DryAIR 300GTS User manual

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Service Manual
PN# 003-702872
Apr-2016
Version 1.0
DRYAIR Manufacturing Corp.
400 Service Road,
St. Brieux, SK, Canada, SOK 3V0
Tel: [phone]
Fax: [phone]
[email protected]
DRYAIR Manufacturing Corp.
P.O Box 264
Bradner, Ohio 43406
Cell: 419-467-9902 1-888-750-1700
[e-mail]
[e-mail]

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Table of Contents
1. Warranty Policies& Claim Procedures...................................................................................1-1
Warranty Policies................................................................................................................................1-1
Basic warranty policy.................................................................................................................................... 1-1
Extended warranty policy............................................................................................................................. 1-1
Exceptions to the warranty policies ............................................................................................................. 1-2
Warranty Claim Procedure .................................................................................................................1-3
2. Safety Concerns.........................................................................................................................2-1
General Safety Guidelines ..................................................................................................................2-1
Water Heater Module..........................................................................................................................2-2
Trailer Safety ......................................................................................................................................2-2
Heat Transfer Fluid.............................................................................................................................2-2
MSDS Information..............................................................................................................................2-2
3. Generic Information .................................................................................................................3-1
Recommended Maximum Hose Lengths............................................................................................3-1
Formulas & General Information........................................................................................................3-2
Fuel Consumption...............................................................................................................................3-4
Heat Transfer Fluid (HTF)..................................................................................................................3-4
Brands ........................................................................................................................................................... 3-4
Fluid Maintenance ........................................................................................................................................ 3-4
Concentration Testing .................................................................................................................................. 3-5
Solution pH Testing....................................................................................................................................... 3-5
System Flushing ............................................................................................................................................ 3-5
Mixing Ratios ................................................................................................................................................ 3-6
Adjusting Solution Concentration................................................................................................................. 3-7
Heat Exchanger (CME) Volumes.......................................................................................................3-7
Portable Heat Exchanger Volumes.....................................................................................................3-8
4. DRYAIR Components ..............................................................................................................4-1
Heat Exchangers .................................................................................................................................4-1
Elevation Concerns ....................................................................................................................................... 4-1
Setting up for Higher Elevations ................................................................................................................... 4-1
Reconditioning Procedures.................................................................................................................4-3
Water Heater’s Heat Exchanger Cleaning Procedure.........................................................................4-4
SERVICE TIPS...................................................................................................................................4-6
SMOKE TESTING............................................................................................................................................ 4-6
FUEL PUMP ................................................................................................................................................... 4-6
NOZZLES........................................................................................................................................................ 4-6

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DRAFT ........................................................................................................................................................... 4-7
STACK TEMPERATURE CONDITIONS............................................................................................................. 4-7
Riello F40 Trouble Shooting Chart....................................................................................................4-9
Hose Reel..........................................................................................................................................4-10
Reconditioning Procedure .......................................................................................................................... 4-10
Plate Heat Exchanger........................................................................................................................4-10
Reconditioning Procedure .......................................................................................................................... 4-10
Mixing/Booster.................................................................................................................................4-11
Reconditioning Procedure .......................................................................................................................... 4-11
Portable Heat Exchangers.................................................................................................................4-11
Reconditioning Procedure .......................................................................................................................... 4-11
Manifolds..........................................................................................................................................4-11
Reconditioning Procedure .......................................................................................................................... 4-11
Hoses.................................................................................................................................................4-12
Reconditioning Procedure .......................................................................................................................... 4-12
5. Plumbing Components..............................................................................................................5-1
Y-Strainer............................................................................................................................................5-1
Safety Relief Valve.............................................................................................................................5-2
Pressure Bypass Valve........................................................................................................................5-3
Drain Valve.........................................................................................................................................5-3
Cold Start Fluid Pre-Heater (if equipped)...........................................................................................5-4
Thermostatic Control Valve................................................................................................................5-4
Automatic Air Bleed Vent..................................................................................................................5-4
Flow Reverser Valves.........................................................................................................................5-5
6. Electrical Components..............................................................................................................6-1
Flow Reverser.....................................................................................................................................6-1
Aquastats.............................................................................................................................................6-4
Flame Roll-Out Switch (Figure 6-17).................................................................................................6-7
Flow Switch (Figure 6-18)..................................................................................................................6-8
High Limit Control (Manual Reset) (Figure 6-20) .............................................................................6-9
High Limit Control (Automatic Reset) (Figure 6-21).........................................................................6-9
High Pressure Switch............................................................................Error! Bookmark not defined.
Ignition Module (Figure 6-22)..........................................................................................................6-10
Low Pressure Switch.........................................................................................................................6-10
Low Water Cut-Off...........................................................................................................................6-10
Main Gas Valve (2 Stage) (Figure 6-25) ..........................................................................................6-12
Micro Switch (Figure 6-26)..............................................................................................................6-13
Pilot Valve (Figure 6-27)..................................................................................................................6-13

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Proportional Temperature Control (Figure 6-28) .............................................................................6-13
Pumps (Figure 6-29) .........................................................................................................................6-14
Redundant Valve 100% Shut Off .....................................................................................................6-14
Solenoid Valve 100% Shut Off.........................................................................................................6-14
Thermostat (Figure 6-32)..................................................................................................................6-15
Transformer.......................................................................................................................................6-15
Valve Actuator (Figure 6-33)............................................................................................................6-15
Adjustable FrequencyDrive..............................................................................................................6-16
7. Optional Equipment..................................................................................................................7-2
Generators...........................................................................................................................................7-2
8. Appendix....................................................................................................................................8-1
Electrical Schematics..........................................................................................................................8-1
Model GTS 2100-0300 .................................................................................................................................. 8-1
Model GTS 2100-0600, 2100-0900............................................................................................................... 8-3
Model 2100-0900 FLEX................................................................................................................................. 8-4
Model CHU 2000-1200 ................................................................................................................................. 8-5
Model CHU 2100-0400, 2100-0600, 2100-0900, 2100-1200 ....................................................................... 8-8
Model Steam Plate –HESF 1000................................................................................................................... 8-9
Model HE80 Fan Coil................................................................................................................................... 8-14
Model HE200 Fan Coil................................................................................................................................. 8-13
Model HE600 Fan Coil................................................................................................................................. 8-15
Model MAXCOIL.......................................................................................................................................... 8-16
Model Hose Reel HR2250 ........................................................................................................................... 8-17
Model Hose Reel HR6000 ........................................................................................................................... 8-18
Model Hose Reel HRA series....................................................................................................................... 8-19
Model Mixing Booster ................................................................................................................................ 8-20
Model Pump Booster Mixing Valve ............................................................................................................ 8-21
Model Plate Heat Exchanger Glycol to Glycol ............................................................................................ 8-16
Model Humidistat Fan Coil Control ............................................................................................................ 8-17
9. Weights and Dimensions...........................................................................................................9-1
10. MATERIAL SAFETY DATA SHEET..................................................................................10-1
11. Operator Notes ........................................................................................................................11-1

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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......................................................................................................................Error! Bookmark not defined.
Figure 3-5 Refractometer............................................................................................................................................................................3-5
Figure 3-6 pH Tester...................................................................................................................................................................................3-5
Figure 4-1 Smoke Scales .............................................................................................................................................................................4-1
Figure 4-2 2000-1200 Orifices....................................................................................................................................................................4-1
Figure 4-3 Spot Smoke Tester .....................................................................................................................................................................4-1
Figure 4-4 Flue Gas Analyzer.....................................................................................................................................................................4-1
Figure 4-5 2000-1200 Exploded..................................................................................................................................................................4-4
Figure 4-6 2100-0300 Exploded..................................................................................................................................................................4-5
Figure 4-7 2100-xxxx Exploded...................................................................................................................................................................4-5
Figure 5-1 Strainer Screen..........................................................................................................................................................................5-1
Figure 5-2 'Y'- Strainer................................................................................................................................................................................5-1
Figure 5-3 Safety Relief Valve.....................................................................................................................................................................5-2
Figure 5-4 Pressure Bypass Valve ..............................................................................................................................................................5-3
Figure 5-5 Drain Valve...............................................................................................................................................................................5-3
Figure 5-6 Cold Start Fluid Pre-Heater......................................................................................................................................................5-4
Figure 5-7 Thermostatic Control Valve.......................................................................................................................................................5-4
Figure 5-8 Automatic Air Bleed Vent..........................................................................................................................................................5-4
Figure 5-9 Flow Reverser Schematic ..........................................................................................................................................................5-5
Figure 5-12 Flow Reverser Schematic ........................................................................................................................................................5-8
Figure 6-1 Flow Reverser Actuator Wiring.................................................................................................................................................6-1
Figure 6-2 Electrical Panel.........................................................................................................................................................................6-1
Figure 6-3 Transformer Wiring...................................................................................................................................................................6-2
Figure 6-4 Short Electrical Strip.................................................................................................................................................................6-2
Figure 6-5 Timer Wiring .............................................................................................................................................................................6-2
Figure 6-6 Flow Reverser Actuator Wiring.................................................................................................................................................6-2
Figure 6-7 Electrical Panel.........................................................................................................................................................................6-3
Figure 6-8 Transformer Wiring...................................................................................................................................................................6-3
Figure 6-9 Short Electrical Strip.................................................................................................................................................................6-3
Figure 6-10 Timer Wiring ...........................................................................................................................................................................6-3

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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.............................................................................................................................................................................6-8
Figure 6-18 Flow Switch Power Connections.............................................................................................................................................6-8
Figure 6-19 High Limit Control (Manual Reset).........................................................................................................................................6-9
Figure 6-20 High Limit Control (Automatic Reset).....................................................................................................................................6-9
Figure 6-21 Ignition Module....................................................................................................................................................................6-10
Figure 6-22 Model –Safgard 650.............................................................................................................................................................6-11
Figure 6-23 Model - Guard Dog (PS-851-M-120)....................................................................................................................................6-11
Figure 6-24 Honeywell (V8944B) & (V8944C).........................................................................................................................................6-12
Figure 6-25 Micro Switch BZE6-2RN2.....................................................................................................................................................6-13
Figure 6-26 Basotrol H91WG-1................................................................................................................................................................6-13
Figure 6-27 Johnson A350PS-1C..............................................................................................................................................................6-13
Figure 6-28 Goulds Pumps........................................................................................................................................................................6-14
Figure 6-29 Honeywell V88A....................................................................................................................................................................6-14
Figure 6-30 Honeywell V5055...................................................................................................................................................................6-14
Figure 6-31 Johnson A19ABA...................................................................................................................................................................6-15
Figure 6-32 Honeywell ML7984 ...............................................................................................................................................................6-15
Figure 6-33 Penta Power (KBVF).............................................................................................................................................................6-16
Figure 6-34 ATV11....................................................................................................................................................................................6-16
Figure 8-1 Model GTS 2100-0300 ..............................................................................................................................................................8-1
Figure 8-2 Model GTS 2100-0600, 2100-0900 ...............................................................................................Error! Bookmark not defined.
Figure 8-3 Model 2100-0900 FLEX................................................................................................................Error! Bookmark not defined.
Figure 8-4 Model CHU 2000-1200.................................................................................................................Error! Bookmark not defined.
Figure 8-5 Model CHU 2100-0400, 2100-0600, 2100-0900, 2100-1200........................................................Error! Bookmark not defined.
Figure 8-6 Model Steam Plate –HESF 1000..............................................................................................................................................8-9
Figure 8-7 Model HE80 Fan Coil.............................................................................................................................................................8-14
Figure 8-8 Model HE200 Fan Coil...........................................................................................................................................................8-13
Figure 8-9 Model HE600 Fan Coil...........................................................................................................................................................8-15
Figure 8-10 Model MAXCOIL ..................................................................................................................................................................8-16
Figure 8-11 Model Hose Reel HR2250 .....................................................................................................................................................8-17

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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......................................................................................................................................8-17
Table of Tables
Table 3-1 Fuel Consumption.......................................................................................................................................................................3-4
Table 3-2 pH................................................................................................................................................................................................3-5
Table 3-3 Mixing Ratios..............................................................................................................................................................................3-6
Table 3-4 Heat Exchanger Volumes............................................................................................................................................................3-7
Table 3-5 Hose Volumes..............................................................................................................................................................................3-7
Table 3-6 Potable Heat Exchanger Volumes...............................................................................................................................................3-8
Table 4-1 Flue Gas Analyzer Results.............................................................................................................................................................4-2
Table 4-2 Service Tips.................................................................................................................................................................................4-6
Table 6-1 A421 Settings...............................................................................................................................................................................6-5
Table 6-2 A419 Setting................................................................................................................................................................................6-5
Table 6-3 Sensor Readings..........................................................................................................................................................................6-7
Table 6-4 VFD Trouble shooting...............................................................................................................................................................6-16
Table 9-1 Weights and Dimensions.............................................................................................................................................................9-1

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Version 0.0
PN 003-702872
Warranty Policies& Claim Procedures 1-1
1.Warranty Policies& Claim Procedures
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
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.
•Any parts that are covered by an extended warranty published by DRYAIR are an exception
to the Basic Warranty policy and are to be warranted as per the details of the Extended
Warranty Policy.
•Labor is covered as per DRYAIR flat labor 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 warranted 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
Heat
exchanger
•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%