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Conair GasTrac User Manual
Summary of GasTrac
Page 1
Gastrac instant access parts and service (800) 458-1960 (814) 437-6861 www.Conairnet.Com the conair group, inc. One conair drive pittsburgh, pa 15202 phone: (412) 312-6000 fax: (412)-312-6001 process air heater ugd014/0497 installation maintenance operation troubleshooting.
Page 2
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 manual...
Page 3: Able Of
Ugd014/0497 gastrac process air heater t able of c ontents i ntroduction . . . . . . . . . . . . . . . . . . .1-1 purpose of the user guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2 how the guide is organized . . . . . . . . . . . . . . . . . . . . . . . .1-2 your responsibilities as a us...
Page 4: Able Of
Gastrac process air heater ugd014/0497 t able of c ontents t roubleshooting . . . . . . . . . . . . . . . .6-1 before beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 a few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 when an alarm occurs . . ...
Page 5: 1-1
1-1 ugd014/0497 gastrac process air heater ● 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 .1-5 i ntroduction.
Page 6: 1-2
Gastrac process air heater ugd014/0497 1-2 i ntroduction 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 dia...
Page 7: 1-3
Ugd014/0497 gastrac process air heater i ntroduction 1-3 we design equipment with the user’s safety in mind. You can avoid the potential hazards identified on this machine by fol- lowing the procedures outlined below and elsewhere in the user guide and related instructional materials. Attention: r e...
Page 8: 1-4
Gastrac process air heater ugd014/0497 1-4 i ntroduction warning : hot surfaces. 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 exc...
Page 9: 1-5
Ugd014/0497 gastrac process air heater i ntroduction 1-5 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 prod...
Page 11: 2-1
2-1 ugd014/0497 gastrac process air heater ● 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 ● specificat...
Page 12: Hat Is The
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 equip- ment to a less-expensive gas source. The gastrac contain...
Page 13: Ypical
T ypical a pplications ugd014/0497 gastrac process air heater d escription 2-3 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. Mezzani...
Page 14: Orks
H ow i t w orks gastrac gas-fired process air heater ugd014/0497 2-4 d escription esc sel combustion blower run man 234.0 250.0 sp2 op1 op2 rem hold 2216 esc sel the gastrac has three interfaced controls that: ● ignite the metal-ceramic burner and monitor the gastrac combustion circuit. ● heat the d...
Page 15: Orks
H ow i t w orks ugd014/0497 gastrac process air heater d escription 2-5 100 150 200 250 300 350 400 0 50 100 150 200 50 0 100 150 200 250 300 350 400 0 50 100 150 200 50 0 the process air circuit the combustion air circuit the process blower in the host dryer sends dehumidified air into the gastrac ...
Page 16: 2-6
Gastrac process air heater ugd014/0497 2-6 d escription 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 burn- er. The four pressure switches monitor gas pressure and p...
Page 17: 2-7
Ugd014/0497 gastrac process air heater d escription 2-7 gastrac upright models combustion air filter proportional mixer mixes air and gas in the correct proportion to produce the required heat. F uel t rain f eatures and c ontrols combustion air blower gas inlet pressure gauge manual gas supply shut...
Page 18: Pecifications
S pecifications : g as t rac gastrac process air heater ugd014/0497 2-8 d escription h w d dimensions h w d weight air inlet/outlet in./cm in./cm in./cm lbs/kg diameter in./cm cgt700hh horizontal model 61/154.9 37/93.9 74/187.9 1115/505.7 12/30 cgt700hv upright model 67/170.2 39/99 64/162.6 1115/505...
Page 19: 2-9
Ugd014/0497 gastrac process air heater d escription 2-9 s pecifications : m ain p ower s upply w ire the main power wire must be: ● grounded and secured with a strain relief. ● correctly sized for the current drawn. Allowable ampacities of copper conductors u.S.A. Canada european community 75˚c insu...
Page 21: 3-1
3-1 ugd014/0497 gastrac process air heater ● 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 p...
Page 22: Npacking
U npacking the b oxes gastrac process air heater ugd014/0497 3-2 i nstallation carefully remove the gastrac and components from their shipping containers. Remove all packing material , protective paper, tape and plastic. Be sure to examine packing material before discarding. What looks like filler m...
Page 23: Reparing For
Select a location for the gastrac. The location: ❒ should be between the host dryer and the hopper. For minimal heat loss, the gastrac should be no more than 10 feet from the drying hopper. The gastrac control must be within 10 feet of the drying hopper inlet, unless optional cable extensions for th...
Page 24: Nstalling The
Move the gastrac to the selected location. Be sure to position the gastrac so that you can easily: ❒ connect the gas and main power supplies. ❒ install the flue stack. ❒ connect process air hoses or lines between the host dryer, gastrac and drying hopper. Secure the gastrac to the mounting surface. ...
Page 25: Nstalling The
The gastrac is a forced draft system, using a variable speed combustion blower and a sealed combustion chamber. The tem- perature of combustion gases in the flue can reach 750˚ f. Install the exhaust ducting and flue. Consult government codes and a qualified mechanical con- tractor for detailed inst...
Page 26: Onnecting
The process air lines carry dehumidified air from the host dryer to the gastrac, and from the gastrac to the drying hop- per. 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 t...
Page 27: Onnecting
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. Insert the main power wire through the knockout in the electrical enclosure. Secure the wire with a rubber compression fitting or strain relief....
Page 28: As And
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. Check all electrical connections . ❒ shut off power to the unit and verify that the gastrac and its b...
Page 29: Esting The
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 set- point temperature. ◆ the burner controller begins a 10-second initiation, which ends when the display indicates standby ....
Page 31: 4-1
4-1 ugd014/0497 gastrac process air heater ● gastrac operating features . . . .4-2 ● the gastrac control . . . . . . . . . .4-3 ● to start drying . . . . . . . . . . . . . .4-4 ● to stop drying . . . . . . . . . . . . . .4-5 o peration.
Page 32: Rac
G as t rac o perating f eatures gastrac process air heater ugd014/0497 4-2 o peration esc sel cooling exhaust filter prevents contaminants from entering the elec- trical enclosure through the exhaust vent. The gastrac control this is the primary operating control. You turn the gastrac on or off, ent...
Page 33: 4-3
Ugd014/0497 gastrac process air heater o peration 4-3 t he g as t rac c ontrol run man 235.0 250.0 sp2 op1 op2 rem hold 2216 the gastrac control is the primary operator interface. This control may have been mounted in a remote location. Run button push to start the gastrac. Emergency stop button pus...
Page 34: Tart
The temperature controller is factory configured to start and operate in automatic mode. Start the host dryer. Turn the main power disconnect to the i or on position. ◆ the variable speed controller turns on. Press the power switch to on. ◆ the power on/off switch illuminates. ◆ the temperature cont...
Page 35: 4-5
Ugd014/0497 gastrac process air heater o peration 4-5 t o s top d rying press the red stop button. ◆ the green indicator light turns off. ◆ the gas inlet valves should close. ◆ the combustion blower should stop. Press the on/off switch to off. ◆ the burner control turns off. ◆ the temperature contro...
Page 37: 5-1
5-1 ugd014/0497 gastrac process air heater ● 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 ultraviol...
Page 38: Reventative
P reventative m aintenance c hecklist gastrac process air heater ugd014/0497 5-2 m aintenance routine maintenance will ensure optimum operation and per- formance of the gastrac. We recommend the following main- tenance schedule and tasks. ● weekly, or as often as needed ❒ clean the gastrac combustio...
Page 39: Leaning
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. Stop the gastrac. Press the red stop button, then press the rocker switch to off . Disconnect and lock out main power. Remo...
Page 40: Eplacing The
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 0.125 inch. The gap should be between 0.07 and 0.09 inch. ● the igniter insulation is cracked ...
Page 41: 5-5
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. Coat the threads of the igniter with a high...
Page 42: 5-6
A dirty ultraviolet flame detector may fail to recognize burner ignition, which will cause the gastrac to alarm and shut down automatically. Stop the gastrac. Press the red stop but- ton, then press the rock- er switch to off . Disconnect and lock out main power. Remove the flame detector. Loosen th...
Page 43: 6-1
6-1 ugd014/0497 gastrac process air heater ● 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 . . . . . . . . . . ...
Page 44: Efore
B efore b eginning gastrac process air heater ugd014/0497 6-2 t roubleshooting 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...
Page 45: Hen An
When there is a problem with the gastrac the alarm light will illuminate and the gastrac will shutdown. W hen an a larm o ccurs ugd014/0497 gastrac process air heater t roubleshooting 6-3 h ow to i dentify the c ause of an a larm run man 235.0 250.0 sp2 op1 op2 rem hold 2216 alarm light the single a...
Page 46: Emperature
T emperature c ontroller a larms gastrac process air heater ugd014/0497 6-4 t roubleshooting alarm deviation band the drying, or process circuit, tem- perature is higher or lower than the set- point alarm band allows. Sensor break the sensor input for rtd temperature probe has failed. Possible cause...
Page 47: 6-5
Ugd014/0497 gastrac process air heater t roubleshooting 6-5 alarm loop break the actual drying temperature did not approach the set- point within the loop break time. There may be a problem in the combustion or process air circuit. Power failure the line voltage to the temperature controller is too ...
Page 48: 6-6
Gastrac process air heater ugd014/0497 6-6 t roubleshooting alarm the rom self test failed. The ram self test failed. Watchdog failure keyboard failure. Input circuit failure possible cause the temperature con- troller is defective. The temperature con- troller is defective. The temperature con- tro...
Page 49: Urner
B urner c ontroller a larms ugd014/0497 gastrac process air heater t roubleshooting 6-7 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: press the gastrac sto...
Page 50: 6-8
Gastrac process air heater ugd014/0497 6-8 t roubleshooting alarm 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 techni- cians equipped with the correct tools and trained in t...
Page 51: Urner
B urner c ontroller a larms ugd014/0497 gastrac process air heater t roubleshooting 6-9 alarm or warning: the gastrac should be tested and repaired only by qualified techni- cians equipped with the correct tools and trained in the maintenance and repair of elec- trical systems and industrial gas app...
Page 52: Ariable
V ariable s peed c ontroller a larms gastrac process air heater ugd014/0497 6-10 t roubleshooting alarm power loss under voltage over voltage motor stall possible cause dc bus voltage remained below 85% nominal for more than 5 seconds on power up. Dc bus voltage fell below the minimum. Dc bus voltag...
Page 53: 6-11
Ugd014/1097 gastrac process air heater t roubleshooting 6-11 alarm motor overload over temperature over current eeprom fault possible cause the internal electronic overload tripped. Excessive heat was detected in the variable speed control. Excessively high current was detected in the hard- ware tri...
Page 54: 6-12
Gastrac process air heater ugd014/1097 6-12 t roubleshooting alarm phase u fault phase v fault phase w fault phase uv short fault phase uw short fault possible cause the controller has detect- ed a phase u-to-ground fault between the con- troller and combustion blower motor. The controller has detec...
Page 55: 6-13
Ugd014/0497 gastrac process air heater t roubleshooting 6-13 alarm phase vw short fault power test fault possible cause excessive voltage was detected between the v and w controller output phases. An electrical fault was detected during the initial start-up sequence. Solution ❒ check for a shorted c...
Page 56: 6-14
Gastrac process air heater ugd014/0497 6-14 t roubleshooting alarm the control panel alarm light is on, but no other controller alarm messagesor lights are displayed. Warning: the gastrac should be tested and repaired only by qualified techni- cians equipped with the correct tools and trained in the...
Page 57: 6-15
Ugd014/0497 gastrac process air heater t roubleshooting 6-15 alarm the control panel alarm light is on, but no other controller alarm messagesor lights are displayed. Warning: the gastrac should be tested and repaired only by qualified techni- cians equipped with the correct tools and trained in the...
Page 59: A-1
Ims0002/0797 s ervice i nformation a ppendix a-1 conair has made the largest investment in customer sup- port in the plastics industry. Our service experts are avail- able to help with any problem you might have installing and operating your equipment. Your conair sales represen- tative also can hel...
Page 60: A-2
W arranty i nformation ims0003/0796 a ppendix a-2 e quipment g uarantee p erformance w arranty w arranty l imitations 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 nor...