USER GUIDE UGD014- 0497 GasTrac - conairgroup.com€¦ · Manual Number: UGD 01 4- 97 Serial Number(s): Model Number(s): DISCLAIMER: C o n airsh ltb ef c dU Gu , consequential d amg

GasTracProcess Air Heater

U S E R G U I D E

UGD014-0497

Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861

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It’s a good idea to record the model and serial number(s) of your equipment and thedate 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 togetherfor documentation of your equipment.

Date:

Manual Number: UGD014-0497

Serial Number(s):

Model Number(s):

DISCLAIMER: Conair 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 theimplied warranties of merchantability and fitness for a particular purpose.

Copy r i gh t 1997 l Cona i r l A l l r i gh t s r ese r ved

UGD014/0497 GasTrac Process Air Heater

TABLE OFCONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . .1-1Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . . .1-2How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . . .1-2Your responsibilities as a user . . . . . . . . . . . . . . . . . . . . . . .1-2ATTENTION: Read this so no one gets hurt . . . . . . . . . . . .1-3How to use the lockout device . . . . . . . . . . . . . . . . . . . . . . .1-5

DESCRIPTION . . . . . . . . . . . . . . . . . . . . .2-1What is the GasTrac? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4Fuel train features and controls . . . . . . . . . . . . . . . . . . . . . .2-6Specifications: GasTrac . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8Specifications: Exhaust flue . . . . . . . . . . . . . . . . . . . . . . . . .2-9Specifications: Main power supply . . . . . . . . . . . . . . . . . . .2-9

INSTALLATION . . . . . . . . . . . . . . . . . . . . .3-1Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3Installing the GasTrac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4Replacing the host dryer’s process air heater . . . . . . . . . . . .3-4Installing the exhaust flue . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5Connecting process air lines . . . . . . . . . . . . . . . . . . . . . . . . .3-6Connecting the gas supply . . . . . . . . . . . . . . . . . . . . . . . . . .3-6Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . .3-7Installing the RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

OPERATION . . . . . . . . . . . . . . . . . . . . . . .4-1GasTrac operating features . . . . . . . . . . . . . . . . . . . . . . . . . .4-2The GasTrac control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3To start drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4To stop drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

MAINTENANCE . . . . . . . . . . . . . . . . . . . . .5-1Preventative maintenance checklist . . . . . . . . . . . . . . . . . . .5-2Cleaning the combustion air filter . . . . . . . . . . . . . . . . . . . .5-3Cleaning the electrical enclosure filters . . . . . . . . . . . . . . . .5-3Replacing the spark igniter . . . . . . . . . . . . . . . . . . . . . . . . . .5-4Cleaning the ultraviolet flame detector . . . . . . . . . . . . . . . .5-6Cleaning the burner sight glass . . . . . . . . . . . . . . . . . . . . . . .5-6

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GasTrac Process Air Heater UGD014/0497

TABLE OFCONTENTS

TROUBLESHOOTING . . . . . . . . . . . . . . . . .6-1Before beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2When an alarm occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3How to identify the cause of an alarm . . . . . . . . . . . . . . . . .6-3Temperature controller alarms . . . . . . . . . . . . . . . . . . . . . . .6-4Burner controller alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7Variable speed controller alarms . . . . . . . . . . . . . . . . . . . . .6-10Flue gas high temperature limit switch . . . . . . . . . . . . . . .6-14Process high temperature limit switch . . . . . . . . . . . . . . . .6-15

APPENDIXService/Warranty Information . . . . . . . . . . . . . . . .Appendix A

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1-1UGD014/0497 GasTrac Process Air Heater

l Purpose of the User Guide . . . .1-1l How the guide is organized . . . .1-2l Your responsibilities as a user .1-2l ATTENTION: Read this so

no one gets hurt . . . . . . . . . . . .1-3l How to use the lockout device .1-5

INTRODUCTION

GasTrac Process Air Heater UGD014/04971-2 INTRODUCTION

This User Guide describes the GasTrac process air heater andexplains step-by-step how to install, operate, maintain andrepair this equipment.

Before installing this product, please take a few moments toread the User Guide and review the diagrams and safety infor-mation in the instruction packet. You also should review man-uals covering associated equipment in your system. Thisreview won’t take long, and it could save you valuable instal-lation and operating time later.

Symbols have been used to help organize the User Guide andcall your attention to important information regarding safeinstallation and operation.

Symbols within triangles warn of conditions that couldbe hazardous to users or could damage equipment.Read and take precautions before proceeding.Numbers within shaded squares indicate tasks or stepsto be performed by the user.

A diamond indicates the equipment’s response to anaction performed by the user.

An open box marks items in a checklist.

A shaded circle marks items in a list.

You must be familiar with all safety procedures concerninginstallation, operation and maintenance of this equipment.Responsible safety procedures include:

l Thorough review of this User Guide, paying particularattention to hazard warnings, appendices and relatedmaterials and diagrams.

l Thorough review of the equipment itself, with carefulattention to voltage sources, gas supply, intended use andwarning labels.

l Thorough review of instruction manuals for associatedequipment.

l Step-by-step adherence to instructions outlined in thisUser Guide.

PURPOSE OFTHE USERGUIDE

HOW THEGUIDE ISORGANIZED

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YOURRESPONSIBILITYAS A USER

UGD014/0497 GasTrac Process Air Heater INTRODUCTION 1-3

We design equipment with the user’s safety in mind. You canavoid the potential hazards identified on this machine by fol-lowing the procedures outlined below and elsewhere in theUser Guide and related instructional materials.

ATTENTION:READ THIS SO NOONE GETS HURT

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WARNING: Follow instructions carefully.Incorrect installation, operation or maintenance ofthis product can result in a fire, explosion orother hazards causing property damage, severepersonal injury or loss of life.

Only licensed electrical/mechanical contractors, orindividuals experienced with the installation of nat-ural gas piping, process air ducting, thermal insula-tion, exhaust ducting and regional codes for indus-trial gas appliances, should install the GasTrac.

The GasTrac should be maintained and repairedby qualified technicians who are equipped with thecorrect tools and are experienced in the mainte-nance and repair of industrial gas appliances.

Inspection and testing of gas supply piping,exhaust ducting and the GasTrac gas controls andsafety features should be performed periodically toensure safe operation.

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WARNING: If gas odor is detected...r Open doors and/or windows to vent the gas.r Do not touch electrical switches.r Extinguish all open flames.r Immediately have qualified personnel deter-mine the source of the gas leak and repair it.

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WARNING: Do not store or placeaerosol, compressed gas or flammablematerials on or near this equipment.The hot temperatures associatedwith the drying process maycause aerosols or other flammable materials placed orstored near the GasTrac toexplode.

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GasTrac Process Air Heater UGD014/04971-4 INTRODUCTION

WARNING: Hot surfaces.Temperatures inside the GasTrac canreach more than 800Þ F. Always shutdown the GasTrac and host dryer andwait for them to cool before servicing. Donot remove the safety guard covering theGasTrac burner and heat exchanger.

WARNING: Disconnect and lock outmain power before servicing.The GasTrac is connected to high volt-age. Always disconnect and lock out themain power source to the GasTrac beforeservicing. Also disconnect and lock outmain power to the host dryer before ser-vicing the GasTrac. Failure to disconnectand lock out this voltage source couldresult in severe personal injury.

WARNING: Shut off main gas supplyand purge heat exchanger and gaslines before servicing.If the fuel train, burner, ultraviolet sensor,sight glass or ignition are to be serviced,it is important that the GasTrac heatexchanger and gas lines are purged ofnatural gas. Failure to eliminate thispotential source of a gas leak could resultin severe damage, personal injury or lossof life.

WARNING: Do not operate theGasTrac with safety features disabledor removed.The GasTrac has been equipped withnumerous guards, controls and devicesto ensure safe operation. Never removeor disable these devices to sustain pro-duction. Operating without these devicescould lead to hazardous conditions thatcan damage the facility or cause severeinjury or loss of life.

ATTENTION:READ THIS SO NOONE GETS HURT

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UGD014/0497 GasTrac Process Air Heater INTRODUCTION 1-5

CAUTION: Before performing maintenanceor repairs on this product, you should disconnectand lock out electrical power sources to preventinjury from unexpected energization or start-up. Alockable device has been provided to isolate thisproduct from potentially hazardous electricity.

Lockout is the preferred method of isolating machines orequipment from energy sources. Your Conair product isequipped with the lockout device pictured below. To use thelockout device:

Stop or turn off the equipment.

Isolate the equipment fromelectrical power.Turn the rotary disconnectswitch to Off, or O position.

Secure the device with anassigned lock or tag.

The equipment is now locked out.

WARNING: Before removing lockoutdevices and returning switches to the ON position,make sure that all personnel are clear of themachine, tools have been removed and all safetyguards reinstalled.

HOW TO USETHE LOCKOUTDEVICE

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l What is the GasTrac? . . . . . . . . .2-1l Typical applications . . . . . . . . . .2-2l How it works . . . . . . . . . . . . . . . .2-4l Fuel train features

and controls . . . . . . . . . . . . . .2-6l Specifications: GasTrac . . . . . . .2-8l Specifications: Exhaust flue . . .2-9l Specifications: Main power

supply wire . . . . . . . . . . . . . . .2-9

DESCRIPTION

The GasTrac Process Air Heater is a stand-alone, gas-firedheater designed to replace the electric process air heater in anexisting dehumidifying dryer or crystalizer. The GasTracallows plastics processors to convert existing electric equip-ment to a less-expensive gas source.

The GasTrac contains a metal-ceramic burner, heat exchanger,combustion system and temperature controller to set andmaintain the temperature of the air entering a drying hopper.The host dryer’s desiccant beds dry the air. The host dryer’sprocess blower circulates air through the GasTrac heatexchanger and the hopper.

The GasTrac’s temperature controller, ignition system andburner safeguards communicate with the host dryer through aRS-485 serial interface port.

The GasTrac can be used successfully in applications thatrequire:

l Drying of hygroscopic plastics at temperatures rangingfrom 250Þ F to 350Þ F.

l Hot air drying of non-hygroscopic plastics.l Process, or drying, air flow of 600 to 1800 cfm. Higheror lower air flow ranges may be achieved, dependingon the model of the host dryer and the GasTrac select-ed.

l Central drying, using an existing electric dryer with asingle GasTrac or multiple GasTrac units.

The GasTrac has been designed and configured at the factoryfor use with natural gas only. If you want to use a differentgas fuel source, such as propane, you must contact Conair.

WHAT IS THEGASTRAC?

GasTrac Process Air Heater UGD014/04972-2 DESCRIPTION

TYPICALAPPLICATIONS

TYPICALAPPLICATIONS

UGD014/0497 GasTrac Process Air Heater DESCRIPTION 2-3

The GasTrac may be installed on a mezzanine or on the floorbetween the host dryer and the drying hopper. You can useflexible hose or pipe to deliver air between the host dryer, theGasTrac and the drying hopper.

Mezzanineinstallation

Floorinstallation

HOW IT WORKS

GasTrac Gas-Fired process Air Heater UGD014/04972-4 DESCRIPTION

ESC SEL

Combustion Blower

RUNMAN

234.0250.0SP2

OP1

OP2

REM

HOLD

2216

ESC SEL

The GasTrac has three interfaced controls that:l Ignite the metal-ceramic burner and monitor the GasTraccombustion circuit.

l Heat the dry air to the setpoint temperature.l Monitor the air temperature as it enters the drying hopper. l Automatically adjust the mixture of combustion air andgas to maintain the setpoint temperature.

TemperatureRTD probe atthe hopperinlet

The Temperature ControllerYou enter the setpoint temperature in the Temperature Controller on themain GasTrac control. The temperature controller monitors temperature atthe drying hopper inlet. When the actual temperature must increase ordecrease to maintain setpoint, this controller sends a 4 to 20 MA signal tothe variable speed controller.

Burner ControllerThe Burner Controller is activatedwhen you press the RUN button onthe main GasTrac control. The burnercontroller sends a signal to the sparkigniter, which fires the metal-ceramicburner. This controller continues tomonitor the fuel train, combustionblower and other combustion systemsfor possible problems.

Variable Speed ControllerThe Variable Speed Controller automatically adjusts the speed of the combus-tion blower by varying the frequency and voltage of the signal. Increasing thespeed increases the air-to-fuel mixture and the heat output of the burner.

4 to 20 MAsignal

varyingfrequency

HOW IT WORKS


100

150200

250

300

350

4000

50

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150

200

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150200

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300

350

4000

50

100

150

200

50

0

The Process Air Circuit

The Combustion Air Circuit

The process blower in the hostdryer sends dehumidified air intothe GasTrac heat exchanger.The heated dry air exits

the GasTrac. The air isblown by the host dryerto the drying hopper.

The air is heated to the setpoint temperatureas it passes over and around the burnercylinder and surrounding baffles.

The combustion blowerpulls ambient air intothe combustion circuitthrough a filter. The airis then blown to theproportional gas mixer.

1a2 Gas and air are mixed

in the proportionneeded to achieve thesetpoint temperature.

The GasTrac has two separate air circuits: the combustion aircircuit and the process air circuit.

Gas entersthe fuel train.1b

The air/gas mixtureenters the burner,where it is ignitedby a spark.

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Combustion air flows through the burnercylinder and the exhaust tube bundles.

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Combustiongases exhaustthrough a flue.

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The fuel train includes two automatic and manual safety gasshutoff valves, four pressure switches, and a gas regulator andgovernor to assure safe feeding of gas to the combustion burn-er. The four pressure switches monitor gas pressure andprocess air flow. The GasTrac will automatically shut down ifa pressure switch senses an unsafe condition.

FUEL TRAINFEATURES ANDCONTROLS

GasTrac horizontal models

Combustion air filter

Zero Gas Governorcontrols the gas feed tothe proportional mixer.

Manual burnerinlet gas shut-off valve

Proportional MixerMixes air and gas inthe correct proportionto produce the requiredheat.

Combustion airpressure switch

Primary automaticsafety shutoff valve

Secondary automatic safetyshutoff valve

Process air differential pressure switch

Combustion air blower

Low gas pressure switch

High gas pressure switch

Gas inlet pressure gaugeManual gas supplyshutoff valve

Regulated gas pressure gauge

Gas pressure regulator


GasTrac upright models

Combustion air filter

Proportional MixerMixes air and gas inthe correct proportionto produce the requiredheat.

FUEL TRAINFEATURES ANDCONTROLS

Combustion air blower

Gas inlet pressure gauge

Manual gas supplyshutoff valve

Regulated gas pressure gauge

Gas pressure regulator

Zero Gas Governorcontrols the gas feed tothe proportional mixer.

Manual burnerinlet gas shut-off valve

Primary automaticsafety shutoff valve

Secondary automatic safetyshutoff valve

Process air differential pressure switch

High gas pressure switch

Low gas pressure switch

Combustion airpressure switch

SPECIFICATIONS: GASTRAC


H

W

D

Dimensions H W D Weight Air inlet/outletin./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 12/30CGT700HV Upright Model 67/170.2 39/99 64/162.6 1115/505.7 12/30CGT500HH Horizontal Model 61/154.9 37/93.9 64/162.6 880/399.2 8/20.3CGT500HV Upright Model 65/165.1 39/99 64/162.6 880/399.2 8/20.3CGT350HH Horizontal Model 54/137.2 29/73.7 66/167.6 695/315.2 8/20.3CGT350HV Upright Model 58/147.3 31/78.7 56/142.2 695/315.2 8/20.3Remotable GasTrac control 3.5/8.9 12.5/31.7 6/15.2 — —

W

H

W

D

CGTHH horizontal model CGTHV upright model

HD

RemotableGasTrac control

CGT700 models CGT500 models CGT350 modelsGeneralTemperature range 250-350ÞF / 122-177ÞC 250-350ÞF / 122-177ÞC 250-350ÞF / 122-177ÞCMaximum Flue Temperature 750ÞF / 399ÞC 750ÞF / 399ÞC 750ÞF / 399ÞCCombustion blower 1.5 Hp Peripheral 1 Hp Peripheral 1 Hp PeripheralIgnition source Spark igniter, interrupted Spark igniter, interrupted Spark igniter, interruptedBurner type Metal-ceramic Metal-ceramic Metal-ceramicMinimum burner capacity 150,000 BTU/hr 125,000 BTU/hr 90,000 BTU/hrMaximum burner capacity 700,000 BTU/hr 500,000 BTU/hr 350,000 BTU/hrGas consumption 230 CFH @ 250ÞF/1200 CFM 150 CFH @ 250ÞF/800 CFM 105 CFH @ 250ÞF/600 CFM

675 CFH @ 350ÞF/1800 CFM 465 CFH @ 350ÞF/1200 CFM 325 CFH @ 350ÞF/800 CFMGas pressure to regulator 10 - 20 inches of water / 2.49 - 4.98 kilopascalsGas pressure from regulator 4 - 7 inches of water / 0.99 - 1.74 kilopascalsGas heating value 1000 BTU/ft3

ElectricalAvailable voltages / Total Amps240 V/3 phase/60 Hz 4.8 A 2.5 A 2.0 A380 V/3 phase/50 Hz 3.0 A 1.6 A 1.3 A415 V/3 phase/50 Hz 2.7 A 1.5 A 1.2 A480 V/3 phase/60 Hz 2.4 A 1.3 A 1.0 ATotal Kilowatts 1.9 kw 1.0 kw 0.8 kw

Emissions (all models)Primary excess air 10% - 30%Oxygen (O2) [Ideal 3%-4%] 2% - 5% acceptable rangeCarbon Dioxide (CO2) 9% - 10.5%Carbon Monoxide (CO) < 10 ppm corrected to 3% O2NOX < 20 ppm corrected to 3% O2Unburned hydrocarbons < 10 ppm corrected to 3% O2

NOTE: Elevations 3000 feet above sea level must be specified at time of purchase.

All GasTrac models meet: UL 372, UL 795, FM, CGA,AGA, NFPA 54, NFPA 79,NFPA 86 and IAS


SPECIFICATIONS: MAIN POWER SUPPLY WIREThe main power wire must be:l Grounded and secured with a strain relief.l Correctly sized for the current drawn.

Allowable ampacities of Copper ConductorsU.S.A. Canada European Community

75ÞC insulation 90ÞC insulation 70ÞC insulation; 40ÞC ambient airConductor 30ÞC ambient air 40ÞC ambient air Ground wire Conductor MaximumSize AWG Maximum Full Load Amps Size AWG Size mm2 Full Load Amps

14 15 13 14 2,5 1612 20 17 12 4 2310 30 27 10 6 298 43 47 10 10 40

NOTE: Local or regional electrical guidelines may have specifications that differ from the above national codes.You should comply with the codes for your area.

SPECIFICATIONS: EXHAUST FLUEThe 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 combustiongases produced by this appliance. The purchaser is responsible for installing anexhaust flue that meets all local, regional and national codes in the installation area.For you safety, Conair recommends that you consult a licensed mechanical contrac-tor who is familiar with gas flue and ducting codes in your area.

GasTrac operating characteristicsMaximum flue temperature 750ÞF / 399ÞCMinimum vent size (single unit installation) CGT350: 4 in. / 10.2 cm

CGT500: 6 in. / 15 cmCGT700: 6 in. / 15 cm

Vent pressure at flue collar 1 to 2 in. water column

Installation recommendationsr Provide each GasTrac with a dedicated, vertical stack that exits thebuilding vertically through a rain-protected roof penetration. Limit anyhorizontal ducting runs to 4 feet.

r Use a stainless steel, fabricated chimney flue.r Vent size should be 6 inches in diameter. If you connect multipleGasTrac units to a stack manifold, adjust the stack size accordingly.

r Static pressure at the flue collar must not exceed 1 to 2 inches watercolumn.

r Install an induced draft fan between the GasTrac exhaust outlet andstack ducting, if you have more than 1 to 2 inches water column pres-sure at the flue collar while the GasTrac is operating.


l Unpacking the boxes . . . . . . . . .3-2l Preparing for installation . . . . . .3-3l Installing the GasTrac . . . . . . . . .3-4l Replacing the host dryer’s

process air heater . . . . . . . . .3-4l Installing the exhaust flue . . . . .3-5l Connecting process air lines . . .3-6l Connecting the gas supply . . . .3-6l Connecting the main power . . . .3-7l Installing the RTD probe . . . . . .3-7l Testing the installation . . . . . . . .3-8

INSTALLATION

UNPACKINGTHE BOXES

GasTrac Process Air Heater UGD014/04973-2 INSTALLATION

Carefully remove the GasTrac and componentsfrom their shipping containers.

Remove all packing material, protective paper, tape and plastic. Be sure to examine packing material beforediscarding. What looks like filler may contain parts, hard-ware or instructional materials.

Carefully inspect all components. Make sure youhave the correct model and all necessary hardware. Checkfor any damage that may have occurred during shipping. Ifyou do find freight damage, you should immediately file adamage claim against the delivering carrier.

Take a moment to record serial numbers, electri-cal power and gas specifications in the blanks provided onthe back of the User Guide title page. This informationwill be helpful if you ever need service or parts.

You are now ready to begin installation.Follow all preparation steps beginning on the next page.

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Optional RemoteControl Bracket

If you ordered the optionalbracket for mounting theGasTrac control in aremote location, see theAppendix for installationinstructions.

Exhaustflue elbow

Exhaustflue Tee

1 “V” clamp

2 “V”clamps

Temperatureprobe (RTD)

Exhaustflue Tee

Temperatureprobe (RTD)

The GasTrac Process Air Heater arrives assembled. The RTDtemperature probe is packaged inside the electrical enclosure.Depending on the model and options ordered, you alsoshould receive boxes containing V clamps and piping toattach the GasTrac exhaust to a customer-installed flue.

CGT horizontal model CGT upright model

Select a location for the GasTrac. The location:r Should be between the host dryer and the hopper.For minimal heat loss, the GasTrac should be no more than10 feet from the drying hopper. The GasTrac control mustbe within 10 feet of the drying hopper inlet, unless optionalcable extensions for the RTD temperature probe have beenpurchased.r Must allow for installation of an exhaust flue thatmeets all local, regional and national codes. Ideally, eachGasTrac should have a dedicated vertical stack that exitsthe building through a rain-protected roof penetration.r Must provide minimum clearance for safe opera-tion and maintenance. For efficient combustion, youmust not obstruct air flow around the

unit.

Install electrical power to the selected location.The GasTrac requires a grounded, three-phase powersource. Check the GasTrac’s serial tag for the correct amps,voltage and cycles for your model. All electrical wiringshould be completed by qualified personnel and shouldcomply with government codes in your region.

Install gas piping to the selected location.Gas delivery piping should be sized to provide the ratedgas flow to the GasTrac at a delivery pressure of about 12inches water column (about 1/2 psig). All gas piping shouldbe completed by qualified personnel and should complywith government codes in your region.

PREPARING FORINSTALLATION

UGD014/0497 GasTrac Process Air Heater INSTALLATION 3-3

WARNING: Follow instructions carefully.Incorrect installation of this product can result in afire, explosion or other hazards causing propertydamage, severe personal injury or loss of life. Onlylicensed electrical/mechanical contractors, or indi-viduals experienced with the installation of naturalgas piping, process air ducting, thermal insulationand exhaust ducting, should install the GasTrac.

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18 inches

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NOTE: For reliable longtermperformance, the gas supplyline should include:r A water trap to collect

water condensing in thegas line.

r An in-line, basket-typefilter to collect rust, pipescale or welding slag.

Move the GasTrac to the selected location.Be sure to position the GasTrac so that you can easily:r Connect the gas and main power supplies.r Install the flue stack.r Connect process air hoses or lines between the hostdryer, GasTrac and drying hopper.

Secure the GasTrac to the mounting surface.We have provided 1 3/8-inch diameter holes in the base ofthe GasTrac for bolting the unit to a mounting surface.

You must disconnect the host dryer’s process heater becausethe GasTrac replaces it. You will need the wiring diagramsand instruction manuals for your host dryer to determinewhich wires to disconnect and which air lines to remove orreroute.

Disconnect and lock out power to the hostdryer. If the dryer has been operating recently, wait forthe dryer too cool down before continuing to Step 2.

Disconnect the electrical wires between the hostdryer control and the process heating elements.

Disconnect and reroute the process air lines.The host dryer’s process air outlet must be connected tothe GasTrac instead of the drying hopper. To reduce thepressure drop in the process air circuit, you may need toremove the process heater or reroute process air lineswithin the dryer to bypass the process heater. Refer to themanuals and diagrams that came with your dryer.

INSTALLING THEGASTRAC


WARNING: You are responsible for thestructural integrity of this installation.If you are installing the GasTrac on a mezzanine,the host dryer or another device, be sure that themounting surface can support the weight of theGasTrac. See the specification tables for weights.

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CAUTION: Use a suitable lifting device tomove the GasTrac.The GasTrac models weigh up to 1,400 pounds.Always use a forklift or other suitable lifting deviceto move the unit. The GasTrac has been equippedwith forklift rails.

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DISCONNECTINGTHE DRYER’SPROCESS AIRHEATER

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The GasTrac is a forced draft system, using a variable speedcombustion blower and a sealed combustion chamber. The tem-perature of combustion gases in the flue can reach 750Þ F.

Install the exhaust ducting and flue.Consult government codes and a qualified mechanical con-tractor for detailed installation instructions and assistance.See the SPECIFICATIONS pages of this User Guide for GasTracoperating characteristics and general recommendations.

Connect the flue to the GasTrac’s exhaust outlet.Attach the T pipe to the GasTrac’sexhaust outlet using the V clampprovided. Connect the T pipe to theexhaust flue. On an upright model,you must attach the elbow to theexhaust outlet before connectingthe T pipe and flue.

Insulate the flue and exhaust T assembly.Exhaust flue and T temperatures can reach 750Þ F.

Install a condensate trap and drain.Condensate occurs where flue gases cool below their dewpoint. This condensate can be highly corrosive. Drainingand disposal should be done in compliance with applicablesafety and environmental codes in your area.

INSTALLING THEEXHAUST FLUE


WARNING: Do not operate the GasTracwithout a properly installed exhaust flue.You must install an exhaust flue to vent the combus-tion gases produced by the GasTrac. The installationshould comply with government codes in your areaand be done by a qualified mechanical contractorfamiliar with industrial flue and ducting systems.

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T pipe

T pipe

V clamp

Elbow

Flue

Exhaust outlet

Condensatedrain

Flue

Condensatedrain

V clamp

Exhaustoutlet

TIP: A condensate trapand drain can be madeby bending a piece ofstainlesssteel tubing.Secure thedrain to theT pipe usingthe appropriate compression fitting.

The process air lines carry dehumidified air from the hostdryer to the GasTrac, and from the GasTrac to the drying hop-per. These air lines can be flexible hose or pipe. The air linebetween the GasTrac and host dryer can be uninsulated. Werecommend an insulated air line between the GasTrac and thedrying hopper to minimize heat loss.

Connect the GasTrac process air inlet to the hostdryer’s process air outlet. Secure the air lines withhose or pipe clamps.

Connect the GasTrac process air outlet to the dry-ing hopper air inlet. Secure the air lines with hose orpipe clamps.

CONNECTINGPROCESS AIRLINES


NOTE: Do not allowthe flexible hoses tokink or crimp.

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CONNECTINGTHE GASSUPPLY

WARNING: For your safety, we recommend thatthese steps be completed by a qualified mechanicalcontractor in compliance with all applicable naturalgas codes in your region.

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Check all gas lines for leaks. Use a gas detectingdevice or apply soapy water around pipe and fittings.

Purge the gas lines after pipe and fittings are knownto be free of leaks. The lines must be free of air, rust,scale, pipe dope and welding slag.

Connect the gas supply line to the inlet on theGasTrac fuel train. Make sure that a water trap and inlinebasket filter has been installed on the supply line.

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GAS INLET FITTING SIZESModel NPT sizeCGT350 3/4 in.CGT500 3/4 in.CGT700 1 in.

Process airfrom dryer

Process airto hopper

Process airto hopper

Gas supplyinlet

Upright model Horizontal model

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Open the GasTrac electrical enclosure.Turn the disconnect dial on the GasTrac’s doorto the Off position. Turn the captive screw, andswing the door open.

Insert the main power wire through the knockout inthe electrical enclosure. Secure the wire with a rubbercompression fitting or strain relief.

Connect the power wires to the three terminalsat the top of the disconnect holder.

Connect the ground wire to either groundingpoint shown in the diagram.

CONNECTINGMAIN POWER


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CAUTION: Electrical hazard.Always disconnect and lock out the mainpower sources before making electricalconnections. Electrical connections shouldbe made only by qualified personnel.

IMPORTANT: Always refer tothe wiring diagrams that came withthe GasTrac for the most accurateinformation about electrical com-ponents and connections.

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INSTALLING THERTD PROBE

The RTD probe monitors the temperature of the drying air asit enters the hopper. If the probe is not installed correctly, tem-perature readings will be inaccurate.

Insert the probe in thedelivery air inlet of thehopper. The end of the probemust not touch the walls ofthe inlet pipe. Most hoppersprovide a hole that is compat-ible with the probe’s 1/8-inchNPT compression fitting.

Plug the probe’s cableinto the GasTrac controlbox. Coil any excess cable andsecure with a wire tie.

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You have completed the installation. Now its time to makesure everything works. Qualified electrical and mechanicalpersonnel should be available during the systems check andthe installation test.

Check all electrical connections.r Shut off power to the unit and verify that the GasTracand its burner controller are adequately grounded.Inadequate grounding can cause controller error mes-sages and nuisance alarms.

r With power off to the GasTrac and the host dryer,verify that all terminal connections are tight and all newwiring has adequate strain relief.

Check gas piping and ducting.r Verify that the gas delivery piping is rigidly support-ed.

r Verify that exhaust gas ducting is secured, adequatelyinsulated and free of leaks.

Check the GasTrac fuel train for leaks.Turn on the gas supply to the GasTrac. Open the primarygas shutoff valve. Use a gas leak detection device or asquirt bottle of soapy water to detect leaks around gas pipeand fitting joints. Open the secondary gas shutoff valve,and continue checking for leaks using the same procedure.

Start the host dryer. Monitor the dryer during the first few minutes of operationto verify that the start-up operating sequences are correct.

Turn on the gas supply to the GasTrac.All manual shut-off valves in the gas supply line and theGasTrac fuel train must be in the open position. Beforeproceeding, use a detection device or soapy water to checkfor gas leaks in the GasTrac fuel train.

Turn on main power to the GasTrac.Turn the main disconnect dial to the I or ONposition.If everything is installed correctly:u The variable speed control’s display willilluminate.

GAS ANDELECTRICALSYSTEMCHECKS


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WARNING: Be sure lines are free of leaks.To prevent accident or injury, all gas lines, includingthe GasTrac’s factory-mounted gas train, should bechecked for leaks before firing the burner.

TESTING THEINSTALLATION

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Press the Power switch to ON.u The Power ON/OFF switch illuminates.u The temperature controller begins a 3-second self-test. The display will flash between STANDBY and thesetpoint temperature.

u The Burner Controller begins a 10-second initiation,which ends when the display indicates STANDBY.

Set the drying temperature.Press the the up or down arrow on the temperature con-troller until 250ÞF appears in the lower display.

Press the RUN button.u The green RUN light will illuminate after the BurnerController finishes initializing.

u The combustion blower will start and run for 90 sec-onds to purge any residual gas from the burner.

u After the 90-second purge, the burner will ignite onlow fire (low blower speed) for about 15 seconds. Theburner will alternate between high and low fire asrequired to maintain the setpoint temperature.

Verify the combustion blower is rotating in thecorrect direction.The combustion blower uses three-phase blower. Hold astrip 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.Disconnect and lock out the main power source. Reverseany two incoming electrical leads on the blower and repeatthe test procedure.

Allow the actual temperature to reach setpoint.Press the STOP button.u The green RUN indicator light turns off.u The gas inlet valves should close.u The combustion blower should stop.u The burner and temperature controllers should dis-play STANDBY.

Allow the actual temperature to reach setpoint.

TESTING THEINSTALLATION


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BURNER START UP NOTE:If the burner fails to igniteand the red alarm light illumi-nates, there may still be airin the gas lines. Check theburner controller display. Ifthe alarm LED is illuminated,press the reset button on thefront of the electrical enclo-sure. If not, refer to theTROUBLESHOOTING section ofthe User Guide and theburner controller manual.


l GasTrac operating features . . . .4-2l The GasTrac control . . . . . . . . . .4-3l To start drying . . . . . . . . . . . . . . .4-4l To stop drying . . . . . . . . . . . . . . .4-5

OPERATION

GASTRACOPERATINGFEATURES

GasTrac Process Air Heater UGD014/04974-2 OPERATION

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Cooling Exhaust FilterPrevents contaminantsfrom entering the elec-trical enclosure throughthe exhaust vent.

The GasTrac ControlThis is the primary operating control. Youturn the GasTrac on or off, enter the setpointdrying temperature and start or stop theGasTrac using this remotable control. Agreen light indicates the GasTrac is running.A red light indicates an alarm condition.

Main PowerDisconnect SwitchTurn the lockable dial toprovide or disconnectelectrical power to theGasTrac.

The OPERATING section introduces the GasTrac operating fea-tures and explains how to use the primary GasTrac control tostart and stop drying. For detailed information about theTemperature, Burner and Variable Speed Controllers, see themanufacturer’s manuals in the instruction packet.

Electrical EnclosureCooling Fan and FilterDraws outside airthrough the enclosureto cool electrical com-ponents.

Process High TemperatureLimit SwitchShuts down the GasTrac whenthe process, or drying, tempera-ture exceeds 450ÞF.

Flue Gas High TemperatureLimit SwitchShuts down the GasTracwhen the combustion exhausttemperature exceeds 800ÞF.

High Temperature LimitSwitch Reset ButtonPush to reset the flue gas andprocess high temperature limitswitches.

Burner ControllerThe Burner Controller is activatedwhen you press the RUN buttonon the main GasTrac control. Theburner controller sends a signal tothe spark igniter, which fires themetal-ceramic burner. This con-troller continues to monitor thefuel train, combustion blower andother combustion components forpossible problems.

Variable Speed ControllerThe Variable Speed Controller automati-cally adjusts the speed of the combustionblower by varying the frequency and volt-age of the signal. Increasing the speedincreases the air-to-fuel mixture and theheat output of the burner.

UGD014/0497 GasTrac Process Air Heater OPERATION 4-3

THE GASTRACCONTROL

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The GasTrac control is the primary operator interface. Thiscontrol may have been mounted in a remote location.

Run ButtonPush to startthe GasTrac.

Emergency Stop ButtonPush to shutdown theGasTrac during an emer-gency. Pull to restorepower before restarting.

Alarm Light An illuminated light Indicates theGasTrac has shutdown on analarm condition. The Trouble-shooting section will help youidentify and correct the problem.

Run LightAn illuminatedlight indicatesthe GasTrac isoperating.

Power On/OffThis switch sends power tothe burner controller, theGasTrac control and theprocess and safeguard relaydevices The switch illumi-nates when power is ON.

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Temperature Controller

OP1: Indicates the variable frequency controller output is active.

SP2: Indicates the controller will control to setpoint #2 when in automatic mode.

MAN: Indicates the controller is being manually operated by the operator.

Actualtemperature

Setpointtemperature

Page buttonPress to select parameter lists during setup and configuration of the controller.

Scroll buttonPress to scroll through parameter lists to select a parameter to modify.

Down buttonPress to decrease a value or scroll down through a list.

Up buttonPress to increase a value or scroll up through a list.

See the Eurotherm TemperatureController manual in the instructionpacket for a full description of alarmmessages, programming modes andparameters.

Stop ButtonPush to stopthe GasTrac.

The temperature controller is factory configured to start andoperate in automatic mode.

Start the host dryer.Turn the main power disconnect tothe I or ON position.u The variable speed controller turns on.

Press the Power switch to ON.u The Power ON/OFF switch illuminates.u The temperature controller begins a 3-second self-test. The display will flash between STANDBY and thesetpoint temperature.

u The Burner Controller begins a 10-second initiation,which ends when the display indicates STANDBY.

Set the drying temperature.Press the the up or down arrow on thetemperature controller until the recom-mended drying temperature appears inthe lower display.

Press the RUN button.u The green RUN light will illuminate after the BurnerController finishes initializing.

u The combustion blower will start and run for 90 sec-onds to purge any residual gas from the burner.

u After the purge, the burner will ignite on low fire(low blower speed) for about 15 seconds. The burnerwill alternate between high and low fire as required tomaintain the setpoint temperature.

TO STARTDRYING

GasTrac Process Air Heater UGD014/04974-4 OPERATION

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NOTE: The temperature units were set at thefactory in ÞF or ÞC, as specified in the order.To see which temperature unit was set:Press the button once. F or C will be displayed.To change the temperature unit:See the Eurotherm Temperature Controller manual

UGD014/0497 GasTrac Process Air Heater OPERATION 4-5

TO STOPDRYING

Press the red STOP button.u The green indicator light turns off.u The gas inlet valves should close.u The combustion blower should stop.

Press the ON/OFF switch to OFF.u The burner control turns off.u The temperature controller turns off.

Turn the main power disconnect off.u The variable speed control displayremains lit for a brief period. Then it becomesblank.

Turn the host dryer off after at least 2 minutes.

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IMPORTANT: Do not shut down the host dryer beforestopping the GasTrac.After stopping the GasTrac, allow the host dryer’sprocess blower to continue running for a minimum of 2minutes. This prevents excessive heat from building upin the GasTrac.

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CAUTION: Voltage presentSome voltage will be present in the vari-able speed drive for a brief period afterpower has been turned off. When thevoltage is gone, the variable speed con-trol display will become blank.


l Maintenance checklist . . . . . . . .5-2l Cleaning the combustion

air filter . . . . . . . . . . . . . . . . . . . .5-3l Cleaning the electrical

enclosure filters . . . . . . . . . . . .5-3l Replacing the spark igniter . . . .5-4l Cleaning the ultraviolet

flame detector . . . . . . . . . . . . . .5-6l Cleaning the burner

sight glass . . . . . . . . . . . . . . . . .5-6

MAINTENANCE

PREVENTATIVEMAINTENANCECHECKLIST

GasTrac Process Air Heater UGD014/04975-2 MAINTENANCE

Routine maintenance will ensure optimum operation and per-formance of the GasTrac. We recommend the following main-tenance schedule and tasks.

l Weekly, or as often as neededr Clean the GasTrac combustion air filter.

You may need to clean the filter more often thanweekly. Frequency depends on the amount of dustin your facility’s air.

r Clean the GasTrac electrical enclosure filters.You may need to clean the filters more often thanweekly. Frequency depends on the amount of dustin your facility’s air.

l Monthlyr Inspect air hoses and hose connections.

Check for damage, kinks or loose hose clamps.Replace any hoses that show signs of damage orwear. Reposition and tighten loose hose clamps.

r Inspect and test safety controls.Fuel safety shutoff valves, combustion safeguardsand temperature and pressure switches should beinspected and tested by trained personnel.

r Inspect the burner sight glass.Clean the sight glass, if needed. Replace the sightglass if you see cracks or any other defect.

l Every six monthsr Inspect the GasTrac metal-ceramic burner.

While the unit is fired, look through the sight glassat the burner. The burner surface should be glowingorange with an even flame. Blue flames, flamesprojecting from the burner surface, or cracks ordark spots on the burner surface indicate damage.You may need to replace the burner.

r Inspect piping, wiring and electrical connections.Check for leaks, corrosion and loose connections.Replace any component that shows signs of dam-age or wear. Tighten loose connections.

l Annuallyr Replace the spark igniter.

To assure optimum performance, you shouldreplace the spark igniter once a year.

r Clean the ultraviolet flame detector lens.Use alcohol and a soft cloth.

You must clean the combustion air intake filter periodically. Aclogged filter reduces air flow through the combustion circuit,which reduces burner efficiency and heat output.

Stop the GasTrac.Press the red STOPbutton, then press therocker switch to OFF.

Disconnect and lock out main power.

Remove the filter shroud.Remove the wing nut and washerthat holds the shroud in place.Lift the shroud up and off.

Remove the filter.Remove the wing nut and washerthat holds the filter in place. Liftthe filter up and off.

Clean the filter.Vacuum or blow dirt and debrisfrom the filter using vacuum orlow-pressure compressedair. When using com-pressed air, blow frominside the filter towardthe outside.

Reassemble .Repeat steps 3 and 4 inreverse order to replacethe filter.

CLEANING THECOMBUSTIONFILTER

UGD014/0497 GasTrac Process Air Heater MAINTENANCE 5-3

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NOTE: Replace anyfilter that has crackedend gaskets or istorn, worn or cloggedwith so much dirt thatit cannot be cleaned.4

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CLEANING THEELECTRICALENCLOSUREFILTERS

Periodically, you should clean the filters covering thecooling fan inlet and outlet on the electrical enclosure.

Remove the the thumbscrews and filters.Clean the filters. Use vacuum or low-pressure com-pressed air to remove loose debris.Wash the filters in warm, soapywater, then rinse and air dry.Replace torn or worn filters.

Reassemble.

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The spark igniter should be replaced at least once a year toassure trouble-free operation. You should replace the igniterbefore the annual period, if you inspect it and find:l The spark gap is less than 0.125 inch. The gap shouldbe between 0.07 and 0.09 inch.

l The igniter insulation is crackedl The spark electrodes are warped or taper to a needle-like shape.

Do not operate the GasTrac with a worn or damaged sparkigniter. A badly burned or warped igniter can cause burnerignition failure.

Stop the GasTrac.Press the red STOPbutton, then press therocker switch to OFF.

Disconnect and lock out main power.Remove the igniter wire. Pull the wire boot, not the wire,away from the spark igniter. If thewire or its boot is cracked, youshould replace it.

Remove the spark igniter.Use a 7¼8 inch sparkplug socket and ratchetto loosen the igniter.Pull the igniter straightout of the GasTrac. Donot allow the sparkigniter to touch theburner surface.

REPLACING THESPARK IGNITER


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IMPORTANT: Whenremoving or inserting thespark igniter, do not allowthe igniter electrode orgrounding rod to touch theburner. You could damagethe burner surface.

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TIP: Before removing the spark igniter for inspection,use a felt tip marker to mark the position of the igniterin its threaded hole. Byindexing the position,you will able to returnthe igniter to the correctposition after inspection. The igniter must beinstalled so that theground rod is 180Þ away from the burner surface.

WARNING: Hot surfacesAllow the GasTracto cool beforeremoving the burn-er guard to performmaintenance.

Mark the position of the grounding rod on thenew spark igniter, using a felt tip marker. This index markmust end up 180Þ away from the burner surface when thespark igniter is inserted and tightened. The electrodeshould be closest to the burner surface.

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 notbend the electrode, and do not allow the spark igniter totouch the burner surface.

Screw the igniter into the threaded fitting.Tighten by handfirst. Then use asocket and ratchetto tighten theigniter one turn ora partial turn untilthe index mark onthe igniter is 180Þaway from theburner surface.

Push the boot and wire onto the spark igniter.Push until you feel the boot snap into place.

UGD014/0497 GasTrac Process Air Heater MAINTENANCE 5-5

Electrode

Grounding rod

5 REPLACING THESPARK IGNITER

180Þ

WARNING: Do not over tighten the spark igniter.You could damage the porcelain insulator.

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A dirty ultraviolet flame detector may fail to recognize burnerignition, which will cause the GasTrac to alarm and shut downautomatically.

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 the mounting nut while hold-ing the flame detector, then pull thedetector away from the viewing hole.

Clean the viewing hole lens.Use a soft cloth or cotton swabmoistened with alcohol.

Replace the flame detector.Align the detector over theviewing hole, and thread the silvermounting nut onto the coupling.Hand tighten first. Then use awrench to tighten the nut an additional quarter turn.


CLEANING THEULTRAVIOLETFLAMEDETECTOR

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CLEANING THEBURNER SIGHTGLASS


A dirty sight glass prohibits inspection or viewing of themetal-ceramic burner during operation.

Stop the GasTrac. Disconnect and lock outmain power.

Remove the screws on thesight glass bracket.

Clean the sight glass.Use a clean soft cloth or cotton swabmoistened with alcohol.

Coat the screw threads witha high-temperature anti-seize com-pound.

Replace the sight glass.Tighten the screws in the bracketto hold the glass in place.

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l Before beginning . . . . . . . . . . . . .6-2l A few words of caution . . . . . . . .6-2l When an alarm occurs . . . . . . . .6-3l How to identify the cause

of an alarm . . . . . . . . . . . . . . . . .6-3l Temperature controller

alarms . . . . . . . . . . . . . . . . . . . . .6-4l Burner controller alarms . . . . . .6-7l Variable speed controller

alarms . . . . . . . . . . . . . . . . . . . .6-10l Flue gas high temperature

limit switch . . . . . . . . . . . . . . . .6-14l Process high temperature

limit switch . . . . . . . . . . . . . . . .6-15

TROUBLESHOOTING

BEFOREBEGINNING

GasTrac Process Air Heater UGD014/04976-2 TROUBLESHOOTING

You can avoid most problems by following the recommendedinstallation and maintenance procedures outlined in this UsersGuide. If you do have a problem, this section will help youdetermine what caused it and tell you how to fix it.

Before you begin troubleshooting:

r Find the wiring and assembly diagram youreceived with your GasTrac. These diagrams will note anycustom features such as special wiring or alarm capabili-ties not covered in the User Guide.

r Find the instruction manuals and diagrams thatwere shipped with the GasTrac and your host dryer.

r Find any installation diagrams or notes which mayhave been generated at the time the GasTrac was

installed.

A FEW WORDSOF CAUTION

WARNING: The GasTrac should be maintainedand repaired by qualified technicians who areequipped with the correct tools and are experi-enced in the maintenance and repair of industrialgas appliances.

WARNING: Hot surfaces.Temperatures inside the GasTrac can reachmore than 800Þ F. Always shut down theGasTrac and host dryer and wait for them to coolbefore servicing.

WARNING: Disconnect and lock out mainpower before servicing.The GasTrac is connected to high voltage.Always disconnect and lock out the main powersource to the GasTrac before servicing. Also dis-connect and lock out the main power to the hostdryer before servicing the GasTrac. Failure todisconnect and lock out this voltage source couldresult in severe personal injury.

WARNING: Shut off main gas supply andpurge heat exchanger and gas lines beforeservicing.Failure to eliminate this potential source of a gasleak could result in severe damage, personalinjury or loss of life.

When there is a problem with the GasTrac the alarm light willilluminate and the GasTrac will shutdown. WHEN AN

ALARM OCCURS

UGD014/0497 GasTrac Process Air Heater TROUBLESHOOTING 6-3

HOW TOIDENTIFY THECAUSE OF ANALARM

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Alarm light

The single alarm may be caused by any one of five majorcontrol components or another device within the GasTrac.

Check the controllers for alarm messages.Causes of the more probable alarm messages can befound in this section of the User Guide. If you don’t findthe alarm message here, then see the manufacturer’s man-ual for that particular controller. These manuals can befound in the instruction packet that came with yourGasTrac.

Check the limit switches for contact closure.Possible causes of switch failure can be found in this section of the User Guide.

Check the GasTrac electrical and gas systems.These checks should be performed only by trained electri-cal and gas technicians equipped with the proper tools.

Control components and indications of failure:

l Temperature controllerDisplays a flashing alarm message.

l Burner controllerDisplays a flashing alarm message.

l Variable speed controllerDisplays a flashing alarm message.

l Process outlet high temperature limit switchVerify switch contact closure.

l Flue gas high temperature limit switchVerify switch contact closure.

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TEMPERATURECONTROLLERALARMS


AlarmDeviationBand

The drying, orprocess circuit, tem-perature is higher orlower than the set-point alarm bandallows.

SensorBreak

The sensor input forRTD temperatureprobe has failed.

Possible causeIs something blocking orrestricting the flow ofdrying, or process, air?

Is the RTD temperatureprobe installed correctly?

Is the temperature rangefor the deviation band toonarrow?

Is the RTD temperatureprobe connection loose orincorrectly installed?

Is the RTD temperatureprobe damaged?

Solutionr Check the process filter inthe host dryer. Clean or replacethe filter if it is clogged ordamaged.r Check the process air hosesfor leaks, crimps, blockage orloose connections. Removeobstructions. Repair leaks orloose connections.r Check the process air blow-er in the host dryer. If it is notrunning correctly, see thedryer’s manual.

Make sure the sensing end ofthe RTD probe is positionednear the center of the processair line at the hopper inlet.Temperature readings will beincorrect if the sensing end istoo close to the wall of theinlet hose or pipe.

Increase the deviation band5ÞF at a time. The default set-ting is 20ÞF. To avoid nuisancealarms, do not adjust this bandmore than necessary.

r Verify that the RTD temper-ature probe is installed.r Check for a loose RTD con-nection at the GasTrac controlor the process air inlet of thehopper.

Replace the RTD temperatureprobe.

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The Temperature Controller will flash an alarmmessage in the upper or lower display window.

WARNING: The GasTrac should be test-ed and repaired only by qualified techniciansequipped with the correct tools and trained inthe maintenance and repair of electrical sys-tems and industrial gas appliances.

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AlarmLoopBreak

The actual dryingtemperature did notapproach the set-point within the loopbreak time. Theremay be a problem inthe combustion orprocess air circuit.

PowerFailure

The line voltage tothe TemperatureController is too low.


Is the GasTrac combus-tion air filter dirty?

Is the Variable SpeedController operating cor-rectly?

Is the setpoint correct?

Is the GasTrac being sup-plied with the correctvoltage?

Is there a loose or faultyconnection in the electri-cal circuit?

Solutionr Check the process filter inthe host dryer. Clean the filter,or replace it if it is damaged.r Check the process air hosesfor leaks, crimps, blockage orloose connections. Removeobstructions. Repair leaks orloose connections.r Check the process air blow-er in the host dryer. If it is notrunning correctly, see thedryer’s manual.

Clean the combustion air filter.Replace the filter if it is torn ortoo clogged with dirt to clean.

Check the Variable SpeedController for error or alarmmessages. See the VariableSpeed Controller pages in thisTROUBLESHOOTING section and inthe Allen-Bradley controllermanual.

Make sure the setpoint is with-in the range specified for yourGasTrac unit.

Check the main power supplyto the GasTrac and the electri-cal circuits supplying power tothe control panel and the tem-perature controller.

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Alarm

The ROM self testfailed.

The RAM self testfailed.

Watchdog failure

Keyboard failure

Input Circuit failure

Possible causeThe temperature con-troller is defective.

The temperature con-troller is defective.


A button on the tempera-ture controller keypad isstuck or was pressed dur-ing power up.


SolutionReplace the temperature 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 theGasTrac control off and the onusing the POWER ON/OFFswitch. Do not touch any but-tons on the temperature con-troller.





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BURNERCONTROLLERALARMS


When there is a problem related to theburner or ignition, the burner controllerdisplays a fault code and illuminates analarm light. To restart the GasTrac after aburner controller alarm:

Press the GasTrac STOP button.Press the burner RESET button.Press the GasTrac RUN button.

Alarm

Flame did not occurwithin the 4-secondflame establishingperiod.

WARNING:The GasTracshould be testedand repaired onlyby qualified techni-cians equippedwith the correcttools and trained inthe maintenanceand repair of elec-trical systems andindustrial gasappliances.

Possible causeIs the spark igniter pro-viding a spark?

Is there a problem withthe gas supply?

Is the lens of the ultravio-let sensor dirty?

Is negative pressure inthe building affecting sta-tic pressure of the com-bustion exhaust flue?

Is the burner controllerdefective?

SolutionRestart the GasTrac while watch-ing through the sight glass. If youdon’t see a spark during the 4-second ignition period:r Verify there is power suppliedto the transformer during theignition period.r Check the wire and connec-tions between the transformerand spark igniter.r Check the spark igniter.Replace if damaged.

If the burner fails to light eventhough you can see a spark:r Verify that the gas supply ison and that the gas shutoffvalves are open during theignition period.r Restart the GasTrac 4 or 5times to purge any air that maybe in the gas lines.r Verify that the gas pressureregulator is set to supply thecorrect pressure.

If the burner ignites and thengoes out, check the lens for dirt.Clean if necessary.

Verify that the static pressure ofthe combustion exhaust flue is 1to 2 inches of water column. Ifnot, you may need to add a draftfan to the flue to create the cor-rect static pressure.

If none of the solutions above canresolve the problem, you mayneed to replace the burner con-troller.

123

LOCKOUT #16*Flame Out Timer*

!


Alarm

The main flamefailed after RUN waspushed and theflame had beenestablished for atleast 10 seconds.


Possible causeAre the gas shutoff valvesopen?

Did the ultraviolet flamedetector fail to send anadequate signal?

Are the safety pressureswitches malfunctioningor detecting incorrectpressures?

Is the gas pressure regu-lator adjusted correctly?

Solutionr Verify that the manual gasshutoff valves are open.

r Verify that the automatic gasshutoff valves remain openafter burner ignition. If auto-matic shutoff valves are notopening, check the solenoidelectrical connections.

During operation, the flame sig-nal should fluctuate between1.25V and 5V D.C.r Verify that the ultravioletflame detector lens is clean.

r Check for blockage in thecooling air line between theultraviolet sensor and com-bustion air blower. The tem-perature at the sensor mustbe less than 215ÞF.

r The sensor or flame amplifi-er may need to be replaced.

Reset the GasTrac, press RUNand check the LED lights onthe process air, combustion air,low gas and high gas pressureswitches during the 90-secondpurge cycle. If a light is notgreen, check for leaks, block-age or other problems thatcould interfere with air or gasflow detected by that switch.

Make sure the gas pressure reg-ulator is adjusted to supply thepressure outlined in theSPECIFICATIONS pages.




123

LOCKOUT #17*Main Flame Fail*

!



Alarm

OR

WARNING:The GasTrac

should be testedand repaired onlyby qualified techni-cians equippedwith the correcttools and trained inthe maintenanceand repair of elec-trical systems andindustrial gasappliances.

Possible causeIs the combustion blowerintake filter clogged?

Are the safety pressureswitches malfunctioningor detecting incorrectpressures?

Did the airflow interlockfail closed?

SolutionClean the filter. Replace thefilter if it is worn, torn or soclogged with dirt that it can’tbe cleaned.

Reset the GasTrac, press RUNand check the LED lights onthe process air, combustion air,low gas and high gas pressureswitches during the 90-secondpurge cycle. If a light is notgreen, check for leaks, block-age or other problems thatcould interfere with air or gasflow detected by that switch.

Switch the burner controllerRUN/TEST button to TEST.Press the RUN button on theGasTrac control. Measure thevoltage between terminal 7 andG (ground). You should find120V present if the interlock isworking.



123

LOCKOUT #23

!

LOCKOUT #32

VARIABLE SPEEDCONTROLLERALARMS


Alarm

Power Loss

Under Voltage

Over Voltage

Motor Stall

Possible causeDC Bus Voltage remainedbelow 85% nominal formore than 5 seconds onpower up.

DC Bus Voltage fell belowthe minimum.

DC Bus Voltage exceededthe maximum.

Motor has stalled.

SolutionCheck for proper incoming ACvoltage.

Check for low incoming ACvoltage or power interruption.The under voltage trip pointfor 200-240 VAC units is: 210VDC, which is equal to 150VAC incoming voltage.The under voltage trip pointfor 380-460 VAC units is: 390VDC, which is equal to 275VAC incoming voltage.

Bus over voltage may becaused by motor regeneration.Check for high incoming ACvoltage.The over voltage trip point for200-240 VAC units is: 410VDC, which is equal to 290VAC incoming voltage.The under voltage trip pointfor 380-460 VAC units is:815VDC, which is equal to575 VAC incoming voltage.

Check for physical or mechan-ical blockage of the combus-tion blower fan.

07 03

07 04

07 05

07 06

ESC SEL

When a problem occurs, the variable speedcontroller displays the parameter 07 and atwo-digit fault code. You must correct theproblem before restarting the GasTrac. Torestart after an alarm:

Turn the power disconnect OFF then ON.Press the GasTrac RUN button.

12

WARNING: The GasTrac should be tested andrepaired only by qualified technicians equipped with thecorrect tools and trained in the maintenance and repairof electrical systems and industrial gas appliances.

!

Fault code


Alarm

Motor Overload

Over Temperature

Over current

EEPROM Fault

Possible causeThe internal electronicoverload tripped.

Excessive heat wasdetected in the variablespeed control.

Excessively high currentwas detected in the hard-ware trip circuit.

The controller EEPROMhas invalid data.

Solutionr Check for physical ormechanical blockage of thecombustion blower fan.

r Check for a faulty combus-tion blower motor.

r Clean the air filters on bothsides of the GasTrac electri-cal enclosure. Verify thatthe cooling fan in the elec-trical enclosure is operatingcorrectly.

r Check for dirty or blockedheat sink passages or afaulty fan inside the vari-able speed controller.

r Check for a short circuit atthe variable speed controloutput.

r Check for physical ormechanical blockage of thecombustion blower fan.

Reset EEPROM. See ResettingFactory Defaults in the AllenBradley variable speed con-troller manual.

07 07

07 08

07 12

07 32


ESC SEL



12


!

Fault code


Alarm

Phase U Fault

Phase V Fault

Phase W Fault

Phase UV ShortFault

Phase UW ShortFault

Possible causeThe controller has detect-ed a phase U-to-groundfault between the con-troller and combustionblower motor.

The controller has detect-ed a phase V-to-groundfault between the con-troller and combustionblower motor.

The controller has detect-ed a phase W-to-groundfault between the con-troller and combustionblower motor.

Excessive voltage wasdetected between the Uand V controller outputphases.

Excessive voltage wasdetected between the Uand W controller outputphases.

Solutionr Check the wiring betweenthe control and motor fordamage or incorrect connec-tions.

r Make sure the motorground is wired correctly.

r Check the wiring betweenthe control and motor fordamage or incorrect connec-tions.


r Check the wiring betweenthe control and motor fordamage or incorrect connec-tions.


r Check for a shorted con-dition in the wiring to thecontroller.

r Check motor wiring for ashorted condition.

r Check for a shorted con-dition in the wiring to thecontroller.

r Check motor wiring.

07 38

07 39

07 40

07 41

07 42


ESC SEL



12


!

Fault code


Alarm

Phase VW ShortFault

Power Test Fault

Possible causeExcessive voltage wasdetected between the Vand W controller outputphases.

An electrical fault wasdetected during the initialstart-up sequence.

Solutionr Check for a shorted con-dition in the wiring to thecontroller.

r Check motor wiring.

r Check wiring to the con-troller.

r Check wiring to themotor.

07 43

07 48

VARIABLE SPEEDCONTROLLERALARMSESC SEL



12


!

Fault code


AlarmThe control panelalarm light is on, butno other controlleralarm messagesorlights are displayed.


Possible causeIs the temperature limitswitch faulty?

Does the combustionair/fuel train need tun-ing?

SolutionPush the reset button on theGasTrac electrical enclosureand restart the GasTrac. If thealarm occurs again, a qualifiedelectrician should verify thatthe latching alarm contacts ofthe flue gas high temperaturelimit switch are closed.

This must be done by a quali-fied technician who is trainedin the maintenance of industri-al gas appliances, and who isfamiliar with tuning proce-dures outlined in the variouscontroller, valve and switchmanuals that came with theGasTrac.If the alarm persists, call theConair Service Department.

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 800ÞF,the GasTrac shuts down and the alarm light illuminates.

FLUE GAS HIGHTEMPERATURELIMIT SWITCH

RUNMAN

235.0250.0SP2

OP1

OP2

REM

HOLD

2216

alarm light

!


AlarmThe control panelalarm light is on, butno other controlleralarm messagesorlights are displayed.



Is the drying temperaturesetpoint incorrect?

Is the temperature limitswitch faulty?

Is the temperature con-troller faulty?

Solutionr Check the process filter inthe host dryer. Clean or replacethe filter if it is clogged ordamaged.r Check the process air hosesfor leaks, crimps, blockage orloose connections. Removeobstructions. Repair leaks orloose connections.r Make sure the process airblower in the host dryer is run-ning correctly.

Check the setpoint on the tem-perature controller. Enter anew setpoint, if necessary.Press the reset button on theGasTrac electrical enclosureand restart the GasTrac.

Press the reset button on theGasTrac electrical enclosureand restart the GasTrac.If thealarm occurs again, a qualifiedelectrician should verify thatthe latching alarm contacts ofthe process high temperaturelimit switch are closed.

If the alarm persists, replacethe temperature controller.

The process high temperature switch monitors the temperatureof a type J thermocouple mounted in the GasTrac process airoutlet. If the process air outlet temperature exceeds 450Þ F,the GasTrac shuts down and the alarm light illuminates.

RUNMAN

235.0250.0SP2

OP1

OP2

REM

HOLD

2216

alarm light

PROCESS HIGHTEMPERATURELIMIT SWITCH

!

SERVICE INFORMATION APPENDIX A-1

We’re Here to He lpConair has made the largest investment in customer support in the plasticsindustry. Our service experts are available to help with any problem youmight have installing and operating your equipment. Your Conair salesrepresentative also can help analyze the nature of your problem, assuringthat it did not result from misapplication or improper use.

How to Contac t Cus tomer Ser v iceTo contact Customer Service personnel, call:

You can commission Conair service personnel to provide on-site service bycontacting the Customer Service Department.

Before You Ca l l . . .If you do have a problem, please complete the following checklistbefore calling Conair:

� Make sure you have all model, control type and serial numbers from theserial tag, and parts list numbers for your particular equipment. Servicepersonnel 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 guideto help you.

� Check that the equipment has been operated as described in this manual.

� Check accompanying schematic drawings for information on special considerations.

Additional manuals and prints foryour Conair equipment may beordered through the CustomerService or Parts Department for a nominal fee. Most manuals canbe downloaded free of chargefrom the product section of theConair website. www.conairgroup.com

NOTE: Normal operating hours are 8:00 am - 5:00 pm (EST). After hours emergencyservice is available at the same phone number.

�

APPENDIX A-2 WARRANTY INFORMATION IMS0003/0795

Equ ipment Guaran teeConair guarantees the machinery and equipment on this order, for a period as defined in thequotation from date of shipment, against defects in material and workmanship under the nor-mal use and service for which it was recommended (except for parts that are typicallyreplaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limitedto replacing, at our option, the part or parts determined by us to be defective after examina-tion. The customer assumes the cost of transportation of the part or parts to and from thefactory.

Per fo rmance War ran tyConair warrants that this equipment will perform at or above the ratings stated in specificquotations covering the equipment or as detailed in engineering specifications, provided theequipment is applied, installed, operated and maintained in the recommended manner as out-lined 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 unlessfailure 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 customerat which time a Return Goods Authorization Number (RGA) will be issued by Conair’sService Department. Returned equipment must be well crated and in proper operating con-dition, including all parts. Returns must be prepaid.

Purchaser must notify Conair in writing of any claim and provide a customer receipt andother evidence that a claim is being made.

Warran ty L imi ta t ionsExcept for the Equipment Guarantee and Performance Warranty stated above, Conairdisclaims all other warranties with respect to the equipment, express or implied, aris-ing by operation of law, course of dealing, usage of trade or otherwise, including butnot limited to the implied warranties of merchantability and fitness for a particularpurpose.

Documents

USER GUIDE UGD014- 0497 GasTrac - conairgroup.com€¦ · Manual Number: UGD 01 4- 97 Serial Number(s): Model Number(s): DISCLAIMER: C o n airsh ltb ef c dU Gu , consequential d amg