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www.conairnet.com
USER GUIDE
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 • 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 • Spec
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Please record your equipment’s It’s a good idea to record the model and serial number(s) of your equipment and model and serial number(s) and the date you received it in the User Guide. Our service department uses this infor- the date you received it in the mation, along with the manual number, to provide help for the specific equipment spaces provided. you installed. Please keep this User Guide and all manuals, engineering prints and parts lists together for documentation of your equipment. Dat
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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 Descriptio
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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
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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 rep
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iv l Table of Contents
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1 Introduction SECTION 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 Introduction l 1-1
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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 i
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1 Introduction 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 associate
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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 haza
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1 Introduction 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 u
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1-6 l Introduction
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2 Description SECTION 2 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 Description l 2-1
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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
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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 diff
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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
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2 Description How it Works (continued) How the HAD Works 1 Centrifugal Blower Assembly 2 Control Center Drying Hopper Temperature Control 3 Electric Heater Assembly 4 Hose (15 ft) 8 5 Insulated Hose (3 ft) 6 6 RTD Process Temperature 2 7 RTD Process Protection 5 8 Outlet Filter Sock 7 3 1 4 Description l 2-5
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Specifications: HTC MODELS 600 - 5000 C B D A F E I G 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 I
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2 Description Specifications: HTC for Hot Air Dryers (HAD) C B D F A E I G H 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} Heate
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2-8 l Description
