Mobile Diesel Heaters GRY-D / GRY-I Service Training Course 1 Rev. No. 3 January 24, 2011 GRY-I Indirect-fired Diesel Heaters • • • GRY-I 15 WE GRY-I 25 WE GRY-I 40 WE GRYP 15 AP GRYP 25 AP GRYP 40 AP 2 GRY-D Direct-fired Diesel Heaters • • • • • • GRY-D GRY-D GRY-D GRY-D GRY-D GRY-D 15 WE 20 HE 20 WE 28 WE 40 WE 60 WE GRYP 15 GRYP 20 M GRYP 20 GRYP 28 GRYP 40 GRYP 60 PV 3 GRY-I General Assembly Compressor Exhaust Pipe Burner Head Motor Fan Combustion Chamber Fuel Tank 4 GRY-D General Assembly Outlet Flame Shield Burner Head Compressor Fan Combustion Chamber (open) Motor Fuel Tank 5 Fan Motor Assembly Motors 70 W 100 W 150 W 250 W 2800 rpm 2800 rpm 2800 rpm 2800 rpm 2 poles 2 poles 2 poles 2 poles GRY-D GRY-D GRY-D GRY-D 15 20 28 GRY-I 15 40/60 GRY-I 25/40 6 Fuel Circuit Vent Pipe The fuel circuit is composed of : fuel tank fuel suction hose fuel filter (air compressor) (air valve) (air hoses) nozzle holder (combustion head) nozzle Fuel Filter Nozzle Holder Burner Head Nozzle Air Fuel GRY-D Models (except 15 and 60) Vent Pipe Nozzle Holder Nozzle Holder Burner Head Fuel Filter Nozzle Nozzle Fuel Filter Burner Head Air Fuel Air GRY-D 15 WU Fuel Air Cutoff Valve GRY-I Models & GRY-D 60 7 Air Compressor Assembly Rear Guard Inlet Filter Filter Casing Pressure Adjustment Valve Pressure Port Cap Gasket Outlet Filter Cover Plate Stator Rotor Coupling Air Line to Nozzle Blade 8 Rotary Compressor Blade Stator Joint Rotor 9 Air compressor Inlet (Low Pressure) Filter 10 Air compressor Outlet (High Pressure) Filter 11 Burner Assembly (old and new design) Old New 12 Burner Assembly Ignition Electrode Swirl Blades Safety Thermostat Combustion Head Nozzle Holder Fuel Nozzle 13 Combustion Head (current design) Air Fuel O-ring Seal 14 Combustion Head (old design) Washer Spring Washers Rubber Seal 15 Nozzle & Nozzle Holder O-ring Fuel Inlet Air Inlet 16 STANDARD NOZZLE Pressurized FUEL Inlets Pressurized FUEL Inlets Syphon Nozzle vs. Standard Nozzle Nozzle Orifice Turbulence Chamber Tangential Channels SYPHON NOZZLE Pressurized AIR Inlets Pressurized AIR Inlets Nozzle Orifice Fuel Inlet Fuel Inlet Turbulence Chamber Tangential Channels 17 Burner Head on Combustion Chamber 18 GRY-D 15 Combustion Head Vent Pipe Nozzle Holder Fuel Filter Burner Head Nozzle Fuel Air 19 GRY-I Combustion chamber detail 20 GRY-I Fuel Filter and Air Valve Air Valve Air Valve Fuel Filter Vent Hole 21 Safety Controls Flame Sensor and Thermostat • Flame Sensor (Photoresistor) – Detects false flame signals or anticipated ignition – Checks flame failure at ignition – Checks flame failure during operation • Safety thermostat (Limit Control, OPTIONAL for USA models) Limit Control Flame Sensor 22 Line Fuse 23 Principle of Operation GRY-D 24 Principle of Operation GRY-I 25 Ignition Sequence GRY-D 15/20/28/40 T1 T2 SW M M T PH F PS 6 sec SW M T PH F PS SWITCH MOTOR TRANSFORMER PHOTOCELL FLAME AIR PRESSURE SWITCH T1 T2 START TIME WORK TIME XX sec work end 0 sec 26 Ignition Sequence GRY-D 60 & GRY-I 15/25/40 T1 T2 T3 T4 SW M M T SV PH F PS 10 sec SW M T SV PH F PS SWITCH MOTOR TRANSFORMER AIR SOLENOID VALVE PHOTOCELL FLAME AIR PRESSURE SWITCH T1 T2 T3 T4 PREVENTILATION TIME START TIME WORK TIME POST-VENTILATION TIME 16 sec 45 sec XX work end 0 sec 27 Wiring Diagrams 28 Wiring Diagrams 29 GRY-D GRY-I Service Procedures 30 Rotor-Stator Clearances 31 Correct Stator vs. Rotor Positioning 0.5 mm (0.2”) spacer plate Stator Fixing Screws 32 Air pressure adjustment Pressure Adjusting Screw Pressure Gauge 33 GRY-D Appearance of front disc BAD COMBUSTION GOOD COMBUSTION 34 Ignition Electrode Gap 35 Electronic control boards GRY-I GRY-D 36 Pressure Adjustment Valve Nut Screw Spring Ball Gasket 37 Air Ducting (Indirect Heaters only) GRY-I 25&40 WU GRY-I 15 WU Max Duct Lenght ~ 8 m (25 ft) Max Duct Lenght ~ 6 m (20 ft) 38 Draining Fuel from Tank 39 Fuel Suction Hose Hose Gasket Bottom Spacer (important!) 40 Tank Cap 41 Typical Air Temperatures on Direct and Indirect Heaters 42 Service & Maintenance Equipment Measuring devices Electric Multimeter (V, A, ) PC Flame Sensor Tester Kit Pressure Gauge Kit (incl. hose and fitting) Smoke Index Tester 43