www.conairnet.com USER GUIDE UGD031/0106 Hopper Temperature Controller Process Air Heater, 30 to 270 kW. For use with Conair Carousel Plus Series W Dryers and HADs.
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.
Ta b l e o f C o n t e n t s 1-1 I n t r o d u c t i o n 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . .
DIAGNOSTICS How to identify the cause of a problem . . . . . . . . . . . . . . . . . . . . . 6-4 Shut down alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Passive alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 REPAIR Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Checking heater solid state relays. . . . . . . . . . . . . . . . . . . . . . . . .
i v l Ta b l e o f C o n t e n t s
SECTION 1 Purpose of the user guide . . . . . . . . . . . . . . 1-2 How the guide is organized . . . . . . . . . . . . . 1-2 Yo u r r e s p o n s i b i l i t i e s a s a u s e r . . . . . . . . . . . 1 - 3 AT T E N T I O N : Read this so no one gets hurt . . . . . . . . 1-4 How to use the lockout device . . . . . . . . . . .
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.
Yo u r R e s p o n s i b i l i t y a s a U s e r • 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.
AT T E N T I O N : 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. WA R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n , o r servicing may result in equipment damage or p e r s o n a l i n j u r y.
How to Use the Lockout Device ON 2 Isolate the equipment from the electric power. Turn the rotary O OFF 1 Stop or turn off the equipment. disconnect switch to the OFF, or “O” position. 3 Secure the device with an assigned lock or tag. Insert a lock or tag in the holes to prevent movement. ON O OFF 4 The equipment is now locked out.
1-6 l Introduction
SECTION 2 What is the HTC process air heater? . . . . . . . 2-2 Ty p i c a l a p p l i c a t i o n s . . . . . . . . . . . . . . . . . . 2 - 3 How it works . . . . . . . . . . . . . . . . . . . . . . 2-4 Specifications: HTC models 600 - 5000 . . . . . 2-6 Specifications: HTC for Hot Air Dryers (HAD) .
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).
Ty p i c a l A p p l i c a t i o n s 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. 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.
H o w i t Wo r k s 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.
H o w i t Wo r k s (continued) How the HAD Works Centrifugal Blower Assembly Control Center Electric Heater Assembly Hose (15 ft) Insulated Hose (3 ft) RTD Process Temperature RTD Process Protection Outlet Filter Sock Drying Hopper Temperature Control 8 6 2 5 7 3 1 4 Description l 2-5 2 Description 1 2 3 4 5 6 7 8
Specifications: HTC MODELS 600 - 5000 C B D A F E I G MODEL HTC Carousel Plus dryer model Performance characteristics Temperature range Flow rate cfm Pressure drop@flow rate inches WC† {mm} WC† HTC-30H* HTC-60H* HTC-90H* HTC-120H* HTC-180H* HTC-270H* W600 W800 W1000 W1600 W2400 W3200 W5000 1600 2500 300 3.0 {76.2} 400 500 150° - 375° F {66° - 191° C} 800 1200 1.8 2.3 {45.7} {58.4} 4.0 {101.6} 3.8 {96.5} 5.9 {149.9} 6.4 {162.6} 8 8 31.4 {79.8} 10.1 {25.7} 10.7 {27.2} 1.75 {4.
Specifications: HTC for Hot Air Dryers (HAD) C B D F A E I Hot air dryer model Performance characteristics Temperature range Flow rate cfm Pressure drop@flow rate inches WC† {mm} WC† HTC-30B* HTC-30A* HTC-60A* HTC-90A* HTC-120A* HTC-180A* 800 1000 1600 2400 3200 5000 300 400 500 1600 2500 3.0 5.0 {76.2} {127} 3.2 {81.2} 5.4 {137.2} 6.1 {155.0} 6.4 {163.0} 8.0 {203.2} 5 5 31.4 {79.8} 10.1 {25.7} 10.7 {27.2} 0 {0} 5 5 27.5 {69.9} 13.6 {34.5} 10.7 {27.2} 5.9 {15.0} 8 8 27.5 {69.
2-8 l Description
SECTION 3 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 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 . . . . . .
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.
Preparing for Installation The HTC process air heater is easy to install, if you prepare the mounting area properly. 1 Make 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.
Installation of the HTC Control Model HTC 120 HTC Control Center 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.
Location and Mounting of the HTC Heater Assembly Models HTC 30, 60 and 90 ✐ IMPORTANT: Always refer to the wiring diagrams that came with your heater before making electrical connections. CAUTION: You are responsible for the structural integrity of this installation. HTC Heater 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.
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.
I n s t a l l i n g t h e I s o l a t i o n Va l v e s ✐ NOTE: Isolation valves should be installed when multiple hoppers are connected to a single dryer or blower. ON O tion. Lock out the main power (see Page 1-5 for complete lock out information). OFF 1 Turn the disconnect dial on the control center door to the Off or “O” posi- 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.
C o n n e c t i n g t h e Po w e r o n m o d e l s HTC 180 and 270 IMPORTANT: Always refer to the wiring diagrams that came with your heater before making electrical connections. 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.
C o n n e c t i n g t h e Po w e r ( c o n t i n u e d ) on models HTC 180 and 270 6 Insert the supplied heater power wire through a knockout in the side or bottom of the control center. Secure the wire with a rubber compression fitting or strain relief if conduit is not used. 7 Connect the heater power wires to the control center’s terminal block and IMPORTANT: Always refer to the wiring diagrams that came with your heater before making electrical connections.
Connecting the Control Wires Models HTC 180 and 270 ON OFF IMPORTANT: Always refer to the proper wiring diagram supplied with your equipment before making electrical connections. O CAUTION: Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by qualified personnel. 1 Refer to the wiring diagram that came with your control.
C o n n e c t i n g t h e RT D S e n s o r s 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.
C o n n e c t i n g t h e RT D S e n s o r s (continued) 3 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.
C o n n e c t i n g t h e RT D S e n s o r s (continued) 3 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.
C o n n e c t i n g t h e RT D S e n s o r s (continued) 3 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.
Te s t i n g t h e I n s t a l l a t i o n You have completed the HTC installation. Now it’s time to make sure everything works. 1 Make 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: • • • • 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.
Te s t i n g t h e I n s t a l l a t i o n (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. Startup / Shutdown Heaters Enable Standby For Startup: 1. With heaters in Standby, turn on blower or dryer. 2. Enable heaters. For Shutdown: 1.
SECTION 4 Operation The HTC process air heater: control panel DC . . . . . . . . . . . . . . . . . . . . . . 4-2 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 . . . . . . . . . . . . . . . . . . . . . . .
T h e H T C P r o c e s s A i r H e a t e r : C o n t r o l Pa n e l D C Increment/Decrement Buttons Used to increase or decrease values. Setpoint Display Actual Display Shows the setpoint value. Shows the actual temperature value. Startup / Shutdown Heaters Enable Heater Enable/Standby Also is used to reset shut down alarms (see “Troubleshooting” Section 6) and to “Autotune” the controller (see “Autotuning” Section 4). Scroll Button Standby Press to scroll through the closed loop menu 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.
POWER ON (Default Screen) 1 888 888 2 sec All LEDs On 2 dC 004 2 sec Software Version 3 res in 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 5 dEv + or - Deviation Band Press + or - to change setpoint. Press Scroll to enter the value Press Scroll Button again for Setback Return Temperature Setpoint 5A 180 Srt (Optional) Press + or - to change setpoint.
Setback Setup Screens Press Scroll Button and + key at the same time again for 2 sec to get in.
Control Function Descriptions General Screens Function SCREEN 1 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. 888 888 SCREEN 2 dC 004 SCREEN 3 res in SCREEN 4 Setpoint Actual 250 250 SCREEN 5 20 4-6 l Operation dEv After the self-checking process is complete, this screen flashes for 2 seconds and displays the software version.
Control Function Descriptions (continued) General Screens Function SCREEN 5A Srt Setback Screen 1 (Setback Setpoint). When setback is enabled, this is the hopper outlet temperature at which the setback becomes active. PSt Setback Screen 2 (Process Setpoint). The process setpoint is the temperature the control tries to maintain when functioning in the setback mode. 180 SCREEN 5B 140 ✐ NOTE: Setback is optional.
Control Function Descriptions Process Screens (continued) Function 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. SCREEN 6 Pro cES SCREEN 7 250 Hi.L SCREEN 8 3 4-8 l Operation Lbb This is the process header screen.
Control Function Descriptions (continued) Process Screens Function SCREEN 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 temperature 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.
Control Function Descriptions Process Screens Function SCREEN 14 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).
Control Function Descriptions Process Protection Screens * * Accessed from the Process Screens. SCREEN 16 Protection Pro tEc 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.
Control Function Descriptions Process Protection Screens (continued) Function * Accessed from the Process Screens. SCREEN 19 10 H.dL SCREEN 20 325 d.AL SCREEN 21 180 4-12 l Operation d.dL 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.
Control Function Descriptions (continued) DC Resin Setup Function Screen 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. SCREEN 30 Set bAc SCREEN 31 250 20 ban This shows the setback return band setting.
Control Function Descriptions (continued) DC Resin Setup Function Screen SCREEN 33 10 sls SCREEN 34 Ldr 0 SCREEN 34A Sbt OFF SCREEN 34B SbL 4-14 l Operation OFF 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.
Control Function Descriptions (continued) DC Resin Setup Function Screen SCREEN 35 2 P.dL SCREEN 35A 10 A.dL 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.
Control Function Descriptions Setup Screens (continued) Function 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. SCREEN 36 Set uP SCREEN 37 tyP Res SCREEN 38 Prt ON OFF For HAD and “W” dryer models only. This screen turns the setback “On” or “Off”.
Control Function Descriptions Te s t M o d e Screens (continued) 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. SCREEN 43 tE St SCREEN 44 * in.1 OFF in.2 ON 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.
Control Function Descriptions Te s t M o d e Screens * (continued) Function * Outputs 1, 2, and 4 are not used in the HTC. SCREEN 50 ou.3 OFF SCREEN 52 ou.5 OFF SCREEN 53 ou.6 4-18 l Operation OFF 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.
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 P1 Description Process Temperature Deviation Alarm LED 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.
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.
Initial Operation (For Carousel Plus Dryer HTC) 1 Hopper material: Fill the hopper with the material to be heated. 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.
Autotuning ✒ 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). 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.
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.
N o r m a l O p e r a t i o n To S t a r t H e a t i n g 1 Determine what the HTC’s setpoint must be for your process and material. 2 Make sure there is material in the hopper. 3 Start the dryer or process blower to begin air flow. Set the proper flow on ON the blower if equipped. OFF 4 Turn on the main power to the HTC. Make sure the HTC’s disconnect dial O is in the ON position. This powers up the control and the display lights will illuminate. 5 Set the drying temperature.
N o r m a l O p e r a t i o n To S t o p H e a t i n g Startup / Shutdown 1 Turn the heater to “Standby”. Heaters Enable IMPORTANT: Always turn off the HTC BEFORE the dryer or process blower. Standby For Startup: 1. With heaters in Standby, turn on blower or dryer. 2. Enable heaters. For Shutdown: 2 Allow the HTC to cool to below 100°F (37.8°C). 1. Switch heaters to Standby. 2. Wait 60 seconds before turning off blower or dryer. 3 Turn off the blower or dryer.
4-26 l Operation
SECTION 5 Maintenance Preventative maintenance checklist . . . . . . .
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.
SECTION 6 Tr o u b l e s h o o t i n g 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 Pa s s i v e a l a r m s . . . . . . . . . . . . . . . . . . . . 6-8 R E PA I R Replacing fuses . . . . . . . . . . . . . . . . . . . . 6-9 Checking heater solid state relays . . . . . . .
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 3 4 Address the alarm message and fix the problem.
Before Beginning (continued) See warnings below. Open the control center to check fuses and heater contactors. ❏ Find the wiring and equipment diagrams that were shipped with your heater. These diagrams 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. A Fe w Wo r d s o f C a u t i o n The HTC process air heater is equipped with numerous safety devices.
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.
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 Solution 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. The process high temperature is not at least 10°F (5.
Shut Down Alarms (continued) Problem Possible cause Solution A3 There is an air flow blockage or loose hoses. Remove the blockage. Process Heater High Temperature – The snap switch in the process heater tube opens due to excessive temperature. Tighten any loose hoses. The isolation contactor failed in the closed position. Replace the isolation contactor. The heater solid state relays (SSRs) failed. Replace the failed heater solid state relays (SSRs). No air flow or the airflow is reversed.
Shut Down Alarms (continued) Problem Possible cause Solution 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. The Process RTD temperature probe is not installed correctly. Make sure the RTD temperature probe tip is in the center of the hopper inlet tube or heater manifold.
Pa s s i v e A l a r m s 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 Possible cause Solution P1 One of the solid state relays (SSRs) has failed. Replace the failed solid state relays (SSR).
Replacing Fuses ON OFF 1 Disconnect and lockout the main power supply. O 2 Open the control center. 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. 3 Check the fuse.
Checking Heater Solid State Relays ON 2 Open the control center door. O OFF 1 Disconnect and lockout the main power supply. 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. 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.
C h e c k i n g o r R e p l a c i n g Te m p e r a t u r e 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. 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.
Replacing the Heating Elements ON O OFF 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. IMPORTANT: Always refer to the wiring diagrams that came with your heater to locate specific electrical components.
Replacing the Heating E l e m e n t s (continued) ✐ Note: For larger units (above 60 kW), it may be necessary to remove the front heaters to access the rear heaters. Clamps to insulated hose to the outlet of the heatRemove ing element. Remove the hose. 7 Remove the hose clamp securing the 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.
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 heater, disconnect and lockout the main power. O OFF ON 2 Gain access to the heating elements by removing screws that secure the heating element cover to the enclosure.
Replacing the Air Flow Differential P r e s s u r e S w i t c h (continued) 6 Remove the mounting hardware securing the pressure switch to the heating element enclosure. 7 Align the new pressure switch with the mounting 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.
6 - 1 6 l Tr o u b l e s h o o t i n g
We ’ r e H e r e t o H e l p 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.
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.
Blower Installation and Maintenance ✐ Note: This addendum applies only if you have 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. purchased a Conair Hot Air Dryer (HAD). 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.
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.
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. IMPORTANT: Always refer to the wiring diagrams that came with your blower before making electrical connections.
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.
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. Start/Stop Button 2 Throttle the blower discharge damper ¼ open. (It is shown fully open in this photo.) Discharge Damper Fully Closed Fully Open 3 The fan may now be brought up to speed.
B a l a n c e a n d Vi b r a t i o n 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.
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.
Fa n B e a r i n g M a i n t e n a n c e 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.
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.
Vi b r a t i o n L e v e l o f R e p l a c e m e n t 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.
B l o w e r Tr o u b l e s h o o t i n g 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 Possible cause Solution The blower does not meet capacity or pressure ratings. Total resistance of system is higher than anticipated.
B l o w e r Tr o u b l e s h o o t i n g (continued) Problem Possible cause Solution Excessive vibration and/or noise (continued). Worn bearings. Replace the worn bearings. Damaged wheel or motor. Replace the damaged wheel and/or motor. Broken or loose bolts and setscrews. Tighten or replace all loose bolts and/or setscrews as needed. Bent shaft. Replace the motor. Fan wheel or driver unbalanced. Balance the wheel or driver following factory instructions.
B l o w e r Tr o u b l e s h o o t i n g (continued) Problem Possible cause Solution Overheated bearings. Too much grease. Remove and excess grease (see "Fan Bearing Maintenance" [page AD-8] and "Motor Maintenance" [page AD-9] for lubrication instructions). Damaged wheel or driver. Replace the damaged wheel or driver. Bent shaft. Replace the motor. Abnormal end thrust. Make sure all spacers and shims are in good condition. Replace as necessary. Dirt in bearings.
O r d e r i n g S p a r e Pa r t s 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. AD-14 l Addendum Wheel: Be sure to indicate direction of rotation as viewed from drive side, type of wheel, and the operating speed.
Specifications: Hot Air Dryer (HAD) Blower B A C Hot Air Dryer model (HAD) 600 RECOMMENDED MODEL HTC* HTC-30B† 800 1000 1600 2400 3200 5000 HTC-60A† HTC-90A† HTC-120A† HTC-120A† 800 1200 1600 2500 32 30 {813} {762} 7.5 {5.6} 30 {762} 7.5 {5.6} 28 {711} 10 {7.5} 30 {762} 15 {11.2} 33 {838} 25 {18.