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3
Installation
Installation l 3-9
Opening the Dryer Doors
(W1600 - 5000)
Carousel Plus W Series 1600-5000 Dryers designed after August 2007 will have
locking side panel door bolts.
To unlock the side panel door bolts:
1 Rotate the two (2) locking door bolts on the dryer door counterclockwise
with a regular screw driver.
2 Close the dryer doors and rotate the two (2) locking door bolts clockwise
to resecure the dryer doors.
Checking for Proper Air Flow
This procedure is needed on W600-5000 models if the phase detection option was
not ordered with the dryer.
CAUTION: If the air flow 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.
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 Press the START button then the STOP button.
1
2
3
4
5
6
7
8
9
Clear
0
Enter
Adjust Setpoint
Acknowledge
Alarm
Start
Stop
Select
Category
Menu
Scroll List
Prev
Next
Auto Start
Dewpoint Control
Process Blower Regen. Blower
Regen. Heater
1000
3
3
Start
Stop
IMPORTANT: This procedure must be performed before the dryer’s air hoses are
connected to the hopper or before loading material into the hopper.
(continued)
Dryer Door
Locking Bolts (2)
(W1600-5000)
- Carousel Plus Dryer 1
- 4-1 Operation 4
- 5-1 Maintenance 5
- 6-1 Troubleshooting 5
- B Appendix 6
- C Appendix 6
- Introduction 7
- Purpose of the User Guide 8
- How the Guide is Organized 8
- Your Responsibility as a User 9
- ATTENTION: 10
- Read this so no one gets hurt 10
- How to Use the Lockout Device 12
- Description 13
- Typical Applications 14
- How It Works 16
- How It Works (continued) 17
- Series Dehumidifying Dryers 19
- Carousel Plus W Series 20
- Dehumidifying Dryer Options 20
- Installation 21
- Unpacking the Boxes 22
- Preparing for Installation 23
- Desiccant Wheel 24
- Installing the Regeneration 24
- Exhaust Cover 24
- Installation l 3-5 25
- Air Outlet Adapters 26
- Connecting the Main Power 28
- Opening the Dryer Doors 29
- Checking for Proper Air Flow 29
- Connecting the Air Hoses to a 32
- Single Hopper (W600 - 1000) 32
- Single Hopper (W1600 - 5000) 33
- ResinWorks 34
- Connecting the Dryer to 35
- Connecting Air Hose Adapters 36
- Optional Precooler 38
- Testing the Installation 39
- Using Communications 40
- Operation 41
- : Control Panel DC-2 42
- Carousel Plus W Series Dryer 42
- Control Functions 43
- Control Function Flow Charts 43
- How to Navigate the Menu Tree 43
- POWER ON 44
- Operation l 4-5 45
- SCREEN # 46
- Operation l 4-7 47
- 4-8 l Operation 48
- Screen # 49
- Operation l 4-9 49
- 4-10 l Operation 50
- Function 51
- Control Function Descriptions 51
- To Start Drying 74
- To Stop Drying 75
- To Start Drying (continued) 75
- How to Use the Supervisor’s 76
- Password 76
- Password (continued) 77
- Dewpoint Control 78
- Using the Auto Start Timer 79
- 4-40 l Operation 80
- Maintenance 81
- Preventative Maintenance 82
- Checklist 82
- Checking the Dewpoint 83
- Cleaning the Hopper 85
- Cleaning the Process Filter 86
- 5-8 l Maintenance 88
- Cleaning the Aftercooler/ 89
- Intercooler Coils 89
- Intercooler Coils (continued) 90
- Inspecting Hoses and Gaskets 91
- 5-12 l Maintenance 92
- Before Beginning 94
- Before Beginning (continued) 95
- A Few Words of Caution 95
- Acknowledge 96
- Alarm LED and 96
- Possible cause 100
- Solution 100
- Shutdown Alarms 100
- Passive Alarms 101
- Additional Alarms 105
- Dewpoint Troubleshooting 107
- Poor Material Drying 108
- Troubleshooting 108
- Troubleshooting (continued) 109
- Replacing Fuses 113
- Regeneration heater 114
- Troubleshooting l 6-23 115
- (W600 - 1000) 116
- (W600 - 1000) (continued) 117
- (W1600 - 2400) 118
- (W1600 - 2400) (continued) 119
- (W3200 - 5000) 120
- (W3200 - 5000) (continued) 121
- Replacing the Desiccant Wheel 122
- Assembly (W600 - 1000) 122
- Motor (W600 - 1000) 124
- Motor (W1600 - 5000) 125
- We’re Here to Help 127
- Before You Call 127
- Equipment Guarantee 128
- Performance Warranty 128
- Warranty Limitations 128
- Cleaning the Precooler Coils 129
- Demister (W600 - 1000) 130
- Demister 131
- C-3 l Appendix 132
- Addendum 133
- Communication Protocols for 133
- Common Controls 133
- Table of Contents 135
- D-1 SPI Communications 136
- A Appendix 136
- Modbus Communications 137
- Description of Modbus 138
- Communications 138
- Installing the Modbus 138
- Communication Hardware 138
- Modbus Communications l A-3 139
- A-4 l Modbus Communications 140
- Ethernet Communications 141
- Description of Ethernet 142
- Installing the Ethernet 142
- DeviceNet 145
- (continued) 146
- Using the DeviceNet 147
- Installing the EDS Files 149
- Gateway Parameter List 156
- SPI Communications 157
- Hardware 158
- Software 158
- Software (continued) 159
- Supported Dryer SPI Commands 160
- Modbus RS-232/485 Serial 165
- Communication Parameters 165
- Related Drawings 167
- Modbus TCP/IP 168
- Communications Parameters 168
- Appendix l A-5 169
- A-6 l Appendix 170
- Appendix l A-7 171
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