Conair UGD031/0106 User manual

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.
Copyright 2006 l The Conair Group l All rights reserved

Table of Contents
1-1 Introduction
Purpose of the user guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Your responsibilities as a user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
ATTENTION: Read this so no one gets hurt . . . . . . . . . . . . . . . . . . . 1-4
How to use the lockout device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2-1 Description
What is the HTC process air heater? . . . . . . . . . . . . . . . . . . . . . . . .2-2
Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Specifications: HTC Models 600 - 5000 . . . . . . . . . . . . . . . . . . . . . 2-6
Specifications: HTC for Hot Air Dryers (HAD) . . . . . . . . . . . . . . . . . . 2-7
3-1 Installation
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Preparing for installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installation of the HTC control models HTC 30, 60, and 90 . . . . . . . 3-3
Installation of the HTC control model HTC 120 . . . . . . . . . . . . . . . . 3-4
Installation of the HTC control models HTC 180 and 270. . . . . . . . . 3-4
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
1
Introduction l 1-1
1
Introduction

✐
Purpose of the User Guide
This User Guide describes the Conair Hopper Temperature Controller
(HTC) process air heater and explains step-by-step how to install, 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
◆
❒
•
✒
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.
1
Introduction

ATTENTION:
Read this so no one gets hurt
We design equipment with the user’s safety in mind.You can avoid the potential
hazards identified on this machine by following the procedures outlined below and
elsewhere in the User Guide.
WARNING: Improper installation, operation, or
servicing may result in equipment damage or
personal injury.
This equipment should be installed, adjusted, and serviced by qualified
technical personnel who are familiar with the construction, operation,
and potential hazards of this type of machine.
All wiring, disconnects, and fuses should be installed by qualified 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

1
Introduction
Introduction l 1-5
How to Use the Lockout Device
CAUTION: Before performing maintenance or repairs on this product,you should disconnect and lockout electri-
cal power sources to prevent injury from unexpected energization or start-up. A lockable device has been pro-
vided 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:
11Stop or turn off the equipment.
22Isolate the equipment from the electric power. Turn the rotary
disconnect switch to the OFF, or “O” position.
33Secure the device with an assigned lock or tag. Insert a lock or tag
in the holes to prevent movement.
44The equipment is now locked out.
WARNING: Before removing lockout devices and returning switches 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:
11Remove the lock or tag.
22Turn the rotary disconnect switch to the ON or “I”position.
ON
OOFF
ON
O OFF
ON
O OFF

1-6 l Introduction

Description l 2-1
Description
What is the HTC process air heater?. . . . . . . 2-2
Typical applications. . . . . . . . . . . . . . . . . . 2-3
How it works . . . . . . . . . . . . . . . . . . . . . . 2-4
Specifications: HTC models 600 - 5000. . . . . 2-6
Specifications: HTC for Hot Air Dryers (HAD) . 2-7
SECTION
2
2
Description

What is the HTC Process Air
Heater?
The HTC process air heater is designed to control the temperature of dry air as
it enters a material hopper. This process air heater can be set to increase, or
“raise”, the temperature of air that was dehumidified at a central dryer or from
a blower as part of hot air drying.
The HTC includes a control center, heater box with electric heating elements,
an airflow differential pressure switch, and an RTD temperature probe(s).
The differential pressure switch places the HTC in standby mode to save energy
and prevent heating element damage when air flow is not present.
2-2 l Description

Description l 2-3
2
Description
Typical Applications
Carousel Plus “W” Dryer
The HTC process air heater is designed for use with a dehumidifying device
that supplies dry air, such as a central dehumidifying dryer in which the process
heaters (if present) have been disabled, or with a stand alone blower for hot air
drying.
The HTC can be used successfully in applications that require:
•Drying temperatures up to 350°F (176.7°C) (250°F [121.1°C] on HAD
models).
•The ability to dry multiple materials requiring different drying temperature
setpoints in a central drying system. (Requires separate HTCs / hoppers.)
•The ability to easily take a hopper “off-line” for cleaning without shutting
down the entire central drying system.
Hot Air Dryer (HAD)
The HTC process air heater,for use with a hot air dryer such as a Conair model
HAD, connects plant air motivated by a Conair blower assembly to a material dry-
ing 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 temper-
ature controller shuts off power to the heating elements if they get too hot and
an alarm is generated.
An air flow differential pressure switch detects air flow by sensing the natural
drop of pressure due to flow through the heater. This prevents damage to the
heater elements or material in the hopper on loss of air flow.
The temperature controller alarms if the heating elements are heating too hot. It
also alarms if the heating elements are not heating enough.
How the HTC Works
D r y i n g H o pp e r T e m p e r a t u r e C o n t r o l
Heaters
Startup /
Shutdown
For Startup:
1.With heaters in
Standby,turn on
blower or dryer.
2.Enable heaters.
For Shutdown:
1.Switch heaters to
Standby.
2.Wait 60 seconds
before turning off
blower or dryer.
Enable
Standby
Temperature Controller
Control Center
Hopper Inlet
Heater Box
Heating Element
ProcessTemperature RTD
Process Protection RTD

Description l 2-5
How it Works (continued)
How the HAD Works
D r y i n g H o pp e r T em p e r a t u r e C o n t r o l
2
1
3
4
5
6
8
7
1 Centrifugal Blower Assembly
2 Control Center
3 Electric Heater Assembly
4 Hose (15 ft)
5 Insulated Hose (3 ft)
6 RTD Process Temperature
7 RTD Process Protection
8 Outlet Filter Sock
2
Description

Specifications: HTC MODELS 600 - 5000
2-6 l Description
A
BC
D
E
F
GI
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
nozzleabove theheater box {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
Voltage 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 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.
TPDS022-0106

Description l 2-7
Specifications: HTC for Hot Air Dryers (HAD)
A
BC
D
E
F
H
GI
2
Description
MODEL HTC HTC-30B* HTC-30A* HTC-60A* HTC-90A* HTC-120A* HTC-180A*
Hot air dryer model 600 800 1000 1600 2400 3200 5000
Performance characteristics
Temperature range 120° - 250° F {49° - 121° C}
Flow rate cfm 300 400 500 800 1200 1600 2500
Pressure drop@flow rate
inches WC†3.0 5.0 3.2 5.4 6.1 6.4 8.0
{mm} WC†{76.2} {127} {81.2} {137.2} {155.0} {163.0} {203.2}
Dimensions inches {cm} and weight lb {kg}
Heater box dimensions
Inlet size (OD) 5 5 8 8 8 12
Outlet size selection (OD) 5 5 8 8 8 12
A - Height 31.4 {79.8} 27.5 {69.9} 27.5 {69.9} 32.0 {81.3} 31.0 {79.0} 34.0 {86.3}
B - Width 10.1 {25.7} 13.6 {34.5} 13.6 {34.5} 15.9 {40.4} 16.0 {40.6} 18.0 {45.7}
C - Depth 10.7 {27.2} 10.7 {27.2} 10.9 {28.0} 16.0 {40.6} 17.0 {43.2} 20.0 {50.8}
D - Height of discharge 0 {0} 5.9 {15.0} 2.0 {5.1} 1.0 {2.5} 2.0 {5.1} 1.0 {2.5}
nozzle above heater box
E - Height of inlet nozzle
below the heater box 8.0 {20.3} 11.4 {30.0} 8.0 {20.3} 11.0 {27.9} 13.0 {33.0} 13.0 {33.0}
Installed weight lb {kg} 37 {17} 58 {26} 78 {35} 93 {42} 102 {46} 131 {59}
Control center dimensions
F - Height 24.0 {61.0} 24.0 {61.0} 24.0 {61.0} 36.0 {91.4} 48.0 {122.0} 60.0 {152.4}
G - Width 24.0 {61.0} 24.0 {61.0} 24.0 {61.0} 30.0 {76.2} 36.0 {91.4} 42.0 {106.7}
H - Depth 10.0 {25.4} 10.0 {25.4} 10.0 {25.4} 10.0 {25.4} 10.0 {25.4} 12.0 {30.5}
I - Clearance for heat sink 3.0 {7.6} 3.0 {7.6} 3.0 {7.6} 3.0 {7.6} 3.0 {7.6} 3.0 {7.6}
Installed weight lb {kg} 150.0 {68.0} 150.0 {68.0} 150.0 {68.0} 180.0 {81.6} 250.0 {113.0} consult Conair
Voltage 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