Conair UGD031/0106 User Manual
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Conair UGD031/0106 User Manual

For process air heater, 30 to 270 kw.
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U S E R G U I D E
UGD031/0106
Hopper Temperature
Controller
Process Air Heater, 30 to 270 kW.
For use with Conair Carousel Plus Series W Dryers and HADs.
INTRODUCTION
•
Purpose of the User Guide
Read this so no one gets hurt
heater?
•
Typical applications
HTC models 600 - 5000
•
lation
•
Installation of the HTC control models 30, 60, and 90
the HTC control models 180 and 270
Location and mounting of the HTC heater assembly model 120
els 180 and 270
•
Connecting the HTC heater assembly to the dryer or blower and hopper
•
Connecting the power on models HTC 180 and 270
Corporate Office: 412.312.6000
•
How the guide is organized
•
How to use the lockout device
•
How it works
•
Specifications: HTC Carousel Plus process air dryer
Specifications: HTC for HAD
•
Location and mounting of the HTC heater assembly models 30, 60, and 90
•
l
Instant Access 24/7 (Parts and Service): 800.458.1960
•
Your responsibilities as a user
•
DESCRIPTION
•
INSTALLATION
•
Unpacking the boxes
•
Installation of the HTC control model 120
•
Location and mounting of the HTC heater assembly mod-
Connecting the control wiring on models 180 and 270
www.conairnet.com
•
ATTENTION:
•
What is the HTC process air
•
Specifications:
•
Preparing for instal-
•
Installation of
•
Installing the isolation valves
l
Parts and Service: 814.437.6861
•
•

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Summary of Contents for Conair UGD031/0106

  • Page 1 U S E R G U I D E UGD031/0106 Hopper Temperature Controller Process Air Heater, 30 to 270 kW. For use with Conair Carousel Plus Series W Dryers and HADs. INTRODUCTION • Purpose of the User Guide • How the guide is organized •...
  • Page 2 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.

  • Page 3: Table Of Contents

    Ta b l e o f C o n t e n t s I n t r o d u c t i o n Purpose of the user guide ....... . 1-2 How the guide is organized .
  • Page 4 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 .
  • Page 5 Blower installation and maintenance ..... . AD-1 Note: This addendum applies only if you have purchased a Conair Hot Air Dryer (HAD).
  • Page 6 l Ta b l e o f C o n t e n t s...
  • Page 7 S E C T I O N I n t r o d u c t i o n P u r p o s e o f t h e u s e r g u i d e ....1 - 2 H o w t h e g u i d e i s o r g a n i z e d .

  • Page 8: I N T R O D U C T I O N

    P u r p o s e o f t h e U s e r G u i d e 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.

  • Page 9: Your Responsibilities As A User

    Yo u r R e s p o n s i b i l i t y a s a U s e r You must be familiar with all safety procedures concerning installation, opera- tion and maintenance of this equipment. Responsible safety procedures include: •...

  • Page 10: At T E N T I O N

    AT T E N T I O N : R e a d t h i s s o n o o n e g e t s h u r t 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.

  • Page 11: How To Use The Lockout Device

    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: Stop or turn off the equipment.
  • Page 12 1 - 6 l I n t r o d u c t i o n...

  • Page 13: D E S C R I P T I O N

    S E C T I O N D e s c r i p t i o n W h a t i s t h e H T C p r o c e s s a i r h e a t e r ? ..2 - 2 Ty p i c a l a p p l i c a t i o n s .
  • Page 14 W h a t i s t h e H T C P r o c e s s A i r H e a t e r ? The HTC process air heater is designed to control the temperature of dry air as it enters a material hopper.

  • Page 15: Typical Applications

    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.

  • Page 16: How It Works

    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.
  • Page 17 H o w i t Wo r k s ( c o n t i n u e d ) How the HAD Works 1 Centrifugal Blower Assembly 2 Control Center 3 Electric Heater Assembly rying opper emperature ontrol 4 Hose (15 ft) 5 Insulated Hose (3 ft) 6 RTD Process Temperature 7 RTD Process Protection...
  • Page 18 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. 2 - 6 l D e s c r i p t i o n...

  • Page 19: Specifications: Htc For Hot Air Dryers (Had)

    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. D e s c r i p t i o n l 2 - 7...
  • Page 20 2 - 8 l D e s c r i p t i o n...

  • Page 21: I N S T A L L A T I O N

    S E C T I O N I n s t a l l a t i o n U n p a c k i n g t h e b o x e s ....3 - 2 P r e p a r i n g f o r i n s t a l l a t i o n .

  • Page 22: Unpacking The Boxes

    U n p a c k i n g t h e B o x e s The HTC process air heater comes in two boxes. Depending on the model and options ordered, the boxes could include: Standard Equipment • Heater assembly;...

  • Page 23: Preparing For Installation

    P r e p a r i n g f o r I n s t a l l a t i o n The HTC process air heater is easy to install, if you prepare the mounting area properly. Make sure the mounting area provides: A grounded power source supplying the correct current for your HTC model.
  • Page 24 RTD is too short for your instal- per to allow connection of the lation, contact Conair Parts RTD temperature probe. Department (800.458.1960) to purchase an extension cable. The control center can be...

  • Page 25: Location And Mounting Of The Htc Heater Assembly

    L o c a t i o n a n d M o u n t i n g o f t h e H T C IMPORTANT: Always refer to H e a t e r A s s e m b l y M o d e l s H T C 3 0 , the wiring diagrams that came 6 0 a n d 9 0 with your heater before making...

  • Page 26: Connecting The Htc Heater Assembly To The Dryer Or Blower

    C o n n e c t i n g t h e H T C H e a t e r A s s e m b l y t o t h e D r y e r o r B l o w e r a n d H o p p e r The inlet of the HTC heater assembly should be plumbed to the air source (usually a blower or central dehumidification dryer).

  • Page 27: Installing The Isolation Valves

    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. Turn the disconnect dial on the control center door to the Off or “O”...
  • Page 28 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 H T C 1 8 0 a n d 2 7 0 IMPORTANT: Always refer The electrical connection consists of bringing power into the control center and to the wiring diagrams that wiring the heater power from the control center to the heater assembly.
  • Page 29 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 ) o n m o d e l s H T C 1 8 0 a n d 2 7 0 Insert the supplied heater power wire through a knockout in the side or IMPORTANT: Always refer to bottom of the control center.

  • Page 30: M O D E L S H T C 1 8 0 A N D 2 7 0

    C o n n e c t i n g t h e C o n t r o l W i r e s M o d e l s H T C 1 8 0 a n d 2 7 0 IMPORTANT: Always refer to the proper wiring diagram supplied with your equipment before making electrical connections.

  • Page 31: Connecting The Rtd Sensors

    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 IMPORTANT: Always refer setback option if installed or the process protection to the wiring diagrams that sensor depending on the configuration of the system.
  • Page 32 C o n n e c t i n g t h e RT D S e n s o r s ( c o n t i n u e d ) Route the process temperature RTD cable to the control center. Plug the con- nector into receptacle in the side of the control center labeled “Process”.
  • Page 33 Tighten the nuts to lock the RTD probe in place. Note: If the length of the setback RTD is too short for your installation, Typical Hopper Process contact Conair Parts Department Setback RTD (800.458.1960) to purchase an Location extension cable. From outside the United States, call 814.437.6861.
  • Page 34 C o n n e c t i n g t h e RT D S e n s o r s ( c o n t i n u e d ) Route the process setback RTD cable to the control center. Plug the connector into the lower receptacle in the side of the control center.

  • Page 35: Testing The Installation

    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. 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.
  • Page 36 Te s t i n g t h e I n s t a l l a t i o n ( c o n t i n u e d ) Adjust the setpoint to the desired hopper inlet temperature. Use the Setpoint Adjust buttons to set the temperature.
  • Page 37 S E C T I O N O p e r a t i o n 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 p a n e l D C .

  • Page 38: The Htc Process Air Heater: Control Panel Dc

    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 S e t p o i n t A c t u a l I n c r e m e n t / D e c r e m e n t D i s p l a y...

  • Page 39: Htc Dc Control Functions

    H T C D C C o n t r o l F u n c t i o n s 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. C o n t r o l F u n c t i o n F l o w C h a r t s The following flow charts provide a quick summary of the control functions.
  • Page 40 POWER ON 2 sec All LEDs On 2 sec Software Version (Default Screen) Process Setpoint and Actual Temp (Default Screen) Press + or - to change setpoint. Press Scroll Button for Process Deviation Alarm Setpoint (Dev) + or - Deviation Band Press + or - to change setpoint.
  • Page 41 Setback Setup Screens Setup Screens Test Mode Screens * The test mode screens become Press Scroll Button and + key at the Press Scroll Button and + key at the visable if tSt (screen 41) is turned on. same time again for 2 sec to get in. same time for 10 sec to get in.

  • Page 42: Control Function Descriptions

    C o n t r o l F u n c t i o n D e s c r i p t i o n s F u n c t i o n General Screens Once the power is turned on, this screen is SCREEN 1 displayed for 2 seconds while the control performs its self-checking process.
  • Page 43 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n General Screens NOTE: Setback is optional.
  • Page 44 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n Process Screens To access the process screens, press the “Scroll”...
  • Page 45 SCREEN12 * automatically adjusted used to change the integral value for the by the autotune proce- process control loop. The “+/-” buttons dures. Conair does not can be used to change the integral value recommend they be setpoint. adjusted individually.
  • Page 46 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n Process Screens SCREEN 14 This is the process heater autotune screen.
  • Page 47 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n P r o c e s s P r o t e c t i o n When at screen 6, page 4-8, (or the process...
  • Page 48 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n P r o c e s s P r o t e c t i o n S c r e e n s...
  • Page 49 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n D C R e s i n S e t u p S c r e e n To access the DC resin setup screens, press...
  • Page 50 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n D C R e s i n S e t u p S c r e e n This is the setback load rate setpoint.
  • Page 51 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n D C R e s i n S e t u p S c r e e n SCREEN 35...
  • Page 52 The setting on screen 42 factory default settings (not necessarily for should not be changed with- Ld.d a specific model). Conair does not recom- out the direction of Conair mend using this function unless instructed Service Personnel. to by a Conair Service Technician.
  • Page 53 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n Te s t M o d e S c r e e n s To access the test mode screens, press "+"...
  • Page 54 C o n t r o l F u n c t i o n D e s c r i p t i o n s ( c o n t i n u e d ) F u n c t i o n Te s t M o d e S c r e e n s * * Outputs 1, 2, and 4 are not used...

  • Page 55: Htc Dc Control Alarms

    H T C D C C o n t r o l A l a r m s ASSIVE LARMS Passive alarms flash the alarm code and display process temperature until the alarm condition goes away, or it becomes a shutdown alarm. C o d e D e s c r i p t i o n A l a r m L E D...

  • Page 56: Initial Operation (For Had Only)

    I n i t i a l O p e r a t i o n ( F o r H A D O n l y ) Hopper material: Fill the hopper with the material to be heated. Blower inlet filter: Verify that the area around the inlet filter is clean and free of debris.

  • Page 57: I N I T I A L O P E R A T I O N ( F O R H A D O N L

    I n i t i a l O p e r a t i o n ( F o r C a r o u s e l P l u s D r y e r H T C ) Hopper material: Fill the hopper with the material to be heated.

  • Page 58: Autotuning

    A u t o t u n i n g Follow the procedure below to “Autotune” the HTC. Tip: Conair recommends that the autotune should Use the selector switch and put the HTC control into “Standby”. be run from a cold start.
  • Page 59 A u t o t u n i n g ( c o n t i n u e d ) To return to the normal control, cycle the heater to Standby and then back to Enable. If “Tune Error 1” is displayed, the autotune was not successful and the process must be repeated.

  • Page 60: Normal Operation To Start Heating

    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 Determine what the HTC’s setpoint must be for your process and material. Make sure there is material in the hopper.

  • Page 61: Normal Operation To Stop Heating

    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 Turn the heater to “Standby”. Heaters Enable IMPORTANT: Always turn off the HTC BEFORE the dryer or process blower. Standby For Startup: 1.
  • Page 62 4 - 2 6 l O p e r a t i o n...

  • Page 63: M A I N T E N A N C E

    S E C T I O N M a i n t e n a n c e P r e v e n t a t i v e m a i n t e n a n c e c h e c k l i s t ..5 - 2 M a i n t e n a n c e l 5 - 1...
  • Page 64 P r e v e n t a t i v e M a i n t e n a n c e C h e c k l i s t The HTC process air heater requires little maintenance. We recommend the fol- lowing maintenance schedule and tasks.

  • Page 65: Tr O U B L E S H O O T I N G

    S E C T I O N Tr o u b l e s h o o t i n g B e f o r e b e g i n n i n g ....6 - 2 A f e w w o r d s o f c a u t i o n .

  • Page 66: Before Beginning

    B e f o r e B e g i n n i n g 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.

  • Page 67: A Few Words Of Caution

    B e f o r e B e g i n n i n g ( c o n t i n u e d ) 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 dia- grams are the best reference for correcting a problem.
  • Page 68 H o w t o I d e n t i f y t h e C a u s e o f a P r o b l e m Most heater malfunctions are indicated by an illuminated Alarm light on the HTC process air heater control panel.

  • Page 69: S H U T D O W N A L A R M S

    S h u t D o w n A l a r m s 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. Problem Possible cause Solution...
  • Page 70 S h u t D o w n A l a r m s ( c o n t i n u e d ) Problem Possible cause Solution Process Heater High There is an air flow blockage or loose Remove the blockage.
  • Page 71 S h u t D o w n A l a r m s ( c o n t i n u e d ) Problem Possible cause Solution Process Protection The Process RTD temperature probe is Make sure the RTD temperature probe High Temperature –...

  • Page 72: Pa S S I V E A L A R M S

    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 contin- ues 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.

  • Page 73: R E P L A C I N G F U S E S

    R e p l a c i n g F u s e s Disconnect and lockout the main power supply. Open the control center. Fuse Blocks To locate the appropriate fuse and replacement part, refer to the wiring diagrams that IMPORTANT: Always refer came with your HTC.

  • Page 74: C H E C K I N G H E A T E R S O L I D S T A T E R E L A Y

    C h e c k i n g H e a t e r S o l i d S t a t e R e l a y s Disconnect and lockout the main power supply. Open the control center door. Locate the process solid state relays (SSRs).
  • Page 75 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 S e n s o r s 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.
  • Page 76 R e p l a c i n g t h e H e a t i n g E l e m e n t s Disconnect and lockout the main power. Gain access to the heating elements by removing screws that secure the heating element cover to the enclosure.
  • Page 77 R e p l a c i n g t h e H e a t i n g E l e m e n t s ( c o n t i n u e d ) Note: For larger units (above 60 kW), it may be necessary to Clamps Remove the hose clamp securing the...
  • Page 78 R e p l a c i n g t h e A i r F l o w D i f f e r e n t i a l P r e s s u r e S w i t c h If the air flow differential pressure switch fails to detect the pressure drop between the heater inlet and outlet, it should be replaced.
  • Page 79 R e p l a c i n g t h e A i r F l o w D i f f e r e n t i a l P r e s s u r e S w i t c h ( c o n t i n u e d ) Remove the mounting hardware securing the pressure switch to the heating element enclosure.
  • Page 80 6 - 1 6 l Tr o u b l e s h o o t i n g...

  • Page 81: We're Here To Help

    We ’ r e H e r e t o H e l p Additional manuals and prints for Conair has made the largest investment in customer support in the plastics indus- your Conair equipment may be try. Our service experts are available to help with any problem you might have ordered through the Customer installing and operating your equipment.

  • Page 82: Equipment Guarantee

    (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. The customer assumes the cost of transportation of the part or parts to and from the factory.
  • Page 83 Note: This addendum applies only if you have This addendum will assist you in installing and maintaining your HAD blower. purchased a Conair Hot By following the general instructions presented, you will prolong the life of the Air Dryer (HAD).
  • Page 84 H a n d l i n g 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 visi- bly noticeable, but can cause vibration problems.
  • Page 85 W i r i n g t h e S t a r t e r IMPORTANT: Always refer to the The electrical connection consists of bringing power to the starter on the blower wiring diagrams that came with assembly. The incoming power should match the rated nameplate power your blower before making electri- required on the serial tag on the blower.
  • Page 86 B e f o r e S t a r t - u p Before start-up, the following should be verified. Fasteners - All foundation bolts, wheel hub setscrews, wheel locking bolts, and bearing locking collars must be tight. Bearings - Check the bearings and make certain they are properly lubricated. Fan Wheel - Turn over the rotating assembly by hand to insure that it runs free and does not bind or strike the fan housing.
  • Page 87 S t a r t - u p Using the Start/Stop button, ”Jog" the motor to check for proper wheel rotation. The motor should be started in accordance with the manufac- turer's recommendations. Arrows on the fan indi- cate the proper direction of rotation and airflow. Start/Stop Button Throttle the blower discharge...
  • Page 88 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).
  • Page 89 Make sure the wheel is rotating in the proper direction. Never run the fan at a higher speed or temperature than is shown on the fan nameplate. Contact Conair with any questions. CAUTION: Wear eye protection. If you use compressed air to clean the equip- ment, you must wear eye protection and observe all OSHA and other safety regulations pertaining to the use of compressed air.
  • Page 90 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) conform- ing 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).
  • Page 91 M o t o r M a i n t e n a n c e 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.
  • Page 92 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 I m p e l l e r s All replacement impellers are dynamically balanced by the manufacturer prior to shipment.
  • Page 93 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. Possible cause Solution...
  • Page 94 B l o w e r Tr o u b l e s h o o t i n g ( c o n t i n u e d ) Problem Possible cause Solution Excessive vibration and/or Worn bearings. Replace the worn bearings.
  • Page 95 B l o w e r Tr o u b l e s h o o t i n g ( c o n t i n u e d ) Problem Possible cause Solution Overheated bearings. Too much grease. Remove and excess grease (see "Fan Bearing Maintenance"...
  • Page 96 Length and diameter. Motors: The name of the motor manufacturer, motor model number, and serial number from the motor nameplate must be supplied to Conair for repairs or replacement. A D - 1 4 l A d d e n d u m...
  • Page 97 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. A d d e n d u m l A D - 1 5...

This manual is also suitable for:

Hopper temperature controllerHtc

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