Table of Contents
Advertisement
Quick Links
Advertisement
Chapters
Table of Contents
Summary of Contents for Conair GasTrac
- Page 1 GasTrac Process Air Heater Installation Maintenance Operation Troubleshooting The Conair Group, Inc. Instant Access One Conair Drive Parts and Service Pittsburgh, PA 15202 (800) 458-1960 Phone: (412) 312-6000 (814) 437-6861 Fax: (412)-312-6001 www.conairnet.com UGD014/0497...
- Page 2 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 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.
-
Page 3: Table Of Contents
ESCRIPTION What is the GasTrac? ......2-2 Typical applications ......2-2 How it works . - Page 4 Process high temperature limit switch ....6-15 PPENDIX Service/Warranty Information ....Appendix A GasTrac Process Air Heater UGD014/0497...
-
Page 5: Introduction
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 UGD014/0497 GasTrac Process Air Heater... -
Page 6: Purpose Of The User Guide
This User Guide describes the GasTrac process air heater and URPOSE OF explains step-by-step how to install, operate, maintain and repair this equipment. UIDE Before installing this product, please take a few moments to read the User Guide and review the diagrams and safety infor- mation in the instruction packet. -
Page 7: Attention: Read This So No One Gets Hurt
Inspection and testing of gas supply piping, exhaust ducting and the GasTrac gas controls and safety features should be performed periodically to ensure safe operation. - Page 8 Temperatures inside the GasTrac can reach more than 800˚ F. Always shut ONE GETS HURT 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.
-
Page 9: 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: Stop or turn off the equipment. -
Page 11: Description
ESCRIPTION What is the GasTrac? ..2-1 Typical applications ..2-2 How it works ....2-4 Fuel train features and controls . -
Page 12: What Is The Gastrac
Process, or drying, air flow of 600 to 1800 cfm. Higher or lower air flow ranges may be achieved, depending on the model of the host dryer and the GasTrac selected. Central drying, using an existing electric dryer with a single GasTrac or multiple GasTrac units. -
Page 13: Typical Applications
The GasTrac may be installed on a mezzanine or on the floor YPICAL between the host dryer and the drying hopper. You can use flexible hose or pipe to deliver air between the host dryer, the PPLICATIONS GasTrac and the drying hopper. -
Page 14: How It Works
The Temperature Controller You enter the setpoint temperature in the Temperature Controller on the main GasTrac control. 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 variable speed controller. - Page 15 The GasTrac has two separate air circuits: the combustion air ORKS circuit and the process air circuit. The Combustion Air Circuit The combustion blower pulls ambient air into the combustion circuit Gas and air are mixed Combustion through a filter. The air...
-
Page 16: Fuel Train Features And Controls
EATURES AND er. The four pressure switches monitor gas pressure and process air flow. The GasTrac will automatically shut down if ONTROLS a pressure switch senses an unsafe condition. - Page 17 High gas Gas pressure regulator pressure switch Regulated gas pressure gauge Low gas pressure switch Secondary automatic safety Primary automatic shutoff valve safety shutoff valve Process air differential pressure switch ESCRIPTION UGD014/0497 GasTrac Process Air Heater...
-
Page 18: Specifications: Gastrac
1.9 kw 1.0 kw 0.8 kw Emissions (all models) Primary excess air 10% - 30% All GasTrac models meet: Oxygen (O ) [Ideal 3%-4%] 2% - 5% acceptable range UL 372, UL 795, FM, CGA, Carbon Dioxide (CO 9% - 10.5%... -
Page 19: Specifications: Main Power Supply
PECIFICATIONS XHAUST 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. -
Page 21: 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 . -
Page 22: Unpacking The Boxes
The GasTrac Process Air Heater arrives assembled. The RTD NPACKING temperature probe is packaged inside the electrical enclosure. Depending on the model and options ordered, you also OXES should receive boxes containing V clamps and piping to attach the GasTrac exhaust to a customer-installed flue. -
Page 23: Preparing For Installation
Gas delivery piping should be sized to provide the rated gas line. gas flow to the GasTrac at a delivery pressure of about 12 An in-line, basket-type fil- inches water column (about psig). All gas piping... -
Page 24: Installing The Gastrac
The GasTrac has been equipped with forklift rails. 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. -
Page 25: Installing The Exhaust Flue
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. -
Page 26: Connecting Process Air Lines
The process air lines carry dehumidified air from the host ONNECTING 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 ROCESS between the GasTrac and host dryer can be uninsulated. We... - Page 27 Electrical connections should be made only by qualified personnel. 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.
-
Page 28: Testing The Installation
YSTEM Check all electrical connections HECKS Shut off power to the unit and verify that the GasTrac and its burner controller are adequately grounded. Inadequate grounding can cause controller error mes- sages and nuisance alarms. With power off to the GasTrac and the host dryer, verify that all terminal connections are tight and all new wiring has adequate strain relief. - Page 29 If the paper or string blows away from the filter, the blow- er is rotating in the wrong direction. Stop the GasTrac. Disconnect and lock out the main power source. Reverse any two incoming electrical leads on the blower and repeat the test procedure.
-
Page 31: Operation
PERATION GasTrac operating features ..4-2 The GasTrac control ..4-3 To start drying ....4-4 To stop drying ....4-5... -
Page 32: Gastrac Operating Features
The O section introduces the GasTrac operating fea- PERATING tures and explains how to use the primary GasTrac control to start and stop drying. For detailed information about the PERATING Temperature, Burner and Variable Speed Controllers, see the manufacturer’s manuals in the instruction packet. - Page 33 The GasTrac control is the primary operator interface. This control may have been mounted in a remote location. ONTROL Power On/Off This switch sends power to Alarm Light the burner controller, the An illuminated light Indicates the GasTrac control and the...
-
Page 34: To Start Drying
After the purge, the burner will ignite on low fire (low blower speed) for about 15 seconds. The burner will alternate between high and low fire as required to main- tain the setpoint temperature. PERATION GasTrac Process Air Heater UGD014/0497... -
Page 35: To Stop Drying
IMPORTANT: Do not shut down the host dryer before stopping the GasTrac. RYING 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. -
Page 37: Maintenance
... . .5-6 Cleaning the burner sight glass ....5-6 UGD014/0497 GasTrac Process Air Heater... -
Page 38: Preventative Maintenance Checklist
Routine maintenance will ensure optimum operation and per- REVENTATIVE formance of the GasTrac. We recommend the following main- tenance schedule and tasks. AINTENANCE Weekly, or as often as needed HECKLIST Clean the GasTrac combustion air filter. You may need to clean the filter more often than weekly. -
Page 39: Cleaning The Combustion Air Filter
Clean the filters. ILTERS Use vacuum or low-pressure com- pressed air to remove loose debris. Wash the filters in warm, soapy water, then rinse and air dry. Replace torn or worn filters. Reassemble. AINTENANCE UGD014/0497 GasTrac Process Air Heater... -
Page 40: Replacing The Spark Igniter
The spark electrodes are warped or taper to a needle- WARNING: like shape. Hot surfaces Do not operate the GasTrac with a worn or damaged spark Allow the GasTrac igniter. A badly burned or warped igniter can cause burner to cool before ignition failure. - Page 41 Coat the threads of the igniter with a high-temper- ature conductive anti-seize compound. Carefully insert the igniter into GasTrac. Insert the igniter straight into the threaded fitting. Do not bend the electrode, and do not allow the spark igniter to touch the burner surface.
-
Page 42: Cleaning The Ultraviolet Flame Detector
A dirty ultraviolet flame detector may fail to recognize burner LEANING THE ignition, which will cause the GasTrac to alarm and shut down LTRAVIOLET automatically. LAME Stop the GasTrac. 2216 235.0 Press the red but- STOP 250.0 ETECTOR ton, then press the rock-... -
Page 43: Troubleshooting
....6-14 Process high temperature limit switch ....6-15 UGD014/0497 GasTrac Process Air Heater... -
Page 44: Before Beginning
Before you begin troubleshooting Find the wiring and assembly diagram received with your GasTrac. These diagrams will note any custom features such as special wiring or alarm capabili- ties not covered in the User Guide. -
Page 45: When An Alarm Occurs
When there is a problem with the GasTrac the alarm light will HEN AN illuminate and the GasTrac will shutdown. LARM CCURS 2216 235.0 250.0 HOLD Alarm light The single alarm may be caused by any one of five major control components or another device within the GasTrac. -
Page 46: Temperature Controller Alarms
The Temperature Controller will flash an alarm EMPERATURE message in the upper or lower display window. ONTROLLER WARNING: The GasTrac should be test- ed and repaired only by qualified technicians HOLD LARMS equipped with the correct tools and trained in the maintenance and repair of electrical sys- tems and industrial gas appliances. - Page 47 The Temperature Controller will flash an alarm EMPERATURE message in the upper or lower display window. ONTROLLER WARNING: The GasTrac should be test- ed and repaired only by qualified technicians HOLD LARMS equipped with the correct tools and trained in the maintenance and repair of electrical sys- tems and industrial gas appliances.
- Page 48 The Temperature Controller will flash an alarm EMPERATURE message in the upper or lower display window. ONTROLLER WARNING: The GasTrac should be test- ed and repaired only by qualified technicians HOLD LARMS equipped with the correct tools and trained in the maintenance and repair of electrical sys- tems and industrial gas appliances.
- Page 49 When there is a problem related to the URNER burner or ignition, the burner controller displays a fault code and illuminates an ONTROLLER alarm light. To restart the GasTrac after a burner controller alarm: LARMS Press the GasTrac button. STOP Press the burner button.
-
Page 50: Burner Controller Alarms
URNER When there is a problem related to the burner or ignition, the burner controller ONTROLLER displays a fault code and illuminates an alarm light. To restart the GasTrac after a LARMS burner controller alarm: Press the GasTrac button. STOP Press the burner button. - Page 51 When there is a problem related to the URNER burner or ignition, the burner controller displays a fault code and illuminates an ONTROLLER alarm light. To restart the GasTrac after a LARMS burner controller alarm: Press the GasTrac button. STOP Press the burner button.
-
Page 52: Variable Speed Controller Alarms
Turn the power disconnect then Press the GasTrac button. 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. - Page 53 Turn the power disconnect then Press the GasTrac button. 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.
- Page 54 Turn the power disconnect then Press the GasTrac button. 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.
- Page 55 Turn the power disconnect then Press the GasTrac button. 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.
-
Page 56: Flue Gas High Temperature Limit Switch
The flue gas high temperature switch monitors the tempera- ture of a type J thermocouple mounted in the flue gas outlet. When the combustion exhaust gas temperature exceeds 800˚F, EMPERATURE the GasTrac shuts down and the alarm light illuminates. IMIT WITCH alarm light 2216 235.0... -
Page 57: Process High Temperature Limit Switch
The process high temperature switch monitors the temperature ROCESS of a type J thermocouple mounted in the GasTrac process air outlet. If the process air outlet temperature exceeds 450˚ F, the EMPERATURE GasTrac shuts down and the alarm light illuminates. - Page 59 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 help analyze the nature of your problem, assuring that it did not result from misapplication or improper use.
- Page 60 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.