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Conair GasTrac User Manual Download Page 5

1-1

UGD014/0497

GasTrac Process Air Heater

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Purpose of the User Guide  . . . .1-1

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How the guide is organized . . . .1-2

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Your responsibilities as a user   .1-2

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ATTENTION: Read this so 

no one gets hurt  . . . . . . . . . . .1-3

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How to use the lockout device   .1-5

I

NTRODUCTION

Summary of Contents for GasTrac

Page 1: ...nd 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 Mainten...

Page 2: ...er UGD014 0497 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 dam ages in connection with th...

Page 3: ...1 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 C...

Page 4: ...tion 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 temperatu...

Page 5: ...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...

Page 6: ...to users or could damage equipment Read and take precautions before proceeding Numbers within shaded squares indicate tasks or steps to be performed by the user A diamond indicates the equipment s res...

Page 7: ...g and regional codes for indus trial gas appliances should install the GasTrac The GasTrac should be maintained and repaired by qualified technicians who are equipped with the correct tools and are ex...

Page 8: ...could result in severe personal injury WARNING Shut off main gas supply and purge heat exchanger and gas lines before servicing If the fuel train burner ultraviolet sensor sight glass or ignition are...

Page 9: ...machines or equipment from energy sources Your Conair product is equipped with the lockout device pictured below To use the lockout device Stop or turn off the equipment Isolate the equipment from ele...

Page 10: ......

Page 11: ...ss 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 Specifications Exhaust flue 2 9 Specifications Main powe...

Page 12: ...ller ignition system and burner safeguards communicate with the host dryer through a RS 485 serial interface port The GasTrac can be used successfully in applications that require Drying of hygroscopi...

Page 13: ...RIPTION 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...

Page 14: ...The temperature controller monitors temperature at the drying hopper inlet When the actual temperature must increase or decrease to maintain setpoint this controller sends a 4 to 20 MA signal to the...

Page 15: ...t temperature as it passes over and around the burner cylinder and surrounding baffles The combustion blower pulls ambient air into the combustion circuit through a filter The air is then blown to the...

Page 16: ...TRAIN FEATURES AND CONTROLS GasTrac horizontal models Combustion air filter Zero Gas Governor controls the gas feed to the proportional mixer Manual burner inlet gas shut off valve Proportional Mixer...

Page 17: ...tion air blower Gas inlet pressure gauge Manual gas supply shutoff valve Regulated gas pressure gauge Gas pressure regulator Zero Gas Governor controls the gas feed to the proportional mixer Manual bu...

Page 18: ...ted Spark igniter interrupted Spark igniter interrupted Burner type Metal ceramic Metal ceramic Metal ceramic Minimum burner capacity 150 000 BTU hr 125 000 BTU hr 90 000 BTU hr Maximum burner capacit...

Page 19: ...er 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 contr...

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Page 21: ...allation 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...

Page 22: ...d gas specifications in the blanks provided on the back of the User Guide title page This information will be helpful if you ever need service or parts You are now ready to begin installation Follow a...

Page 23: ...ified personnel and should comply with government codes in your region Install gas piping to the selected location Gas delivery piping should be sized to provide the rated gas flow to the GasTrac at a...

Page 24: ...ontrol and the process heating elements Disconnect and reroute the process air lines The host dryer s process air outlet must be connected to the GasTrac instead of the drying hopper To reduce the pre...

Page 25: ...T temperatures can reach 750 F Install a condensate trap and drain Condensate occurs where flue gases cool below their dew point This condensate can be highly corrosive Draining and disposal should be...

Page 26: ...NOTE Do not allow the flexible hoses to kink or crimp 1 2 CONNECTING THE GAS SUPPLY WARNING For your safety we recommend that these steps be completed by a qualified mechanical contractor in complian...

Page 27: ...sources before making electrical connections Electrical connections should be made only by qualified personnel IMPORTANT Always refer to the wiring diagrams that came with the GasTrac for the most ac...

Page 28: ...e or a squirt bottle of soapy water to detect leaks around gas pipe and fitting joints Open the secondary gas shutoff valve and continue checking for leaks using the same procedure Start the host drye...

Page 29: ...phase blower Hold a strip of paper or piece of string near the blower inlet filter If the paper or string blows away from the filter the blow er is rotating in the wrong direction Stop the GasTrac Di...

Page 30: ......

Page 31: ...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 OPERATION...

Page 32: ...on packet Electrical Enclosure Cooling Fan and Filter Draws outside air through the enclosure to cool electrical com ponents Process High Temperature Limit Switch Shuts down the GasTrac when the proce...

Page 33: ...process and safeguard relay devices The switch illumi nates when power is ON RUN MAN 234 0 250 0 SP2 OP1 OP2 REM HOLD 2216 Temperature Controller OP1 Indicates the variable frequency controller outpu...

Page 34: ...er display Press the RUN button The green RUN light will illuminate after the Burner Controller finishes initializing The combustion blower will start and run for 90 sec onds to purge any residual gas...

Page 35: ...riod Then it becomes blank Turn the host dryer off after at least 2 minutes 1 2 3 4 RUN MAN 235 0 250 0 SP2 OP1 OP2 REM HOLD 2216 1 2 IMPORTANT Do not shut down the host dryer before stopping the GasT...

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Page 37: ...ter 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...

Page 38: ...safety controls Fuel safety shutoff valves combustion safeguards and temperature and pressure switches should be inspected and tested by trained personnel Inspect the burner sight glass Clean the sig...

Page 39: ...air When using com pressed air blow from inside the filter toward the outside Reassemble Repeat steps 3 and 4 in reverse order to replace the filter CLEANING THE COMBUSTION FILTER UGD014 0497 GasTrac...

Page 40: ...ace it Remove the spark igniter Use a 7 8 inch spark plug socket and ratchet to loosen the igniter Pull the igniter straight out of the GasTrac Do not allow the spark igniter to touch the burner surfa...

Page 41: ...readed fitting Do not bend the electrode and do not allow the spark igniter to touch the burner surface Screw the igniter into the threaded fitting Tighten by hand first Then use a socket and ratchet...

Page 42: ...dditional quarter turn GasTrac Process Air Heater UGD014 0497 5 6 MAINTENANCE CLEANING THE ULTRAVIOLET FLAME DETECTOR RUN MAN 235 0 250 0 SP2 OP1 OP2 REM HOLD 2216 WARNING Hot surfaces Allow the GasTr...

Page 43: ...ution 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 temperat...

Page 44: ...TION WARNING The GasTrac should be maintained and repaired by qualified technicians who are equipped with the correct tools and are experi enced in the maintenance and repair of industrial gas applian...

Page 45: ...ufacturer s man ual for that particular controller These manuals can be found in the instruction packet that came with your GasTrac Check the limit switches for contact closure Possible causes of swit...

Page 46: ...onnections Check the process air blow er in the host dryer If it is not running correctly see the dryer s manual Make sure the sensing end of the RTD probe is positioned near the center of the process...

Page 47: ...ructions Repair leaks or loose connections Check the process air blow er in the host dryer If it is not running correctly see the dryer s manual Clean the combustion air filter Replace the filter if i...

Page 48: ...ature con troller or return it to the facto ry for repair Replace the temperature con troller or return it to the facto ry for repair Switch the power to the GasTrac control off and the on using the P...

Page 49: ...the burner controller defective Solution Restart the GasTrac while watch ing through the sight glass If you don t see a spark during the 4 second ignition period Verify there is power supplied to the...

Page 50: ...the flame signal should fluctuate between 1 25V and 5V D C Verify that the ultraviolet flame detector lens is clean Check for blockage in the cooling air line between the ultraviolet sensor and com bu...

Page 51: ...t the GasTrac press RUN and check the LED lights on the process air combustion air low gas and high gas pressure switches during the 90 second purge cycle If a light is not green check for leaks block...

Page 52: ...may be caused by motor regeneration Check for high incoming AC voltage The over voltage trip point for 200 240 VAC units is 410 VDC which is equal to 290 VAC incoming voltage The under voltage trip po...

Page 53: ...heat sink passages or a faulty fan inside the variable speed controller Check for a short circuit at the variable speed control output Check for physical or mechanical blockage of the combustion blow...

Page 54: ...wiring between the control and motor for damage or incorrect connec tions Make sure the motor ground is wired correctly Check the wiring between the control and motor for damage or incorrect connec ti...

Page 55: ...the con troller Check wiring to the motor 07 43 07 48 VARIABLE SPEED CONTROLLER ALARMS ESC SEL When a problem occurs the variable speed controller displays the parameter 07 and a two digit fault code...

Page 56: ...alarm occurs again a qualified electrician should verify that the latching alarm contacts of the flue gas high temperature limit switch are closed This must be done by a quali fied technician who is t...

Page 57: ...e or loose connections Remove obstructions Repair leaks or loose connections Make sure the process air blower in the host dryer is run ning correctly Check the setpoint on the tem perature controller...

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Page 59: ...following checklist before calling Conair Make sure you have all model serial and parts list numbers for your particular equipment Service personnel will need this information to assist you Make sure...

Page 60: ...ill 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...

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