n t i n u e d ) Delivery Air Heater Setup...
  • Page 88 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e S e t u p s c r e e n ( c o n t i n u e d ) Delivery Air SP Setup...
  • Page 89 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e L o g i n / L o g o u t s c r e e n Security Manager Home O p e r a t i o n l...
  • Page 90 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n Dryer Overview Screen NOTE: On this Overview screen, live data is displayed.

  • Page 91: Control Function Descriptions - Stand Alone Configuration

    C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Dryer Detail Screen To access the Dryer Detail screen:...
  • Page 92 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Delivery Air Heater Screen NOTE: Depending on which options...
  • Page 93 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) DM-II Drying Monitor Screen (if equipped) NOTE: Depending on...
  • Page 94 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Dryer System Setup screen NOTE: Your DC-T control should...
  • Page 95 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Dryer Options screen To access the Dryer Options screen:...
  • Page 96 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Autostart Setup screen NOTE: Proper login is required to...
  • Page 97 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Alarm Setup screen To access the Alarm Setup screen:...
  • Page 98 Press the Settings button from the Home screen. with Conair. Press the Alarm Setup button. Conair’s Instant Access 24/7 Parts and Service Press the Passive Alarm Setup button for the Passive alarms you would like to config- number is ure (screen 1 or screen 2- if applicable).
  • Page 99 IMPORTANT: Factory default alarm setpoints should not be changed without first consulting with Conair. Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861. O p e r a t i o n l...
  • Page 100 NOTE: It is not typically necessary to use the Regen PID Auto Tune or the Reset PID Values to Factory button. Contact the Conair Service department if you h ave questions about these items. Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861.
  • Page 101 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) I/O Setup screen To access the I/O Setup screen:...
  • Page 102 Conair. The Dryer Dewpoint Sensor Setup screen provides the user with the ability to adjust the set- Conair’s Instant Access 24/7 tings for the Dewpoint sensors. This screen allows for adjustment of: Parts and Service number is 800-458-1960.
  • Page 103 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Digital I/O Status screen To access the I/O Status screen:...
  • Page 104 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Digital Output Test screen NOTE: Dryer must be...
  • Page 105 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Temperature Sensor Setup screen To access the Temperature...
  • Page 106 NOTE: It is not typically necessary to use the PID Auto Tune or the Reset PID Values to Factory button. Contact the Conair Service department if you h ave questions about these items. Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861.
  • Page 107 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Delivery Air Setpoint Setup screen To access the Setpoint Setup screen:...
  • Page 108 To load the factory default Ethernet settings: Press the Load Factory Default Ethernet Settings button. NOTE: Conair’s default IP address Press the button to confirm that you want to load the factory setting for the DC-T control is default settings. Press the X button if you want to exit without 10.1.12.1 as shown in the graphic...
  • Page 109 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Trending NOTE: Depending on your DC-T...
  • Page 110 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Dry Air Temperature Trend To access the Dry Air Temperature...
  • Page 111 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Dryer Dewpoint Trend To access the Dryer Dewpoint...
  • Page 112 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Material Temperature Trends To access the Material Temperature Trends screen:...
  • Page 113 C o n t r o l F u n c t i o n D e s c r i p t i o n s - S t a n d A l o n e C o n f i g u r a t i o n ( c o n t i n u e d ) Alarms When an alarm occurs, an audible...
  • Page 114 4 - 8 0 l O p e r a t i o n...
  • Page 115 O p e r a t i o n l 4 - 8 1...
  • Page 116 Press the green arrow. A pop up window screens or make changes to will appear with a keypad. various setttings. Conair rec- ommends that the administra- Using the keypad, enter your tor logs in first and changes username.

  • Page 117: Resinworks Dryer Configuration

    S t a r t i n g t h e D r y e r To start the dryer: Turn on the main power to the dryer and system components. Check to make sure that all disconnect dials are in the “ON” position. Fill the drying hopper with material.

  • Page 118: Adjusting The Temperature Setpoint

    Any changes to the setpoint temperature once the dryer is operating will affect the on time value. To minimize energy usage, Conair recommends usign the lowest setpoint tempera- ture that is required to dry your material and maintain the required material throat tempera- ture.

  • Page 119: Stopping The Dryer

    S t o p p i n g t h e D r y e r The DC-T Dryer control is programmed to follow a procedure for proper stopping the dryer. Once the stop button has been pressed (or the Autostop time is reached), the heaters will be turned off (RW hopper heaters, heater pack, or other hopper heater) and the dryer blower will continue to run until the regen temperature reaches the factory set cooldown setpoint.

  • Page 120: Stopping The Dryer In An Emergency

    The CF LED indicates that the HMI has a valid Compact Flash card inserted. Conair recommends that a valid Compact Flash card be in the system at all times. The Compact Flash is used to save trending data and other valuable information.

  • Page 121: Alarm Email And Text Notification

    The DC-T can send out Alarm messages as emails or text messages when this option is pur- chased. The option requires activation by Conair service personal. It also requires a fixed IP address for the DC-T HMI and access to a DNS server to connect to the Internet. This function resides in the HMI so the HMI must be on for this feature to work.

  • Page 122: Email Alarm Activation And Address Setup

    E m a i l A l a r m A c t i va t i o n a n d A d d r e s s S e t u p Once the email option has been activated, the email configuration button is visible on the System Settings screen.

  • Page 123: Configuring The Email And Text Addresses

    C o n f i g u r i n g t h e E m a i l a n d Te x t A d d r e s s e s Email List Setup screen Email by Shift: This box will enable/disable the shift emails. When the shift is enabled, three different email/text addresses can be added for each configured shift.

  • Page 124: Text Messaging Addressing

    Te x t M e s s a g i n g A d d r e s s i n g In order to set up the correct address for text messages, the phone number and carrier of the number is used.
  • Page 125 D r y e r RT D I n t e g r i t y S h u t D o w n A l a r m E m a i l s RTD Integrity Shut Down Alarm Emails screen This screen shows the enable/disable buttons for all of the possible RTD integrity dryer shut down alarms.
  • Page 126 D r y e r Pa s s i v e A l a r m E m a i l s NOTE: Proper login is required to change these settings. Dryer Passive Alarm Emails screen This screen shows the enable/disable buttons for all of the possible Dryer Passive alarms. Depending on the dryer configuration, some of these alarms may be hidden.
  • Page 127 H o p p e r A l a r m E m a i l s NOTE: Proper login is required to change these settings. Hopper Alarm Emails screen This screen shows the enable/disable buttons for all of the possible Hopper alarms. This set of screens will only be available for DC-T systems in a Central Dryer or Resinworks con- figuration with one or more hoppers.

  • Page 128: Dc-T Web Access Logon And Security

    DC-T screens. The default settings for the Web Server logon are: User Name: conair (case sensitive) Password: Web Server (case sensitive -- Capitals and space for extra security) A button (Web Server Setup) was added to the Central/ResinWorks and Stand Alone dryer settings screens.

  • Page 129: Web Server Setup Screen

    We b S e r v e r S e t u p S c r e e n NOTE: Proper login is required to change these settings. Administrative security level (level 6) is required to access this screen. The Current User Name and Password will be shown on this screen in the “Current:”...
  • Page 130 4 - 9 6 l O p e r a t i o n...

  • Page 131: Maintenance

    S E C T I O N M a i n t e n a n c e P r e v e n t a t i v e M a i n t e n a n c e C h e c k l i s t ... 5 - 2 C h e c k i n g t h e D e w p o i n t .

  • Page 132: Preventative Maintenance Checklist

    P r e v e n t a t i v e M a i n t e n a n c e C h e c k l i s t Routine maintenance will ensure optimum operation and performance of the W Dryer.

  • Page 133: C H E C K I N G T H E D E W P O I N T

    Even if NOTE: Portable dewpoint moni- your dryer has a dewpoint readout, comparing it to a portable instrument periodically will tors purchased from Conair are confirm that the dewpoint sensor and readout is performing properly. provided with a male connector...

  • Page 134: Cleaning The Hopper

    C l e a n i n g t h e H o p p e r ( 1 5 0 - 2 0 0 ) CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the dryer and drying hopper. The hopper, spreader cone, and discharge assembly should be cleaned thoroughly between material changes to prevent resin contamination.

  • Page 135: Cleaning The Process Filter

    C l e a n i n g t h e P r o c e s s F i l t e r 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. Push in on the sides to release the tabs on the front cover.
  • Page 136 C l e a n i n g t h e P r o c e s s F i l t e r ( c o n t i n u e d ) Remove outer filter and clean it with soapy water. Let air dry.

  • Page 137: Cleaning The Regeneration Filter

    C l e a n i n g t h e R e g e n e r a t i o n F i l t e r 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.

  • Page 138: Cleaning The Aftercooler Coils

    C l e a n i n g t h e A f t e r c o o l e r C o i l s 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.

  • Page 139: Cleaning The Precooler Coils

    C l e a n i n g t h e P r e c o o l e r C o i l s If you have the optional precooler, you need to clean the coils to keep it working efficiently. Cleaning frequency depends on the type and amount of material you process.

  • Page 140: Cleaning The Volatile Trap On The Demister

    C l e a n i n g t h e Vo l a t i l e Tr a p o n t h e D e m i s t e r Stop the dryer and lockout the main power. Remove the thumbscrews then remove the volatile demister cover.

  • Page 141: Inspecting Hoses And Gaskets

    I n s p e c t i n g h o s e s a n d g a s k e t s Loose or damaged hoses and gaskets can allow moisture to seep into the closed-loop dry- ing system.

  • Page 142: Cleaning The Dc-T Hmi Screen

    C l e a n i n g t h e D C - T H M I S c r e e n Dirt, grease, or dust on the screen can make it difficult to see and use. Periodically clean the screen to keep dirt from accumulating on the screen.
  • Page 143 S E C T I O N Tr o u b l e s h o o t i n g B e f o r e b e g i n n i n g ......6 - 2 A f e w w o r d s o f c a u t i o n .
  • Page 144 B e f o r e B e g i n n i n g 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.

  • Page 145: Before Beginning

    A Fe w Wo r d s o f C a u t i o n 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.
  • Page 146 H o w t o I d e n t i f y t h e C a u s e o f a P r o b l e m Most dryer malfunctions are indicated in the pop up Alarm bar at the top of the control screen.

  • Page 147: How To Identify The Cause Of A Problem

    H o w t o I d e n t i f y t h e C a u s e o f a P r o b l e m ( c o n t i n u e d ) When an alarm message is displayed: Press the “Silence and Ack Alarms”...
  • Page 148 H o w t o I d e n t i f y t h e C a u s e o f a P r o b l e m ( c o n t i n u e d ) Press the “Alarm Log”...
  • Page 149 S h u t d o w n A l a r m s When an alarm condition appears on the control screen, it may be a shut- NOTE: Some alarms can be set for down or a passive alarm. If the alarm is a shutdown alarm, the dryer will shutdown or passive.

  • Page 150: Shutdown Alarms

    S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The When supplied for central dryer will shut down automatically to prevent damage to the equipment or personnel. The drying applications, these dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 151 S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The When supplied for central dryer will shut down automatically to prevent damage to the equipment or personnel. The drying applications, these dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 152 S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The When supplied for central dryer will shut down automatically to prevent damage to the equipment or personnel. The drying applications, these dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 153 S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer will shut down automatically to prevent damage to the equipment or personnel. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 154 S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer will shut down automatically to prevent damage to the equipment or personnel. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 155 S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer will shut down automatically to prevent damage to the equipment or personnel. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 156 S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer will shut down automatically to prevent damage to the equipment or person- nel.
  • Page 157 S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer will shut down automatically to prevent damage to the equipment or personnel. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 158 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continue to operate, but this problem could prevent correct drying of your material. When supplied for central The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.

  • Page 159: Passive Alarms

    Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent correct drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 160 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 161 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent correct drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 162 For more information on The control board has failed. updating your dryer to uti- Replace the control board. lize this and other features, contact Conair. Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861.
  • Page 163 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent correct drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 164 HMI. Dryer board failure. Cycle power to the dryer control board. Call Conair Service. Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437-6861. There is no software revision Loose connection or wiring is not cor-...

  • Page 165: Additional Alarms

    Defect in the main control board. Replace main control board. Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960. Outside the U.S., dial 814-437- 6861.
  • Page 166 Conair Parts at (800) 458 1960 for the addition of a volatile trap. Analog option board/sensor malfunction Verify dryer dewpoint readings with a calibrated portable dewpoint meter.
  • Page 167 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.

  • Page 168: Poor Material Drying Troubleshooting

    Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) Once it is determined which of the four requirements that is not being satisfied, refer to the following list of possible causes and solutions.
  • Page 169 Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) Residence Time - The time your material supplier has determined that the material in use must be heated to its drying temperature to achieve proper drying.

  • Page 170: Repair

    Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) 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.
  • Page 171 -20 to -40° F {-29 to -40° C}. If your dryer does not United States, call: have a dewpoint readout, you can check the dewpoint with a portable dewpoint (814) 437 6861 instrument. Conair sells a variety of portable dewpoint meters. Contact Conair Parts. Problem Possible cause Solution Low regeneration temperature.
  • Page 172 R e p l a c i n g F u s e s Disconnect and lockout the main power supply. Open the electrical enclosure door. Check the fuse. If necessary, pull the fuse out and replace it with a fuse of the same type and rating.
  • Page 173 C h e c k i n g H e a t e r S o l i d S t a t e R e l a y s Disconnect and lockout the main power supply. Open the electrical enclosure. Locate the process or regeneration relays.
  • Page 174 C h e c k i n g o r R e p l a c i n g Te m p e r a t u r e S e n s o r s The Carousel Plus W series dryer uses RTD sensors to monitor the temperatures of the dry- ing air, the return air, the regeneration outlet, the regeneration inlet process protection and setback at the outlet of the hopper.

  • Page 175: Regeneration Heater Tube

    R e p l a c i n g t h e H e a t e r s R e g e n e r a t i o n H e a t e r Tu b e Stop the dryer, disconnect the power, and follow proper lockout procedures.
  • Page 176 R e p l a c i n g t h e H e a t e r s P r o c e s s H e a t e r Tu b e Stop the dryer, disconnect the power, and follow proper lockout procedures.

  • Page 177: Process Heater Tube

    R e p l a c i n g t h e H e a t e r s P r o c e s s H e a t e r Tu b e ( c o n t i n u e d ) While supporting the heater tube, remove the hose and clamp at the top Clamp...
  • Page 178 R e p l a c i n g t h e D e s i c c a n t W h e e l When desiccant becomes clogged or contaminated, you should replace the desiccant wheel to ensure optimum performance. Stop the dryer, disconnect the power, and follow proper lockout procedures.

  • Page 179: Replacing The Desiccant Wheel

    R e p l a c i n g t h e D e s i c c a n t W h e e l M o t o r Stop the dryer, disconnect and lockout the main power. Open both side panels.

  • Page 180: We're Here To Help

    Conair equipment may be ordered through the Customer Conair has made the largest investment in customer support in the plastics industry. Our service Service or Parts Department for a experts are available to help with any problem you might have installing and operating your equip- nominal fee.

  • Page 181: Equipment Guarantee

    E q u i p m e n t G u a r a n t e e 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 nor- mal use and service for which it was recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.).
  • Page 182 ( O p t i o n a l ) Precoolers are available from Conair. You can add a precooler to the Carousel Plus W series dryer by ordering the optional pre- cooler assembly. Installation is easy. Contact Conair Parts...
  • Page 183 I n s t a l l i n g a P r e c o o l e r ( O p t i o n a l ) ( c o n t i n u e d ) Prepare the precooler for installation.
  • Page 184 B - 3 l A p p e n d i x...

  • Page 185: Dc-T Modbus Tcp/Ip Read Only Data

    www.conairgroup.com S E C T I O N Addendum DC-T Modbus TCP/IP Read Only Data V02 2/3/2014 A p p e n d i x C l C - 1...
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This manual is also suitable for:

Carousel plus w300Carousel plus w200Carousel plus w150Carousel plus w400

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