Wacker Neuson HI260 User manual

Category
Air blowers/dryers
Type
User manual
Operator’s Manual
Indirect-Fired Air Heaters
HI260
Type HI260
Document 5200018378
Date
0716
Revision 04
Language EN
5200018378
Copyright notice
© Copyright 2016 by Wacker Neuson Production Americas LLC
All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the
machine. Any other type of reproduction is prohibited without express
written permission from Wacker Neuson Production Americas LLC.
Any type of reproduction or distribution not authorized by Wacker
Neuson Production Americas LLC represents an infringement of valid
copyrights. Violators will be prosecuted.
Trademarks
All trademarks referenced in this manual are the property of their
respective owners.
Manufacturer
Wacker Neuson Production Americas LLC
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957
www.wackerneuson.com
Original instructions
This Operator’s Manual presents the original instructions. The original
language of this Operator’s Manual is American English.
HI260 Foreword
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Foreword
THESE HEATERS ARE SUITABLE FOR OUTDOOR OR INDOOR USE.
ADEQUATE VENTILATION MUST BE PROVIDED.
THIS HEATER IS INTENDED FOR USE PRIMARILY AS TEMPORARY HEATING
OF BUILDINGS UNDER CONSTRUCTION, ALTERATION, OR REPAIR.
CHECK WITH YOUR LOCAL FIRE SAFETY AUTHORITY IF YOU HAVE
QUESTIONS ABOUT APPLICATIONS.
Certain standards govern the use of fuel gases and heat-producing products in
specific applications. Your local authority can advise you about these.
THE INSTALLATION OF THE UNIT SHALL BE IN ACCORDANCE WITH THE
REGULATIONS OF THE AUTHORITIES HAVING JURISDICTION.
WARNING
GENERAL HAZARD—FAILURE TO COMPLY WITH THE PRECAUTIONS AND
INSTRUCTIONS PROVIDED WITH THIS HEATER CAN RESULT IN DEATH,
SERIOUS BODILY INJURY AND PROPERTY LOSS OR DAMAGE FROM
HAZARDS OF FIRE, EXPLOSION, BURN, ASPHYXIATION, CARBON
MONOXIDE POISONING, AND / OR ELECTRICAL SHOCK.
â–º ONLY PERSONS WHO CAN UNDERSTAND AND FOLLOW THESE
INSTRUCTIONS SHOULD USE OR SERVICE THIS HEATER.
â–º IF YOU NEED ASSISTANCE OR HEATER INFORMATION SUCH AS AN
INSTRUCTION MANUAL OR LABEL, ETC. CONTACT THE
MANUFACTURER.
WARNING
WORK SITE FIRE, BURN, INHALATION, AND EXPLOSION HAZARDS.
â–º KEEP SOLID COMBUSTIBLES, SUCH AS BUILDING MATERIALS, PAPER,
OR CARDBOARD AT A SAFE DISTANCE AWAY FROM THE MACHINE AS
RECOMMENDED BY THE INSTRUCTIONS.
â–º NEVER USE THIS MACHINE IN SPACES WHICH DO OR MAY CONTAIN
VOLATILE OR AIRBORNE COMBUSTIBLES, OR PRODUCTS SUCH AS
GASOLINE, SOLVENTS, PAINT THINNER, DUST PARTICLES, OR
UNKNOWN CHEMICALS.
WARNING
NOT FOR HOME OR RECREATIONAL VEHICLE USE.
â–º OPERATE THE MACHINE ONLY FOR APPLICATIONS SPECIFIED IN
MACHINE DESCRIPTION AND INTENDED USE.
Foreword HI260
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READ AND SAVE THESE INSTRUCTIONS—This manual contains important
instructions for the machine models below. These instructions have been written
expressly by Wacker Neuson Production Americas LLC and must be followed
during installation, operation, and maintenance of the machines.
Machine
identification
A nameplate listing the model number, item number, revision number, and serial
number is attached to this machine. The location of the nameplate is shown above.
Serial number
(S/N)
For future reference, record the serial number in the space provided below. You will
need the serial number when requesting parts or service for this machine.
Machine
documentation
â–  From this point forward in this documentation, Wacker Neuson Production
Americas LLC will be referred to as Wacker Neuson.
■ Keep a copy of the Operator’s Manual with the machine at all times.
â–  For spare parts information, please see your Wacker Neuson Dealer, or visit the
Wacker Neuson website at http://www.wackerneuson.com/.
â–  When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
Expectations
for
information in
this manual
â–  This manual provides information and procedures to safely operate and
maintain the above Wacker Neuson model(s). For your own safety and to
reduce the risk of injury, carefully read, understand, and observe all instructions
described in this manual.
â–  Wacker Neuson expressly reserves the right to make technical modifications,
even without notice, which improve the performance or safety standards of its
machines.
â–  The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson reserves the right to change any
portion of this information without notice.
Machine Item Number
HI260 5200018503, 5200018504
HI 260
wc_gr011827
Serial Number:
HI260 Foreword
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â–  The illustrations, parts, and procedures in this manual refer to Wacker Neuson
factory-installed components. Your machine may vary depending on the
requirements of your specific region.
Manufacturer’s
approval
This manual contains references to approved parts, attachments, and
modifications. The following definitions apply:
â–  Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.
â–  Approved modifications are those performed by an authorized Wacker
Neuson service center according to written instructions published by Wacker
Neuson.
â–  Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following
consequences:
â–  Serious injury hazards to the operator and persons in the work area
â–  Permanent damage to the machine which will not be covered under warranty
Contact your Wacker Neuson dealer immediately if you have questions about
approved or unapproved parts, attachments, or modifications.
Foreword HI260
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Original Declaration of Conformity
2016-CE-HI260_WN_en_FM10.fm
EC Declaration of Conformity
Manufacturer
Wacker Neuson Production Americas LLC, N92W15000 Anthony Avenue,
Menomonee Falls, Wisconsin USA
Product
Product
Product category
Product function
Item number
HI260
Heating Equipment
To heat air
5200018503
5200018504
Conformity Assessment Procedure
According to ANNEX VIII
Directives and Standards
We hereby declare that this product meets and complies with the relevant regulations and
requirements of the following directives and standards:
2006/42/EC, 2014/30/EU, 2014/35/EU
ISO 12100:2010/11/15
EN 13309, EN 61000-6-2
EN 60204-1, EN 60529, EN 60335-1
Authorized Person for Technical Documents
Robert Raethsel, Wacker Neuson Produktion GmbH & Co. KG, Wackerstrasse 6, 85084
Reichertshofen, Germany
Menomonee Falls, WI, USA, 16.6.16
Keith Herr
Vice President and Managing Director
For Wacker Neuson
Michael Hanson
Manager, Product Engineering
For Wacker Neuson
Jeff Volden
Director, Product Engineering
For Wacker Neuson
Table of Contents
HI260
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Foreword 3
EC Declaration of Conformity 7
1 Safety Information 13
1.1 Signal Words Used in this Manual ..................................................... 13
1.2 Machine Description and Intended Use ............................................. 14
1.3 Safety Guidelines for Operating the Machine ..................................... 15
1.4 Service Safety .................................................................................... 18
1.5 Safety Guidelines for Operating Combustion Burners ....................... 20
1.6 Safety Guidelines for Lifting the Machine ........................................... 21
2 Labels 22
2.1 Label Locations .................................................................................. 22
2.2 Label Meanings .................................................................................. 23
3 Lifting and Transporting 27
3.1 Lifting the Machine ............................................................................. 27
3.2 Preparing the Machine for Transport on a Truck or Trailer ................ 28
4 Machine Setup 29
4.1 Preparing the Machine for First Use ................................................... 29
4.2 Recommended Fuel ........................................................................... 30
4.3 Refueling the Machine ........................................................................ 31
4.4 Positioning the Machine for Indoor Use ............................................. 32
4.5 Positioning the Machine for Outdoor Use ........................................... 34
4.6 Suggested Venting ............................................................................. 37
4.7 Electrical Requirements ..................................................................... 38
4.8 Connecting Power to the Machine ..................................................... 39
4.9 Flex Ducting Options .......................................................................... 40
4.10 Ducting Guidelines ............................................................................. 41
5 Controls 43
5.1 Control Panel ...................................................................................... 43
5.2 Control Display Screen ....................................................................... 44
5.3 Options Menu ..................................................................................... 45
Table of Contents
HI260
10
6 Operation 47
6.1 Before Starting the Machine ...............................................................47
6.2 Starting, Operating, and Stopping the Machine ..................................49
6.3 Emergency Stop .................................................................................53
6.4 Fault Conditions and Remedies ..........................................................54
6.5 Using the Recirculation Damper .........................................................55
7 Burner Setup 56
7.1 Burner Settings ...................................................................................56
7.2 Setting Up the Burner .........................................................................57
7.3 Analyzing the Combustion ..................................................................58
7.4 Removing the Burner for Maintenance ...............................................59
7.5 Replacing the Burner Nozzle ..............................................................60
7.6 Checking and Adjusting the Electrodes ..............................................62
7.7 Checking and Adjusting the Combustion Head ..................................63
7.8 Checking and Adjusting the Fuel Pressure .........................................64
7.9 Adjusting the Burner Low-Fire Settings ..............................................65
7.10 Adjusting the Burner High-Fire Settings .............................................67
8 General Maintenance 69
8.1 Periodic Maintenance Schedule .........................................................69
8.2 Inspecting the Machine .......................................................................70
8.3 Cleaning the Machine .........................................................................71
8.4 Replacing the Blower Belt ...................................................................72
8.5 Removing and Installing the Burner (Complete) .................................74
8.6 Inspecting the Heat Exchanger ...........................................................76
8.7 Replacing the Fuel Filter .....................................................................79
8.8 Storage ...............................................................................................80
8.9 Preparing the Machine for Seasonal Operation ..................................81
8.10 Machine Disposal and Decommissioning ...........................................82
9 Troubleshooting 84
9.1 Machines with Oil Burners ..................................................................84
wc_bo5200018378_04_FM10T
Table of Contents
HI260
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10 Technical Data 85
10.1 Machine .............................................................................................. 85
10.2 Dimensions ......................................................................................... 86
11 Schematics 87
11.1 Electrical Schematic ........................................................................... 88
11.2 Electrical Schematic Components ...................................................... 89
11.3 Burner and Blower Motor ................................................................... 90
11.4 Burner and Blower Motor Components .............................................. 91
11.5 Electrical Schematic - Phase Sequence Monitoring Device ............... 92
11.6 Ladder Logic Diagram ........................................................................ 93
11.7 Components ....................................................................................... 97
Table of Contents
HI260
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HI260 Safety Information
1 Safety Information
1.1 Signal Words Used in this Manual
This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE
signal words which must be followed to reduce the possibility of personal injury,
damage to the equipment, or improper service.
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
â–º Obey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
â–º To avoid death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
â–º To avoid possible death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
â–º To avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.
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Safety Information HI260
1.2 Machine Description and Intended Use
Machine
description
The HI260 Heaters are indirect-fired air heaters. The machine consists of the
following components:
â–  Combustion chamber and heat exchanger
â–  Centrifugal blower
â–  Burner
â–  High-temperature shut-down switch(es)
â–  Fuel tank on select models
Fuel is consumed in a closed combustion chamber. Room air or outside air
(depending on the application) is pulled in by the centrifugal blower and blown over
the hot heat exchanger. This clean, dry, hot air is then blown into the space to be
heated by the centrifugal blower. Access to the blower assembly is protected by a
guard fitted on the air inlet.
Intended use
The HI260 Heaters are intended to provide heat on outdoor sites or indoor sites
and in other rugged applications. The machine may be operated indoors, but only
when it has
proper exhaust venting designed for indoor use, which meets all applicable
regulations.
This machine has been designed and built strictly for the intended use described
above. Using the machine for any other purpose could permanently damage the
machine or seriously injure the operator or other persons on the work site. Machine
damage caused by misuse is not covered under warranty.
This machine has been designed and built in accordance with the latest global
safety standards. It has been carefully engineered to eliminate hazards as far as
practicable, and to increase operator safety through protective guards and labeling.
However, some risks may remain even after protective measures have been taken.
They are called residual risks. On this machine, they may include exposure to:
â–  exhaust emissions
â–  hot surfaces such as exhaust vents
â–  fuel and fuel fumes when refueling
â–  high voltages and arc flash
To protect yourself and others, thoroughly read and understand the safety
information presented in this manual before operating the machine.
Wacker Neuson offers many optional accessories for the machine. These
accessories include the following:
â–  Remote thermostat
â–  Duct adapters (various sizes, available as kits, or individual ducts).
â–  Covers for inlet and outlets (need to be removed before operation)
â–  Exhaust vents and elbows
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HI260 Safety Information
1.3 Safety Guidelines for Operating the Machine
Operator
training
Before operating the machine:
â–  Read and understand the operating instructions contained in all manuals
delivered with the machine.
â–  Familiarize yourself with the location and proper use of all controls and safety
devices.
â–  Contact Wacker Neuson for additional training if necessary.
When operating this machine:
â–  Do not allow improperly trained people to operate the machine. People
operating the machine must be familiar with the potential risks and hazards
associated with it.
Operator
qualifications
Only trained personnel are permitted to start, operate, and shut down the machine.
They also must meet the following qualifications:
â–  have received instruction on how to properly use the machine
â–  are familiar with required safety devices
The machine must not be accessed or operated by:
â–  children
â–  people impaired by alcohol or drugs
Application
area
Be aware of the application area.
â–  Keep unauthorized personnel, children, and pets away from the machine.
â–  Remain aware of changing positions and the movement of other equipment and
personnel in the application area/job site.
â–  Identify whether special hazards exist in the application area, such as toxic
gases or unstable ground conditions, and take appropriate action to eliminate
the special hazards before using the machine.
Be aware of the application area.
â–  Do not operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
Safety
devices,
controls, and
attachments
Only operate the machine when:
â–  All safety devices and guards are in place and in working order.
â–  All controls operate correctly.
■ The machine is set up correctly according to the instructions in the Operator’s
Manual.
â–  The machine is clean.
■ The machine’s labels are legible.
To ensure safe operation of the machine:
â–  Do not operate the machine if any safety devices or guards are missing or
inoperative.
â–  Do not modify or defeat the safety devices.
â–  Only use accessories or attachments that are approved by Wacker Neuson.
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Safety Information HI260
Safe
operating
practices
When operating this machine:
■ Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
When operating this machine:
â–  Do not operate a machine in need of repair.
â–  Do not consume the operating fluids used in this machine. Depending on your
machine model, these operating fluids may include water, wetting agents, fuel
(gasoline, diesel, kerosene, propane, or natural gas), oil, coolant, hydraulic fluid,
heat transfer fluid (propylene glycol with additives), battery acid, or grease.
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while operating this
machine:
â–  Close-fitting work clothes that do not hinder movement
â–  Safety glasses with side shields
â–  Hearing protection
â–  Safety-toed footwear
After Use
â–  Stop the engine when the machine is not being operated.
â–  Close the fuel valve on engines equipped with one when the machine is not
being operated.
â–  Ensure that the machine will not tip over, roll, slide, or fall when not being
operated.
â–  Store the machine properly when it is not being used. The machine should be
stored in a clean, dry location out of the reach of children.
Machine
condition
Only operate the machine when:
â–  The heat exchanger is in proper working order.
â–  All safety devices and guards are in place and in working order.
â–  All controls operate correctly.
■ The machine is set up correctly according to the instructions in the Operator’s
Manual.
â–  The machine is clean.
■ The machine’s labels are legible.
When operating the machine:
â–  Do not modify or defeat the safety devices.
â–  Do not use worn electrical cords.
â–  Do not use faulty fuel supplies.
Heat
exchanger
inspection
The heat exchanger must be inspected twice a year to ensure it is in good working
order. Shorter inspection intervals are recommended for units operating under
extreme transportation or operating conditions.
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HI260 Safety Information
Work space
Follow the guidelines below when placing the machine in the workspace:
â–  Position the machine on a firm, noncombustible, level surface.
â–  Keep the area immediately surrounding and underneath the machine clean,
neat, and free of debris and combustible materials.
â–  Keep the area above the machine clear of debris that could fall on the machine.
â–  Store the machine properly when it is not being used.
â–  Keep unauthorized personnel, children, and pets away from the machine.
When operating the machine:
â–  Do not connect ductwork between the exhaust outlet port and the supply air inlet
port.
â–  Never operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
â–  Do not position the electrical cords under the machine or over the top of the
machine.
DANGER
Exhaust gas from the burner contains carbon monoxide, a deadly poison. Exposure
to carbon monoxide can kill you in minutes.
â–º Never run the machine indoors or in an enclosed area unless the machine is
vented properly.
â–º If your machine has a trailer or generator, do not run the machine indoors.
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Safety Information HI260
1.4 Service Safety
Service
training
Before servicing or maintaining the machine:
â–  Read and understand the instructions contained in all manuals delivered with
the machine.
â–  Familiarize yourself with the location and proper use of all controls and safety
devices.
â–  Only trained personnel shall troubleshoot or repair problems occurring with the
machine.
â–  Contact Wacker Neuson for additional training if necessary.
When servicing or maintaining this machine:
â–  Do not allow improperly trained people to service or maintain the machine.
Personnel servicing or maintaining the machine must be familiar with the
associated potential risks and hazards.
Precautions
When servicing or maintaining the machine:
â–  Read and understand the service procedures before performing any service to
the machine.
â–  All adjustments and repairs must be completed before operating the machine.
Do not operate the machine with a known problem or deficiency.
â–  All repairs and adjustments shall be completed by a qualified technician.
â–  Turn off the machine before performing maintenance or making repairs.
■ Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
â–  Re-install the safety devices and guards after repair and maintenance
procedures are complete.
Machine
modifications
When servicing or maintaining the machine:
â–  Use only accessories/attachments that are approved by Wacker Neuson.
When servicing or maintaining the machine:
â–  Do not defeat safety devices.
â–  Do not modify the machine without the express written approval of Wacker
Neuson.
Replacing
parts and
labels
â–  Replace worn or damaged components.
â–  Replace all missing and hard-to-read labels.
â–  When replacing electrical components, use components that are identical in
rating and performance to the original components.
â–  When replacement parts are required for this machine, use only Wacker
Neuson replacement parts or those parts equivalent to the original in all types of
specifications, such as physical dimensions, type, strength, and material.
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HI260 Safety Information
Cleaning
When cleaning and servicing the machine:
â–  Keep the machine clean and free of debris such as leaves, paper, cartons, etc.
â–  Keep the labels legible.
When cleaning the machine:
â–  Do not clean the machine while it is running.
â–  Never use gasoline or other types of fuels or flammable solvents to clean the
machine. Fumes from fuels and solvents can become explosive.
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while servicing or
maintaining this machine:
â–  Close-fitting work clothes that do not hinder movement
â–  Safety glasses with side shields
â–  Hearing protection
â–  Safety-toed footwear
In addition, before servicing or maintaining the machine:
â–  Tie back long hair.
â–  Remove all jewelry (including rings).
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Safety Information HI260
1.5 Safety Guidelines for Operating Combustion Burners
When using the machine:
â–  Make sure you have proper certification or licensing required by the locality,
state, or province in which the machine is being installed to connect natural gas
or LP.
â–  Clean up any spilled fuel immediately.
â–  Replace the fuel tank cap after refueling the machine.
â–  Refill the fuel tank in a well-ventilated area.
â–  Always keep the oil supply valve shut off if the burner is shut down for an
extended period of time.
When using the machine:
â–  Do not fill or drain the fuel tank near an open flame, while smoking, or while the
machine is running.
â–  Do not smoke when refueling the machine.
â–  Do not smoke when connecting natural gas or LP.
â–  Do not attempt to start the burner when excess oil has accumulated, when the
unit is full of vapors, or when the combustion chamber is very hot.
Note: Some machines may not be capable of supporting natural gas or LP. Please
see the burner manufacturer’s literature for more information.
DANGER
Carbon monoxide. Using this machine indoors CAN KILL YOU IN MINUTES.
Exhaust gas contains carbon monoxide (CO). This is a deadly poison you cannot
see or smell. If you can smell the exhaust, you are breathing CO. Even if you
cannot smell the exhaust, you could be breathing CO.
â–º NEVER operate the machine inside an enclosed area, such as a home, tunnel,
or garage unless it is vented properly.
â–º ONLY use the machine outside and far away from windows, doors, and vents.
These openings can pull in exhaust gas.
â–º ALWAYS use a battery-powered or battery-backup CO alarm in nearby
structures. Even when you use the machine correctly, CO may leak into nearby
structures.
â–º If you start to feel sick, dizzy, or weak after the machine has been running, move
to fresh air IMMEDIATELY. See a doctor. You could have carbon monoxide
poisoning.
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Wacker Neuson HI260 User manual

Category
Air blowers/dryers
Type
User manual

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