Conair UGD031/0106 Bedienungsanleitung

Hopper Temperature

Controller

Process Air Heater, 30 to 270 kW.

For use with Conair Carousel Plus Series W Dryers and HADs.

Corporate Office: 412.312.6000 lInstant 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

heater? • 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 • Location and mounting of the HTC heater assembly models 30, 60, and 90 •

Location andmountingof theHTCheater assembly model120 • Location andmounting of theHTC heater assemblymod-

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 infor-

mation, 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 damages in connection with the furnishing, performance or use of

this information. Conair makes no warranty of any kind with regard to this information, including,

but not limited to the implied warranties of merchantability and fitness for a particular purpose.

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

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

Table of Contents l i

Location and mounting of the HTC heater assembly

models 180 and 270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Connecting the HTC heater assembly to the dryer or blower

and hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Installing the isolation valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Connecting the power on models HTC 180 and 270 . . . . . . . . . . . . 3-8

Connecting the control wires on models HTC 180 and 270. . . . . . 3-10

Connecting the RTD sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

4-1 Operation

The HTC process air heater: control panel DC. . . . . . . . . . . . . . . . . 4-2

HTC DC control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Control function flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Control function descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

HTC DC control alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Initial operation (for HAD only). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Initial operation (for Carousel Plus dryer HTC). . . . . . . . . . . . . . . . 4-21

Autotuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Normal operation to start heating . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Normal operation to stop heating . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

5-1 Maintenance

Preventative maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . 5-2

6-1 Troubleshooting

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

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

ii l Table of Contents

DIAGNOSTICS

How to identify the cause of a problem . . . . . . . . . . . . . . . . . . . . . 6-4

Shut down alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Passive alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

REPAIR

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

AAppendix

We’re here to help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

How to contact customer service . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Before you call... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Equipment guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Performance warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Warranty limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

AD Addendum

Blower installation and maintenance . . . . . . . . . . . . . . . . . . . . . . AD-1

Table 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, oper-

ate, maintain and repair this equipment.

Before installing this product, please take a few moments to read the User

Guide and review the diagrams and safety information in the instruction

packet.You also should review manuals covering associated equipment in

your system. This review won’t take long, and it could save you valuable

installation and operating time later.

How the Guide is Organized

Symbols have been used to help organize the User Guide and call your

attention to important information regarding safe installation and operation.

Symbols within triangles warn of conditions that could be hazardous to users or

could damage equipment. Read and take precautions before proceeding.

Numbers indicate tasks or steps to be performed by the user.

A diamond indicates the equipment’s response to an action performed by the user.

An open box marks items in a checklist.

A circle marks items in a list.

Indicates a tip. A tip is used to provide you with a suggestion that will help you with

the maintenance and the operation of this equipment.

Indicates a note. A note is used to provide additional information about the steps

◆

❒

•

✒

1-2 l Introduction

Introduction l 1-3

Your Responsibility as a User

You must be familiar with all safety procedures concerning installation, opera-

tion and maintenance of this equipment. Responsible safety procedures include:

•Thorough review of this User Guide, paying particular attention

to hazard warnings, appendices, and related diagrams.

•Thorough review of the equipment itself, with careful attention

to voltage sources, intended use, and warning labels.

•Thorough review of instruction manuals for associated equipment.

•Step-by-step adherence to instructions outlined in this User Guide.

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 elec-

trical technicians in accordance with electrical codes in your region.

Always maintain a safe ground. Do not operate the equipment at power

levels other than what is specified on the machine serial tag and data

plate.

WARNING: Voltage hazard

This equipment is powered by three-phase alternating current,

as specified on the 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.

Always disconnect and lock out the incoming main power source before

opening the control center or performing non-standard operating proce-

dures, such as routine maintenance. Only qualified personnel should

perform troubleshooting procedures that require access to the control

center while power is on.

1-4 l Introduction

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