Conair GasTrac User manual

GasTrac
Instant Access
Parts and Service
[phone]
[phone]
www.conairnet.com
The Conair Group, Inc.
One Conair Drive
Pittsburgh, PA 15202
Phone: [phone]
Fax: [phone]
Process Air Heater
UGD014/0497
Installation
Maintenance
Operation
Troubleshooting

It’s a good idea to record the model and serial number(s) of
your equipment and the date you received it in the User
Guide. Our service department uses this information, along
with the manual number, to provide help for the specific
equipment you installed.
Please keep this User Guide and all manuals, engineering
prints and parts lists together for documentation of your
equipment.
Date:
Manual Number: 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.
Please record your
equipment’s model and
serial number(s) and
the date you received it
in the spaces provided.
Copyright 1997 All rights reserved
THE CONAIR GROUP, INC.

UGD014/0497 GasTrac Process Air Heater
TABLE OF
CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1
Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2
How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . .1-2
Your responsibilities as a user . . . . . . . . . . . . . . . . . . . . . .1-2
ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3
How to use the lockout device . . . . . . . . . . . . . . . . . . . . . .1-5
DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1
What is the GasTrac? . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Fuel train features and controls . . . . . . . . . . . . . . . . . . . . .2-6
Specifications: GasTrac . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Specifications: Exhaust flue . . . . . . . . . . . . . . . . . . . . . . . .2-9
Specifications: Main power supply . . . . . . . . . . . . . . . . . . .2-9
INSTALLATION . . . . . . . . . . . . . . . . . . . .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
Connecting the gas supply . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . .3-7
Installing the RTD probe . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1
GasTrac operating features . . . . . . . . . . . . . . . . . . . . . . . . .4-2
The GasTrac control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
To start drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
To stop drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1
Preventative maintenance checklist . . . . . . . . . . . . . . . . . .5-2
Cleaning the combustion air filter . . . . . . . . . . . . . . . . . . .5-3
Cleaning the electrical enclosure filters . . . . . . . . . . . . . . .5-3
Replacing the spark igniter . . . . . . . . . . . . . . . . . . . . . . . .5-4
Cleaning the ultraviolet flame detector . . . . . . . . . . . . . . . .5-6
Cleaning the burner sight glass . . . . . . . . . . . . . . . . . . . . .5-6
i

GasTrac Process Air Heater UGD014/0497
TABLE OF
CONTENTS
TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1
Before beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
When an alarm occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
How to identify the cause of an alarm . . . . . . . . . . . . . . . .6-3
Temperature controller alarms . . . . . . . . . . . . . . . . . . . . . .6-4
Burner controller alarms . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Variable speed controller alarms . . . . . . . . . . . . . . . . . . . .6-10
Flue gas high temperature limit switch . . . . . . . . . . . . . . .6-14
Process high temperature limit switch . . . . . . . . . . . . . . .6-15
APPENDIX
Service/Warranty Information . . . . . . . . . . . . . . . .Appendix A
ii

1-1
UGD014/0497 GasTrac Process Air Heater
●Purpose of the User Guide . . . .1-1
●How the guide is organized . . . .1-2
●Your responsibilities as a user .1-2
●ATTENTION: Read this so
no one gets hurt . . . . . . . . . . .1-3
●How to use the lockout device .1-5
INTRODUCTION

GasTrac Process Air Heater UGD014/0497
1-2 INTRODUCTION
This User Guide describes the GasTrac process air heater and
explains step-by-step how to install, operate, maintain and
repair this equipment.
Before installing this product, please take a few moments to
read the User Guide and review the diagrams and safety infor-
mation in the instruction packet.You also should review man-
uals covering associated equipment in your system. This
review 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 and
call your attention to important information regarding safe
installation and operation.
Symbols within triangles warn of conditions that could
be hazardous 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 response to an
action 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 concerning
installation, operation and maintenance of this equipment.
Responsible safety procedures include:
●Thorough review of this User Guide, paying particular
attention to hazard warnings, appendices and related
materials and diagrams.
●Thorough review of the equipment itself, with careful
attention to voltage sources, gas supply, intended use and
warning labels.
●Thorough review of instruction manuals for associated
equipment.
●Step-by-step adherence to instructions outlined in this
User Guide.
PURPOSE OF
THE USER
GUIDE
HOW THE
GUIDE IS
ORGANIZED
1
◆
❒
●
!
YOUR
RESPONSIBILITY
AS A USER

UGD014/0497 GasTrac Process Air Heater INTRODUCTION 1-3
We design equipment with the user’s safety in mind. You can
avoid the potential hazards identified on this machine by fol-
lowing the procedures outlined below and elsewhere in the
User Guide and related instructional materials.
ATTENTION:
READ THIS SO NO
ONE GETS HURT
!
WARNING: Follow instructions carefully.
Incorrect installation, operation or maintenance of
this product can result in a fire, explosion or
other hazards causing property damage, severe
personal injury or loss of life.
Only licensed electrical/mechanical contractors, or
individuals 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 repaired
by qualified technicians who are equipped with the
correct 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 and
safety features should be performed periodically to
ensure safe operation.
!
WARNING: If gas odor is detected...
❒ Open doors and/or windows to vent the gas.
❒ Do not touch electrical switches.
❒ Extinguish all open flames.
❒ Immediately have qualified personnel determine
the source of the gas leak and repair it.
!
WARNING: Do not store or place
aerosol, compressed gas or flammable
materials on or near this equipment.
The hot temperatures associated
with the drying process may
cause aerosols or other
flammable materials placed or
stored near the GasTrac to
explode.
!

GasTrac Process Air Heater UGD014/0497
1-4 INTRODUCTION
WARNING:Hot surfaces.
Temperatures inside the GasTrac can
reach more than 800˚ F. Always shut
down the GasTrac and host dryer and
wait for them to cool before servicing. Do
not remove the safety guard covering the
GasTrac burner and heat exchanger.
WARNING: Disconnect and lock out
main power before servicing.
The GasTrac is connected to high volt-
age. Always disconnect and lock out the
main power source to the GasTrac before
servicing. Also disconnect and lock out
main power to the host dryer before ser-
vicing the GasTrac. Failure to disconnect
and lock out this voltage source 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 to be serviced,
it is important that the GasTrac heat
exchanger and gas lines are purged of
natural gas. Failure to eliminate this
potential source of a gas leak could result
in severe damage, personal injury or loss
of life.
WARNING: Do not operate the
GasTrac with safety features disabled
or removed.
The GasTrac has been equipped with
numerous guards, controls and devices
to ensure safe operation. Never remove
or disable these devices to sustain pro-
duction. Operating without these devices
could lead to hazardous conditions that
can damage the facility or cause severe
injury or loss of life.
ATTENTION:
READ THIS SO NO
ONE GETS HURT
!
!
!

UGD014/0497 GasTrac Process Air Heater INTRODUCTION 1-5
CAUTION: Before performing maintenance
or repairs on this product, you should disconnect
and lock out electrical power sources to prevent
injury from unexpected energization or start-up. A
lockable device has been provided to isolate this
product from potentially hazardous electricity.
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.
Isolate the equipment from
electrical power.
Turn the rotary disconnect
switch to Off, or O position.
Secure the device with an
assigned lock or tag.
The equipment is now locked out.
WARNING: Before removing lockout
devices and returning switches to the ON position,
make sure that all personnel are clear of the
machine, tools have been removed and all safety
guards reinstalled.
HOW TO USE
THE LOCKOUT
DEVICE
I
O
1
2
3
4
!

2-1
UGD014/0497 GasTrac Process Air Heater
●What is the GasTrac? . . . . . . . . .2-1
●Typical applications . . . . . . . . . .2-2
●How it works . . . . . . . . . . . . . . .2-4
●Fuel train features
and controls . . . . . . . . . . . . .2-6
●Specifications: GasTrac . . . . . . .2-8
●Specifications: Exhaust flue . . .2-9
●Specifications: Main power
supply wire . . . . . . . . . . . . . .2-9
DESCRIPTION

The GasTrac Process Air Heater is a stand-alone, gas-fired
heater designed to replace the electric process air heater in an
existing dehumidifying dryer or crystalizer. The GasTrac
allows plastics processors to convert existing electric equip-
ment to a less-expensive gas source.
The GasTrac contains a metal-ceramic burner, heat exchanger,
combustion system and temperature controller to set and
maintain the temperature of the air entering a drying hopper.
The host dryer’s desiccant beds dry the air. The host dryer’s
process blower circulates air through the GasTrac heat
exchanger and the hopper.
The GasTrac’s temperature controller, 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 hygroscopic plastics at temperatures ranging
from 250˚ F to 350˚ F.
●Hot air drying of non-hygroscopic plastics.
●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.
The GasTrac has been designed and configured at the factory
for use with natural gas only. If you want to use a different gas
fuel source, such as propane, you must contact Conair.
WHAT IS THE
GASTRAC?
GasTrac Process Air Heater UGD014/0497
2-2 DESCRIPTION
TYPICAL
APPLICATIONS

TYPICAL
APPLICATIONS
UGD014/0497 GasTrac Process Air Heater DESCRIPTION 2-3
The GasTrac may be installed on a mezzanine or on the floor
between the host dryer and the drying hopper.You can use
flexible hose or pipe to deliver air between the host dryer, the
GasTrac and the drying hopper.
Mezzanine
installation
Floor
installation

HOW ITWORKS
GasTrac Gas-Fired process Air Heater UGD014/0497
2-4 DESCRIPTION
ESC SEL
Combustion
Blower
RUN
MAN
234.0
250.0
SP2
OP1
OP2
REM
HOLD
2216
ESC SEL
The GasTrac has three interfaced controls that:
●Ignite the metal-ceramic burner and monitor the GasTrac
combustion circuit.
●Heat the dry air to the setpoint temperature.
●Monitor the air temperature as it enters the drying hopper.
●Automatically adjust the mixture of combustion air and
gas to maintain the setpoint temperature.
Temperature
RTD probe at
the hopper
inlet
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.
Burner Controller
The Burner Controller is activated
when you press the RUN button on
the main GasTrac control. The burner
controller sends a signal to the spark
igniter, which fires the metal-ceramic
burner. This controller continues to
monitor the fuel train, combustion
blower and other combustion systems
for possible problems.
Variable Speed Controller
The Variable Speed Controller automatically adjusts the speed of the combustion
blower by varying the frequency and voltage of the signal. Increasing the speed
increases the air-to-fuel mixture and the heat output of the burner.
4 to 20 MA
signal
varying
frequency

HOW ITWORKS
UGD014/0497 GasTrac Process Air Heater DESCRIPTION 2-5
100
150 200 250
300
350
400
0
50
100
150
200
50
0
100
150 200 250
300
350
400
0
50
100
150
200
50
0
The Process Air Circuit
The Combustion Air Circuit
The process blower in the host
dryer sends dehumidified air into
the GasTrac heat exchanger.
The heated dry air exits
the GasTrac.The air is
blown by the host dryer
to the drying hopper.
The air is heated to the setpoint 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
proportional gas mixer.
1a
2Gas and air are mixed
in the proportion
needed to achieve the
setpoint temperature.
The GasTrac has two separate air circuits: the combustion air
circuit and the process air circuit.
Gas enters
the fuel train.
1b
The air/gas mixture
enters the burner,
where it is ignited
by a spark.
3
Combustion air flows through the burner
cylinder and the exhaust tube bundles.
4
Combustion
gases exhaust
through a flue.
5
31
2

GasTrac Process Air Heater UGD014/0497
2-6 DESCRIPTION
The fuel train includes two automatic and manual safety gas
shutoff valves, four pressure switches, and a gas regulator and
governor to assure safe feeding of gas to the combustion burn-
er. The four pressure switches monitor gas pressure and
process air flow. The GasTrac will automatically shut down if
a pressure switch senses an unsafe condition.
FUEL 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
Mixes air and gas in
the correct proportion
to produce the required
heat.
Combustion air
pressure switch
Primary automatic
safety shutoff valve
Secondary
automatic safety
shutoff valve
Process air
differential
pressure switch
Combustion air blower
Low gas
pressure switch
High gas
pressure switch
Gas inlet pressure gauge
Manual gas supply
shutoff valve
Regulated gas pressure gauge
Gas pressure regulator

UGD014/0497 GasTrac Process Air Heater DESCRIPTION 2-7
GasTrac upright models
Combustion air filter
Proportional Mixer
Mixes air and gas in
the correct proportion
to produce the required
heat.
FUEL TRAIN
FEATURES AND
CONTROLS
Combustion 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 burner
inlet gas shut-
off valve
Primary automatic
safety shutoff valve
Secondary
automatic safety
shutoff valve
Process air
differential
pressure switch
High gas
pressure switch
Low gas pressure switch
Combustion air
pressure switch

SPECIFICATIONS: GASTRAC
GasTrac Process Air Heater UGD014/0497
2-8 DESCRIPTION
H
W
D
Dimensions H W D Weight Air inlet/outlet
in./cm in./cm in./cm lbs/kg diameter in./cm
CGT700HH Horizontal Model 61/154.9 37/93.9 74/187.9 1115/505.7 12/30
CGT700HV Upright Model 67/170.2 39/99 64/162.6 1115/505.7 12/30
CGT500HH Horizontal Model 61/154.9 37/93.9 64/162.6 880/399.2 8/20.3
CGT500HV Upright Model 65/165.1 39/99 64/162.6 880/399.2 8/20.3
CGT350HH Horizontal Model 54/137.2 29/73.7 66/167.6 695/315.2 8/20.3
CGT350HV Upright Model 58/147.3 31/78.7 56/142.2 695/315.2 8/20.3
Remotable GasTrac control 3.5/8.9 12.5/31.7 6/15.2 — —
W
H
W
D
CGTHH horizontal model CGTHV upright model
H
D
Remotable
GasTrac control
CGT700 models CGT500 models CGT350 models
General
Temperature range 250-350˚F / 122-177˚C 250-350˚F / 122-177˚C 250-350˚F / 122-177˚C
Maximum Flue Temperature 750˚F / 399˚C 750˚F / 399˚C 750˚F / 399˚C
Combustion blower 1.5 Hp Peripheral 1 Hp Peripheral 1 Hp Peripheral
Ignition source Spark igniter, interrupted 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 capacity 700,000 BTU/hr 500,000 BTU/hr 350,000 BTU/hr
Gas consumption 230 CFH @ 250˚F/1200 CFM 150 CFH @ 250˚F/800 CFM 105 CFH @ 250˚F/600 CFM
675 CFH @ 350˚F/1800 CFM 465 CFH @ 350˚F/1200 CFM 325 CFH @ 350˚F/800 CFM
Gas pressure to regulator 10 - 20 inches of water / 2.49 - 4.98 kilopascals
Gas pressure from regulator 4 - 7 inches of water / 0.99 - 1.74 kilopascals
Gas heating value 1000 BTU/ft3
Electrical
Available voltages / Total Amps
240 V/3 phase/60 Hz 4.8 A 2.5 A 2.0 A
380 V/3 phase/50 Hz 3.0 A 1.6 A 1.3 A
415 V/3 phase/50 Hz 2.7 A 1.5 A 1.2 A
480 V/3 phase/60 Hz 2.4 A 1.3 A 1.0 A
Total 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 range
Carbon Dioxide (CO2) 9% - 10.5%
Carbon Monoxide (CO) < 10 ppm corrected to 3% O2
NOX < 20 ppm corrected to 3% O2
Unburned 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

UGD014/0497 GasTrac Process Air Heater DESCRIPTION 2-9
SPECIFICATIONS:MAIN POWER SUPPLY WIRE
The main power wire must be:
● Grounded and secured with a strain relief.
●Correctly sized for the current drawn.
Allowable ampacities of Copper Conductors
U.S.A. Canada European Community
75˚C insulation 90˚C insulation 70˚C insulation; 40˚C ambient air
Conductor 30˚C ambient air 40˚C ambient air Ground wire Conductor Maximum
Size AWG Maximum Full Load Amps Size AWG Size mm2Full Load Amps
14 15 13 14 2,5 16
12 20 17 12 4 23
10 30 27 10 6 29
8 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 FLUE
The Conair GasTrac is classified under the National Fuel Gas Code [ANSI Z233.1]
as a Category III gas appliance. An exhaust flue is required to vent the combustion
gases produced by this appliance.The purchaser is responsible for installing an
exhaust flue that meets all local, regional and national codes in the installation area.
For you safety, Conair recommends that you consult a licensed mechanical contrac-
tor who is familiar with gas flue and ducting codes in your area.
GasTrac operating characteristics
Maximum flue temperature 750˚F / 399˚C
Minimum vent size (single unit installation) CGT350: 4 in. / 10.2 cm
CGT500: 6 in. / 15 cm
CGT700: 6 in. / 15 cm
Vent pressure at flue collar 1 to 2 in. water column
Installation recommendations
❒Provide each GasTrac with a dedicated, vertical stack that exits the
building vertically through a rain-protected roof penetration. Limit any
horizontal ducting runs to 4 feet.
❒Use a stainless steel, fabricated chimney flue.
❒Vent size should be 6 inches in diameter. If you connect multiple
GasTrac units to a stack manifold, adjust the stack size accordingly.
❒Static pressure at the flue collar must not exceed 1 to 2 inches water
column.
❒Install an induced draft fan between the GasTrac exhaust outlet and
stack ducting, if you have more than 1 to 2 inches water column pres-
sure at the flue collar while the GasTrac is operating.