Conair UGD031/0106 Manual de usuario
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
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❒
•
✒
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
Este manual sirve para los siguientes modelos
2
Tabla de contenidos
Otros manuales de Controladores de temperatura de Conair
