Conair HTC 30 User manual

EnergySmart®Dryer
W Series Models 600 through 5000 with TouchViewTM Technology (Allen-Bradley)
Corporate Office: 724.584.5500 lInstant 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
UGD041-1212
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 equip-
ment 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.
Copyright 2012 l Conair l All rights reserved
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.
✐

Table of Contents
1-1 Introduction
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 Description
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 Installation
Installation - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Unpacking the EnergySmart Dryer System components . . . . . . . . . 3-6
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Table of Contents l i

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
ii l Table of Contents

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
Table of Contents 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
iv l Table of Contents

4-1 Operation
The EnergySmart Dryer System control panel . . . . . . . . . . . . . . . . . 4-2
How to navigate the control screens . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control function flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Login flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Table of Contents l v

5-1 Maintenance
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 Troubleshooting
Before beginning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
vi l Table of Contents

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
AAppendix
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
Table of Contents l vii

viii l Table of Contents

Introduction
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
S E C T I O N
1
Introduction l 1-1
1
Introduction

✐
Purpose of the User Guide
This User Guide describes the Conair EnergySmart®Dryer System with
TouchViewTM Technology and explains step-by-step how to install, oper-
ate, 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.
1
◆
❒
•
✒
1-2 l Introducti on

Introduction l 1-3
Using the EnergySmart Dryer with
Your System
The Conair EnergySmart®Dryer with TouchViewTM Technology 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, opera-
tion 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.
1
Introduction
NOTE: Dryers can be used for
various applications.
✐

1-4 l Introducti on
ATTENTION:
Read this so no one gets hurt
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.
WARNING: Improper installation, operation or
ser vicing may result in equipment damage or
personal injury.
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 elec-
trical 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.
WARNING: Voltage 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)

1
Introduction
Introduction l 1-5
ATTENTION:
Read this so no one gets hurt (continued)
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.
CAUTION: 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).
WARNING: Do not place aerosol, compressed
gas or flammable materials on or near this
equipment.
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 Introducti 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:
1Stop or turn off the equipment.
2Isolate the equipment from the electric power. Turn the rotary
disconnect switch to the OFF, or “O” position.
3Secure the device with an assigned lock or tag. Insert a lock or tag
in the holes to prevent movement.
4The 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:
1Remove the lock or tag.
2Turn the rotary disconnect switch to the ON or “I” position.
ON
O OFF
ON
O OFF

Description l 2-1
Description
Wha t 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
S E C T I O N
2
2
Description

2-2 l Descriptio 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 maxi-
mum system efficiency.
The EnergySmart Dryer System could include:
• EnergySmart Dryer with TouchViewTM Technology (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
1Dryer 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.
✐

Description l 2-3
2
Description
How the EnergySmart Dryer 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 Descriptio 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 heat-
ing 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 tem-
perature 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 set-
point 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