GasTrac Process Air Heater Installation Maintenance Operation Troubleshooting Instant Access Parts and Service (800) 458-1960 (814) 437-6861 www.conairnet.com The Conair Group, Inc.
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INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1 Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2 How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . .1-2 Your responsibilities as a user . . . . . . . . . . . . . . . . . . . . . .1-2 ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3 How to use the lockout device . . . . . . . . . . . . . . . . . . . . . .1-5 TABLE OF CONTENTS DESCRIPTION . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1 Before beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 When an alarm occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3 How to identify the cause of an alarm . . . . . . . . . . . . . . . .6-3 Temperature controller alarms . . . . . . . . . . . . . . . . . . . . . .6-4 Burner controller alarms . . . . . . . . . . . .
INTRODUCTION ● Purpose of the User Guide . . . .1-1 ● How the guide is organized . . . .1-2 ● Your responsibilities as a user .1-2 ● ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3 ● How to use the lockout device .
PURPOSE OF THE USER GUIDE HOW THE GUIDE IS ORGANIZED YOUR RESPONSIBILITY AS A USER This User Guide describes the GasTrac process air heater and explains step-by-step 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.
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 and related instructional materials. ! ATTENTION: READ THIS SO NO ONE GETS HURT ! WARNING: Follow instructions carefully. Incorrect installation, operation or maintenance of this product can result in a fire, explosion or other hazards causing property damage, severe personal injury or loss of life.
! ATTENTION: WARNING: Hot surfaces. READ THIS Temperatures inside the GasTrac can reach more than 800˚ F. Always shut down the GasTrac and host dryer and wait for them to cool before servicing. Do not remove the safety guard covering the GasTrac burner and heat exchanger. SO NO ONE GETS HURT WARNING: Disconnect and lock out main power before servicing. The GasTrac is connected to high voltage. Always disconnect and lock out the main power source to the GasTrac before servicing.
CAUTION: Before performing maintenance or repairs on this product, you should disconnect and lock out 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. 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.
DESCRIPTION ● What is the GasTrac? . . . . . . . . .2-1 ● Typical applications . . . . . . . . . .2-2 ● How it works . . . . . . . . . . . . . . .2-4 ● Fuel train features and controls . . . . . . . . . . . . .2-6 ● Specifications: GasTrac . . . . . . .2-8 ● Specifications: Exhaust flue . . .2-9 ● Specifications: Main power supply wire . . . . . . . . . . . . . .
WHAT IS THE GASTRAC? The GasTrac Process Air Heater is a stand-alone, gas-fired heater designed to replace the electric process air heater in an existing dehumidifying dryer or crystalizer. The GasTrac allows plastics processors to convert existing electric equipment to a less-expensive gas source. The GasTrac contains a metal-ceramic burner, heat exchanger, combustion system and temperature controller to set and maintain the temperature of the air entering a drying hopper.
The GasTrac may be installed on a mezzanine or on the floor between the host dryer and the drying hopper. You can use flexible hose or pipe to deliver air between the host dryer, the GasTrac and the drying hopper.
HOW IT WORKS The GasTrac has three interfaced controls that: ● Ignite the metal-ceramic burner and monitor the GasTrac combustion circuit. ● Heat the dry air to the setpoint temperature. ● Monitor the air temperature as it enters the drying hopper. ● Automatically adjust the mixture of combustion air and gas to maintain the setpoint temperature. The Temperature Controller You enter the setpoint temperature in the Temperature Controller on the main GasTrac control.
The GasTrac has two separate air circuits: the combustion air circuit and the process air circuit. The Combustion Air Circuit 5 Combustion gases exhaust through a flue. 1b 3 2 HOW IT WORKS The combustion blower pulls ambient air into the combustion circuit through a filter. The air is then blown to the proportional gas mixer. 1a Gas and air are mixed in the proportion needed to achieve the setpoint temperature. Gas enters the fuel train.
FUEL TRAIN FEATURES AND CONTROLS The fuel train includes two automatic and manual safety gas shutoff valves, four pressure switches, and a gas regulator and governor to assure safe feeding of gas to the combustion burner. The four pressure switches monitor gas pressure and process air flow. The GasTrac will automatically shut down if a pressure switch senses an unsafe condition.
FUEL TRAIN FEATURES AND CONTROLS GasTrac upright models Proportional Mixer Mixes air and gas in the correct proportion to produce the required heat. Combustion air filter Combustion air pressure switch Zero Gas Governor controls the gas feed to the proportional mixer.
SPECIFICATIONS: GASTRAC H H H D D W Remotable GasTrac control D W W CGTHH horizontal model Dimensions CGT700HH Horizontal Model CGT700HV Upright Model CGT500HH Horizontal Model CGT500HV Upright Model CGT350HH Horizontal Model CGT350HV Upright Model Remotable GasTrac control General Temperature range Maximum Flue Temperature Combustion blower Ignition source Burner type Minimum burner capacity Maximum burner capacity Gas consumption Gas pressure to regulator Gas pressure from regulator Gas heating
SPECIFICATIONS: EXHAUST FLUE The Conair GasTrac is classified under the National Fuel Gas Code [ANSI Z233.1] as a Category III gas appliance. An exhaust flue is required to vent the combustion gases produced by this appliance. The purchaser is responsible for installing an exhaust flue that meets all local, regional and national codes in the installation area. For you safety, Conair recommends that you consult a licensed mechanical contractor who is familiar with gas flue and ducting codes in your area.
INSTALLATION ● Unpacking the boxes . . . . . . . . .3-2 ● Preparing for installation . . . . . .3-3 ● Installing the GasTrac . . . . . . . .3-4 ● Replacing the host dryer’s process air heater . . . . . . . . .3-4 ● Installing the exhaust flue . . . . .3-5 ● Connecting process air lines . .3-6 ● Connecting the gas supply . . . .3-6 ● Connecting the main power . . .3-7 ● Installing the RTD probe . . . . . .3-7 ● Testing the installation . . . . . . . .
UNPACKING THE BOXES The GasTrac Process Air Heater arrives assembled. The RTD temperature probe is packaged inside the electrical enclosure. Depending on the model and options ordered, you also should receive boxes containing V clamps and piping to attach the GasTrac exhaust to a customer-installed flue.
! WARNING: Follow instructions carefully. Incorrect installation of this product can result in a fire, explosion or other hazards causing property damage, severe personal injury or loss of life. Only licensed electrical/mechanical contractors, or individuals experienced with the installation of natural gas piping, process air ducting, thermal insulation and exhaust ducting, should install the GasTrac. 1 PREPARING FOR INSTALLATION Select a location for the GasTrac.
INSTALLING THE GASTRAC ! WARNING: You are responsible for the structural integrity of this installation. If you are installing the GasTrac on a mezzanine, the host dryer or another device, be sure that the mounting surface can support the weight of the GasTrac. See the specification tables for weights. ! CAUTION: Use a suitable lifting device to move the GasTrac. The GasTrac models weigh up to 1,400 pounds. Always use a forklift or other suitable lifting device to move the unit.
! WARNING: Do not operate the GasTrac without a properly installed exhaust flue. You must install an exhaust flue to vent the combustion gases produced by the GasTrac. The installation should comply with government codes in your area and be done by a qualified mechanical contractor familiar with industrial flue and ducting systems. INSTALLING THE EXHAUST FLUE The GasTrac is a forced draft system, using a variable speed combustion blower and a sealed combustion chamber.
CONNECTING PROCESS AIR LINES The process air lines carry dehumidified air from the host dryer to the GasTrac, and from the GasTrac to the drying hopper. These air lines can be flexible hose or pipe. The air line between the GasTrac and host dryer can be uninsulated. We recommend an insulated air line between the GasTrac and the drying hopper to minimize heat loss. 1 Connect the GasTrac process air inlet to the host dryer’s process air outlet. Secure the air lines with hose or pipe clamps.
CAUTION: Electrical hazard. Always disconnect and lock out the main power sources before making electrical connections. Electrical connections should be made only by qualified personnel. 1 CONNECTING MAIN POWER Open the GasTrac electrical enclosure. Turn the disconnect dial on the GasTrac’s door to the Off position. Turn the captive screw, and swing the door open.
GAS AND ELECTRICAL SYSTEM CHECKS You have completed the installation. Now its time to make sure everything works. Qualified electrical and mechanical personnel should be available during the systems check and the installation test. 1 Check all electrical connections. 2 Check gas piping and ducting. ❒ Shut off power to the unit and verify that the GasTrac and its burner controller are adequately grounded. Inadequate grounding can cause controller error messages and nuisance alarms.
TESTING THE INSTALLATION 2216 OP1 OP2 4 SP2 REM 235.0 250.0 RUN MAN HOLD 6 6 5 4 5 6 7 Press the Power switch to ON. ◆ The Power ON/OFF switch illuminates. ◆ The temperature controller begins a 3-second self-test. The display will flash between STANDBY and the setpoint temperature. ◆ The Burner Controller begins a 10-second initiation, which ends when the display indicates STANDBY. Set the drying temperature.
OPERATION ● GasTrac operating features . . . .4-2 ● The GasTrac control . . . . . . . . . .4-3 ● To start drying . . . . . . . . . . . . . .4-4 ● To stop drying . . . . . . . . . . . . . .
GASTRAC OPERATING FEATURES The OPERATING section introduces the GasTrac operating features and explains how to use the primary GasTrac control to start and stop drying. For detailed information about the Temperature, Burner and Variable Speed Controllers, see the manufacturer’s manuals in the instruction packet. The GasTrac Control This is the primary operating control. You turn the GasTrac on or off, enter the setpoint drying temperature and start or stop the GasTrac using this remotable control.
The GasTrac control is the primary operator interface. This control may have been mounted in a remote location. Power On/Off This switch sends power to the burner controller, the GasTrac control and the process and safeguard relay devices The switch illuminates when power is ON. THE GASTRAC CONTROL Alarm Light An illuminated light Indicates the GasTrac has shutdown on an alarm condition. The Troubleshooting section will help you identify and correct the problem. 2216 OP1 OP2 SP2 REM 235.0 250.
TO START DRYING The temperature controller is factory configured to start and operate in automatic mode. 1 2 Start the host dryer. Turn the main power disconnect to the I or ON position. I ◆ The variable speed controller turns on. 2216 OP1 OP2 3 SP2 REM 235.0 250.0 RUN MAN HOLD 5 4 3 4 Press the Power switch to ON. ◆ The Power ON/OFF switch illuminates. ◆ The temperature controller begins a 3-second self-test. The display will flash between STANDBY and the setpoint temperature.
IMPORTANT: Do not shut down the host dryer before stopping the GasTrac. After stopping the GasTrac, allow the host dryer’s process blower to continue running for a minimum of 2 minutes. This prevents excessive heat from building up in the GasTrac. TO STOP DRYING 2216 OP1 OP2 2 SP2 REM 235.0 250.0 RUN MAN HOLD 1 1 Press the red STOP button. 2 Press the ON/OFF switch to OFF. 3 ◆ The green indicator light turns off. ◆ The gas inlet valves should close. ◆ The combustion blower should stop.
MAINTENANCE ● Maintenance checklist . . . . . . . .5-2 ● Cleaning the combustion air filter . . . . . . . . . . . . . . . . . . .5-3 ● Cleaning the electrical enclosure filters . . . . . . . . . . . .5-3 ● Replacing the spark igniter . . . .5-4 ● Cleaning the ultraviolet flame detector . . . . . . . . . . . . .5-6 ● Cleaning the burner sight glass . . . . . . . . . . . . . . . .
PREVENTATIVE MAINTENANCE CHECKLIST Routine maintenance will ensure optimum operation and performance of the GasTrac. We recommend the following maintenance schedule and tasks. ● Weekly, or as often as needed ❒ Clean the GasTrac combustion air filter. You may need to clean the filter more often than weekly. Frequency depends on the amount of dust in your facility’s air. ❒ Clean the GasTrac electrical enclosure filters. You may need to clean the filters more often than weekly.
You must clean the combustion air intake filter periodically. A clogged filter reduces air flow through the combustion circuit, which reduces burner efficiency and heat output. 1 2 3 4 Stop the GasTrac. Press the red STOP button, then press the rocker switch to OFF. 2216 OP1 OP2 SP2 REM 235.0 250.0 RUN MAN HOLD Disconnect and lock out main power. Remove the filter shroud. Remove the wing nut and washer that holds the shroud in place. Lift the shroud up and off. 3 Remove the filter.
REPLACING THE SPARK IGNITER WARNING: Hot surfaces Allow the GasTrac to cool before removing the burner guard to perform maintenance IMPORTANT: When removing or inserting the spark igniter, do not allow the igniter electrode or grounding rod to touch the burner. You could damage the burner surface. The spark igniter should be replaced at least once a year to assure trouble-free operation. You should replace the igniter before the annual period, if you inspect it and find: ● The spark gap is less than 0.
5 Mark the position of the grounding rod on the new spark igniter, using a felt tip marker. This index mark must end up 180˚ away from the burner surface when the spark igniter is inserted and tightened. The electrode should be closest to the burner surface. REPLACING THE SPARK IGNITER Electrode Grounding rod 6 Coat the threads of the igniter with a high-temperature conductive anti-seize compound. 7 8 Carefully insert the igniter into GasTrac. Insert the igniter straight into the threaded fitting.
CLEANING THE ULTRAVIOLET FLAME DETECTOR WARNING: Hot surfaces Allow the GasTrac to cool before removing the burner guard to perform maintenance A dirty ultraviolet flame detector may fail to recognize burner ignition, which will cause the GasTrac to alarm and shut down automatically. 1 2 3 4 Stop the GasTrac. Press the red STOP button, then press the rocker switch to OFF. 2216 OP1 OP2 SP2 REM 235.0 250.0 RUN MAN HOLD Disconnect and lock out main power. Remove the flame detector.
TROUBLESHOOTING ● Before beginning . . . . . . . . . . . .6-2 ● A few words of caution . . . . . . .6-2 ● When an alarm occurs . . . . . . . .6-3 ● How to identify the cause of an alarm . . . . . . . . . . . . . . . .6-3 ● Temperature controller alarms . . . . . . . . . . . . . . . . . . . .6-4 ● Burner controller alarms . . . . . .6-7 ● Variable speed controller alarms . . . . . . . . . . . . . . . . . . .6-10 ● Flue gas high temperature limit switch . . . . . . . . . . . . . . .
BEFORE BEGINNING You can avoid most problems by following the recommended installation and maintenance procedures outlined in this Users Guide. If you do have a problem, this section will help you determine what caused it and tell you how to fix it. Before you begin troubleshooting: ❒ Find the wiring and assembly diagram you received with your GasTrac. These diagrams will note any custom features such as special wiring or alarm capabilities not covered in the User Guide.
When there is a problem with the GasTrac the alarm light will illuminate and the GasTrac will shutdown. WHEN AN ALARM OCCURS 2216 OP1 OP2 SP2 REM 235.0 250.0 RUN MAN HOLD Alarm light The single alarm may be caused by any one of five major control components or another device within the GasTrac. Control components and indications of failure: ● Temperature controller Displays a flashing alarm message. ● Burner controller Displays a flashing alarm message.
TEMPERATURE CONTROLLER ALARMS 2216 OP1 OP2 The Temperature Controller will flash an alarm message in the upper or lower display window. SP2 REM RUN MAN HOLD ! WARNING: The GasTrac should be tested and repaired only by qualified technicians equipped with the correct tools and trained in the maintenance and repair of electrical systems and industrial gas appliances.
2216 OP1 OP2 TEMPERATURE CONTROLLER ALARMS The Temperature Controller will flash an alarm message in the upper or lower display window. SP2 REM RUN MAN HOLD ! WARNING: The GasTrac should be tested and repaired only by qualified technicians equipped with the correct tools and trained in the maintenance and repair of electrical systems and industrial gas appliances. Alarm L.br Loop Break The actual drying temperature did not approach the setpoint within the loop break time.
TEMPERATURE CONTROLLER ALARMS Alarm Err1 2216 OP1 OP2 The Temperature Controller will flash an alarm message in the upper or lower display window. SP2 REM RUN MAN HOLD ! WARNING: The GasTrac should be tested and repaired only by qualified technicians equipped with the correct tools and trained in the maintenance and repair of electrical systems and industrial gas appliances. Possible cause Solution The temperature controller is defective.
When there is a problem related to the burner or ignition, the burner controller displays a fault code and illuminates an alarm light. To restart the GasTrac after a burner controller alarm: 1 Press the GasTrac STOP button. 2 Press the burner RESET button. 3 Press the GasTrac RUN button. Alarm LOCKOUT #16 *Flame Out Timer* Possible cause Solution Is the spark igniter providing a spark? Restart the GasTrac while watching through the sight glass.
BURNER CONTROLLER ALARMS Alarm LOCKOUT #17 *Main Flame Fail* The main flame failed after RUN was pushed and the flame had been established for at least 10 seconds. ! WARNING: The GasTrac should be tested and repaired only by qualified technicians equipped with the correct tools and trained in the maintenance and repair of electrical systems and industrial gas appliances.
BURNER CONTROLLER ALARMS When there is a problem related to the burner or ignition, the burner controller displays a fault code and illuminates an alarm light. To restart the GasTrac after a burner controller alarm: 1 Press the GasTrac STOP button. 2 Press the burner RESET button. 3 Press the GasTrac RUN button. Alarm LOCKOUT #23 Possible cause Solution Is the combustion blower intake filter clogged? Clean the filter.
VARIABLE SPEED CONTROLLER ALARMS Fault code ESC SEL When a problem occurs, the variable speed controller displays the parameter 07 and a two-digit fault code. You must correct the problem before restarting the GasTrac. To restart after an alarm: 1 Turn the power disconnect OFF then ON. 2 Press the GasTrac RUN button.
Fault code ESC SEL When a problem occurs, the variable speed controller displays the parameter 07 and a two-digit fault code. You must correct the problem before restarting the GasTrac. To restart after an alarm: 1 Turn the power disconnect OFF then ON. 2 Press the GasTrac RUN button.
VARIABLE SPEED CONTROLLER ALARMS Fault code ESC SEL When a problem occurs, the variable speed controller displays the parameter 07 and a two-digit fault code. You must correct the problem before restarting the GasTrac. To restart after an alarm: 1 Turn the power disconnect OFF then ON. 2 Press the GasTrac RUN button.
Fault code ESC SEL When a problem occurs, the variable speed controller displays the parameter 07 and a two-digit fault code. You must correct the problem before restarting the GasTrac. To restart after an alarm: 1 Turn the power disconnect OFF then ON. 2 Press the GasTrac RUN button.
FLUE GAS HIGH TEMPERATURE LIMIT SWITCH The flue gas high temperature switch monitors the temperature of a type J thermocouple mounted in the flue gas outlet. When the combustion exhaust gas temperature exceeds 800˚F, the GasTrac shuts down and the alarm light illuminates. alarm light 2216 OP1 OP2 SP2 REM 235.0 250.0 RUN MAN HOLD Alarm Possible cause Solution The control panel alarm light is on, but no other controller alarm messagesor lights are displayed.
The process high temperature switch monitors the temperature of a type J thermocouple mounted in the GasTrac process air outlet. If the process air outlet temperature exceeds 450˚ F, the GasTrac shuts down and the alarm light illuminates. alarm light PROCESS HIGH TEMPERATURE LIMIT SWITCH 2216 OP1 OP2 SP2 REM 235.0 250.0 RUN MAN HOLD Alarm Possible cause Solution The control panel alarm light is on, but no other controller alarm messagesor lights are displayed.
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.
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.
