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Carousel Plus DryerW Series Models 600 through 5000 with DC-2 ControlsCorporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.

1-4 l IntroductionATTENTION:Read this so no one gets hurtWe design equipment with the user’s safety in mind. You can avoid the potentialhazards ident

6-8 l TroubleshootingProblemRegeneration Bloweroverload - If the regenerationblower exceeds its full loadamp rating or the overloadhas tripped due to

Troubleshooting l 6-96TroubleshootingPassive AlarmsIf the amber Acknowledge Alarm LED is blinking, the alarm is a passivealarm. The dryer continues

6-10 l TroubleshootingProblemRegeneration HighTemperature – If the regener-ation temperature exceeds thehigh temperature limit for thespecified time.

6TroubleshootingTroubleshooting l 6-11ProblemProcess Filter Clogged(Option) – The process filterdifferential pressure switch istripped.CFM Low (Opti

6-12 l TroubleshootingProblemRegeneration Outlet RTDIntegrity - The control can notsense the regeneration outletRTD.Dewpoint Deviation High -Displaye

Troubleshooting l 6-13Additional 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. Lo - T

SolutionCheck regeneration filter and cleanand/or replace as necessary.Reduce the temperature of the coolingwater or increase the flow. Connect water

Poor Material DryingTroubleshootingOccasionally, processing problems that are suspected of being caused by poordrying are eventually determined to be

6TroubleshootingTroubleshooting l 6-17Poor Material DryingTroubleshooting (continued)Once it is determined which of the four requirements that is no

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

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

SolutionClean or replace the process filter.Replace any worn or damaged hoses.Tighten all hose clamps to eliminateleaks.Remove any obstructions in the

6-20 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.

6-22 l TroubleshootingIMPORTANT: Always referto the wiring diagrams thatcame with your dryer tolocate specific electricalcomponents. Illustrations in

6TroubleshootingTroubleshooting l 6-23Checking or Replacing TemperatureSensorsThe Carousel Plus W Series Dryer uses RTD sensors to monitor the tempe

6-24 l TroubleshootingReplacing the Regeneration Heater(W600 - 1000)1 Stop the dryer, disconnect the power, and follow proper lockoutprocedures.2 Rem

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

6-26 l TroubleshootingIMPORTANT: Always referto the wiring diagramsthat came with your dryerto locate specific electri-cal components.Illustrations i

Troubleshooting l 6-276TroubleshootingReplacing the Regeneration Heater(W1600 - 2400) (continued)8 Slide the original insulation over the new heater

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

IMPORTANT: Always referto the wiring diagramsthat came with your dryerto locate specific electri-cal components.Illustrations in the UserGuide are int

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

6-30 l TroubleshootingReplacing the Desiccant WheelAssembly (W600 - 1000)When desiccant becomes clogged or contaminated, you should replace thedesicc

Replacing the Desiccant WheelAssembly (W600 - 1000) (continued)10 Lift the new desiccant wheel into the dryer frame, being sure it isoriented properly

Replacing the Desiccant WheelMotor (W600 - 1000)1 Stop the dryer, disconnect and lockout the main power.2 Remove both side panels.3 Disconnect wiring

6TroubleshootingTroubleshooting l 6-33Replacing the Desiccant WheelMotor (W1600 - 5000)1 Stop the dryer, disconnect and lockout the main power.2 Ope

6-34 l TroubleshootingReplacing the Desiccant WheelMotor (W1600 - 5000) (continued)9 Slip the belt onto the sprocket, and adjust the tension spring n

Additional manuals and prints foryour Conair equipment may beordered through the CustomerService or Parts Department for anominal fee. Most manuals ca

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

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

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

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

C-3 l Appendix

AddendumCommunication Protocols forCommon ControlsModbus Communications, Ethernet Communications, DeviceNet GatewayCommunications and SPI Communicatio

DISCLAIMER: The Conair Group, Inc., shall not be liable for errors contained in this User Guide orfor incidental, consequential damages in connection

Table of ContentsA-1 Modbus CommunicationsDescription of Modbus communications . . . . . . . . . . . . . . . . . . . . . A-2Installing the Modbus comm

D-1 SPI CommunicationsDescription of SPI communications. . . . . . . . . . . . . . . . . . . . . . . . . D-2Installing the SPI communication hardware

Modbus CommunicationsDescription of Modbus Communications . . . . A-2Installing the Modbus Communication Hardware . . . . . . . . . . . A-2Using the M

Description of ModbusCommunicationsThe common controls series of products from Conair use standard Modbus com-munications protocol to allow the user t

CAUTION: The list of data that may be read and written to by the user is arrangedin a specific location (parameters 500 to 540). Writing to a locatio

2-2 l DescriptionWhat is the Carousel Plus W SeriesDryer?The Carousel Plus W Series Dehumidifying Dryer produces low-dewpoint air thatremoves moistur

A-4 l Modbus Communications

SECTIONBBEthernetEthernet CommunicationsDescription of Ethernet Communications . . . . B-2Installing the Ethernet Communication Hardware . . . . . . .

(continued)Description of EthernetCommunicationsModbus TCP/IP is a protocol that takes the basic Modbus command set that wasoriginally developed for s

BEthernetInstalling the EthernetCommunication Hardware (continued)4 Once you have entered the correct value, scroll down one more time until“IP Addr P

B-4 l Ethernet Communications

SECTIONCDeviceNetCommunicationsDescription of DeviceNet Communications . . . C-2Installing the DeviceNet Communication Hardware . . . . . . . . . . .

Description of DeviceNetCommunicationsThe Conair Common Control board set allows you to add DeviceNet communica-tions for information interchange with

Using the DeviceNetCommunication Dip Switch Settings(continued)Dip switch 1 provides the DeviceNet MacId address and baud rate using the stan-dard swi

Using the DeviceNetCommunication Dip Switch Settings(continued)Dip switch set 2 identifies the Modbus addresses of controllers connected to theDeviceN

Using the LED Status IndicatorsThere are two LEDs on the gateway which display the status of the communica-tions. The first LED, which is located betw

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

Configuring the DeviceNet SoftwareInstalling the EDS Files (continued)Configuring the DeviceNet SoftwareEDS File Parameter List Configuration OptionsO

Configuring the DeviceNet SoftwareEDS File Parameter List Configuration Options(continued)There are seven types of parameters:Parameter 1 Controll

Configuring the DeviceNet SoftwareEDS File Parameter List Configuration Options(continued)Parameter 6 Input Assembly Type Status only, Status

Configuring the DeviceNet SoftwareAdding the Gateway to the Scan List(continued)4 Close the parameter list and reopen, once you have applied your para

Configuring the DeviceNet SoftwareAdding the Gateway to the Scan List(continued)Press the “Edit I/O Parameter” button to to the configure the I/O para

Configuring the DeviceNet SoftwareAdding the Gateway to the Scan List(continued)6 Select the “OK” button once you have modified your input field size

Configuring the DeviceNet SoftwareGateway Parameter ListSimilarly to the Modbus communications, the Common Controls parameters thatare available are s

SECTIONDSPI CommunicationsDescription of SPI Communications . . . . . . . D-2Installing the SPI Communication Hardware . . . . . . . . . . . D-2Config

Description of SPI CommunicationsThe Society of Plastics Industry (SPI) has defined a standard protocol to be usedfor interconnecting plastics equipme

Configuring the SPI CommunicationSoftware (continued)2 Once the password has been entered, go to “Setup”>”Other”>Comm. 3 When the “Comm” menu is

2-4 l DescriptionHow It WorksThe Process (Drying) Cycle (W1600 - 5000)Process air from the hopper is pulled into the dryer, through the process filte

D-4 l SPI CommunicationsSupported Dryer SPI CommandsSPI protocol defines two different modes, “Select” and “Poll”. “Select” commandsare used to set o

DSPISPI Communications l D-5Supported Dryer SPI Commands(continued)6. Status, Process - Indicates that the status of the process with each “bit” sho

D-6 l SPI CommunicationsSupported Dryer SPI Commands(continued)7. Status, Machine 1 - Indicates that the status of the dryer itself with each “bit” s

DSPISPI Communications l D-7Supported Dryer SPI Commands(continued)8. Status, Machine 2 - This word shows the status of the Dryer itself with each b

D-8 l SPI CommunicationsSupported Dryer SPI Commands(continued)9. Mode, Machine - This is used to start/stop the dryer, acknowledge alarms andobserve

Modbus RS-232/485 SerialCommunication ParametersDC-2 Control Parameters - Used on dryers with DC-2 ControlsRead AreaModbus Register Number Descrip

A-2 l AppendixModbus RS-232/485 SerialCommunication Parameters (continued)Modbus Register Number Description

Modbus RS-232/485 SerialCommunication Parameters (continued)DC Plus Control Parameters - Used on ResinWorks and Hopper TemperatureControllers (HTC)Mo

A-4 l AppendixModbus TCP/IPCommunications Parameters

Appendix l A-5

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

A-6 l Appendix

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2-6 l DescriptionHow It Works (continued)(W2400 and W5000)Protected underUnited States PatentNo. 7,101,414 andother US and ForeignPatents Pending..NO

Description l 2-7Specifications: Carousel Plus WSeries Dehumidifying DryersCABTPDS019-0311-REVMODELS W600*W800*W1000*W1600*††W2400*††W3200*††W5000*†

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 boxe

Installation l 3-33InstallationUnpacking the Boxes (continued)6 Take a moment to record serial numbers and electrical power specificationsin the bla

3-4 l Installation✒Positioning the Dryer on the Floor1 Lift the dryer from the shipping container using a fork truck.2 Position the dryer on the floo

3InstallationInstallation l 3-5Installing the Return Air AdapterThe Carousel Plus W Series Dryer’s return air adapter must be installed.To install t

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 beforemaking electrical connections. Electrical connections sh

3InstallationInstallation l 3-9Opening the Dryer Doors (W1600 - 5000)Carousel Plus W Series 1600-5000 Dryers designed after August 2007 will havelo

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

Checking for Proper Air Flow (continued)3 Visually verify the blower motor ismoving in the correct direction indi-cated by the arrow on the blowerhous

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

Connecting the Air Hoses to aSingle Hopper (W600 - 1000)Using the two flexible hoses provided, connect the inlet of the HTC and outletof the drying h

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

Installation l 3-153InstallationConnecting 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

3InstallationInstallation l 3-17Connecting the Aftercooler andOptional Precooler (W600 - 1000)The aftercooler and/or optional precooler require a s

Connecting the Intercooler andOptional Precooler (W1600 - 5000)The intercooler and/or optional precooler require a source of city, tower, or chillerwa

Testing the InstallationYou have completed the installation. Now it’s time to make sure everything works. 1 Make sure there is no material in the hopp

Opening the dryer doors (W1600-5000) . . . . . . . . . . . . . . . . . . . . . 3-9Checking for proper air flow . . . . . . . . . . . . . . . . . . . .

3-20 l InstallationUsing CommunicationsThe DeviceNet cable feature is a standard feature on W600-5000 dryers with DC-2 controls. It allows the dry

SECTION44OperationOperationCarousel Plus W Series Dryer:control panel DC-2 . . . . . . . . . . . . . . . 4-2Carousel Plus W Series Dryercontrol functi

4-2 l Operation123456789Clear0EnterAdjust SetpointAcknowledgeAlarmStartStopSelectCategoryMenuScroll List PrevNext Auto StartDewpoint ControlProcess

Operation l 4-34OperationCarousel Plus W Series DryerControl FunctionsDryer functions are values that you can set or monitor in the Screen Title and

REGENERATION TEMPACT 350˚F SET 350˚F RETURN AIR TEMPACT 120˚F SET 120˚FPROCESS DEWPOINTACT -47˚F SET -40˚FPOWER ONCONAIR

4OperationDRYER MAIN MENUSTAT SETUP DIAG DRYER STATUSPROC REGEN OTHERDRYER REGENSTATUS SCREENSREGENERATION TEMPACT 350˚F SET

4-6 l OperationSCREEN #12DRYER MAIN MENUSTAT SETUP DIAG36 DRYER SETUPPROC ALM DISP OTHER37 SETUP PROCESSPROC REGN

Operation l 4-7DRYER MAIN MENUSTAT SETUP DIAG DRYER SETUPPROC ALM DISP OTHER SETUP PROCESSPROC REGEN OTHERSETUP R

4-8 l OperationDRYER MAIN MENUSTAT SETUP DIAG DRYER SETUPPROC ALM DISP OTHERALARM ALARMDRYER SETUP CONTROLACTION

DRYER MAIN MENUSTAT SETUP DIAG DRYER SETUPPROC ALM DISP OTHERDRYER SETUP OTHEROPT INSP COM PWDRYER SETUP OPTIONS DRYER SETUP

5-1 MaintenancePreventative maintenance checklist . . . . . . . . . . . . . . . . . . . . . . . . 5-2Checking the dewpoint . . . . . . . . . . . . . .

DRYER MAIN MENUSTAT SETUP DIAGDryer DiagnosticALRM HIST I/O DIAGNOSTIC I/ODRYER DIAGNOSTICSDIAGNOSTIC EVENTSDIGITALLAS

ScreenSCREEN 1SCREEN 2SCREEN 4SCREEN 5FunctionOnce power is turned on, this screen isdisplayed for 3 seconds. It showsCONAIR and the dryer type on th

ScreenSCREEN 11 Dewpoint Controland/or Dewpoint Monitor SCREEN 12 (MAIN MENU)This screen will show the actual dewpointof the process delivery air meas

This is the Dryer Status screen. It can befound by pressing the Select Categorybutton under the word "Stat" on the MainMenu screen 12. Any

ScreenSCREEN 17SCREEN 20SCREEN 21 (Aftercooler/Intercooler Flow Control Option)SCREEN 21 (Aftercooler/Intercooler Flow Control Option)This screen show

This screen shows the measured current oneach leg of the 3-phase power going to the regeneration heater. The RegenerationCurrent Monitor option (see

Function4-16 l OperationControl Function Descriptions(continued)ScreenSCREEN 30 SCREEN 31SCREEN 32SCREEN 33SCREEN 34MODEL CP600-

Operation l 4-174OperationFunctionControl Function Descriptions(continued)This screen shows the temperature insidethe control enclosure. It is meas

Function4-18 l OperationControl Function Descriptions(continued)ScreenSCREEN 40andSCREEN 41SCREEN 37SCREEN 42SCREEN 43REGEN PROP BANDHEAT/COOL 30°FR

4OperationOperation l 4-19FunctionControl Function Descriptions(continued)ScreenSCREEN 44SCREEN 45SCREEN 46SCREEN 47SCREEN 48SCREEN 49This screen sh

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

Function4-20 l OperationControl Function Descriptions(continued)ScreenSCREEN 50SCREEN 51 SCREEN 52SCREEN 53SCREEN 54SCREEN 55This is the maximum val

Operation l 4-214OperationFunctionControl Function Descriptions(continued)ScreenSCREEN 56SCREEN 57This is the auto start screen for the firstday of

Function4-22 l OperationControl Function Descriptions(continued)ScreenSCREEN 58SCREEN 59SCREEN 60ALARM ALARMACTION SETUPREGEN TEMP DEVIATIONON EDIT

Operation l 4-234OperationFunctionControl Function Descriptions(continued)This is an example of an Alarm SetupLoop Break screen. When actualtempera

Function4-24 l OperationControl Function Descriptions(continued)This screen shows the low CFM setpoint.The default is 1 CFM. The default can bechan

Operation l 4-254OperationFunctionControl Function Descriptions(continued)This is the amount of time from start-upthe dryer is allowed to run before

This is the Dryer Setup Other screen. Itcan be found by pressing the SelectCategory button under the word Other onthe Dryer Setup Screen (36). By pre

4OperationFunctionControl Function Descriptions(continued)Operation l 4-27This screen further defines the dryer typeto a model number. Based on the

Function4-28 l OperationControl Function Descriptions(continued)This screen shows the communicationsprotocol. Modbus, DeviceNet, Ethernet orSPI is

Operation l 4-294OperationFunctionControl Function Descriptions(continued)This screen shows the password entryscreen. You can enter a password by u

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

Function4-30 l OperationControl Function Descriptions(continued)This is the password logout screen. Ifnothing is done, the password willautomatical

Operation l 4-314OperationFunctionControl Function Descriptions(continued)This is an example of one of the alarmhistory screens. The first two numb

Function4-32 l OperationControl Function Descriptions(continued)This is the Diagnostic I/O screen. It can befound by pressing the Select Categorybut

Operation l 4-334OperationFunctionControl Function Descriptions(continued)These parameters map which internalvariables are accessible from the userc

4-34 l OperationTo 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

Operation l 4-35To Stop Drying1 Press the STOP button. The Stop LED blinks red.• The blowers continue running for a few minutesto cool the heaters.2

4-36 l OperationHow to Use the Supervisor’sPasswordThe supervisor's password must be entered before you can use or make changes tosome screens

Operation l 4-374OperationHow to Use the Supervisor’sPassword (continued)Be sure to push “ENTER” after entering the password. If the password isent

4-38 l OperationUsing the Dewpoint Monitor andDewpoint Control Your dryer is equipped with a dewpoint monitor and dewpoint control features.You can

4OperationUsing the Auto Start Timer You can set the dryer to start and stop automatically using the Auto Start andAuto Stop functions. Supervisor Pa

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

4-40 l Operation

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

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

5MaintenanceMaintenance l 5-3Checking the DewpointIt is a good idea to monitor the dewpoint performance of your dryer periodicallywith a calibrated

5-4 l MaintenanceChecking the Dewpoint (continued)5 Turn on the portable instrument, and ensure there is positive airflow throughthe sensor.6 Monitor

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

5-6 l Maintenance(continued)CAUTION: Hot surfaces.Always protect yourselffrom hot surfaces insideand outside the dryer anddrying hopper.Cleaning the

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

Cleaning the Regeneration FilterClogged filters reduce air flow and dryer efficiency. Cleaning frequency dependson the condition of your dryer’s ambie

Maintenance l 5-9Cleaning the Aftercooler/Intercooler CoilsYou need to clean the aftercooler/intercooler coils to keep them working efficient-ly. C

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

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 Vo

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 forcorrec

How to Identify the Cause of aProblemDryer alarms are indicated by an illuminated Acknowledge Alarm light on theW series dryer control panel.A problem

6TroubleshootingShutdown AlarmsIf the red Acknowledge Alarm LED is blinking, the alarm is a shutdownalarm. The dryer will shutdown automatically to p

6-6 l TroubleshootingProblemRegeneration RTD Integrity– If the regeneration RTD isfaulty, it shuts down the dryer.Control CommunicationsWatchdog - Th

6TroubleshootingTroubleshooting l 6-7ProblemProcess Blower overload - Ifthe process blower exceeds itsfull load amp rating or theoverload has trippe