DryAIR 600 GTS Series User manual

Operator Manual
Central Mobile Enclosure
600 GTS Series
S.N. 154801 –
DRYAIR Manufacturing Corp.
Box 126, 400 Service Road
St. Brieux, SK, Canada
S0K 3V0
Tel: [phone]
Fax: [phone]

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Table of Contents
1. Warranty Policies & Claim......................................................................................................1-1
Warranty Policies ....................................................................................................................1-1
BasicWarranty Policy..........................................................................................................1-1
Extended Warranty Policy...................................................................................................1-1
Exceptions to the Warranty Policies....................................................................................1-1
Owner Obligations...............................................................................................................1-2
Manufacturer Obligations ....................................................................................................1-2
Warranty Claim Procedure......................................................................................................1-3
2. Safety Concerns.......................................................................................................................2-1
General Safety Guidelines.......................................................................................................2-1
Water Heater Module..............................................................................................................2-1
Heat Transfer Fluid .................................................................................................................2-1
Fluid handling precautions...................................................................................................2-1
First aid measures ................................................................................................................2-1
3. Introduction .............................................................................................................................
Central Mobile Enclosure........................................................................................................
Passive Heat Transfer..............................................................................................................
Circulation Line Heat Exchangers.......................................................................................
Hose Reel.............................................................................................................................
Accessories..............................................................................................................................
Mixing/Booster Pump..........................................................................................................
Optional Remote Manifold ..................................................................................................
Insulated Line Jackets.........................................................................................................
Portable Heat Exchanger......................................................................................................
How the System Works...........................................................................................................
4. Setup (CME)............................................................................................................................4-1
Required Safety Clearances.....................................................................................................4-1
Elevation Concerns..................................................................................................................4-1
Electrical Requirements & Connection...................................................................................4-2
Electrical Connection...........................................................................................................4-2
Heat Transfer Fluid “HTF” .....................................................................................................4-2
Heat Transfer Fluid Specifications ......................................................................................
Fuel..........................................................................................................................................
Primary “HTF” Circulation Lines ...........................................................................................
Burner Removal ......................................................................................................................
Burner Installation...................................................................................................................
5. Operation (CME).....................................................................................................................5-1
Purging Air from the “HTF” Circulation System ...................................................................5-1
Before Firing the System.........................................................................................................5-2
Cold Start Procedure ...............................................................................................................5-4
3-1
3-1
3-2
3-2
3-2
3-2
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3-3
3-3
3-3
3-4
4-3
4-3
4-4
4-4
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Temperate Start Procedure......................................................................................................5-5
Control Settings ...................................................................................................................5-6
Initiate Firing .......................................................................................................................5-6
Purging Air from the Fuel System ..........................................................................................5-7
Adding “HTF” to System ........................................................................................................5-9
6. Setup/Operation (HR2250)......................................................................................................6-1
Manual Controls......................................................................................................................6-1
Reel Power...........................................................................................................................6-1
Reel Direction Modes ..........................................................................................................6-1
Mechanical Drive Components...............................................................................................6-2
Electric Motor......................................................................................................................6-2
Gear Box...........................................................................................................................6-2
Gear Box Specification........................................................................................................6-3
Torque Limiter Clutch.............................................................................................................6-3
7. Troubleshooting (CME) ..........................................................................................................7-1
8. Maintenance.............................................................................................................................8-1
Central Heating Module..........................................................................................................8-1
Daily Checklist.....................................................................................................................8-1
Check for Strong Odor of Gas .............................................................................................8-1
Check Heat Transfer Fluid “HTF” Level Everyday ............................................................8-1
Check the Supply Temperature Gauge ................................................................................8-1
Seasonal Checklist ...............................................................................................................8-1
HR2250................................................................................................................................8-4
Torque Limiter Adjustment .................................................................................................8-5
Gear Box..............................................................................................................................8-7
9. Appendix .................................................................................................................................9-1
Important Certification & Operational Information................................................................9-1
Non-Pressure Vessel Decal..................................................................................................9-1
Certification & Heater Specifications .....................................................................................9-2
Electrical Schematics ..............................................................................................................9-3
Heat Transfer Fluid Preheater Information .............................................................................
Function ...............................................................................................................................
Pros of Using HTF Preheater:..............................................................................................
Cons of Not Using HTF Preheater:......................................................................................
In Conclusion:......................................................................................................................
Material Safety Data Sheets ....................................................................................................
9-7
9-7
9-7
9-7
9-8
9-9

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Figure 1- 600 GTS Central Mobile Enclosure (side view)..........................................................
Figure 2- 600 GTS Central Mobile Enclosure (back view).........................................................
Figure 3- Hose Reel.....................................................................................................................
Figure 4- Mixing/Booster Pump..................................................................................................
Figure 5- Optional Remote Manifold & Fluid Circulation Lines................................................
Figure 6-Portable Heat Exchangers .............................................................................................
Figure 7-How the System Works.................................................................................................
Figure 8-600 GTS Top View.......................................................................................................4-1
Figure 9-600 GTS Side View ......................................................................................................4-1
Figure 10-600 GTS Electrical Hookup (230VAC)......................................................................4-2
Figure 11- Glycol/Water Mixture Chart ......................................................................................
Figure 12-Riello Burner...............................................................................................................
Figure 13-Oil Supply and Return Lines.......................................................................................
Figure 14-Oil Supply and Return Lines.......................................................................................
Figure 15-Supply & Return Isolation Vale in the Open Position................................................5-1
Figure 16-Automatic Air Vent.....................................................................................................5-1
Figure 17-Pump, Water & Flow Reverser Switch.......................................................................5-1
Figure 18-Heat Transfer Fluid Sight Glass..................................................................................5-2
Figure 19-System Pressure Gauge...............................................................................................5-2
Figure 20- Supply & Return Isolation Valve in the Closed Position...........................................5-2
Figure 21-Fuel Return Valve .......................................................................................................5-3
Figure 22-Fuel Supply Valve & Filter.........................................................................................5-3
Figure 23-600 GTS Control Panel...............................................................................................5-4
Figure 24-600 GTS Breaker Box.................................................................................................5-4
Figure 25-Supply Temperature Gauge.........................................................................................5-5
Figure 26-Combution Air & Fuel Temperature Gauges..............................................................5-5
Figure 27-600 GTS Control Panel...............................................................................................5-5
Figure 28-Supply Temperature Gauge.........................................................................................5-6
Figure 29-Circulation Valve Position..........................................................................................5-6
Figure 30-Return Temperature Before Bypass Gauge.................................................................5-7
Figure 31-Pump & Water Heater Switch.....................................................................................5-7
Figure 32-Fuel Line Valves in the Fuel System ..........................................................................5-8
Figure 33-Riello Burner & Fuel Pressure Gauge.........................................................................5-8
Figure 34-Fill/Drain Hose & Plug ...............................................................................................5-9
Figure 35-Supply Ball Valve (open and closed)..........................................................................5-9
Figure 36-Fill/Drain Valve (open and closed).............................................................................5-9
Figure 37-600 GTS Control Panel Pump Switch.......................................................................5-10
Figure 38-Glycol Level Gauge ..................................................................................................5-10
Figure 39-Power & Mode Toggle Switches ................................................................................6-1
Figure 40-Foot Switch .................................................................................................................6-1
Figure 41-Access Door ................................................................................................................6-2
Figure 42-Marathon Electric Motor.............................................................................................6-2
Figure 43-Electric Motor Features & Data..................................................................................6-2
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3-2
3-2
3-3
3-3
3-4
4-3
4-4
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Figure 44-Hub City Gear Box......................................................................................................6-3
Figure 45-Torque Limiter ............................................................................................................6-3
Figure 46-Heat Exchanger Breakdown........................................................................................8-2
Figure 47-Back Washing Y-Strainer ...........................................................................................8-3
Figure 48-Y-Strainer Screen........................................................................................................8-4
Figure 49-Marathon Electric Motor.............................................................................................8-5
Figure 50-Torque Limiter Adjustment.........................................................................................8-6
Figure 51-Torque Limiter Assembly ...........................................................................................8-6
Figure 52- Gear Box ....................................................................................................................8-7
Figure 53-Non-Pressure Vessel Decal.........................................................................................9-1
Figure 54-TUV-SUD Certification Label 600 GTS ....................................................................9-2
Figure 55-TUV-SUD Certification Label 600 GTS (sub 40)......................................................9-2
Figure 56-600 GTS (sub-40) Electrical Schematic......................................................................9-3
Figure 57-600 GTS Electrical Schematic ....................................................................................9-4
Figure 58-HR2250 Electrical Schematic .....................................................................................9-5
Figure 59-Trailer Wiring Schematic............................................................................................9-6
Figure 60-HTF Preheater.............................................................................................................
9-7

Warranty Policies & Claim 1-1
1. Warranty Policies & Claim
DRYAIR MANUFACTURING CORP. (referred to within as DRYAIR) warranties its new,
unused equipment to be free of defects in material and workmanship at the time of delivery to
the original retail purchaser.
Warranty Policies
BasicWarranty 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.
•Any parts that are covered by an extended warranty published by DRYAIR are an exception
to the Basic Warranty Policy and are to be warrantied as per the details of the Extended
Warranty Policy.
•Labour is covered as per DRYAIR flat labour rate.
•The Warranty Policy, terms and conditions, may change from time to time without prior
notice.
•Warranty terms and conditions are transferable in the event of the sale to a second owner.
•Replacement parts will be warrantied for 90 days from the repair date. Bill of sale must
accompany the warranty claim.
•The terms of this Warranty Policy are subject to provincial and state legislation. DRYAIR
reserves the right to make modifications in accordance with provincial and state legislation
without prior notice or obligation.
Extended Warranty Policy
•An extended warranty is available on the heat exchanger unit of the water heater assembly.
The available warranty for a part, under the extended warranty policy, is prorated by 20% per
year.
•Shipment date is the date to be used for the commencement of the warranty period.
•Coverage schedule
Year 1 - 100%
Year 2 - 80%
Year 3 - 60%
Year 4 - 40%
Year 5 - 20%
Exceptions to the Warranty Policies
•Under no circumstance shall the owner be entitled to recover costs for incidental, special or
consequential damages such as, but not limited to: loss of profit or revenue, other commercial
losses, inconvenience and/or replacement equipment rental cost.
•Maintenance, repair or service items not related to warrantable defects
•Loss or damage during shipping
•Failure resulting from lack of or improper maintenance

Warranty Policies & Claim 1-2
•Damage caused by operator abuse, negligence or improper operation
•Damage resulting from improper voltage supply
•Damage from improper installation (installation done by someone other than the
manufacturer)
•Non-defective items replaced at the request of the customer
•Damage due to accidents
•Damage resulting from improper fuel supply (i.e. pressure or contamination)
•Damage resulting from cracked or broken lines occurring during transport
•Damage resulting from use of inadequate or improper fluids (i.e. glycol or oil)
•Mileage is not covered
•Glycol is considered a consumable and will not be covered under the warranty policy.
•Generators carry their own warranty coverage through their own manufacturer. Please refer
generator issues to the OEM. Contact information may be found in the Service & Operator
Manual under Optional Equipment.
Owner Obligations
•It is the responsibility of the owner, at the owner's expense, to transport the equipment to the
service facility of an authorized DRYAIR distributor/dealer or alternately to reimburse the
distributor/dealer for any traveling expenses incurred in fulfilling this warranty.
•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 are to be tagged with a warranty claim number and shipped prepaid to DRYAIR
within 30 days.
Manufacturer Obligations
•DRYAIR reserves the right to continually improve the product’s parts or specifications at
any time without notice or obligation.

Warranty Policies & Claim 1-3
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.
Location of Warranty Depot:
DRYAIR Manufacturing Corp.
400 Service Road, PO Box 126
St. Brieux, SK, Canada
S0K 3V0
Ph. 1 [phone]
•Each warranty claim should only refer to one Serial or Production Schedule numbered unit.
•Warranty parts are to be tagged with a warranty claim number.
•When claiming for warranty labour, the allowable warranty labour rate will be $65.00/hour. The
factory reserves the right to adjust the number of hours claimed where deemed necessary.
•The factory may at times specify allowable labour for certain warranty procedures.
•Mileage and travel time to and from the customer are not eligible for warranty credit.
•Freight charges for warranty parts are not eligible for warranty credit.
•Labour flat rates for component changes:
•Electrical Components - 0.5hr
•Relays
•Switches
•Thermostats
•Breakers
•Electric Motor Changes - 1hr
•Hose Reel
•Plumbing Components - 1hr
•Flow Reverser
•Flow Switch
•Valves
•Glycol Pump Changes - 2hrs
Note: Other labour charges will be at the discretion of DRYAIR

Safety Concerns 2-1
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.
•All guards must be in place when the equipment is in operation.
Water Heater Module
*CAUTION! The water heater is a heating appliance.*
•When dealing with any heating appliance, observe all posted warnings and cautions.
•Keep children and pets away from all piping and fuel accessories.
•The water heater housing panels must be kept closed when the system is operating.
This prevents drafts from affecting water heater operation.
Heat Transfer Fluid
Follow the following precautions and measures when working with “heat transfer fluid”
(“DOWFROST* HTF” & “BOSS CHILL PG”).
Fluid handling precautions
•Ventilation .................. Good general ventilation should be sufficient for most
conditions.
•Respiratory protection. No respiratory protection should be needed.
•Skin protection ............ For brief contact, no precautions other than clean body-
covering clothing should be needed.
.................................... Use impervious gloves when prolonged or frequently repeated
contact should occur.
•Eye Protection ............. Use safety glasses.
First aid measures
•Eyes ............................ Flush eyes with plenty of water