Conair UGD031/0106, Hopper Temperature Controller, HTC User Manual
Hopper Temperature
Controller
Process Air Heater, 30 to 270 kW.
For use with Conair Carousel Plus Series W Dryers and HADs.
Corpora
te Office: 412.312.6000 l Instant Access 24/7 (Parts and Service):800.458.1960 l Parts and Service: 814.437.6861
USER GUIDE
UGD031/0106
www.conairnet.com
INTRODUCTION • Purpose of the User Guide • How the guide is organized • Your responsibilities as a user • ATTENTION:
Read this so no one gets hurt • How to use the lockout device • DESCRIPTION • What is the HTC process air
hea
ter? • Typical applications • How it works • Specifications:HTC Carousel Plus process air dryer • Specifications:
HTC models 600 - 5000 • Specifications:HTC for HAD • INSTALLATION • Unpacking the boxes • Preparing for instal-
lation • Installation of the HTC control models 30,60,and 90 • Installation of the HTC control model 120 • Installation of
the HTC control models 180 and 270 • Loca tion and mounting of the HTC heater assembly models 30, 60, and 90 •
Loca
tion and mounting of the HTC hea
ter assembly model 120
•
Location and mounting of the HTC heater assembly mod-
els 180 and 270 • Connecting the HTC heater assembly to the dryer or blower and hopper • Installing the isolation valves
• Connecting the power on models HTC 180 and 270 • Connecting the control wiring on models 180 and 270 •
Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.
It’s a good idea to record the model and serial number(s) of your equipment and
the date you received it in the User Guide. Our service department uses this information, along with the manual number, to provide help for the specific equipment
you installed.
Please keep this User Guide and all manuals, engineering prints and parts lists
together for documentation of your equipment.
Date:
Manual Number: UGD031/0106
Serial Number(s):
Model Number(s):
DISCLAIMER: The Conair Group, Inc., shall not be liable for errors contained in this User Guide or
for incidental,
consequential dama
ges 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 2006 l
The Conair Group l All rights reserved
Table of Contents
1-1 Introduction
Purpose of the user guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Your responsibilities as a user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
ATTENTION:Read this so no one gets hurt . . . . . . . . . . . . . . . . . . . 1-4
How to use the lockout device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2-1 Description
What is the HTC process air heater? . . . . . . . . . . . . . . . . . . . . . . . .2-2
Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Specifications: HTC Models 600 - 5000 . . . . . . . . . . . . . . . . . . . . . 2-6
Specifications: HTC for Hot Air Dryers (HAD) . . . . . . . . . . . . . . . . . . 2-7
3-1 Installation
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installation of the HTC control models HTC 30, 60, and 90 . . . . . . . 3-3
Installation of the HTC control model HTC 120 . . . . . . . . . . . . . . . . 3-4
Installation of the HTC control models HTC 180 and 270. . . . . . . . . 3-4
Loca
tion and mounting of the HTC hea
ter assembly
models 30,
60,
and 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Loca
tion and Mounting of the HTC hea
ter assembly
model HTC 120
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
T
able of Contents l
i
Location and mounting of the HTC heater assembly
models 180 and 270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Connecting the HTC heater assembly to the dryer or blower
and hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Installing the isolation valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Connecting the power on models HTC 180 and 270 . . . . . . . . . . . . 3-8
Connecting the control wires on models HTC 180 and 270. . . . . . 3-10
Connecting the RTD sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
4-1 Operation
The HTC process air heater: control panel DC. . . . . . . . . . . . . . . . . 4-2
HTC DC control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control function flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control function descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
HTC DC control alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Initial operation (for HAD only). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Initial operation (for Carousel Plus dryer HTC) . . . . . . . . . . . . . . . . 4-21
Autotuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Normal operation to start heating . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Normal operation to stop heating . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
5-1 Maintenance
Preventative maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . 5-2
6-1 Troubleshooting
Before beginning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
ii l
Table of Contents
DIAGNOSTICS
How to identify the cause of a problem . . . . . . . . . . . . . . . . . . . . . 6-4
Shut down alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Passive alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
REP
AIR
Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Checking heater solid state relays. . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Checking or replacing temperature sensors . . . . . . . . . . . . . . . . . 6-11
Replacing the heating elements . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Replacing the air flow differential pressure switch . . . . . . . . . . . . 6-14
A Appendix
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
AD Addendum
Blower installation and maintenance . . . . . . . . . . . . . . . . . . . . . . AD-1
T
able of Contents l
iii
✐
Note: This addendum applies only if you have purchased a Conair Hot
Air Dryer (HAD).
iv l Table of Contents
Introduction
Purpose of the user guide. . . . . . . . . . . . . . 1-2
How the guide is organized . . . . . . . . . . . . . 1-2
Your responsibilities as a user. . . . . . . . . . . 1-3
ATTENTION:
Read this so no one gets hurt . . . . . . . . 1-4
How to use the lockout device . . . . . . . . . . . 1-5
SECTION
1
Introduction l 1-1
1
Introduction
✐
Purpose of the User Guide
This User Guide describes the Conair Hopper Temperature Controller
(HTC) process air heater and explains step-by-step how to install, operate, maintain and repair this equipment.
Before installing this product, please take a few moments to read the User
Guide and review the diagrams and safety information in the instruction
packet. You also should review manuals covering associated equipment in
your system. This review won’t take long, and it could save you valuable
installation and operating time later.
How the Guide is Organized
Symbols have been used to help organize the User Guide and call your
attention to important information regarding safe installation and operation.
Symbols within triangles warn of conditions that could be hazardous to users or
could damage equipment. Read and take precautions before proceeding.
Numbers indicate tasks or steps to be performed by the user.
A diamond indicates the equipment’s response to an action performed by the user.
An open box marks items in a checklist.
A circle marks items in a list.
Indicates a tip. A tip is used to provide you with a suggestion that will help you with
the maintenance and the operation of this equipment.
Indicates a note. A note is used to provide additional information about the steps
1
◆
❒
•
✒
1-2 l Introduction
Introduction l 1-3
Your Responsibility as a User
You must be familiar with all safety procedures concerning installation, operation and maintenance of this equipment. Responsible safety procedures include:
• Thorough review of this User Guide, paying particular attention
to hazard warnings, appendices, and related diagrams.
• Thorough review of the equipment itself, with careful attention
to voltage sources, intended use, and warning labels.
• Thorough review of instruction manuals for associated equipment.
• Step-by-step adherence to instructions outlined in this User Guide.
1
Introduction
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 on this machine by following the procedures outlined below and
elsewhere in the User Guide.
WARNING: Improper installation, operation, or
servicing may result in equipment damage or
personal injury.
This equipment should be installed, adjusted, and serviced by qualified
technical personnel who are familiar with the construction, operation,
and potential hazards of this type of machine.
All wiring, disconnects, and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region.
Always maintain a safe ground. Do not operate the equipment at power
levels other than what is specified on the machine serial tag and data
plate.
WARNING: Voltage hazard
This equipment is powered by three-phase alternating current,
as specified on the machine serial tag and data plate.
A properly sized conductive ground wire from the incoming power
supply must be connected to the chassis ground terminal inside the
electrical enclosure (control center). Improper grounding can result in
severe personal injury and erratic machine operation.
Al
ways disconnect and lock out the incoming main po
wer source before
opening the control center or performing non-standard operating procedures, such as routine maintenance. Only qualified personnel should
perform troubleshooting procedures tha
t require access to the control
center while power is on.
1-4 l Introduction
1
Introduction
Introduction l 1-5
How to Use the Lockout Device
CAUTION: Before performing maintenance or repairs on this product,you should disconnect and lockout electri-
cal 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:
11
Stop or turn off the equipment.
22
Isolate the equipment from the electric power. Turn the rotary
disconnect switch to the OFF, or “O” position.
33
Secure the device with an assigned lock or tag.
Insert a lock or tag
in the holes to prevent movement.
44
The equipment is now locked out.
WARNING: Before removing lockout devices and returning s witches 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 to the heater, turn the rotary disconnect back to the ON position:
11
Remove the lock or tag.
22
Turn the rotary disconnect switch to the ON or “ I” position.
ON
O OFF
ON
O OFF
ON
O OFF
1-6 l Introduction
Description l 2-1
Description
What is the HTC process air heater?. . . . . . . 2-2
Typical applications . . . . . . . . . . . . . . . . . . 2-3
How it works . . . . . . . . . . . . . . . . . . . . . . 2-4
Specifications: HTC models 600 - 5000. . . . . 2-6
Specifications: HTC for Hot Air Dryers (HAD) . 2-7
SECTION
2
2
Description
What is the HTC Process Air
Heater?
The HTC process air heater is designed to control the temperature of dry air as
it enters a material hopper. This process air heater can be set to increase, or
“raise”, the temperature of air that was dehumidified at a central dryer or from
a blower as part of hot air drying.
The HTC includes a control center, heater box with electric heating elements,
an airflow differential pressure switch, and an RTD temperature probe(s).
The differential pressure switch places the HTC in standby mode to save energy
and prevent heating element damage when air flow is not present.
2-2 l Description
Description l 2-3
2
Description
Typical Applications
Carousel Plus “W”Dryer
The HTC process air heater is designed for use with a dehumidifying device
that supplies dry air, such as a central dehumidifying dryer in which the process
heaters (if present) have been disabled, or with a stand alone blower for hot air
drying.
The HTC can be used successfully in applications that require:
• Drying temperatures up to 350°F (176.7°C) (250°F [121.1°C] on HAD
models).
• The ability to dry multiple materials requiring different drying temperature
setpoints in a central drying system. (Requires separate HTCs / hoppers.)
• The ability to easily take a hopper “off-line” for cleaning without shutting
down the entire central drying system.
Hot Air Dryer (HAD)
The HTC process air heater, for use with a hot air dryer such as a Conair model
HAD, connects plant air motivated by a Conair blower assembly to a material drying hopper.
The HTC for HAD can be used successfully in applications that require:
• Drying temperatures up to 250°F (121.1°C).
• Non-hygroscopic materials that are in pellet or flake form (not powder).
• Open loop drying (not recirculated).
The HTC does not have an integral blower to circulate the hot air, so it can not be
used as a stand-alone material preheater. It must be combined with a Conair
Carousel Plus Series “W” dryer or HAD.
2-4 l Description
How it Works
The HTC process air heater works a lot like the thermostat and heater in your
house. The RTD probe measures the temperature of the air entering the hopper.
If this air is not warm enough to properly dry the material in the hopper, the
RTD sends a message to the temperature controller which tells the heater to
begin heating. The heating elements inside the heater enclosure heat until the
RTD probe senses that the air entering the hopper is at the setpoint entered by
the user.
The HTC has a process protection RTD (over-temperature safety). The temperature controller shuts off power to the heating elements if they get too hot and
an alarm is generated.
An air flow differential pressure switch detects air flow by sensing the natural
drop of pressure due to flow through the heater. This prevents damage to the
heater elements or material in the hopper on loss of air flow.
The temperature controller alarms if the heating elements are heating too hot. It
also alarms if the heating elements are not heating enough.
How the HTC Works
D
rying
H
oppe
r
T
emperatur
e
C
ontro
l
H
eaters
S
tartup /
Shutdown
For Startup:
1. With heaters in
Standby, turn on
blower or dryer.
2. Enable heaters.
For Shutdown:
1
. Switch heaters to
Standby.
2
. Wait 60 seconds
before turning off
blower or dryer.
Enable
Standby
Temperature Controller
Control Center
Hopper Inlet
Heater Box
Heating Element
Process Temperature RTD
Process Protection RTD
Description l 2-5
How it Works (continued)
How the HAD Works
D
rying
H
oppe
r
T
emperatur
e
C
ontro
l
2
1
3
4
5
6
8
7
1 Centrifugal Blower Assembly
2 Control Center
3 Electric Heater Assembly
4 Hose (15 ft)
5 Insulated Hose (3 ft)
6 RTD Process Temperature
7 RTD Process Protection
8 Outlet Filter Sock
2
Description
Specifications: HTC MODELS 600 - 5000
2-6 l Description
A
B
C
D
E
F
G
I
MODEL HTC HTC-30H* HTC-60H* HTC-90H* HTC-120H* HTC-180H* HTC-270H*
Carousel Plus dryer model W600 W800 W1000 W1600 W2400 W3200 W5000
Performance characteristics
Temperature range 150° - 375° F {66° - 191° C}
Flow rate cfm 300 400 500 800 1200 1600 2500
Pressure drop@flow rate
inches WC
†
3.0 1.8 2.3 4.0 3.8 5.9 6.4
{mm} WC
†
{76.2} {45.7} {58.4} {101.6} {96.5} {149.9} {162.6}
Dimensions inches {cm} and weight lb {kg}
Heater box dimensions
Inlet size (OD) 8 8 12 12 12 12
Outlet size selection (OD) 8 8 12 12 12 12
A - Height 31.4 {79.8} 27.5 {69.9} 27.0 {68.6} 31.0 {78.7} 34.0 {86.4} 36.4 {92.5}
B - Width 10.1 {25.7} 13.6 {34.5} 16.0 {40.6} 16.0 {40.6} 18.0 {45.7} 24.2 {61.5}
C - Depth 10.7 {27.2} 10.9 {27.7} 10.9 {27.7} 16.0 {40.6} 17.0 {43.2} 17 {43.2}
D - Height of discharge 1.75 1.5 2.0 1.0 2.0 1.0
no z z l e a b o ve the h e a t e r b ox {4.4} {3.8} {5.1} {2.5} {5.1} {2.5}
E - Height of inlet nozzle 10.6 7.1 8 10 13 15.4
below the heater box {26.9} {18.0} {20.3} {25.4} {33.0} {39.1}
Installed weight lb {kg}
‡
38 {17} 37 {17} 78 {35} 93 {43} 102 {46} 131 {59}
Control center dimensions
Height - F 24.0 {61.0} 24.0 {61.0} 36.0 {91.4} 48.0 {122.0} 60.0 {152.4} 60.0 {152.4}
Width - G 24.0 {61.0} 24.0 {61.0} 30.0 {76.2} 36.0 {91.4} 42.0 {106.7} 42.0 {106.7}
Depth - H 10.0 {25.4} 10.0 {25.4} 10.0 {25.4} 10.0 {25.4} 12.0 {30.5} 12.0 {30.5}
Clearance for heat sink - I 3.0 {7.6} 3.0 {7.6} 3.0 {7.6} 3.0 {7.6} 3.0 {7.6} 3.0 {7.6}
Installed weight lb {kg} 150.0 {68.0} 150.0 {68.0} 180.0 {81.6} 250.0 {113.0}
consult Conair consult Conair
V olta ge Full Load Amps
400 V/3 phase/50-60 Hz 43.3 86.6 129.9 173.2 259.8 389.7
480 V/3 phase/50-60 Hz 37.7 75.4 113.1 150.8 226.2 339.3
575 V/3 phase/50-60 Hz 30.1 60.2 90.3 120.4 180.6 270.0
SPECIFICATION NOTES:
*
The HTC
model n
umber reflects the kilo
watts of each unit.For example, HTC-60 has a 60 kilowatt heater.
†
The unit of measure
WC
is w
ater column.
‡
W
eights are appro
ximate
.
Specifications may change without notice. Consult a Conair representative for the most current information.
TPDS022-0106
Description l 2-7
Specifications: HTC for Hot Air Dryers (HAD)
A
B
C
D
E
F
H
G
I
2
Description
MODEL HTC HTC-30B* HTC-30A* HTC-60A* HTC-90A* HTC-120A* HTC-180A*
Hot air dryer model 600 800 1000 1600 2400 3200 5000
Performance characteristics
Temperature range 120° - 250° F {49° - 121° C}
Flow rate cfm 300 400 500 800 1200 1600 2500
Pressure drop@flow rate
inches WC
†
3.0 5.0 3.2 5.4 6.1 6.4 8.0
{mm} WC
†
{76.2} {127} {81.2} {137.2} {155.0} {163.0} {203.2}
Dimensions inches {cm} and weight lb {kg}
Heater box dimensions
Inlet size (OD) 5 5 8 8 8 12
Outlet size selection (OD) 5 5 8 8 8 12
A - Height 31.4 {79.8} 27.5 {69.9} 27.5 {69.9} 32.0 {81.3} 31.0 {79.0} 34.0 {86.3}
B - Width 10.1 {25.7} 13.6 {34.5} 13.6 {34.5} 15.9 {40.4} 16.0 {40.6} 18.0 {45.7}
C - Depth 10.7 {27.2} 10.7 {27.2} 10.9 {28.0} 16.0 {40.6} 17.0 {43.2} 20.0 {50.8}
D - Height of discharge 0 {0} 5.9 {15.0} 2.0 {5.1} 1.0 {2.5} 2.0 {5.1} 1.0 {2.5}
nozzle above heater box
E - Height of inlet nozzle
below the heater box 8.0 {20.3} 11.4 {30.0} 8.0 {20.3} 11.0 {27.9} 13.0 {33.0} 13.0 {33.0}
Installed weight lb {kg} 37 {17} 58 {26} 78 {35} 93 {42} 102 {46} 131 {59}
Control center dimensions
F - Height 24.0 {61.0} 24.0 {61.0} 24.0 {61.0} 36.0 {91.4} 48.0 {122.0} 60.0 {152.4}
G - Width 24.0 {61.0} 24.0 {61.0} 24.0 {61.0} 30.0 {76.2} 36.0 {91.4} 42.0 {106.7}
H - Depth 10.0 {25.4} 10.0 {25.4} 10.0 {25.4} 10.0 {25.4} 10.0 {25.4} 12.0 {30.5}
I - Clearance for heat sink 3.0 {7.6} 3.0 {7.6} 3.0 {7.6} 3.0 {7.6} 3.0 {7.6} 3.0 {7.6}
Installed weight lb {kg} 150.0 {68.0} 150.0 {68.0} 150.0 {68.0} 180.0 {81.6} 250.0 {113.0}
consult Conair
V olta ge Current Amps
400V/3 phase/50-60 Hz 43.3 43.3 86.6 129.9 173.2 259.8
460 V/3 phase/50-60 Hz 37.7 37.7 75.4 113.1 150.8 226.2
575 V/3 phase/50-60 Hz 30.1 30.1 60.2 90.3 120.4 180.6
SPECIFICATION NOTES:
* The HTC model number reflects the kilowatts of each unit. For example, HTC-60 has a 60 kilowatt heater.
† The unit of measure WC is water column.
Specifications may change without notice. Consult a Conair representative for the most current information.
TPDS024-0106
2-8 l Description
Installation l 3-1
Installation
Unpacking the boxes . . . . . . . . . . . . . . . . . 3-2
Preparing for installation . . . . . . . . . . . . . . 3-3
Installation of the HTC control models
HTC 30, 60 and 90 . . . . . . . . . . . . . . . . 3-3
Installation of the HTC control model
HTC 120 . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installation of the HTC control models
HTC 180 and 270. . . . . . . . . . . . . . . . . 3-4
Location and mounting of the HTC heater
assembly models 30, 60, and 90 . . . . . . 3-5
Location and mounting of the HTC heater
assembly model HTC 120 . . . . . . . . . . . 3-5
Location and mounting of the HTC heater
assembly models 180 and 270 . . . . . . . . 3-5
Connecting the HTC heater assembly
to the dryer or blower and hopper . . . . . 3-6
Installing the isolation valves . . . . . . . . . . . 3-7
Connecting the power on models
HTC 180 and 270. . . . . . . . . . . . . . . . . 3-8
Connecting the control wires on
models HTC 180 and 270. . . . . . . . . . . 3-10
Connecting the RTD sensors . . . . . . . . . . . 3-11
Testing the installation . . . . . . . . . . . . . . . 3-15
SECTION
3
3
Installation
3-2 l Installation
Unpacking the Boxes
The HTC process air heater comes in two boxes. Depending on the model and
options ordered, the boxes could include:
Standard Equipment
• Heater assembly;
• Control center;
• 1 insulated hose;
• 1 non-insulated hose;
• 4 hose clamps;
• 2 RTD probes (1 process and 1 process protection);
• Blower (HAD models only).
Optional Equipment
• 1 RTD probe (1 setback).
1 Carefully remove all components from their shipping containers.
2 Re move all packing material, protective paper, tape, and plastic.
3 Carefully inspect all components
to make sure no damage occurred during
shipping, and that you have all the necessary hardware.
4 Take a moment to record serial numbers and electrical power specifications
in the blanks provided on the back of the the User Guide’s title page. The information will be helpful if you ever need service or parts.
5 You are now ready to begin installation. Follow the preparation steps on the
next page.
Installation
l 3-3
3
Description
Preparing for Installation
The HTC process air heater is easy to install, if you prepare the mounting area
properly.
1 Ma ke sure the mounting area provides:
❒❒
A grounded power source supplying the correct current for your
HTC model. All models require three-phase power. Check the HTC’s
serial tag for the correct amps, voltage, and cycles. Field wiring
should be completed by qualified personnel to the planned location for
the HTC. All electrical wiring should comply with your region’s electrical codes.
❒❒
Minimum clearance for safe operation and maintenance.
The HTC control center should be mounted so that its display panel
can be seen and touched easily by an operator.
❒❒
Process air lines installed from the dryer to the HTC location. For
easy maintenance, we recommend using flexible hose to make the final
connection between the process outlet of the dryer or blower and the
HTC.
Installation of the HTC Control
Models HTC 30, 60, and 90
CAUTION: You are responsible for the structural integrity of this
installation.
NOTE: The HTC control is shipped mounted on the left side of the
floor stand on models 30, 60, and 90 (see figure to the right).
NOTE: If, by using your own provisions, you change the mounting
arrangement of the control center to a wall mount unit,
it must be
mounted 6 inches off of the wall to provide clearance for the heat
sink.
✐
✐
HTC Control
Center
3-4 l Installation
Installation of the HTC Control
Model HTC 120
CAUTION: You are responsible for the structural integrity of this
installation.
1 Securely bolt the HTC control to the left side of the floor stand. Use the
supplied locking fasteners to securely mount the HTC control center to the floor
stand to prevent vibration-induced loosening.
NOTE: If, by using your own provisions, you change the mounting arrangement of the control center to a wall mount unit, it must be mounted 6 inches off of the wall to provide
clearance for the heat sink.
Installation of the HTC Control
Models HTC 180 and 270
CAUTION:You are responsible for the structural integrity of this installation.
1 Move the control center into
its final location for operation
(see figure to the right). The
control center must be positioned close enough to the hopper to allow connection of the
RTD temperature probe.
The control center can be
mounted to a wall, the hopper
frame, or a floor stand with customer provided provisions.
Note: If, by using your own provisions, you change the mounting arrangement of the control
center to a wall mount unit,
it must be mounted 6 inches off of the wall to provide c
lear-
ance for the heat sink.
✐
HTC Control Center
(Free-Standing)
✐
HTC Control
Center
✐
Note: If the length of the
process and process protection
RTD is too short for your installation, contact Conair Parts
Department (800.458.1960) to
purchase an extension cable.
From outside the United States,
call 814.437.6861.
CAUTION: Always disconnect
and lock out the main power
sources before making electrical
connections. Electrical connections should be made only by
qualified personnel.
CAUTION: Check the disconnect with a volt meter to insure
that the power is off.
Installation l 3-5
Location and Mounting of the HTC
Heater Assembly Models HTC 30,
60 and 90
CAUTION:You are responsible for the structural integrity of this installation.
Note: The HTC heater assembly is shipped mounted to the back of the floor stand on
Models 30, 60 and 90 (see Figure to the right).
The heater is prewired to the control box on HTC Models 30, 60, and 90.
Location and Mounting of the HTC
Heater Assembly Model HTC 120
CAUTION:You are responsible for the structural integrity of this installation.
1 Securely bolt the HTC heater assembly to the back of the floor stand (see
figure to the right). Use the locking fasteners provided to securely mount the
heater assembly to the floor stand to prevent vibration induced loosening.
The heater is prewired to the control box
on HTC Model 120.
Location and Mounting of the HTC
Heater Assembly Models HTC 180
and 270
CAUTION:You are responsible for the structural integrity of this installation.
1 Securely bolt the HTC heater assembly to the back of the floor stand (see
figure to the right). Use the locking fasteners provided to securely mount the
heater assembly to the floor stand to prevent vibration induced loosening.
2 Refer to the wiring diagram to make the wiring connections for the heater
and control box. Also, see page 3-8, “Connecting the Power.” Only a qualif
ied electrician should make the wiring connections between the control and the
heater. The customer must supply the appropriately sized wire and conduit to
make connections.
✐
HTC Heater
HTC Heater
IMPORTANT: Al ways refer to
the wiring diagrams that came
with your heater before making
electrical connections.
3
Description
Connecting the HTC Heater
Assembly to the Dryer or Blower
and Hopper
The inlet of the HTC heater assembly should be plumbed to the air source (usually
a blower or central dehumidification dryer). This inlet hose should be at least the
size of the heater inlet (lower) connection size (hoses provided). Also, the hose
should be as short and straight as possible to prevent unnecessary frictional losses.
This hose is the un-insulated and will normally be at ambient temperature plus 50
to 90°F. This hose should be properly supported so no weight will be on the
heater inlet connection.
The connection between the heater assembly outlet and the hopper should
be made with the supplied insulated hose. The insulation is important from
an energy standpoint and for personnel protection. Be careful not to block
off any heater sensor mounting locations.
Make sure all hoses are securely clamped to
prevent wasteful leaking. The hoses should be
routed neatly and supported where possible to
prevent undue stress on the heater and hopper
assemblies. Also, the bends should be made
with gradual radiuses. Sharp turns will cause
undue pressure drop.
✒
TIP: Units with elliptical or oval sha ped inlets or outlets require forming the hose to fit
this shape. When tightening the hose clamp, position the screw head on the long radius
portion of the duct.
Connect the filter sock or optional dust collector or cyclone to the hopper discharge. Verify the connections are secure and do not leak.
NOTE: Do not allow the
flexible hoses to kink or
crimp.
✐
3-6 l Installation
3
Description
Installation l 3-7
Installing the Isolation Valves
NOTE: Isolation valves should be installed when multiple hoppers are connected
to a single dryer or blower.
1 Turn the disconnect dial on the control center door to the Off or “O” posi-
tion. Lock out the main power (see Page 1-5 for complete lock out information).
2 Install one isolation valve in the return air line. Secure the hoses on the
valve with hose clamps.
3 Install the other isolation valve in the delivery air line. Secure the hoses on
the valve with hose clamps.
ON
O OFF
✐
3-8 l Installation
Connecting the Power on models
HTC 180 and 270
The electrical connection consists of bringing power into the control center and
wiring the heater power from the control center to the heater assembly. The incoming power should match the rated nameplate power required on the serial tag on the
control center. This power should be clean and have a voltage variation of no more
than +/- 5% of the nameplate voltage. Unless the actual voltage is equal to the
nameplate voltage, the actual kW output of the HTC will vary slightly. The output
varies with the square of the voltage difference.
CAUTION: Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by qualified personnel.
CAUTION: Check the disconnect with a volt meter to insure tha t the po wer is off.
1 Disconnect and lock out the main power sources before making electrical
connections. Electrical connections should be made only by qualified personnel.
2 Turn the disconnect dial on the control center door to the Off or “O” posi-
tion. Turn the captive screw, and swing the control center door open.
3
Insert the main power
cable through a knockout in the side of the control center.
Secure the power cable with a rubber compression fitting or strain relief or use
conduit. Verify that the incoming power is securely attached to the control center
and there is no strain on the incoming power.
4
Connect the power wires
to the three terminals at the top of the power disconnect
holder.
5 Connect the ground wire to the ground lug.
Note: The connection between the heater and control center should be made with
properly sized conductors and properly protected with appropriate conduit (customer supplied).
The routing should be nea
t and away from potential mechanical
damage. The terminations should be landed on the terminals in the control center
and heater junction area. These terminations should be regularly checked to prevent loosening and shorting to ground.
✐
IMPORTANT: Al ways refer
to the wiring diagrams that
came with your heater
before making electrical
connections.
ON
O OFF
Installation l 3-9
3
Description
Connecting the Power (continued)
on models HTC 180 and 270
6
Insert the supplied heater power
wire through a knockout in the side or
bottom of the control center. Secure the wire with a rubber compression fit-
ting or strain relief if conduit is not used.
7 Connect the heater power wires to the control center’s terminal block and
heater ground wire to the ground lugas shown.
8
Insert the other end of heater power
wire through the knockout in the side
of the heater assembly. Secure the wire with a rubber compression fitting or
strain relief if conduit is not used.
9 Connect the heater power wires to the top terminals of the heater assem-
bly’s terminal block and heater ground wires to the ground lugas shown.
Po w er Wires
(Gray - Customer
Supplied)
Ground Wires
(Green - Customer
Supplied)
Ground Wires
(Green/Yellow)
Insert the Power
Wires Here
IMPORTANT: Al ways refer to
the wiring diagrams that
came with your heater before
making electrical connections.
3-10 l Installation
Connecting the Control Wires
Models HTC 180 and 270
1
Refer to the wiring diagram that came with your control.
2 Insert the supplied control wires encased in conduit through a knockout in
the side or bottom of the HTC control center.
3 Connect the high temperature and pressure switch wires to the control
center's terminal block.
4 Insert the other end of the control wires through the knockout in one side
of the HTC heater assembly terminal box.
5 Connect the high temperature and pressure switch wires to the heater
assembly terminal block.
Note: The connection between the heater and control center should be made with
properly sized conductors and properly protected with appropriate conduit (customer supplied). The routing should be neat and away from potential mechanical
damage. The terminations should be landed on the terminals in the control center
and heater junction area. These terminations should be regularly checked to prevent loosening and shorting to ground.
IMPORTANT: Al ways refer to the proper wiring diagram supplied with your
equipment before making electrical connections.
CAUTION: Always disconnect and lock out the main power sources before
making electrical connections. Electrical connections should be made only by
qualified personnel.
ON
O OFF
✐
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