Conair UGD031/0106, Hopper Temperature Controller, HTC User Manual

Download

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.

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

able of Contents l

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

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

Introduction l 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

◆ ❒

•

✒

1-2 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.

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.

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

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:

Stop or turn off the equipment.

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

Secure the device with an assigned lock or tag.

Insert a lock or tag

in the holes to prevent movement.

The equipment is now locked out.

WARNING: Before removing lockout devices and returning 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:

Remove the lock or tag.

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

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

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

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

rying

oppe

emperatur

ontro

eaters

tartup /

Shutdown

For Startup:

1. With heaters in Standby, turn on blower or dryer.

2. Enable heaters.

For Shutdown:

. 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

rying

oppe

emperatur

ontro

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

Description

Specifications: HTC MODELS 600 - 5000

2-6 l Description

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

is w

ater column.

‡

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)

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

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

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

IMPORTANT: Al ways refer to the wiring diagrams that came with your heater before making electrical connections.

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

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.

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.

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.

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.

O OFF

Installation l 3-9

Description

Connecting the Power (continued) on models HTC 180 and 270

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.

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

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.

O OFF

✐

Installation l 3-11

Description

Connecting the RTD Sensors

The lower RTD could be the return air sensor for the setback option if installed or the process protection sensor depending on the configuration of the system. The routing of the sensor cables should be neat and not parallel with the power connections. When a sensor cable must cross over power wiring, the intersection should be made at right angles to reduce the RFI noise transmitted to the sensor cable.

Process Temperature RTD Probe

The RTD sensor connections should be made to the control center via the upper female connections in the side of the control center. The process temperature RTD is to be located in the hopper delivery air inlet. The connection is 1/8 NPT. The sensor should be located ¼ to ¾ of the way in to the diameter of the inlet to obtain the best temperature reading. The controller uses this RTD to monitor and control the setpoint temperature.

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

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).

Insert the process RTD probe into the delivery air inlet on the hopper.

Center the end of the probe in the inlet so that the tip does not touch the inlet tube walls. Tighten the nuts to lock the RTD probe in place.

IMPORTANT: Al ways refer to the wiring diagrams that came with your heater before making electrical connections.

O OFF

(continued)

Connecting the RTD Sensors (continued)

Route the process temperature RTD cable to the control center. Plug the connector into receptacle in the side of the control center labeled “Process”. Hand tighten the connector. Coil any excess cable and secure it with a wire tie.

Process Protection RTD Probe

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

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

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

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).

Insert the process protection RTD probe into the heater assembly outlet nozzle.

Center the end of the probe in the outlet so that the tip does not touch the

inlet tube walls. Tighten the nuts to lock the RTD probe in place.

3-12 l Installa

tion

O OFF

Process Protection R

Probe

Description

Installa

tion l

3-13

Connecting the RTD Sensors (continued)

Route the process protection RTD cable to the control center. Plug the connector into the receptacle in the side of the control center labeled “Protection”. Hand tighten the connector. Coil any excess cable and secure it with a wire tie.

Process Setback RTD Probe (Optional)

The optional process setback RTD probe is a sensor in the outlet of the hopper and is normally supplied with a closed loop dehumidifying dryer system. The purpose of the setback option is to reduce the energy consumption and prevent over drying when material stops flowing through the hopper.

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

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).

Insert the process setback RTD probe into the hopper outlet.

Center the end of the probe in the process air outlet of the hopper so that the tip does not touch the outlet tube walls. Tighten the nuts to lock the RTD probe in place.

O OFF

Typical Hopper

Process Setback RTD Location

Process Air Outlet

(continued)

✐

Note: If the length of the setback 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.

3-14 l Installation

Connecting the RTD Sensors (continued)

Route the process setback RTD cable to the control center. Plug the connector into the lower receptacle in the side of the control center. Hand tighten the connector. Coil any excess cable and secure it with a wire tie.

Installation l 3-15

Description

Testing the Installation

You have completed the HTC installation. Now it’s time to make sure everything works.

1 Ma ke sure there is no material in the hopper. If there is a loader or vacuum

receiver mounted on the hopper, disconnect the material inlet hose at the source.

2 Perform the following safety checks:

• Make sure all components are securely mounted;

• Make sure all hoses are connected to the proper locations and secured

with hose clamps;

• Make sure all sensors are properly installed and secured:

• Make sure all wiring is secure and away from potential mechanical dam-

age;

• Make sure the air filter is clean and has a minimum of 6 in. (15.2 cm)

clearance without any flow obstructions; and

• Make sure the hopper outlet is free from obstructions that would cause

back pressure in the drying hopper.

3 Perform a resistance test. Check the resistance leg to leg and leg to ground to

make sure that each heater and blower are wired correctly. The three legs should have equal resistance +/- 5%. The resistance to ground should be 20 megohms or higher.

4 Turn on the main power to the HTC. Make sure the disconnect dial is in the

ON position. This powers up the control and the display lights will illuminate.

For Hot Air Dryer (HAD) Models Only 5

Bump (rapidly start and stop) the blower motor and verify the motor is turning in the correct rotation according to the labels on the motor. If the

rotation is incorrect, shut off and lock out power and switch any two of the three power legs on the line side of the disconnect provided with the blower.

6 Check the discharge damper setting. The handle on the outlet of the blower

is connected to the discharge damper. This is required to be set to the proper position to deter

mine the pr

oper airflow for the heater/hopper. Adjust the dis-

charge damper until the blower pressure is 20 to 30 in. W.C.

(continued)

O OFF

NOTE: See the blower specifications sheet in the appendix for design supply pressure.

✐

3-16 l Installation

Testing the Installation (continued)

7 Adjust the setpoint to the desired hopper inlet temperature. Use the

Setpoint Adjust ▲ or ▼ buttons to set the temperature. Move the heater enable switch to the enable position. The temperature should stabilize around the setpoint and not significantly overshoot the set temperature.

8 If everything is working properly, the heater’s LED flashes and the tem-

perature climbs towards the setpoint.

For Carousel Plus Dryers 5

Reference the dryer manual and verify the dryer’s blower is running in the correct direction and the dryer is ready for operation.

6 Start the dryer. 7 Adjust the setpoint to the desired hopper inlet temperature. Use the

Setpoint Adjust ▲ or ▼ buttons to set the temperature. Move the heater enable s

witc

h to the enable position. The temperature should stabilize around the set-

point and not significantly overshoot the set temperature.

8 If e

erything is working properly, the heater’s LED flashes and the tem-

perature climbs towards the setpoint.

Heaters

Startup /

Shutdown

For Startup:

1. With heater s 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

Setpoint Adjust Buttons

SECTION

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

Operation l 4-1

Heaters

Startup /

Shutdown

For Startup:

1. With heater s 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

4-2 l Opera

tion

The HTC Process Air Heater: Control Panel DC

Heater Enable/Standby

Also is used to reset shut down alarms (see “Troubleshooting” Section 6) and to “Autotune” the controller (see “Autotuning” Section

4).

Setpoint Display

Shows the setpoint value.

Increment/Decrement Buttons

Used to increase or decrease values.

Actual Display

Shows the actual temperature value.

Acknowledge Alarm Button

Under an alarm condition, pushing the Acknowledge button once turns off the horn and displays the alarm message. Pushing the Acknowledge button a second time turns off the alarm LED.

Scroll Button

Press to scroll through the closed loop menu list. Pressing the Scroll button moves you down the list.

HTC DC Control Functions

HTC functions are values that you can set or monitor. Press the Scroll button until the function you want to set or monitor appears in the LED display.

Control Function Flow Charts

The following flow charts provide a quick summary of the control functions. For an explanation of each control function, see Control Function Descriptions.

Operation l 4-3

Operation

POWER ON

1 888 888

2 sec All LEDs On

2 dC 004

2 sec Software Version

res in



(Default Screen)

4 250 250

Process Setpoint and Actual Temp (Default Screen)

Press + or - to change setpoint.

Press Scroll Button

for Process Deviation Alarm Setpoint (Dev)

5 5dEv

+ or - Deviation Band

Press + or - to change setpoint.

Press Scroll to enter the value

Process Screens Process Protection Screens

Press Scroll Button and + key at the Press Scroll Button and + key at the

same time for 2 sec to get in. same time again for 2 sec to get in.

To get out at any time Press Scroll To get out at any time Press Scroll

button and - key at the same time button and - key at the same time

2 Min timer then return to the default screen

6 Pro cES 16 Pro tEc

Press Scroll again to view next screen Press Scroll again to view next screen

7 375 Hi.L

Process High Limit

17 Act 250

Protect Temperature

Press Scroll again to view next screen

8 3 Lbb

Process Loop Break Band

18 625 H.Al

Protect Hi Alarm SP

Press Scroll again to view next screen

9 10 Lbt

Process Loop Break Time

19 10 H.dL

Protect Hi Alarm Delay

Press Scroll again to view next screen

10 385 H.AL

Process High Alarm Setpoint

20 300 d.AL

Differential Alarm SP

Press Scroll again to view next screen

11 50 Pb

Process Prop

21 80 d.dL

Differential Alarm Delay

Press Scroll again to view next screen 12 16 int

Process Integral

Press Scroll again to view next screen

Press Scroll again to view the first screen

13 2dEr

Process Derivative

Press Scroll again to view next screen 14 tun OFF

Process Autotune

Press + Key to Start Autotune Press Scroll again to view next screen

15 F unt

Units degrees F or degrees C

Press + Key to toggle between F and C

Press Scroll again to view the first screen



Press Scroll Button again for Setback Return Temperature Setpoint

180 Srt

Press Scroll Button again for Process Setback Temperature Setpoint

140 PSt

Press Scroll to enter the value

(Optional)

Press + or - to change setpoint.

Press Scroll to enter the value

Press + or - to change setpoint.

4-4 l Opera

tion

Operation

Setup Screens Test Mode Screens

Press Scroll Button and + key at the same time for 10 sec to get in. To get out at any time Press Scroll To get out at any time Press Scroll button and - key at the same time button and - key at the same time

SEt uP 43 tE St

Press Scroll again to view next screen

tyP Res

Controller Type

44 in.1 OFF

Digital Input 1 status

Press Scroll again to view next screen

Prt ON

Process Protection Install

Press Scroll again to view next screen

47 in.4 ON

Digital Input 4 status

Press Scroll again to view next screen

ou.3

OFF

Press + key to jog output 3

Press Scroll again to view next screen 52 ou.5 OFF

Press + key to jog output 5

Press Scroll again to view next screen 53 ou.6 OFF

Press + key to jog output 6

Press Scroll again to view the first screen

* The test mode screens become visable if tSt (screen 41) is turned on.

Setback Setup Screens

Press Scroll Button and + key at the

To get out at any time Press Scroll button and - key at the same time

Set bAc

Press Scroll again to view next screen

Stb OFF

Setback Install

tSt OFF

Goto Test Mode

Press Scroll again to view next screen

Ld.d OFF

Load Default

Press + Key to Load Default Press Scroll again to view the first screen

ret 250

Press Scroll again to view next screen

20 ban

Press Scroll again to view next screen

10 sls

Press Scroll again to view next screen

Ldr 0

Press Scroll again to view next screen

2 P.dL

Press Scroll again to view next screen

35A

10 A.dL

Press Scroll again to view next screen

Add res

0 500

24 501

2 502

4 504

23 503

Id 1

Not applicable to the HTC Press Scroll again to view next screen



45 in.2 OFF

Digital Input 1 status

Press Scroll again to view next screen

34A

Sbt OFF

Press Scroll again to view next screen

34B

SbL OFF

Press Scroll again to view next screen

Operation l 4-5

4-6 l Opera

tion

General Screens

SCREEN 1

SCREEN 2

SCREEN 3

SCREEN 4 Setpoint Actual

SCREEN 5

888

Function

Control Function Descriptions

888

004

res

250

dEv

Once the power is turned on, this screen is displayed for 2 seconds while the control performs its self-checking process. All LEDs are illuminated during this 2-second interval.

After the self-checking process is complete, this screen flashes for 2 seconds and displays the software version.

After the software version is displayed, this screen appears for 2 seconds and identifies that the control is setup for a wheel dryer (2) or HAD.

This is the default screen. It shows the process air temperature setpoint and the actual temperature measured at the inlet to the drying hopper. The “+/-” buttons can be used to change the setpoint. Holding the “+/-” buttons in will cause the number to ramp up or down faster the longer the button is held. The display will return to the default screen from anyplace in the menu structure if nothing is done for 10 minutes.

This is the process deviation temperature alarm setpoint screen. It is used to set the deviation temperature band around the process temperature setpoint. The range is 5 - 20°F (2.8 - 11.1°C). The “+/-” buttons can be used to change the setpoint. If the temperature goes outside the band, the control will display a passive alarm (P1).

Opera

tion l

4-7

General Screens

SCREEN 5A

SCREEN 5B

Function

Control Function Descriptions

(continued)

Setback Screen 1 (Setback Setpoint). When setback is enabled, this is the hopper outlet temperature at which the setback becomes active.

Setback Screen 2 (Process Setpoint). The process setpoint is the temperature the control tries to maintain when functioning in

the setback mode.

180

Srt

140

PSt

NOTE: Setback is optional.

✐

Operation

To access the process screens, press the “Scroll” and “+” buttons at the same time and hold for two seconds . To get out of the Process screens at any time, press the Scroll and “-” buttons at the same time. After two minutes, you will be returned to the Default screen.

This is the process header screen. It indicates that all items below it pertain to the process temperature control.

This is the process high limit screen. It is used to set the high limit for the process temperature setpoint. The “+/-” buttons can be used to change this value. If set at 250°F, the operator cannot set the process setpoint above 250°F.

This is the process loop break band screen. It is used to set the temperature band for the loop break alarm. The “+/-” buttons can be used to change the setpoint. If outside the deviation band, if the actual tem perature does not move toward the setpoint by this value in the time value in screen 9, a loop break alarm will occur.

Process Screens

SCREEN 6

SCREEN 7

SCREEN 8

Pro

Function

Control Function Descriptions

(continued)

cES

250

Hi.L

Lbb

4-8 l Opera

tion

Operation

Operation l 4-9

This is the process loop break time screen. It is used to set the temperature band time for the loop break alarm. The “+/-” buttons can be used to change the temperature band time. When the actual temperature is outside the deviation band, if the temper ature is not moving toward the setpoint at a rate greater than or equal to the value in screen 8, page 4-8, for the time value in this screen (sec.), then the heater will alarm on loop break. Once the actual temperature is within the deviation band, the loop break is ignored.

This is the process alarm high temperature setpoint screen. It is used to set the temperature at which the process high temperature shutdown alarm (A1) will shutdown the heater and display the alarm. The “+/-” buttons can be used to change the setpoint.

This is the process proportional band screen. It is used to change the proportional band value for the process control loop. The “+/-” buttons can be used to change the proportional band setpoint.

This is the process integral screen. It is used to change the integral value for the process control loop. The “+/-” buttons can be used to change the integral value setpoint.

his is the pr

ocess der

ivative screen. It is

used c

hang

e the der

ivative value for the

ocess control loop. The “+/-” buttons

can be used to c

hange the derivative value

setpoint.

(continued)

Process Screens

SCREEN 9

SCREEN 10

SCREEN 11 *

SCREEN12 *

SCREEN 13 *

Function

Control Function Descriptions (continued)

Lbt

250

H.AL

int

dEr

* These parameters will be

automatically adjusted by the autotune procedures. Conair does not recommend they be adjusted individually.

4-10 l Opera

tion

Process Screens

SCREEN 14

SCREEN 15

Function

Control Function Descriptions (continued)

This is the process heater autotune screen. (See page 4-22 for detailed information on the autotune function.) The autotune procedure should be performed when setting up the system the first time or if the control is inconsistent. Autotuning may take a minute or so to complete. When finished, the display will read “don”. The new PID values are automatically saved (to screens 11, 12, and 13).

This is the temperature units screen. It is used to change the temperature display from °F to °C or °C to °F.

tun

OFF

unt

Opera

tion l

4-11

Operation

Function

Control Function Descriptions (continued)

Process Protection Screens *

SCREEN 16 Protection

SCREEN 17

SCREEN 18

When at screen 6, page 4-8, (or the process screens), to access the process protection screens, press the “Scroll” and “+” buttons at the same time and hold for two seconds from the Process screens. To get out of the Process protection screens at any time, press the “Scroll” and “-“ buttons at the same time. (Refer to the flow charts on pages 4-4 and 4-5.)

This is the process protection header screen. It indicates that all items below it pertain to the process protection actual temperature and alarms.

This screen shows the actual temperature measured at the process protection RTD.

This is the process protection high temperature alarm setpoint screen. If the actual process protection temperature exceeds this setpoint for the length of the process protection high alarm delay (screen 19, page 4-12), the process protection alarm (A49) will trigger and the heater will shutdown. For example if the actual process protection temperature exceeds 625°F (330°C) for 10 seconds, the heater will execute a shutdown alarm. The +/- buttons can be used to change the setpoint.

Pro

tEc

Act

250

625

H.AI

(continued)

* Accessed from the Process

Screens.

4-12 l Opera

tion

Function

Control Function Descriptions (continued)

Process Protection Screens

SCREEN 19

SCREEN 20

SCREEN 21

This is the process protection high alarm delay screen. It is used to set the delay time for the process protection high temperature alarm. If this time delay is exceeded, the heater will execute a shutdown alarm (A49). The “+/-” buttons can be used to change the setpoint.

This is the process differential alarm setpoint screen. If the actual process protection temperature (screen 17, page 4-11) minus the actual process temperature (screen 4, page 4-6) exceeds this setpoint for the length of the process differential alarm delay (screen 21), this alarm (A50) will trigger and the heater will shutdown. For example if the actual process protection temperature is 450°F (232.2°C) and the actual process temperature is 124°F (51.1°C) for 180 seconds (default) or the time set on Screen 21, the heater will execute a shutdown alarm (A50). The “+/-” buttons can be used to change the setpoint.

This is the process differential alarm delay screen. This screen is used to change the process differential alarm delay time. The “+/-” buttons can be used to change the setpoint.

180

d.dL

H.dL

325

d.AL

* Accessed from the Process

Screens.

Operation

Opera

tion l

4-13

Function

Control Function Descriptions (continued)

DC Resin Setup Screen

SCREEN 30

SCREEN 31

SCREEN 32

To access the DC resin setup screens, press the Scroll and “+” buttons at the same time and hold for two seconds from the Process Protection screens (screen 16). To get out of the DC resin setup screens at any time, press the Scroll and “-“ buttons at the same time.

This is the setback option setup screen. It indicates that all items below it pertain to the setback option.

This shows the actual return air temperature measured at the hopper outlet.

This shows the setback return band setting. The value is used to determine when the setback mode is disabled, once the dryer has gone into the setback mode. This example indicates a 20° band width, which means when your hopper outlet temperature is 20° below your setpoint, the dryer will come out of setback mode.

Set

bAc

ret

250

ban

4-14 l Operation

Function

Control Function Descriptions

(continued)

DC Resin Setup Screen

SCREEN 33

SCREEN 34

SCREEN 34A

SCREEN 34B

This is the setback load rate setpoint. (Not available at this time.)

This is the load rate reading. (Not available at this time.)

This is the setback on temperature. It turns the setback on temperature option on or off.

This controls the setback on load rate function. It turns the setback on load rate option on or off. (Not available at this time.)

sls

Ldr

Sbt

OFF

SbL

OFF

Operation

Operation l 4-15

Function

Control Function Descriptions (continued)

DC Resin Setup Screen

SCREEN 35

SCREEN 35A

This is the process heater alarm delay. It is used to delay the process heater alarm. This number is the delay time in seconds that an alarm will occur on loss of process heat.

This is the airflow alarm delay. It is used to delay the airflow alarm. This number is the delay time in seconds that an alarm will occur on loss of airflow.

P.dL

A.dL

4-16 l Operation

Function

Control Function Descriptions (continued)

Setup Screens

SCREEN 36

SCREEN 37

SCREEN 38

Screen 39

Screen 41

Screen 42

To access the setup screens, press the Scroll and “+” buttons at the same time and hold for ten seconds from the Process screens. To get out of the setup screens at any time, press the Scroll and “-“ buttons at the same time.

This is the initial setup screen. It indicates that all items below it pertain to the heater setup.

This screen indicates the hardware to the controller. It will say “Res”.

This screen turns the process protection off and on. The HTC is shipped with this function set to “On” unless the HTC is sold with an HAD.

For HAD and “W” dryer models only. This screen turns the setback “On” or “Off”. The HTC is shipped with function set to “On” if the setback option is installed.

This screen lets you access the Test Mode.To access the test mode screens, press "+" button when you are in the test screen.

To get out of the test mode screens

t any time, press the Scroll and "-" but-

tons at the same time.

This screen returns the control board to the f

actor

y def

ault settings (not necessar

ily for

a specif

ic model). Conair does not r

ecom

mend using this function unless instr

ucted

to b

y a Conair Ser

vice

echnician.

Set

tyP

Res

Prt

Stb

OFF

tSt

OFF

Ld.d

OFF

The setting on screen 42 should not be changed without the direction of Conair Service Personnel.

Control Function Descriptions (continued)

Test Mode Screens

SCREEN 43

SCREEN 44 *

SCREEN 45

SCREEN 47

Function

To access the test mode screens, press "+" button when you are in the test screen (screen 41). To get out of the test mode screens at any time, press the Scroll and "-" buttons at the same time.

This is the Test Mode screen. While in the test mode, you can see the status of the inputs and outputs and you can toggle the outputs on or off by pressing the up and down arrow keys on the control.

This screen shows the state of digital input 1. If the input is open, "OFF" will be displayed. If the input is closed, "ON" will be displayed. Digital input 1 on a heater is the process high temperature switch. This switch is closed during normal operation. It opens when it detects a high temperature inside the process heater tube.

This is the heat enable/disable screen. It shows the state of digital input 2. If the input is open, "OFF" will be displayed. If the input is closed, "ON" will be displayed.

This is the differential pressure (flow switch) screen. It shows the state of digital input 4. If the input is open, "OFF" will be displayed. If the input is closed, "ON" will be displayed.

(continued)

in.1

OFF

in.4

Opera

tion l

4-17

Operation

in.2

* See the supplied electrical draw-

ings to associate instruments to inputs.

4-18 l Operation

Control Function Descriptions (continued)

Test Mode Screens *

SCREEN 50

SCREEN 52

SCREEN 53

Function

This is the output 3 screen. Press the "+" key to jog output 3. Output 3 on a heater is the process heater solid-state relay signal. Pressing the "+" key will cause the process solid-state relays to fire. You can observe the solid-state relay LED to check this output. Since the isolation contactor is open, the heater does not come on because it does not have power.

This is the output 5 screen. Press the "+" key to jog output 5. Output 5 on a heater is the process heater power isolation contactor signal. Pressing the "+" key will cause the isolation contactor to close. Watch the isolation contactor pull in to check this output. Since the solid-state relays are not on, the heaters does not come on because they do not have power.

This is the output 6 screen. Press the "+" key to jog output 6. Output 6 on a heater is the alarm horn. Pressing the "+" key will cause the alarm horn to sound.

ou.3

OFF

ou.6

OFF

ou.5

OFF

* Outputs 1,2, and 4 are not used

in the HTC.

Opera

tion l

4-19

Operation

HTC DC Control Alarms

PASSIVE ALARMS

Passive alarms flash the alarm code and display process temperature until the alarm condition goes away, or it becomes a shutdown alarm.

Code Description Alarm LED

P1 Process Temperature Deviation Blinking Red

SHUTDOWN ALARMS

Shutdown alarms flash the alarm code and display process temperature. The HTC process air heater should stop when the process temperature is below 150°F (65.6°C) but should still flash the alarm code until the Acknowledge Alarm button is pressed. If the alarm condition is still active, the HTC cannot start, it will flash the alarm code again. If the alarm condition is not active, the display should return to the normal default screen display and the HTC is ready to run.

Alarms place the control in “standby” mode. After the alarm is corrected and acknowledged, cycle the heater Standby/Enable switch to “Standby” then back to “Enable” to restart the process control.

Code Description Alarm LED

A1 Process High Temperature Solid Red A2 Process Temperature Loop Break Solid Red A3 Process Heater Box High Temperature Solid Red A10 RTD Integrity Solid Red

A39 EEProm Write Error-Internal Control Solid Red

Board Problem A49 Process Protection High Alarm Solid Red A50 Process Differential Alarm Solid Red

4-20 l Operation

Initial Operation (For HAD Only)

1 Hopper material: Fill the hopper with the material to be heated. 2 Blower inlet filter: Verify that the area around the inlet filter is clean and free

of debris. This will extend the time between service of this filter.

3 Air discharge from the hopper: Verify that the sock filter hose connection to

the dust collector connections are secure and do not leak.

4 Setting of damper after material: The damper valve will need to be opened

to adjust the flow back down to 20 in. W.C. on the pressure gauge. This setting is a suggested setting. If the airflow in the hopper is carrying over material out of the hopper, then the flow rate may be adjusted downward by closing the damper. If the airflow is too low then the heater will go into stand by. If the airflow is too high, the setpoint might not be achievable.

WARNING: Fire potential - The electric heating elements are exposed to the air going into the hopper. It is important that there is no debris in this air stream. Under no circumstances should the HTC be run in a dirty air stream as material passing through the heater could ignite embers and shoot sparks into the hopper, which could catch fire.

5 Auto tuning: When the unit is fully assembled and ready for operation, it

should be tuned to the actual system that it is connected to with material in the hopper. Follow the auto tuning procedure detailed on page 4-22 of this manual.

6 Hopper residence time: The material throughput rate must be determined by

the size of the hopper, the drying time required, and the extent of drying desired for the product.

Initial Operation (For Carousel Plus Dryer HTC)

1 Hopper material: Fill the hopper with the material to be heated.

2 Auto tuning: When the unit is fully assembled and ready for operation, it

should be tuned to the actual system that it is connected to with material in the hopper. Follow the auto tuning procedure detailed on page 4-22 of this manual.

3 Hopper residence time: The material throughput rate must be determined by

the size of the hopper, the drying time required, and the extent of drying desired for the product (see page 4-20).

Operation l 4-21

Operation

4-22 l Operation

Autotuning

Follow the procedure below to “Autotune” the HTC.

1 Use the selector switch and put the HTC control into “Standby”. 2 Adjust the setpoint to a “Normal” setting. 3 Establish the normal operating air flow. 4 Access the Process menu by pressing and holding the Scroll and Plus

keys for 2 seconds until “Process” is displayed.

5 Press the Scroll key until “Tune Off ” is displayed.

6 Press the Plus key and “Tune Set” is displayed. If the control remains on

screen 6, the difference between the setpoint and the actual temperature is not at least the required minimum.

7 Enable the heater after the system stabilizes. The following will display

when autotuning starts.

8 When autotune is complete, “Tune Done” is displayed and the heater is

placed in the Standby mode.

9 Note the

“Pb”,

“int”, and “dEr” values (screens 11, 12, and 13).

Pro

cES

tun

OFF

tun

SEt

tun

Hr.u

tun

don

✒

Tip: Conair recommends that the autotune should be run from a cold start. The minimum temperature difference between the start temperature and the autotune and setpoint temperature you will be running should be 50ºC (122ºF).

Operation l 4-23

Autotuning (continued)

10 To return to the normal control, cycle the heater to Standby and then

back to Enable.

11 If “Tune Error 1” is displayed, the autotune was not successful and the

process must be repeated. The most likely reason for this error is that the difference between the starting temperature and the autotune temperature was not at least 50ºC (122ºF).

tun

Er.1

Operation

Normal Operation To Start Heating

1 Determine what the HTC’s setpoint must be for your process and material. 2 Ma ke sure there is material in the hopper. 3 Start the dryer or process blower to begin air flow. Set the proper flow on

the blower if equipped.

4 Turn on the main power to the HTC. Make sure the HTC’s disconnect dial

is in the ON position. This powers up the control and the display lights will illuminate.

5 Set the drying temperature. Press the Adjust Setpoint ▲ or t buttons to

select the temperature.

7 T

n the heater switch to “Enable” to start heating.

O OFF

Heaters

Startup /

Shutdown

For Startup:

1. With heater s 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

Setpoint Adjust Buttons

4-24 l Operation

Operation

Operation l 4-25

Normal Operation To Stop Heating

1 Turn the heater to “Standby”.

IMPORTANT: Al ways turn off the HTC BEFORE the dryer or process blower.

2 Allow the HTC to cool to below 100°F (37.8°C). 3 Turn off the blower or dryer. 4 Be sure to disconnect and lockout the main power

if you have stopped the

HTC to perform maintenance or repair.

CAUTION: Improper shut down can cause damage to your heater.

Heaters

tartup /

Shutdown

For Startup:

1. With heater s 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

4-26 l Opera

tion

Maintenance

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

SECTION

Maintenance

Maintenance l 5-1

5-2 l Maintenance

Preventative Maintenance Checklist

The HTC process air heater requires little maintenance. We recommend the following maintenance schedule and tasks.

• Whenever you change material or process

❒❒

Change the HTC setpoint if it must be changed.

• Daily or weekly as needed

❒❒

Inspect the inlet and outlet hoses.

Tighten the hose clamps if loose. Replace the hose if worn or damaged.

❒❒

Inspect the filter (if equipped).

Clean or replace the filter as necessary.

• Monthly or as often as needed

❒❒

Inspect the main power wires, heater wires and conduit, and RTD probe wires for damage and wear.

Replace any damaged or worn wire or conduit.

❒❒

Check for any damage to the control panel.

Replace if damaged.

❒❒

Check for damage to the heater box.

Replace if damaged.

❒❒

Clean dirt from exterior surfaces with a cloth dampened with water.

Troubleshooting

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

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

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

SECTION

Troubleshooting

roubleshooting l

6-1

Before Beginning

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 disassembling the HTC process air heater be sure to:

❏ Diagnose causes from the control panel.

1 Press the Acknowledge Alarm button to silence the alarm. 2 Address the alarm message and fix the problem.

3 M ove the heater switch from Enable to Standby. 4 Cycle the heater switch from Standby to Enable to restart normal con-

trol. If the alarm reappears the problem was not fixed.

If the alarm is a passive alarm

you will see P in the screen title display.

If the alarm is a shut down alarm you will see A in the screen title display.

❏ Diagnose causes from the control panel.

You can locate any problem from the front of the heater.

Heaters

Startup /

Shutdown

For Startup:

1. With heater s 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

Acknowledge Alarm Button

Scroll Button

6-2 l

roubleshooting

Before Beginning (continued)

❏ Find the wiring and equipment diagrams that were shipped with your heater. These dia-

grams are the best reference for correcting a problem. The diagrams also will note any custom features, such as special wiring or alarm capabilities, not covered in this User Guide.

Troubleshooting

A Few Words of Caution

The HTC process air heater is equipped with numerous safety devices. Do not remove or disable them. Improper corrective action can lead to hazardous conditions and should never be attempted to sustain production.

WARNING: Only qualified service personnel should examine and correct problems that require opening the dryer’s control center or using electrical wires to diagnose the cause.

WARNING: High voltage.Always stop the HTC process air heater, disconnect and lock out the main power source before troubleshooting or performing repairs.

CAUTION: Hot surfaces.Always protect yourself from hot surfaces inside and outside of the heater.

roubleshooting l

6-3

See warnings below.Open the control center to check fuses and heater contactors.

6-4 l Troubleshooting

How to Identify the Cause of a Problem

Most heater malfunctions are indicated by an illuminated Alarm light on the HTC process air heater control panel.

A problem can trigger two types of alarms:

• Shut Down: The heater has automatically shut down because it detected a

serious problem that could damage your material or dryer.

• Passive: The heater continues to operate, but warns of a problem that could

prevent correct heating of your material. If ignored, this problem could lead to a condition that will shut down the dryer.

When the alarm light is displayed:

1 Press the Acknowledge Alarm button to silence the alarm (see page

4-2).

2 Find the error message in the diagnostics table of this Troubleshooting

section.

3 Cyc

le the heater switch from Enable to Standby and then back to

Enable to clear and restart normal control. If the alarm reappears, the

problem was not fixed.

Heaters

Startup /

Shutdown

For Startup:

1. With heater s 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

Alarm Light

Acknowledge Alarm Button

Troubleshooting

Shut Down Alarms

If the red Acknowledge Alarm LED is solid, the alarm is a shutdown alarm. The heater will shutdown automatically to prevent damage to the equipment or personnel.

Possible cause

The process high temperature is not at least 10°F (5.6°C) above the setpoint.

The RTD temperature probe is not installed correctly.

The air lines are restricted or loose.

SSR has failed.

Output on the board has failed.

Process RTD is loose or has fallen out.

The process heater has failed.

The air lines are restricted or loose.

Output on the board failed “Open”.

Drying or setback setpoint is too low.

Solution

Increase the process high temperature.

Make sure the RTD temperature probe tip is in the center of the hopper inlet tube.

Straighten any crimps in the hoses. Tighten any loose hoses.

Replace the SSR.

Replace the board.

Check the process RTD and tighten if needed.

Check the heater fuses, and resistance across each leg of the process heater.

Straighten any crimps in the hoses. Tighten any loose hoses.

Replace the board.

Adjust the setpoint.

Add additional cooling, either a precooler or an after

cooler

, to the circuit.

Problem

A1 Process High

Temperature – If the process temperature exceeds the process high temperature setpoint, it shuts down the dryer. Defaults are set to 385°F (196.1°C) for 20 sec. for CP HTCs, and 360°F (182.2°C) for 20 sec. for HADs.

A2 Process Temperature

Loop Break – If the process temperature is outside of the operator entered deviation, alarm band (see Process High Temperature Deviation passive alarm) and the process temperature is not moving towards the setpoint at a rate greater than specified. It shuts down the dryer. Defaults are set at 3°F (1.7°C) over 20 sec.

(continued)

Troubleshooting l 6-5

6-6 l

Troubleshooting

Shut Down Alarms (continued)

Problem

A3 Process Heater High

Temperature – The snap switch in the process heater tube opens due to excessive temperature.

A10 RTD Integrity – If a

RTD is faulty.

A39 EEProm Write Error.

Possible cause

There is an air flow blockage or loose hoses.

The isolation contactor failed in the closed position.

The heater solid state relays (SSRs) failed.

No air flow or the airflow is re v ersed.

The connection in the electrical enclosure for the RTD is loose.

The connection of the RTD plug on the control board is loose.

One of the RTDs has failed. The RTD is enabled but wired incorrect-

ly.

Internal control board problem.

Solution

Remove the blockage.

Tighten any loose hoses.

Replace the isolation contactor.

Replace the failed heater solid state relays (SSRs).

Turn on the blower.

Reverse the connection points of the hoses.

Check the operation of the differential pressure switch.

Check the RTD plug connection and tighten if needed.

Check the plug connection and tighten if needed.

Replace the RTD.

Move the wires to the proper terminals (see the wiring diagrams supplied with the unit).

Replace the control board.

roubleshooting l

6-7

Shut Down Alarms (continued)

Problem

A49 Process Protection

High Temperature – If the process protection temperature exceeds the process protection high temperature setpoint, it shuts down the dryer. Defaults are set to 600°F (315.6°C) for 10 sec. for larger HTCs and 400°F (204.4°C) for 10 sec. for smaller HTCs.

A50 Process Protection

Differential Temperature – If the process protection differential temperature exceeds the process protection differential temperature setpoint, it shuts down the dryer. Defaults are set to 175°F (325°C) for 180 sec. (see screen 21, page 4-12).

Possible cause

The Process RTD temperature probe is not installed correctly.

The air lines are restricted or loose.

The Process RTD or Process Protection RTD temperature probe is not installed correctly.

The air lines are restricted or loose.

Solution

Make sure the RTD temperature probe tip is in the center of the hopper inlet tube or heater manifold.

Straighten any crimps in the hoses. Tighten any loose hoses.

Make sure the RTD temperature probe tip is in the heater outlet (see page 3-10).

Straighten any crimps in the hoses. Tighten any loose hoses.

Troubleshooting

Passive Alarms

If the red Alarm LED is blinking, the alarm is a passive alarm. The heater continues to operate, but this problem could prevent correct heating of your material. Note that once the Acknowledge Alarm button is pressed once, the blinking red LED becomes solid. A passive alarm will go away when the alarm condition is cleared.

Problem

P1 Process Temperature

Deviation – The process temperature exceeds the deviation band as entered for the specified time. Default values are 10°F (6°C) for 5 sec.

Possible cause

One of the solid state relays (SSRs) has failed.

The process RTD is loose or has fallen out.

The air hose connections are loose.

The heater has failed.

Solution

Replace the failed solid state relays (SSR).

Check the process RTD and tighten if needed.

Tighten all air hose connections.

Replace the failed heating element (see page 6-12).

6-8 l Troubleshooting

Troubleshooting

Troubleshooting l 6-9

Replacing Fuses

1 Disconnect and lockout the main power supply. 2 Open the control center.

3 Check the fuse. If necessary, pull the fuse out and replace it with a fuse of the

same type and rating.

Fuse Blocks

To locate the appropriate fuse and replacement part, refer to the wiring diagrams that came with your HTC.

IMPORTANT: Always refer to the wiring diagrams that came with your heater to locate specific electrical components. Illustrations in the User Guide are intended to be representative only.

O OFF

Checking Heater Solid State Relays

1 Disconnect and lockout the main power supply. 2 Open the control center door. 3 Locate the process solid state relays (SSRs). Refer to the wiring diagrams that

came with your heater.

4 Check the resistance using an ohmmeter.

6-10 l

Troubleshooting

IMPORTANT: Always refer to the wiring diagrams that came with your heater to locate specific electrical components. Illustrations in the User Guide are intended to be representative only.

Solid state relays

Check the resistance between the terminal screws. If ohms equal zero, replace the relays.

O OFF

Terminal Screws

Troubleshooting

roubleshooting l

6-11

Checking or Replacing Temperature Sensors

The HTC process air heater uses RTD sensors to monitor the process temperature in the hopper inlet, the setback temperature in the hopper outlet, and the process protection temperature in the heater outlet.

To check or replace an RTD sensors:

1 Disconnect and lockout the main power supply. 2 Locate the RTD sensors. 3 Check the sensor positions and conditions. Temperature readings will be

incorrect if the sensors are touching the wall of an air hose or pipe or if the sensor or wiring is damaged. The tip of the sensor should be centered within the air hose or pipe. Sensor wir

es should be attached to the appropriate connection

points on the heater’s control center.

4 To check with ohm meter, measure the resistance across the RTDs. The

resistance should be approximately 110 ohm at room temperature.

5 Replace the sensor, if necessary.

Typical location of the Process RTD at the hopper inlet.

IMPORTANT

: Al ways refer

to the wiring diagrams that came with your heater to locate specific electrical components. Illustrations in the User Guide are intended to be representative only.

O OFF

6-12 l Troubleshooting

Replacing the Heating Elements

1 Disconnect and lockout the main power. 2 Gain access to the heating elements by removing screws that

secure the heating element cover to the enclosure.

3 Remove the heating element cover by tilting

the top away from the enclosure slightly, then lifting the cover up and away from the enclosure.

4 Refer to the “Testing the Installation” section

(page 3-13) and determine which heater(s) is not functioning.

5 Remove the screws securing the electrical

cover plate

to the heating element enclosure.

Remove the electrical cover plate.

6 Note the connection points then disconnect the heating element leads from

the terminals on the terminal block.

IMPORTANT

: Al ways refer

to the wiring diagrams that came with your heater to locate specific electrical components. Illustrations in the User Guide are intended to be representative only.

O OFF

Screws to Remove

- Large Heaters

Heater Wires

Heater Connection Junction Box

Troubleshooting

Troubleshooting l 6-13

Replacing the Heating Elements (continued)

7 Remove the hose clamp securing the

insulated hose to the outlet of the heating element. Remove the hose.

8 Remove the hose clamps securing the

heating element to the heater inlet.

9 Remove the internal hose clamp. 10 Lift the heating element out of the enclosure. 11 Slide the insulation off the heater, or make a cut the entire length of

the insulation sleeve to aid removal.

12 Check the ID mark on the side of the heating element for kW rating

and voltage. The ID mark is on the outside of the tube near the end with the lead wires. Make sure the kW and voltage is the same as the replacement heating element.

13 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 and secure it with duct tape.

14 Set the new heating element into the enclosure. Secure the heating ele-

ment to the heater inlet with the original three (3) hose clamps.

15 Connect the insulated outlet hose the the outlet of the heating element.

Secure the hose with the original hose clamp.

16 Route the hea

ting element leads to the terminal block. Connect the heat-

ing element leads to the original terminals on the terminal block. Reinstall

the electrical cover plate.

17 Reinstall the heating element cover on the enclosure. 18 Test the system to insure that the new heating element is functioning cor-

rectly (see Page 3-13, Step 3).

Clamps to Remove

Clamp

✐

Note: For larger units (above 60 kW), it may be necessary to remove the front heaters to access the rear heaters.

Replacing the Air Flow Differential Pressure Switch

If the air flow differential pressure switch fails to detect the pressure drop between

the heater inlet and outlet, it should be replaced.

1 Stop the heat er, disconnect and lockout the main power. 2 Gain access to the heating elements by removing screws that

secure the heating element cover to the enclosure.

3 Remove the heating element cover by tilting

the top away from the enclosure slightly, then lifting the cover up and away from the enclosure.

4 Note their location then remove the two

wires connected to the pressure switch.

5 Note their locations then disconnect the

hose coming from the heater outlet from the low pressure side of the switch and the hose coming from the heater inlet from the high pressure side of the switch.

6-14 l Troubleshooting

O OFF

IMPORTANT

: Al ways refer

to the wiring diagrams that came with your heater to locate specific electrical components. Illustrations in the User Guide are intended to be representative only.

Troubleshooting

Troubleshooting l 6-15

Replacing the Air Flow Differential Pressure Switch (continued)

6 Remove the mounting hardware securing the

pressure switch to the heating element enclosure.

7 Align the new pressure switch with the mount-

ing holes and secure it to the heating enclosure

using the original mounting hardware.

8 Connect the hose coming from the heater outlet

to the low pressure side of the switch and the hose coming from the heater inlet to the high pressure side of the switch.

9 Connect the two wires to their original location on the pressure switch.

10 Test the system to insure that the new air flow differential switch is detect-

ing the pressure drop between the heater inlet and outlet.

11 Reinstall the heating element cover on the enclosure. 12 Connect the hose coming from the heater outlet to the low pressure side

of the switch and the hose coming from the heater inlet to the high pressure side of the switch.

13 Connec t the two wires to their original location on the pressure switch. 14 Test the system to insure that the new air flow differential switch is detect-

ing the pressure drop between the heater inlet and outlet.

6-16 l

roubleshooting

We’re Here to Help

Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have installing and operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use.

How to Contact Customer Service

To contact Customer Service personnel, call:

NOTE: Normal operating hours a re 8:00 AM - 5:00 PM. After hours emergency

service is available at the same phone number.

From outside the United States, call: 814-437-6861

You can commission Conair service personnel to provide on-site service by contacting the Customer Service Department. Standard rates include an on-site hourly rate, with a one-day minimum plus expenses.

Before You Call...

If you do have a problem, please complete the following checklist before calling Conair:

❒

Make sure you have all model, control type from the serial tag, and parts list numbers for your particular equipment. Service personnel will need this information to assist you.

❒

Make sure power is supplied to the equipment.

❒

Make sure that all connectors and wires within and between control systems and related components have been installed correctly.

❒

Chec

k the tr

oub

leshooting guide of this man

ual f

or a solution.

❒

hor

oughl

y e

xamine the instr

uction manual(s) for associated equipment, especial-

ly controls. Each manual may have its own troubleshooting guide to help you.

❒

Check that the equipment has been operated as described in this manual.

❒

Check accompanying schematic drawings for information on special considerations.

Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Department for a nominal fee, or visit the product section of the Conair website www.conairnet.com.

ppendix l

A-1

✐

A-2 l Appendix

Equipment Guarantee

Conair guarantees the machinery and equipment on this order, for a period as defined in the quotation from date of shipment, against defects in material and workmanship under the normal use and service for which it was recommended (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.

Performance Warranty

Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the equipment or as detailed in engineering specifications, provided the equipment is applied, installed, operated and maintained in the recommended manner as outlined in our quotation or specifications.

Should performance not meet warranted levels, Conair at its discretion will exercise one of the following options:

• Inspect the equipment and perform alterations or adjustments to satisfy

performance claims. (Charges for such inspections and corrections will be waived unless failure to meet warranty is due to misapplication, improper installation, poor maintenance practices or improper operation.)

• Replace the original equipment with other Conair equipment that will meet

original performance claims at no extra cost to the customer.

• Refund the invoiced cost to the customer. Credit is subject to prior notice by the

customer at which time a Return Goods Authorization Number (RGA) will be issued by Conair’s Service Department. Returned equipment must be well crated and in proper operating condition, including all parts. Returns must be prepaid.

Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is being made.

Warranty Limitations

Except for the Equipment Guarantee and Performance Wa rranty stated above, Conair disclaims all other warranties with respect to the equipment, express or implied, arising by operation of law, course of dealing, usage of tr

ade or otherwise, including but not limited to the implied warranties of

merchantability and fitness for a particular purpose.

Blower Installation and Maintenance

This addendum will assist you in installing and maintaining your HAD blower. By following the general instructions presented, you will prolong the life of the equipment, while preventing unexpected downtime.

Receiving

All shipments are F.O.B. It is, therefore, in the interest of the buyer to carefully inspect all shipments before they are accepted from the freight carrier. Upon delivery, be sure that all items listed on the bill of lading and packing list (inserted in the plastic envelope attached to the shipment) have been received. Partial shipments are sometimes made.

The units are skidded, boxed, or crated to fully comply with rail or trucking requirements for shipment. Accessories are sometimes shipped separately due to handling space requirements.

Although all equipment is carefully inspected and prepared for shipment at the factory, damage to the fan and/or drive parts may occur due to rough handling during shipment.

Any shortage, breakage, or damage noticed at time of delivery should be indicated to the carrier's representative. Damage noticed after delivery should be reported to the carrier at once. Request their inspection of the shipment and fill out a concealed damage inspection report.

Addendum l AD-1

✐

Note: This addendum applies only if you have purchased a Conair Hot Air Dryer (HAD).

AD-2 l

Addendum

Handling

Small units should be handled carefully and lifted only by the base, never by the shaft, coupling, motor, or housing. Large units should be lifted by the base or by the lifting eyes. Precautions should be taken to avoid dropping or jarring the equipment as this can cause damage to the shaft or wheel, which is not visibly noticeable, but can cause vibration problems.

Installation

Fans and motors should be mounted on structurally sound foundations. Concrete is the best, however, other types designed properly are acceptable. Equipment should be leveled on the foundation and shimmed or grouted in place. This will prevent putting the fan structure into a bind by bolting it down on an uneven surface.

As a general rule, if vibration isolators are used, the fan should first be bolted to a structural steel base and the isolation takes place between the structural steel base and the foundation. This prevents the fan base from floating due to uneven weight distribution and/or drive forces when mounted directly to vibration isolators.

✒

TIP: Extended Storage - Units

that will be held in storage for a period of up to two (2) years should have special provisions so operation-readiness can be maintained. Motors should be equipped with internal space heaters kept on continuously. Units should be crated and covered with polyethylene film. In addition, impellers should be hand-rotated once a month. For best results, keep the units sheltered in a cool, dry location.

Wiring the Starter

The electrical connection consists of bringing power to the starter on the blower assembly. The incoming power should match the rated nameplate power required on the serial tag on the blower. This power should be clean and have a voltage variation of no more that +/- 5% of the nameplate voltage.

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.

1 Disconnect and lock out the main power sources before making electrical

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

Remove the cover from the main power control box on the blower assembly.

Route the main power

cable through the power control box. 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 blower assembly and there is no strain on the incoming power wires.

Connect the power wires

to the three terminals on the upper side of the starter

power disconnect.

5 Connect the ground wire to the ground lug.

Addendum l AD-3

✐

IMPORTANT: Al ways refer to the wiring diagrams that came with your blower before making electrical connections.

Po w er Wires (Black- Customer Supplied)

Ground

Wire (Green - Customer Supplied)

Note: The connections a t the starter should be made with properly sized conductors and properly protected with appropriate conduit. The routing should be neat and away from potential mechanical damage. The terminations should be landed on the terminals on the starter. These terminations should be regularly checked to prevent loosening and shorting to ground.

Before Start-up

Before start-up, the following should be verified.

1 Fasteners - All foundation bolts, wheel hub setscrews, wheel locking bolts,

and bearing locking collars must be tight.

2 Bearings - Check the bearings and make certain they are properly lubricated. 3 Fan Wheel - Turn over the rotating assembly by hand to insure that it runs

free and does not bind or strike the fan housing. If the wheel strikes the housing, the wheel may have to be moved on the shaft.

4 Motor - Check the electrical wiring to the motor. The current characteristics

of the supply line must agree with the motor nameplate rating. The motor should be wired and fused in accordance with the National Electric Code (NEC) and local codes.

5 Ducts - Duct connections from the fan to the duct work must not be distort-

ed. Ducts should never be supported by the fan. All duct joints should be sealed to prevent air leaks. All debris should be removed from the ductwork and the fan.

6 Resistance Check - Check the resistance leg to leg and leg to ground to make

sure that the starter is wired correctly. The three legs should have equal resistance +/- 5%. The resistance to ground should be 20 megohms or higher.

AD-4 l

Addendum

IMPORTANT: Al ways refer to the wiring diagrams that came with your blower before checking electrical connections.

Start-up

1 Using the Start/Stop button, ”Jog" the motor

to check for proper wheel rotation. The motor should be started in accordance with the manufacturer's recommendations. Arrows on the fan indicate the proper direction of rotation and airflow.

2 Throttle the blower discharge

damper ¼ open. (It is shown fully open in this photo.)

3 The fan may now be brought

up to speed. Watch for anything unusual such as vibration, overheating of bearings and motor, etc.

4 Throttle the discharge damper until the pressure is 15-20" WC. 5 Check the motor amperage against the nameplate amperage to

make sure the motor is not overloading.

Addendum l AD-5

Start/Stop Button

Discharge Damper

Fully Closed

Fully Open

Balance and Vibration

All fan impellers are dynamically balanced prior to installation in the fan assembly. After assembly, fans supplied with motors are test run and fine-tune balanced to reduce vibration levels to acceptable limits as shown in table below (from AMCA Standard 204-96).

After field installation, fans will need to be checked prior to commissioning to assure that the vibration levels do not change significantly from those achieved at the factory. It is recommended that the velocity values in the table below are not exceeded by more than 10% when field installed.

Fan Application Category Rigid Mounted Flexible Mounted

mm/sec (in./sec) mm/sec (in./sec)

BV-3 3.8 (0.15) 5.1 (0.20)

The installed vibration level of any fan is not solely dependent on the balance grade. Installation factors such as the mass and stiffness of the supporting system will influence the "as installed" vibration level (refer to AMCA Publication 202, Troubleshooting).

AD-6 l Addendum

General Maintenance

1 Inspection - A definite time schedule for inspecting all rotating parts and

accessories should be established. The frequency of inspection depends on the severity of operation and the locality. Inspections might be weekly at first in order to set up the schedule.

2 Alignment - The shaft must not be cocked in the bearings. Misalignment

can cause overheating, wear to dust seals, bearing failure, and vibration.

3 Hardware - Check the tightness of all bolts and setscrews. 4 Lubrication - Check the fan and motor bearings and add lubricant if neces-

sary. Be careful not to over grease as this can damage bearing seals.

5 Air Flow - Make sure there is no debris or unnecessary obstructions to air-

flow in the outlet or inlet ductwork.

6 Bearings - On high-speed fans, the bearings tend to run hot. Therefore, do

not replace a bearing because it feels hot to the touch. Place a pyrometer or contact thermometer against the pillow block and check the temperature. Pillow block and flange mount bearings can have housing surface temperatures of 200°F (93°C) before the cause of overheating should be investigated.

7 Wheel - Inspect the wheel blades for accumulation of dust and dirt. Clean

thoroughly with a stream of water jet, compressed air, or a wire brush. This will help prevent an unbalanced condition. If the blades are aluminum, be careful not to damage them. Cover the bearings so water does not enter the pillow block. The wheel should have proper clearances to prevent the blades from striking the housing. Make sure the wheel is rotating in the proper direction. Never run the fan at a higher speed or temperature than is shown on the fan nameplate. Contact Conair with any questions.

Addendum l AD-7

CAUTION: Wear eye protection. If you use compressed air to clean the equipment, you must wear eye protection and observe all OSHA and other safety regula

tions pertaining to the use of compressed air.

Fan Bearing Maintenance

For most applications, a lithium base grease (such as Mobilith AW2) conforming to a NLGI Grade 2 consistency should be used. This type of grease inhibits rust, is water resistant, and has a temperature range of -30 to 200°F (-34.3 to

93.3°C), with intermittent highs of 250°F (121°C). For extreme duty and higher temperature applications, use Mobilith SHC220 synthetic hydrocarbon grease.

When greasing bearings, it is important not to over-grease. This is especially true if the bearings are equipped with extended grease lines and the bearings are not visible. In this case, more bearing failures occur due to over-greasing than under-greasing. It is best to give the bearing just one "shot" of grease periodically if the bearings are not visible. When the bearings are visible, pump in grease until a small bead of grease forms around the bearing seals. It is very important that fan bearing greasing take place while the fan is operating.

AD-8 l

Addendum

CAUTION: Caution should be taken while working on and near rotating equipment to avoid personal injury.

Motor Maintenance

Lubricate the motor bearings to the manufacturer's recommendations. Lubrication recommendations are included with the packet attached to the fan. Should this packet be missing, the following will apply:

Integral Horsepower Ball Bearings Motors: Motors having pipe plugs or grease fittings should be re-lubricated while warm and at standstill. Replace one (1) pipe plug on each end shield with a grease fitting. Remove the other plug for grease relief. On low pressure, grease, run, and lubricate until the new grease appears at the grease relief. Allow the motor to run for ten (10) minutes to expel any excess grease. Replace the pipe plugs. Motors not having pipe plugs or grease fittings can be re-lubricated by removing the end shield, cleaning the grease cavity, and refilling three-fourths or circumference of the cavity.

Recommended Re-lubrication Intervals (General Guide Only)

Horse Power Standard Duty Severe Duty Extreme Duty

Range 8 hr/day 25 hr/day Very Dirty

Dirty-Dusty High Ambients

1.5 - 7.5 5 yrs. 3 yrs. 9 mos. 10 - 40 3 yrs. 1 yr. 4 mos. 50 - 150 1 yr. 9 mos. 4 mos.

Recommended Motor Greases

Polyrex EM - Exxon Oil Company

SRI #2 - Chevron Oil Company

Addendum l AD-9

Vibration Level of Replacement Impellers

All replacement impellers are dynamically balanced by the manufacturer prior to shipment. Occasionally, an impeller that has been factory-balanced will yield poor balance/vibration results when installed and operated. This does not mean that the impeller was incorrectly balanced at the factory. It can result from differences between test-stand conditions and operating conditions. A factory test stand has different bearings, bearing spans, structural response, stiffness, mechanical impedance, and by necessity, running speeds. The test stand cannot duplicate the actual "fan system" and its response. For these reasons, the "fan system" vibration levels must be checked after installing a replacement impeller. Refer to the "Balance and Vibration" section for acceptable vibration levels.

AD-10 l Addendum

Addendum l AD-11

Blower Troubleshooting

In the event that trouble is experienced in the field, the following Troubleshooting Table lists the most common blower difficulties. These points should be checked before contacting Conair Customer Service.

Problem

The blower does not meet capacity or pressure ratings.

Excessive vibration and/or noise.

Possible cause

Total resistance of system is higher than anticipated.

Dampers or variable inlet vanes are not properly adjusted.

Poor fan inlet or outlet conditions.

Air leaks in system.

Damaged wheel.

Incorrect direction or rotation.

Unstable foundation, fan bolted to an uneven foundation, not shimmed or grouted properly.

Foreign material in fan causing unbalance.

Solution

Reduce the system restrictions by shortening the hoses, reducing the number of turns, and/or increasing the plenum size.

Open the damper to increase the flow; close the damper to decrease flow.

Clear all obstructions from the air inlet and outlet.

If an inlet filter is used, clean or replace the filter as needed.

Seal all possible air leaks in the system.

Replace the damaged wheel.

Reverse the electrical connections at the motor.

Reinstall the unit following the installation instructions detailed in the "Installation Instructions" on page AD-2.

Clean the fan and fan housing.

(continued)

AD-12 l Addendum

Blower Troubleshooting (continued)

Problem

Excessive vibration and/or noise (continued).

Possible cause

Worn bearings.

Damaged wheel or motor.

Broken or loose bolts and setscrews.

Bent shaft.

Fan wheel or driver unbalanced.

120 cycle magnetic hum due to electrical input.

Fan delivering more than rated capacity.

Loose dampers or variable inlet vanes.

Fan rotation in wrong direction.

Vibration transmitted to the fan from some other source.

Solution

Replace the worn bearings.

Replace the damaged wheel and/or motor.

Tighten or replace all loose bolts and/or setscrews as needed.

Replace the motor.

Balance the wheel or driver following factory instructions.

Check for high or unbalanced voltage.

Reduce the flow by throttling the discharge damper.

Tighten any loose dampers or inlet vanes.

Reverse the electrical connections at the motor starter.

Make sure the fan is properly isolated from the rest of the system.

Addendum l AD-13

Blower Troubleshooting (continued)

Problem

Overheated bearings.

Possible cause

Too much grease.

Damaged wheel or driver.

Bent shaft.

Abnormal end thrust.

Dirt in bearings.

Solution

Remove and excess grease (see "Fan Bearing Maintenance" [page AD-8] and "Motor Maintenance" [page AD-9] for lubrication instructions).

Replace the damaged wheel or driver.

Replace the motor.

Make sure all spacers and shims are in good condition. Replace as necessary.

Clean and lubricate the bearings (see "Fan Bearing Maintenance" [page AD-8] and "Motor Maintenance" [page AD-9] for lubrication instructions).

Ordering Spare Parts

Contact Conair's Parts Department and supply the following information:

1 Conair order number/serial number. 2 Fan serial number stamped on nameplate. 3 Fan code and model stamped on nameplate. 4 Fan arrangement. 5 Description of the part required. 6 Part number, if the part is a casting. 7 Special materials, paints, and / or coatings.

Wheel: Be sure to indicate direction of rotation as viewed from drive side,

type of wheel, and the operating speed.

Shaft: Length and diameter.

Motors: The name of the motor manufacturer, motor model number, and

serial number from the motor nameplate must be supplied to Conair for repairs or replacement.

AD-14 l Addendum

Addendum l AD-15

Specifications: Hot Air Dryer (HAD) Blower

Hot Air Dryer mode

l (HAD) 600 800 1000 1600 2400 3200 5000

RECOMMENDED MODEL HTC*

HTC-30B

†

HTC-30B†HTC-30A†HTC-60A

†

HTC-90A

†

HTC-120A

†

HTC-120A

†

Performance characteristics

Flow rate cfm 300 400 500 800 1200 1600 2500 Disc. pressure @flow rate

inches WC

‡

25 32 30 30 28 30 33

{mm} WC

‡

{635} {813} {762} {762} {711} {762} {838}

Motor Hp kW 5 {3.7} 7.5 {5.6} 7.5 {5.6} 10 {7.5} 15 {11.2} 25 {18.6}

Dimensions inches {cm} and weight lb {kg}

Outlet size selection (OD) 5 5 8 8 8 12 A - Height 42 {107} 42 {107} 42 {107} 42 {107} 42 {107} 42 {107} B - Width 33 {84} 33 {84} 33 {84} 33 {84} 33 {84} 33 {84} C - Length 39 {99} 39 {99} 42 {107} 42 {107} 80 {203} 82 {208}

Weight

Installed weight lb {kg}

250 {113} 320 {145} 380 {172} 500 {227} 700 {317} 900 {408}

V olta ge Full Load Amps

400V/3 phase/50 Hz 9.1 13.2 13.2 16.8 25.2 40.8 460 V/3 phase/60 Hz 7.6 11 11 14 21 34 575 V/3 phase/60 Hz 6.1 9 9 11 17 27

Noise level

with standard soundproofing < 90 dbA @ 5 ft.

SPECIFICATION NOTES:

* For single hopper system. † The HTC model number reflects the kilowatts of each unit.For example, HTC-60 has a 60 kilowatt heater.

‡

The unit of measure WC is water column.

Weights are approximate.

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

TPDM024-0106

Conair UGD031/0106, Hopper Temperature Controller, HTC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual