Conair HTC 30, HTC 180, HTC 270, W600-1000, HTC 60 User Manual

...

EnergySmart

Dryer

W Series Models 600 through 5000 with TouchViewTMTechnology (Allen-Bradley)

Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861

U S E R G U I D E UGD0 41-1212

www.conairgroup.com

Conair recommends recording the model and serial number(s) of your equipment and the date you received it in the User Guide. Our service department uses this information, 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: UGD0041-1212

Serial Number(s):

Model Number(s):

Software Version(s):

Panelview Plus Operator Interface Terminal

Firmware Version Number:

Application File Name:

Programmable Logic Controller:

Firmware Version Number:

Application File Name:

Please record your equipment’s model and serial number(s) and the date you received it in the spaces provided.

DISCLAIMER: Conair 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.

Co p yr ig ht 2 01 2 l C on ai r l A l l ri gh ts r es er ve d

NOTE: The software, firmware and application file information for your specific EnergySmart Dryer System is contained on a serial tag that was attached to the inside of the EnergySmart Dryer’s control panel during assembly.

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Table of Contents

1-1 Intr odu cti on

Purpose of the user guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Using the EnergySmart Dryer with your system . . . . . . . . . . . . . . . 1-3

Your responsibilities as a user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

ATTENTION: Read this so no one gets hurt . . . . . . . . . . . . . . . . . . . 1-4

How to use the lockout device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2-1 Descrip tio n

What is the EnergySmart Dryer System? . . . . . . . . . . . . . . . . . . . . .2-2

Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

How the EnergySmart Dryer System works . . . . . . . . . . . . . . . . . . .2-3

Specifications: EnergySmart Carousel Plus W Series

Dehumidifying Dryers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hopper Temperature Controller (HTC) . . . . . . . . . . . . . . . . . . . . . . . 2-5

GasTrac (CGT) Process Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Dust Collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Positive Displacement (PD) Pumps . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

CH Series Insulated Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Drying Monitor, DM-II Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

EnergySmart Dryer control options . . . . . . . . . . . . . . . . . . . . . . . . 2-13

3-1 Install a tio n

Installation - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Unpacking the EnergySmart Dryer System components . . . . . . . . . 3-6

Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

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Positioning the CH hopper floor stand . . . . . . . . . . . . . . . . . . . . . . . 3-8

Installation of the HTC control

(Models HTC 30, 60 and 90) . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

(Models HTC 120) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

(Models HTC 180 and 270) . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Location and mounting of the HTC heater assembly

(Models HTC 30, 60 and 90) . . . . . . . . . . . . . . . . . . . . . . . . 3-11

(Models HTC 120) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

(Models HTC 180 and 270) . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Installing the CH hopper cone section . . . . . . . . . . . . . . . . . . . . . . 3-12

Installing the CH hopper door, upper and lid sections . . . . . . . . . . 3-13

Installing the cyclone (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Installing the drying monitor probe . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Installing the receiver(s) (optional). . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Installing the purge valve(s) (optional) . . . . . . . . . . . . . . . . . . . . . . 3-25

Installing the modular distribution box(es) (optional) . . . . . . . . . . . 3-25

Securing the CH hopper to the floor . . . . . . . . . . . . . . . . . . . . . . . 3-26

Location and mounting of the GasTrac heater . . . . . . . . . . . . . . . . 3-27

Location and mounting of the dust collector (optional) . . . . . . . . . 3-28

Location and mounting of the vacuum pump(s)

and dust collector(s) (optional) . . . . . . . . . . . . . . . . . . . . . . 3-30

Positioning the dryer on the floor . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Removing the cable tie from the desiccant wheel

(W600-1000 models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Installing the regeneration exhaust cover . . . . . . . . . . . . . . . . . . . 3-31

Installing the return air inlet and air outlet adapters

(W1600-5000 models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Installing the overhead process air duct

(W3200-5000 models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

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Installation - Piping/Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Optional hard piping kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Connecting the heat sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Hopper Temperature Controller (HTC) as heat source . . . . . 3-37

GasTrac as heat source. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Connecting the dryer to the heat source . . . . . . . . . . . . . . . . . . . . 3-39

Connecting the dust collector (optional). . . . . . . . . . . . . . . . . . . . . 3-40

Connecting the cyclone separator (optional) . . . . . . . . . . . . . . . . . 3-41

Installing the Dwyer 641 air velocity transmitter . . . . . . . . . . . . . . 3-42

Installing the level switch (optional). . . . . . . . . . . . . . . . . . . . . . . . 3-44

Adjusting the level sensor (optional) . . . . . . . . . . . . . . . . . . . . . . . 3-45

Installing the process protection RTD sensor. . . . . . . . . . . . . . . . . 3-46

Location of the process material temperature probe (RTD) . . . . . . 3-47

Installing the GasTrac RTD sensor . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

Installing the return air dew point line. . . . . . . . . . . . . . . . . . . . . . 3-49

Installation - Main Power Connections . . . . . . . . . . . . . . . . . . . 3-51

Connecting main power to the dryer . . . . . . . . . . . . . . . . . . . . . . . 3-52

Connecting main power to the HTC

(Models HTC 30, 60, 90 and 120) . . . . . . . . . . . . . . . . . . . . 3-53

(Models HTC 180 and 270) . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Connecting main power to the GasTrac. . . . . . . . . . . . . . . . . . . . . 3-56

Connecting main power to the vacuum pump(s) (optional) . . . . . . 3-57

Connecting main power to the dust collector(s) (optional) . . . . . . . 3-57

Installation - Conveying Lines . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Connecting the conveying lines to the receiver(s) (optional). . . . . . 3-60

Connecting the conveying lines to the purge valve(s) (optional) . . . 3-60 Connecting the conveying lines to the vacuum pump(s) and

dust collector(s) (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Installation - Water Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Typical water lines installation drawing. . . . . . . . . . . . . . . . . . . . . 3-64

Ta bl e of Con te n ts l iii

Connecting the aftercooler/intercooler and optional

precooler (W600-1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Connecting the aftercooler/intercooler and optional

precooler (W1600-5000) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

Installation - Control and Communications Wiring. . . . . . . . . . 3-67

Connecting the HTC to the HTC controller . . . . . . . . . . . . . . . . . . . 3-68

Connecting the RTD sensors (HTC only) . . . . . . . . . . . . . . . . . . . . 3-70

Connecting the GasTrac RTD sensors . . . . . . . . . . . . . . . . . . . . . . 3-72

Connecting the drying monitor probe to the dryer . . . . . . . . . . . . . 3-73

Connecting the receiver to the level switch (optional) . . . . . . . . . . 3-74

Connecting the EnergySmart Dryer control to system

components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75

Installation - Compressed Air Lines . . . . . . . . . . . . . . . . . . . . . 3-85

Connecting the compressed air lines (optional) . . . . . . . . . . . . . . . 3-86

Installation - Gas Piping and Exhaust Flue . . . . . . . . . . . . . . . . 3-87

Typical gas line installation drawing . . . . . . . . . . . . . . . . . . . . . . . 3-88

Installing the Conair GasTrac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89

Connecting the gas and the exhaust flue to the GasTrac. . . . . . . . 3-92

Installation - Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95

Checking for proper air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

Testing the variable frequency drive (VFD). . . . . . . . . . . . . . . . . . . 3-99

Testing the installation of the HTC. . . . . . . . . . . . . . . . . . . . . . . . 3-100

Checking the gas and electrical systems of the GasTrac . . . . . . . 3-102

Testing the installation of the GasTrac. . . . . . . . . . . . . . . . . . . . . 3-103

Testing the primary receiver (optional) . . . . . . . . . . . . . . . . . . . . 3-105

Testing the secondary receiver (optional) . . . . . . . . . . . . . . . . . . 3-107

Configuring the Dwyer 641 air velocity transmitter . . . . . . . . . . . 3-109

Configuring the DM-II drying monitor . . . . . . . . . . . . . . . . . . . . . 3-110

Configuring the level switch (optional). . . . . . . . . . . . . . . . . . . . . 3-110

Using communications (optional). . . . . . . . . . . . . . . . . . . . . . . . . 3-113

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4-1 Op era tio n

The EnergySmart Dryer System control panel . . . . . . . . . . . . . . . . . 4-2

How to navigate the control screens . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Control function flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Operation flow chart 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Operation flow chart 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Operation flow chart 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Setup flow chart 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Equipment setup flow chart 1 . . . . . . . . . . . . . . . . . . . . . . . 4-11

Equipment setup flow chart 2 . . . . . . . . . . . . . . . . . . . . . . . 4-12

Communications setup flow chart . . . . . . . . . . . . . . . . . . . . 4-13

Example setpoint change . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Control function descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

EnergySmart Dryer System security levels . . . . . . . . . . . . . . . . . . 4-54

EnergySmart Dryer System Modbus communications . . . . . . . . . . 4-56

Starting the EnergySmart Dryer System

(Without OptiMizer™ mode) . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Adjusting the EnergySmart Dryer System

(Without OptiMizer™ mode) . . . . . . . . . . . . . . . . . . . . . . . . 4-62

Starting the EnergySmart Dryer System

(With OptiMizer™ mode). . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

Stopping the EnergySmart Dryer System. . . . . . . . . . . . . . . . . . . . 4-71

Using dryer recipes (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74

Copying files from the EnergySmart Dryer System . . . . . . . . . . . . 4-80

Using Dewpoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

Using OptiMizer™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85

Ta bl e of Con te n ts l v

5-1 Main ten anc e

Preventative maintenance checklist . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Inspecting the hoses, piping and gaskets . . . . . . . . . . . . . . . . . . . . 5-8

Cleaning the CH hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Maintaining the Dwyer 641 air velocity transmitter . . . . . . . . . . . . 5-10

Cleaning the combustion filter of the GasTrac . . . . . . . . . . . . . . . . 5-11

Cleaning the electrical enclosure filter of the GasTrac. . . . . . . . . . 5-12

Replacing the spark igniter of the GasTrac . . . . . . . . . . . . . . . . . . 5-13

Cleaning the ultraviolet flame detector of the GasTrac. . . . . . . . . . 5-15

Cleaning the process filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Cleaning the regeneration filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Cleaning the aftercooler/intercooler coils. . . . . . . . . . . . . . . . . . . . 5-19

Cleaning the volatile trap on the demister

(W600-1000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Cleaning the volatile trap on the demister

(W1600-5000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Cleaning the precooler coils (optional). . . . . . . . . . . . . . . . . . . . . . 5-23

Replacing the regeneration heater

(W600-1000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

(W1600-2400). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

(W3200-5000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Checking dew point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

Cleaning the dust collector (optional). . . . . . . . . . . . . . . . . . . . . . . 5-32

Cleaning the cyclone separator (optional) . . . . . . . . . . . . . . . . . . . 5-32

6-1 Troub les hoo tin g

Before beginning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

vi l Ta bl e of Co n te nt s

DIAGNOSTICS

How to identify the cause of a problem . . . . . . . . . . . . . . . . . . . . . 6-4

Shutdown alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Passive alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Dew point troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Poor material drying troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 6-29

REPAIR

Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

Checking heater solid state relays. . . . . . . . . . . . . . . . . . . . . . . . . 6-35

Checking or replacing temperature sensors . . . . . . . . . . . . . . . . . 6-36

Replacing the desiccant wheel assembly (W600-1000). . . . . . . . . 6-37

Replacing the desiccant wheel motor (W600-1000) . . . . . . . . . . . 6-39

Replacing the desiccant wheel motor (W600-1000) . . . . . . . . . . . 6-40

A Ap pen dix

We’re here to help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

How to contact customer service . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Before you call... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Equipment guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Performance warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Warranty limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Conair print numbers list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

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vi i i l Ta bl e of C on te nt s

Introduction

Purpos e of the user guide . . . . . . . . . . . . . . 1- 2

How the guide is o rganiz e d . . . . . . . . . . . . . 1 - 2

Using the Energ y S mart Dry e r

with your system . . . . . . . . . . . . . . . . . 1- 3

Yo u r r e s ponsib i l i ties as a us e r . . . . . . . . . . . 1-3

ATTENT I O N:

Read this so n o o n e ge t s hu r t . . . . . . . . 1-4

How to u se t h e l o c kout device . . . . . . . . . . . 1-6

S E C T I O N

In t ro du ct io n l 1 -1

In t rod u ctio n

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Purpose of the User Guide

This User Guide describes the Conair EnergySmart®Dryer System with TouchViewTMTechnology 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 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.

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1- 2 l Int ro d uc ti on

In t ro du ct io n l 1 -3

Using the EnergySmart Dryer with Your System

The Conair EnergySmart®Dryer with TouchViewTMTechnology used within your system is factory configured to be used as a central dryer only. Therefore, this manual incorporates the information necessary to use these dryers for central drying applications.

Your Responsibility as a User

You must be familiar with all safety procedures concerning installation, operation 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.

In t rod u ctio n

NOTE: Dryers can be used for various applications.

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1- 4 l Int ro d uc ti on

ATTENTION: Read this so no one gets h urt

We design equipment with the user’s safety in mind. You can avoid the potential hazards identified within this system by following the procedures outlined below and elsewhere in the User Guide.

WA RNING: Impro p e r i n s tallati o n , operat i o n o r serv i c ing m ay r e sult in e quipmen t dam a g e o r persona l inj u r y.

This equipment should be installed, adjusted and serviced by qualified technicians who are familiar with the construction, operation and potential hazards of this type of machinery.

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 equipment at power levels other than what is specified on the machine serial tag and data plate.

WA RNING: Vo ltage hazard

This equipment is powered by three-phase alternating current, as specified on the equipment’s serial tags and data plates. Reference optional additional equipment’s manuals for their power requirements.

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)

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In t ro du ct io n l 1 -5

ATTENTION: Read this so no one gets h urt

(c on ti nu ed )

We design equipment with the user’s safety in mind. You can avoid the potential hazards identified within this system by following the procedures outlined below and elsewhere in the User Guide.

CA UTION: 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 exhaust outlet and the Hopper Temperature Controller (HTC) or GasTrac Dryer (CGT).

WA RNING: Do not p lace aerosol , c o mpresse d gas o r f l a mmable mater i als o n o r nea r thi s equipme n t .

The hot temperatures associated with the drying process may cause aerosols or other flammable materials placed on the dryer or hopper to explode.

1- 6 l Int ro d uc ti on

How to Use the Lockout Device

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 product 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:

Stop or turn off the equipment.

Isolate the equipment from the electric power. Turn the rotary disconnect switch to the OFF, or “O” position.

Secure the device with an assigned lock or tag. Insert a lock or tag

in the holes to prevent movement.

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, turn the rotary disconnect back to the ON position:

Remove the lock or tag.

Turn the rotary disconnect switch to the ON or “I” position.

O OFF

De s cr ip ti on l 2- 1

Description

What is the E nergy S m art D rye r Sys t e m ? . . . . 2-2

Typica l a p p l icat i o n s . . . . . . . . . . . . . . . . . . 2- 2

How the Energ y S mart Drye r Sy s t e m w o r ks . . . 2-3 Specif i c a tion s : E n ergyS m a rt C a rousel

Plus W Series Dehu m i d ifying Dr y ers . . . . 2-4

Hopper Temp e r a ture Cont r o l ler ( HTC) . . . 2-5

GasTrac (CGT) Proce s s A ir H e ater . . . . . . 2-6

Dust Collec t o r s . . . . . . . . . . . . . . . . . . 2- 7

Po sitive Displ a c ement (PD) Pumps . . . . . 2-8

CH S e ries Insula t ed H o ppers . . . . . . . . . 2 - 9

Dry i n g M o n i tor, DM-II Mode l . . . . . . . . 2-1 2

Energ y S mart Dry e r co n t r ol o p tions . . . . 2-13

S E C T I O N

De s cri p tion

2- 2 l Des cr i pt io n

What is the EnergySmart®Dryer System?

Energy efficient drying and superior end product are the results of having precise control of your drying process. The EnergySmart Dryer System control allows you to optimize your system settings to achieve consistent drying results that boost your plant-wide efficiency and produce high quality final product. An OptiMizer™ Mode automatically adjusts the air flow and temperature of your process for maximum system efficiency.

The EnergySmart Dryer System could include:

• EnergySmart Dryer with TouchViewTMTechnology (Allen-Bradley control)

• CH Hopper with an integrated cyclone - optional

• Heater (gas or electric)

• Dust collector(s) - optional

• Patented DM-II drying monitor technology

• Receiver(s) - optional

• Vacuum pump(s) - optional

• Audible alarm

Typical Applications

1 Dryer on the floor, a single CH Hopper with a Hopper Temperature Controller

(HTC) or GasTrac Dryer (CGT) package on a floor stand.

The EnergySmart Dryer System can be used successfully in applications that require:

• A contamination-free drying environment

• A constant flow of dehumidified air

• Throughput rates of 400 to 5,000 lbs {181 to 2,268 kg} per hour (some

materials can be run at higher rates).

• Dew points of -40°F {-40°C}.

NOTE: The EnergySmart

W600 - 5000 dryer provides no heat to the process air. A separate heat source is required at the hopper inlet to heat the air to the required drying temperature.

✐

De s cr ip ti on l 2- 3

De s cri p tion

How the EnergySmart Dr yer System Works

The drying circuit is a traditional desiccant drying system. The dryer supplies low dew point air that has passed through a heater (HTC or GasTrac) into the bottom of a CH Hopper. The air moves up through the hopper picking up moisture from the material as it transfers its heat into the material. Once the air is at the top of the hopper, it returns to the dryer after passing through optional filtration to remove fines. Once in the dryer, the air is cooled by passing through a cooling coil to lower the temperature so that the air can be dried as it passes through the desiccant where the moisture is absorbed.

Specifications: EnergySmart Carousel Plus W Series Dehumidifying Dryers

2- 4 l Des cr i pt io n

TPDX019-0712

SPECIFICATION NOTES:

Dryers W600-W5000 that are central dryers do not have process heaters. Hopper Temperature Controllers (HTC’s) or GasTrac Dryers (CGT’s) are used at the hopper for heating the process air. See the Hopper Temperature Controller (HTC) and GasTrac Dryer (CGT) specification sheets for further technical information.

†

Total amps listed apply to dryer only, see the Hopper Temperature Controller (HTC) or GasTrac (CGT) specification sheets for additional power requirements.

‡

Dryers running at 50 Hz will have 17% less airflow, and a 17% reduction in material throughput.

Total kW listed at a regeneration temperature of 350°F {177°C}. The total kW listed reflects the kW of the dryer only. It does not include any external heat source, for example the Hopper Temperature Controller (HTC) or Gastrac Dryer (CGT).

** 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.

‡‡

Not available in Allen Bradley models.

Specifications may change without notice. Consult a Conair sales representative for the most current information.

APPLICATION NOTES:

All dryers are supplied with an aftercooler/intercooler as standard. The aftercooler/intercooler reduces the temperature of the return air from the drying hopper, improving the efficiency of the desiccant. The aftercooler/intercooler must be connected with the proper water flow rate and temperature to attain the rated throughput.

When to use central models

Models W600 - W5000 of Carousel Plus dryers are all configured as central dryers. Central dryers do not have process heaters. These models should be used when drying multiple materials that require different drying temperatures. Central models dehumidify the process air, which is then heated to the correct setpoint by a Hopper Temperature Controller (HTC) or GasTrac Dryer (CGT).

When to use additional filtration

The standard return air cartridge filter is sized for the airflow of each dryer model and is suited for most applications. You should consider adding an optional dust collector and/or volatile trap if:

●

The material contains excessive fines. An additional dust collector or cyclone will extend time between filter

cleaning.

●

The material produces volatiles during drying which condense into a waxy or oily residue. A volatile trap will

help to protect the desiccant.

MODELS W600

W800

W1000

W1300

W1600

W2000

W2400

W3200

W4000

W5000

Performance characteristics (with full hopper)

Drying temperature All models 100°- 375°F {38°- 191°C} with options Dew point All models -40°F {-40°C}

Dimensions inches {cm}

A - Height 93.8 {238.3} 92.2 {134.2} 98.3 {249.7} B - Width 49.3 {125.2} 53.9 {136.9} 58.2 {147.8} C - Depth 72.4 {183.9} 106.6 {270.8} 123.6 {313.9} Outlet/inlet hose diameter 8.0 {20.3} 12.0 {30.5} 12.0 {30.5}

Approximate weight lbs {kg}

Installed 1300 {590} 1300 {590} 1400 {636} 1600 {726} 2000 {907} Shipping 1495 {678} 1495 {678} 1515 {687} 2620 {1188} 3385 {1535}

Voltage -

Standard/Central

Full load amps

†

400 V/3 phase/50 Hz

‡

89.2 / 34.3 89.2 / 34.3 116.6 / 34.2 152.7 / 42.9 159.4 / 49.6 194.1 / 56.8 221.7 / 57.0 282.7 / 90.5 317.0 / 97.7 371.9 / 97.4 460 V/3 phase/60 Hz 77.6 / 29.8 77.6 / 29.8 101.5 / 29.8 133.4 / 37.8 138.6 / 43.0 168.9 / 49.4 192.8 / 49.4 247.3 / 80.0 275.9 / 84.7 323.7 / 84.7 575 V/3 phase/60 Hz 62.1 / 23.9 62.1 / 23.9 81.1 / 23.8 106.6 / 30.2 110.8 / 34.4 135.1 /39.6 154.2 / 39.6 197.7 / 64.0 220.6 / 67.8 258.7 / 67.7 380 V/3 phase/60 Hz

‡‡

93.9 / 36.1 93.9 / 36.1 122.7 / 36.0 160.7 / 45.2 167.8 / 52.2 204.3 / 59.8 233.4 / 60.0 297.6 / 95.3 333.7 / 102.8 391.5 / 102.5

Total kilowatts§kW {BTU/min} 53 {3017} / 53 {3017} / 72 {4098} / 95 {5407} / 95 {5407} / 114 {6489} / 133 {7570} / 152 {8652} / 190 {10809} / 228 {12972} /

15 {854} 15 {854} 15 {584} 19 {1081} 19 {1081} 19 {1081} 19 {1081} 38 {2157} 38 {2157} 38 {2157}

Water requirements {for aftercooler/intercooler or optional precooler}

Recommended temperature

††

45°- 85°F {7° - 29°C} 45°- 85°F {7° - 29°C} 45°- 85°F {7° - 29°C} Water flow gal./min. {liters/min.} 6 - 25 {22.7 - 94.6} 12 - 40 {45.4 - 151.4} 15 - 50 {56.8 - 189.3} Water connections NPT 1 1/2 inch NPT 1 1/2 inch NPT 1 1/2 inch NPT

Specifications: Hopper Temper ature Controller (HTC)

MODEL HTC HTC-30H* HTC-60H* HTC-90H* HTC-120H* HTC-180H* HTC-270H*

Carousel Plus dryer model W600 W800 W1000 W1600 W2400 W3200 W5000 Performance characteristics

Temperature range 150° - 375° F {66° - 191° C} Flow rate cfm 300 400 500 800 1200 1600 2500 Pressure drop@flow rate inches WC

†

3.0 1.8 2.3 4.0 3.8 5.9 6.4

{mm} WC

†

{76.2} {45.7} {58.4} {101.6} {96.5} {149.9} {162.6}

Dimensions inches {cm} and weight lb {kg} Heater box dimensions

Inlet size (OD) 8812 12 12 12 Outlet size selection (OD) 8812 12 12 12 A - Height 31.4 {79.8} 27.5 {69.9} 27.0 {68.6} 31.0 {78.7} 34.0 {86.4} 36.4 {92.5} B - Width 10.1 {25.7} 13.6 {34.5} 16.0 {40.6} 16.0 {40.6} 18.0 {45.7} 24.2 {61.5} C - Depth 10.7 {27.2} 10.9 {27.7} 10.9 {27.7} 16.0 {40.6} 17.0 {43.2} 17.0 {43.2} D - Height of discharge 1.75 1.5 2.0 1.0 2.0 1.0

nozzle above the heater box {4.4} {3.8} {5.1} {2.5} {5.1} {2.5} E - Height of inlet nozzle 10.6 7.1 8.0 10.0 13.0 15.4 below the heater box {26.9} {18.0} {20.3} {25.4} {33.0} {39.1} Installed weight lb {kg}

‡

38 {17} 37 {17} 78 {35} 93 {43} 102 {46} 131 {59}

Control center dimensions

Height - F 24.0 {61.0} 24.0 {61.0} 36.0 {91.4} 48.0 {122.0} 60.0 {152.4} 60.0 {152.4} Width - G 24.0 {61.0} 24.0 {61.0} 30.0 {76.2} 36.0 {91.4} 42.0 {106.7} 42.0 {106.7} Depth - H 10.0 {25.4} 10.0 {25.4} 10.0 {25.4} 10.0 {25.4} 12.0 {30.5} 12.0 {30.5} Clearance for heat sink - I 3.0 {7.6} 3.0 {7.6} 3.0 {7.6} 3.0 {7.6} 3.0 {7.6} 3.0 {7.6} Installed weight lb {kg} 150.0 {68.0} 150.0 {68.0} 180.0 {81.6} 250.0 {113.0} consult Conair consult Conair

Voltage full load amps

400 V/3 phase/50-60 Hz 44 87 131 175 261 381 480 V/3 phase/50-60 Hz 38 76 114 152 227 340 575 V/3 phase/50-60 Hz 30 61 91 122 182 272

SPECIFICATION NOTES:

* The HTC model number reflects the kilowatts of each unit. For example, HTC-60 has a 60 kilowatt heater. † The unit of measure WC is water column. ‡

Weights are approximate.

Specifications may change without notice. Consult a Conair representative for the most current information.

TPDS022-0808

De s cr ip ti on l 2- 5

De s cri p tion

MODELS CGT150 CGT250 CGT350 CGT500 CGT700

Performance characteristics

Temperature range ºF {ºC} 250 - 350 {122 - 177} Maximum flue temperature ºF {ºC} 750 {399} Combustion blower 0.5 Hp peripheral 0.5 Hp peripheral 1 Hp peripheral 1 Hp peripheral 1 Hp peripheral

Ignition source Spark igniter, interrupted

Burner type Metal-ceramic Minimum burner capacity BTU/hr 40,000 75,000 90,000 125,000 150,000

Maximum burner capacity BTU/hr 150,000 225,000 350,000 500,000 700,000

Gas consumption*

CFH @250ºF {L/hour} 50 {1416} 90 {2549} 105 {2973} 150 {4248} 230 {6513}

CFH @350ºF {L/hour} 140 {3964} 215 {6088} 325 {9203} 465 {13167} 675 {19114} Gas pressure to regulator In. H2O {kPa} 10 - 20 {2.49 - 4.98} Gas pressure from regulator In. H2O {kPa} 4 - 7 {0.99 - 1.74} Gas heating rate BTU/ft

1000

Dimensions in. {mm}

A - Height 54 {1372} 61{1549} 61 {1549} 61 {1549} 61 {1549} B - Width 29 {737} 37 {940} 37 {940} 37 {940} 37 {940} C - Length 66 {1676} 64 {1626} 74 {1880} 74 {1880} 74 {1880} Air inlet/outlet, OD 8 {203} 8 {203} 8 {203} 8 {203} 12 {300}

Approximate weight lb {kg}

Installed 600 {272} 600 {272} 600 {272} 600 {272} 600 {272} Shipping 700 {317} 700 {317} 700 {317} 700 {317} 600 {272}

Voltage Total amps

380V/3 phase/50Hz 3.0 3.0 1.6 1.3 3.0 415V/3 phase/50Hz 3.0 2.7 1.5 1.2 3.0 240V/3 phase/60Hz 3.0 4.8 2.5 2.0 3.0 480V/3 phase/60Hz 3.0 2.4 1.3 1.0 3.0

Emissions

<10 ppm corrected to 3% O

<20 ppm corrected to 3% O

<10 ppm corrected to 3% O

Carbon Monoxide (CO) NOX Unburned hydrocarbons

10 - 30%

2 - 5%

9 - 10.5%

Primary excess air Oxygen (O2) (ideal 3 - 4%) Carbon Dioxide (CO

All GasTrac components meet:

UL372, UL795, FM, CGA, AGA, NFPA 54, NFPA 79, NFPA 86 and IAS

Specifications: GasTrac (CGT) Process Air Heater

SPECIFICATION NOTES:

*Designed for natural gas. For alternate fuel, contact your Conair representative.

Specifications may change without notice. Consult a Conair representative for the most current information.

2- 6 l Des cr i pt io n

TPDS009-0408

MODELS 18087803 18087801 Uninsulated or Insulated Uninsulated Insulated Dimensions inches {cm}

A - Height 96.5 {245} 96.5 {245} B - Height to centerline 81.3 {207} 81.3 {207} C - Clearance below canister 41.0 {104} 41.0 {104} D - Depth 53.1 {135} 43.9 {112} E - Width 42.2 {107} 42.2 {107} Air inlet/outlet 8 12

Weight lb {kg}

Installed 150 {68} 160 {73} Shipping 180 {82} 190 {86}

SPECIFICATION NOTES:

Specifications can change without

notice. Check with a Conair representative for the most current information.

Specifications: Dust Collectors

Air outlet

Air inlet

De s cr ip ti on l 2- 7

De s cri p tion

MODELS DC1 DC2 Performance Characteristics

Pump size range Hp {kW} * 3-7.5 {2.2-5.6} 10-25 {7.5-18.7} Vacuum line size OD in {mm} 1.5-2.5 {38.1-63.5} 2.25-4.0 {57.2-101.6} Filter area ft2{M2} 42.8 {4.0} 100.3 {9.3} Maximum collection capacity ft3{liters} 1.1 {31.1} 2.1{59.4} Recommended dust collection ft3{liters} 0.75 {21.2} 1.0 {28.3}

Dimensions inches {cm}

A - Height 58.0 {147.3} 67.0 {170.1} B - Width 15.0 {38.1} 19.0 {48.3}

Depth 20.0 {50.8} 19.0 {48.3}

Weight lb {kg}

Installed 110 {50} 150 {68} Shipping 140 {64} 280 {127} Voltage total amps 120V/1 phase/60Hz 1.0 1.0

Compressed air requirement

80-120 psi {5.5-8.3 bars}

SPECIFICATION NOTES:

* Model DC1 works with Conair pump models PSS3, PSS6, PD3, PD5, PD7.5.

Model DC2 works with PSS11, PD10, PD15, PD25.

Specifications can change without notice. Check with a Conair representative for the most current information.

out

Model DC1 and DC2

TPCS012-0408

MODELS PD3 PD5 PD7.5 PD10 PD15 PD25 Motor Type* TEFC TEFC TEFC TEFC TEFC TEFC

Performance

Horsepower 357.5 10 15 25 Standard CFM at Material Pickup Point @ 10" Hg 52.6 76.6 121.2 154.5 201.1 346.2 Average Sound Level (dbA) @ 8", 10" and 12" Hg 86 86.3 86 85.8 88.8 93

Dimensions in. {mm}

Standard Inlet Size (OD) 1.5 {38} 1.75 {44} 2.25 {57} 2.5 {64} 3.0 {76} 4.0 {102} Exhaust Line Size (OD) 2.5 {64} 2.5 {64} 2.5 {64} 4.0 {102} 4.0 {102} 4.0 {102} Height (H) 37 {940} 37 {940} 41 {1041} 51 {1295} 51 {1295} 52 {1321} Width (W) 35 {889} 35 {889} 35 {889} 39.5 {1003} 39.5 {1003} 39.5 {1003} Depth (D) 27 {686} 27 {686} 27 {686} 33 {838} 33 {838} 34 {864} Installed Weight / lb {kg} 325 {147} 325 {147} 370 {168} 625 {283} 640 {290} 960 {435} Voltage Total Amps 240 7.6 12 18.8 28 39 59 480 3.8 6 9.4 14 19.5 29.5 575 2.9 4.8 7.5 10.7 16 27

* Energy-saving, high efficiency motors

are also available.

Specifications: Positive Di splacement (PD) Pumps

MODELS PD3 PD5 PD7.5 PD10 PD15 PD25 SUPER (ANY MODEL) Performance

Average Sound Level (dbA) @ 8", 10" and 12" Hg

61.9 69.8 76.2 79.3 86.0 90.0 Under 60 dbA

Enclosure Construction Painted Steel Natural Aluminum Painted Steel Allowance Space for Service Access / in

48 (Opposite Vacuum Inlet) 36 (Opposite Vacuum Inlet) 36 (Front, Next to Filter)

Dimensions in. {mm}

Height (H) 49 {1245} 64 {1626} 96 {2438} Width (W) 54 {1372} 55 {1397} 70 {1778} Depth (D) 32 {813} 36 {914} 50 {1270}

SPECIFICATIONS FOR PUMPS WITH SOUND ENCLOSURES

Specifications not listed below are the same as those listed above. All Sound Enclosures include a cooling fan 115 VAC @ 2 amps.

SPECIFICATION NOTES:

Specifications can change with-

out notice. Check with a Conair representative for the most current information.

2- 8 l Des cr i pt io n

TPCS026-0408

Specifications: CH Series Insulated Hoppers

Without Integrated Cyclone (Fig. 1)

With Integrated Cyclone (Fig. 2)

De s cr ip ti on l 2- 9

De s cri p tion

TPDS006-0408 REV

Specifications: CH Series Insulated Hoppers

MODEL CH54-70 CH54-85 CH54-99 CH54-114 CH54-129 CH64-158 CH64-187 CH64-215 CH64-248 FIGURE NUMBER Fig. 1 Fig. 1 Fig. 1 Fig. 1 Fig. 1 Fig. 1 Fig. 1 Fig. 1 Fig. 1 Performance characteristics

Capacity ft3{liter} 70 {1982} 85 {2407} 99 {2804} 114 {3228} 129 {3653} 158 {4475} 187 {5296} 215 {6089} 248 {7023} Capacity @ 35 lb/ft

2450 2975 3465 3990 4515 5530 6545 7525 8680

Dimensions inches {cm}

A - Inside diameter 54 {137} 54 {137} 54 {137} 54 {137} 54 {137} 64 {163} 64 {162} 64 {162} 64 {163} B - Hopper height 101.3 {257}120.1 {305} 132.1 {336} 138.1 {351} 150.1{381} 144.6

{367}

158.6 {403} 174.6 {443} 192.6 {489} C - Overall height 136.8 {347}154.8 {393} 166.8 {424} 170.8 {434} 182.8 {464} 177.9 {452} 189.9 {482} 207.9 {528} 225.9 {574} D - Width 69.4 {176} 69.4 {176} 69.4 {176} 69.4 {176} 69.4 {176} 76.0 {193} 76.0 {193} 76.0 {193} 76.0 {193} E - Depth 69.4 {176} 69.4 {176} 69.4 {176} 69.4 {176} 69.4 {176} 76.0 {193} 76.0 {193} 76.0 {193} 76.0 {193} Air inlet (OD) 8 {20.3} 8 {20.3} Air outlet (OD) 8 {20.3} 8 {20.3} Material discharge (ID) 6 {15.2} 6 {15.2}

Weights lb {kg}

Installed weight (hopper only) 1100 {499}1250 {567} 1450 {658} 1550 {703} 1650 {748} 1850 {839} 2050 {930} 2150 {975} 2250 {1021}

Mounting interfaces

Hopper loader (Top) IT07 IT07 IT07 IT07 IT07 IT07 IT07 IT07 IT07 Material discharge (Bottom) IB03 IB09 IB09 IB09 IB09 IB09 IB09 IB09 IB09

MODEL CH74-245 CH74-366 CH74-487 CH100-450 CH100-675 CH100-900 FIGURE NUMBER Fig. 1 Fig. 1 Fig. 1 Fig. 1 Fig. 1 Fig. 1 Performance characteristics

Capacity ft3{liter} 245 {6938} 366 {10365} 487 {13792} 450 {12743} 675 {19114} 900 {25485} Capacity @ 35 lb/ft

8575 12810 17045 15750 23625 31500

Dimensions inches {cm}

A - Inside diameter 74 {188} 74 {188} 74 {188} 100 {254} 100 {254} 100 {254} B - Hopper height 170.2 {432} 218.2 {554} 266.2 {676} 199 {505} 249 {632} 297 {754} C - Overall height 193.7 {492} 241.7 {614} 289.7 {736} 219 {556} 269 {683} 317 {805} D - Width 90.5 {229.9} 90.5 {229.9} 90.5 {229.9} 120.0 {305} 120.0 {305} 120.0 {305} E - Depth 90.5 {229.9} 90.5 {229.9} 90.5 {229.9} 120.0 {305} 120.0 {305} 120.0 {305} Air inlet (OD) 12 {30.5} 12 {30.5} Air outlet (OD) 12 {30.5} 12 {30.5} Material discharge (ID) 8 {20.3} 11.875 {30.2}

Approximate weight lb {kg}

Installed weight (hopper only) 3230 {1465} 3830 {1737} 5030 {2282} 9750 {4423} 10800 {4899} 11850 {5375}

Mounting interfaces

Hopper loader (Top) IT07 IT07 IT07 IT07 IT07 IT07 Material discharge (Bottom) IB09 IB09 IB09 IB09 IB09 IB09

Without Integrated Cyclone

SPECIFICATION NOTES:

Specifications can change without notice. Check with a Conair representative for the most current information.

IT07

4 equally spaced mounting clips on a

16.375 in. {416 mm} diameter bolt circle

IB09

16 bolt holes, 7/16 in. {11 mm}, on a 16.25 in. {413 mm} square plate

Top for hopper loaders

Bottom at discharge

2- 1 0 l D es cr ip t io n

TPDS006-0408 REV

With Integrated Cyclone

Specifications: CH Series Insulated Hoppers

SPECIFICATION NOTES:

Specifications can change without notice. Check with a Conair representative for the most current information.

IT07

4 equally spaced mounting clips on a

16.375 in. {416 mm} diameter bolt circle

IB09

16 bolt holes, 7/16 in. {11 mm}, on a 16.25 in. {413 mm} square plate

Top for hopper loaders

Bottom at discharge

MODEL CH54-70 CH54-85 CH54-99 CH54-114 CH54-129 CH64-158 CH64-187 CH64-215 CH64-248 FIGURE NUMBER Fig. 2 Fig. 2 Fig. 2 Fig. 2 Fig. 2 Fig. 2 Fig. 2 Fig. 2 Fig. 2 Performance characteristics

apacity ft3{liter} 70 {1982} 85 {2407} 99 {2804} 114 {3228} 129 {3653} 158 {4475} 187 {5296} 215 {6089} 248 {7023}

Capacity @ 35 lb/ft

2450 2975 3465 3990 4515 5530 6545 7525 8680

imensions inches {cm}

A - Inside diameter 54 {137} 54 {137} 54 {137} 54 {137} 54 {137} 64 {163} 64 {162} 64 {162} 64 {163} B

- Hopper height 101.3 {257}120.1 {305} 132.1 {336} 138.1 {351} 150.1{381} 144.6

{367}

158.6 {403} 174.6 {443} 192.6 {489}

- Overall height 140.6 {357}157.6 {400} 169.6 {431} 175.6 {446} 187.6 {477} 182.4 {463} 194.4 {494} 212.4 {539} 230.4 {585} D - Width 96.4 {245} 96.4 {245} 96.4 {245} 96.4 {245} 96.4 {245} 101.8 {259} 101.8 {259} 101.8 {259} 101.8 {259} E - Depth 96.4 {245} 96.4 {245} 96.4 {245} 96.4 {245} 96.4 {245} 101.8 {259} 101.8 {259} 101.8 {259} 101.8 {259} Air inlet (OD) 8 {20.3} 8 {20.3} Air outlet (OD) 8 {20.3} 8 {20.3} Material discharge (ID) 6 {15.2} 6 {15.2}

Approximate weight lb {kg}

Installed weight

(hopper and cyclone) 1650 {748}1800 {816} 2000 {907} 2100 {953} 2200 {998} 2400 {1089} 2600 {1179} 2700 {1225} 2800 {1270}

Mounting interfaces

Hopper loader (Top) IT07 IT07 IT07 IT07 IT07 IT07 IT07 IT07 IT07 Material discharge (Bottom) IB03 IB09 IB09 IB09 IB09 IB09 IB09 IB09 IB09

MODEL CH74-245 CH74-366 CH74-487 FIGURE NUMBER Fig. 2 Fig. 2 Fig. 2 Performance characteristics

Capacity ft3{liter} 245 {6938} 366 {10365} 487 {13792} Capacity @ 35 lb/ft

8575 12810 17045

Dimensions inches {cm}

A - Inside diameter 74 {188} 74 {188} 74 {188} B - Hopper height 170.2 {432} 218.2 {554} 266.2 {676} C - Overall height 263.5 {669} 311.5 {791} 479.5 {1218} D - Width 118.6 {301} 118.6 {301} 118.6 {301} E - Depth 118.6 {301} 118.6 {301} 118.6 {301} Air inlet (OD) 12 {30.5} Air outlet (OD) 12 {30.5} Material discharge (ID) 8 {20.3}

Approximate weight lb {kg}

Installed weight (hopper and cyclone) 3780 {1715} 4380 {1987} 5580 {2531}

Mounting interfaces

Hopper loader (Top) IT07 IT07 IT07 Material discharge (Bottom) IB09 IB09 IB09

De s cr ip ti on l 2- 11

De s cri p tion

TPDS006-0408 REV

Angled Probe

Allows the DM-II to be used on hoppers that have insufficient clearance for correctly mounting the probe around loading devices.

Probe Mounting Adapter Kit

(Includes half coupling, two mounting plates, screws and gasket)

NOTE: The mounting adapter

kit will only be included if the DM-II was ordered as a retrofit kit. Otherwise, the adapter plate will already be in place on the hopper.

The DM-II package includes:

●

Drying monitoring probe

●

Connecting cable

●

Pre-wired dryer panel

●

Light tower

Specifications: Dr ying Monitor, DM-II Model

✐

SPECIFICATION NOTES:

Specifications can change without notice. Check with a Conair representative for the most current information.

Drying Hopper # Conair Part #

CH 54-70 1819080140

CH 54-85 1819080141

CH 54-99 1819080142

CH 54-114 1819080123

CH 54-129 1819080143

CH 64-158 1819080125

CH 64-187 1819080126

CH 64-215 1819080127

CH 64-248 1819080144

CH 74-245 1819080126

CH 74-366 1819080145

CH 100-450 1819080132

CH 100-675 1819080133

CH 100-900 1819080134

2- 1 2 l D es cr ip t io n

Energ ySmart Dryer Control Options

• Visual alarms - The visual alarm is a blinking red alarm light that alerts the user to

any shut down alarm.

• Trending screens - The trending screens display temperature, air flow, dew point and

differential pressure of the EnergySmart Dryer System. Each can be used to graph

real-time data of a running dryer system.

• Recipe storage screen - The recipe storage screen is used to store and instantly recall

specific dryer parameters that are used with different types of material. Up to 99 dryer

recipes can be saved within the control.

• Loading control screens - Dedicated screens control the function and activation of up

to two (2) optional receivers. Loading, dump and purge times can be individually

altered for each receiver.

• Communications - Allows the dryer to be networked to industrial control systems.

De s cr ip ti on l 2- 13

De s cri p tion

2- 1 4 l D es cr ip t io n

In s ta ll at io n l 3 -1

Installation

Ins t a l l a tion - G e n e r a l . . . . . . . . . . . . . . . . . . . . . 3-5

Unpacking the EnergySmart™ Dryer System

components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . 3-7

Positioning the CH hopper floor stand . . . . . . . . . . . . . . 3-8

Installation of the HTC control

(Models HTC 30, 60 and 90) . . . . . . . . . . . . . . . . . 3-9

(Models HTC 120) . . . . . . . . . . . . . . . . . . . . . . . . 3-10

(Models HTC 180 and 270) . . . . . . . . . . . . . . . . . 3-10

Location and mounting of the HTC heater assembly

(Models HTC 30, 60 and 90) . . . . . . . . . . . . . . . . 3-11

(Models HTC 120) . . . . . . . . . . . . . . . . . . . . . . . . 3-11

(Models HTC 180 and 270) . . . . . . . . . . . . . . . . . 3-11

Installing the CH hopper cone section . . . . . . . . . . . . . 3-12

Installing the CH hopper door, upper and lid sections . . 3-13

Installing the cyclone (optional) . . . . . . . . . . . . . . . . . . 3-17

Installing the drying monitor probe . . . . . . . . . . . . . . . 3-22

Installing the receiver(s) (optional). . . . . . . . . . . . . . . . 3-25

Installing the purge valve(s) (optional) . . . . . . . . . . . . . 3-25

Installing the modular distribution box(s) (optional) . . . . 3-25

Securing the CH hopper to the floor . . . . . . . . . . . . . . . 3-26

Location and mounting of the GasTrac heater . . . . . . . . 3-27

Location and mounting of the dust collector (optional). . 3-28 Location and mounting of the vacuum pump(s)

and dust collector(s) (optional) . . . . . . . . . . . . . . . 3-30

Po s i t ioning the d r y e r o n the floor . . . . . . . . . . . 3 - 3 1

Rem o v i n g t h e cab l e tie from the d esiccant

whe e l (W60 0 - 1 0 0 0 m o d e l s ) . . . . . . . . . . . . 3-3 1

S E C T I O N

In s tal l a tio n

Installation ( con t inu e d)

Ins t a l l i n g t h e r e g e n e r a t i on e x h aust c over . . . . . 3 -31

Ins t a l l i n g t h e r e t u r n a i r ada pte r . . . . . . . . . . . . 3- 3 2

Ins t a l l i n g t h e r e t u r n a i r inl e t and air outlet

ada pte r s (W16 0 0 - 5 0 0 0 m o d e l s) . . . . . . . . . 3-33

Ins t a l l i n g t h e o v e r h e a d p r o c ess a i r

duc t (W320 0 - 5 0 0 0 m o d e l s ) . . . . . . . . . . . . 3 - 3 4

Ins t a l l a tion - P i p i n g /Hoses . . . . . . . . . . . . . . . . . 3-35

Opt i o n a l h a r d pip i n g kit s . . . . . . . . . . . . . . . . . 3-36

Con n e c t i n g t h e h e a t sourc e s . . . . . . . . . . . . . . 3-37

Hop p e r tem p e r a t u r e c o n t r o ller ( H TC) a s

hea t source . . . . . . . . . . . . . . . . . . . 3-37

Gas Tr a c a s he a t source . . . . . . . . . . . . . . 3 - 3 8

Con n e c t i n g t h e d r yer to the h e a t s o u r c e . . . . . . 3 - 3 9

Con n e c t i n g t h e d u s t col l e c t o r ( o p t i onal) . . . . . . 3-40

Con n e c t i n g t h e c y clone separ a tor (opti o n a l ) . . . . 3 - 4 1

Ins t a l l i n g t h e D w y e r 6 4 1 air velocit y

tra n s m i t t er . . . . . . . . . . . . . . . . . . . . . . . 3 - 4 2

Ins t a l l i n g t h e l e v e l s wit c h (opt i o n a l ) . . . . . . . . . 3- 4 4

Adj u s t i n g t h e lev e l sens o r (opt i o n a l ) . . . . . . . . . 3-45

Ins t a l l i n g t h e p r o c e s s p r o t e ction RTD sensor . . . 3 - 4 6 Loc a ti o n of the process material temperature

pro b e (RT D ) . . . . . . . . . . . . . . . . . . . . . . 3 - 4 7

Ins t a l l i n g t h e G a s Trac RTD sensor . . . . . . . . . . 3 - 4 8

Ins t a l l i n g t h e r e t u r n a i r dew point line . . . . . . . 3 - 4 9

Ins t a l l a tion - M a i n Po wer C o nnections . . . . . . 3-51

Connecting main power to the dryer . . . . . . . . . . . . . . 3-52

Connecting main power to the HTC

(Models HTC 30, 60, 90 and 120) . . . . . . . . . . . . . 3-53

3- 2 l Ins ta l la ti on

Installation ( con t inu e d)

(Models HTC 180 and 270) . . . . . . . . . . . . . . . . . 3-54

Connecting main power to the GasTrac . . . . . . . . . . . . 3-56

Connecting main power to the vacuum pump(s)

(optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Connecting main power to the dust collector(s)

(optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Ins t a l l a tion - C o n v e y ing L i n es . . . . . . . . . . . . . . 3-59

Con n e c t i n g t h e c o n v e y i ng l i n es t o t h e

rec e i v e r ( s) ( o p t ional) . . . . . . . . . . . . . . . . 3-60

Con n e c t i n g t h e c o n v e y i ng l i n es t o t h e purg e

val v e s (op t i o n a l ) . . . . . . . . . . . . . . . . . . . 3 - 60

Con n e c t i n g t h e c o n v e y i ng l i n es t o t h e vacu u m

pum p ( s ) an d dust collect o r ( s ) ( o p t i o n al) . . . 3 - 61

Ins t a l l a tion - W ater L i nes . . . . . . . . . . . . . . . . . 3- 6 3

Typic a l water lines installa tio n drawing . . . . . . . 3-64

Con n e c t i n g t h e a f t e r c o oler/inter c o o l e r

and option a l prec o o l e r ( W 6 0 0 - 1 000) . . . . . . 3 - 6 5

Con n e c t i n g t h e a f t e r c o oler/inter c o o l e r

and option a l prec o o l e r ( W 1 6 0 0 - 5000) . . . . . 3-66

Ins t a l l a tion - C o n t r o l a n d Com m u n i c ations

Wir i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

Con n e c t i n g t h e H T C to the HTC c o ntroller . . . . . 3-68

Con n e c t i n g t h e R T D s e n s o rs ( H T C o n l y ) . . . . . . . 3 -70

Con n e c t i n g t h e G a s Trac RTD sensors . . . . . . . . . 3 - 7 2

Con n e c t i n g t h e d r ying monito r probe to

the dryer . . . . . . . . . . . . . . . . . . . . . . . . 3-73

Con n e c t i n g t h e r e c e i v e r t o t h e leve l

switch (optio n a l ) . . . . . . . . . . . . . . . . . . . 3 -74

In s ta ll at io n l 3 -3

In s tal l a tio n

3- 4 l Ins ta l la ti on

Installation ( con t inu e d)

Con n e c t i n g t h e E n e r g y S m a r t D r y e r con t r o l

to system compone n t s . . . . . . . . . . . . . . . 3 - 7 5

Ins t a l l a tion - C o m p r e ssed A ir L i n e s . . . . . . . . . . . 3-85

Con n e c t i n g t h e c o m p r e s sed a i r l i n e s

(op t i o n a l ) . . . . . . . . . . . . . . . . . . . . . . . . 3-86

Ins t a l l a tion - G a s Pipi n g and Exhaust Flue . . . . . . 3-87

Typic a l gas line installa tio n drawing . . . . . . . . . 3-88

Ins t a l l i n g t h e C o n a i r G a s Trac . . . . . . . . . . . . . . 3-89

Con n e c t i n g t h e g a s and the exhaust flue to

the GasTr a c . . . . . . . . . . . . . . . . . . . . . . 3 - 9 2

Ins t a l l a tion - Te s ting . . . . . . . . . . . . . . . . . . . . . 3 - 95

Che c k i n g f o r prop e r air flow . . . . . . . . . . . . . . 3-96

Te s t i ng t h e v a r i a b le f r e quency drive (VFD) . . . . . 3 - 9 9

Te s t i ng t h e i n s t a l la tion o f t h e H T C . . . . . . . . . 3- 1 00

Che c k i n g t h e gas and electrica l syste m s

of the GasTr a c . . . . . . . . . . . . . . . . . . . . 3 - 1 02

Te s t i ng t h e i n s t a l la tion o f t h e G a s Trac . . . . . . . 3-103

Te s t i ng t h e p r i m a r y rec e i v e r ( o p t i o n al) . . . . . . 3-1 0 5

Te s t i ng t h e s e c o n d ar y r e c e i v e r ( o p t ional) . . . . . 3 - 107

Con f i g u r i ng t h e D w y e r 6 4 1 air veloci t y

tra n s m i t t er . . . . . . . . . . . . . . . . . . . . . . 3-109

Con f i g u r i ng t h e D M - I I d r ying

mon i t o r . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 10

Con f i g u r i ng t h e l e v e l s wi t c h (op t i o n a l ) . . . . . . . 3-110

Usi n g comm u n i c a t i o n s ( o p t ional) . . . . . . . . . . 3 - 1 1 3

Installation - General

In s ta ll at io n - Ge ne ra l l 3 -5

In s tal l a tio n

Unpacking the EnergySmart™ Dryer System Components

Because of their size and shape and the multiple sizes in which the hopper is available, the components of the EnergySmart Dryer System come packaged for shipping in the best available manner. The EnergySmart System components include, depending on the model and options ordered:

! EnergySmart Dryer with TouchView Technology - Allen-Bradley control ! CH Hopper - with or without integrated cyclone - optional ! Heater (HTC or GasTrac) ! Dust Collector(s) - optional ! DM-II Drying Monitor ! Receiver(s) - up to two (2) - optional ! Vacuum pump - up to two (2) - optional ! Hard piping kit - optional

1 For the EnergySmart Dryer System components that are mounted to

pallets, remove the hardware securing each component to its pallet, then remove the component from the pallet. With a forklift, hoist or crane carefully move the components to their approximate installation locations.

2 Remove all packing material, protective paper, tape and plastic, including any

inserted inside the components.

3 Carefully inspect all components to ensure no damage occurred during ship-

ping, and that you have all the necessary hardware. If any damage is found, notify the shipping agent immediately.

4 Take a moment to record serial numbers and electrical power specifications

in the blanks provided on the back of the User Guide's title page. This information will be helpful if you ever need service or parts.

5 You are now ready to begin installation. Follow the preparation steps in the

next section.

6 Determine if your application is electric or gas. Disregard installation

steps for options not used.

3- 6 l Ins ta l la ti on - G en er al

NOTE: Some components may

be strapped to their shipping pallet, remove as necessary.

✐

In s tal l a tio n

In s ta ll at io n - Ge ne ra l l 3 -7

Preparing for Installation

The EnergySmart Dryer System is easy to install if you plan the location and prepare the installation area properly.

1 Make sure the installation area provides:

❒

Grounded power sources supplying the correct voltages and currents for your system components. Check each component's serial

tag for the correct amps, voltage, phase and cycles. Field wiring to each component should be completed by qualified electrical personnel. All electrical wiring should comply with your region's electrical codes.

❒

Minimum clearance above and around each component for safe operation and maintenance. Refer to the component manuals sup-

plied with your EnergySmart Dryer System to determine minimum clearances needed for each component.

❒

A mounting area that will support the weight of the fully loaded CH Hopper, floor stand and the other system components. Refer to the

specifications supplied with your EnergySmart Dryer System for the weights of each component.

❒

A source of water for the aftercooler/intercooler or optional precooler of the dryer. The water source must be tower, city or chiller

water at temperatures of 45° to 85°F {7° to 29°C}. Refer to the specifications supplied with your system for the flow rate. Piping should be installed to the dryer location. Flexible hose can be used to connect the water pipes to the aftercooler/intercooler or optional precooler.

❒

If the heat source supplied with your EnergySmart Dryer System is a GasTrac (CGT), the installation location must provide for an exhaust flue and gas lines that meet all applicable local, regional and national codes. Conair recommends that the GasTrac should have

a dedicated vertical stack that exits the building through a rain-protected roof penetration. See Installation section entitled, Connecting the Gas

and the Exhaust Flue to the GasTrac.

❒

Material and conveying lines installed. If you plan to use optional vacuum receivers to fill the CH Hopper, install conveying lines to the hopper location as well as to the optional vacuum pump(s) and its associated dust collector(s) used within your EnergySmart Dryer System.

3- 8 l Ins ta l la ti on - G en er al

Positioning the CH Hopper Floor Stand

WARNING: You are responsible for the structural integrity of this installation.

CAUTION: Care should be taken while moving the main CH Hopper floor stand and

sections to ensure that no damage occurs during assembly.

IMPORTANT: You will need to consider the installation of your entire dryer system before permanently placing any system component, see Installation - Piping and

Hoses for reference.

Due to the varying size of Conair CH Hoppers, Conair recommends:

• Following all applicable local building and safety codes

1 Make sure the installation location for the CH Hopper meets all provisions for

clearances, will support the weight of the fully loaded hopper and provides space for the installation of the other system components, such as optional receivers. See the specifications and drawings supplied with your system for

details.

2 Using a forklift, hoist or crane, move the floor stand to its installation location.

NOTE: For EnergySmart Dryer

Systems supplied with "small" hoppers, the floor stand and cone section may be pre-assembled from Conair.

✐

In s tal l a tio n

In s ta ll at io n - Ge ne ra l l 3 -9

Installation of the HTC Control

(Mode ls HT C 30, 60 , a nd 90 )

CAUTION: You are responsible for the structural integrity of this installation.

NOTE: The HTC control is shipped mounted on the left side of the CH Hopper floor stand

on models 30, 60 and 90.

NOTE: If, by using your own provisions, you change the mounting arrangement of the

control center to a wall mount unit, it must be mounted 6 inches {152.4 mm} off of the wall to provide clearance for the heat sink.

✐

HTC Control Center

(continued)

NOTE: If using a GasTrac for the

drying system heat source, see

Installation section entitled, Installing the CH Hopper Cone Section.

✐

Installation of the HTC Control

(c on ti nu ed ) (Mod el HT C 120)

CAUTION: You are responsible for the structural integrity of this

installation.

1 Securely bolt the HTC control to the left side of the floor stand. Use the

supplied locking fasteners to securely mount the HTC control center to the floor stand to prevent vibration-induced loosening.

NOTE: If, by using your own provisions, you change the mounting arrangement of the control center to a wall mount unit, it must be mounted 6 inches {152.4 mm} off of the wall to provide clearance for the heat sink.

Installation of the HTC Control

(c on ti nu ed ) ( Mo de ls HTC 180 and 27 0)

CAUTION: You are responsible for the structural integrity of this installation.

1 Move the control center into

its final location for operation

(see figure to the right). The control center must be positioned close enough to the hopper to allow connection of the RTD temperature probe.

The control center can be mounted to a wall, the hopper frame or a floor stand with customer supplied provisions.

✐

HTC Control Center (Free-Standing)

✐

HTC Control Center

✐

NOTE: If the lengths of the process and process protection RTD wiring are too short for your installation, contact Conair Parts Department (800.458.1960) to purchase extension cables. From outside the United States, call 814.437.6861.

(continued)

3- 1 0 l I ns ta ll a ti on - Ge ne r al

NOTE: If using a GasTrac for the

drying system heat source,

see Installation section entitled, Installing the CH Hopper Cone Section.

✐

CAUTION: Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by qualified personnel.

CAUTION: Check the disconnect with a volt meter to ensure that the power is off.

Location and Mounting of the HTC Heater Assembly

(Mode ls HT C 30, 60 and 90)

CAUTION: You are responsible for the structural integrity of this installation.

NOTE: The HTC heater assembly is shipped mounted to the back of the floor stand on

Models 30, 60 and 90 (see figure to the right).

NOTE: The heater is prewired to the control box on HTC Model 30, 60 and 90.

Location and Mounting of the HTC Heater Assembly (M od el HTC 120)

CAUTION: You are responsible for the structural integrity of this installation.

1 Securely bolt the HTC heater assembly to the back of the floor stand (see

figure to the right). Use the locking fasteners provided to securely mount the heater assembly to the floor stand to prevent vibration-induced loosening.

NOTE: The heater is prewired to the control box on HTC Model 120.

Location and Mounting of the HTC Heater Assembly

(Mode ls HT C 180 and 270)

CAUTION: You are responsible for the structural integrity of this installation.

1 Securely bolt the HTC heater assembly to the back of the floor stand (see

figure to the right). Use the locking fasteners provided to securely mount the heater assembly to the floor stand to prevent vibration-induced loosening.

2 Refer to the wiring diagram to make the wiring connections for the heater

and control box. Only a qualified electrician should make the wiring connections between the control and the heater. The customer must supply the appropriately-sized wire and conduit to make connections.

✐

HTC Heater

IMPORTANT: Always refer to the wiring diagrams that came with your HTC before making electrical connections.

✐

In s ta ll at io n - Ge ne ra l l 3 -1 1

In s tal l a tio n

✐

Installing the CH Hopper Cone Section

Install the hopper cone section on the floor stand using the following steps.

IMPORTANT: You will need to consider the location of the CH Hopper’s delivery air inlet in relation to the dryer installation location for proper setup.

IMPORTANT: You will need to consider the location of the HTC heater outlet in relation to the CH Hopper air inlet location for proper setup.

1 If any hoses, wires, etc. were attached to the floor stand and cone

section (for shipping purposes), make sure they are positioned away from the mating surfaces of the assemblies so they will not be damaged during this procedure.

2 Using a forklift, hoist or crane, lift the cone section assembly above

the floor stand.

CAUTION: To prevent accident and injury, lift the cone and hopper sections onto the floor stand assembly using a forklift, hoist or crane.

3 Set the cone section on the floor stand as shown. Make sure the holes

in the cone section mounting lugs align with the holes in the top of the floor stand assembly.

4 Secure the cone section to the floor stand assembly using the supplied

hardware.

NOTE: For EnergySmart Dryer Systems supplied with "small" hoppers, the floor stand and cone section may be pre-assembled at the factory. If your floor stand and cone section are pre-assembled and you have secured the floor stand to the floor,

see Installation section entitled, Installing the CH Hopper Door, Upper and Lid Sections.

✐

3- 1 2 l I ns ta ll a ti on - Ge ne r al

NOTE: If using carbon steel hop-

pers, be sure to clean out the hopper prior to use. Conair applies a rust inhibitor that must be removed several hours before using the hopper.

✐

Installing the CH Hopper Door, Upper and Lid Sections

IMPORTANT: Before installing the hopper door, upper (if applicable), and lid sections of the CH Hopper, careful consideration should be given to

the following:

• When installing the hopper door section, make sure the hopper door is posi-

tioned to allow easy access into the hopper to aid in installation and to facilitate hopper cleaning and maintenance in the future.

• When installing the hopper lid section, make sure to identify the location of the

hopper’s return air outlet. The lid section has multiple piping options that can be connected to an optional cyclone or traditional CH Hopper outlet, then to an optional dust collector and finally to the dryer’s return air inlet. Consider all piping/hosing possibilities when installing the dryer, heater (gas or electric), optional dust collector and optional cyclone before making the installation permanent.

Hoppe r D oo r Section

To install the hopper door section of the CH Hopper:

1 Apply sealer around the lip on the top of the cone section.

2 Using a forklift, hoist or crane, lift the hopper door section assembly above

the cone section.

CAUTION: To prevent accident and injury, lift the hopper door section onto the cone section using a forklift, hoist or crane.

NOTE: When applying the sealer, do not cover the holes in the cone section lip. Apply the sealer around the holes so you will have a good seal but not interfere with the mounting hardware that will be used to secure the hopper door section to the cone section.

✐

✒

TIP: Conair recommends applying strip and stick sealer 1/8 inches {3.2 mm} from the inside to the edge of the CH Hopper.

NOTE: When installing the hopper door section, make sure the hopper door is positioned to allow easy access into the hopper to aid in the continuing installation and to facilitate hopper cleaning and maintenance in the future.

✐

In s ta ll at io n - Ge ne ra l l 3 -1 3

In s tal l a tio n

(continued)

Installing the CH Hopper Door, Upper and Lid Sections (c on tin ue d)

Hoppe r D oo r Section ( co nt in ued )

3 Set the hopper door section on the cone section as shown. As the hopper

door section is positioned on the cone section, make sure the holes in the hopper door section align with the holes in the cone section.

4 Secure the hopper door section to the cone section using the supplied

hardware.

3- 1 4 l I ns ta ll a ti on - Ge ne r al

(continued)

Installing the CH Hopper Door, Upper and Lid Sections (continued)

Hoppe r U pp er Section(s ) ( I f App l ica b le)

To install the hopper upper section(s) of the CH Hopper:

1 Apply sealer around the lip on the top of the hopper door section.

2 Using a forklift, hoist or crane, lift the hopper upper section assembly

above the hopper door section.

CAUTION: To prevent accident and injury, lift the hopper upper section onto the hopper door section using a forklift, hoist or crane.

IMPORTANT: Line up the sight glasses of the hopper upper section(s) with the sight glasses of the hopper door section.

3 Set the hopper upper section on the hopper door section. As the hopper

upper section is positioned on the hopper door section, make sure the holes in the upper section align with the holes in the door section.

4 Secure the hopper upper section to the hopper door section using the

supplied hardware.

NOTE: If more than one (1) hopper upper section is to be installed, repeat the steps

detailed in this section for each hopper upper section.

✐

NOTE: When applying the sealer, do not cover the holes in the hopper door section lip. Apply the sealer around the holes so you will have a good seal but not interfere with the mounting hardware that will be used to secure the hopper upper section to the hopper door section.

✐

✒

TIP: Conair recommends applying strip and stick sealer 1/8 inches {3.2 mm} from the inside to the edge of the CH Hopper.

In s ta ll at io n - Ge ne ra l l 3 -1 5

In s tal l a tio n

(continued)

Installing the CH Hopper Door, Upper and Lid Sections (continued)

Hoppe r L id Section

IMPORTANT: Improper mounting of the hopper lid will cause interference when

installing the DM-II monitor probe and optional integrated cyclone. See the illustration below for recommended hopper lid mounting locations.

To install the hopper lid section of the CH Hopper:

1 Apply sealer around the lip on the top of the hopper door or hopper upper

section, if applicable.

2 Using a forklift, hoist or crane, lift the hopper lid section assembly above

the hopper door or hopper upper section.

3 Set the hopper lid section on the hopper door or hopper upper section as

shown below. As the hopper lid section is positioned on the hopper door or hopper upper section, make sure the holes in the hopper lid section align with the holes in the hopper door or hopper upper section.

4 Secure the hopper lid section to the hopper door or hopper upper section

using the supplied hardware.

CAUTION: To prevent accident and injury, lift the hopper lid section onto the hopper door or hopper upper sections using a forklift, hoist or crane.

NOTE: When applying the sealer, do not cover the holes in the upper section lip. Apply the sealer around the holes so you will have a good seal but not interfere with the mounting hardware that will be used to secure the hopper lid section to the hopper upper section.

✐

✒

TIP: Conair recommends applying strip and stick sealer 1/8 inches {3.2 mm} from the inside to the edge of the CH Hopper.

WARNING: To accomplish the following steps, it may be necessary for personnel to enter the CH Hopper assembly. If it is necessary to enter the hopper assembly, all applicable OSHA procedures for working within a confined space MUST BE followed.

3- 1 6 l I ns ta ll a ti on - Ge ne r al

Installing the Cyclone (optional)

The optional cyclone separator is designed to be mounted to the return air outlet of the CH Hopper.

IMPORTANT: The optional cyclone is designed to be connected to the return air circuit of the CH Hopper, then connected to an optional dust collector or to the dryer’s air inlet.

To install the cyclone to the CH Hopper:

1 Using a forklift, hoist or crane, raise the cyclone’s mounting bracket to its

installation location on the side of the CH Hopper. Installation location depends upon your system setup.

2 Remove the five (5) bolts located on the top of the lid of the hopper. The

removal of the five (5) bolts is dependent upon the installation location of the cyclone.

3 Remove the five (5) bolts located on the hopper upper section or hopper

door section of the hopper. The removal of the five (5) bolts is dependent upon the installation location of the cyclone.

CAUTION: To prevent accident and injury, move the cyclone separator to its mounting location using a forklift, hoist or crane.

In s ta ll at io n - Ge ne ra l l 3 -1 7

In s tal l a tio n

Top Bolt Pattern

Bottom Bolt Pattern

(continued)

IMPORTANT: Reference your system layout drawings for the correct cyclone bracket bolt pattern usage before it is installed.

Installing the Cyclone (optional) (continued)

4 Bolt the cyclone bracket to the CH Hopper, using the hardware removed

in Steps 2 and 3. Do not fully tighten the bolts, the cyclone installation may need to be adjusted for hard piping of the cyclone’s inlet and outlet ports.

5 Using a forklift, hoist or crane, raise the cyclone body to its installation

location on the bracket mounted to the CH Hopper. Installation location depends upon your system setup.

6 Mount the cyclone body to its installation location on the bracket using the

supplied hardware. Do not tighten the bolts, the cyclone installation may need to be adjusted for hard piping of the cyclone’s inlet and outlet ports.

7 Locate the three (3) 90 degree pieces of tubing. These pieces will connect

the CH Hopper to the cyclone.

8 Bolt two (2) of the pieces of 90 degree tubing together using the supplied

hardware. Be sure to place the supplied gasket between the two (2) pieces of tubing before tightening the tube bolts. One of the pieces includes the dew point return port; the port should be located on the same end as the connection of the two (2) pieces of 90 degree tubing.

CAUTION: To prevent accident and injury, move the cyclone separator to its mounting location using a forklift, hoist or crane.

3- 1 8 l I ns ta ll a ti on - Ge ne r al

(continued)

Bolts (4)

(Two (2) for each side)

Installing the Cyclone (optional) (continued)

9 Bolt the third piece of 90 degree tubing to the assembly in Step 8 using the

supplied hardware. The third piece of 90 degree tubing should be bolted to the end of the assembly in Step 8 that DOES NOT have the dew point return port. Be sure to place the supplied gasket between the two (2) pieces of tubing before tighten the tube bolts.

10 Loosely bolt the now finished tubing assembly to the CH Hopper’s return

air outlet and to the cyclone’s air inlet, using the supplied hardware. Be sure to place the supplied gaskets between the tubing assembly and the CH Hopper outlet and cyclone air inlet before tightening bolts. Mounting location is dependent upon the installation location of the cyclone.

In s ta ll at io n - Ge ne ra l l 3 -1 9

In s tal l a tio n

Dew Point Return Port

Gasket

(continued)

3- 2 0 l I ns ta ll a ti on - Ge ne r al

Installing the Cyclone (optional) (continued)

11 Be sure to make any adjustments necessary to the cyclone or tubing

assembly.

12 Tighten all bolts within the cyclone and tubing assemblies with an

appropriately-sized wrench.

13 Locate the 45 degree piece of tubing.

14 Bolt the 45 degree piece of tubing to the outlet of the cyclone using the

supplied hardware. Be sure to place the supplied gasket between the tubing and the cyclone outlet before tightening bolts. Mounting orientation is dependent upon your system’s configuration.

15 Bolt the straight piece of tubing to the assembly in Step 14 using the sup-

plied hardware. Be sure to place the supplied gasket between the two (2) pieces of tubing before tighten the tube bolts.

45 Degree Tubing

(continued)

In s ta ll at io n - Ge ne ra l l 3 -2 1

In s tal l a tio n

Installing the Cyclone (optional) (continued)

16 Locate the supplied hosing used for the cyclone’s waste container.

17 Connect the hosing to the straight piece of tubing installed in Step 15

using the supplied hose clamp.

18 Route the hose to the waste container. Make sure all hoses are securely

clamped to prevent wasteful leaking. The hoses should be routed neatly and supported where possible to prevent undue stress on cyclone assembly.

19 Connect the hosing to the waste container’s lid using the supplied hose

clamp.

NOTE: Do not allow the flexible hoses to kink or crimp.

✐

Installing the Drying Monitor Probe

From the Top of the CH Hopper

The Drying Monitor (DM) probe can be inserted through the existing hole in the top of the CH Hopper lid section and secured to a threaded coupling with an appropriate fitting.

1 Insert the DM probe through the

coupling in the top of the hopper lid section.

2 Screw the fitting into the coupling.

Tighten the fitting with an appropriately-sized wrench.

3 Position the probe so it extends from

just above the top of the hopper lid section into the hopper, with the tip of

the probe approximately in-line with the bottom edge of the dry air spreader cone.

4 Push the compression sleeve into the fitting.

5 Tighten the nut over the sleeve. The com-

pression sleeve will crimp the tube to hold the probe in place. Be sure to position the connector on the DM probe in such a way as to avoid interference with cables, receiver, etc. Use an appropriately-sized wrench to tighten the nut so that it covers all the threads of the fitting.

NOTE: The DM probe's cable will be connected to the probe and the dryer later in the installation process.

✐

Sleeve

Coupling

DM Probe Location

Connector

3- 2 2 l I ns ta ll a ti on - Ge ne r al

(continued)

Installing the Drying Monitor Probe

(c on ti nu ed )

Through the Door of the CH Hopper

The Drying Monitor (DM) probe can also be installed from the inside of the CH Hopper and secured to the hopper lid section.

1 Remove the two (2) adapter plates from the probe mounting assembly. Set

the adapter plates aside for use in Step 5.

2 Insert the probe and mounting assembly through the door of the CH

Hopper.

3 Pull the probe and mounting assembly through the hole in the top of the

hopper. Fold the gasket around the probe so that it will fit through the hole.

4 Place the gasket over the probe hole.

5 Place the adapter plates over the gas-

ket and secure them to the hopper with three (3) 10-32 UNF screws.

Make sure the adapter plate with the threaded hole is on the bottom, and that

the slots in the adapter plates are oriented in the opposite direction as shown (See the drawing on the next page).

6 Secure the coupling to the adapter plates with the four (4) 10-32 UNF

screws.

7 Screw the fitting into the coupling. Tighten with an appropriately-sized

wrench.

8 Make sure the probe is the correct size. The probe should extend from just

above the top of the hopper into the hopper, with the tip approximately in-

line with the bottom edge of the diffuser cone.

DM Probe Location

In s ta ll at io n - Ge ne ra l l 3 -2 3

In s tal l a tio n

(continued)

Installing the Drying Monitor Probe

(c on ti nu ed )

Through the Door of the CH Hopper (c ont in ued )

9 Push the compression sleeve into the

fitting.

10 Tighten the nut over the sleeve. The

compression sleeve will crimp the tube to hold the probe in place. Be sure to position the connector in such a way as to avoid interference of the cable with the receiver, etc. Use an appropriatelysized wrench to tighten the nut so that it covers the threads.

Gasket

Sleeve

Coupling

Hopper

Nut

Fitting

Adapter plate

Threaded adapter plate

3- 2 4 l I ns ta ll a ti on - Ge ne r al

In s tal l a tio n

Installing the Receiver(s) (o pt io na l)

If a receiver is to be mounted to the top of the CH Hopper, auxiliary hopper or machine throat, follow the installation instructions, specifications and wiring diagrams supplied with the receiver. Also refer to the receiver's installation instructions and operations manual for power, level switch and compressed air connections/specifications.

Installing the Purge Valve(s ) (op ti ona l)

If a purge valve is to be mounted to the bottom of the CH Hopper or auxiliary hopper follow the installation instructions, specifications, and wiring diagrams supplied with the valve. Also refer to the purge valve's installation instructions and operations manual for power, compressed air connections/specifications.

Installing the Modular Distribution Box(es) (op ti on al )

If a modular distribution box is to be mounted to the bottom of the CH Hopper or auxiliary hopper follow the installation instructions, specifications, and wiring diagrams supplied with the box. Also refer to the modular distribution box's installation instructions and operations manual compressed air connections/specifications.

In s ta ll at io n - Ge ne ra l l 3 -2 5

Securing the CH Hopper to the Floor

WARNING: You are responsible for the structural integrity of this installation.

IMPORTANT: Fasten the CH Hopper floor stand to a rigid floor structure. This will add rigidity to the installation and help to prevent accidents during operation and maintenance of the CH Hopper.

Due to the varying size of Conair CH Hoppers, Conair recommends:

• Following all applicable local building and safety codes

• Using anchoring techniques and hardware suitable for the size and weight of a

fully loaded CH Hopper. See Description section entitled, Specifications: CH

Series Insulated Hoppers.

1 Secure the floor stand to the floor; following all applicable building and

safety codes.

✐

NOTE: The footpads on the floor stand have existing holes that can be used for anchoring the floor stand depending on the local building and safety codes.

3- 2 6 l I ns ta ll a ti on - Ge ne r al

In s tal l a tio n

Location and Mounting of the GasTrac Heater (i f equipped)

The GasTrac supplied with the EnergySmart Dryer System is designed to be mounted to the floor near the CH Hopper air inlet.

1 Using a forklift, hoist or crane, move the GasTrac to its installation

location near the air inlet of the CH Hopper.

CAUTION: To prevent accident and injury, move the GasTrac to its location by using a forklift, hoist or crane.

2 Position the GasTrac so that the gas, main power supply and exhaust flue

can be connected easily.

IMPORTANT: You will need to consider the location of the CH Hopper’s delivery air inlet and the dryer installation location to properly install the GasTrac.

3 Secure the GasTrac to the mounting location floor using the holes in the

base of the GasTrac. Check to ensure that the mounting method meets all local, regional and national codes and regulations.

NOTE: Electrical, control, air flow, gas and exhaust flue connections to the GasTrac will be covered later in the installation process.

✐

In s ta ll at io n - Ge ne ra l l 3 -2 7

✐

NOTE: If your system has electrical heaters, for the drying system heat source, see Installation

section entitled, Location and Mounting of the HTC.

Location and Mounting of the Dust Collector (op ti on al )

The optional dust collector that is used with your EnergySmart Dryer System is designed to be mounted to the floor near the CH Hopper and optional integrated cyclone.

To install the optional dust collector:

1 Using a forklift, hoist or crane, move the dust collector to its installation

location near the CH Hopper and optional integrated cyclone.

IMPORTANT: You will need to consider the installation of your entire dryer system before permanently placing any system component.

CAUTION: To prevent accident and injury, move the dust collector to its mounting location using a forklift, hoist or crane.

2 Secure the dust collector to the mounting location on the floor by using the

holes in the legs of the dust collector. Ensure that the mounting method meets all local, regional and national codes and regulations.

(continued)

3- 2 8 l I ns ta ll a ti on - Ge ne r al

Inlet

Outlet

In s tal l a tio n

Location and Mounting of the Dust Collector (op ti on al ) ( co nti nu ed)

3 Ensure that the hoses from the dif-

ferential pressure transmitter, mounted to the dust collector leg, have not become detached from the

dust collector's inlet and outlet tubes during installation.

NOTE: Electrical, control and air flow connections to the dust collector will be covered later in the installation process.

✐

NOTE: Dust collector shown with straight legs. Your EnergySmart Dryer system will be supplied with dust collectors with “kick-out” legs.

In s ta ll at io n - Ge ne ra l l 3 -2 9

Pressure Differential Transmitter

Location and Mounting of the Vacuum Pump(s) and Dust Collector(s) ( opti o nal )

The optional vacuum pump(s) and associated dust collector(s) supplied with the EnergySmart Dryer System are designed to be mounted to the floor and in any convenient location near the CH Hopper.

1 Using a forklift, hoist or crane, move the vacuum pump(s) and associated

dust collector(s) to their installation location.

CAUTION: To prevent accident and injury, move the vacuum pump(s) and associated dust collector(s) to their locations by using a forklift, hoist or crane.

2 Position the equipment so that the main power supply, communication

cables and conveying lines can be connected easily.

IMPORTANT: You will need to consider the location of all EnergySmart Dryer System components to properly install the vacuum pump(s) and associated dust collector(s).

3 Secure the vacuum pump(s) and associated dust collector(s) to their

mounting locations on the floor by using the holes in the base of each component. Ensure that the mounting method meets all local, regional and

national codes and regulations.

3- 3 0 l I ns ta ll a ti on - Ge ne r al

Positioning the Dryer on the Floor

To position the dryer:

1 Lift the dryer from the shipping container using a fork truck.

2 Position the dryer on the floor near the CH Hopper. Make sure the location

allows easy connection to the heat source (HTC or GasTrac), water connections and to the outlet of the optional dust collector.

Removing the Cable Tie from the Desiccant Wheel (W 6 0 0 - 1000 m o dels)

The EnergySmart Dryer’s desiccant wheel cable tie must be removed while installing the dryer.

To remove the cable tie:

1 Open the dryer side panels and remove the cable tie securing the desiccant

wheel, if it was not done while unpacking the dryer.

Installing the Regeneration Exhaust Cover

The EnergySmart Dryer’s regeneration exhaust cover must be installed before using the dryer.

To install the regeneration exhaust cover:

1 Remove the exhaust cover that is attached to the dryer’s shipping pallet.

2 Locate the bolt pattern on the top of the dryer, over top of the regeneration

exhaust outlet.

3 Position the regeneration exhaust cover over top of the regeneration

exhaust outlet, aligning both bolt patterns.

4 Secure the regeneration exhaust cover with supplied hardware, using an

appropriately-sized wrench.

✒

Desiccant Cable Tie

Regeneration Exhaust Cover

In s ta ll at io n - Ge ne ra l l 3 -3 1

In s tal l a tio n

Installing the Return Air Adapter

The EnergySmart Dryer’s return air adapter must be installed before using the dryer.

To install the return air adapter:

1 Remove the return air adapter that is attached to the dryer’s shipping

pallet.

2 Locate the bolt pattern on the top of the dryer, over top of the return air

inlet.

3 Position the return air adapter over top of the return air inlet, aligning

both bolt patterns.

4 Secure the return air adapter with supplied hardware, using an

appropriately-sized wrench.

Return Air Inlet Adapter

3- 3 2 l I ns ta ll a ti on - Ge ne r al

NOTE: If your system has hard piping, use the instructions in the next section.

✐

An optional hard piping kit for your EnergySmart Dryer system is available from Conair.

Contact Conair Parts (800) 458 1960 From outside of the United States, call: (814) 437 6861

In s tal l a tio n

Installing the Return Air Inlet and Air Outlet Adapters (W1600 - 5000)

The EnergySmart Dryer’s return air inlet and air outlet adapters will be removed when the dryer is shipped.

To install the return air inlet and air outlet adapters:

1 Remove the return air inlet and dry air outlet adapters that are attached to

the dryer’s shipping pallet.

2 Locate the bolt patterns on the top of the dryer, over top of the return air

inlet and dry air outlet.

3 Position the return air adapter over top of the return air inlet, aligning both

bolt patterns.

4 Secure the return air adapter with supplied hardware, using an

appropriately-sized wrench.

5 Position the dry air outlet adapter over top of the dry air outlet, aligning

both bolt patterns.

6 Secure the dry air outlet adapter with supplied hardware, using an

appropriately-sized wrench.

Dry Air Outlet Adapter

Return Air Inlet Adapter

NOTE: An optional hard piping kit for your EnergySmart Dryer system is available from Conair.

Contact Conair Parts (800) 458 1960 From outside of the United States, call: (814) 437 6861

✐

In s ta ll at io n - Ge ne ra l l 3 -3 3

Installing the Overhead Process Air Duct (W3200 - 5 0 0 0)

The EnergySmart Dryer’s overhead process air duct will be removed when the dryer is shipped.

To install the overhead process air duct:

1 Remove the overhead process air duct that is attached to the dryer’s ship-

ping pallet. The piping will be shipped as one unit with included gaskets (2).

2 Locate the bolt patterns on the top of the dryer, over top of the overhead

process air duct inlet and outlet.

3 Position the overhead process air duct over top of the overhead process air

duct inlet and outlet making sure to place supplied gaskets between the overhead process air duct and the inlet and outlet of the dryer, align all bolt

patterns.

4 Secure the piping with supplied hardware, using an appropriately-sized

wrench.

Overhead Process Air Duct

Gaskets (2)

3- 3 4 l I ns ta ll a ti on - Ge ne r al

Installation - Hard Piping Kits

In s ta ll at io n - Pi pi ng / Ho se s l 3- 3 5

In s tal l a tio n

Optional Hard Piping Kits

The following sections detail the pipe/hose connections between the components of the EnergySmart Dryer System. The piping can consist of hard piping or flexible tubes.

Conair offers both 8 inch and 12 inch {203.2 and 304.8 mm}hard piping kits that can be used for your EnergySmart Dryer System installation. For more information concerning hard piping kits, contact your Conair Representative.

3- 3 6 l I ns ta ll a ti on - Pi pi n g/ Ho se s

An optional hard piping kit for your EnergySmart Dryer system is available from Conair.

Contact Conair Parts (800) 458 1960 From outside of the United States, call: (814) 437 6861

NOTE: Do not allow

the flexible hoses to kink or crimp.

✐

Connecting the Heat Sources

Hoppe r Te mperature Co nt ro ller (HTC) as He at Sourc e

NOTE: If your EnergySmart Dryer System was supplied with a GasTrac as the heat

source, see Installation section entitled, Connecting the Heat Sources, Gastrac Heat

Source.

1 Using insulated hard piping or flexible hose, connect the HTC outlet to

the air inlet of the CH Hopper. If flexible hose is used, make sure it is securely clamped.

Make sure all hoses are securely clamped to prevent wasteful leaking. The hoses should be routed neatly and supported where possible to prevent undue stress on the heater and hopper assemblies. Also, the bends should be made with gradual radiuses. Sharp turns will cause undue pressure drops.

✐

HTC Outlet to CH Hopper Inlet Connection

In s ta ll at io n - Pi pi ng / Ho se s l 3- 3 7

In s tal l a tio n

(continued)

An optional hard piping kit for your EnergySmart Dryer system is available from Conair.

Contact Conair Parts (800) 458 1960 From outside of the United States, call: (814) 437 6861

3- 3 8 l I ns ta ll a ti on - Pi pi n g/ Ho se s

Connecting the Heat Sources ( co nti nu ed)

GasTra c as Heat Sour ce

1 Using insulated hard piping or flexible hose, connect the GasTrac outlet to

the air inlet of the CH Hopper. If an insulated flexible hose is used, make sure it is securely clamped.

NOTE: Do not allow the flexible hoses to kink or crimp.

✐

An optional hard piping kit for your EnergySmart Dryer system is available from Conair.

Contact Conair Parts (800) 458 1960 From outside of the United States, call: (814) 437 6861

Connecting the Dryer to the Heat Source

1 Using hard piping or flexible hose, connect the delivery air outlet to the

inlet of the HTC or GasTrac. If a flexible hose is used, make sure it is securely clamped.

In s ta ll at io n - Pi pi ng / Ho se s l 3- 3 9

(Dryer Connection to HTC Shown)

HTC Inlet

Dryer Outlet

NOTE: Do not allow the flexible hoses to kink or crimp.

✐

In s tal l a tio n

An optional hard piping kit for your EnergySmart Dryer system is available from Conair.

Contact Conair Parts (800) 458 1960 From outside of the United States, call: (814) 437 6861

Connecting the Dust Collector ( op tio na l)

1 Using uninsulated hard piping or flexible hose, connect the optional dust

collector outlet to the EnergrySmart Dryer return air inlet. If a flexible hose is used, make sure it is securely clamped.

Dust Collector Outlet

Dryer Inlet

NOTE: Do not allow

the flexible hoses to kink or crimp.

✐

3- 4 0 l I ns ta ll a ti on - Pi pi n g/ Ho se s

An optional hard piping kit for your EnergySmart Dryer system is available from Conair.

Contact Conair Parts (800) 458 1960 From outside of the United States, call: (814) 437 6861

Connecting the Cyclone Separator

(o pt io na l)

1 Using uninsulated hard piping or flexible hose, connect the cyclone outlet

to the optional dust collector inlet or dryer return air inlet. If a flexible

hose is used, make sure it is securely clamped.

Outlet to Dust Collector

Inlet from Cyclone

NOTE: Do not allow

the flexible hoses to kink or crimp.

✐

In s tal l a tio n

In s ta ll at io n - Pi pi ng / Ho se s l 3- 4 1

An optional hard piping kit for your EnergySmart Dryer system is available from Conair.

Contact Conair Parts (800) 458 1960 From outside of the United States, call: (814) 437 6861

Installing the Dwyer 641 Air Velocity Transmitter

The Dwyer 641 Air Velocity Transmitter (AVT) supplied with the EnergySmart Dryer System should be installed within 8 or 12 in. {203.2 or 304.8 mm} customer-supplied pipe using a 5/16 × 1/4 in. NPT compression fitting.

IMPORTANT: The AVT should be installed in a straight piece of pipe, on the return air side of the EnergySmart Dryer. Conair recommends locating the probe toward the end of long straight section of pipe to allow the air flow as much length as possible to straighten out before it comes in contact with the probe. Placing the probe too close to a transition or bend will influence air flow readings.

To install the AVT:

1 Determine the best location to install the AVTs following the

recommendations above.

2 If Conair’s hard piping kit was not purchased with your system, drill and

tap customer-supplied 8 or 12 in. {203.2 or 304.8 mm} 2 ft. {0.6 m} long pipe with a 7/16 in. drill bit and 1/4 in. - 18 NPT tap.

AVT in Dryer Return Air Circuit (Shown with hard piping kit)

(continued)

3- 4 2 l I ns ta ll a ti on - Pi pi n g/ Ho se s

NOTE: To order Conair's

optional hard piping kit for your EnergySmart Dryer System, contact your Conair representative at: US 800458-1960, International +1-814-437-6861.

✐

Installing the Dwyer 641 Air Velocity Transmitter (c on ti nu ed )

3 Screw the compression fitting into the customer-supplied pipe.

4 Orient the air velocity probe so that the flow direction arrow stamped on

the NUT used to secure the transmitter is pointing in the direction of the air flow. The arrow is located on the nut below the conduit bodies.

5 Center in pipe. This will allow you to adjust the air velocity probe in the cen-

ter of the air stream.

Air Flow Direction Arrows Located on the Nut

In s tal l a tio n

In s ta ll at io n - Pi pi ng / Ho se s l 3- 4 3

NOTE: Refer to Dwyer 641 Instructions found in the Appendix of this manual.

✐

3- 4 4 l I ns ta ll a ti on - Pi pi n g/ Ho se s

Installing the Level Switch (o pti on al)

The level switch is installed on the side of the CH Hopper. The level switch’s probe will be inserted through the hopper’s side wall at the customer desired level to signal the dryer’s control to start a loading cycle to refill the hopper.

1 Remove the port plug at the material level that will start a loading cycle with

an appropriately-sized Allen wrench. Several port plugs are located along the side of the CH Hopper.

2 Locate the level switch.

3 Apply Teflon tape to the installation threads of the level switch.

4 Insert the level switch into the material port selected in Step 1.

5 Install the level switch by rotating the probe and engaging the threads in

Step 3, using an appropriately-sized wrench.

6 Connect the wiring to the level switch as detailed in the supplied wiring

diagram.

Material Level Ports

Threads

CH Hopper Wall

IMPORTANT: Always refer to the wiring diagrams that came with your level switch before making electrical connections.

(continued)

In s tal l a tio n

In s ta ll at io n - Pi pi ng / Ho se s l 3- 4 5

Adjusting the Level Sensor (o pt ion al )

The level sensor should be adjusted both with ambient temperature and with operation temperature. Refer to the instruction manual that came with your level sensor for further detail. To calibrate the unit:

1 Turn both the COARSE and FINE potentiometers fully counter-clockwise.

The COVERED internal indicator light should be off.

2 Turn the COARSE poten-

tiometer slowly clockwise to the point where the COVERED indicator light just turns on and says on.

3 Turn the FINE potentiometer

slowly clockwise until the COVERED indicator light just turns OFF. (If the course

potentiometer has been carefully adjusted, this should occur when the fine potentiometer is between the 8 and 10 o’clock positions.) Now continue to turn the FINE potentiometer clockwise to the desired sensitivity setting.

High sensitivity: 1/16 turn Medium sensitivity: 1/8 turn Low sensitivity: 1/4 to 1/2 turn

IMPORTANT: The calibration potentiometers are delicate electronic devices. Do not use excessive force when adjusting.

NOTE: It may be convenient to think of the FINE potentiometer as a clock face and envision the distance between consecutive hour numbers. Turning the FINE potentiometer clockwise one hour position past the point at which the covered indicator just turns off would provide a high sensitivity setting. Two hour positions past that point would provide a medium sensitivity setting.

✐

3- 4 6 l I ns ta ll a ti on - Pi pi n g/ Ho se s

Installing the Process Protection RTD Sensor

(H T C Onl y )

The process protection RTD probe is a safety sensor that prevents the HTC’s heater from overheating in case of a process temperature sensor failure or insulated hose failure.

The process protection RTD sensor senses the temperature leaving the heater assembly to prevent damage to the process or the product within the CH Hopper. It generates an alarm on the HTC control panel (A-49 or A-50) and shuts the heater off if the air temperature exceeds the process protection setpoint. The element for this sensor is to be mounted in the heater assembly outlet nozzle before the insulated hose is connected.

1 Insert the process protection RTD probe into the heater assembly outlet

nozzle. Center the end of the probe in the outlet so that the tip does not touch the inlet tube walls.

2 Tighten compression fitting of the

probe to lock the RTD in place.

3 Route the process protection RTD

cable towards the location of the HTC control panel.

Process

Protection RTD

Probe

In s tal l a tio n

In s ta ll at io n - Pi pi ng / Ho se s l 3- 4 7

Location of the Process Material Temperature Probe (RTD)

The EnergySmart Dryer control is configured to utilize data from an RTD probe, located within your system, which senses the temperature of the process material leaving the CH Hopper. However, the EnergySmart Dryer System does not provide a location for a material temperature probe. Therefore, the process material temperature probe must be incorporated downstream of the CH Hopper and within your delivery system.

Conair recommends that you check the throat of the machine to which your material is being delivered for an existing tap location that can be used to mount the RTD. If none exists, a second option is to incorporate RTD mounting capabilities into the piping/flange that will connect to the bottom of the CH Hopper after the slide gate.

Conair recommends locating the RTD probe, when possible, within 30 ft {9.15 m} of the EnergySmart Dryer.

NOTE: If the length of the supplied RTD cable is too short for your installation, route the cable into a junction box then connect additional twisted pair wire cable of the appropriate length. Route the added cable to the EnergySmart Dryer control panel.

✐

Junction boxes are available from Conair.

Contact Conair Parts (800) 458 1960 From outside of the United States, call: (814) 437 6861

Installing the RTD Sensor

The RTD sensor monitors the temperature of the drying air as it enters the CH Hopper. If the probe is not installed correctly, temperature readings will be inaccurate.

1 Insert the probe into the air inlet

port of the CH Hopper. The end of the probe must not touch the walls of the inlet pipe.

2 Tighten the compression fitting

to lock the RTD probe in place.

3 Route the GasTrac RTD cable

towards the location of the GasTrac control panel.

RTD Probe

3- 4 8 l I ns ta ll a ti on - Pi pi n g/ Ho se s

In s tal l a tio n

In s ta ll at io n - Pi pi ng / Ho se s l 3- 4 9

Installing the Return Air Dew Point Line

The return air dew point line allows the dehumidifying dryer to monitor the moisture contained in the air leaving the CH Hopper via the dry air return port. If the line is not installed correctly, dew point readings will be inaccurate.

1 Install the dew point line fitting

into the port located at the dry

air return circuit as it leaves the

CH hopper and before it enters

the optional cyclone.

2 Connect the supplied short (3 to

4 ft {0.9 to 1.2 m}) copper tube

to the dew point line fitting.

Route the copper tube down

towards the EnergySmart Dryer.

The copper tube is needed to dissi-

pate heat from the sample air.

3 Connect the supplied Teflon

tubing to the end of the copper tube using the compression fitting supplied. Route the Teflon tubing towards

the Return Air Dew Point fitting on the back of the EnergySmart Dryer.

4 Cut the supplied Teflon tubing to the proper

length.

5 Connect the Teflon tubing to the Return Air

Dew Point fitting on the back of the EnergySmart Dryer.

NOTE: The small fitting to the left of the Return Air dew point fitting on the back of the dryer allows the dew point to be checked with a hand held device.

✐

Dew Point Line Fitting

3- 5 0 l I ns ta ll a ti on - Pi pi n g/ Ho se s

In s tal l a tio n

Installation - Main Power Connections

In s ta ll at io n - Ma in P ow er Con n ec ti on s l 3 -5 1

3- 5 2 l I ns ta ll a ti on - Ma in Po we r Co nn ec ti on s

Connecting Main Power to the Dryer

CAUTION: Always disconnect and lock out the main power sources before making

electrical connections. Electrical connections should be made only by qualified personnel.

1 Open the dryer’s electrical enclosure. Turn the disconnect dial on the dryer

door to the Off or “O” position. Turn the captive screw and swing the door open.

2 Insert the main power wire through the knockout in the side of the enclo-

sure or the rear of the dryer (the dryer’s electrical wire connection location was a factory option and may be connected through the front or the rear of the dryer). Secure the wire with an appropriately-sized strain relief.

3 Connect the power wires to the three (3) terminals at the top of the power

disconnect holder.

4 Connect the ground wire to the ground lug as shown in the photo.

IMPORTANT: Always refer to the wiring diagrams that came with your EnergySmart Dryer before making electrical connections.

O OFF

In s tal l a tio n

In s ta ll at io n - Ma in P ow er Con n ec ti on s l 3 -5 3

Connecting Main Power to the HTC

(Mode ls HT C 30, 60 , 9 0 a nd 120)

The electrical connection for the HTC models 30, 60, 90 and 120 only consists of bringing power to the control center. The incoming power should match the rated nameplate power required on the serial tag on the control center. See Description

section entitled, Specifications: Hopper Temperature Controller (HTC). This power

should be clean and have a voltage variation of no more than +/- 5% of the nameplate voltage. Unless the actual voltage is equal to the nameplate voltage, the actual kW output of the HTC will vary slightly. The output varies with the square of the voltage difference.

CAUTION: Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by a qualified technician.

CAUTION: Check the disconnect with a volt meter to ensure that the power is off.

1 Disconnect and lock out the main power before making electrical connec-

tions. Electrical connections should be made only by a qualified technician.

2 Turn the disconnect dial on the control center door to the Off or “O”

position. Turn the captive screw and swing the control center door open.

Insert the main power

cable through a knockout in the side of the control center.

Secure the power cable with an appropriately-sized strain relief or use customersupplied conduit. Verify that the incoming power is securely attached to the control center and there is no strain on the incoming power.

Connect the power wires

to the three terminals at the top of the power disconnect

holder.

5 Connect the ground wire to the ground lug.

IMPORTANT: Always refer to the wiring diagrams that came with your HTC before making electrical connections.

O OFF

(continued)

Connecting Main Power to the HTC

(c on ti nu ed )

(Mode ls HT C 180 and 27 0)

The electrical connection consists of bringing power into the control center and wiring the power from the control center to the heater assembly. The incoming power should match the rated nameplate power required on the serial tag on the control center. See Description section entitled, Specifications: Hopper Temperature

Controller (HTC). This power should be clean and have a voltage variation of no

more than +/- 5% of the nameplate voltage. Unless the actual voltage is equal to the nameplate voltage, the actual kW output of the HTC will vary slightly. The output varies with the square of the voltage difference.

CAUTION: Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by a qualified

technician.

CAUTION: Check the disconnect with a volt meter to ensure that the power is off.

1 Disconnect and lock out the main power before making electrical connec-

tions. Electrical connections should be made only by a qualified technician.

2 Turn the disconnect dial on the control center door to the Off or “O”

position. Turn the captive screw and swing the control center door open.

Insert the main power

cable through a knockout in the side of the control center.

Connect the power wires

to the three terminals at the top of the power disconnect

holder.

5 Connect the ground wire to the ground lug.

NOTE: The connection between the heater and control center should be made with proper-

ly-sized conductors and protected with appropriate conduit (customer supplied). The routing should be neat and away from potential mechanical damage. The terminations should be landed on the terminals in the control center and heater junction area. These terminations should be regularly checked to prevent loosening and shorting to ground.

3- 5 4 l I ns ta ll a ti on - Ma in Po we r Co nn ec ti on s

✐

IMPORTANT: Always refer to the wiring diagrams that came with your HTC before making electrical connections.

O OFF

(continued)

In s tal l a tio n

In s ta ll at io n - Ma in P ow er Con n ec ti on s l 3 -5 5

Connecting Main Power to the HTC

(c on ti nu ed )

(Mode ls HT C 180 and 27 0) ( co nti nu ed )

Insert the customer-supplied heater power

wire through a knockout in the

side or bottom of the control center. Secure the wire with an appropriately-

sized strain relief, if conduit is not used.

7 Connect the heater power wires to the control center’s terminal block and

heater ground wire to the ground lug, as shown.

Insert the other end of heater power

wire through the knockout in the side

of the heater assembly. Secure the wire with an appropriately-sized strain

relief, if conduit is not used.

9 Connect the heater power wires to the top terminals of the heater assem-

bly’s terminal block and heater ground wires to the ground lug, as shown.

Power Wires (Gray - Customer Supplied)

Ground Wires (Green - Customer Supplied)

Ground Wires (Green/Yellow)

Insert the Power Wires Here

IMPORTANT: Always refer

to the wiring diagrams that came with your HTC before making electrical connections.

3- 5 6 l I ns ta ll a ti on

Connecting Main Power to the GasTrac

1 Open the GasTrac electrical enclosure. Turn the disconnect dial on the GasTrac’s

door to the Off or “O” position. Turn the captive screw, and swing the door open.

2 Insert the main power wire through

the knockout in the electrical enclosure. Secure the wire with an appro-

priately-sized relief.

3 Connect the power wires to the

three (3) terminals at the top of the disconnect holder.

4 Connect the ground wire to either

grounding point shown in the diagram.

Honeywell

ESCSEL

IMPORTANT: Always refer to the wiring diagrams that came with the GasTrac before making electrical connections.

CAUTION: Electrical Hazard. Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by qualified personnel.

O OFF

In s tal l a tio n

In s ta ll at io n l 3 -5 7

Connecting Main Power to the Vacuum Pump(s) (o pt io na l)

1 Connect power. Refer to the accompanying wiring diagram for connection of

the main power supply. IMPORTANT: You must provide a wall-mounted

disconnect for three-phase electrical connection. Incoming voltage and current must match the electrical specifications on the pump data plate and serial tag.

WARNING: 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 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.

2 Check for proper rotation of the pump after power has been connected

and before operation.

Connecting Main Power to the Dust Collector(s)

(o pt io na l)

Proper operation of the optional dust collector depends upon its internal vacuum valve opening whenever the vacuum pump is energized. Electrical connections are provided by a 3-conductor cable connected to the dust collector. This cable should be connected to the vacuum pump control enclosure to provide simultaneous operation of the dust collector when the pump is activated. On automatic unload/reload dust collectors, the cable is attached to the reload control enclosure, which distributes power to the various solenoids for the auto reload function of the dust collector.

IMPORTANT: Always refer to the wiring diagrams that came with the vacuum pump(s) before making electrical connections.

IMPORTANT: Always refer to the wiring diagrams that came with the dust collector(s) before making electrical connections.

3- 5 8 l I ns ta ll a ti on - Pi pi n g/ Ho se s

In s tal l a tio n

In s ta ll at io n - Ma in P ow er Con n ec ti on s l 3 -5 9

Installation - Conveying Lines

3- 6 0 l I ns ta ll a ti on - Ma in Po we r Co nn ec ti on s

Connecting the Conveying Lines to the Receiver(s) (o pt io na l)

If an optional receiver is mounted to the top of the CH Hopper, follow the instructions supplied with the receiver to connect the conveying lines. Also refer to the receiver's installation instructions and operations manual for power, level switch and compressed air connections/specifications.

If a secondary optional receiver is to be used, follow the instructions supplied with the receiver to connect the conveying lines. Also refer to the receiver's installation instructions and operations manual for power, level switch and compressed air connections/specifications

Connecting the Conveying Lines to the Purge Valv e(s) ( op ti on al)

In s tal l a tio n

Connecting the Conveying Lines to the Vacuum Pump(s) and Dust Collector(s) ( op ti on al )

1 Connect the vacuum line from the optional receiver to the air inlet of the

optional dust collector.

2 Connect the vacuum line from the dust collector’s air outlet to the vacuum

pump’s air inlet.

3 Repeat Steps 1 and 2 if a second optional receiver, dust collector and vacu-

um pump are to be used.

Make sure all hoses are securely clamped to prevent wasteful leaking. The hoses should be routed neatly and supported where possible to prevent undue stress. Also, the bends should be made with gradual radiuses. Sharp turns will cause undue pressure drops.

Air Inlet

Air Outlet

Collection Chamber

Floor Stand

To Material Supply

NOTE: Vacuum pump shown above is 180º out of position.

✐

NOTE: Do not allow the flexible hoses to kink or crimp.

✐

In s ta ll at io n - Ma in P ow er Con n ec ti on s l 3 -6 1

3- 6 2 l I ns ta ll a ti on - Co nv e yi ng L in es

Installation - Water Lines

In s tal l a tio n

In s ta ll at io n - W at er L in es l 3- 63

BACK OF DRYER

WATER CONNECTION

**IT IS RECOMMEND THAT FLEX LINE BE USED TO

ALLOW FOR EASIER REMOVAL OF CONDENSER.

SEE INDIVIDUAL UNIT SPECIFICATION SHEET FOR UNIT SPECIFIC SIZES

CUSTOMER HARD PLUMB WATER CONNECTION

3- 6 4 l I ns ta ll a ti on - W a te r Lin e s

Typical Water Lines Installation Drawing

Conair recommends providing supply and return water valves at this location.

Recommended Water Flow Rates

Dryer Model gal./min. {liters/min.} 600 15 {56.8} 800 15 {56.8} 1000 20 {75.7} 1600 25 {94.6} 2400 25 {94.6} 3200 30 {113.6} 5000 30 {113.6}

In s tal l a tio n

In s ta ll at io n - W at er L in es l 3- 65

Connecting the Aftercooler/ Intercooler and Optional Precooler

(W6 0 0 - 1000)

The aftercooler and/or optional precooler require a source of city, tower, or chiller water and a discharge or return line. You can use water at temperatures of 45 to 85°F {7 to 29°C}.

1 Connect the water supply line to

the aftercooler/intercooler or precooler inlet. If a manual shut

off valve is used, it should be mounted on the inlet line.

2 Connect the water discharge or

return line with the pressure relief valve to the aftercooler/ intercooler or precooler outlet.

Use the bracket supplied to secure the pressure relief valve to the back of the dryer.

IMPORTANT: Turn the water off when the dryer is not in use to prevent condensation.

Aftercooler/Intercooler Inlet

Aftercooler/Intercooler Outlet

✒

TIP: Make the water supply and dis-

charge / return connections with flexible hoses at least 24 in. (61 cm) long. This allows you to easily remove the aftercooler/ intercooler assembly for cleaning.

✒

TIP: If an optional flow control is

also being installed with the aftercooler/intercooler, the manual shut off valve should be installed on the inlet line for the flow control.

NOTE: Models W600-1000

dryer aftercooler/intercooler

and dry air delivery configura-

tion shown. Location on larg-

er models are different. Refer

to the labeling on your dryer.

✐

3- 6 6 l I ns ta ll a ti on - W a te r Lin e s

Connecting the Intercooler and Optional Precooler (W1600 - 5 0 00)

The intercooler and/or optional precooler require a source of city, tower, or chiller water and a discharge or return line. You can use water at temperatures of 45 to 85°F {7 to 29°C}.

1 Connect the water supply line to

the aftercooler/intercooler or precooler inlet. If a manual shut

off valve is used, it should be mounted on the inlet line.

2 Connect the water discharge or

return line with the pressure relief valve to the aftercooler/ intercooler or precooler outlet.

Use the bracket supplied to secure the pressure relief valve to the back of the dryer.

IMPORTANT: Turn the water off when the dryer is not in use to prevent condensation.

Aftercooler/Intercooler Inlet

Aftercooler/Intercooler Outlet

✒

TIP: Make the water supply and dis-

charge / return connections with flexible hoses at least 24 in. (61 cm) long. This allows you to easily remove the aftercooler/ intercooler assembly for cleaning.

✒

TIP: If an optional flow control is

also being installed with the aftercooler/intercooler, the manual shut off valve should be installed on the inlet line for the flow control.

Recommended Water Flow Rates

Dryer Model gal./min. {liters/min.} 600 15 {56.8} 800 15 {56.8} 1000 20 {75.7} 1600 25 {94.6} 2400 25 {94.6} 3200 30 {113.6} 5000 30 {113.6}

Installation - Control & Communication Wiring

In s tal l a tio n

In s ta ll at io n - Co nt ro l & Co mm un i ca ti on W i ri ng l 3- 67

Wiring the HTC (Electric Process Heater) to the HTC Controller

IMPORTANT: Always refer to the proper wiring diagram supplied with your

equipment before making electrical connections.

CAUTION: Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by qualified personnel.

1 Refer to the wiring diagram that came with your control.

2 Insert the control wires through a knockout in the side or bottom of the HTC

control center. Secure with a appropriately-sized strain relief, if conduit is not used.

3 Connect the high temperature and pressure switch wires to the control

center's terminal block.

4 Insert the other end of the control wires through the knockout in one side of

the HTC heater assembly terminal box. Secure with a appropriately-sized strain relief, if conduit is not used.

5 Connect the high temperature and pressure switch wires to the heater

assembly terminal block.

IMPORTANT: The connection between the heater and control center should be made with customer supplied wire that has properly sized conductors and properly protected with customer-supplied conduit. The routing should be neat and away from potential mechanical damage. The terminations should be landed on the terminals in the control center and heater junction area. These terminations should be regularly checked to prevent loosening and shorting to ground.

O OFF

(continued)

3- 6 8 l I ns ta ll a ti on - Co nt r ol & Co mm u ni ca ti on Wi ri ng

IMPORTANT: Always refer

to the wiring diagram that came with your HTC before making electrical connections.

In s tal l a tio n

In s ta ll at io n - Co nt ro l & Co mm un i ca ti on W i ri ng l 3- 69

Connecting the HTC to the HTC Controller ( co nt in ued )

6 Insert the heater power wire through a knockout in the side or bottom of

the HTC control center. Secure the wire with an appropriately-sized strain relief, if conduit is not used.

7 Connect the heater power wires to the control center’s terminal block and

heater ground wire to the ground lug as shown.

8 Insert the other end of heater power wire through the knockout in the side

of the heater assembly. Secure the wire with an appropriately-sized strain relief, if conduit is not used.

9 Connect the heater power wires to the top terminals of the heater assem-

bly’s terminal block and heater ground wires to the ground lug as shown.

Power Wires

(Customer

Supplied)

Ground WIres

(Green - Customer

Supplied)

Ground Wires

Green

Insert the Power Wires Here

3- 7 0 l I ns ta ll a ti on - Co nt r ol & Co mm u ni ca ti on Wi ri ng

Connecting the RTD Sensors (HTC o nly )

The routing of the RTD sensor cables should be neat and not parallel with the power connections. When a sensor cable must cross over power wiring, the intersection should be made at right angles (90 degree) to reduce the RFI noise transmitted to the sensor cable.

Pro ce ss Temperatur e RT D P ro be

The process RTD sensor connection should be made to the HTC’s control panel

CAUTION: Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by qualified personnel.

1 Disconnect and/or lock out main power to

the HTC.

2 Route the process temperature RTD cable

from hopper inlet to the HTC’s control panel. Plug the connector into receptacle in

the side of the control center labeled “Process”. Hand tighten the connector. Coil any excess cable and secure it with a wire tie.

Pro ce ss Pr otection RTD Pro be

The process protection RTD probe is a safety sensor that prevents the HTC’s heater from overheating in case of a process temperature sensor failure or insulated hose failure.

The process protection RTD sensor senses the temperature leaving the heater assembly to prevent damage to the process or the product in the CH Hopper. It generates an alarm (A-49 or A-50) at the HTC control panel and shuts the heater off if the air temperature exceeds the process protection setpoint. The element for this sensor is to be mounted in the heater assembly outlet nozzle before the insulated hose is connected.

IMPORTANT: Always refer to the wiring diagrams that came with your HTC before making electrical connections.

(continued)

Conair HTC 30, HTC 180, HTC 270, W600-1000, HTC 60 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual