Conair Hopper Temperature Controller UGD031 Manuel d'utilisateur

Hopper TemperatureControllerProcess Air Heater, 30 to 270 kW.For use with Conair Carousel Plus Series W Dryers and HADs.Corporate Office: 412.312.6000

ATTENTION:Read this so no one gets hurtWe design equipment with the user’s safety in mind. You can avoid the potentialhazards identified on this machi

1IntroductionIntroduction l 1-5How to Use the Lockout DeviceCAUTION: Before performing maintenance or repairs on this product,you should disconnect

1-6 l Introduction

Description l 2-1DescriptionWhat is the HTC process air heater?. . . . . . . 2-2Typical applications. . . . . . . . . . . . . . . . . . 2-3How it wo

What is the HTC Process AirHeater?The HTC process air heater is designed to control the temperature of dry air asit enters a material hopper. This pr

Description l 2-32DescriptionTypical ApplicationsCarousel Plus “W” DryerThe HTC process air heater is designed for use with a dehumidifying deviceth

2-4 l DescriptionHow it WorksThe HTC process air heater works a lot like the thermostat and heater in yourhouse. The RTD probe measures the temperat

Description l 2-5How it Works (continued)How the HAD WorksDrying Hopper Temperature Control213456871 Centrifugal Blower Assembly2 Control Center3

Specifications: HTC MODELS 600 - 50002-6 l DescriptionABCDEFGIMODEL HTC HTC-30H* HTC-60H* HTC-90H* HTC-120H* HTC-180H* HTC-270H*Carousel Plus dryer m

Description l 2-7Specifications: HTC for Hot Air Dryers (HAD)ABCDEFHGI2DescriptionMODEL HTC HTC-30B* HTC-30A* HTC-60A* HTC-90A* HTC-120A* HTC-180A*H

Please record your equipment’smodel and serial number(s) andthe date you received it in thespaces provided.It’s a good idea to record the model and se

2-8 l Description

Installation l 3-1InstallationUnpacking the boxes . . . . . . . . . . . . . . . . . 3-2Preparing for installation . . . . . . . . . . . . . . 3-3Ins

3-2 l InstallationUnpacking the BoxesThe HTC process air heater comes in two boxes. Depending on the model andoptions ordered, the boxes could inclu

Installationl 3-33DescriptionPreparing for InstallationThe HTC process air heater is easy to install, if you prepare the mounting areaproperly.1 Make

3-4 l InstallationInstallation of the HTC ControlModel HTC 120CAUTION: You are responsible for the structural integrity of this installation.1 Secure

CAUTION: Always disconnectand lock out the main powersources before making electricalconnections. Electrical connec-tions should be made only byquali

Connecting the HTC HeaterAssembly to the Dryer or Blowerand HopperThe inlet of the HTC heater assembly should be plumbed to the air source (usuallya b

3DescriptionInstallation l 3-7Installing the Isolation ValvesNOTE: Isolation valves should be installed when multiple hoppers are connectedto a sin

3-8 l InstallationConnecting the Power on modelsHTC 180 and 270The electrical connection consists of bringing power into the control center andwiring

Installation l 3-93DescriptionConnecting the Power (continued)on models HTC 180 and 270 6Insert the supplied heater powerwire through a knockout in

Table of Contents1-1 IntroductionPurpose of the user guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2How the guide is organize

3-10 l InstallationConnecting the Control WiresModels HTC 180 and 2701Refer to the wiring diagram that came with your control.2 Insert the supplied c

Installation l 3-113DescriptionConnecting the RTD SensorsThe lower RTD could be the return air sensor for thesetback option if installed or the proc

Connecting the RTD Sensors (continued)3Route the process temperature RTD cable to the control center. Plug the con-nector into receptacle in the side

3DescriptionInstallation l 3-13Connecting the RTD Sensors (continued)3Route the process protection RTD cable to the control center. Plug the con-ne

3-14 l InstallationConnecting the RTD Sensors (continued)3Route the process setback RTD cable to the control center. Plug the connectorinto the lowe

Installation l 3-153DescriptionTesting the InstallationYou have completed the HTC installation. Now it’s time to make sure everythingworks. 1 Make s

3-16 l InstallationTesting the Installation (continued)7 Adjust the setpoint to the desired hopper inlet temperature. Use theSetpoint Adjust ▲ or ▼

SECTION44OperationOperationThe HTC process air heater: control panel DC . . . . . . . . . . . . . . . . . . . . . . 4-2HTC DC control functions . . .

HeatersStartup /ShutdownFor Startup:1. With heaters in Standby, turn on blower or dryer.2. Enable heaters.For Shutdown:1. Switch heaters

HTC DC Control FunctionsHTC functions are values that you can set or monitor. Press the Scroll button untilthe function you want to set or monitor ap

Location and mounting of the HTC heater assembly models 180 and 270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Connecting the HTC

POWER ON1 888 8882 sec All LEDs On2 dC 0042 sec Software Version3res in(Default Screen)4 250 250Process Setpoint and Actual Temp (Default Screen)

4Operation363738Setup Screens Test Mode ScreensPress Scroll Button and + key at the same time for 10 sec to get in.To get out at any time P

4-6 l OperationGeneral ScreensSCREEN 1SCREEN 2SCREEN 3SCREEN 4Setpoint ActualSCREEN 5 888FunctionControl Function Descriptions888dC004resin2502502

Operation l 4-7General ScreensSCREEN 5ASCREEN 5BFunctionControl Function Descriptions (continued)Setback Screen 1 (Setback Setpoint).When setback is

To access the process screens, press the“Scroll” and “+” buttons at the same timeand hold for two seconds . To get out ofthe Process screens at any t

4OperationOperation l 4-9This is the process loop break time screen.It is used to set the temperature band timefor the loop break alarm. The “+/-”

4-10 l OperationProcess ScreensSCREEN 14SCREEN 15FunctionControl Function Descriptions (continued)This is the process heater autotune screen.(See pa

Operation l 4-114OperationFunctionControl Function Descriptions (continued)ProcessProtectionScreens *SCREEN 16 ProtectionSCREEN 17SCREEN 18When at s

4-12 l OperationFunctionControl Function Descriptions (continued)ProcessProtectionScreensSCREEN 19SCREEN 20SCREEN 21This is the process protection h

4OperationOperation l 4-13FunctionControl Function Descriptions (continued)DC Resin SetupScreenSCREEN 30SCREEN 31SCREEN 32To access the DC resin set

DIAGNOSTICSHow to identify the cause of a problem . . . . . . . . . . . . . . . . . . . . . 6-4Shut down alarms . . . . . . . . . . . . . . . . . . .

4-14 l OperationFunctionControl Function Descriptions (continued)DC Resin SetupScreenSCREEN 33SCREEN 34SCREEN 34ASCREEN 34BThis is the setback load

4OperationOperation l 4-15FunctionControl Function Descriptions (continued)DC Resin SetupScreenSCREEN 35SCREEN 35AThis is the process heater alarm d

4-16 l OperationFunctionControl Function Descriptions (continued)Setup ScreensSCREEN 36SCREEN 37SCREEN 38 Screen 39Screen 41Screen 42To access the s

Control Function Descriptions (continued)Test ModeScreensSCREEN 43 SCREEN 44 *SCREEN 45SCREEN 47 FunctionTo access the test mode screens, press "

4-18 l OperationControl Function Descriptions (continued)Test ModeScreens *SCREEN 50SCREEN 52 SCREEN 53FunctionThis is the output 3 screen. Press t

Operation l 4-194OperationHTC DC Control AlarmsPASSIVE ALARMSPassive alarms flash the alarm code and display process temperature until thealarm cond

4-20 l OperationInitial Operation (For HAD Only)1 Hopper material: Fill the hopper with the material to be heated. 2 Blower inlet filter: Verify tha

Initial Operation (For Carousel Plus Dryer HTC)1 Hopper material: Fill the hopper with the material to be heated. WARNING: Fire potential - The elect

4-22 l OperationAutotuningFollow the procedure below to “Autotune” the HTC.1 Use the selector switch and put the HTC control into “Standby”.2 Adjust

Operation l 4-23Autotuning (continued)10 To return to the normal control, cycle the heater to Standby and thenback to Enable.11 If “Tune Error 1” is

iv l Table of Contents

Normal Operation To Start Heating1 Determine what the HTC’s setpoint must be for your process and material.2 Make sure there is material in the hopper

4OperationOperation l 4-25Normal Operation To Stop Heating1 Turn the heater to “Standby”.IMPORTANT: Always turn off the HTC BEFORE the dryer or proc

4-26 l Operation

MaintenancePreventative maintenance checklist . . . . . . . 5-2SECTION5Maintenance5Maintenance l 5-1

5-2 l MaintenancePreventative MaintenanceChecklistThe HTC process air heater requires little maintenance. We recommend the fol-lowing maintenance sc

TroubleshootingBefore beginning. . . . . . . . . . . . . . . . . . . . 6-2A few words of caution . . . . . . . . . . . . . . 6-3DIAGNOSTICSHow to id

Before BeginningYou can avoid most problems by following the recommended installation andmaintenance procedures outlined in this User Guide. If you d

Before Beginning (continued)❏ Find the wiring and equipment diagrams that were shipped with your heater. These dia-grams are the best reference for co

6-4 l TroubleshootingHow to Identify the Cause of aProblemMost heater malfunctions are indicated by an illuminated Alarm light on the HTCprocess air

6TroubleshootingShut Down AlarmsIf the red Acknowledge Alarm LED is solid, the alarm is a shutdown alarm.The heater will shutdown automatically to pre

IntroductionPurpose of the user guide. . . . . . . . . . . . . . 1-2How the guide is organized. . . . . . . . . . . . . 1-2Your responsibilities as a

6-6 l TroubleshootingShut Down Alarms (continued)ProblemA3 Process Heater HighTemperature – The snap switchin the process heater tubeopens due to exc

Troubleshooting l 6-7Shut Down Alarms (continued)ProblemA49 Process ProtectionHigh Temperature – If theprocess protection temperatureexceeds the pr

Passive AlarmsIf the red Alarm LED is blinking, the alarm is a passive alarm. The heater contin-ues to operate, but this problem could prevent correc

6TroubleshootingTroubleshooting l 6-9Replacing Fuses1 Disconnect and lockout the main power supply.2 Open the control center.3 Check the fuse. If ne

Checking Heater Solid State Relays1 Disconnect and lockout the main power supply.2 Open the control center door.3 Locate the process solid state relay

6TroubleshootingTroubleshooting l 6-11Checking or Replacing TemperatureSensorsThe HTC process air heater uses RTD sensors to monitor the process tem

6-12 l TroubleshootingReplacing the Heating Elements1 Disconnect and lockout the main power.2 Gain access to the heating elements by removing screws

6TroubleshootingTroubleshooting l 6-13Replacing the Heating Elements (continued)7 Remove the hose clamp securing theinsulated hose to the outlet of

Replacing the Air Flow DifferentialPressure SwitchIf the air flow differential pressure switch fails to detect the pressure drop betweenthe heater inl

6TroubleshootingTroubleshooting l 6-15Replacing the Air Flow DifferentialPressure Switch (continued)6 Remove the mounting hardware securing thepress

✐Purpose of the User GuideThis User Guide describes the Conair Hopper Temperature Controller(HTC) process air heater and explains step-by-step how to

6-16 l Troubleshooting

We’re Here to HelpConair has made the largest investment in customer support in the plastics indus-try. Our service experts are available to help with

A-2 l AppendixEquipment GuaranteeConair guarantees the machinery and equipment on this order, for a period asdefined in the quotation from date of shi

Blower Installation andMaintenanceThis addendum will assist you in installing and maintaining your HAD blower.By following the general instructions pr

AD-2 l AddendumHandlingSmall units should be handled carefully and lifted only by the base, never bythe shaft, coupling, motor, or housing. Large un

Wiring the StarterThe electrical connection consists of bringing power to the starter on the blowerassembly. The incoming power should match the rate

Before Start-upBefore start-up, the following should be verified.1 Fasteners - All foundation bolts, wheel hub setscrews, wheel locking bolts,and bear

Start-up1 Using the Start/Stop button, ”Jog" the motorto check for proper wheel rotation. The motorshould be started in accordance with the manuf

Balance and VibrationAll fan impellers are dynamically balanced prior to installation in the fanassembly. After assembly, fans supplied with motors a

General Maintenance1 Inspection - A definite time schedule for inspecting all rotating parts andaccessories should be established. The frequency of i

Introduction l 1-3Your Responsibility as a UserYou must be familiar with all safety procedures concerning installation, opera-tion and maintenance o

Fan Bearing MaintenanceFor most applications, a lithium base grease (such as Mobilith AW2) conform-ing to a NLGI Grade 2 consistency should be used.

Motor MaintenanceLubricate the motor bearings to the manufacturer's recommendations.Lubrication recommendations are included with the packet atta

Vibration Level of ReplacementImpellersAll replacement impellers are dynamically balanced by the manufacturer priorto shipment. Occasionally, an impe

Addendum l AD-11Blower TroubleshootingIn the event that trouble is experienced in the field, the following TroubleshootingTable lists the most comm

AD-12 l AddendumBlower Troubleshooting (continued)ProblemExcessive vibration and/or noise (continued).Possible causeWorn bearings.Damaged wheel or mo

Addendum l AD-13Blower Troubleshooting (continued)ProblemOverheated bearings.Possible causeToo much grease.Damaged wheel or driver.Bent shaft.Abnor

Ordering Spare PartsContact Conair's Parts Department and supply the following information:1 Conair order number/serial number.2 Fan serial numbe

Addendum l AD-15Specifications: Hot Air Dryer (HAD) BlowerABCHot Air Dryer model (HAD) 600 800 1000 1600 2400 3200 5000RECOMMENDED MODEL HTC*HTC-30