Conair 5000 Betriebsanweisung Seite 1

Carousel Plus DryerW Series Models 600 through 5000 with DC-1 ControlsCorporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.

ATTENTION:Read this so no one gets hurtWe design equipment with the user’s safety in mind. You can avoid the potentialhazards identified on this machi

Replacing the Regeneration Heater(W3200 - 5000)1 Stop the dryer, disconnect and lockout the main power.2 Locate the heater(s). Open the side panels of

Replacing the Regeneration Heater(W3200 - 5000) (continued)6 Loosen the two (2) lower clamps that secure the regeneration manifoldand tubing to the de

6-32 l TroubleshootingReplacing the Desiccant WheelAssembly (W600 - 1000)When desiccant becomes clogged or contaminated, you should replace the desic

Replacing the Desiccant WheelAssembly (W600 - 1000) (continued)10 Lift the new desiccant wheel into the dryerframe, being sure it is oriented properly

6-34 l TroubleshootingReplacing the Desiccant WheelMotor (W600 - 1000)1 Stop the dryer, disconnect and lockout the main power.2 Remove both side pane

Troubleshooting l 6-356TroubleshootingReplacing the Desiccant WheelMotor(W 1600 - 5000)1 Stop the dryer, disconnect and lockout the main power.2 Ope

6-36 l TroubleshootingReplacing the Desiccant WheelMotor (W1600 - 5000) (continued)9 Slip the belt onto the sprocket, and adjust the tension spring n

Appendix l A-1We’re Here to HelpConair has made the largest investment in customer support in the plastics indus-try. Our service experts are availa

A-2 l AppendixEquipment GuaranteeConair guarantees the machinery and equipment on this order, for a period asdefined in the quotation from date of shi

Appendix l B-1Cleaning the Precooler CoilsYou need to clean the precooler coils to keep them working efficiently. Cleaningfrequency depends on the

1IntroductionIntroduction l 1-5ATTENTION:Read this so no one gets hurt(continued)We design equipment with the user’s safety in mind. You can avoid t

C-1 l AppendixCleaning the Volatile Trap on theDemister(W600 - 1000)1 Stop the dryer and lockout the main power.2 Remove the thumbscrews then remove t

Appendix l C-2Cleaning the Volatile Trap on theDemister (W1600 -5000)1 Stop the dryer and lockout the main power.2 Remove the thumbscrews then remov

1-6 l IntroductionHow to Use the Lockout DeviceCAUTION: Before performing maintenance or repairs on this product, you shoulddisconnect and lockout e

Description l 2-1DescriptionWhat is the Carousel Plus W Series Dryer? . . 2-2Typical applications . . . . . . . . . . . . . . . . . . 2-2How it work

What is the Carousel Plus W SeriesDryer?The Carousel Plus W Series dehumidifying dryer produces low-dewpoint air thatremoves moisture from hygroscopic

Description l 2-32DescriptionTypical Applications (continued)Model Drying Temperature RangeLow temperature (with precooler)* 100° - 150°F {38° - 66°

How It Works2-4 l DescriptionThe Process (Drying) Cycle (W1600 - 5000)Process air from the hopper is pulled into the dryer, through the process filte

2DescriptionHow It Works (continued)(W600 - 1600 and 3200)Description l 2-5W-series 1600-5000intercooler location only.W-series 600-1000aftercooler

2-6 l DescriptionHow It Works (continued)(W2400 and 5000)Protected underUnited States PatentNo. 7,101,414 andother US and ForeignPatents Pending..NOT

Specifications: Carousel Plus WSeries Dehumidifying DryersCABDescription l 2-72DescriptionTPDS019-0311-REVMODELS W600*W800*W1000*W1600*††W2400*††W32

Please record your equipment’smodel and serial number(s) andthe date you received it in thespaces provided.It’s a good idea to record the model and se

2-8 l DescriptionCarousel Plus W SeriesDehumidifying Dryer Options• Volatile trap (only in conjunction with aftercooler/intercooler) - The volatile t

Installation l 3-1InstallationUnpacking the boxes . . . . . . . . . . . . . . . . . 3-2Preparing for installation . . . . . . . . . . . . . . 3-3Pos

3-2 l InstallationUnpacking the BoxesThe Carousel Plus W Series Dryer comes in one to four boxes, depending on themodel and options ordered. The box(

Installation l 3-3Unpacking the Boxes (continued)6 Take a moment to record serial numbers and electrical power specificationsin the blanks provided

3-4 l InstallationPositioning the Dryer on the Floor1 Lift the dryer from the shipping container using a fork truck.2 Position the dryer on the floor

3InstallationInstallation l 3-5Installing the Return Air Adapter(W600 - 1000)The Carousel Plus W Series Dryer’s return air adapter must be installed

Installing the Return Air Inlet andAir Outlet Adapters (W1600 - 5000)The Carousel Plus W Series Dryer’s return air inlet and air outlet adapters will

Installing the Overhead Process AirDuct (W3200 - 5000)The Carousel Plus W Series Dryer’s overhead process air duct will be removedwhen the dryer is sh

Connecting the Main PowerCAUTION: Always disconnect and lock out the main power sources before mak-ing electrical connections. Electrical connections

Auto StartDryer StatusProcess Blower Regen. BlowerRegen. HeaterSet Point Actual1 Process Temp.2 Regen. Temp.3 Return Air Temp.4 Auto Start5 Load

Table of Contents1-1 IntroductionPurpose of the user guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2How the guide is organiz

3-10 l InstallationChecking for Proper Air Flow (continued)3 Visually verify the blower motor ismoving in the correct direction indi-cated by the arr

Installation l 3-113InstallationChecking for Proper Air Flow (continued)4 If air flow is incorrect disconnect power, follow proper lockout procedure

3-12 l InstallationConnecting the Air Hoses to aSingle Hopper (W600 - 1000)Using the two flexible hoses provided, connect the inlet of the HTC and o

Installation l 3-133InstallationConnecting the Air Hoses to aSingle Hopper (W1600 - 5000)Using the two flexible hoses provided, connect the inlet o

3-14 l InstallationNOTE: Do not allow theflexible hoses to kink orcrimp. ✐Connecting the Air Hoses to aResinWorksUsing the two flexible hoses provide

3InstallationInstallation l 3-15Connecting the Dryer to the Hopper If your dryer hose connection and your hopper HTC hose connection are not thesame

3-16 l InstallationConnecting Air Hose AdaptersDepending on the hopper you purchased you may need to install an air hoseadapter to connect the hopper

Installation l 3-173InstallationConnecting the Aftercooler andOptional Precooler (W600 - 1000)The aftercooler and/or optional precooler require a s

3-18 l InstallationConnecting the Intercooler andOptional Precooler (W1600 - 5000)The intercooler and/or optional precooler require a source of city,

Mounting a Loader on the Hopper If you have a Conair loader or vacuum receiver, you canuse the flange and mounting clips provided on the top ofthe hop

Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Connecting the air hoses to a single hopper (W600-1000) .

3-20 l InstallationTesting the Installation (continued)4 Press the STOP button. If everything is installed correctly:• The blowers will continue runn

SECTION44OperationOperationCarousel Plus W Series Dryer: control panel DC-1. . . . . . . . . . . . . . . . 4-2Carousel Plus W Series Dryer DC-1 contro

4-2 l OperationAuto StartDryer StatusProcess Blower Regen. BlowerRegen. HeaterSet Point Actual1 Process Temp.2 Regen. Temp.3 Return Air Temp.4 A

Carousel Plus W Series Dryer DC-1Control FunctionsDryer functions are values that you can set or monitor. Press the Scroll button toaccess the functi

POWER ONscreen #1 Pr up5 sec2CP 6005 sec - Model Disignator3C v2.0 3.001 sec - Control Software Version4d v2.0 3.001 sec - Display Software Version51

4OperationOperation l 4-5Once power is turned on, this screen is dis-played for 5 seconds while the controlgoes through self-checking.Once power is

4-6 l OperationScreenSCREEN 7SCREEN 8100FunctionControl Function Descriptions (continued)This screen shows the actual return airtemperature measured

Operation l 4-7ScreenSCREEN 13 (Dewpoint Monitor/Dewpoint Control Option)SCREEN 14 FunctionControl Function Descriptions (continued)If the dryer has

ScreenScreens 18-24 require access code 754.SCREEN 18 (Set up Screen)SCREEN 19 (Set up Screen)SCREEN 21 (Set up Screen)Regeneration DifferentialTemper

4OperationOperation l 4-9ScreenScreens 18-24 require access code 754.SCREEN 22 (Set up Screen)Regeneration Air TemperatureSCREEN 24 Aftercooler/Inte

Cleaning the regeneration filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8Cleaning the aftercooler/intercooler coils. . . . . . . .

4-10 l OperationControl Function Descriptions (continued)ScreenScreen 28-43 require access code 755.SCREEN 30 (Test Mode Screen)SCREEN 31 (Test Mode

4OperationOperation l 4-11ScreenScreen 28-43 require access code 755.SCREEN 34 (Test Mode Screen)SCREEN 35 (Test Mode Screen)SCREEN 37 (Test Mode Sc

4-12 l OperationScreenScreen 28-43 require access code 755.SCREEN 40 (Test Mode Screen)SCREEN 41 (Test Mode Screen)SCREEN 42 (Test Mode Screen)SCREE

4OperationOperation l 4-13ScreenAccess code 756 required.SCREEN 44 (Alarm Screen) FunctionControl Function Descriptions (continued)1P3AThis is the f

4-14 l OperationScreenScreen 47 require access code 754.SCREEN 47 (Degree F/Degree C)FunctionControl Function Descriptions (continued)This is the te

Operation l 4-15To Start Drying1 Make sure there is material in the hopper.2 Turn on the main power to the dryer. Make sure the dryer’s disconnect d

4-16 l OperationTo Stop Drying1 Press the STOP button. The Stop LED blinks red.• The blowers continue running for a few minutesto cool the heaters.2

Using the Auto Start CountdownFunctionThe countdown function allows the user to set the Carousel Plus W SeriesDryer to automatically start at a predet

4-18 l OperationNOTE: For more information concerning specific dewpoint control screens, see ControlFunction Descriptions, page 4-5.✐Using Dewpoint

MaintenancePreventative maintenance checklist . . . . . . . 5-2Checking the dewpoint . . . . . . . . . . . . . . . . 5-3Cleaning the hopper. . . . . .

iv l Table of ContentsA AppendixWe’re here to help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1How to contact custo

5-2 l MaintenancePreventative MaintenanceChecklistRoutine maintenance will ensure optimum operation and performance of the W Series Carousel Plus Dry

5MaintenanceMaintenance l 5-3✐NOTE: Portable dewpoint moni-tors purchased from Conair areprovided with a male connectorthat plugs into the dewpointc

Checking the Dewpoint (continued)5 Turn on the portable instrument, and ensure there is positive airflow throughthe sensor.6 Monitor the readout and a

5MaintenanceMaintenance l 5-5Cleaning the HopperCAUTION: Hot surfaces. Always protect yourself from hot surfaces inside andoutside the dryer and dry

5-6 l MaintenanceCleaning the Process FilterClogged filters reduce air flow and dryer efficiency. Cleaning frequency dependson how much material you

Maintenance l 5-75MaintenanceCleaning the Process Filter (continued)3 Remove the filter wing nut, then remove the filter.4 Remove outer filter and

5-8 l MaintenanceCleaning the Regeneration FilterClogged filters reduce air flow and dryer efficiency. Cleaning frequency dependson the condition of

Maintenance l 5-95MaintenanceCleaning the Aftercooler/Intercooler CoilsYou need to clean the aftercooler/intercooler coils to keep them working effi

Cleaning the Aftercooler/Intercooler Coils (continued)5 Clean the assembly using a mild soap and water. Let the assemblydry thoroughly before installa

Cleaning the Precooler CoilsYou need to clean the precooler cooling coils to keep them working efficiently. SeeAppendix B for details.Cleaning the Vol

IntroductionPurpose of the user guide. . . . . . . . . . . . . . 1-2How the guide is organized. . . . . . . . . . . . . 1-2Using the Carousel Plus W S

5-12 l Maintenance

TroubleshootingBefore beginning. . . . . . . . . . . . . . . . . . . . 6-2A few words of caution . . . . . . . . . . . . . . 6-3DIAGNOSTICSHow to id

Before BeginningYou can avoid most problems by following the recommended installation andmaintenance procedures outlined in this User Guide. If you d

Before Beginning (continued)❏ Find the wiring and equipment diagrams that were shippedwith your dryer. These diagrams are the best reference for corre

How to Identify the Cause of aProblemDryer alarms are indicated by an illuminated Acknowledge Alarm light on the WSeries Dryer control panel. Shutdown

6TroubleshootingTroubleshooting l 6-5AlarmsA problem can trigger two types of alarms:• Shutdown (A#): If the red Acknowledge Alarm LED is blinking,

6-6 l TroubleshootingAlarms• Shutdown (A#): The dryer has automatically shut down because it has detect-ed a serious problem that could damage your m

6TroubleshootingTroubleshooting l 6-7Alarms• Shutdown (A#): The dryer has automatically shut down because it has detect-ed a serious problem that co

6-8 l TroubleshootingAlarms• Shutdown (A#): The dryer has automatically shut down because it has detect-ed a serious problem that could damage your m

Troubleshooting l 6-96TroubleshootingAlarms• Shutdown (A#): The dryer has automatically shut down because it has detect-ed a serious problem that co

✐Purpose of the User GuideThis User Guide describes the Conair Carousel Plus W Series Dryer andexplains step-by-step how to install, operate, maintain

6-10 l TroubleshootingAlarms• Shutdown (A#): The dryer has automatically shut down because it has detect-ed a serious problem that could damage your

6TroubleshootingTroubleshooting l 6-11Alarms• Shutdown (A#): The dryer has automatically shut down because it has detect-ed a serious problem that c

6-12 l TroubleshootingAlarms• Shutdown (A#): The dryer has automatically shut down because it has detect-ed a serious problem that could damage your

Troubleshooting l 6-136TroubleshootingAlarms• Shutdown (A#): The dryer has automatically shut down because it has detect-ed a serious problem that c

6-14 l TroubleshootingAlarms• Shutdown (A#): The dryer has automatically shut down because it has detect-ed a serious problem that could damage your

Troubleshooting l 6-15Additional AlarmsAlong with the alarm indicators, you may encounter additional messages that indi-cate a problem within the co

Additional AlarmsAlong with the alarm indicators, you may encounter additional messages that indi-cate a problem within the control. ProblemEr. H - Th

Dewpoint TroubleshootingUnder normal operating conditions, the dryer will produce dewpoints in the rangeof -40 to -20° F {-40 to -29° C}. However, you

Poor Material DryingTroubleshootingOccasionally, processing problems that are suspected of being caused by poor dry-ing are eventually determined to b

Poor Material DryingTroubleshooting (continued)Once it is determined which of the four requirements that is not being satisfied,refer to the following

Introduction l 1-3Using the Carousel Plus W Seriesas a Central DryerThe Conair Carousel Plus W600-5000 Series Dryers are factory configured tobe use

Poor Material DryingTroubleshooting (continued)Residence Time - The time your material supplier has determined that the materialin use must be heated

Poor Material DryingTroubleshooting (continued)Airflow - The airflow in the process drying circuit must be adequate to carry anddistribute the heat th

6-22 l TroubleshootingPoor Material DryingTroubleshooting (continued)Dewpoint - The process air must be at a low dewpoint so it can efficiently colle

6TroubleshootingReplacing Fuses1 Disconnect and lockout the main power supply.2 Open the electrical enclosure door.3 Check the fuse with an ohmmeter.

6-24 l TroubleshootingIMPORTANT: Always referto the wiring diagrams thatcame with your dryer tolocate specific electricalcomponents. Illustrations in

6TroubleshootingTroubleshooting l 6-25Checking or Replacing TemperatureSensorsThe Carousel Plus W Series Dryer uses RTD sensors to monitor the tempe

Replacing the Regeneration Heater(W600 - 1000)1 Stop the dryer, disconnect the power, and follow proper lockoutprocedures.2 Remove the right side pane

Replacing the Regeneration Heater(W600 - 1000) (continued)8 Compare the markings on the outside of the regeneration heater tube toensure the new one h

Replacing the Regeneration Heater(W1600 - 2400)1 Stop the dryer, disconnect and lockout the main power.2 Locate the heater. Open the side panels of th

6TroubleshootingTroubleshooting l 6-29Replacing the Regeneration Heater(W1600 - 2400) (continued)8 Slide the original insulation over the new heater