Crystallizer Models CR4, CR10, CR21, CR42, CR85, and CR135

Crystallizer Models CR4, CR10, CR21, CR42, CR85, and CR135
www.conairnet.com
USER GUIDE
UGD026-1210
Crystallizer
Models CR4, CR10, CR21, CR42, CR85, and CR135
Corporate Office: 412.312.6000 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861
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 information, 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: UGD026-1210
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 2010 l The Conair Group l All rights reserved
Ta b l e o f C o n t e n t s
1-1 I n t r o d u c t i o n
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 D e s c r i p t i o n
What is the crystallizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
3-1 I n s t a l l a t i o n
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Securing the crystallizer floor stand assembly to the floor. . . . . . . . 3-6
Installing the main crystallizer assembly on the
floor stand assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Connecting the process air hose to the agitating hopper air inlet . . 3-8
Connecting the return air hose to the cyclone separator . . . . . . . . . 3-9
Installing the process RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Connecting the residence RTD probe . . . . . . . . . . . . . . . . . . . . . . 3-11
Installing the rotary discharge valve . . . . . . . . . . . . . . . . . . . . . . . 3-12
Connecting the load level sensor and safety switches . . . . . . . . . 3-14
Connecting the agitator gear drive to the control panel . . . . . . . . 3-15
Installing a high temperature loader . . . . . . . . . . . . . . . . . . . . . . . 3-16
Connecting the load demand cable (If an optional
loader is installed on the crystallizer) . . . . . . . . . . . . . . . . . 3-17
Ta b l e o f C o n t e n t s l i
Connecting the process blower to process heater inlet . . . . . . . . 3-18
Connecting the process blower to control panel . . . . . . . . . . . . . . 3-19
Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Checking for proper rotation and operation . . . . . . . . . . . . . . . . . 3-22
Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
4-1 O p e r a t i o n
Crystallizer control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Control function flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control function description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Crystallizer initial setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
5-1 M a i n t e n a n c e
Preventative maintenance checklist . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Cleaning the process air filter (CR4 and CR10) . . . . . . . . . . . . . . . . 5-3
Cleaning the process air filter (CR21 and CR135) . . . . . . . . . . . . . . 5-6
Cleaning the cyclone separator filter sock . . . . . . . . . . . . . . . . . . . . 5-8
Cleaning the cyclone separator collection tank . . . . . . . . . . . . . . . 5-10
Cleaning the heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Cleaning the agitating hopper (Minor cleaning) . . . . . . . . . . . . . . . 5-13
Cleaning the agitating hopper and removable cone section
(Major cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Cleaning the aftercooler coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Inspecting hoses and gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
6-1 Tr o u b l e s h o o t i n g
Before beginning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
How to identify the cause of a problem . . . . . . . . . . . . . . . . . . . . . 6-4
Alarm indicators
i i l Ta b l e o f C o n t e n t s
Passive alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Shutdown alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Replacing the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Checking the heater solid state relay . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Checking or replacing the temperature sensors . . . . . . . . . . . . . . . . . 6-19
Replacing the air-throttling valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Replacing the blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Replacing the lower agitator section. . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Replacing the agitator gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Replacing the agitator air seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Replacing the agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Replacing the agitator (Alternative method) . . . . . . . . . . . . . . . . . . . . 6-35
Replacing the agitator inner bearing. . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
A
Appendix
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
B
Appendix
Hub city worm gear drives instructions . . . . . . . . . . . . . . . . . . . . . B-1
C
Appendix
Replacing the heater (smaller models) . . . . . . . . . . . . . . . . . . . . . . C-1
Replacing the heater (larger models) . . . . . . . . . . . . . . . . . . . . . . . C-5
D
Appendix
Installing an aftercooler (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Cleaning the aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
E
Appendix
TCF series quick reference guide . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Ta b l e o f C o n t e n t s l i i i
i v l Ta b l e o f C o n t e n t s
SECTION
1
Purpose of the user guide . . . . . . . . . . . . . . 1-2
How the guide is organized . . . . . . . . . . . . . 1-2
Yo u r r e s p o n s i b i l i t i e s a s a u s e r . . . . . . . . . . . 1 - 3
AT T E N T I O N :
Read this so no one gets hurt . . . . . . . . 1-4
How to use the lockout device . . . . . . . . . . . 1-5
Introduction l 1-1
1
Introduction
Introduction
Purpose of the User Guide
This User Guide describes the Conair Crystallizer and explains step-bystep how to install, operate, 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.
1
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.
✒
✐
1-2 l Introduction
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
you are following throughout the manual.
Yo u r R e s p o n s i b i l i t y a s a U s e r
• 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.
Introduction l 1-3
1
Introduction
You must be familiar with all safety procedures concerning installation, operation, and maintenance of this equipment. Responsible safety procedures
include:
AT T E N T I O N :
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.
WA R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n , o r
servicing may result in equipment damage or
p e r s o n a l i n j u r y.
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 electrical 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.
WA R N I N G : Vo l t a g e h a z a r d
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. 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 electrical enclosure or performing non-standard operating
procedures, such as routine maintenance. Only qualified personnel
should perform troubleshooting procedures that require access to the
electrical enclosure while power is on.
1-4 l Introduction
How to Use the Lockout Device
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:
1 Stop or turn off the equipment.
2 Isolate the equipment from the electric power. Turn the rotary
disconnect switch to the OFF, or “O” position.
3 Secure the device with an assigned lock or tag. Insert a lock or tag
in the holes to prevent movement.
4 The 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 crystallizer, turn the rotary disconnect back to the ON
position:
1 Remove the lock or tag.
2 Turn the rotary disconnect switch to the ON or “I” position.
Introduction l 1-5
1
Introduction
CAUTION: Before performing maintenance or repairs on this product, you should
disconnect and lockout electrical power sources to prevent injury from unexpected
energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity.
1-6 l Introduction
SECTION
2
What is the crystallizer?. . . . . . . . . . . . . . . 2-2
Ty p i c a l a p p l i c a t i o n s . . . . . . . . . . . . . . . . . . 2 - 3
How it works . . . . . . . . . . . . . . . . . . . . . . 2-4
Specifications . . . . . . . . . . . . . . . . . . . . . . 2-6
Description l 2-1
2
Description
Description
What is the Crystallizer?
Conair crystallizers allow processors to convert amorphous pellets or reclaimed
flake into a crystalline state in preparation for high-temperature drying. The agitating hopper may also be used to keep other non free-flowing materials from bridging.
The crystallizer system may consist of the following components:
• Blower;
• Heater(s)
• Agitating hopper
• Floor stand
• Material discharge valve
• One insulated process air hose and other uninsulated hoses
• Process residence temperature probes
• Cyclone separator filtration system
• Air filters
• System process controls
2-2 l Description
Ty p i c a l A p p l i c a t i o n s
Loader
Loader
Crystallizer
Blower
Cyclone
Gaylord tilter
Description l 2-3
2
Description
Surge bin
H o w I t Wo r k s
Heated air is passed through the bed of amorphous material in the agitating hopper
where the heat is absorbed. The amorphous material will begin to crystallize at its
glass transition temperature (typically 180 - 200°F [82.2 - 93.3°C]). The blades of
the agitator auger inside the hopper gently turn to lift and tumble the material.
This action prevents agglomeration of the material during the transition between
amorphous and crystalline states.
Once the set temperature profile within the agitating hopper is achieved, the crystallizer will deliver the crystalline material ready to be dried and processed. The
system also has the capability to allow the material to cool to a preset temperature
within the agitating hopper before delivery.
A high temperature loader can be used with the system to load amorphous material
to the top of the agitating hopper to keep the hopper full.
2-4 l Description
H o w I t Wo r k s
(continued)
FILTER BAG (no filter if Dust Collector used)
RETURN
AIR
CYCLONE
GEAR
BOX
LOADER
RESIDENCE
TEMPERATURE RTD
DUST
COLLECTION
6
PROCESS
RTD
HEAT SOURCE (Electric and/or Gas)
AGITATING
HOPPER
PROCESS
PROTECTION
RTD
HEATER HI-TEMP
SAFETY SWITCH
THROTTLING
VALVE
DISCHARGE VALVE
2
3
HIGH
LEVEL SENSOR
INLET AIR
FILTER
4
OPTIONAL CLOSED LOOP
5
HIGH
LEVEL SENSOR
(IF NOT BELOW
DISCHARGE VALVE)
1 RETURN AIR RTD WITH CLOSED LOOP OPERATION (OPTION)
2 DUST COLLECTION (OPTION)
3 AFTERCOOLER (OPTION)
4 DE-MISTER (OPTION)
5 VOLATILE TRAP (OPTION)
6 AUX TEMP RTD (OPTION)
1
RETURN AIR
RTD
BLOWER
SURGE BIN
OR GAYLORD
LOW LEVEL
SENSOR (option)
Description l 2-5
2
Description
HOPPER FILL
LEVEL SENSOR
Specifications: CR4-CR135
Model CR4 and CR10
Model CR21 - CR135
Blower
E
D
A
A
FRONT VIEW
*
FRONT VIEW
MODELS
Performance characteristics
Throughput ft3/hr {l/hr}
Heater energy source
Air circuit
Dimensions inches {mm}
A - Overall crystallizer height
B - Overall crystallizer width
C - Overall crystallizer depth
D - Blower height†
E - Blower width†
F - Blower depth†
Approximate weight lbs {kg}
Crystallizer installed
Surge bin installed
Blower installed
Voltage total amps
230V/3 phase/60 Hz
400V/3 phase/50 Hz
460V/3 phase/60 Hz
575V/3 phase/60 Hz
Discharge type (via rotary air lock)
Surge bin 10 ft3 {281 l/hr}
Surge bin 17 ft3 {481 l/hr}
Blower noise level
C
SIDE VIEW
FRONT VIEW
CR4†
CR10†
4 {113}
10 {283}
electric or natural gas electric or natural gas
F
C
B
SIDE VIEW
SIDE VIEW
CR21†
CR42†
21 {595}
42 {1189}
electric or natural gas electric or natural gas
TPDM028-0408
B
CR85†
CR135†
85 {2407}
135 {3823}
electric or natural gas electric or natural gas
open or closed loop
open or closed loop
open or closed loop
open or closed loop
open or closed loop
open or closed loop
159.2 {4043.7}
66.0 {1676.4}
70.5 {1790.7}
NA
NA
NA
169.0 {4292.6}
66.0 {1676.4}
75.0 {1905.0}
NA
NA
NA
192.5 {4889.5}
69.0 {1752.6}
70.1 {1780.5}
37.8 {960.1}
32.5 {825.5}
68.4 {1734.4}
226.8 {5760.7}
79.1 {2009.1}
81.4 {2067.6}
37.8 {960.1}
32.5 {825.5}
70.4 {1788.2}
261.8 {6649.7}
86.3 {2192.0}
94.2 {2392.7}
37.8 {960.1}
32.5 {825.5}
77.5 {1968.5}
281.1 {7139.9}
98.3 {2496.8}
106.3 {2700.0}
45.8 {1163.3}
37.5 {952.5}
80.6 {2047.2}
2863 {1299}
270 {122}
NA
3130 {1420}
270 {122}
NA
3315 {1504}
650 {295}
700 {318}
4422 {2006}
650 {295}
800 {363}
6590 {2989}
650 {295}
900 {408}
7754 {3517}
650 {295}
1100 {499}
38.8
22.3
19.3
15.5
NA
55.6
48.4
38.7
NA
107.5
93.5
74.8
NA
159.1
138.4
110.7
NA
292.5
254.4
203.5
NA
305.3
265.5
212.4
standard
NA
standard
NA
standard
NA
NA
standard
NA
standard
NA
standard
<90 dbA @5 ft.
SPECIFICATION NOTES:
* Shown with optional cyclone mounted on stand this applies to model CR4 only.
† The blowers on models CR4 and CR10 are located on the stand. Blowers on models CR21, CR42, CR85 and CR135 are independent of the stand,
adequate space will need to be planned for positioning of the blower on these models.
Specifications may change without notice. Consult a Conair representative for the most current information.
2-6 l Description
SECTION
3
Installation
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . 3-2
Preparing for installation . . . . . . . . . . . . . . . . . 3-4
Securing the crystallizer floor stand
assembly to the floor . . . . . . . . . . . . . . . . . 3-6
Installing the main crystallizer assembly on the
. . . . . . . . . . . . . . . . 3-7
Connecting the process air hose to the
agitating Hopper air inlet
. . . . . . . . . . . . . 3-8
Connecting the return air hose to the
cy cl o n e s e p a r a t o r . . . . . . . . . . . . . . . . . . . 3 - 9
I n s t a l l i n g t h e p r o c e s s RT D p r o b e . . . . . . . . . . . 3 - 1 0
C o n n e c t i n g t h e r e s i d e n c e RT D p r o b e
. . . . . . . . 3-11
Installing the rotary discharge valve . . . . . . . . . 3-12
Connecting the load level sensor and
safety switches
. . . . . . . . . . . . . . . . . . . 3-14
Connecting the agitator gear drive to the
control panel . . . . . . . . . . . . . . . . . . . . . 3-15
Installing a high temperature loader . . . . . . . . . 3-16
Connecting the load demand cable (If an optional
loader is installed on the crystallizer) . . . . 3-17
Connecting the process blower to process
heater inlet . . . . . . . . . . . . . . . . . . . . . . 3-18
Connecting the process blower to control panel . 3-19
Connecting the main power
. . . . . . . . . . . . . . 3-20
Checking for proper rotation and operation . . . . . 3-22
Te s t i n g t h e i n s t a l l a t i o n . . . . . . . . . . . . . . . . . . 3 - 2 7
Installation l 3-1
3
Installation
floor stand assembly
Unpacking the Boxes
The crystallizer comes in two or more boxes, depending on the model and options
ordered. The boxes could include (depends on the options selected):
Main
Crystallizer
Assembly
Floor Stand
Assembly
{
{
Not Shown:
Residence Air RTD Probe
Process RTD Probe
Heater(s)
Hoses
Agitator
Gear Drive
Agitating
Hopper
Hopper Fill
Level Sensor
Removable Cone
Section
Slide Gate
Process Air Filter
Rotary Discharge
Valve
Cyclone
Separator
Control Panel
Discharge Fill
Level Sensor
Floor Stand
Blower
Front of Crystallizer
1 Carefully remove the main crystallizer assembly (agitating hopper, removable cone section, and material slide gate), the floor stand assembly (floor
stand, controls, control panel enclosure, blower, process air filter, and cyclone
separator) and any other components from their shipping containers and set
upright. Note that the main crystallizer assembly and the floor stand assembly
are secured to their shipping container with bolts that pass through the bottom
of the shipping container.
2 Remove all packing material, protective paper, tape, and plastic, including
any inserted in the agitating hopper.
3-2 l Installation
Unpacking the Boxes
(continued)
3 Carefully inspect all components to make sure no damage occurred during
shipping, and that you have all the necessary hardware. If any damage is
found, notify the shipping agent immediately.
✐
4 Take a moment to record serial numbers and electrical power specifications in the blanks provided on the back of the User Guide's title page. The
information will be helpful if you ever need service or parts.
NOTE: Most larger main crystallizer assemblies will be laid on side
for shipment. Place upright and
remove shipping bracket to prepare for installation.
5 You are now ready to begin installation. Follow the preparation steps on the
next page.
✐
CR4 includes: Floor stand, controls, control panel enclosure, blower,
process air filter and cyclone separator.
NOTE: Depending on the model
you ordered, your floor stand
may contain different components.
CR10 includes: Floor stand, controls, control panel enclosure, blower and
process air filter.
CR21, CR42, CR85 and CR135 include: Floor stand, controls and control
panel enclosure.
Installation l 3-3
3
Installation
Floor Stand Components by Model:
Preparing for Installation
The crystallizer is easy to install if you plan the location and prepare the installation area properly.
1 Make sure the installation area provides:
❒ A grounded power source supplying the voltage and correct current
for your crystallizer model. Check the crystallizer’s serial tag for the correct
amps, voltage, phase, and cycles. Field wiring should be completed by qualified personnel to the planned location for the crystallizer. All electrical wiring
should comply with your region’s electrical codes.
✒
❒ A source of water, if you intend to configure the crystallizer as a
closed-loop system using an aftercooler. The crystallizer’s optional aftercooler can use tower, city, or chiller water at temperatures of 40° to 85°F (4°
to 29°C). Pipe should be run to the planned crystallizer location. Use flexible
hose to connect the water pipes to the aftercooler.
Tip: Conair recommends
manual shut-off valves
be installed in the water
supply lines.
✐
✐
3-4 l Installation
NOTE: On the larger crystallizer systems, water usage may exceed the smaller crystallizer system usage range of 1 to 2 gallon per minute {3.8-7.6 liters/min.}.
❒ Minimum clearance for safe operation and maintenance. You should
maintain a minimum of 36 in. (91 cm) clearance on at least three sides of the
crystallizer.
NOTE: The minimum clearance listed does not take into account a stand alone cyclone
separator filtration system. If a stand alone cyclone separator filtration system is used,
its location and size must be considered when determining the minimum clearance
needed.
Preparing for Installation
(continued)
❒ A mounting area that will support the weight of the crystallizer, floor
stand, fully-loaded agitating hopper, and (if applicable) a fully-loaded high
temperature loader.
❒ Material and conveying lines installed. If you plan to use vacuum or
compressed air loaders to fill the agitating hopper, install conveying lines to
the crystallizer location.
3
Installation
Installation l 3-5
Securing the Crystallizer Floor
Stand Assembly to the Floor
WARNING: You are responsible for the structural integrity of this installation.
After removing all crystallizer components from their shipping containers and
inspecting all components for damage due to shipping, move the components to
the prepared installation location. A forklift, hoist, or crane should be used to
move the components.
CAUTION: Care should be taken while moving the main crystallizer assembly and
the floor stand assembly to ensure that no damage is done to any of the components mounted to these assemblies.
It is important to fasten the floor stand assembly to a rigid floor structure. This
will add rigidity to the installation and help to prevent accidents during operation
and maintenance of the crystallizer.
Tools for installation:
❒ Forklift, hoist, or crane
❒ Other tools as dictated by the
specific installation
Due to the varying size of Conair crystallizers, we recommend that you:
• Follow all applicable local building and safety codes;
• Use anchoring techniques and hardware suitable for the size and weight of the
crystallizer; and
• Do not install any crystallizer components until the floor stand is secured to the
floor.
3-6 l Installation
Installing the Main Crystallizer
Assembly on the Floor Stand
Assembly
After the floor stand assembly has been secured to the floor, install the main crystallizer assembly on the floor stand using the following steps.
1 Make sure that all hoses and / or wires attached to the floor stand and
main crystallizer assemblies are positioned away from the mating surfaces of
the assemblies so they will not be damaged during this procedure.
2 Using a forklift, hoist, or crane, lift the main
crystallizer assembly above the floor stand.
stand as shown. Make sure the holes in the
main crystallizer assembly align with the holes in
the floor stand assembly.
❒ Forklift, hoist, or crane
❒ Appropriate size wrenches or
sockets and ratchets
4 Secure the main crystallizer assembly to the
floor stand assembly using the
supplied bolts.
✐
NOTE: Make sure that the fork lift tubes are in line with the open side of the floorstand.
Installation l 3-7
3
Tools for installation:
3 Set the main crystallizer assembly on the floor
Installation
CAUTION: To prevent accident and injury, lift the
main crystallizer assembly onto the floor stand
assembly using a forklift, hoist, or crane.
Connecting the Process Air Hose to
the Agitating Hopper Air Inlet
Mounting
Hardware:
❒ One hose clamp
1 Route the process air hose to the process air inlet on the removable cone section using the short insulated hose section. Attach the other end to the process
heater outlet.
2 Route the process air hose to the process air inlet
on the removable cone section using the short insulated hose section. Attach the other end to the process
heater outlet.
3 With the supplied hose clamp loosely on the
process air hose, slide the hose onto the process
air inlet tube and the heater outlet.
✐
NOTE: Do not allow the
flexible hoses to kink or
crimp.
4 Tighten the clamps to secure the process air hose
to the air inlet and heater outlet.
Tools for installation:
❒ Flat blade screwdriver
❒ Ladder
3-8 l Installation
CAUTION: Because of the high temperature of the air passing through the process
air hose, insulation should be installed on the hose in any area where it can be
accidentally touched during crystallizer operation.
Connecting the Return Air Hose to
t h e C y cl o n e S e p a r a t o r ( O p t i o n )
1 The crystallizer is shipped with the return air hose that needs to be connected to Mounting
the agitating hopper outlet. Use the supplied hose to interconnect. Route the
return air hose from the hopper outlet to the return air inlet on the cyclone
separator.
Hardware:
❒ One hose clamp (if
supplied)
2 With the supplied hose clamp loosely on the return
air hose, slide the hose onto the return air inlet
tube on the cyclone separator.
3 Tighten the clamp to secure the return air hose to
the return air inlet.
NOTE: Do not allow the
flexible hoses to kink or
crimp.
HOPPER OUTLET
Tools for installation:
❒ Flat blade screwdriver
❒ Ladder
CAUTION: Because of the high
temperature of the air passing
through the return air hose,
insulation should be installed
on the hose in any area where
it can be accidentally touched
during crystallizer operation.
AIR INLET FLANGE
CYCLONE INLET
✐
NOTE: The cyclone may be mounted on a stand or self-standing.
Installation l 3-9
3
Installation
✐
I n s t a l l i n g t h e P r o c e s s RT D P r o b e
✐
The Process RTD Probe monitors the temperature of the process air as it enters the
agitator hopper air inlet. If the probe is not installed correctly, temperature readings
will be inaccurate.
NOTE: The process RTD probe
may have been connected to
the crystallizer control panel
enclosure and temporarily
secured to the process air hose
before the unit was shipped.
Free the RTD probe from the
process air hose and examine
its connection at the crystallizer control panel to ensure it is
still properly connected. If the
probe is not connected to the
control panel, connect it now.
Tools for installation:
PROCESS RTD RECEPTACLE
1 Route the process RTD
to the process air inlet on
the removable cone
section.
❒ Appropriate size wrench
2 Insert the process RTD
probe at the process air
inlet on the agitator
hopper. The end of the
probe MUST NOT touch
the walls of the inlet. The
tip of the probe should be
approximately in the
center of the tube. Tighten
the nuts to lock the probe
in place.
3 Coil any excess cable and secure it with a wire tie.
3-10 l Installation
C o n n e c t i n g t h e R e s i d e n c e RT D P r o b e
The residence RTD probe monitors the temperature of the material within the agitating
hopper. If the probe is not installed and connected correctly, temperature readings will
be inaccurate.
✐
RESIDENCE RTD
PROBE
NOTE: The residence RTD
probe was mounted in the
agitating hopper before
the unit was shipped.
Inspect the mounting to
ensure it was not damaged during shipping or
unpacking.
cable to the top of the
crystallizer control panel
enclosure.
2 Plug the probe’s cable into the residence RTD receptacle on the top of the crystallizer control panel enclosure. The receptacle is the second from the left when
viewed from the front of the control panel enclosure. Hand tighten the connector.
Coil any excess cable and secure it with a wire tie.
PROCESS
PROTECTION RTD
RECEPTACLE
PROCESS RTD
RECEPTACLE
RESIDENCE RTD
RECEPTACLE
Tools for installation:
❒ Ladder
✐
NOTE: If the process protection RTD has not yet been
connected to the control
panel enclosure, make that
connection now. The
process protection RTD connection is the third from the
left when viewed from the
front of the control panel
enclosure.
Installation l 3-11
3
Installation
1 Route the residence RTD
Installing the Rotary Discharge
Va l v e
The rotary discharge valve and material discharge chute were shipped with the
crystallizer but not mounted to the unit. Follow the instruction below to install the
rotary discharge valve and material discharge chute.
1 Using a forklift,
hoist, or crane, raise
the rotary discharge
valve up to the slide
gate on the bottom
of the removable
cone section.
2 Align the holes in
Tools for installation:
❒ Forklift, hoist, or crane
❒ Appropriate size wrenches or
sockets and ratchets
❒ Ladder
the discharge valve
with the tapped holes
in the slide gate
mechanism.
3 Secure the discharge valve to
the slide gate mechanism using
the four self-locking bolts supplied.
4 Align the holes in the material
discharge chute with the holes at
the bottom of the delivery auger.
Secure the material discharge
chute to the delivery auger using
the four self-locking bolts supREAR
plied.
OF
CRYSTALLIZER
✐
3-12 l Installation
NOTE: The fill level sensor in the
material discharge chute should be
oriented towards the rear of the
crystallizer.
I n s t a l l i n g t h e R o t a r y D i s c h a r g e Va l v e
(continued)
6 Connect the power /
control quick connect
cable to the receptacle on
the discharge valve.
7 Route the quick connect cable for the fill level sensor from the crystallizer control
panel enclosure to the fill level sensor.
8 Connect the quick connect cable to
the receptacle on the fill level sensor.
9 Coil any excess cables and
secure with wire ties. Make sure
you leave enough slack so the
cables can be disconnected to
allow for cleaning of the removable
cone section.
✐
DISCHARGE
FILL LEVEL
SENSOR
NOTE: Rotation will be checked later.
Installation l 3-13
3
Installation
CAUTION: Always refer to the wiring diagrams that came with your crystallizer before
making electrical connections. Electrical connections should be made only by qualified
personnel.
5 Route the power /
control quick connect
cable from the crystallizer
control panel enclosure to
the rotary discharge valve.
The connector will be a 4
pin connector and will be
exiting from the bottom of
the control enclosure.
C o n n e c t i n g t h e L o a d L e v e l S e n s o r,
Safety Switches, and Loader
✐
CAUTION: Always refer to the wiring diagrams that came with your crystallizer
before making electrical connections. Electrical connections should be made only
by qualified personnel.
NOTE: The load level sensor was installed in the
agitating hopper before the
unit was shipped. Inspect
the mountings to ensure
they were not damaged
during shipping or unpacking.
The wires for the load
level sensor and safety
switches are routed to a
main junction box on
the side of the agitating
hopper before shipment. The cable exiting the junction box
must be routed and
connected in the control panel enclosure.
HOPPER FILL
SENSOR
MAIN
JUNCTION
BOX
SAFETY
SWITCHES
Tools for installation:
❒ Flat blade screwdriver
❒ Ladder
1 Route the 8 pin
yellow cable from the main junction to the right side of the crystallizer control panel then into the control panel enclosure through existing holes.
1 TB
3-14 l Installation
Connecting the Agitator Gear Drive
t o t h e C o n t r o l Pa n e l
✐
CAUTION: Always refer to the wiring diagrams that came with your crystallizer
before making electrical connections. Electrical connections should be made only
by qualified personnel.
NOTE: The connections at the agitator gear drive were made before the unit was
shipped. Inspect the connections to ensure they were not damaged during shipping or
unpacking.
1 Route the cable from the
2 Refer to the wiring diagram
supplied with the crystallizer to
confirm the correct connection
point within the control panel
enclosure.
Tools for installation:
❒ Flat blade screwdriver
❒ Ladder
3 Connect the wires from the agitator
gear drive to the agitator contactor
(1 M terminals).
4 Coil any excess cable from the agitator gear drive and secure it with wire
ties.
✐
NOTE: Rotation will be checked later.
1M
2M
Installation l 3-15
3
Installation
AGITATOR
GEAR DRIVE
CONNECTIONS
agitator gear drive to the
crystallizer control panel then into
the control panel enclosure.
I n s t a l l i n g a H i g h Te m p e r a t u r e
Loader
Tools for installation:
❒ Forklift, hoist, or crane
❒ Dependent on application
✒
If a high temperature loader is to be mounted to the top of the agitating hopper,
follow the installation instructions, specifications, and wiring diagrams supplied
with the loader. Also refer to the loader's installation instructions and operations
manual for power, level switch, and compressed air connections / specifications.
Tip: Conair recommends
that a high temperature
loader be installed in a
crystallizer system purchased from Conair for
recirculation of material
during startup.
Installing Additional Level Sensors
There are additional level sensors that could be placed in the crystallizing system.
To add the high level sensor:
1 Place the high level sensor in the discharge chute of the material discharge
(gaylord fill).
2 Route the 5 (five) pin yellow cable from the bottom of the crystallizer control enclosure to the sensor and plug it in. Operation will be checked during
start up.
To add the optional low level sensor:
1 Place the low level sensor at the bottom of the surge bin. This senses low
level.
2 Route the 6 (six) pin yellow cable from the bottom of the crystallizer control enclosure to the sensor and plug it in. Operation will be checked during
start up.
3-16 l Installation
Connecting the Loader Demand
Cable (If an Optional Loader Is
Installed on the Crystallizer)
CAUTION: Always refer to the wiring diagrams that came with your crystallizer
before making electrical connections. Electrical connections should be made only
by qualified personnel.
1 Route the cable from the loader to the right side of the crystallizer control
panel then into the control panel enclosure through existing hole.
2 Refer to the wiring diagram supplied with the crystallizer to determine the
correct connection point within the control panel enclosure.
✐
NOTE: Refer to the information supplied with your
loader for more specific
instructions regarding
loader demand. See
Operation section entitled,
Control Function
Description, for information
on control screens 16 and
16A which are used to set
loader demand.
Tools for installation:
❒ Flat blade screwdriver
❒ Ladder
1 TB
Installation l 3-17
3
control panel.
NOTE: If the loader was
supplied by Conair, the
connection was made. See
Installation section entitled,
Connecting the Load Level
Sensor, Safety Switches, and
Loader. Simply connect the
cable to the UTB on the
loader. If your loader was
not supplied by Conair, you
will need to wire the loader
into the cable that is
extending from the junction
box.
Installation
3 Connect the wires from the loader to the 1 TB terminals in the crystallizer
✐
Connecting Process Blower to
Process Heater Inlet
1 On CR21 - CR135 crystallizers the process
✐
NOTE: Do not allow the
flexible hoses to kink or
crimp.
blower is a self-standing blower. This will
need connected to the process heater inlet
using the supplied un-insulated hose.
2 With the supplied hose clamp loosely on
the process air hose, slide the hose onto
the process air inlet tube.
3 Tighten the clamp to secure the process
air hose to the air inlet. (Rotation will be
checked later.)
✐
3-18 l Installation
NOTE: See Appendix section entitled, “Blower Installation and Maintenance” for more information.
Connecting the Process Blower to
t h e C o n t r o l Pa n e l
✐
CAUTION: Always refer to the wiring diagrams that came with your crystallizer
before making electrical connections. Electrical connections should be made only
by qualified personnel.
NOTE: The connections at the process blower were made before the unit was shipped.
Inspect the connections to ensure they were not damaged during shipping or unpacking.
On larger units (CR21, CR42, CR85 and CR135) that have a self-standing blower
the connection will need to be made from the blower to the control enclosure.
1 Route the cable from the process blower to the crystallizer control panel then
into the control panel enclosure.
Tools for installation:
2 Refer to the wiring diagram sup-
❒ Flat blade screwdriver
❒ Ladder
plied with the crystallizer to
confirm the correct connection point
within the control panel enclosure.
3 Connect the wires from the process
blower to the blower contactor
(2 M terminals).
4 Coil any excess cable from the
process blower and secure it with
wire ties.
✐
2M
NOTE: Rotation will be checked later.
✐
NOTE: The heater wires are often
connected at the factory and
shipped connected. If your heater
is not connected, refer to your
wiring guide to make the connections.
Installation l 3-19
C o n n e c t i n g t h e M a i n Po w e r
CAUTION: Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by qualified
personnel.
1 Turn the disconnect dial on the
crystallizer control panel door to
the Off or “O” position. Lock out
the main power (see Page 1-5 for
complete lock out information).
Open the control panel door to access
the crystallizer’s electrical enclosure.
2 Insert the main power wire through
the knockout in the top of the enclosure. Secure the wire with a rubber compression fitting or strain relief.
3-20 l Installation
C o n n e c t i n g t h e M a i n Po w e r
(continued)
IMPORTANT: Always refer
to the wiring diagrams that
came with your crystallizer
before making electrical
connections.
top of the power disconnect holder.
4 Connect the ground wire to the ground lug as shown
in the photo.
Installation l 3-21
3
Installation
3 Connect the power wires to the three terminals at the
Checking for Proper Rotation and
Operation of Crystallizer
Components (Models CR4 and
CR10)
CAUTION: Always
disconnect and lock
out the main power
sources before making electrical connections. Electrical
connections should
be made only by
qualified personnel.
All components were tested at Conair and verified to be in phase. When these
items were disconnected before shipment and reconnected by the installer they
could have been wired out of phase.
IMPORTANT: This procedure must be performed before loading material into the
hopper.
CAUTION: This step must be performed before the crystallizer is put into operation.
1 Open the air-throttling valve located between the blower and the heater.
AIR THROTTLING
VALVE
2 Turn on the main power to the crystallizer. Make sure the crystallizer's disconnect dial is in the ON position. This powers up the
control.
3 Press the Start button (for no more than 5-10 seconds) followed
by the Stop button. Pressing the Start button will cause
the blower to start “winding-up” and pressing the Stop
button cuts the power to the blower which will take a
few seconds to “wind down”.
3-22 l Installation
Checking for Proper Rotation and
Operation of Crystallizer Components
( M o d e l C R 4 a n d C R 1 0 ) (continued)
4 Place your hand over the process air filter intake.
If suction is present, the crystallizer has been wired in phase.
If you feel air blowing from the intake, the crystallizer has
been wired out of phase and must be rewired.
5 Verify that the rotation of the agitator gear box on the
top of the crystallizer is correct. From the top looking
downward, rotation should be clockwise.
AIR FILTER
INTAKE
6 If both air flow and agitator rotation are incorrect
CAUTION: Always disconnect and lock out the main power
sources before making electrical connections. Electrical connections should be made only by qualified personnel.
1M
WARNING: All wiring, disconnects, and fuses should be installed by qualified electrical 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.
Installation l 3-23
3
Installation
simply switching two of the three incoming lines will put the
entire unit in correct rotation.
If rotation is incorrect on the agitator, then two of the
three wires will need to be switched on the contactor that is
feeding the agitator gear drive (1M).
Checking for Proper Rotation and
Operation of Crystallizer
Components (Models CR21, CR42,
CR85, and CR135)
CAUTION: Always
disconnect and lock
out the main power
sources before making electrical connections. Electrical
connections should
be made only by
qualified personnel.
IMPORTANT: This procedure must be performed before loading material into the
hopper.
CAUTION: This step must be performed before the crystallizer is put into operation.
1 Open the air-throttling valve located between the blower and the heater.
2 Turn on the main power to the crystallizer. Make sure the crystallizer's disconnect dial is in the ON position. This powers up the control.
3 Press the Start button (for no more than 5-10 seconds) followed
by the Stop button. Pressing the Start button will cause the blower
to start “winding-up” and pressing the Stop button cuts the power
to the blower which will take a few seconds to “wind
down”.
3-24 l Installation
Checking for Proper Rotation and
Operation of Crystallizer Components
(Models CR21, CR42, CR85, and CR135)
(continued)
4 Verify that the process blower impeller is rotating correctly according the the rotation
arrow.
5 Verify that the rotation of the agitator gear box on the top of the crystallizer is correct. From the top looking downward, rotation should be clockwise.
6 If both air flow and agitator rotation are incorrect, switch two of the three wires on
CAUTION: Always disconnect and lock out the main power
sources before making electrical connections. Electrical connections should be made only by qualified personnel.
2M
1M
WARNING: All wiring, disconnects, and fuses should be installed by qualified electrical 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.
Installation l 3-25
3
Installation
contactor 2M.
If rotation is incorrect on the agitator, then two of the three wires will need to be
switched on the contactor that is feeding the agitator gear drive (1M).
IMPORTANT:
This procedure
must be performed before
loading material
into the hopper.
CAUTION: This
step must be
performed
before the crystallizer is put into
operation.
Checking for Proper Rotation and
Operation of Crystallizer
Components- Material Discharge
Rotation Models CR21, CR42, CR85
a n d C R 1 3 5 (continued)
1 With power on to control, set crystallizer mode to manual. See Operation
section entitled, Control Function Flow Charts.
2 Enable material discharge. See Operation section entitled, Control Function
Flow Charts.
3 Discharge
should
start. Look
at rotation
of shaft on
the material discharge.
✐
CAUTION: Always
disconnect and lock
out the main power
sources before making
electrical connections.
Electrical connections
should be made only by
qualified personnel.
3-26 l Installation
NOTE: Refer to the arrow on the side of the discharge. Rotation should be in the
direction of the arrow.
4 If incorrect, switch the wires from the VFD to the motor.
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 installation. Now it’s time to make sure everything works.
1 Make sure there is no material in the agitating hopper. If you have mounted
a loader or vacuum receiver on the hopper, disconnect the material inlet hose at
the source.
2 Turn on the main power to the crystallizer. Make sure the crystallizer’s disconnect dial is in the ON position. This powers up the control.
3 Set the process temperature. Use the soft keys and numeric keypad to set the
process and residence temperatures See Operation section for more detailed
instructions.
If everything is installed correctly:
• The process blower turns on.
• The process heater turns on.
• The agitator turns on.
5 Press the STOP button.
If everything is installed correctly:
• The process blower will continue
running as needed to cool the
heater.
6 The test is over. If the crystallizer performed the normal operating sequences
as outlined, you can load the agitating hopper and begin operation. If it did not,
see Troubleshooting section for more detailed instructions.
Installation l 3-27
3
Installation
4 Press the START button.
3-28 l Installation
SECTION
4
Operation
Crystallizer control panel . . . . . . . . . . . . . . 4-2
Control function flow charts . . . . . . . . . . . . 4-3
Control function description . . . . . . . . . . . . 4-8
Crystallizer initial setup . . . . . . . . . . . . . . 4-21
4
Operation
Operation l 4-1
C r y s t a l l i z e r C o n t r o l Pa n e l
The crystallizer control panel provides an intuitive, user-friendly method to interface
with the crystallizer. Information is viewed and entered at the control panel.
Soft Keys
LCD Screen
The soft keys are denoted by the arrowhead on each. During setup and operation,
the operator can use these keys to choose the next "page" to be accessed. Text
will appear directly above the key identifying its current function. Think of the
text as the soft key function indicator or title. The soft keys will be referred to in
this manual from left to right as SK 1, SK 2, and SK 3 respectively.
The screen shows various information and pages
depending on operator actions. In addition, it is
used to indicate warnings and alarms. It is used
mostly for viewing the status of the crystallizer
and for setting parameters.
Red Parenthesis
Blue
Parenthesis
The red parenthesis
indicates that material is being held
because it has not
been in the hopper at
temperature long
enough.
The blue parenthesis indicates
that Setback
(option) is in
operation and
heater is working
properly.
SK 1
Soft key #1
SK 2
Fixed
Function
Keys
Soft key #2
The fixed function keys are
located below
and to the sides
of the numeric
keys. They
contain universal symbols and
text. The fixed
function keys
are Exit, Menu,
Mute, Lower,
Raise, Next,
and Prev (previous).
SK 3
4-2 l Operation
Soft key #3
Lower and Raise
The Lower and Raise keys are used to
adjust the speed of the material discharge.
Lower decreases material discharge speed.
Raise increases material discharge speed.
Pop Up Numeric Keypad
A pop up window (which opens
when you press on a setpoint)
has keys numbered 0 through 9.
The numbers permit data entry
of the parameters.
Control Function Flow Charts
MAIN DISPLAY AREA
PROCESS TEMP. OVERVIEW
MAIN DISPLAY AREA
RESIDENCE TEMP. OVERVIEW
1
PRESS TO ACCESS THE
MENU AREA
MENU
4
2
EXIT
OR
PREV
PREV
PROCESS 350 F >
Man
Off
Set
NEXT
<
RESIDENCE 180 F
Man
Off
Set
SEE MAIN DISPLAY AREA
RESIDENCE TEMP. OVERVIEW
SELECT MODE
Auto
Manual Cool
3
Process Setpoint
Temp. 200 F
2a
MODE HAS BEEN SET TO
" AUTO "
MODE HAS BEEN SET TO
" MANUAL "
PREV
NOTE: Setpoints can be
set/adjusted by touching
the setpoint and using the
pop up keypad and the
enter key. At the bottom of
the pop up keypad, the
setpoint range is listed for
your convenience.
2c
MODE HAS BEEN SET TO
" COOL DOWN "
Operation l 4-3
4
2b
MATERIAL TAKE AWAY
ENABLE ON/OFF
OR
Operation
✐
EXIT
Control Function Flow Charts
(Cont.)
MAIN DISPLAY AREA
RESIDENCE TEMP. OVERVIEW
4
PRESS TO ACCESS THE
MENU AREA
<
MENU
RESIDENCE 180 F
Man
Off
Set
PREV
PRESS TO RETURN TO MAIN
PROCESS TEMP. DISPLAY
EXIT
OR
PREV
5
SELECT MODE
Auto
Manual Cool
MODE HAS BEEN SET TO
" AUTO "
MODE HAS BEEN SET TO
" MANUAL "
MODE HAS BEEN SET TO
" COOL DOWN "
4-4 l Operation
Residence Setpoint
Temp. 180 F
✐
MATERIAL TAKE AWAY
ENABLE ON/OFF
EXIT
OR
PREV
NOTE: Setpoints can be
set/adjusted by touching
the setpoint and using the
pop up keypad and the
enter key. At the bottom of
the pop up keypad, the
setpoint range is listed for
your convenience.
Control Function Flow Charts
MENU AREA
DISPLAY OVERVIEW
(Accessed by pressing the menu button)
(Cont.)
✐
6
NOTE: Some items may not
be present depending on
control configuration and
options purchased.
PRESS TO ACCESS THE
MENU AREA
MENU
Note: Batch timer only
available in manual mode
EXIT
7
OR
BATCH TIME 000:00
Reset
Off
Set
PREV
10
PRESS TO RESET
Batch timer
Enable On/Off
8
OR
PREV
FLTXX PAXX CLEARED
ALARM CODE
9
EXIT
OR
PREV
PREV
10a
EXIT
Batch Timer Setpoint
020 Min
OR
10b
PROC. PROTECTION
TEMP. 375 F
Mat'l Takeaway Alarm
Delay 180 Sec
EXIT
OR
PREV
Operation l 4-5
4
SELECT ALARM AREA
FltLog
MtlFull
EXIT
Operation
Control Function Flow Charts
MAIN AREA
6
11c
AUXILIARY#2 183 F
Man
Off
11a
RETURN AIR 175F
Man
Off
EXIT
OR
TO MODE SELECT
PREV
MATERIAL TAKEAWAY
ENABLE ON/OFF
TO MODE SELECT
11b
MATERIAL TAKEAWAY
ENABLE ON/OFF
AUXILIARY#1 186 F
Man
Off
TO MODE SELECT
MATERIAL TAKEAWAY
ENABLE ON/OFF
IF THE OPTION IS NOT INSTALLED
THE OPTION SELECTED
IS NOT AVAILABLE
IS DISPLAYED ON THE SCREEN
4-6 l Operation
EXIT
OR
PREV
EXIT
OR
PREV
(Cont.)
Control Function Flow Charts
✐
Select Area
MAINT.
FACTORY
MENU
X2
✐
(PASSWORD REQUIRED
TO ACCESS MAINT AREA)
12
(Cont.)
NOTE: Language settings are also
selected in this maintenance area.
MAINTAINENCE AREA
DISPLAY OVERVIEW
16b
16a
NOTE: The password
to access the Maint
area is: “6209”.
SELECT UNITS
SELECT
DEV.
V BAND
°F
°C
Process
Resdnc
EXIT
OR
PREV
SELECT DEV. BAND
Process
Resdnc
Loader Demand State
Closed
OR
PREV
15a
Deviation Band Alarm
Temp. 010°F
EXIT
OR
PREV
14a
14
EXIT
OR
PREV
PREV
BASE UNIT OUTPUTS >
000000000010
< EXP. CARD OUTPUTS
0000000000000001
NEXT
15b
EXIT
OR
PREV
Residence Temp.
Band 10°F
EXIT
OR
PREV
Operation l 4-7
4
PREV
EXIT
Operation
BASE UNIT INPUTS
000001100000
EXIT
OR
16a
15
13
Control Function Description
This section describes the control function screens, how to set the crystallizing
parameters, and how to navigate between the control screens.
✐
NOTE: Throughout this section, Soft Key 1 will be referred to as "SK 1", Soft Key 2 as
"SK 2", and Soft Key 3 as "SK 3".
Screen
SCREEN 1
PROCESS 350 F >
Man
Off
Set
Function
After initialization, the Process Temperature screen is
visible. The default display for this screen is the actual
process temperature. This is the actual temperature of
the air that is being delivered to the crystallizing hopper.
From this screen, you can select several options. By
pressing SK 1, the Operating Mode of the discharge can
be changed. By pressing SK 2, the Discharge can be
toggled on or off. By pressing SK 3, the Process
Temperature Setpoint can be changed. This is the main
control screen and the screen will always default to this
screen.
SCREEN 2
Auto
SELECT MODE
Manual
Cool
Pressing SK 1 from the Process Temperature screen
(Screen 1) will allow you to change the Operating Mode
of the crystallizer. This is a very important selection and
should be selected on the basis of how the crystallizer
will be operated.
✐
NOTE: This SK 1 selection is available on each Mode screen
to allow the user to toggle between modes.
If, after accessing the Select Mode screen, you decide
not to change the Operating Mode, simply press the
EXIT or PREV fixed function keys to return to the
Process Temperature screen.
4-8 l Operation
Control Function Description
Screen
SCREEN 2a
MODE HAS BEEN SET TO
“AUTO”
(Cont.)
Function
Auto Mode Selection - This mode should be selected
(SK 1) for an on-line process when the crystallizer is
feeding a continuous process(s) and the material is being
discharged at a rate that co-corresponds with the amount
of material that is being loaded into the crystallizer.
When running in Automatic Mode, there are a few factors that will control the operation of the discharge valve.
The first is residence temperature, the second is the material hopper level, and the third is the hopper discharge
material level.
SCREEN 2b
MODE HAS BEEN SET TO
“ MANUAL”
Cool Down Mode Selection - This mode can be selected
(SK 3) to cool down a batch of material before discharging the material from the crystallizing hopper. It is
important to note that the material can only be cooled
down to a temperature above the lowest temperature that
can be supplied to the crystallizing hopper. Most likely,
this temperature will be about 130°F (54.4°C). It should
be sufficient to cool the material to a level so it can be
safely discharged to Gaylord.
Operation l 4-9
4
MODE HAS BEEN SET TO
“COOL DOWN”
Operation
SCREEN 2c
Manual Mode Selection - This mode should be selected
(SK 2) when the operator will be controlling the operation of the discharge manually. The discharge will not be
controlled from the residence temperature, however, the
residence temperature will create a passive alarm if set
improperly. This mode should be used when the initial
heel of crystalline material is being made or a single
batch of material is being processed. In this mode the
discharge valve can be opened with the crystallizer
stopped or running.
Control Function Description
Screen
SCREEN 3
Process Setpoint
Temp. 200 F
(Cont.)
Function
To change the air temperature delivery setpoint or
process setpoint, from Screen 1 press SK 3 (Set). When
pressed, you will move to the Process Setpoint screen,
which allows you to view and change the actual process
setpoint. To change this value, use the numeric keypad
and enter the new value at which you would like to
process material. When done, press ENTER to accept
the new value.
If, after accessing the Process Setpoint screen, you
decide not to change the setpoint, simply press the EXIT
or PREV fixed function keys to return to the Process
Temperature screen.
SCREEN 4
<
RESIDENCE 180 F
Man
Off
Set
In the upper right corner of the Process Temperature
screen (Screen 1), there is a right carrot. By selecting
the NEXT fixed function key, you enter the Residence
Temperature screen. This screen displays the actual temperature of the material as sensed by the RTD probe
located 2/3rds of the way up the crystallizer hopper
body. This temperature is an important part of the
process and ensures that the material is maintaining a
temperature sufficient for the crystallizing process to
occur. Once the crystallizer is running and has reached
stabilization, the actual residence temperature should be
noted. This is about where the unit will continue to run
as long as the throughput remains constant and the
incoming material level stays full.
If, after accessing the Residence Temperature screen, you
decide not to change the residence temperature, simply
press the EXIT or PREV fixed function keys to return to
the Process Temperature screen.
4-10 l Operation
Control Function Description
(Cont.)
Screen
Function
SCREEN 5
Once the correct value for the residence temperature is
known, it should be entered into the control as a controlling factor for the process. By pressing SK 3 (Set) on the
Residence Temperature screen (Screen 4), you will
access the Residence Setpoint screen that allows you to
enter the value that was determined as a stabilization
point. Depending on the operating mode selected, if this
actual residence temperature deviates below this setpoint
temperature by 10°F (5.5°C) (the default setting), the discharge will stop and not run until the residence temperature reaches this value again.
Residence Setpoint
Temp 180 F
If, after accessing the Residence Setpoint screen, you
decide not to change the residence setpoint, simply press
the EXIT or PREV fixed function keys to return to the
Residence Temperature screen.
Operation l 4-11
4
Operation
Residence Temperature Impact on Automatic Mode Once the actual residence temperature is reached, the
auger can be enabled (this does not occur automatically,
it must be enabled once the residence setpoint is
reached). Once the discharge is enabled, it will run as
long as the material discharge level sensor is uncovered,
the material hopper level stays covered, and the residence
temperature stays equal to the set level (within 10°F
[5.5°C]). If the temperature falls 10°F (5.5°C) below this
setpoint, alarm PA 1 will flash and the discharge will disable until the temperature comes back in the 10°F
(5.5°C) deviation band. When it does, the discharge will
re-enable and start to discharge material again.
Control Function Description
(Cont.)
Screen
Function
SCREEN 5 (Cont.)
Residence Temperature Impact on Manual Mode Residence temperature does not disable the discharge
while running in the Manual Mode. In Manual Mode,
the residence temperature can be used for monitoring the
process but it will not control the process. This mode
should be used when the unit is running a small batch or
the material is being circulated on start up to make the
initial pre-charge of crystalline material. If a tighter constraint needs to be held on the process, the crystallizer
should be run in Automatic Mode. To take advantage of
all of the alarms, the unit should be run in Automatic
Mode.
SCREEN 6
By pressing the MENU fixed function key one time, you
can access the SELECT AREA screen. From this main
menu screen, there are six selections. Batch, Process
Protection, Alarms, Return Air, and the Auxiliary
Temperature areas can be accessed by pressing the
appropriate button.
✐
4-12 l Operation
NOTE: If an option is not enabled, the button will not be displayed.
Control Function Description
(Cont.)
Screen
Function
SCREEN 7
By pressing BATCH on the Select Area screen (Screen
6), you will access the Batch Timer screen. This is useful
if you would like to agitate and heat a batch of material
for a known length of time.
BATCH TIME 000:00
Reset
Off
Set
✐
NOTE: This selection is only available in the Manual Mode
and cannot be selected in any other mode.
If the unit is in the Manual Mode and the Batch Timer is
currently running, the actual incrementing accumulated
time will be displayed on this screen. If SK 1 (Reset) is
selected, the timer-accumulated value will be reset to
zero. SK 2 (Off / On) enables and disables the Batch
Timer.
SCREEN 8
Once a value is keyed in for a Batch Time, you will be
sent back to the Batch Timer screen. To enable the timer,
press SK 2 (Off / On) and the timer will start to accumulate to the batch setpoint. When the accumulated value
reaches the preset value, an alarm (PA 8) will sound and
indicate that the batch is ready to be discharged. When
the alarm (PA 8) is acknowledged, the timer will automatically reset and the Batch Mode will switch to Off.
Operation l 4-13
4
Operation
Batch Timer Setpoint
020 Min
By pressing SK 3 (Set) on the Batch Timer screen
(Screen 7), you can enter the desired Batch Time Setpoint
for which you would like to crystallize the current batch.
Once the desired batch time is entered through the
numeric keys, press ENTER. If, after accessing the
Batch Time Setpoint screen, you decide not to set the
batch setpoint, simply press the EXIT or PREV fixed
function keys to return to the Batch Timer screen
Control Function Description
(Cont.)
Screen
Function
SCREEN 9
By pressing Prtctn from the SELECT AREA screen
(Screen 6), the user will be able to view the Process
Protection Temperature. This is the temperature of the
process air at the outlet of the heater tube(s) and is a
valuable troubleshooting tool if a temperature problem
arises. This is the actual value that the Process
Protection Temperature Differential is monitoring along
with the actual Process Temperature.
PROC.PROTECTION
TEMP. 375 F
SCREEN 10
SELECT ALARM AREA
FltLog
MtlFull
SCREEN 10a
FLTXX PAXX CLEARED
ALARM CODE
4-14 l Operation
By pressing Alarm from the main SELECT AREA
screen (Screen 6), the user can access two commonly
used alarms areas. These areas are accessible from SK 1
(FltLog [Fault Log]) and from SK 3 (MtlFull [Material
Full]).
The FltLog (fault log) is an actual log of the last 20
alarms that occurred for the crystallizer. This screen will
show the fault log number (FLT 0 - FLT 19), what alarm
the fault is (PA 1 - PA 8) or (AL 1 - AL 14), if the alarm
is still active or cleared, and what the description of the
actual code is (much like what is displayed on the screen
when an actual alarm occurs). This log will run as "first
in" and "first out" so after the first alarm is logged, it will
cycle out of the log after 19 additional alarms are
encountered. To scroll between Fault Logs, press the
NEXT or PREV fixed function keys.
Control Function Description
(Cont.)
Screen
Function
SCREEN10b
The MtlFull (material full) alarm is the time delay from
when the material discharge level sensor is made until the
passive alarm (PA 6) is displayed. This alarm should be
set at a value sufficient to notify you if a problem has
occurred downstream of the crystallizer and material is
no longer being taken away from the crystallizer. When
this alarm occurs, the material discharge will stop until
the level sensor clears itself of material.
Mat’l Takeaway Alarm
Delay 180 Sec
To view the optional Return Air RTD (if purchased),
press Return Air to view the return air temperature of the
process return air temperature at the blower inlet.
✐
NOTE: This is only used for closed looped operation where the
return air temperature of the blower is critical.
SCREENS 11b & c
AUXILIARY#1 186 F
Man
Off
The two additional RTD's (Auxiliary Temp. #1) and
(Auxiliary Temp. #2) respectively are for monitoring two
other locations in the crystallizer hopper body. These are
also optional and added for customers who require additional material monitoring capabilities.
AUXILIARY#2 183 F
Man
Off
Operation l 4-15
4
RETURN AIR 175F
Man
Off
Operation
SCREEN 11a
Control Function Description
Screen
Function
SCREEN 12
By pressing the MENU fixed function key two times (or
once from SELECT AREA screen [Screen 11]), you will
enter a SELECT AREA screen that allows you to view
two selections: SK 1 (MAINT.) and SK 3 (FACTORY).
You should not need to enter the FACTORY setup menu.
By pressing SK 1 (MAINT.) and keying in the correct
password through the keypad when prompted (default
password for this area is 6209), you will enter a
SELECT MAINT. AREA screen. Form this screen you
will be able to view, monitor, or change six separate
areas (Input Status, Output Status, and Deviation Band,
Loader Demand, Units F or C, and Language).
SCREEN 13
By pressing Input Status on the MAINT. AREA screen
(Screen 12), you will be able to view the state of base
unit inputs that the PLC is monitoring. This is a very
handy troubleshooting screen and will allow the user to
ensure that the correct inputs are on or off as necessary.
Viewing from the left to the right, the table should
decrease in order from input 11 to input 0. The base unit
inputs are below:
11
10
9
8
7
6
5
4
3
2
1
0
4-16 l Operation
(Cont.)
=
=
=
=
=
=
=
=
=
=
=
=
Spare
Material takeaway level sensor
Loader demand
Variable speed discharge fault
Spare
Door and cone safety switches
Agitator motor overload contact
Process blower overload contact
Agitator motor overload
System stop
System start
Emergency stop / master control relay
Control Function Description
(Cont.)
Screen
Function
SCREEN 14
By pressing Output Status on the MAINT. AREA screen
(Screen 12), you can view the state of the outputs (BASE
UNITS OUTPUTS - Screen 14) that the PLC is monitoring. This also is a very handy troubleshooting tool that
allows the user to monitor the actual outputs that are
enabled at the time of viewing. The first screen will be
the base unit PLC outputs and by selecting NEXT, you
can view the EXP. CARD OUTPUTS screen (Screen
14a).
Operation l 4-17
4
Operation
BASE UNIT OUTPUTS (Screen 14) (From left to right)
11
=
Spare
10
=
Material takeaway full
9
=
Material takeaway increase speed
8
=
Material takeaway decrease speed
7
=
Material takeaway run / stop
6
=
Spare
5
=
Spare
4
=
Spare
3
=
Spare
2
=
Process blower on / off
1
=
Agitator motor overload contact
0
=
Master control relay
Control Function Description
(Cont.)
Screen
Function
SCREEN 14a
Press NEXT on Screen 14 to access the EXP. CARD
OUTPUTS screen (Screen 14a) to view the expanded
card outputs, which are listed below.
EXP. CARD OUTPUTS (Screen 14a) (From left to right)
15
=
Spare
14
=
Spare
13
=
Spare
12
=
Spare
11
=
Spare
10
=
Spare
9
=
Spare
8
=
Spare
7
=
Alarm light
6
=
Alarm horn
5
=
Process heater on / off
4
=
Process heater on / off
3
=
Process heater on / off
2
=
Process heater on / off
1
=
Process heater on / off
0
=
Process heater on / off
SCREEN 15
SELECT DEV. BAND
Process
Resdnc
4-18 l Operation
By pressing Deviation Bands from the MAINT. AREA
screen (Screen 12), you can chose between the two more
commonly accessed Deviation Band Temperatures:
Process Deviation Band (SK 1 - Process) and Residence
Temperature Deviation Band Alarm
(SK 3 - Resdnc).
Control Function Description
(Cont.)
Screen
Function
SCREEN 15a
By pressing SK 1 (Process) on Screen 15, you will view
the Deviation Band Alarm screen (Screen 15a) for the
process. This is the value that the actual process temperature can deviate from the setpoint above or below before
alarm PA 2 will initiate. The default value for this band
is 10°F (5.5°C) and should be sufficient for most processes. If you entered this screen by accident, or decide that
you do not want to change the temperature, press EXIT
or PREV to leave the screen.
Deviation Band Alarm
Temp. 010°F
SCREEN 15b
Residence Temp.
Band 10°F
Operation l 4-19
4
Operation
By pressing SK 3 (Resdnc) on Screen 15, you will view
the Residence Temp. Band screen (Screen 15b). This
temperature is the amount that the actual residence temperature can deviate below the residence temperature setpoint before the auger will be disabled in Auto Mode.
Normally, 10°F (5.5°C) should be sufficient for most
applications once the residence temperature stabilization
temperature is determined. If you entered this screen by
accident, or decide that you do not want to change the
temperature, press EXIT or PREV to leave the screen.
Control Function Description
(Cont.)
Screen
Function
SCREEN 16a
From this screen, you can select the demand type for the
loading system that is supplying material to the crystallizer. The choices are Closed or Open, which refers to
the type of demand the system is looking for in its normal state. Most, but not all of Conair loaders will
require a closed setting that is the default setting.
Pressing SK 2 will toggle from Closed to Open. If you
entered this screen by accident, or decide that you do not
want to change the temperature, press EXIT or PREV to
leave the screen.
Loader Demand State
Closed
SCREEN 16b
°F
SELECT UNITS
SCREEN 16c
4-20 l Operation
°C
From this screen, you can select either °F or °C for operation.
From this screen, you can select either English or
Spanish language platform.
Crystallizer Initial Set Up
After the crystallizer is installed and the correct operation of all of the components
is tested the crystallizer is ready to operate. Before starting perform the following
additional steps:
I n p u t Te m p e r a t u r e S e t p o i n t ( s ) - P r o c e s s
Input the correct crystallizing temperature setpoint for the material that you will be
running. This temperature can vary greatly depending on material type; therefore
Conair cannot recommend the correct temperature. Contact your material supplier
for suggested temperature setpoints.
1 Select SK 3 from the Main screen.
2 Input your required tem-
Process Setpoint
Temp. 200 F
I n p u t Te m p e r a t u r e S e t p o i n t ( s ) - R e s i d e n c e
The residence temperature is the temperature level that is maintained in the agitating stage during operation. Initially this temperature should be set very low so it
will not cause any nuisance alarms.
1 Select “Next” (a fixed function key) from the Main screen.
<
2 Select “Set”.
RESIDENCE 180 F
Man
Off
Set
3 Use the pop up keypad and input a temperature of approximately 100°F (38°C) and
press “Enter”. The temperature will be adjusted for your
process later.
Residence Setpoint
Temp 180 F
Operation l 4-21
4
Operation
perature. You can press
on the temperature and use
the pop up keypad to enter
the desired setpoint, followed by the green enter
arrow.
PROCESS 350 F >
Set
Off
Man
Crystallizer Initial Set Up
(Cont.)
A i r- f l o w a d j u s t m e n t
The blowers that are provided with the crystallizers are capable of operating in a
wide range of airflow situations. It will be necessary to adjust the correct airflow
for your particular application. Before starting adjust the throttling valves to about
the 70% level (see below). The airflow will be fine tuned later in the process.
Essentially, the airflow will needed be adjusted so that your required temperature
can be maintained at the required throughput. If too much airflow is supplied it
will cause carryover problems from the agitating hopper, possibly percolate the
material, and possibly generate enough pressure in the top of the hopper to keep
the material from discharging from the loader. If too little air flow is supplied, the
material will not heat adequately and will process incorrectly.
✐
AIR THROTTLING
VALVE
NOTE: Depending on your crystallizer size and model, you may have
the larger or smaller throttling valve
shown to the right.
AIR THROTTLING
VALVE
4-22 l Operation
C r y s t a l l i z e r I n i t i a l S e t U p (Cont.)
Select Mode
For initial start-up it is recommended to start in the Manual mode (Man). This will
allow you alter temperatures and other settings during start-up without causing any
nuisance alarms. This can be done by selecting SK1 from the main screen and then
selecting manual mode (see operation 4-3). If the bottom left of the main screen
indicates "Man" the manual mode is already set.
1 Select SK 1 from the Main screen.
PROCESS 350 F >
Set
Off
Man
2 Select Manual mode. The screen will
display, “Mode has been set to MANUAL”.
Auto
SELECT MODE
Manual
Cool
Operation l 4-23
4
Operation
MODE HAS BEEN SET TO
“ MANUAL”
Crystallizer Initial Set Up
(Cont.)
Level Sensor Location and Adjustment
There are several
optional level sensors that may be
HOPPER FILL
installed in the
LEVEL SENSOR
crystallizing system. A level sensor is typically
SEVERAL
placed toward the
LEVEL SENSOR LOCATIONS
(DEPENDING ON MODEL)
top of the agitating hopper to
AGITATING
HOPPER
control material
level in the hopper. Another can
be placed in the
DISCHARGE VALVE
discharge chute
HIGH
below the materiLEVEL SENSOR
al discharge or
HIGH
placed in the
SURGE BIN
LEVEL SENSOR
OR GAYLORD
(IF NOT BELOW
upper section of
DISCHARGE VALVE)
the surge bin,
which controls a
LOW
LEVEL SENSOR (OPT.)
fill point and protects the discharge
auger. Additionally, there is an optional sensor that could be placed in the bottom
of the surge bin that controls alarming for low-level situations. During initial
assembly and testing, Conair adjusts the empty setting for these sensors but it is
very possible that during the initial start-up the sensors may need to be readjusted,
especially for the full settings. The sensor may need to be readjusted when the
level sensor temperature reaches the actual material temperature and most likely
will need to be readjusted if you plan on running several material types of varying
bulk densities.
}
The manufacturer’s operational manual for the level sensor is included as an
appendix to this user guide. Refer to the manufacturer’s manual for proper adjustment and operation.
4-24 l Operation
Crystallizer Initial Set Up
(Cont.)
Initial Hopper Filling
✐
✐
NOTE: One sensor in
hopper as standard.
NOTE: The LED sensor light blinks when material is not in contact with the sensor. The LED
sensor light is on solid when the sensor is covered with material.
NOTE: The sensor may need to be readjusted when the level sensor temperature reaches the
actual material temperature and most likely will need to be readjusted if you plan on running
several material types of varying bulk densities.
Operation l 4-25
4
✐
LEVEL
SENSOR
LED LIGHT
Operation
During initial filling of the agitating hopper the material level in the hopper
should be watched closely to make sure that the sensor is switching states
when the material reaches it. This can be done by watching the LED indicator
on the sensor. Watch the
level through the sight glasses in the hopper, when the
material comes in contact
with the sensor the LED
indicator should change state
SIGHT
and the loader should stop
GLASSES
loading. Once it stops it
(LOCATION
should not load again until
MAY VARY
the level drops below the
DEPENDING
sensor and remains below for ON MODEL)
about seven seconds. If the
LED does not change state
when the material comes in
contact with the sensor,
adjust it accordingly. Conair
recommends watching a few
cycles to make sure that the
operation is consistent. If the
LED does change state and
the loader continues to load
there is a problem with the demand wiring on the installed loader and it will need
to be repaired.
C r y s t a l l i z e r I n i t i a l S e t U p (Cont.)
Initial Surge Bin Filling or Gaylor Filling
After the crystallizing process is complete and the material is discharged from the
crystallizer, it may also be necessary to adjust the level sensor that is controlling
the fill point of
the surge bin.
DISCHARGE VALVE
This level sensor
may be placed
HIGH
LEVEL SENSOR
in the material
discharge chute
HIGH
SURGE BIN
or in the top of
LEVEL SENSOR
OR GAYLORD
(IF
NOT
BELOW
the surge bin. It
DISCHARGE VALVE)
is very important
LEVEL
to insure that
SENSOR
LOW
LED LIGHT
this level sensor
LEVEL SENSOR (OP
is working correctly, if material
CAUTION: If the level
backs up into the material discharge damage could occur. This can be done by
sensor is not working
watching the LED indicator on the sensor. Watch the level in the surge bin through
properly, damage to
the sight glass or lid in the surge bin, when the material comes in contact with the
equipment may
sensor the LED indicator should change state and the material discharge should
occur.
stop running. Once it stops it should not run again until the level drops below the
sensor. Conair recommends watching a few cycles to make sure that the operation
is consistent. Refer to the level sensor manufacturer’s instruction guide located in
the appendix of this user guide for adjustment instructions.
✐
4-26 l Operation
NOTE: The LED sensor light blinks when material is not in contact with the sensor. The LED
sensor light is on solid when the sensor is covered with material.
C r y s t a l l i z e r I n i t i a l S e t U p (Cont.)
Discharge Auger Operation and Calibration
The discharge auger can be operated by pressing the SK2
button while on the main display area screen. Pressing the
key once will start the discharge and pressing it again will
X
stop the discharge.
Pressing the raise or lower fixed function
keys on the crystallizer control panel controls the VFD frequency output, which in
turn changes the speed of the discharge.
1
2
3
4
5
6
7
8
9
0
MENU
MUTE
LOWER
EXIT
RAISE
ENTER
PREV
NEXT
VIEWING
WINDOW
Operation l 4-27
4
Operation
The frequency setting can be
viewed through the viewing window in the right side of the
Crystallizer control panel. When
the crystallizer is in operation the
speed should be adjusted to match
the rated throughput of the crystallizer. Throughputs are listed in
the chart below.
DELETE
PROCESS 350 F >
Man
Off
Set
Crystallizer Initial Set Up
(Cont.)
Discharge Auger Calibration
The material discharge auger can be adjusted to operate over a wide range of material
output rates. It is a good practice to determine what VFD setting will correspond to a
particular rate for your particular material type. This will allow you to know exactly
how many pounds per hour of material you are discharging simply by looking at the
VFD setting. Complete the following steps to calibrate your discharge auger:
1 Fill the crystallizer with the material that you plan to process.
2 Start running the discharge auger at full speed -60 Hz.
3 Use a vessel (fiber drum or other appropriate sized bucket) to capture a oneminute sample of material. More or less can be used, but the calculations below
are to calculate using a minute of captured material. If a different time interval is
used, the calculation would need to be altered accordingly.
4 Weigh the vessel. Make sure you zero the scale so that you are only reading material weight (not the weight of the vessel.)
5 For this example, we will assume that our one-minute sample weighed 10 pounds.
After this value is measured, perform the following calculations:
(10 pounds / minute) * (60 minutes / hour) = 600 pounds / hour @ full 60 Hz setting
From this information we can determine what our setting would need to be to achieve
a certain pounds per hour output for each particular crystallizer size by the following:
For this example assume that we require 400 pounds / hour output.
(600 pounds / hour) / 60 Hz (maximum output) = 10 pounds per hour /1 Hz setting
(400 pounds / hour) / (10 pounds per hour / 1 Hz setting) = 40 Hz setting to achieve
rate
4-28 l Operation
This method can be used to determine the output of any crystallizer and to determine
the exact setting for any particular output required. It is important to remember that
this calibration is only good for one material, if your process changes material you
will need to perform this calibration each time.
C r y s t a l l i z e r I n i t i a l S e t U p (Cont.)
Initial Start Up
1 Press Start. All the components should start and the actual temperature should
start to climb to your actual set point. If this does not happen, review corrective
actions in the troubleshooting section of this manual. Once the system is operating and at steady temperature the initial crystallizing process can be started.
When the crystallizer is started it will be necessary to create or add a pre-charge of
crystalline material into the cone section of the agitating hopper. This pre-charge of
material will help to ensure that no agglomeration occurs in the cone section,
which could impede the flow of material from the agitating hopper. Two different
methods can be used to accomplish this.
The first and easiest method of charging the crystallizer is with a batch of crystalline material (same material you are processing). If you do not have any precrystalline material, refer to the alternative method on the next page.
WARNING: Gloves
and safety glasses
are recommended
when performing this
process. The material is going to become
hot and without
proper precautions,
burns could occur.
removable cone section.
3 Once this material is placed into the agitating hopper and the unit is running,
load amorphous material on top of the crystalline material until the hopper is full.
4 Refer to the level sensor adjustment portion of the set-up section while filling material.
5 Once the hopper is initially full let the material heat and agitate until the
residence temperature probe reads similar to the process setpoint temperature. Usually this process takes about one hour. You should be able to see the
crystallizing process occurring in the various sight glasses and eventually
throughout the entire hopper.
Once this initial process is complete you are now ready to start dynamic operation
of the crystallizing system. You will be able to bring amorphous material into the
top of the crystallizing hopper and discharge fully crystalline material from the
bottom of the hopper.
continued. . .
Operation l 4-29
4
Operation
2 Fill the hopper with enough material to reach a level which fully fills the
C r y s t a l l i z e r I n i t i a l S e t U p (Cont.)
Initial Start Up (Con’t)
Alternatively, if no pre-crystalline material exists or if a small batch of material is
going to be processed complete the following:
2 Add two or three loads of material into the hopper and start the material
discharge. It is possible with this small amount of material in the hopper that
the airflow may need adjusted for the material to dump correctly from the
loader. Once the hopper is filled to a higher level the airflow can be increased.
3 Begin to circulate the material from the outlet of the discharge auger back
into the loader.
4 Continue this process until the first few loads of material has changed
states and is now crystalline.
5 Add one or two more loads of material and continue to circulate the mateWARNING: Gloves
and safety glasses
are recommended
when performing this
process. The material is going to become
hot and without
proper precautions,
burns could occur.
rial.
6 Continue this process until the removable cone section is full of free flowing crystalline material.
7 Once it is full, stop the material re-circulation and fill the hopper (monitor
agitating hopper material level sensor).
8 Once the hopper is initially full, let the material heat and agitate until the
residence temperature probe reads similar to the process setpoint temperature. Usually this process takes about one hour. You should be able to see the
crystallizing process occurring in the various sight glasses and eventually
throughout the entire hopper.
Once this initial process is complete you are now ready to start dynamic operation
of the crystallizing system. You will be able to bring amorphous material into the
top of the crystallizing hopper and discharge fully crystalline material from the
bottom of the hopper.
4-30 l Operation
C r y s t a l l i z e r I n i t i a l S e t U p (Cont.)
Dynamic Operation
Dynamic operation can be achieved in both the manual mode "Man" and the automatic mode "Auto" but the "Auto" mode will give much better control of the crystallizing system. During operation in "Auto" mode the on board PLC is monitoring
various points in the process to make sure that you are getting the required residence time at temperature in the hopper to complete the crystallizing process. This
is achieved by monitoring both the material level and material temperature in the
hopper. Conair recommends that “Auto” mode be used when possible. To
PROCESS
operate in “Auto”:
Man
Off
350 F
>
Set
1 Press SKI from the main display area.
2 Select Auto (SKI) again. You will get indication that the mode is
switched to Auto.
Auto
SELECT MODE
Manual
Cool
3 Press SK2 on the main display area and set the VFD output at the
MODE HAS BEEN SET TO
“AUTO”
to make sure that the level sensor in the agitating hopper is calling for
material when the material level drops below the sensor –if it is not adjust
as necessary. (Refer to the manufacturer’s instructions for the level sensor for
proper adjustment procedures.)
5 Continue dynamic operation and monitor the various level sensor probes
in the surge bin or material discharge chute. If the unit is filling a gaylord
there will be one level sensor placed in the discharge chute under the discharge
valve, which will disengage when the gaylord is full. When this level is met
PA11 will enable and the discharge valve will disengage. Once a new gaylord is
placed under the crystallizer the alarm can be silenced and the process will need
to be restarted which can be done by turning the discharge auger to on (SK2). If
the unit is filling a surge bin the material level will fill between two sensors in
the surge bin. The bottom sensor will start the discharge valve and the upper
sensor will disable the discharge valve. This operation will allow the valve discharge rate to be tuned to the rate of the system and eliminate constant starting
and stopping of the discharge valve.
continued. . .
Operation l 4-31
4
4 Watch the hopper level during the initial start of dynamic operation
Operation
speed required for your process. (See discharge valve operation and
calibration section.) Material will begin to discharge at the required rate.
After a certain time, amorphous material should also load into the top of
the agitating hopper.
C r y s t a l l i z e r I n i t i a l S e t U p (Cont.)
Dynamic Operation (Con’t)
When the system is running you will see that the Residence temperature is
decreasing as the new material is being processed through the crystallizing hopper.
This will continue for some time but will eventually reach a stabilization point.
This stabilization point is where your system is going to run on a continuous basis
at your current throughput.
Once this temperature is determined, set the Residence temperature to a level of
about 15°F (-9.44°C) below thatXmeasured
2 Use
3 the4following
5 steps to set the
1 level.
Residence temperature:
1 Selecting the
"next" fixed
function key
from the main
screen.
DELETE
6
7
8
MENU
MUTE
LOWER
EXIT
RAISE
2 Selecting "Set" (see operation 4¬4).
3 Click the temperature setpoint to enter the
residence temperature desired. This will
insure that the correct material temperature is
maintained in the hopper during the crystallizing process.
If the material temperature drops below this level
the discharge will disable and an alarm will be initiated. If this occurs most likely something has
changed in the process such as material throughput, airflow through the hopper, or temperature
level of the incoming air. Refer to the
Troubleshooting section of this user guide to
determine the cause of the alarm.
4-32 l Operation
9
<
0
ENTER
PREV
NEXT
RESIDENCE 180 F
Man
Off
Set
C r y s t a l l i z e r I n i t i a l S e t U p (Cont.)
Shutdown and Restart
If you are required to shut the crystallizer down for some reason there are certain
steps that should be taken to minimize the amount of work required when re-starting the system. The main objective is to maintain a certain amount of crystalline
material in the agitating hopper so that a new charge of crystalline material will not
need to be made when re-starting.
1 Run the crystallizer until it is about half empty during shutdown.
2 Stopping the material discharge. Allow the crystallizer to heat and agitate
until the material is fully crystalline.
3 Shutdown the crystallizer. If necessary, a couple hundred pounds of material
can be discharged from the crystallizer and saved in a separate container to be
reloaded during the start-up process.
4
Operation
Operation l 4-33
C r y s t a l l i z e r I n i t i a l S e t U p (Cont.)
Batch Mode and Cool Down Mode
IMPORTANT: If you are running a batch of material, it is also important to
cool down the batch before discharging the material to gaylords or drums.
(See Operation section entitled, “Control Function and Description” for
more information.)
Another method of running the crystallizer is in batch mode. This mode will allow
you to fill the crystallizer with a certain amount of material and run it for a set
X 1 2 3 4 5
length of time. Once the time is complete an alarm will sound that indicate that the
material is ready to discharge. To begin6using7batch8mode:
9 0
DELETE
1 Press the
“Menu” button
(only once).
ENTER
EXIT
MENU
2 Press “Batch”.
3 Press the SK3 button to set the
batch timer setpoint. Enter the
amount of time (in minutes)
desired for your operation. Time
can be entered by clicking the setpoint time and using the pop up
keypad to enter the setpoint.
4 Press the SK2 button to turn
the batch timer on. An alarm
will sound when the batch is complete.
4-34 l Operation
MUTE
RAISE
LOWER
PREV
NEXT
SECTION
5
Maintenance
Preventative maintenance checklist . . . . . . . 5-2
Cleaning the process air filter
(CR4 and CR10) . . . . . . . . . . . . . . . . . . 5-3
Cleaning the process air filter
(CR21 and CR135) . . . . . . . . . . . . . . . . 5-6
C l e a n i n g t h e cy cl o n e s e p a r a t o r f i l t e r s o c k . . . 5 - 8
C l e a n i n g t h e cy cl o n e s e p a r a t o r
Cleaning the heat sink . . . . . . . . . . . . . . . 5-12
Cleaning the agitating hopper
( M i n o r cl e a n i n g ) . . . . . . . . . . . . . . . . 5 - 1 3
Cleaning the agitating hopper and
r e m o v a b l e c o n e s e c t i o n ( M a j o r cl e a n i n g ) 5 - 1 4
Cleaning the aftercooler coils . . . . . . . . . . 5-21
Inspecting hoses and gaskets . . . . . . . . . . 5-21
Maintenance l 5-1
5
Maintenance
collection tank . . . . . . . . . . . . . . . . . 5-10
Preventative Maintenance
Checklist
Routine maintenance will ensure optimum operation and performance of the crystallizer. We recommend the following maintenance schedule and tasks.
• Whenever you change materials
❒ Clean the loader that fills the agitating hopper (see the appropriate
loader user guide.)
❒ Clean the agitator hopper and removable cone section.
❒ Empty and clean the cyclone separator collecting tank and dust filter.
• We e k l y, o r a s o f t e n a s n e e d e d
❒ Clean the return air and dust collector filters.
You may need to clean filters more often than weekly. Frequency depends
on how much material you process and how dusty or full of fines it is.
❒ Inspect hoses and hose connections.
Check for damage, kinks, or loose hose clamps. Replace any hoses that
show signs of damage or wear. Reposition and tighten loose hose clamps.
• Monthly
❒ Clean the optional aftercooler coils (closed loop systems only).
You may need to clean the coils more often than monthly. Frequency will
depend on the type and volume of material you process.
• Every six months
✐
5-2 l Maintenance
❒ Inspect gaskets for damage or wear.
Damaged gaskets can allow moisture to seep into the closed-loop drying
system. Replace any gasket that is torn or cracked.
NOTE: See the maintenance sections of the other manufactures manuals included in the
appendix of this manual.
Cleaning the Process Air Filter
(CR4 and CR10)
A clogged process air filter reduces airflow and crystallizer efficiency. Cleaning
frequency depends on how much material you process and how dusty it is.
✐
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance
activity.
Tools for cleaning:
❒ Vacuum or air
compressor
❒ Cleaning cloth
CAUTION:Hot surfaces. Always protect yourself from hot surfaces inside and
outside the crystallizer.
1 Isolate the equipment from the electric power by turning the rotary disconnect switch to the OFF, or "O" position. See Section 1 - Introduction for complete lockout procedures.
2 Remove the process air filter lid by removing the speed nut securing it to
the process air filter assembly.
5
Maintenance
Maintenance l 5-3
Cleaning the Process Air Filter ( c o n t i n u e d )
3 Remove the process air filter element by removing the speed nut securing the
filter in the process air filter canister then lifting the element from the process
air filter canister.
4 Clean the process air filter element using a vacuum or compressed air. If
using a vacuum, repeatedly apply the vacuum to the outside of the filter element
until all debris is removed. If using compressed air, clean the filter element by
blowing the compressed air from the inside out. Replace the filter if it is
damaged, worn, or still clogged after cleaning.
CAUTION: If you use compressed air to clean any filters or equipment, you must
wear eye protection and observe all OSHA and other safety regulations pertaining to the use of compressed air.
5 Clean the inside of the process air filter canister and remove any debris in
the canister.
6 Install the filter element in the process air filter canister by aligning it on
the stud then sliding it into the canister.
5-4 l Maintenance
Cleaning the Process Air Filter ( c o n t i n u e d )
7 Secure the filter element in the canister
by installing the speed nut. Snug the
nut by hand to insure a tight fit at the
bottom of the filter.
8 Install the process air filter lid on the
stud then slide it onto the canister. Secure
the lid by installing and tightening the
speed nut.
5
Maintenance
Maintenance l 5-5
Tools for cleaning:
❒ Vacuum or air
compressor
❒ Cleaning cloth
Cleaning the Process Air Filter
(CR21 and CR135)
A clogged process air filter reduces airflow and crystallizer efficiency. Cleaning
frequency depends on how much material you process and how dusty it is.
✐
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance
activity.
CAUTION:Hot surfaces. Always protect yourself from hot surfaces inside and
outside the crystallizer.
1 Isolate the equipment from the electric power by turning the rotary disconnect switch to the OFF, or "O" position. (See Section 1 - Introduction for complete lockout procedures.)
2 Remove the bolts or nuts that are
holding the filter end cap in place.
3 Remove the end cap.
4 Remove the filter media.
✐
5-6 l Maintenance
NOTE: In closed loop systems, clean the
filter and, if applicable, clean the secondary dust collector.
Cleaning the Process Air Filter
( C R 2 1 a n d C R 1 3 5 ) (continued)
5 Clean the process air filter element using an industrial vacuum cleaner. If
using a vacuum, repeatedly apply the vacuum to the outside of the filter element
until all debris is removed.
Replace the filter if it is damaged, worn, or still clogged after cleaning.
CAUTION: If you use compressed air to clean any filters or equipment, you must
wear eye protection and observe all OSHA and other safety regulations pertaining to the use of compressed air.
6 Reinstall in reverse order.
5
Maintenance
Maintenance l 5-7
C l e a n i n g t h e C y cl o n e S e p a r a t o r
Filter Sock
✐
Tools for cleaning:
❒ Flat blade screwdriver
❒ Vacuum or air
compressor
✐
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance activity.
CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and
outside the crystallizer.
NOTE: A cyclone separator filter sock is used in an open loop system. If the crystallizer
is configured as a closed-loop system, see Appendix C for aftercooler cleaning information.
1 Isolate the equipment from the electric power by
✐
turning the rotary disconnect switch to the OFF, or
"O" position. (See Section 1 - Introduction for complete lockout procedures.)
NOTE: The cyclone separator filter sock should be removed and
cleaned before emptying and
cleaning the cyclone separator
collection tank. As the filter
sock is removed, debris can fall
from the filter into the collection
tank.
CAUTION: Because of the size
of the particles collected by the
cyclone separator filter sock,
appropriate respiratory protection measures must be taken
before attempting to remove or
clean the filter sock. Contact
you Safety Administrator about
the procedures approved by
your company and O.S.H.A. for
specific respiratory protection
measures.
2 Remove the cyclone separator
filter sock by loosening the clamp
and lifting the filter sock from the
cyclone separator return air outlet.
5-8 l Maintenance
C l e a n i n g t h e C y cl o n e S e p a r a t o r
F i l t e r S o c k (continued)
3 Carefully turn the filter sock inside
out.
4 Clean the filter sock using an industrial vacuum cleaner. If using a vacuum, repeatedly apply the vacuum to
the turned-out surface of the filter
sock until all dust and debris are
removed. Replace the filter sock if it
is damaged, worn, or clogged after
cleaning.
CAUTION: If you use compressed
air to clean any filters or equipment, you must wear eye protection and observe all OSHA and
other safety regulations pertaining
to the use of compressed air.
5 If re-installing the original filter sock, carefully turn the filter bag outside in.
outlet.
7 Secure the filter sock to the cyclone separator by tightening the clamp around
the base of the filter and the return air outlet.
Maintenance l 5-9
5
Maintenance
6 Install the filter sock on the cyclone separator by sliding it over the return air
C l e a n i n g t h e C y cl o n e S e p a r a t o r
C o l l e c t i o n Ta n k
✐
Tools for cleaning:
❒ Container to hold contents
of the collection tank
❒ Cleaning cloth
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance
activity.
CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and
outside the crystallizer.
1 Isolate the equipment from the electric power
by turning the rotary disconnect switch to the
OFF, or "O" position. (See Section 1 - Introduction
for complete lockout procedures.)
✐
NOTE: The cyclone separator filter sock
should be removed and cleaned before
emptying and cleaning the cyclone separator collection tank. As the filter sock
is removed, debris can fall from the filter into the collection tank.
2 Release the three latches securing
the collection tank to the bottom of
the cyclone separator. The collection
tank should be held in place as the
clamps are released.
5-10 l Maintenance
C l e a n i n g t h e C y cl o n e S e p a r a t o r
C o l l e c t i o n Ta n k ( c o n t i n u e d )
3 Lower the collection tank down and away
from the cyclone separator.
4 Empty the contents of the collection tank
into a suitable container and wipe any
residue from the tank.
5 Align the collection tank with the bottom of
the cyclone separator.
6 Lift the collection tank up to meet the
bottom of the cyclone separator and secure
the latches.
5
Maintenance
Maintenance l 5-11
Cleaning the Heat Sink
There is a heat sink mounted to the back of the control panel enclosure. If this
becomes covered with dust or material you are processing, its functioning will be
effected.
Tools for cleaning:
❒ Vacuum, brush, or air
compressor
HEAT SINK
1 Using a vacuum, brush, or air compressor, clear any dust or material from
the heat sink.
CAUTION:If you use compressed air to clean any filters or equipment, you must
wear eye protection and observe all OSHA and other safety regulations pertaining to the use of compressed air.
5-12 l Maintenance
Cleaning the Agitating Hopper
(Minor Cleaning)
✐
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance
activity.
CAUTION: Hot surfaces. Always protect yourself
from hot surfaces inside and outside the crystallizer.
CAUTION: Be sure that you have disconnected and
locked out the main power supply. There is a severe
risk of personal injury should the agitator become
energized while accessing it for cleaning or repair.
Tools for cleaning:
❒ Appropriate size wrenches
or sockets and ratchets
❒ Cleaning cloth or industrial
vacuum cleaner
❒ Ladder
1 Disconnect and lockout the main power supply.
2 Remove all of the bolts securing the door to the agitating hopper.
Open the door.
3 Inspect the gasket on the
top lip of the removable
cone section. Replace the
gasket if it is damaged or
show signs of wear.
CAUTION: If you use compressed air to clean any filters or equipment, you must
wear eye protection and
observe all OSHA and other
safety regulations pertaining
to the use of compressed air.
5 Close the door and secure
it to the agitating hopper
using the bolts removed in
Step 2. Be careful not to
cross-thread the bolts.
Maintenance l 5-13
5
agitating hopper and the
agitator auger using a
cleaning cloth or
an industrial vacuum
cleaner. Make sure
to thoroughly clean the sur
faces. Pellets can lay on
top of the blades in difficult
to see areas.
Maintenance
4 Clean the inside of the
Cleaning the Agitating Hopper and
R e m o va b l e C o n e S e c t i o n ( M a j o r
Cleaning)
Tools for cleaning:
❒ Forklift, hoist, or crane
❒ Appropriate size wrenches
or sockets and ratchets
❒ Cleaning cloth or air
compressor
❒ Container suitable for
collecting removed
material
LIFTING: Danger of injury to
personnel or equipment.
✐
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance
activity.
CAUTION: Hot surfaces. Always protect yourself from
hot surfaces inside and outside the crystallizer.
CAUTION: Be sure that you have disconnected and
locked out the main power supply. There is a severe
risk of personal injury should the agitator become energized while accessing it for cleaning or repair.
1 Disconnect and lockout the main power supply.
Use proper precautions when
lifting. If the weight is
unevenly distributed when
lifted the unit may tip and
injure people or damage the
equipment. Use the eye bolts
provided to lift the crystallizer.
AGITATING HOPPER
REMOVABLE CONE
SECTION
2 Remove the process air hose from
the process air inlet tube by loosening the clamps and pulling the hose
from the inlet tube.
5-14 l Maintenance
Cleaning the Agitating Hopper and
R e m o va b l e C o n e S e c t i o n ( M a j o r
C l e a n i n g ) (continued)
3 Remove the process RTD from the
process air inlet tube by loosening the fitting and pulling the RTD from the inlet
tube.
4 Remove the power/control cable from
the rotary discharge valve and the material
level sensor by loosening the quick connector and pulling the cable from its
receptacle.
removable cone section and
rotary discharge valve with a
forklift, hoist, or crane (lifting
device).
Maintenance l 5-15
5
Maintenance
5 Support the weight of the
Cleaning the Agitating Hopper and
R e m o va b l e C o n e S e c t i o n ( M a j o r
C l e a n i n g ) (continued)
6 Release the four latches securing the removable cone section to the bottom of
the agitating hopper and, using the forklift, hoist, or crane, lower the removable
cone section and rotary discharge valve.
✐
✐
NOTE: The removable cone section and discharge valve must be lowered straight down
from the agitating hopper because the lower agitator auger section extends well below
the bottom of the agitating hopper.
NOTE: Larger crystallizer models are bolted
together and not held
with clamps.
7 Move the removable cone
section and rotary
discharge valve away from
the crystallizer once they
have been lowered enough
to clear the lower agitator
auger section. Set the
assembly on the floor.
5-16 l Maintenance
Cleaning the Agitating Hopper and
R e m o va b l e C o n e S e c t i o n ( M a j o r
C l e a n i n g ) (continued)
✐
NOTE: There are two locating pins in the rim of the removable cone section. These are used to
ensure proper alignment of the removable cone section, the screen in the cone section, and the
agitating hopper.
8 Remove the screen from
inside the removable cone
section.
9 Clean the screen and the
inside of the removable cone
section using a cleaning cloth.
Check to make sure the vents
of the screen are not clogged
with material. If any material
is lodged in the vents, use a
cleaning cloth or an industrial
vacuum cleaner, if necessary,
to dislodge the material (see
photos below).
LOCATING
PIN
Maintenance l 5-17
5
Maintenance
CAUTION: If you use compressed air to clean any filters or equipment, you must wear eye
protection and observe all OSHA and other safety regulations pertaining to the use of
compressed air.
Cleaning the Agitating Hopper and
R e m o va b l e C o n e S e c t i o n ( M a j o r
C l e a n i n g ) (continued)
10 Remove all of the bolts
securing the door to the agitating
hopper. Open the door.
11 Inspect the gasket on the top lip
of the removable cone section.
Replace the gasket if it is damaged
or show signs of wear.
12 Clean the inside of the
agitating hopper, the
agitator auger, the breaker
bars, and the lower agitator
auger section using a
cleaning cloth.
13 Close the door and
secure it to the
agitating hopper using the
bolts removed in Step 10.
14 Install the screen in the
removable cone section by
aligning the holes in the lip
of the screen with the two
locating pins on the cone
section.
LOCATING PIN
5-18 l Maintenance
Cleaning the Agitating Hopper and
R e m o va b l e C o n e S e c t i o n ( M a j o r
C l e a n i n g ) (continued)
15 Move the removable cone
section into installation
position below the agitating
hopper. Make sure that all
latches are open and out of
the way.
16 Install the removable cone
section on the agitating
hopper by slowly raising it
up until it is flush with the
bottom of the agitating
hopper.
CAUTION: Ensure that the locating pins on the removable cone section are
aligned with the holes in the bottom of the agitating hopper. If they are not
properly aligned, the removable cone section and / or the agitating hopper can
be damaged.
17 Secure the removable cone section to the agitating hopper by closing the
four latches (may be bolted on larger crystallizer models). Once it is fully
secure, relieve the pressure on the lifting device used and remove the lifting
device.
Maintenance l 5-19
5
Maintenance
LOCATING PIN
Cleaning the Agitating Hopper and
R e m o va b l e C o n e S e c t i o n ( M a j o r
C l e a n i n g ) (continued)
18 Install the power / control cable
on the rotary discharge valve
and the material level sensor by
plugging the cable into its
receptacle and tightening the
quick connector.
19 Install the process RTD in the
process air inlet tube by inserting
it into the process air inlet tube
and tightening the fitting.
20 Connect the process air
hose to the process air
inlet tube by sliding the
hose onto the inlet tube
and tightening the clamp.
5-20 l Maintenance
Cleaning the Aftercooler Coils
If you are running the crystallizer as a closed-loop system using the optional aftercooler, you need to clean the cooling coils to keep them working efficiently. See
the appendix for details.
Inspecting Hoses and Gaskets
Loose or damaged hoses and gaskets can allow moisture to seep into the crystallizer system if you are using either an open loop or closed-loop system.
1 Follow the hose routing of all the hoses and inspect all hoses, clamps,
fittings, and gaskets.
2 Tighten any loose hose clamps or fittings.
3 Replace worn or damaged hoses and gaskets.
5
Maintenance
Maintenance l 5-21
5-22 l Maintenance
SECTION
6
Tr o u b l e s h o o t i n g
Before beginning . . . . . . . . . . . . . . . . . . . . 6-2
A few words of caution
. . . . . . . . . . . . . . 6-3
How to identify the cause of a problem . . . . 6-4
Alarm indicators
Pa s s i v e a l a r m s . . . . . . . . . . . . . . . . . . . . 6 - 5
Shutdown alarms . . . . . . . . . . . . . . . . 6-10
Replacing the fuses . . . . . . . . . . . . . . . . . 6-17
Checking the heater solid state relay . . . . . 6-18
Checking or replacing the
temperature sensors . . . . . . . . . . . . . . . 6-19
R e p l a c i n g t h e a i r- t h r o t t l i n g v a l v e . . . . . . . . 6 - 2 0
Replacing the blower . . . . . . . . . . . . . . . . 6-21
Replacing the agitator gear drive . . . . . . . . 6-26
Replacing the agitator air seal . . . . . . . . . . 6-29
Replacing the agitator . . . . . . . . . . . . . . . 6-31
Replacing the agitator (Alt. method) . . . . . . 6-35
Replacing the agitator inner bearing . . . . . . 6-37
Tr o u b l e s h o o t i n g l 6 - 1
6
Troubleshooting
Replacing the lower agitator section . . . . . . 6-23
Before Beginning
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 begin to take diagnostic actions, be sure to:
❏ Diagnose cause(s) of the problem from the control panel.
1
2
3
6 - 2 l Tr o u b l e s h o o t i n g
Access the alarm screens to determine the cause of the alarm.
Address the alarm message and fix the problem.
Clear the alarm. If the alarm reappears the problem
was not fixed.
Before Beginning
(continued)
❏ Diagnose causes from inside the control panel. You can locate many problems from the
control panel.
See warnings
below. Open the
electrical enclosure
to check fuses and
heater contactors.
❏ Find the wiring and equipment diagrams that were shipped with your crystallizer. These
diagrams are the best reference for correcting a problem. The diagrams also will note any
custom features, such as special wiring or alarm capabilities, not covered in this User Guide.
A Fe w Wo r d s o f C a u t i o n
The crystallizer is equipped with numerous safety devices. Do not remove or
disable them. Improper corrective action can lead to hazardous conditions and
should never be attempted to sustain production.
WARNING: High voltage. Always stop the crystallizer, disconnect and
lock out the main power source before troubleshooting or performing
repairs.
CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside
and outside of the crystallizer.
Tr o u b l e s h o o t i n g l 6 - 3
6
Troubleshooting
WARNING: Only qualified service personnel should examine and correct
problems that require opening the crystallizer’s control panel or using
electrical wires to diagnose the cause.
How to Identify the Cause of a
Problem
Most crystallizer malfunctions are indicated by an alarm messages that appear in
the LCD display on the crystallizer’s control panel.
A problem can trigger two types of alarms:
• Shut Down: The crystallizer has automatically shut down because it detected a
serious problem that could damage your material or crystallizer.
• Passive: The crystallizer continues to operate, but warns of a problem that
could prevent correct crystallization of your material. If ignored, this problem
could lead to a condition that will shut down the crystallizer.
When the alarm is displayed:
1 Press the Mute button to silence the audible alarm and display the alarm
message.
2 Find the error message in the diagnostics tables of this Troubleshooting
section.
3 Note that pressing the Mute button a second time will clear the alarm.
6 - 4 l Tr o u b l e s h o o t i n g
Alarm Indicators
Pa s s i v e A l a r m s
Problem
Possible cause
Solution
PA1 Residence
Temperature UnsatisfactoryActual display is "Residence
Temp. Unsatisfactory".
The material discharge is set at a level
above the rated throughput of the crystallizer or the value is set incorrectly for
normal operation.
Make sure that the crystallizer is running
at the stated throughput.
This alarm indicates that the
material temperature inside of
the crystallizer hopper body
has dropped below a level that
is required to fully crystallize
the material during operation.
If this occurs in manual mode,
the discharge will shutdown,
alarm, and wait until the residence temperature reaches the
required setpoint again. The
crystallizer should continue to
operate normally except for the
discharge.
✐
NOTE: Conair cannot determine this
value. The customer will need to
determine the temperature at which
their process stabilizes then and proceed. This temperature should generally be around 200 - 250°F (93.3 121.2°C).
The residence RTD has been removed
from the crystallizing hopper.
Visually inspect the RTD to make sure
that it is still inserted into the side of the
crystallizer.
The process airflow throttling valve is
not open to a level sufficient enough to
provide adequate airflow to the system.
Check the airflow throttling valve and
adjust accordingly.
The return air filter is clogged.
Clean or replace the return air filter.
The air sock (filter bag) located on the
outlet of the cyclone filtration system is
clogged and is creating a back pressure
on the system, limiting the airflow
through the hopper.
Clean or replace the air sock (filter bag)
on the cyclone filtration system (if
equipped).
6
Troubleshooting
Tr o u b l e s h o o t i n g l 6 - 5
Alarm Indicators
(Cont.)
Pa s s i v e A l a r m s
Problem
Possible cause
Solution
PA2 Temperature
One of the solid state relays (SSRs) controlling the heater(s) has failed.
Replace the failed SSRs.
The process RTD was removed from the
air stream.
Check the process RTD and tighten if
necessary.
The process air supply hoses are loose.
Tighten all air hose connections.
Material throughput has been reduced or
stopped. As the material sets in static
mode, the temperature profile of the
material in the crystallizing hopper will
continue to rise. If this occurs, the
return air temperature of the system will
rise to a level that is insufficient for the
process blower.
If the material throughput for the system
has stopped, it may be necessary to
lower the process temperature until the
system throughput resumes again.
The airflow in the crystallizing hopper is
at a level that is higher than required to
thoroughly crystallize the material at the
throughput of the system.
Adjust the airflow throttling valve as
necessary.
The material level in the hopper is incorrect.
Make sure that the material level sensor
in the crystallizing hopper is covered. If
not, fill the hopper to the correct level.
The aftercooler coil (closed-loop system
only) may not have sufficient water flow
to remove the required amount of heat
from the system.
Adjust the water flow to the aftercooler
as necessary.
Deviation from SetpointActual display is "Process
Temp. Deviation".
This alarm indicates that the
actual temperature has
dropped below or above the
required setpoint by more than
the default value of 5°F
(2.3°C) or the user-specified
value. This only occurs after
the required process setpoint
has been reached one time.
The deviation band is set at
10° F (5.5°C) (default value).
This corresponds to a setting
of 5°F (2.3°C) above and
below setpoint.
PA3 Return Air
Unsatisfactory-Actual display
is "Return Air Unsatisfactory".
This alarm indicates that the
return air temperature has elevated to a temperature above
150°F (65.6°C). This temperature is close to the maximum
temperature that should be
returning to the blower assembly. This alarm will only be
enabled in closed loop operation.
6 - 6 l Tr o u b l e s h o o t i n g
Alarm Indicators
(Cont.)
Pa s s i v e A l a r m s
Problem
Possible cause
Solution
PA4 Low Hopper Material
Level-Actual display is "Low
Hopper Material Level".
It is possible that some problem may
have occurred with the loading system.
This may include, but not limited to, the
material pickup tube is out of the material, the material supply is empty, or the
vacuum pump could have a problem.
Check the material supply and the rest of
the vacuum system.
There may be a problem with the crystallizing hopper material level indicator.
Check the material level sensor that is in
the top of the crystallizing hopper.
It is difficult to determine what may have
caused a VFD problem. Possible causes
include, but are not limited to: an overheating problem or something may have
become lodged in the discharge.
Check the VFD fault code on the display
of the VFD. Check the supplied manual
for a reference to the code (see VFD
appendix). Fix as necessary.
The wires supplying power to the unit
may have become loose.
Check all wiring and make sure the
power cable is plugged into the discharge .
This alarm indicates that the
material level sensor has been
uncovered for more than 120
seconds after the level was initially met. If in Auto mode,
the discharge auger will disable.
PA5
Material Takeaway
Motor Protector OverloadActual displayed is "Material
Takeaway Drive Fault".
This alarm indicates that the
variable frequency drive
(VFD) fault is tripped. This
indicates that a problem has
occurred with the discharge
motor or the VFD itself.
6
Troubleshooting
Tr o u b l e s h o o t i n g l 6 - 7
Alarm Indicators
(Cont.)
Pa s s i v e A l a r m s
Problem
Possible cause
Solution
PA6 Material Takeaway
Full-Actual display is
"Material Takeaway Full".
The Gaylord or other vessel that the
crystallizer is filling is full.
Disable the discharge and empty or
change the Gaylord under the crystallizer discharge.
This alarm indicates that the
surge bin or distribution box
under the crystallizer is full.
The discharge will disable as
long as this fill sensor is covered. Once the sensor is
uncovered it will automatically restart as long as the unit is
in automatic and the residence
RTD temperature is above the
setpoint. Regardless of mode,
the discharge will stop and
wait for the material level to
clear before restarting the discharge. This alarm will be
displayed if the sensor is covered for 120 seconds or
longer.
The process that the crystallizer is feeding is stopped.
Make sure that the process the crystallizer is feeding is still operating.
There is a problem with the loading system that is removing material from the
crystallizer.
Check the material takeaway loading
system or process to ensure that there
are no problems.
There is a problem with the material
takeaway level sensor.
Check the material discharge sensor that
resides below the discharge valve and
make sure that it is plugged in and
adjusted correctly.
PA7 Material Surge Bin
Level Low (Optional)Actual display is "Material
Surge Bin Level Low".
The crystallizer may be not be running
at a rate sufficient to keep up with the
required material throughput level.
Check the rate of the discharge and
adjust accordingly.
It is possible that the crystallizer discharge has been inadvertently disabled.
Make sure the discharge is enabled.
This alarm indicates that the
device being filled from the
material discharge is low in
level. This could cause the
process to be starved. The
alarm will occur 120 seconds
after the level is initially met
in the surge bin.
6 - 8 l Tr o u b l e s h o o t i n g
✐
NOTE: This alarm will occur, but the takeaway will not turn off if the optional low level
sensor is present but not covered.
Alarm Indicators
(Cont.)
Pa s s i v e A l a r m s
Problem
Possible cause
Solution
PA8 Batch Timer
Complete-Actual display is
"Batch Timer Complete".
The batch that was processing is completed.
None. The crystallizer is ready to
process another batch.
The connection in the electrical enclosure for the process RTD is loose.
The RTD is not installed into the receptacle on the top of the control panel enclosure.
Remove power from the system and
check all wiring connections for the
RTD in question.
Make sure the RTD is installed into the
receptacle in the top of the control panel
enclosure.
The RTD is faulty.
Replace the RTD.
see PA9 above.
see PA9 above.
PA11
Gaylord being filled
is full -Actual display is
"Gaylord is full".
The gaylord being filled is full.
Acknowledge the alarm and restart the
discharge valve after the gaylord is
replaced.
This alarm indicates that the
gaylord being filled under the
crystallizer is filled. Once the
alarm is muted, the process
will have to be manually
restored.
There is a problem with the material take
away level sensor or it is adjusted incorrectly.
Check to make sure the sensor is
plugged in and adjusted properly.
This alarm indicates that the
batch timer has reached the
user-defined setpoint. When
the MUTE button is pressed,
the timer will be reset and the
timer will disable until it is set
again. No other steps can be
taken.
PA9 AUX Temp #1 RTD
Malfunction-Actual display is
"Temp 1 RTD Integrity".
This alarm indicates that the
process temperature RTD is
not connected to the control or
that the RTD is faulty.
PA10
AUX Temp #2 RTD
Malfunction-Actual display is
"Temp 1 RTD Integrity".
This alarm is the same as PA9
but #2 instead of #1.
6
Troubleshooting
Tr o u b l e s h o o t i n g l 6 - 9
Alarm Indicators
(Cont.)
Shutdown Alarms
Problem
Possible cause
Solution
AL1
The emergency stop button has been
pressed.
Determine why the button was pressed,
release the button, and restart the unit.
AL2 Check Process
Blower Overload-Actual display is "Process Blower
Overload Tripped".
The process blower current draw has
exceeded the full load amperage rating
of the motor.
Press the mute button and wait about 15
minutes with the power on for the overload to automatically reset. If the alarm
occurs again, have a qualified electrician
monitor the current draw of the motor.
This alarm will cause an
immediate shutdown and indicates that the process blower
overload is tripped.
The process blower has mechanically
failed or is unable to rotate freely.
Remove the power from the unit and
check the blower for mechanical failure
and free rotation. After inspecting, wait
3 to 15 minutes with power on to the
crystallizer to allow the overload to
reset. Once reset, attempt to restart the
unit.
The process blower has failed electrically.
Remove power from the unit and make
sure that no wires have come unhooked
or have shorted. Fix the wiring as necessary. Wait 3 to 15 minutes, or until the
overload resets, and then restart the unit.
The overload is set incorrectly.
With the power removed, check the setting on the overload. It should be 125%
of the maximum current draw on the
nameplate of the unit. Adjust as necessary, wait 3 to 15 minutes for the overload to reset, and then restart the unit.
Emergency Stop
Button is Pressed-Actual display is "Check Emergency
Stop Push Button".
This alarm indicates that the
Emergency Stop Button was
pressed.
6 - 1 0 l Tr o u b l e s h o o t i n g
Alarm Indicators
Shutdown Alarms
Solution
AL3 Check Agitator
Motor Overload-Actual display is "Agitator Motor
Overload Tripped".
The agitator motor current draw has
exceeded the full load amperage rating of
the motor.
Press the mute button and wait about 15
minutes with the power on for the overload to automatically reset. If the alarm
occurs again, have a qualified electrician
monitor the current draw of the motor.
This alarm will cause an
immediate shutdown and indicates that the agitator motor
overload is tripped.
The agitator may be experiencing higher
than normal resistance in the material.
Make sure that the temperature is set at
the correct value to sufficiently crystallize the material. If the temperature is
too high or low, the material may be
agglomerating more than normal.
The agitator motor has failed electrically.
Remove power from the unit and make
sure that no wires have come unhooked
or have shorted. Fix the wiring as necessary. Wait 3 to 15 minutes, or until the
overload resets, and then restart the unit.
There is a problem with the double
reduction gearbox.
Visually inspect the double reduction
gearbox and make sure that there are no
major oil leaks occurring anywhere on
the gearbox. Remove the oil fill plug
and make sure that the oil level is just to
bottom of this hole. Additionally, make
sure that there are no obstructions on
any of the breather holes towards the top
of the gearbox.
The overload is set incorrectly.
With the power removed, check the setting on the overload. It should be 125%
of the maximum current draw on the
nameplate of the unit. Adjust as necessary, wait 3 to 15 minutes for the overload to reset, and then restart the unit.
Tr o u b l e s h o o t i n g l 6 - 1 1
6
Possible cause
Troubleshooting
Problem
Alarm Indicators
(Cont.)
Shutdown Alarms
Problem
Possible cause
Solution
AL4 Process Heater High
Temperature Limit-Actual
display is "Process Heater
High Temp. Switch".
There may be an airflow blockage or a
loose hose in the system.
Make sure that there are no crimps in
any of the hoses feeding the heater tube,
make sure all of the hoses are in position
and tight, and make sure that the airflow
throttling valve is open to the blower.
The isolation contactor may have failed
in the closed position.
Replace the isolation contactor.
The solid state relays may have failed.
Replace the failed solid state relays.
The connection in the electrical enclosure for the process RTD is loose.
Remove power from the system and
check all the wiring connections for the
RTD in question.
The RTD is not installed into the receptacle on the top of the control panel
enclosure.
Make sure the RTD is installed into the
receptacle in the top of the control panel
enclosure.
The RTD is faulty.
Replace the RTD.
This alarm indicates that the
process heater internal safety
snap switch is open, which
indicates an over temperature
condition.
AL5 Delivery Air RTD
Malfunction-Actual display is
"Process Temp. RTD
Malfunction".
This alarm indicates that the
process temperature RTD is
not connected to the control or
that the RTD is faulty.
6 - 1 2 l Tr o u b l e s h o o t i n g
Alarm Indicators
(Cont.)
Shutdown Alarms
Problem
Possible cause
Solution
AL6 Return Air
Temperature Exceeded
Limit-Actual display is
"Return Air Temp. High
Limit".
The material throughput has been
reduced or stopped. As the material sets
in static mode, the temperature profile of
the material in the crystallizing hopper
will continue to rise. If this occurs, the
return air temperature of the system will
rise to a level that is insufficient for the
process blower (closed-loop system
only).
If the material throughput for the system
has stopped, it may be necessary to
lower the process temperature until the
system throughput resumes again.
The airflow in the crystallizing hopper is
at a level that is higher than required to
thoroughly crystallize the material at the
throughput of the system.
Adjust the airflow throttling valve as
necessary.
Check the material level in the hopper.
Make sure that the material level sensor
in the crystallizing hopper is covered. If
not, fill the crystallizer to the correct
level.
The aftercooler coil may not have sufficient water flow to remove the required
amount of heat from the system (closedloop system only).
Adjust the water flow to the aftercooler
as necessary.
This alarm indicates that the
return air has elevated above
the standard default value of
180°F (82.2°C), which is too
high for normal operation.
6
Troubleshooting
Tr o u b l e s h o o t i n g l 6 - 1 3
Alarm Indicators
(Cont.)
Shutdown Alarms
Problem
Possible cause
Solution
AL7
The connection in the electrical enclosure for the process RTD is loose.
Remove power from the system and
check all the wiring connections for the
RTD in question.
The RTD is not installed into the plug on
the top of the control panel enclosure.
Make sure that the RTD is installed into
the receptacle in the top of the control
panel enclosure.
The RTD is faulty.
Replace the RTD.
AL8 Process Temperature
Loop Break-Actual display is
"Process Temp. Loop Break".
The process RTD may not be directly
centered in the air stream or has fallen
out of the air stream.
Check the process air RTD positioning
and tightness and adjust or tighten if
necessary.
This alarm indicates that the
temperature is either low or
high (outside of the deviation
band). This indicates that the
temperature is not changing
2°F (0.9°C) towards the
process setpoint every 20 seconds.
The process heater element, fuses, or
SSR may have failed.
Remove power from the unit and check
the resistance of the heater fuses and the
heater element with an ohmmeter.
Replace the heater fuse(s), heater element, or SSR if any of these have failed.
The airlines feeding the crystallizer may
be restricted or loose.
Straighten or fix any crimps in the hose
and tighten the clamps as necessary.
Airflow is flowing in the wrong direction.
Reverse any two main power wires and
check the direction of the air flow. See
Return Air RTD
Malfunction-Actual display is
"Return Air RTD
Malfunction".
This alarm indicates that the
return air temperature RTD is
not connected to the control or
the RTD is faulty. This alarm
is only active when the option
is installed.
Section 3 - Installation for more
information.)
6 - 1 4 l Tr o u b l e s h o o t i n g
Alarm Indicators
(Cont.)
Shutdown Alarms
Solution
AL9 Residence
Temperature RTD
Malfunction-Actual display is
"Residence Temp RTD
Malfunction".
The connection in the control panel
enclosure for the process RTD is loose.
Remove power from the system and
check all the wiring connections for the
RTD in question.
The RTD is not installed into the plug on
the top of the control panel enclosure.
Make sure that the RTD is installed into
the receptacle in the top of the control
panel enclosure.
The RTD is faulty.
Replace the RTD.
The connection in the control panel
enclosure for the process RTD is loose.
Remove power from the system and
check all the wiring connections for the
RTD in question.
The RTD is not installed into the plug on
the top of the control panel enclosure.
Make sure that the RTD is installed into
the receptacle in the top of the control
panel enclosure.
The RTD is faulty.
Replace the RTD.
The process airlines are restricted or
loose.
Check for any airflow blockages in the
process line between the heater outlet
and the crystallizer inlet. Make sure that
the airflow throttling valve on the crystallizer is open to provide a sufficient
amount of airflow to the system.
The process RTD has fallen out of the air
stream.
Check the process air RTD and tighten
or adjust as necessary.
This alarm indicates that the
residence temperature RTD is
not connected to the control or
that the RTD is faulty.
AL10
Process Protection
RTD Malfunction -Actual
display is "Process Prot. RTD
Malfunction".
This alarm indicates that the
process protection RTD is not
connected to the control or that
the RTD is faulty.
AL 11
Process Protection
Temperature Differential Actual display is "Process
Prot. Temp Deviation".
This alarm indicates that the
process protection temperature
is at a temperature of 150°F
(65.5°C) higher than the actual
air temperature entering the
crystallizing hopper for 30 seconds. This temperature is the
actual temperature at the outlet
of the heater tube.
Tr o u b l e s h o o t i n g l 6 - 1 5
6
Possible cause
Troubleshooting
Problem
Alarm Indicators
(Cont.)
Shutdown Alarms
Problem
Possible cause
Solution
AL12
Process Protection
Over Temperature-Actual
display is "Process Prot.
Temp. High Limit".
The process protection RTD is not
installed correctly.
Make sure that the process protection
RTD is installed correctly and that the
RTD is in the hottest part of the air
stream (in the center of the tube).
This alarm indicates that the
process heater has reached a
temperature of 600°F
(315.5°C), which is more than
the maximum allowed at the
RTD.
The airlines are restricted, are loose, or
have come unhooked.
Fix any restricted or kinked process airlines and tighten the clamps as necessary.
The airflow throttling valve is closed or
adjusted at a level not suitable for correct operation.
Check the airflow throttling valve and
adjust accordingly.
AL13
The safety switches on the door are not
positioned within 0.375 in. (9.35 mm) of
one another.
Reposition the safety switches as necessary.
The hopper clean out door is open
Close the hopper clean out door.
The removable cone section is not in
position on the hopper.
Correctly position / install the removable
cone section.
If everything is on position, it is possible
that the fuseable link in the actuator part
of the door switch has failed. This fuseable link insures that the device will not
weld shut and cause user injury.
Check the safety switches and fuseable
links more closely and replace if necessary.
AL14
Process Heater
Percentage Output 95%
-Actual display is "Process
Control = or > than 95%".
The process RTD is not located in the
proper position to sense the correct air
temperature or may have been inadvertently removed from the air stream.
Check the position of the process RTD
and adjust as necessary.
This alarm indicates that the
process heater(s) have been
locked at 95% or better for
120 seconds or more. This
will cause an immediate shutdown.
The process air hose feeding the hopper
is removed or unhooked.
Make sure the process air hose is hooked
to the hopper air inlet.
The airflow throttling valve on the blower is shut or cut back too far for correct
operation.
Adjust the airflow throttling valve as
necessary.
The process blower is providing too
much airflow.
Adjust the airflow throttling valve as
necessary.
Check Hopper
Door Safety Switch or Cone
Safety Switch-Actual display
is "Safety Switch Open".
This alarm will cause an
immediate shutdown and indicates that either the hopper
clean out door is open or the
cone section is removed from
the hopper.
6 - 1 6 l Tr o u b l e s h o o t i n g
Replacing the Fuses
1 Disconnect and lockout the main power supply.
2 Open the control panel door.
3 Locate or identify the suspected faulty fuse.
4 Check the fuse. If necessary, pull the fuse out and replace it with a fuse of the
same type and rating.
Fuse Blocks
To locate the appropriate fuse
and replacement part, refer to
the wiring diagrams that
came with your crystallizer.
IMPORTANT: Always refer
to the wiring diagrams that
came with your crystallizer
to locate specific electrical
components. Illustrations in
the User Guide are intended
to be representative only.
6
Troubleshooting
Tr o u b l e s h o o t i n g l 6 - 1 7
Checking the Heater Solid State
Relay
1 Disconnect and lockout the main power supply.
2 Open the control panel door.
3 Locate the process heater solid state relay. Refer to the wiring diagrams that
came with your dryer.
4 Turn power on to the machine.
IMPORTANT: Always refer
to the wiring diagrams that
came with your crystallizer
to locate specific electrical
components. Illustrations in
the User Guide are intended
to be representative only.
✐
NOTE: Measure voltage using
a voltmeter across the two
high voltage connections of
each relay. (Shown here circled in red.)
6 - 1 8 l Tr o u b l e s h o o t i n g
5 Start the dryer.
6 Measure voltage across the high voltage connections using a voltmeter.
When relay is energized, as indicated by the LED (green) voltage should be
read 0 (zero). When relay is de-energized, LED off, full voltage should be
measured across the relay. When relay is off, if voltage reads zero, relay is
bad and needs replaced. Repeat this procedure for each relay.
Process heater
solid state relays
If ohms equal zero or infinity,
replace the relays.
Checking or Replacing the
Te m p e r a t u r e S e n s o r s
The crystallizer uses RTD sensors to monitor the process air and residence temperatures. In addition, optional RTD sensors can be ordered with the system to monitor temperatures at other locations within the system.
RESIDENCE RTD
PROBE
IMPORTANT: Always refer
to the wiring diagrams
that came with your crystallizer to locate specific
electrical components.
Illustrations in the User
Guide are intended to be
representative only.
PROCESS RTD
PROBE
To check or replace an RTD sensor:
1 Disconnect and lockout the main power supply.
2 Locate the RTD sensors.
3 Check the sensor positions and conditions. Temperature readings will be
4 To check with ohm meter, measure the resistance across the RTD. The
resistance should be approximately 110 ohms at room temperature.
5 Replace the sensor, if necessary.
Tr o u b l e s h o o t i n g l 6 - 1 9
6
Troubleshooting
incorrect, if the sensors are touching the wall of an air hose or pipe or if the sensor or wiring is damaged. The tip of the sensor should be centered within the air
hose or pipe. Sensor wires should be attached to the appropriate connection
points in the crystallizer’s control panel or micro-processor board.
R e p l a c i n g t h e A i r- T h r o t t l i n g Va l v e
(CR4-CR10 models)
✐
Tools for replacement:
❒ Appropriate size wrenches
or sockets and ratchets
❒ Flat blade screwdriver
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance
activity.
CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the crystallizer.
1 Disconnect and lockout the main power
supply.
2 Remove the hose connecting the airthrottling valve to the heater by loosening
the hose clamp and pulling the
hose from air-throttling valve
outlet.
3 Free the air throttling valve
from the mounting bracket by
removing the four nuts and
bolts.
4 Inspect the seals and replace
if necessary.
AIR-THROTTLING VALVE
5 Install the new air-throttling valve by aligning it with the holes in the
mounting bracket and securing it using the original hardware.
6 Connect the hose from the bottom of the heater to the air-throttling valve
outlet and secure it by tightening the hose clamp.
✐
6 - 2 0 l Tr o u b l e s h o o t i n g
NOTE: On Crystallizer models CR2, CR42, CR85, and
CR135 - The damper valve is integral in the outlet of
the blower and should not need servicing.
Replacing the Blower
✐
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance
activity.
CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and
outside the crystallizer.
Tools for replacement:
❒ Appropriate size wrenches
or sockets and ratchets
❒ Flat blade screwdriver
1 Disconnect and lockout the main power
supply.
2 Reference the wiring diagram and / or trace the wires
from the blower into the control panel enclosure. Disconnect the wires from the blower
junction box.
3 Remove the hose connecting
the process air filter to the
blower air inlet by loosening
the hose clamp and pulling
the hose from blower air inlet.
by loosening the hose clamp and pulling the hose from blower air outlet.
5 Free the blower from its mounting bracket by removing the four nuts and
bolts.
6 Remove the manifolds/hose adapters from the blower and reinstall them on
the new blower.
Tr o u b l e s h o o t i n g l 6 - 2 1
6
Troubleshooting
4 Remove the hose connecting the blower air outlet to the air-throttling valve
Replacing the Blower
(continued)
7 Install the new blower by aligning it with the holes in the mounting bracket
and securing it using the original hardware removed in Step 5.
8 Connect the hose from the bottom of air-throttling valve to the blower air
outlet and secure it by tightening the hose clamp.
9 Connect the hose from the process air filter to the blower air inlet and
secure it by tightening the hose clamp.
CAUTION:Always refer to the wiring diagrams that came with your crystallizer
before making electrical connections. Electrical connections should be made
only by qualified personnel.
10 Reference the wiring diagram to re-attach the blower wires within the
junction box of the new blower.
11 Make sure the blower fuses are not blown before trying the new blower.
6 - 2 2 l Tr o u b l e s h o o t i n g
Replacing the Lower Agitator
Section
✐
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance
activity.
CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the crystallizer.
1 Disconnect and lockout the main power
supply.
Tools for replacement:
❒ Forklift, hoist, or crane
❒ Appropriate size wrenches
or sockets and ratchets
❒ Container suitable for
collecting removed material
❒ Block of wood
❒ Mallet or hammer
2 Remove the removable cone
section and discharge valve by
referring to Section 5, “Cleaning
the Agitating Hopper and
Removeable Cone”and following
Steps 2 through 7.
3 Break the lower agitator
Tr o u b l e s h o o t i n g l 6 - 2 3
6
Troubleshooting
auger section loose from the
upper agitator auger by using
a block of wood and hammer
or mallet to drive the lower
agitator auger section in a
clockwise direction.
Replacing the Lower Agitator
S e c t i o n (continued)
4 Remove the lower agitator section
by turning it clockwise by hand until
it is unthreaded from the upper
agitator.
5 Coat the male threads on the new
lower agitator section with antiseizing compound to lubricate and
protect the threads.
6 Install the new lower agitator section by aligning it with the threads inside of
the upper agitator and turning it counter-clockwise by hand until it is
completely threaded into the upper agitator.
6 - 2 4 l Tr o u b l e s h o o t i n g
Replacing the Lower Agitator Section
(continued)
7 Tighten the lower agitator section by using a block of wood and a hammer or mallet to
"bump" the auger section in a counter-clockwise direction.
8 Install the removable cone section
and discharge valve by referring to
Section 5, “Cleaning the Agitating
Hopper and Removeable Cone”and following Steps 13 through 20.
6
Troubleshooting
Tr o u b l e s h o o t i n g l 6 - 2 5
Replacing the Agitator Gear Drive
✐
Tools for replacement:
❒ Forklift, hoist, or crane
❒ Appropriate size wrenches
or sockets and ratchets
❒ Appropriate size Allen
wrench
❒ Ladder
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance
activity.
CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the crystallizer.
1 Disconnect and lockout the main power
supply.
CAUTION: Always refer to
the wiring diagrams that
came with your crystallizer
before making electrical
connections. Electrical connections should be made
only by qualified personnel.
2 Disconnect the power / control
cable at the agitator gear
drive by disconnecting the
wires on the motor junction
box.
6 - 2 6 l Tr o u b l e s h o o t i n g
Replacing the Agitator Gear Drive
(continued)
3 Loosen the two setscrews in the agitator gear drive cap that secure the key in
the agitator shaft.
4 Remove the main bolt that
MAIN BOLT
extends through the top of the
gear drive into the agitator
shaft.
✐
SETSCREW
(second setscrew
not shown in photograph)
NOTE: As the bolt is loosened,
the agitator shaft will begin to
slide down out of the gear
drive.
5 Remove the key from the
keyway in the interface of the
agitator shaft and gear drive.
6 Free the agitator gear drive by
removing the four bolts that
secure it to the mounting bracket.
✐
BOLTS
7 Remove the agitator gear drive using a hoist or crane to lift it straight up from
the mounting bracket and agitator shaft.
8 Lift the new agitator gear drive above the agitator shaft using a hoist or
crane and align it with the shaft.
9 Carefully lower the agitator drive gear on to the agitator shaft and align
the holes in the gear drive with the holes in the mounting bracket.
Tr o u b l e s h o o t i n g l 6 - 2 7
6
Troubleshooting
NOTE: If the air seal on the agitator
shaft is to be replaced, the agitator
gear drive can be removed complete with the mounting bracket by
removing the bolts that secure the
mounting bracket to the hopper lid.
(See "Replacing the Air Seal" on
page 6-31.)
Replacing the Agitator Gear Drive
(continued)
10 Secure the agitator gear drive to the mounting bracket by installing the
original bolts removed in Step 7.
11 Align the keyway on the agitator shaft with the keyway in the gear drive
and insert the key removed in Step 5.
12 Install the gear drive and start the main bolt in the agitator shaft.
13 Fully tighten the main bolt in the gear drive.
✐
NOTE: As the bolt is being tightened, the agitator shaft will be pulled up until seated
against the gear drive cap.
14 Fully tighten the two
MAIN BOLT
setscrews in the agitator gear
drive cap that secure the
keys in the agitator shaft.
CAUTION: Always refer to the wiring
diagrams that came with your crystallizer before making electrical connections. Electrical connections
should be made only by qualified
personnel.
SETSCREW
(second setscrew
not shown in photograph)
15 Connect the power / control cable at the agitator gear drive by connecting
the wires into the junction box of the new motor.
6 - 2 8 l Tr o u b l e s h o o t i n g
Replacing the Agitator Air Seal
✐
NOTE: Turn off the crystallizer and allow it to
cool before attempting any maintenance activity.
CAUTION: Hot surfaces. Always protect
yourself from hot surfaces inside and outside the crystallizer.
Tools for replacement:
❒ Appropriate size wrenches
or sockets and ratchets
❒ Appropriate size Allen
wrench
❒ Ladder
1 Disconnect and lockout the main power
supply.
2 Remove bolts from agitator seal holder.
3 Remove the two covers from the air seal
holder.
4 Remove split air seal from air seal holder. Note the top and bottom
of the seal.
6
Troubleshooting
Tr o u b l e s h o o t i n g l 6 - 2 9
Replacing the Agitator Air Seal
(continued)
5 Reinstall using
reverse of removal.
6 - 3 0 l Tr o u b l e s h o o t i n g
Replacing the Agitator
There are two different methods for replacing the agitator depending on the head
room clearance available and lifting capabilities available in your application. The
following method is for lifting the agitator out the top of the crystallizer (this
method is not for low clearance situations. Use the alternative method listed on
later pages for low clearance removal.)
✐
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance
activity.
CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the crystallizer.
Tools for replacement:
❒ Hoist or crane
❒ Appropriate size wrenches
or sockets and ratchets
❒ Appropriate size Allen
wrench
❒ Hammer
❒ Drift
❒ Ladder
1 Disconnect and lockout the main power
supply.
2 Remove the removable cone section and discharge valve by referring to Section 5, “Cleaning .
the Agitating Hopper and Removeable Cone” and
following Steps 2 through 7.
3 Remove the lower agitator auger section by
referring to Section 6, “Replacing the Lower
Agitator Auger” and following Steps 3 and 4.
drive by referring to Section 6, “Replacing the
Agitator Gear Drive” and following Steps 2
through 8.
5 Loosen the breaker bars in the agitating hopper by removing the bolts that
secure the breaker bars to the hopper.
Tr o u b l e s h o o t i n g l 6 - 3 1
6
Troubleshooting
4 Remove the agitator gear
Replacing the Agitator
(continued)
6 Drive the breaker bars from their mounting holes using a hammer and
suitable drift.
✐
NOTE: Be careful not to harm
the female threads in the
end of the breaker bars.
7 Fully remove the breaker
bars from the hopper by
pulling them out from the
opposite end of the hopper.
WARNING: The agitating hopper
lid will be removed during the
next steps. Since various types of
loaders or delivery systems can
be mounted to the lid for use with
the crystallizer, it is the RESPONSIBILITY OF THE USER to determine if the loader or delivery system must be removed before the
agitating hopper lid can be safely
removed.
8 Remove the loader or delivery
system from the agitating hopper
lid if determined to be necessary
(see WARNING above).
9 Free the agitating hopper lid by
removing the bolts securing it to
the hopper.
10 Remove the agitating hopper
lid using a suitable hoist or crane.
6 - 3 2 l Tr o u b l e s h o o t i n g
Replacing the Agitator
(continued)
11 Remove the agitator by lifting it straight up out of the agitating hopper
using a suitable hoist of crane.
CAUTION: As the agitator is being lifted from the hopper, care should be taken
to ensure that the residence RTD and hopper fill level sensor are not damaged.
This can be avoided by manipulating the agitator position as it is pulled up and
away from the hopper.
12 Examine the agitator
inner bearing located in the
bearing support, mid-way in
the agitating hopper. If the
bearing shows signs of wear,
see Section 6, “Replacing the
Agitator Auger Inner
Bearing” for instructions.
13 Install the new agitator by lifting it above the agitating hopper, aligning it
with the hopper, then slowly lowering it into the hopper. Make sure that the
agitator auger properly aligns with and completely seats in main bearing in the
bottom of the hopper.
CAUTION: As the agitator is being lowered into the hopper, care should be taken
to ensure that the hopper fill level sensor and residence RTD are not damaged.
This can be avoided by manipulating the agitator position as it is lowered into
the hopper.
any damage is detected, replace the gasket.
WARNING: The agitating hopper lid will be installed during the next steps.
Since various types of loaders or delivery systems can be mounted to the lid for
use with the crystallizer, it is the RESPONSIBILITY OF THE USER to determine if
the loader or delivery system must be removed before the agitating hopper lid
can be safely installed.
Tr o u b l e s h o o t i n g l 6 - 3 3
6
Troubleshooting
14 Examine the condition of the gasket at the top of the agitating hopper. If
Replacing the Agitator
(continued)
15 Align the agitating hopper lid with the hopper then lower it into place using
a suitable hoist or crane.
16 Secure the agitating hopper lid by installing the bolts removed in Step 9.
17 If the loader or delivery system was removed from the agitating hopper
lid, reinstall it at this time (see WARNING on previous page).
18 Slide the breaker bars into the side of the hopper. Make sure they align
properly with holes in the opposite side of the hopper. Once properly aligned,
they can be driven into place if necessary.
19 Secure the breaker bars using the original hardware removed in Step 5. Do
not over-tighten the bolts securing the breaker bars. Equipment damage can
occur.
20 Install the agitator gear drive by referring to Section 6, “Replacing the
Agitator Gear Drive” and following Steps 8 through 16.
21 Install the lower agitator auger section by referring to Section 6, “Replacing
the Lower Agitator Section” and following Steps 5 and 6.
22 Install the removable cone section and discharge valve by referring to
Section 5, “Cleaning the Agitating Hopper and Removeable Cone”and following Steps 13 through 20.
6 - 3 4 l Tr o u b l e s h o o t i n g
Replacing the Agitator (Alternative
Method)
There are two different methods for replacing the agitator depending on the head
room clearance available and lifting capabilities available in your application. The
following method is for lowering the agitator out the bottom of the crystallizer
This method is for low overhead clearance situations.
✐
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance
activity.
CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the crystallizer.
Tools for replacement:
❒ Hoist or crane
❒ Appropriate size wrenches
or sockets and ratchets
❒ Appropriate size Allen
wrench
❒ Hammer
❒ Drift
❒ Ladder
❒ Cable
1 Disconnect and lockout the main power
supply.
2 Remove the removable cone section and discharge valve by referring to
Section 5, “Cleaning the Agitating Hopper and Removeable Cone” and following Steps 2 through 7.
3 Remove the lower agitator
4 Loosen the breaker bars in
the agitating hopper by
removing the bolts that secure
the breaker bars to the hopper.
Tr o u b l e s h o o t i n g l 6 - 3 5
6
Troubleshooting
auger section by referring to
Section 6, “Replacing the
Lower Agitator Auger
Section” and following Steps
3 and 4.
Replacing the Agitator Alternative
M e t h o d ) (continued)
5 Drive the breaker bars
from their mounting holes
using a hammer and
suitable drift.
✐
NOTE: Be careful not to harm
the female threads in the end
of the breaker bars.
6 Fully remove the breaker
bars from the hopper by
pulling them out from the
opposite end of the hopper.
7 Referring to Section 6, “Replacing
Agitator Gear Drive” and perform
steps 3-5.
8 Install an eye bolt or similar into the
location where the main bolt was
removed. Hook a cable to similar
onto the eye bolt.
9 Remove the inner support. Refer to
Section 6, “Replacing the Agitator
Inner Support Bearing” steps
4-5.
10 Lower shaft through the
bottom of the crystallizer.
Carefully rotate the agitator to
miss sensors and RTD’s while
lowering.
6 - 3 6 l Tr o u b l e s h o o t i n g
Replacing the Agitator Inner
Support Bearing
✐
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance
activity.
CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and outside the crystallizer.
1 Disconnect and lockout the main power
Tools for replacement:
❒ Appropriate size wrenches
or sockets and ratchets
❒ Appropriate size Allen
wrench
❒ Hammer
❒ Ladder
supply.
2 Remove the removable cone section and discharge valve by referring to
Section 5, “Cleaning the Agitating Hopper and Removeable Cone (Major
Cleaning)” and following Steps 2 through 7.
3 Remove the lower agitator auger section by referring to Section 6,
“Replacing the Lower Agitator Auger Section” and following Steps
3 and 4.
4 Remove bolts installed above the lower bearing support.
6
Troubleshooting
Tr o u b l e s h o o t i n g l 6 - 3 7
Replacing the Agitator Inner
S u p p o r t B e a r i n g (continued)
5 Lift bearing support upward and turn clockwise (looking bottom up) and
remove.
6 Remove bearing and
replace.
7 Installation is reverse of
removal. Make sure to use
Loctite and fully tighten the
bolts above the inner bearing
support. (Removed in step 4.)
6 - 3 8 l Tr o u b l e s h o o t i n g
We ’ r e H e r e t o H e l p
Conair has made the largest investment in customer support in the plastics industry. Our
service experts are available to help with any problem you might have installing and operating your equipment. Your Conair sales representative also can help analyze the nature of
your problem, assuring that it did not result from misapplication or improper use.
How to Contact Customer Service
To contact Customer Service personnel, call:
✐
Additional manuals and prints for
your Conair equipment may be
ordered through the Customer
Service or Parts Department for a
nominal fee. Most manuals can
be downloaded free of charge
from the product section of the
Conair website.
www.conairgroup.com
NOTE: Normal operating hours are 8:00 am - 5:00 pm. After hours emergency
service is available at the same phone number.
From outside the United States, call: 814-437-6861
You can commission Conair service personnel to provide on-site service by contacting the Customer Service Department. Standard rates include an on-site hourly
rate, with a one-day minimum plus expenses.
B e f o r e Yo u C a l l . . .
If you do have a problem, please complete the following checklist before
calling Conair:
❒ Make sure you have all model, control type from the serial tag, and parts list numbers
for your particular equipment. Service personnel will need this information to assist you.
❒ Make sure power is supplied to the equipment.
❒ Make sure that all connectors and wires within and between control systems and related
components have been installed correctly.
❒ Check the troubleshooting guide of this manual for a solution.
❒ Thoroughly examine the instruction manual(s) for associated equipment, especially controls. Each manual may have its own troubleshooting guide to help you.
❒ Check that the equipment has been operated as described in this manual.
❒ Check accompanying schematic drawings for information on special considerations.
Tr o u b l e s h o o t i n g l 6 - 3 9
Equipment Guarantee
Conair guarantees the machinery and equipment on this order, for a period as
defined in the quotation from date of shipment, against defects in material and
workmanship under the normal use and service for which it was recommended
(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.
Pe r f o r m a n c e Wa r r a n t y
Conair warrants that this equipment will perform at or above the ratings stated in
specific quotations covering the equipment or as detailed in engineering specifications, provided the equipment is applied, installed, operated and maintained in the
recommended manner as outlined in our quotation or specifications.
Should performance not meet warranted levels, Conair at its discretion will
exercise one of the following options:
• Inspect the equipment and perform alterations or adjustments to satisfy
performance claims. (Charges for such inspections and corrections will be
waived unless failure to meet warranty is due to misapplication, improper
installation, poor maintenance practices or improper operation.)
• Replace the original equipment with other Conair equipment that will meet
original performance claims at no extra cost to the customer.
• Refund the invoiced cost to the customer. Credit is subject to prior notice by the
customer at which time a Return Goods Authorization Number (RGA) will be
issued by Conair’s Service Department. Returned equipment must be well crated
and in proper operating condition, including all parts. Returns must be prepaid.
Purchaser must notify Conair in writing of any claim and provide a customer receipt
and other evidence that a claim is being made.
Wa r r a n t y L i m i t a t i o n s
Except for the Equipment Guarantee and Performance Warranty stated
above, Conair disclaims all other warranties with respect to the equipment,
express or implied, arising by operation of law, course of dealing, usage of
trade or otherwise, including but not limited to the implied warranties of
merchantability and fitness for a particular purpose.
A-2 l Appendix
Appendix l B-1
Replacing the Heater
✐
Tools for replacement:
❒ Appropriate size wrenches
or sockets and ratchets
❒ Flat blade screwdriver
❒ Utility knife
(smaller models)
NOTE: Turn off the crystallizer and allow it to cool before attempting any maintenance
activity.
CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside and
outside the crystallizer.
1 Isolate the equipment from the electric
power by turning the rotary disconnect
switch to the OFF, or "O" position. See
Section 1 - Introduction for complete
lockout procedures.
SHEET METAL BOLT
2 Loosen the heater cover by removing
the two sheet metal bolts located near
the top left and right sides of the heater
cover.
3 Remove the heater cover by tilting
the top away from the heater and
then lifting it out of the slots in the
heater mounting bracket.
C-1 l Appendix
Replacing the Heater
els)
4
(smaller mod-
(continued)
Remove and save the heater RTD and fitting. They
will be installed in the new heater.
5 Remove the insulation
from the heater tube by
cutting the insulation with
a utility knife line from
top to bottom. Spread the
insulation apart and slide
it off the heater. Be
careful not to destroy the
insulation, it will be
reinstalled later in this
process.
6 Remove the process air hose from the top of the heater by
loosening the hose clamp and pulling the hose off of the
heater outlet.
7 Remove the air inlet
hose from the bottom
of the heater by
loosening the hose
clamp and pulling the
hose off of the
heater inlet.
Appendix l C-2
Replacing the Heater
(smaller models)
(continued)
8 Reference the wiring diagram and / or trace the wires from the heater into
the control panel enclosure. Disconnect the wires from the relays and terminal
strips
9 Loosen the heater tube by loosening the two acorn nuts that secure the "U"
bolt on the heater.
10 Remove the heater tube by sliding it out of the "U" bolt, lifting it from the
✐
mounting bracket, and pulling the wires through the conduit at the same time.
NOTE: It may be necessary to disconnect the conduit from the control panel enclosure
and / or the heater mounting bracket to ease the wire removal / insertion.
11 Check the ID mark on the side of the heater for kW rating and voltage.
The ID mark is on the outside of the tube near the end with the lead wires.
Make sure the kW and voltage is the same as the replacement heater.
12 Insert the new heater tube through the "U" bolt and into the mounting
bracket. Note that the RTD opening should be pointing directly away from
the back of the crystallizer. Tighten the acorn nuts on the "U" bolt to secure
the heater.
13 Feed the heater wires through the conduit to the control panel enclosure.
Applying petroleum jelly on the tips of the new heater wires to will make it
easier to feed them through the conduit to the control panel enclosure.
CAUTION:Always refer to the wiring diagrams that came with your crystallizer
before making electrical connections. Electrical connections should be made
only by qualified personnel.
14 Reference the wiring diagram to re-attach the heater wires within the
control panel enclosure.
15 Slide the original insulation onto the heater. Make sure the hole for the
RTD aligns with the RTD mounting hole. Use duct tape to cover the seam
that was cut in the insulation during removal and to hold the insulation on the
heater.
16 Install the RTD and fitting in the 1/8" (3.18 mm) NPT hole near the top of
C-3 l Appendix
the heater tube (in the same place it was removed from in Step 4).
Replacing the Heater
(smaller models)
(continued)
17 Re-install the air inlet hose on the air inlet at the bottom of the heater.
Tighten the hose clamp.
18 Re-install the process air hose on the process air outlet at the top the heater.
Tighten the hose clamp.
19 Re-install the heater cover by aligning the tabs on the bottom of the heater
cover with the slots in the heater mounting bracket. Tilt the top of the cover
up towards the heater and install the two sheet metal bolts removed in Step 2
to secure the cover.
20 Make sure the heater fuses are not blown before trying the new heater.
Appendix l C-4
O OFF
ON
Replacing the Heating Elements
(larger models)
1 Disconnect and lockout the main power.
2 Gain access to the heating elements by removing screws that
secure the heating element cover to the enclosure.
3 Remove the heating element cover by tilting
the top away from the enclosure slightly, then
lifting the cover up and away from the enclosure.
IMPORTANT: Always refer
to the wiring diagrams
that came with your
heater to locate specific
electrical components.
Illustrations in the User
Guide are intended to be
representative only.
Replacement heating
elements are available from
Conair.
Contact Conair Parts
(800) 458 1960
From outside of the
United States, call:
(814) 437 6861
4 Determine which heater(s) is not functioning.
See Installation section entitled, Testing the
Installation.
5 Remove the screws securing the electrical
cover plate to the heating element enclosure.
Remove the electrical cover plate.
Screws to Remove
- Large Heaters
6 Disconnect the heating element leads from the terminals on the terminal
block, after noting connection points.
Heater
Wires
Heater
Connection
Junction Box
C-5 l Appendix
(continued)
Replacing the Heating
Elements (larger models)
7 Remove the hose clamp securing the
insulated hose to the outlet of the
heating element. Remove the hose.
✐
(continued)
Clamps
to
Remove
Note: For larger units (above 60
kW), it may be necessary to
remove the front heaters to
access the rear heaters.
8 Remove the hose clamps securing the
heating element to the heater inlet.
9 Remove the internal hose clamp.
10 Lift the heating element out of the enclosure.
11 Slide the insulation off the heater, or make a cut the entire length of
the insulation sleeve to aid removal.
12 Check the ID mark on the side of the heating element for kW rating
Clamp
and voltage. The ID mark is on the outside of the tube near the end with the
lead wires. Make sure the kW and voltage is the same as the replacement
heating element.
13 Slide the original insulation over the new heater or, if the insulation was
cut for removal, wrap the cut insulation sleeve around the new heater and
secure it with duct tape.
14 Set the new heating element into the enclosure. Secure the heating ele-
Replacement heating
elements are available from
Conair.
Contact Conair Parts
(800) 458 1960
From outside of the
United States, call:
(814) 437 6861
ment to the heater inlet with the original three (3) hose clamps.
15 Connect the insulated outlet hose to the outlet of the heating element.
Secure the hose with the original hose clamp.
16 Route the heating element leads to the terminal block. Connect the
heating element leads to the original terminals on the terminal block.
Re-install the electrical cover plate.
17 Re-install the heating element cover on the enclosure.
18 Test the system to ensure that the new heating element is functioning
correctly.
Appendix l C-6
Installing an Aftercooler
(Optional for
Closed-Loop Systems Only)
The aftercooler option is used only if the crystallizer will be configured as a
"closed loop" system. Its function is to cool the return air before it is returned to
the process air filter and blower for recirculation.
You can add an aftercooler to the crystallizer by ordering the optional aftercooler
assembly. Installation is easy.
The optional aftercooler requires a source of city, tower, or chiller water and a discharge or return line. You can use water at temperatures up to 85°F (30°C). But the
water flow should be at least 2 gal/min (7.6 liters/min).
1 Stop the crystallizer and lockout the main power.
2 Install the aftercooler near the crystallizer in close proximity to the cyclone
separator and process air filter.
✒TIP: Make the water supply and dis- 3 Connect the water supply line to the aftercooler inlet. If a manual shut off
charge / return connections with
valve is used, it should be mounted on the inlet line.
flexible hoses at least 24 in.
(61 cm) long. This allows you to
easily remove the aftercooler
assembly for cleaning.
D-1 l Appendix
4 Connect the water discharge or return line to the aftercooler outlet.
✐
NOTE: Water to the aftercooler should be turned off when the crystallizer is not running to prevent condensation.
Cleaning the Aftercooler
If your crystallizer is configured as a closed-loop system and uses an
aftercooler, you need to clean the aftercooler coils to keep them working
efficiently. Cleaning frequency depends on the type and amount of
material you process.
1 Stop the crystallizer and lockout the main power.
2 Turn off the water flow to the water supply line. Disconnect
supply and return lines.
3 Remove the hardware securing the aftercooler in the
aftercooler housing.
✒TIP: If the aftercooler was installed using the recommended 24 inch (61 cm) of flexible
hoses, there is no need to disconnect the hoses from the aftercooler inlet and outlet.
4 Remove the aftercooler assembly from the aftercooler housing.
5 Clean the aftercooler assembly using a mild soap and water. Let the
aftercooler dry thoroughly before installation.
CAUTION: During the cleaning process, DO NOT cut or remove the
stainless steel wire that holds the aftercooler assembly together.
6 Inspect the condition of the gasket. If it is damaged, replace the gasket.
7 Reassemble by repeating the steps in reverse order.
Appendix l D-2
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