1. Manuals
  2. Brands
  3. Conair Manuals
  4. Dryer
  5. HTC 30
  6. User manual

Conair HTC 30 User Manual

Energysmart dryer w series models 600 through 5000 with touchview technology
Hide thumbs
Table of Contents

  • English

  • Unknown

    • I N S T a L L a T I O N

    • Installation - General
      • I N S T a L L a T I O N - G E N E R a L
      • Unpacking the Energysmart Dryer System Components
      • Unpacking the Energysmart™ Dryer System
      • Preparing for Installation
      • Positioning the CH Hopper Floor Stand
      • Installation of the HTC Control
        • (Models HTC 30, 60 and 90)
        • (Models HTC 180 and 270)
      • Location and Mounting of the HTC Heater Assembly
        • (Models HTC 30, 60 and 90)
        • (Models HTC 180 and 270)
      • Installing the CH Hopper Cone Section
      • Installing the CH Hopper Door, Upper and Lid Sections
      • Installing the Cyclone (Optional)
      • Installing the Drying Monitor Probe
      • Securing the CH Hopper to the Floor
      • Location and Mounting of the Gastrac Heater
      • Location and Mounting of the Vacuum Pump(S)
      • Positioning the Dryer on the Floor
      • Removing the Cable Tie from the Desiccant Wheel
        • (W600-1000 Models)
      • Installing the Regeneration Exhaust Cover
      • Installing the Return Air Inlet and Air Outlet Adapters

    • Installation - Piping/Hoses
      • Optional Hard Piping Kits
      • Connecting the Heat Sources
        • Gastrac as Heat Source
      • Connecting the Dryer to the Heat Source
      • Connecting the Cyclone Separator (Optional)
      • Installing the Dwyer 641 Air Velocity Transmitter
      • Installing the Process Protection RTD Sensor
      • Location of the Process Material Temperature Probe (RTD)
      • Installing the Return Air Dew Point Line

    • Installation - Main Power Connections
      • Connecting Main Power to the Dryer
      • Connecting Main Power to the HTC
        • (Models HTC 30, 60, 90 and 120)
        • (Models HTC 180 and 270)
      • Connecting Main Power to the Gastrac
      • Connecting Main Power to the Vacuum Pump(S)

    • Installation - Conveying Lines
      • (Optional)
      • Connecting the Conveying Lines to the Receiver(S) (Optional)
      • Connecting the Conveying Lines to the Vacuum Pump(S) and
      • I N S T a L L a T I O N - Wa T E R L I N E

    • Installation - Water Lines
      • Typical Water Lines Installation Drawing
      • Precooler (W600-1000)
      • Connecting the HTC to the HTC Controller
        • C O N N E C T I N G T H E RT D S E N S O R S ( H T C O N L
        • C O N N E C T I N G T H E G a S Tr a C RT D S E N S O R
      • Connecting the Drying Monitor Probe to the Dryer
      • Connecting the Energysmart Dryer Control to System
        • Components

    • Installation - Compressed Air Lines
      • Connecting the Compressed Air Lines (Optional)

    • Installation - Gas Piping and Exhaust Flue
      • Typical Gas Line Installation Drawing
      • Installing the Conair Gastrac
        • I N S T a L L I N G T H E C O N a I R G a S Tr a
      • Connecting the Gas and the Exhaust Flue to the Gastrac

    • Installation - Testing
      • Checking for Proper Air Flow
        • C H E C K I N G F O R P R O P E R a I R F L O W
      • Testing the Variable Frequency Drive (VFD)
        • Te S T I N G T H E V a R I a B L E F R E Q U E N Cy D R I V E ( V F
      • Testing the Installation of the HTC
        • Te S T I N G T H E I N S T a L L a T I O N O F T H E H T
      • Checking the Gas and Electrical Systems of the Gastrac
      • Testing the Installation of the Gastrac
        • Te S T I N G T H E I N S T a L L a T I O N O F T H E G a S Tr a
        • Te S T I N G T H E P R I M a R y R E C E I V E R ( O P T I O N a
        • Te S T I N G T H E S E C O N D a R y R E C E I V E R ( O P T I O N a
      • Configuring the Dwyer 641 Air Velocity Transmitter
      • Configuring the DM-II Drying Monitor
        • Te S T I N G T H E I N S T a L L a T I O N
      • The Energysmart Dryer System Control Panel
      • How to Navigate the Control Screens
      • Control Function Flow Charts
        • Login Flow Chart
        • Operation Flow Chart 2
        • Operation Flow Chart 3
        • Setup Flow Chart 1
        • Equipment Setup Flow Chart 1
        • Equipment Setup Flow Chart 2
        • Communications Setup Flow Chart
        • Example Setpoint Change
      • Control Function Descriptions
      • Copying Files from the Energysmart Dryer System
      • Using Dewpoint
      • Using Optimizer
        • C L E a N I N G T H E P R O C E S S F I L T E R
        • C L E a N I N G T H E R E G E N E R a T I O N F I L T E R
        • C L E a N I N G T H E P R E C O O L E R C O I L S
      • B E F O R E B E G I N N I N G
        • A Fe W wo R D S O F C a U T I O N
        • H O W T O I D E N T I F y T H E C a U S E O F a P R O B L E M
        • Shutdown Alarms
        • S H U T D O W N a L a R M S
          • Cleaning the Aftercooler/Intercooler Coils
          • Energysmart Dryer System Modbus Communications
        • Repair
        • Repair
        • A S S E M B L y
        • M O T O R
        • M O T O R
        • We're here to Help
        • Equipment Guarantee

Advertisement

Quick Links

www.conairgroup.com
U S E R G U I D E
UGD041-1212
EnergySmart
Dryer
®
W Series Models 600 through 5000 with TouchView
Technology (Allen-Bradley)
TM
Corporate Office: 724.584.5500
l
Instant Access 24/7 (Parts and Service): 800.458.1960
l
Parts and Service: 814.437.6861

Advertisement

Chapters

Table of Contents
loading

Related Manuals for Conair HTC 30

Summary of Contents for Conair HTC 30

  • Page 1 www.conairgroup.com U S E R G U I D E UGD041-1212 EnergySmart Dryer ® W Series Models 600 through 5000 with TouchView Technology (Allen-Bradley) Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861...
  • Page 2 Firmware Version Number: Application File Name: 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.

  • Page 3: Table Of Contents

    Ta b l e o f C o n t e n t s I n t r o d u c t i o n Purpose of the user guide ....... . 1-2 How the guide is organized .
  • Page 4 Installation of the HTC control (Models HTC 30, 60 and 90) ......3-9 (Models HTC 120) ....... . 3-10 (Models HTC 180 and 270) .
  • Page 5 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 .
  • Page 6 Typical gas line installation drawing ..... . . 3-88 Installing the Conair GasTrac ......3-89 Connecting the gas and the exhaust flue to the GasTrac .
  • Page 7 O p e r a t i o n The EnergySmart Dryer System control panel ....4-2 How to navigate the control screens ......4-3 Control function flow charts .
  • Page 8 M a i n t e n a n c e Preventative maintenance checklist ......5-2 Inspecting the hoses, piping and gaskets ....5-8 Cleaning the CH hopper .
  • Page 9 Warranty limitations ........A-2 Conair print numbers list ....... . A-3...
  • Page 10 v i i i l Ta b l e o f C o n t e n t s...
  • Page 11 S E C T I O N I n t r o d u c t i o n P u r p o s e o f t h e u s e r g u i d e ....1 - 2 H o w t h e g u i d e i s o r g a n i z e d .

  • Page 12: I N T R O D U C T I O N

    P u r p o s e o f t h e U s e r G u i d e This User Guide describes the Conair EnergySmart Dryer System with ® TouchView Technology and explains step-by-step how to install, oper- ate, maintain and repair this equipment.

  • Page 13: Using The Energysmart Dryer With Your System

    U s i n g t h e E n e r g y S m a r t D r y e r w i t h Yo u r S y s t e m The Conair EnergySmart Dryer with TouchView Technology used within your ®...

  • Page 14: At T E N T I O N

    AT T E N T I O N : R e a d t h i s s o n o o n e g e t s h u r t We design equipment with the user’s safety in mind. You can avoid the potential hazards identified within this system by following the procedures outlined below and elsewhere in the User Guide.

  • Page 15: Attention: Read This So No One Gets Hurt

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

  • Page 16: How To Use The Lockout Device

    Lockout is the preferred method of isolating machines or equipment from energy sources. Your Conair product is equipped with the lockout device pictured below. To use the lockout device: Stop or turn off the equipment.

  • Page 17: D E S C R I P T I O N

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

  • Page 18: Typical Applications

    W h a t i s t h e E n e r g y S m a r t D r y e r ® S y s t e m ? Energy efficient drying and superior end product are the results of having precise control of your drying process.

  • Page 19: How The Energysmart Dryer System Works

    H o w t h e E n e r g y S m a r t D r y e r S y s t e m Wo r k s 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.

  • Page 20: Specifications: Energysmart Carousel Plus W Series

    †† 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. TPDX019-0712...
  • Page 21 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. D e s c r i p t i o n l 2 - 5...
  • Page 22 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 D e s c r i p t i o n...

  • Page 23: Dust Collectors

    Model DC1 and DC2 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 TPCS012-0408 the most current information.
  • Page 24 PD25 Specifications can change with- Motor Type* TEFC TEFC TEFC TEFC TEFC TEFC out notice. Check with a Conair Performance representative for the most cur- Horsepower rent information. Standard CFM at Material Pickup Point @ 10" Hg 52.6 76.6 121.2 154.5...
  • Page 25 S p e c i f i c a t i o n s : C H S e r i e s I n s u l a t e d H o p p e r s Without Integrated Cyclone (Fig.
  • Page 26 Top for hopper loaders Specifications can change without 4 equally spaced IB09 16 bolt holes, 7/16 in. notice. Check with a Conair repre- mounting clips on a {11 mm}, on a 16.25 in. sentative for the most current 16.375 in. {416 mm} {413 mm} square plate information.
  • Page 27 CH74-366 CH74-487 Specifications can change with- FIGURE NUMBER Fig. 2 Fig. 2 Fig. 2 Performance characteristics out notice. Check with a Conair Capacity ft {liter} 245 {6938} 366 {10365} 487 {13792} representative for the most Capacity @ 35 lb/ft 8575...
  • Page 28 Connecting cable Pre-wired dryer panel Light tower SPECIFICATION NOTES: Specifications can change without notice. Check with a Conair representative for the most current information. 2 - 1 2 l D e s c r i p t i o n...

  • Page 29: E N E R G Y S M A R T D R Y E R C O N T R O L O P T I O N

    E n e r g y S m a r t D r y e r C o n t r o l O p t i o n s • Visual alarms - The visual alarm is a blinking red alarm light that alerts the user to any shut down alarm.
  • Page 30 2 - 1 4 l D e s c r i p t i o n...

  • Page 31: I N S T A L L A T I O N

    Installation of the HTC control (Models HTC 30, 60 and 90) ....3-9 (Models HTC 120) ......3-10 (Models HTC 180 and 270) .
  • Page 32 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...
  • Page 33 I n s t a l l a t i o n ( c o n t i n u e d ) (Models HTC 180 and 270) ....3-54 Connecting main power to the GasTrac .
  • Page 34 I n s t a l l a t i o n ( c o n t i n u e d ) C o n 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 c o n t r o l t o s y s t e m c o m p o n e n t s .

  • Page 35: Installation - General

    I n s t a l l a t i o n - G e n e r a l I n s t a l l a t i o n - G e n e r a l l 3 - 5...

  • Page 36: Unpacking The Energysmart Dryer System Components

    U n p a c k i n g t h e E n e r g y S m a r t ™ D r y e r S y s t e m C o m p o n e n t s 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.

  • Page 37: Preparing For Installation

    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.

  • Page 38: Positioning The Ch Hopper Floor Stand

    Installation - Piping and Hoses for reference. NOTE: For EnergySmart Dryer Due to the varying size of Conair CH Hoppers, Conair recommends: Systems supplied with "small" hoppers, the floor stand and cone •...

  • Page 39: Installation Of The Htc Control

    I n s t a l l a t i o n o f t h e H T C C o n t r o l ( M o d e l s H T C 3 0 , 6 0 , a n d 9 0 ) CAUTION: You are responsible for the structural integrity of this installation.

  • Page 40: (Models Htc 180 And 270)

    RTD wiring Move the control center into are too short for your installation, its final location for operation contact Conair Parts Department (see figure to the right). The (800.458.1960) to purchase control center must be posi- extension cables. From outside the tioned close enough to the United States, call 814.437.6861.

  • Page 41: Location And Mounting Of The Htc Heater Assembly

    L o c a t i o n a n d M o u n t i n g o f t h e H T C IMPORTANT: Always refer H e a t e r A s s e m b l y to the wiring diagrams that came with your HTC before ( M o d e l s H T C 3 0 , 6 0 a n d 9 0 )

  • Page 42: Installing The Ch Hopper Cone Section

    NOTE: If using carbon steel hop- pers, be sure to clean out the hopper prior to use. Conair Using a forklift, hoist or crane, lift the cone section assembly above applies a rust inhibitor that must the floor stand.

  • Page 43: Installing The Ch Hopper Door, Upper And Lid Sections

    (gas or electric), optional dust collector and optional cyclone before making the installation permanent. TIP: Conair recommends applying strip and stick sealer 1/8 inches H o p p e r D o o r S e c t i o n {3.2 mm} from the inside to the...
  • Page 44 I n s t a l l i n g t h e C H H o p p e r D o o r, U p p e r a n d L i d S e c t i o n s ( c o n t i n u e d ) H o p p e r D o o r S e c t i o n ( c o n t i n u e d )
  • Page 45 ( I f A p p l i c a b l e ) To install the hopper upper section(s) of the CH Hopper: TIP: Conair recommends applying strip and stick sealer 1/8 inches Apply sealer around the lip on the top of the hopper door section.
  • Page 46 H o p p e r L i d S e c t i o n IMPORTANT: Improper mounting of the hopper lid will cause interference when TIP: Conair recommends applying installing the DM-II monitor probe and optional integrated cyclone. See the illustra- strip and stick sealer 1/8 inches tion below for recommended hopper lid mounting locations.

  • Page 47: Installing The Cyclone (Optional)

    I n s t a l l i n g t h e C y cl o n e (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 cir- cuit of the CH Hopper, then connected to an optional dust collector or to the dryer’s air inlet.
  • Page 48 I n s t a l l i n g t h e C y cl o n e (optional) (continued) 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.
  • Page 49 I n s t a l l i n g t h e C y cl o n e (optional) (continued) Dew Point Return Port Gasket Bolt the third piece of 90 degree tubing to the assembly in Step 8 using the supplied hardware.
  • Page 50 I n s t a l l i n g t h e C y cl o n e (optional) (continued) Be sure to make any adjustments necessary to the cyclone or tubing assembly. Tighten all bolts within the cyclone and tubing assemblies with an appropriately-sized wrench.
  • Page 51 I n s t a l l i n g t h e C y cl o n e (optional) (continued) Locate the supplied hosing used for the cyclone’s waste container. Connect the hosing to the straight piece of tubing installed in Step 15 using the supplied hose clamp.

  • Page 52: Installing The Drying Monitor Probe

    I n s t a l l i n g t h e D r y i n g M o n i t o r P r o b e 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.
  • Page 53 I n s t a l l i n g t h e D r y i n g M o n i t o r P r o b e ( c o n t i n u e d ) 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.
  • Page 54 I n s t a l l i n g t h e D r y i n g M o n i t o r P r o b e ( c o n t i n u e d ) Through the Door of the CH Hopper ( c o n t i n u e d ) Push the compression sleeve into the...
  • Page 55 I n s t a l l i n g t h e R e c e i v e r ( s ) ( o p t i o n a 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.

  • Page 56: Securing The Ch Hopper To The Floor

    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 •...

  • Page 57: Location And Mounting Of The Gastrac Heater

    L o c a t i o n a n d M o u n t i n g o f t h e G a s Tr a c H e a t e r ( i f e q u i p p e d ) NOTE: If your system has electri- The GasTrac supplied with the EnergySmart Dryer System is designed to be cal heaters, for the drying sys-...
  • Page 58 L o c a t i o n a n d M o u n t i n g o f t h e D u s t C o l l e c t o r ( o p t i o n a l ) 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.
  • Page 59 L o c a t i o n a n d M o u n t i n g o f t h e D u s t C o l l e c t o r ( o p t i o n a l ) ( c o n t i n u e d ) Ensure that the hoses from the dif- Pressure ferential pressure transmitter,...

  • Page 60: Location And Mounting Of The Vacuum Pump(S)

    L o c a t i o n a n d M o u n t i n g o f t h e Va c u u m P u m p ( s ) a n d D u s t C o l l e c t o r ( s ) ( o p t i o n a l ) The optional vacuum pump(s) and associated dust collector(s) supplied with the...

  • Page 61: Positioning The Dryer On The Floor

    Po s i t i o n i n g t h e D r y e r o n t h e F l o o r To position the dryer: Lift the dryer from the shipping container using a fork truck. Position the dryer on the floor near the CH Hopper.
  • Page 62 Position the return air adapter over top of the return air inlet, aligning both bolt patterns. An optional hard piping kit for your EnergySmart Dryer system Secure the return air adapter with supplied hardware, using an is available from Conair. appropriately-sized wrench. Contact Conair Parts (800) 458 1960 From outside of the...

  • Page 63: Installing The Return Air Inlet And Air Outlet Adapters

    Dry Air Return Air Outlet Inlet Adapter 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...
  • Page 64 I n s t a l l i n g t h e O v e r h e a d P r o c e s s A i r D u c t ( W 3 2 0 0 - 5 0 0 0 ) The EnergySmart Dryer’s overhead process air duct will be removed when the dryer is shipped.

  • Page 65: Installation - Piping/Hoses

    I n s t a l l a t i o n - H a r d P i p i n g K i t s I n s t a l l a t i o n - P i p i n g / H o s e s l 3 - 3 5...

  • Page 66: Optional Hard Piping Kits

    EnergySmart Dryer System. The piping can consist of hard piping or flexi- ble 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 informa- tion concerning hard piping kits, contact your Conair Representative.

  • Page 67: Connecting The Heat Sources

    Make sure all hoses are securely clamped to your EnergySmart Dryer system prevent wasteful leaking. The hoses should be is available from Conair. routed neatly and supported where possible to Contact Conair Parts prevent undue stress on the heater and hopper (800) 458 1960 assemblies.

  • Page 68: Gastrac As Heat Source

    CH Hopper. If an insulated flexible hose is used, make sure it is securely clamped. An optional hard piping kit for your EnergySmart Dryer system is available from Conair. Contact Conair Parts (800) 458 1960 From outside of the...

  • Page 69: Connecting The Dryer To The Heat Source

    (Dryer Connection to HTC Shown) An optional hard piping kit for Make sure all hoses are securely clamped to your EnergySmart Dryer system is available from Conair. prevent wasteful leaking. The hoses should be routed neatly and supported where possible to Contact Conair Parts...
  • Page 70 Dryer Inlet An optional hard piping kit for your EnergySmart Dryer system is available from Conair. Make sure all hoses are securely clamped to Contact Conair Parts prevent wasteful leaking. The hoses should be (800) 458 1960...

  • Page 71: Connecting The Cyclone Separator (Optional)

    EnergySmart Dryer system prevent undue stress on the heater and hopper is available from Conair. assemblies. Also, the bends should be made with gradual radiuses. Sharp turns will cause Contact Conair Parts undue pressure drops.

  • Page 72: Installing The Dwyer 641 Air Velocity Transmitter

    Determine the best location to install the AVTs following the recommendations above. 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.
  • Page 73 I n s t a l l i n g t h e D w y e r 6 4 1 A i r Ve l o c i t y Tr a n s m i t t e r ( c o n t i n u e d ) Screw the compression fitting into the customer-supplied pipe.
  • Page 74 I n s t a l l i n g t h e L e v e l S w i t c h ( o p t i o n a l ) 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.
  • Page 75 A d j u s t i n g t h e L e v e l S e n s o r ( o p t i o n a l ) The level sensor should be adjusted both with ambient temperature and with opera- tion temperature.

  • Page 76: Installing The Process Protection Rtd Sensor

    I n s t a l l i n g t h e P r o c e s s P r o t e c t i o n RT D S e n s o r ( H T C O n l 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.

  • Page 77: Location Of The Process Material Temperature Probe (Rtd)

    CH Hopper and within your delivery system. Conair recommends that you check the throat of the machine to which your mate- rial is being delivered for an existing tap location that can be used to mount the RTD.
  • Page 78 I n s t a l l i n g t h e RT D S e n s o r 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 inaccu- rate.

  • Page 79: Installing The Return Air Dew Point Line

    I n s t a l l i n g t h e R e t u r n A i r D e w Po i n t L i n e The return air dew point line allows the dehumidifying dryer to monitor the mois- ture contained in the air leaving the CH Hopper via the dry air return port.
  • Page 80 3 - 5 0 l I n s t a l l a t i o n - P i p i n g / H o s e s...

  • Page 81: Installation - Main Power Connections

    I n s t a l l a t i o n - M a i n Po w e r C o n n e c t i o n s I n s t a l l a t i o n - M a i n Po w e r C o n n e c t i o n s l 3 - 5 1...

  • Page 82: Connecting Main Power To The Dryer

    C o n n e c t i n g M a i n Po w e r t o t h e D r y e r CAUTION: Always disconnect and lock out the main power sources before making electrical connections.

  • Page 83: Connecting Main Power To The Htc

    C o n n e c t i n g M a i n Po w e r t o t h e H T C ( M o d e l s H T C 3 0 , 6 0 , 9 0 a n d 1 2 0 ) The electrical connection for the HTC models 30, 60, 90 and 120 only consists of bringing power to the control center.

  • Page 84: (Models Htc 180 And 270)

    C o n n e c t i n g M a i n Po w e r t o t h e H T C ( c o n t i n u e d ) ( M o d e l s H T C 1 8 0 a n d 2 7 0 ) The electrical connection consists of bringing power into the control center and IMPORTANT: Always refer wiring the power from the control center to the heater assembly.
  • Page 85 C o n n e c t i n g M a i n Po w e r t o t h e H T C ( c o n t i n u e d ) ( M o d e l s H T C 1 8 0 a n d 2 7 0 ) ( c o n t i n u e d ) IMPORTANT: Always refer Insert the customer-supplied heater power wire through a knockout in the...

  • Page 86: Connecting Main Power To The Gastrac

    C o n n e c t i n g M a i n Po w e r t o t h e G a s Tr a c Open the GasTrac electrical enclosure. Turn the disconnect dial on the GasTrac’s door to the Off or “O”...

  • Page 87: Connecting Main Power To The Vacuum Pump(S)

    C o n n e c t i n g M a i n Po w e r t o t h e Va c u u m P u m p ( s ) ( o p t i o n a l ) Connect power.
  • Page 88 3 - 5 8 l I n s t a l l a t i o n - P i p i n g / H o s e s...

  • Page 89: Installation - Conveying Lines

    I n s t a l l a t i o n - C o n v e y i n g L i n e s I n s t a l l a t i o n - M a i n Po w e r C o n n e c t i o n s l 3 - 5 9...

  • Page 90: (Optional)

    C o n n e c t i n g t h e C o n v e y i n g L i n e s t o t h e R e c e i v e r ( s ) ( o p t i o n a l ) If an optional receiver is mounted to the top of the CH Hopper, follow the instruc- tions supplied with the receiver to connect the conveying lines.

  • Page 91: Connecting The Conveying Lines To The Vacuum Pump(S) And

    C o n n e c t i n g t h e C o n v e y i n g L i n e s t o t h e Va c u u m P u m p ( s ) a n d D u s t C o l l e c t o r ( s ) ( o p t i o n a l ) Connect the vacuum line from the optional receiver to the air inlet of the...
  • Page 92 3 - 6 2 l I n s t a l l a t i o n - C o n v e y i n g L i n e s...

  • Page 93: Installation - Water Lines

    I n s t a l l a t i o n - Wa t e r L i n e s I n s t a l l a t i o n - Wa t e r L i n e s l 3 - 6 3...

  • Page 94: Typical Water Lines Installation Drawing

    Ty p i c a l Wa t e r L i n e s I n s t a l l a t i o n D r a w i n g CUSTOMER HARD PLUMB WATER CONNECTION Conair recommends providing supply and return water valves at this location.

  • Page 95: Precooler (W600-1000)

    C o n n e c t i n g t h e A f t e r c o o l e r / I n t e r c o o l e r a n d O p t i o n a l P r e c o o l e r ( W 6 0 0 - 1 0 0 0 ) TIP: Make the water supply and dis- The aftercooler and/or optional precooler require a source of city, tower, or chiller...
  • Page 96 C o n n e c t i n g t h e I n t e r c o o l e r a n d O p t i o n a l P r e c o o l e r ( W 1 6 0 0 - 5 0 0 0 ) The intercooler and/or optional precooler require a source of city, tower, or chiller water and a discharge or return line.
  • Page 97 I n s t a l l a t i o n - C o n t r o l & C o m m u n i c a t i o n W i r i n g I n s t a l l a t i o n - C o n t r o l &...
  • Page 98 W i r i n g t h e H T C ( E l e c t r i c P r o c e s s H e a t e r ) t o t h e H T C C o n t r o l l e r IMPORTANT: Always refer to the proper wiring diagram supplied with your equipment before making electrical connections.

  • Page 99: Connecting The Htc To The Htc Controller

    C o n n e c t i n g t h e H T C t o t h e H T C C o n t r o l l e r ( c o n t i n u e d ) Insert the heater power wire through a knockout in the side or bottom of the HTC control center.

  • Page 100: C O N N E C T I N G T H E Rt D S E N S O R S ( H T C O N L

    C o n n e c t i n g t h e RT D S e n s o r s ( H T C o n l y ) IMPORTANT: Always refer The routing of the RTD sensor cables should be neat and not parallel with the to the wiring diagrams power connections.
  • Page 101 C o n n e c t i n g t h e RT D S e n s o r s ( H T C o n l y ) ( c o n t i n u e d ) Process Protection RTD Probe (continued) CAUTION: Always disconnect and lock out the main power sources before making...

  • Page 102: C O N N E C T I N G T H E G A S Tr A C Rt D S E N S O R

    Route the GasTrac RTD cable to the GasTrac control center. Plug the RTD cable into the GasTrac control center. Coil any excess cable and secure with a wire tie. NOTE: Conair recommends locat- ing the RTD probe, when possible, within 30 ft {9.15 m} of the GasTrac control center.

  • Page 103: Connecting The Drying Monitor Probe To The Dryer

    C o n n e c t i n g t h e D r y i n g M o n i t o r IMPORTANT: Always refer P r o b e t o t h e D r y e r to the wiring diagrams that came with your Drying Monitor before...
  • Page 104 C o n n e c t i n g t h e R e c e i v e r t o t h e L e v e l S w i t c h ( o p t i o n a l ) IMPORTANT: Always Refer to your specific receiver’s manual for instructions to connect the level switch.
  • Page 105 NOTE: The communications interconnecting “daisy chain” wire starts at its connection point at the EnergySmart Dryer control, then is connected to the other system compo- nents. NOTE: Conair recommends the connections between the EnergySmart Dryer and system components should be made...
  • Page 106 C o n 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 C o n t r o l t o S y s t e m C o m p o n e n t s IMPORTANT: Always refer to the wiring diagrams ( c o n t i n u e d )

  • Page 107: Connecting The Energysmart Dryer Control To System

    C o n 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 C o n t r o l t o S y s t e m C o m p o n e n t s IMPORTANT: Always refer to the wiring diagrams ( c o n t i n u e d )
  • Page 108 C o n 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 C o n t r o l t o S y s t e m C o m p o n e n t s IMPORTANT: Always refer to the wiring diagrams ( c o n t i n u e d )
  • Page 109 C o n 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 C o n t r o l t o S y s t e m C o m p o n e n t s ( c o n t i n u e d ) Connect the communication inter-connecting wire of the HTC to the EnergySmart Dryer electrical panel as detailed in the supplied wiring dia-...
  • Page 110 IMPORTANT: Always refer to the wiring diagrams that came with your EnergySmart Dryer System before making electrical connections. NOTE: Conair recommends the connections between the EnergySmart Dryer and system components should be made with properly sized conductors and properly protected with appropriate conduit (customer supplied).

  • Page 111: Components

    C o n n e c t i n g t h e E n e r g y S m a r t C o n t r o l Pa n e l t o t h e S y s t e m IMPORTANT: Always refer C o m p o n e n t s ( c o n t i n u e d )
  • Page 112 Electrical connections should be made only by quali- fied personnel. To connect the vacuum pump to the EnergySmart Dryer electrical panel: NOTE: Conair recommends the connections between the Disconnect and/or lock out main power to the EnergySmart Dryer and EnergySmart Dryer and sys- vacuum pump.
  • Page 113 CAUTION: Always disconnect and lock out the main power sources before mak- ing electrical connections. Electrical connections should be made only by quali- fied personnel. NOTE: Conair recommends To connect the receiver to the EnergySmart Dryer electrical panel: the connections between the...
  • Page 114 C o n n e c t i n g t h e E n e r g y S m a r t C o n t r o l t o S y s t e m C o m p o n e n t s ( c o n t i n u e d ) Connecting the Air Pressure Sensor The EnergySmart Drying System uses data from the Dwyer 616 Differential...

  • Page 115: Installation - Compressed Air Lines

    I n s t a l l a t i o n - C o m p r e s s e d A i r L i n e s I n s t a l l a t i o n - C o m p r e s s e d A i r L i n e s l 3 - 8 5...

  • Page 116: Connecting The Compressed Air Lines (Optional)

    C o n n e c t i n g t h e C o m p r e s s e d A i r L i n e s ( o p t i o n a l ) If individual components require compressed air, follow the instructions supplied with the equipment to connect the compressed air lines.

  • Page 117: Installation - Gas Piping And Exhaust Flue

    I n s t a l l a t i o n - G a s P i p i n g a n d E x h a u s t F l u e ( G a s Tr a c o n l y ) I n s t a l l a t i o n - G a s P i p i n g a n d E x h a u s t F l u e l 3 - 8 7...

  • Page 118: Typical Gas Line Installation Drawing

    Ty p i c a l G a s L i n e I n s t a l l a t i o n D r a w i n g EXHAUST GAS VENT CONSULT YOUR HVAC CONTRACTOR FOR PROPER INSTALLATION MAX.

  • Page 119: Installing The Conair Gastrac

    700 {19.8} 1 in. NOTE: Conair strongly recommends that a “drop tube” be utilized when piping the gas line into the GasTrac. This will help to prevent any oil or metal shavings, created dur- ing the installation process, from entering the GasTrac. If this action is not completed, warranty on components in gas line will be voided.

  • Page 120: I N S T A L L I N G T H E C O N A I R G A S Tr A

    ( c o n t i n u e d ) Proper Exhaust Recommendations Conair recommends that the customer contact a local contractor that can determine the proper line size based on specific conditions. The following information may be required for the contractor to make a proper...
  • Page 121 I n s t a l l i n g t h e C o n a i r G a s Tr a c ( c o n t i n u e d ) If an extremely long length of exhaust ducting is used, Conair recommends using condensation traps as necessary. For every 1,000 cubic feet {28.3 cubic meters} of gas burned, 6 gallons {22.7 L} of water vapor will be produced in...

  • Page 122: Connecting The Gas And The Exhaust Flue To The Gastrac

    E x h a u s t F l u e t o t h e G a s Tr a c WARNING: Conair strongly recommends that the steps below be completed by a qualified mechanical contractor in compliance with all applicable natural gas codes in your region.
  • Page 123 CGT350 3/4 in. CGT500 3/4 in. CGT700 1 in. NOTE: Conair strongly recom- mends that a “drop tube” be Drop Tube utilized when piping the gas line into the GasTrac. This will help to prevent any oil or metal shavings, created during the installation process, from enter- ing the GasTrac.
  • Page 124 3 - 9 4 l I n s t a l l a t i o n - G a s P i p i n g a n d E x h a u s t F l u e...

  • Page 125: Installation - Testing

    I n s t a l l a t i o n - Te s t i n g I n s t a l l a t i o n - Te s t i n g l 3 - 9 5...

  • Page 126: Checking For Proper Air Flow

    C h e c k i n g f o r P r o p e r A i r F l o w IMPORTANT: This procedure must be performed before loading material into the hopper. CAUTION: If the air flow direction is incorrect due to improper phase connection, material from the hopper can be pulled back into the dryer, causing permanent damage to this equipment.

  • Page 127: C H E C K I N G F O R P R O P E R A I R F L O W

    WARNING: All wiring, C h e c k i n g f o r P r o p e r A i r F l o w ( c o n t i n u e d ) disconnects, and fuses should be installed by qualified electrical tech- From the Login Screen (Screen 1), press the “Dehumid Drying”...
  • Page 128 C h e c k i n g f o r P r o p e r A i r F l o w ( c o n t i n u e d ) If air flow is incorrect disconnect power, follow proper lockout procedures and swap any 2 of the 3 incoming main power wires.

  • Page 129: Testing The Variable Frequency Drive (Vfd)

    Te s t i n g t h e Va r i a b l e F r e q u e n c y D r i v e ( V F D ) Press the “Local/Remote” button to switch the blower VFD on the back of the EnergySmart Dryer from the default of “Remote”...

  • Page 130: Testing The Installation Of The Htc

    Te s t i n g t h e I n s t a l l a t i o n o f t h e H T C IMPORTANT: The EnergySmart Dryer must be running to perform this test. Make sure there is no material in the CH Hopper.

  • Page 131: Te S T I N G T H E I N S T A L L A T I O N O F T H E H T

    Te s t i n g t h e I n s t a l l a t i o n o f t h e H T C ( c o n t i n u e d ) Adjust the HTC’s setpoint to the required hopper inlet temperature.

  • Page 132: Checking The Gas And Electrical Systems Of The Gastrac

    C h e c k i n g t h e G a s a n d E l e c t r i c a l S y s t e m s o f t h e G a s Tr a c WARNING: All wiring, disconnects and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region.

  • Page 133: Testing The Installation Of The Gastrac

    Te s t i n g t h e I n s t a l l a t i o n o f t h e G a s Tr a c Start the Energy Smart Dryer, see Operation Section, Starting the Dryer. IMPORTANT: The EnergySmart Monitor the dryer during the first few minutes of operation to verify that the Dryer must be running to per-...
  • Page 134 Te s t i n g t h e I n s t a l l a t i o n o f t h e G a s Tr a c ( c o n t i n u e d ) Verify the combustion blower is rotating in the correct direction.

  • Page 135: Te S T I N G T H E P R I M A R Y R E C E I V E R ( O P T I O N A

    Te s t i n g t h e P r i m a r y R e c e i v e r ( o p t i o n a l ) Make sure there is no material in the Primary hopper. Disconnect the material supply hose of the optional receiver at the source.
  • Page 136 Te s t i n g t h e P r i m a r y R e c e i v e r ( o p t i o n a l ) ( c o n t i n u e d ) Press the “Enable”...

  • Page 137: Te S T I N G T H E S E C O N D A R Y R E C E I V E R ( O P T I O N A

    Te s t i n g t h e S e c o n d a r y R e c e i v e r ( o p t i o n a l ) Make sure there is no material in the secondary hopper. Disconnect the material supply hose of the receiver at the source.
  • Page 138 Te s t i n g t h e S e c o n d a r y R e c e i v e r ( o p t i o n a l ) ( c o n t i n u e d ) Press the “Enable”...

  • Page 139: Configuring The Dwyer 641 Air Velocity Transmitter

    C o n f i g u r i n g t h e D w y e r 6 4 1 A i r Ve l o c i t y Tr a n s m i t t e r The Dwyer 641 Air Velocity Transmitter must be programmed within the EnergySmart NOTE: For detailed pro- Dryer control for the correct dryer size before testing.

  • Page 140: Configuring The Dm-Ii Drying Monitor

    C o n f i g u r i n g t h e D M - I I D r y i n g M o n i t o r Setting Up the Drying Monitor-II (DM-II) NOTE: To understand the navigation of the DM-II NOTE: Option must be enabled in Alarm Setup screen.

  • Page 141: Te S T I N G T H E I N S T A L L A T I O N

    Te s t i n g t h e I n s t a l l a t i o n You have completed the installation. Now it’s time to check to ensure all components operate together correctly. Be sure that there is no material in the CH Hopper. If you have mounted an optional vacuum receiver on the hopper, disconnect the material inlet hose at the source.
  • Page 142 Te s t i n g t h e I n s t a l l a t i o n From the System Control Screen (Screen 16), press the “Start System” button. If everything is installed correctly: • The regeneration and process blowers turn on. If process blower does not turn on, verify that the VFD is set to “Remote •...
  • Page 143 O p e r a t i o n S E C T I O N T h e E n e r g y S m a r t D r y e r S y s t e m c o n t r o l p a n e l .

  • Page 144: The Energysmart Dryer System Control Panel

    T h e E n e r g y S m a r t D r y e r S y s t e m C o n t r o l Pa n e l On power-up, the EnergySmart Dryer control displays the initial system "Login"...

  • Page 145: How To Navigate The Control Screens

    H o w t o N a v i g a t e t h e C o n t r o l S c r e e n s Navigate through the Energy Smart Dryer Control Screens by touching any navigation "buttons"...
  • Page 146 H o w t o N a v i g a t e t h e C o n t r o l S c r e e n s ( c o n t i n u e d ) The user name, password and other information can be entered using the pop-up keyboard window that appears when an appropriate field is touched.
  • Page 147 H o w t o N a v i g a t e t h e C o n t r o l S c r e e n s ( c o n t i n u e d ) When a system component is to be selected from a list of parameters, the "Up"...

  • Page 148: Control Function Flow Charts

    C o n t r o l F u n c t i o n F l o w C h a r t s L o g i n F l o w C h a r t NOTE: Depending on your user login level, some functions may not be available.

  • Page 149: Operation Flow Chart 2

    C o n t r o l F u n c t i o n F l o w C h a r t s ( c o n t i n u e d ) O p e r a t i o n F l o w C h a r t 1 (continued) O p e r a t i o n l 4 - 7...
  • Page 150 C o n t r o l F u n c t i o n F l o w C h a r t s ( c o n t i n u e d ) O p e r a t i o n F l o w C h a r t 2 These screens are optional.

  • Page 151: Operation Flow Chart 3

    C o n t r o l F u n c t i o n F l o w C h a r t s ( c o n t i n u e d ) O p e r a t i o n F l o w C h a r t 3 These screens are optional.

  • Page 152: Setup Flow Chart 1

    C o n t r o l F u n c t i o n F l o w C h a r t s ( c o n t i n u e d ) S e t u p F l o w C h a r t 1 4 - 1 0 l O p e r a t i o n (continued)

  • Page 153: Equipment Setup Flow Chart 1

    C o n t r o l F u n c t i o n F l o w C h a r t s ( c o n t i n u e d ) E q u i p m e n t S e t u p F l o w C h a r t 1 These screens are optional.

  • Page 154: Equipment Setup Flow Chart 2

    C o n t r o l F u n c t i o n F l o w C h a r t s ( c o n t i n u e d ) E q u i p m e n t S e t u p F l o w C h a r t 2 These screens are optional.

  • Page 155: Communications Setup Flow Chart

    C o n t r o l F u n c t i o n F l o w C h a r t s ( c o n t i n u e d ) C o m m u n i c a t i o n s S e t u p F l o w C h a r t (continued) 4 - 1 3 O p e r a t i o n l...

  • Page 156: Example Setpoint Change

    C o n t r o l F u n c t i o n F l o w C h a r t s ( c o n t i n u e d ) E x a m p l e S e t Po i n t C h a n g e NOTE: Only white background boxes with numbers in them can be changed.

  • Page 157: Control Function Descriptions

    C o n t r o l F u n c t i o n D e s c r i p t i o n s Screen 1A - Login Screen NOTE: From the "Login" screen, a user can navigate through all of the EnergySmart Dryer Control screens without logging onto the system.
  • Page 158 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Press the "Enter" button to return to the "User/Password" window, after the user name or password has been entered.
  • Page 159 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 2 - System Overview Screen NOTE: When a "Magnifying Glass"...
  • Page 160 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 3 - Process Heater: Dehumidified Air Circuit Screen NOTE: Screen 3 shows the type of heater installed in the Dehumidifying Drying Circuit of...
  • Page 161 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 4 - Dehumidifying Dryer Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 162 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 5 - Primary Hopper Loader Screen (optional) NOTE: Set points boxes are white with heavy black borders.
  • Page 163 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 6 - Dehumidifying Drying Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 164 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 7 - Drying Monitor Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 165 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 8 - Trending Screen (optional) To access the Trending Screen (Screen 8): Press the "Trending"...
  • Page 166 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 9 - Material Temperature Trending Screen (optional) To access the Material Temperature Trending Screen (Screen 9): Press the "Material Temp."...
  • Page 167 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 10 - Air Flow Trending Screen (optional) To access the Air Flow Trending Screen (Screen 10): Press the "Air Flow"...
  • Page 168 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 11 - Air Temperature Trending Screen (optional) To access the Air Temperature Trending Screen (Screen 11): Press the "Air Temp."...
  • Page 169 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 12 - Dew Point Trending Screen (optional) To access the Dew Point Trending Screen (Screen 12): Press the "Dew Point"...
  • Page 170 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 13 - Differential Pressure Trending Screen (optional) To access the Differential Pressure Trending Screen (Screen 13): Press the "Differential Pressure"...
  • Page 171 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 14 - Alarm Log Screen To access the Alarm Log Screen (Screen 14): Press the "Alarm Log"...
  • Page 172 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 15 - Recipe Screen (optional) To access the Recipe Screen (Screen 15): Press the "Recipes"...
  • Page 173 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 16 - System Control Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 174 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 17 - Auto Start Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 175 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 18 -Secondary Hopper Loader Screen (optional) NOTE: Set points boxes are white with heavy black borders.
  • Page 176 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 19 - Main Setup Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 177 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 20 -Equipment Setup Screen To access the Equipment Setup Screen (Screen 20): Press the "Equipment Setup"...
  • Page 178 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 21 -Dehumidified Air Circuit Setup Screen To access the Dehumidified Air Circuit Setup Screen (Screen 21): Press the "Dry Air Setup”...
  • Page 179 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 22 -Dehumidified Air Circuit PID Setup Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 180 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 23 -Ethernet Setup Screen (optional) NOTE: Set points boxes are white with heavy black borders.
  • Page 181 (not installed or installed), primary loader (not installed or installed) and secondary Conair to install a new option. loader (not installed or installed). The user can also view the other system parameters, start the system, stop the system, initiate a system Cool Down or return to the "Login"...
  • Page 182 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 25 -Instrument Setup 1 Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 183 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 26 -Regeneration Heat PID Setup Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 184 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 27 -Instrument Setup 2 Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 185 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 28 -Secondary Hopper Loader Setup Screen (optional) None To access the Secondary Hopper Loader Setup Screen (Screen 28): Press the "Loader”...
  • Page 186 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 29 - Primary Hopper Loader Setup Screen (optional) None To access the Primary Hopper Loader Setup Screen (Screen 29): Press the "Loader”...
  • Page 187 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 30 -Instrument Setup 3 Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 188 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 31 - OptiMizer™ Setup Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 189 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 32 - Close HMI Screen To access the Close HMI Screen (Screen 32): Press the "Close HMI”...
  • Page 190 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 33 - Test Outputs Screen NOTE: The test outputs function will be disabled when the dryer system is operating normally.
  • Page 191 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 34 - Communications Setup Screen To access the Comms Setup Screen (Screen 34): Press the "Comms Setup"...
  • Page 192 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 35 - Read Data Communications Setup Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 193 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) The user can also view the other system parameters, start the system, stop the system, initiate a system Cool Down or return to the "Login"...
  • Page 194 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 37 - Alarm Setup 1 Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 195 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) Screen 38 - Alarm Setup 2 Screen NOTE: Set points boxes are white with heavy black borders.
  • Page 196 The EnergySmart Dryer System is shipped with the password security level set at "Supervisor". For information on how to change security levels, contact you Conair Technical Service representative. The following table and accompanying text gives an overview of the security levels and description of the functions available at each level.
  • Page 197 E n e r g y S m a r t D r y i n g S y s t e m S e c u r i t y L e v e l s ( c o n t i n u e d ) SUPER (Supervisor) Levels A, B, &...
  • Page 198 E n e r g y S m a r t D r y e r S y s t e m M o d b u s C o m m u n i c a t i o n s Data from the following EnergySmart Dryer System components are communicated via the programmable logic controller (PLC) located in the control panel.
  • Page 199 E n e r g y S m a r t D r y e r S y s t e m M o d b u s C o m m u n i c a t i o n s ( c o n t i n u e d ) One message is polled every 2/10 of a second.
  • Page 200 S t a r t i n g t h e E n e r g y S m a r t D r y e r S y s t e m NOTE: Always verify process set- point against recipe setpoint so that material or equipment is not dam- W i t h o u t O p t i M i z e r M o d e...
  • Page 201 S t a r t i n g t h e E n e r g y S m a r t D r y e r S y s t e m ( c o n t i n u e d ) W i t h o u t O p t i M i z e r M o d e NOTE: Screen 3 shows the type of...
  • Page 202 S t a r t i n g t h e E n e r g y S m a r t D r y e r S y s t e m ( c o n t i n u e d ) W i t h o u t O p t i M i z e r M o d e Navigate to the System Control Screen (Screen 8) after all setpoints have be...
  • Page 203 As the system is running it will take several hours for all components to reach a steady-state running condition. Conair recommends waiting until the system is in a constant steady state before making changes to temperature and air flow setpoints.
  • Page 204 Adjust the air flow setpoint of the dryer’s process blower. The output of the dryer’s process blower is regulated by a variable frequency drive (VFD). NOTE: Conair recommends using The VFD can lower blower’s total output to match your processing machine’s CFM or AutoControl.
  • Page 205 A d j u s t i n g t h e E n e r g y S m a r t D r y e r S y s t e m ( c o n t i n u e d ) W i t h o u t O p t i M i z e r M o d e Too large of a change to the air flow can cause an alarm at the heater (HTC or...
  • Page 206 A d j u s t i n g t h e E n e r g y S m a r t D r y e r S y s t e m ( c o n t i n u e d ) W i t h o u t O p t i M i z e r M o d e When the processing machine is turned off and material is not being taken away...
  • Page 207 Any changes made to the setpoint temperature or air flow will affect the on time ing machine to react. This value shown. To minimize energy usage, Conair recommends using the lowest may cause changes to barrel setpoint temperature that is required to dry your material and maintain the temperatures, back pressures, required material throat temperature.
  • Page 208 A d j u s t i n g t h e E n e r g y S m a r t D r y e r S y s t e m ( c o n t i n u e d ) W i t h o u t O p t i M i z e r M o d e Increasing hopper outlet temperatures or increasing air flow will increase the...
  • Page 209 S t a r t i n g t h e E n e r g y S m a r t D r y e r S y s t e m W i t h O p t i M i z e r M o d e To start the EnergySmart Dryer System: Turn on the main power to the EnergySmart Dryer and system compo-...
  • Page 210 S t a r t i n g t h e E n e r g y S m a r t D r y e r S y s t e m W i t h O p t i M i z e r M o d e Navigate to the System Control Screen (Screen 8).
  • Page 211 S t a r t i n g t h e E n e r g y S m a r t D r y e r S y s t e m W i t h O p t i M i z e r M o d e Once the processing machine has been started, the OptiMizer™...
  • Page 212 S t a r t i n g t h e E n e r g y S m a r t D r y e r S y s t e m W i t h O p t i M i z e r M o d e Navigate to the Recipe Screen (Screen 15).
  • Page 213 S t o p p i n g t h e E n e r g y S m a r t D r y e r S y s t e m There are three (3) ways to stop the EnergySmart Dryer System from the CAUTION: Improper EnergySmart Dryer: shutdown can cause...
  • Page 214 S t o p p i n g t h e E n e r g y S m a r t D r y e r S y s t e m ( c o n t i n u e d ) To stop the EnergySmart Dryer System using “System Cool down”: Stop the processing machine and stop taking material out of the hopper.
  • Page 215 S t o p p i n g t h e E n e r g y S m a r t D r y e r S y s t e m ( c o n t i n u e d ) To stop the EnergySmart Dryer System in an Emergency: NOTE: Using the Emergency Stop Press the “Emergency Stop”...
  • Page 216 U s i n g D r y e r R e c i p e ( o p t i o n a l ) The EnergySmart Dryer stores and instantly recalls up to 99 drying recipes that are customer-configured for specific materials.
  • Page 217 U s i n g D r y e r R e c i p e s ( o p t i o n a l ) ( c o n t i n u e d ) C r e a t i n g a n d S a v i n g N e w D r y e r R e c i p e s To create a new dryer recipe: Navigate to the Recipes Screen (Screen 15).
  • Page 218 U s i n g D r y e r R e c i p e s ( o p t i o n a l ) ( c o n t i n u e d ) C r e a t i n g a n d S a v i n g D r y e r R e c i p e s Press the “Enter”...
  • Page 219 U s i n g D r y e r R e c i p e s ( o p t i o n a l ) ( c o n t i n u e d ) U p d a t i n g D r y e r R e c i p e s To update a dryer recipe: Navigate to the Recipes Screen (Screen 15).
  • Page 220 U s i n g D r y e r R e c i p e s ( o p t i o n a l ) ( c o n t i n u e d ) D e l e t i n g D r y e r R e c i p e s To delete a dryer recipe: Navigate to the Recipes Screen (Screen 15).
  • Page 221 U s i n g D r y e r R e c i p e s ( o p t i o n a l ) ( c o n t i n u e d ) D o w n l o a d i n g D r y e r R e c i p e s To upload a dryer recipe for use: Navigate to the Recipes Screen (Screen 15).
  • Page 222 C o p y i n g F i l e s f r o m t h e E n e r g y S m a r t D r y e r S y s t e m If the files will be copied onto a USB flash Memory drive.

  • Page 223: Copying Files From The Energysmart Dryer System

    C o p y i n g F i l e s f r o m t h e EnergySmart Dryer System ( c o n t i n u e d ) Double-click the "My Computer" icon. Browse to the following directory: \Storage Card\Rockwell Software/RSViewME\Logs\ES1_TS_Dryer_C\DigLog\Data_Log1 You will see two files in this directory: "DataLog1.log"...
  • Page 224 Copy the files from the USB flash disk or memory card to a directory on your computer. Run the application "RSView Enterprise File Viewer.exe". Contact Conair if you need to obtain a copy of the software. 4 - 8 2...
  • Page 225 C o p y i n g F i l e s f r o m t h e EnergySmart Dryer System ( c o n t i n u e d ) Open the "DataLog1.log" file in the RSView Enterprise File Viewer. Be sure to select the same time zone as that in which the files were logged.

  • Page 226: Using Dewpoint

    U s i n g D e w p o i n t Log in as OPER and navigate to the Dryer screen. Press the block for “Dewpoint” to enter setpoint. A number pad will open. Enter a value of -39 or higher. Click enter to enter your setting.
  • Page 227 This designation helps determine the path that the control takes in order to deliver dry resin at the desired temperature. The setpoints and system set- tings shown in this document are the default settings recommended by Conair when using the OptiMizer™ system.
  • Page 228 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) The Initial delay and Pre-dry modes occur when no material is being used. When the dryer is running and the OptiMizer™...
  • Page 229 Selection information into the controller and enable/disable the Material Temperature Averaging. Due to the nature of the resin flow, the material tempera- ture measured by the Conair RTD probe at the IMM or extruder throat tends to fluctuate greatly. The Material Temperature Averaging, when enabled, smoothes out the temperature signal from the Conair RTD probe.
  • Page 230 The top graph illustrates the digital input from the extruder or molding machine selection, and the bottom graph shows how the OptiMizer™ uses material temperature signal from the Conair RTD to determine material usage. NOTE: If this machine run signal is lost during OptiMizer™ operation, the system returns to the Pre-dry system settings and mode of operation.
  • Page 231 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) Once the Dynamic Tune process is complete and the system has reached the opti- mal settings for the first time using this recipe, a message will be displayed prompting the operator to save changes to the current recipe.
  • Page 232 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) Optimized System Status Text Optimized Recipe Operation An Optimized recipe is one that has already been learned by the system, and has been proven to reach the desired material conditions.
  • Page 233 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) OptiMizer™ Setup Before the OptiMizer™ function is started, the operator should confirm that the setup parameters are set properly.
  • Page 234 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) System Login Screen The System Login Screen is used as the main navigation and security access point for the entire system.
  • Page 235 O p e r a t i o n l 4 - 9 3...
  • Page 236 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) OptiMizer™ Pre-dry Setup Screen The OptiMizer™ Pre-dry Setup screen shows all of the time values for the Pre-dry mode of OptiMizer™...
  • Page 237 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) OptiMizer™ Dry Air Temperature Setup Screen The OptiMizer™ Dry Air Temperature Setup screen shows all of the setpoints for the Delivery Air Temperature when the OptiMizer™...
  • Page 238 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) OptiMizer™ Minimum Airflow Setup Screen This OptiMizer™ Airflow Setup screen displays Minimum Airflow values for each of the various dryer and hopper models.
  • Page 239 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) OptiMizer™ Maximum Airflow Setup Screen This OptiMizer™ Airflow Setup screen displays Maximum Airflow values for each of the various dryer models.
  • Page 240 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) OptiMizer™ Quick Up Setup Screen The OptiMizer™ Quick Up Setup screen is used to enter the setpoints for the Quick Up sequence.
  • Page 241 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) OptiMizer™ Status Screen The OptiMizer™ Status screen is used to monitor the overall status of the OptiMizer™...
  • Page 242 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) Recipe Setup and Management The key to the OptiMizer™ operation is the recipe. Creating and managing the recipes are the most important part of having the most efficient OptiMizer™...
  • Page 243 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) Moves the highlight bar to the last recipe name in the list.
  • Page 244 In this popup, the word ‘unit’ is used instead of ‘recipe’; that is the default term from the HMI Panel software and cannot be changed by Conair. Press the ‘Edit (F2)’ button and enter the name of the new recipe. After the name has been entered, press the enter button and the name will be saved.

  • Page 245: Using Optimizer

    U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) Shows the status of the current recipe function. The download, upload, create, restore, save, and delete func- tions show a status in this box that shows progress, completion, and errors.
  • Page 246 Auto Cool down is enabled.. Material Target Material Target Temperature setpoint as measured at Temperature (°F) the IMM or extruder machine throat by the Conair Material Temperature RTD. Material Maximum Material Maximum Temperature should be set to the Temperature (°F) highest temperature the material can withstand as determined by the material manufacturer.
  • Page 247 • Material Target Temperature (°F) – This temperature setpoint is for the material at the IMM or extruder machine throat as measured by the Conair Material Temperature RTD. The main goal of the OptiMizer™ operation is to keep the material temperature at this setpoint using the least amount of energy as possible.
  • Page 248 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) Example Recipe for a W1000 System The following table shows an example of an Optimized recipe for a W1000 Dryer with a 64”...
  • Page 249 U s i n g t h e O p t i M i z e r ™ ( c o n t i n u e d ) System Running, Temperatures below setpoints, material usage: In this case, the system will skip over all of the Pre-dry steps and go into the Dynamic Delay step and through the OptiMizer™...
  • Page 250 4 - 1 0 8 l O p e r a t i o n...
  • Page 251 M a i n t e n a n c e S E C T I O N P r e v e n t a t i v e m a i n t e n a n c e c h e c k l i s t ..5 - 2 I n s p e c t i n g h o s e s , p i p i n g a n d g a s k e t s .
  • Page 252 C h e c k l i s t Routine maintenance will ensure optimum operation and performance of the NOTE: For detailed maintenance EnergySmart™ Dryer System and its components. Conair recommends the instructions for the components following maintenance schedule and tasks.
  • Page 253 Open the petcock on the bottom of the trap to drain. If you see oil, Conair recommends installing a coalescing type filter ahead of the standard moisture removing filter Check and clean the pump inlet filter.
  • Page 254 Reposition and tighten loose hose clamps and/or pipe fittings. Change the vacuum pump’s oil. The vacuum pump has been filled with the proper oil and tested by Conair before shipment. Even so, this oil should be changed periodically. Use SAE 40 regular or an equivalent oil.
  • Page 255 P r e v e n t a t i v e M a i n t e n a n c e C h e c k l i s t ( c o n t i n u e d ) •...
  • Page 256 P r e v e n t a t i v e M a i n t e n a n c e C h e c k l i s t ( c o n t i n u e d ) •...
  • Page 257 P r e v e n t a t i v e M a i n t e n a n c e C h e c k l i s t ( c o n t i n u e d ) •...
  • Page 258 I n s p e c t i n g H o s e s , P i p i n g a n d G a s k e t s Loose or damaged hoses, piping and gaskets can allow moisture to seep into the closed-looped drying circuits.
  • Page 259 C l e a n i n g t h e C H H o p p e r CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the dryer and drying hopper. The hopper, spreader cone, and discharge assembly should be cleaned thoroughly between material changes to prevent resin contamination.
  • Page 260 M a i n t a i n i n g t h e D w y e r 6 4 1 A i r Ve l o c i t y Tr a n s m i t t e r The AVT probe will collect dirt and dust from the air stream.
  • Page 261 OSHA and other safety regulations pertaining to the use of compressed air. Replacement filters are available from Conair. Reassemble. Repeat Steps 3 and 4 in reverse order to replace the filter. Contact Conair Parts (800) 458 1960...
  • Page 262 Periodically, you should clean the filters covering the cooling fan inlet and outlet on the GasTrac’s electrical enclosure. To clean the filter: Replacement filters are Remove the the thumb screws and filters. available from Conair. Contact Conair Parts (800) 458 1960 From outside of the United States, call: (814) 437 6861 Clean the filters.
  • Page 263 Conair. Do not operate the GasTrac with a worn or dam- aged spark igniter. A badly burned or warped Contact Conair Parts igniter can cause burner ignition failure. (800) 458 1960 From outside of the Stop the GasTrac. Press the red...
  • Page 264 Replacement igniters are Mark the position of the grounding rod on the new spark igniter, using a available from Conair. felt tip marker. This index mark must end up 180° away from the burner sur- face when the spark igniter is inserted and tightened. The electrode should be Contact Conair Parts closest to the burner surface.
  • Page 265 Hand tighten first. Then using an appropriately-sized wrench to tighten the nut an additional quarter turn. Replacement flame detectors are available from Conair. Contact Conair Parts (800) 458 1960 From outside of the United States, call:...
  • Page 266 Remove the screws on the sight glass bracket. maintenance. Clean the sight glass. Use a clean soft cloth or cotton swab moistened with alcohol. Replacement sight glasses are available from Conair. Coat the screw threads with a high-temperature Contact Conair Parts antiseize compound. (800) 458 1960 From outside of the Replace the sight glass.

  • Page 267: C L E A N I N G T H E P R O C E S S F I L T E R

    Remove the filter wing nut, then Replacement process filters are remove the filter. available from Conair. Clean the filter by laying it on its Contact Conair Parts side and gently tapping it on the...

  • Page 268: C L E A N I N G T H E R E G E N E R A T I O N F I L T E R

    Clean the filter by laying it on filters are available from its side and gently tapping it on Conair. the floor. Replace damaged, worn, or Contact Conair Parts clogged filters. (800) 458 1960 From outside of the Reverse the procedure to United States, call: reinstall the regeneration filter.
  • Page 269 C l e a n i n g t h e A f t e r c o o l e r / I n t e r c o o l e r C o i l s You need to clean the aftercooler/intercooler coils to keep them working efficient- ly.
  • Page 270 Clean the assembly using a mild soap and water. Let the assembly dry thoroughly before installation. Replacement gaskets are available from Conair. NOTE: In cases of heavy volatiles, steam cleaning or the use of solvents, such as acetone, may be necessary. Be sure to test a small area with the solvent Contact Conair Parts you have selected to be sure there is no adverse reaction.
  • Page 271 C l e a n i n g t h e Vo l a t i l e Tr a p o n t h e D e m i s t e r ( W 6 0 0 - 1 0 0 0 ) Stop the dryer and lockout the main power.
  • Page 272 C l e a n i n g t h e Vo l a t i l e Tr a p o n t h e D e m i s t e r ( W 1 6 0 0 - 5 0 0 0 ) Stop the dryer and lockout the main power.

  • Page 273: C L E A N I N G T H E P R E C O O L E R C O I L S

    C l e a n i n g t h e P r e c o o l e r C o i l s You need to clean the precooler coils to keep them working efficiently. Cleaning frequency depends on the type and amount of material you process. Stop the dryer and lockout the main power.
  • Page 274 R e p l a c i n g t h e R e g e n e r a t i o n H e a t e r ( W 6 0 0 - 1 0 0 0 ) Stop the dryer and lockout the main power.
  • Page 275 R e p l a c i n g t h e R e g e n e r a t i o n H e a t e r ( W 6 0 0 - 1 0 0 0 ) ( c o n t i n u e d ) Compare the markings on the outside of the regeneration heater tube to ensure the new one has the same voltage and kW ratings as the original heater...
  • Page 276 R e p l a c i n g t h e R e g e n e r a t i o n H e a t e r ( W 1 6 0 0 - 2 4 0 0 ) Stop the dryer and lockout the main power.
  • Page 277 R e p l a c i n g t h e R e g e n e r a t i o n H e a t e r ( W 1 6 0 0 - 2 4 0 0 ) ( c o n t i n u e d ) Slide the original insulation over the new heater, or if the insulation was cut for removal, wrap the cut insulation sleeve around the new heater tube and...
  • Page 278 R e p l a c i n g t h e R e g e n e r a t i o n H e a t e r ( W 3 2 0 0 - 5 0 0 0 ) Stop the dryer, disconnect and lockout the main power.
  • Page 279 R e p l a c i n g t h e R e g e n e r a t i o n H e a t e r ( W 3 2 0 0 - 5 0 0 0 ) ( c o n t i n u e d ) Loosen the two (2) lower clamps that secure the regeneration manifold and tubing to the desiccant wheel bracket.
  • Page 280 C h e c k i n g t h e D e w Po i n t Conair recommends monitoring the dew point performance of your dryer periodi- NOTE: Portable dew point cally with a calibrated portable dew point monitor, to ensure it is performing at monitors purchased from Conair maximum capacity.
  • Page 281 In the event the dew point in not satisfactory, refer to the Troubleshooting section of the manual, under Process dew point alarm for DC2. Replacement dew point monitors, male connectors and dew point check ports are available from Conair. Contact Conair Parts (800) 458 1960 From outside of the United States, call:...
  • Page 282 C l e a n i n g t h e D u s t C o l l e c t o r ( o p t i o n a l ) Replacement dust collector filters are available from Conair. A clogged filter in a dust collector will negatively affect air flow and the Contact Conair Parts EnergySmart Drying System's efficiency.
  • Page 283 C l e a n i n g t h e D u s t C o l l e c t o r ( o p t i o n a l ) ( c o n t i n u e d ) Empty any material from the tank into an appropriate container.
  • Page 284 C l e a n i n g t h e D u s t C o l l e c t o r ( o p t i o n a l ) ( c o n t i n u e d ) TIP: If gasket on the filter tank becomes loose or detached from the filter...
  • Page 285 C l e a n i n g t h e C y cl o n e S e p a r a t o r ( o p t i o n a l ) A filled cyclone separator barrel will negatively affect air flow and the EnergySmart Drying System's efficiency.
  • Page 286 5 - 3 6 l M a i n t e n a n c e...
  • Page 287 S E C T I O N Tr o u b l e s h o o t i n g B e f o r e b e g i n n i n g ....6 - 2 A f e w w o r d s o f c a u t i o n .

  • Page 288: B E F O R E B E G I N N I N G

    B e f o r e B e g i n n i n g You can avoid most problems by following the recommended installation and maintenance procedures outlined in this User Guide. If you do have a problem, this section will help you determine what caused it and how to fix it. Before you start accessing any EnergySmart Dryer System component, be sure to: Diagnose causes from the control panel.

  • Page 289: A Fe W Wo R D S O F C A U T I O N

    A Fe w Wo r d s o f C a u t i o n The EnergySmart™ PET Drying System and its components are equipped with numerous safety devices. Do not remove or disable them. Improper cor- rective action can lead to hazardous conditions and should never be attempted to sustain production.

  • Page 290: H O W T O I D E N T I F Y T H E C A U S E O F A P R O B L E M

    H o w t o I d e n t i f y t h e C a u s e o f a P r o b l e m Most EnergySmart™ PET Drying System malfunctions are indicated in the Status Box on the Control Panel screens.
  • Page 291 H o w t o I d e n t i f y t h e C a u s e o f a P r o b l e m ( c o n t i n u e d ) When the audible alarm is heard or optional alarm light illuminates: Press the “Alarm Log”...
  • Page 292 H o w t o I d e n t i f y t h e C a u s e o f a P r o b l e m ( c o n t i n u e d ) Find the error message in the diagnostics table of this troubleshooting section or the troubleshooting section of the applicable component User Manual.

  • Page 293: S H U T D O W N A L A R M S

    S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer will shut down automatically to prevent damage to the equipment or personnel.
  • Page 294 S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer will shut down automatically during a to prevent damage to the equipment or personnel.
  • Page 295 S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer will shut down automatically during a to prevent damage to the equipment or personnel.
  • Page 296 S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer will shut down automatically during a to prevent damage to the equipment or personnel.
  • Page 297 S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer will shut down automatically during a to prevent damage to the equipment or personnel.
  • Page 298 S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer will shut down automatically during a to prevent damage to the equipment or personnel.
  • Page 299 S h u t d o w n A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer will shut down automatically during a to prevent damage to the equipment or personnel.
  • Page 300 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 301 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 302 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 303 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.

  • Page 304: Energysmart Dryer System Modbus Communications

    Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 305 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 306 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 307 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 308 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 309 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 310 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 311 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 312 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 313 Pa s s i v e A l a r m s If an alarm occurs, a red dialog box is displayed on the dryer’s touch screen control. The dryer continues to operate, but this problem could prevent cor- rect drying of your material. The dialog box will indicate whether the alarm is a shut down alarm or a passive alarm.
  • Page 314 Conair Parts at (800) 458 1960 for the addition of a volatile trap. Analog option board/sensor malfunction Verify dryer dew point readings with a calibrated portable dew point meter.
  • Page 315 If your Conair dryer is equipped with the Setback feature, you should familiarize yourself with it, and make use of it. If not, you may want to contact Conair to determine if it can be added to your dryer.

  • Page 316: Repair

    Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) Once it is determined which of the four requirements that is not being satisfied, refer to the following list of possible causes and solutions.
  • Page 317 Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) Residence Time - The time your material supplier has determined that the material in use must be heated to its drying temperature to achieve proper drying.

  • Page 318: Repair

    Po o r M a t e r i a l D r y i n g Tr o u b l e s h o o t i n g ( c o n t i n u e d ) Air flow - The air flow in the process drying circuit must be adequate to carry and distribute the heat throughout the entire bed of material inside the hopper.
  • Page 319 -20 to -40° F {-29 to -40° C}. If your dryer does not United States, call: have a dew point readout, you can check the dew point with a portable dew point (814) 437 6861 instrument. Conair sells a variety of portable dew point meters. Contact Conair Parts. Problem Possible cause Solution Low regeneration temperature.
  • Page 320 R e p l a c i n g F u s e s Disconnect and lockout the main power supply. Open the electrical enclosure door. Check the fuse with an ohmmeter. If necessary, pull the fuse out and replace it with a fuse of the same type and rating.
  • Page 321 C h e c k i n g H e a t e r S o l i d S t a t e R e l a y s CAUTION: Always disconnect and lock out the main power sources before making electrical connections.
  • Page 322 C h e c k i n g o r R e p l a c i n g Te m p e r a t u r e S e n s o r s IMPORTANT : Always refer to the wiring diagrams that came with your dryer The Carousel Plus W Series Dryer uses RTD sensors to monitor the temperatures...

  • Page 323: A S S E M B L Y

    R e p l a c i n g t h e D e s i c c a n t W h e e l A s s e m b l y ( W 6 0 0 - 1 0 0 0 ) When desiccant becomes clogged or contaminated, you should replace the desiccant wheel to ensure optimum performance.
  • Page 324 R e p l a c i n g t h e D e s i c c a n t W h e e l A s s e m b l y ( W 6 0 0 - 1 0 0 0 ) ( c o n t i n u e d ) Lift the new desiccant wheel into the dryer frame, being sure it is ori-...

  • Page 325: M O T O R

    R e p l a c i n g t h e D e s i c c a n t W h e e l M o t o r ( W 6 0 0 - 1 0 0 0 ) Stop the dryer, disconnect and lockout the main power.

  • Page 326: M O T O R

    R e p l a c i n g t h e D e s i c c a n t W h e e l M o t o r ( W 1 6 0 0 - 5 0 0 0 ) Stop the dryer, disconnect and lockout the main power.
  • Page 327 R e p l a c i n g t h e D e s i c c a n t W h e e l M o t o r ( W 1 6 0 0 - 5 0 0 0 ) ( c o n t i n u e d ) Slip the belt onto the sprocket, and adjust the tension spring nut to its original position.

  • Page 328: We're Here To Help

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

  • Page 329: Equipment Guarantee

    (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination. The customer assumes the cost of transportation of the part or parts to and from the factory.
  • Page 330 TouchView/ES1 Prints Allen- Control Wiring Modbus Comms wiring Interconnect wiring ES1 VFD wiring HTC wiring Gas Trac Wiring l l A z i s A - 3 l A p p e n d i x...

This manual is also suitable for:

Htc 180Htc 270W600-1000Htc 60W1600-5000W3200-5000 ... Show all

Table of Contents