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[Type here] Table of Figures Figure 2-1 Safety Decals ..........................Error! Bookmark not defined. Figure 3-1 One Way ............................Error! Bookmark not defined. Figure 3-2 Two Way ............................Error! Bookmark not defined. Figure 3-3 Manifold to Portable Heat Exchanger ................... Error! Bookmark not defined. Figure 3-4 Ground Thaw Loops ........................
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[Type here] Figure 6-11 A421 ......................................6-4 Figure 6-12 Long Electrical Strips ................................6-4 Figure 6-13 A419 ......................................6-5 Figure 6-14 Johnson (A350A/B) Electronic Temperature Control ......................6-6 Figure 6-15 Johnson (S350C Temperature Slave Stage Module) ........................ 6-6 Figure 6-16 Flame Roll Out Switch ................................6-7 Figure 6-17 Flow Switch .....................................
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[Type here] Figure 8-12 Model Hose Reel HR6000 ..............................8-18 Figure 8-13 Model Hose Reel HRA series ..............................8-19 Figure 8-14 Model Mixing Booster ................................8-20 Figure 8-15 Model Pump Booster Mixing Valve ............................8-21 Figure 8-16 Model Plate Heat Exchanger Glycol to Glycol ........................8-16 Figure 8-17 Model Humidistat Fan Coil Control ............................
Warranty Policies Basic warranty policy • DRYAIR will repair or replace, at its option, without charge, any defective part of the equipment for a period of twelve (12) months from delivery to the first retail purchaser, F.O.B St. Brieux, SK., Canada or Bowling Green, Ohio.
• It is the responsibility of the owner to read, understand and implement the maintenance, safety and operational guidelines as laid out in the Operation and Maintenance Guide. • All parts to be tagged with warranty claim number and shipped prepaid to DRYAIR within 30 days.
Warranty Claim Procedure • All warranty credits must be processed with the DRYAIR Warranty Claim Form. • All warranty parts, unless otherwise specified, are to be returned to DRYAIR along with a completed Warranty Claim Form. Note: Prior to returning warranty parts, please call for an authorization number and shipping instructions from the Warranty department in Canada.
Version 0.0 PN 003-702872 2.Safety Concerns General Safety Guidelines • Make certain that the operator reads and understands all the information in this manual. • All unauthorized people must be kept away from the equipment when in operation. • Maintain instructional and safety decals. Replace damaged decals (Figure 2-1).
• Check the tire tread on all tires for indications of wear, or misalignment. • Test the signal lights, brake lights, and park lights for proper operation. • All Dryair trailers are equipped with electric brakes that require a controller in the tow vehicle.
Version 0.0 PN 003-702872 3.Generic Information Recommended Maximum Hose Lengths “Central Heating Unit” to “Manifold” • One way – 300 feet (Figure 3-1) • Two way – 400 feet each way (Figure 3-2). “Manifold” to “Portable Heat Exchanger” • 100 feet (Figure 3-3). Ground Thaw Loops •...
Version 0.0 PN 003-702872 ADD DIAGRAM OF UNIT GOING UP 70 FT THEN ALSO GOING UP WITH PLATE HEAT EXCHANGER. Formulas & General Information Hose length required for ground thaw or concrete curing. Where: = Hose Length required to cover area. SF= Area of ground to be thawed or concrete to cure.
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Version 0.0 PN 003-702872 This section will cover a typical setup using a complete DRYAIR system. Because this is a closed system it is possible to go vertically up to 70ft from the heat source. This makes it ideal in a multi-story construction application.
As a bare minimum, the solution should be analyzed for glycol concentration, solution pH and general quality. Dryair recommends that a complete flush and HTF replacement every five years. Generic Information...
This method is significantly more accurate than litmus paper tests. The pH tester (Figure 3-6) is used to check the pH level of the heat transfer fluid. Below is a pH chart. For Dryair product, anything below 7 is unacceptable.
This Model is fairly easy to convert for higher elevations. Dryair offers complete burner tray conversions to accommodate high altitude usage. Dryair also carries four different orifices (Fig 4-1) for the 2000-1200 depending on elevation and if the machine is set-up for propane or natural gas or a complete burner tray is also available with the correct orifices already installed.
G-4 Illinois School Code (BOCA Code) G-5 Long Island Code (LILCO) G-6 Minnesota Code G-7 New Mexico Code G-8 Washington State Code G-9 Kentucky Code G-10 United States Post Office G-12 California Code G-13 Double Block & Bleed with Commercial Grade Ignition (C2A) DRYAIR Components...
Trailered Units • Wash all road and work site debris from machine. • Check all trailer lights and trailer brakes. • Inspect tires and replace as necessary. • Ensure that the trailer axels and wheel bearings are properly serviced. DRYAIR Components...
Figure 4-5 2000-1200 Exploded bricks/refractory board (1-4). This may cause them to chip and break apart. This procedure should be performed outdoors. Wear a dust mask and safety glasses when performing this task. DRYAIR Components...
• Clean burner tubes (2-5) with a steel round brush or a rag on a piece of rod. • When cleaning model 300 unit item 2-7 will need to be replaced • Vacuum all debris. Figure 4-7 2100-xxxx Exploded Figure 4-6 2100-0300 Exploded DRYAIR Components...
Settings Settings Head (tube base to front High flange) Low Fire High Fire Fire Fire 1.75x60 Model 300 GTS Oil 1.0” Fired c/w F10 Model 600/600 GTS 3.50x60B Oil Fired c/w F20 1" Burner Model 900/900 Flex 5.00x60B 1.5” Oil Fired c/w F20 Burner 3.50x60B...
• To check stack temperature it will be necessary to use a Flue Gas Analyzer (Fig 4-1). • The overfire draft of an appliance can increase or decrease stack temperatures. A high overfire draft will cause the combustion gases to be pulled through the appliance, increasing stack temperature. DRYAIR Components...
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• An increased flow time through the appliance heat exchanger will increase thermal efficiency and lower stack temperatures. • Check to see if there are any secondary air leaks in the appliance (example: inspection door open). Any such leaks will increase stack temperature. DRYAIR Components...
• Check the heat transfer fluid’s pH level utilizing a pH tester. If pH level is below 7, the heat transfer fluid must be removed from the system or corrosion of the metallic components will take place over a period of time. • Verify operation of plate heat exchanger. DRYAIR Components 4-10...
• Check the heat transfer fluid’s freeze point utilizing a refractometer. Verify that it is at the proper level for the area the systems are operating in. A test sample must be removed at a quick connect joint. DRYAIR Components 4-11...
• Check the heat transfer fluid’s pH level utilizing a pH tester. If pH level is below 7, the heat transfer fluid must be removed from the system or corrosion of the heat exchanger will take place over a period of time. DRYAIR Components 4-12...
Version 0.0 PN 003-702872 5.Plumbing Components (some units may not be equipped with y-strainer or have had the screen removed. Use either way is permitted) Y-Strainer The “Y” strainer contains a screen, which will stop any debris in the system from damaging any plumbing components.
This valve opens when the fluid circuit pressure exceeds 60 p.s.i. Although this valve is required, it has no function with the DRYAIR system. The DRYAIR system is an open fluid loop with an atmospherically vented fluid tank and zero pressure in the heat exchanger.
Version 0.0 PN 003-702872 Pressure Bypass Valve The pressure bypass valve (Figure 5-4) maintains a minimum fluid flow through the water heater as outside circuits are closed off. It also ensures that fluid flow through the external circuits is optimum for the number of portable heat exchangers operating.
Version 0.0 PN 003-702872 Cold Start Fluid Pre-Heater (if equipped) The cold start fluid pre-heater (Figure 5-6) is utilized to preheat the heat transfer fluid prior to firing of the burner. This will avoid the rough, inefficient combustion results associated with cold start-ups.
Version 0.0 PN 003-702872 Flow Reverser Valves Model: 2100-0600 & 2100-0900 The flow from these units are reversed using two three way valves that operate automatically by power actuators (Figure 5-9). These help in creating an even ground thaw or an even Supply Return Return...
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Version 0.0 PN 003-702872 Servicing the three way valves 1. Ensure that the system is off and no pressure on either side of the valves. 2. Take note of the dial location as this will be important in the reassembly (Fig 5-10).
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Version 0.0 PN 003-702872 6. Lift off the outer protective cap (Fig 5-13). Figure 5-13 Valve with Protective Cap in Place 7. Rotate the retaining nut either direction to align the lock tabs (Fig 5-14 & 5-15). Figure 5-14 Lock Washer (Locked) Figure 5-15 Lock Washer (Unlocked) Plumbing Components...
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Version 0.0 PN 003-702872 8. With the locking washer removed, carefully remove the valve stem taking care not to damage the O- Ring (Fig 5-16 & 5-17). 9. Inspect the valve stem for damage 10. Using the valve stem, check to see if the valve can move easily.
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Version 0.0 PN 003-702872 Model: 200GTS/300GTS/400GTS/650GTS The flow from these units are reversed using one four-way valve (Figure 5-18) that operate automatically by a power actuator. Like the 2100-0600 and 2100-0900 this helps in creating an even ground thaw or an even concrete cure. This will save time and money. The actuator is activated by a timer that can be adjusted by the end user depending on application.
Version 0.0 PN 003-702872 6.Electrical Components Flow Reverser The flow reverser has an electrical component that should be checked first before the mechanical/plumbing side of the valve. This will prevent air getting into the system or the creation of leaks. White Model: All GTS Units Black...
Version 0.0 PN 003-702872 8. Locate the 24VAC transformer inside the panel (Figure 6-3). 9. Check for voltage on both sides of the 120VAC transformer as indicated below. 10. If there is 120VAC coming into the transformer and nothing on the other 24VAC side, replace transformer.
Version 0.0 PN 003-702872 7. If no power can be found here remove the panel by removing the four screws indicated (Figure 6-7). Figure 6-7 Electrical Panel 8. Locate the 24VAC transformer inside the panel (Figure 6-8). 9. Check for voltage on both sides of the transformer as indicated.
Version 0.0 PN 003-702872 Aquastats (A421 will replace A419) Although most Aquastats can go much higher, it is highly recommended that the MAXIMUM temperature of the heat exchanger NOT EXCEED 180ºF. A421 Series Electronic Temperature Control P/N 005-900676 The A421 series controls feature a lockable front-panel touchpad for setup and adjustment, and an LCD for viewing the temperature and status of other functions.
Version 0.0 PN 003-702872 Table 6-1 A421 Settings A419 Series Electronic Temperature Control P/N 005-900676 The A419 (Figure 6-13) shares some of the same features as the A421 and will be phased out in future models. Refer to the trouble shooting guide for the A421.
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Version 0.0 PN 003-702872 Aquastat (1st Stage) stage aqua-stat controls the water heater’s outgoing water temperature. The 1 Model - Johnson (A350A/B) Electronic Temperature Control (Figure 6-14) P/N 006-702126 Check and verify that there is 24 volts between terminal COM & 24V terminals located on the top left side of the control.
Version 0.0 PN 003-702872 Sensor Check Table 6-3 Sensor Readings P/N 006-702391, or 005-703932 (depending on length) Check temperature sensor for proper resistance 1 Disconnect the sensor from the control. Using an ohmmeter, measure the resistance across the two sensor leads (see Temperature/Resistance Graph to right).
Version 0.0 PN 003-702872 Flow Switch (Figure 6-18) The flow switch will shut down the water heater if fluid flow is insufficient. Model -WATTS (FS-200-W series) P/N 006-700778 To verify that control is operating properly the power check must be done with the central heating unit running. Model 2000-0250 &...
Version 0.0 PN 003-702872 Hi limit control Manual Reset (Figure 6-20) P/N 006-702140 The high limit shuts down the water heater when excessive temperatures of 200ºF are reached. Note: When tripped, the manual reset button must be pressed to reset the high limit controller.
Version 0.0 PN 003-702872 Ignition Module (Figure 6-22) P/N 006-701212 The ignition module sparks the igniter, powers up the pilot valve, and powers up the main gas valve. Model - Honeywell (SH8600 & SH8610 Ignition Module) Note: Make sure water heater is functioning before performing power check.
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Version 0.0 PN 003-702872 Model – Safgard 650 (Figure 6-23) (Most Common LWCO) Check for 120 volts between 2 & 1. Check for 120 volts between 2 & P2. Figure 6-23 Model – Safgard 650 Model - Guard Dog (PS-851-M-120) (Figure 6-24) Note: This low water cut-off is only on the Model 2000- 1200 G6.
Version 0.0 PN 003-702872 Low Water Cut Off (200/300/400/650 GTS units) Check for fluid in reservior tank. If fluid is present check for 24V power in and out of the sensor. If no power, check the wiring schematic for correct orientation of the float valve.
The pilot valve controls the gas feed to the pilot. Check for 24 volts between the two terminals. If no power check for 24V at PV on ignition module. If power at pilot valve, contact Dryair for assistance. Model - Basotrol H91WG-1 P/N 006-701218...
Version 0.0 PN 003-702872 Pumps (Figure 6-29) P/N 012-800055 (2000-1200, 2100-0900) P/N 012-800054 (2100-0600/600GTS/650GTS) P/N 012-800052 (2100-0400/200GTS/300GTS/400GTS) The pump circulates the heat transfer fluid in the fluid circulation system. Model - NPE Model - 2000-1200, 2100-0600, 2100-0900 and the Plate Heat Exchanger.
Version 0.0 PN 003-702872 Thermostat (Figure 6-32) The thermostat controls the ambient air temperature in the building by cutting power to the fan blower. Check for 120 volt power between terminals 1 & 3 and Neutral or Ground. Model - Johnson A19ABA P/N 005-701111 Figure 6-32 Johnson A19ABA...
Version 0.0 PN 003-702872 Adjustable FrequencyDrive P/N 012-701545 The adjustable frequency drive converts 1 phase power to 3 phase power, controls the motor speed and the forward and reverse. Model - Penta Power (KBVF) (Figure 6-34) Check for 110 volts between L1 & L2. Table 6-4 VFD Trouble shooting Figure 6-34 Penta Power (KBVF) Trouble shooting for drive is done utilizing the indicator lights located...
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Version 0.0 PN 003-702872 If the drive has not restarted after 6 minutes, the drive locks and the procedure is abandoned until the drive is powered down and back up again. Factory setting: function inactive. Restart authorized with the following faults: drive thermal overload, motor thermal overload, and line supply overvoltage, overvoltage on deceleration, line phase loss, and line supply under voltage.
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Version 0.0 PN 003-702872 This necessitates gradually loosening the belt as the hose is unloaded: less spool inertia (from decreased mass) requires less braking. Note that for transport of the hose reel it is advisable to maintain sufficient tension on the hose reel to arrest any rotation of the hose reel spool caused by motion of the unit.
7.Optional Equipment Generators Dryair typically offers two different generators. The Multiquip DAC7000 and Kubota GL7000. They are both of similar size and capacity. They both also operate using diesel fuel which makes either of them a good choice as the portable units that utilize them also operate with diesel fuel.
Version PN 003-702872 8.Appendix Electrical Schematics (newest revision level, some wiring may differ for the following electrical schematics. If older schematics are needed contact DRYAIR service department. Model GTS 2100-0300 Figure 8-1 Model GTS 2100-0300 Appendix...
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Version PN 003-702872 Model 200 GTS Appendix...
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Version PN 003-702872 Model 400 GTS Appendix...
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