Wacker Neuson HP252 User manual

Type
User manual
5000189353 02 0111
5000189353
Operator’s Manual
Hydronic Air Heater
HP 252D
Copyright
notice
© Copyright 2011 by Wacker Neuson Corporation.
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 Corporation.
Any type of reproduction or distribution not authorized by Wacker Neuson Corporation
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 Corporation
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.
Foreword
wc_tx001627gb.fm 3
Foreword
Machines
covered by
this manual
This manual covers machines with the following item numbers:
Machine
documentation
 Keep a copy of the Operator’s Manual with the machine at all times.
î‚„ Use the separate Parts Book supplied with the machine to order replacement
parts.
î‚„ If you are missing any of these documents, please contact Wacker Neuson
Corporation to order a replacement or visit www.wackerneuson.com.
î‚„ 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
î‚„ 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.
î‚„ Wacker Neuson Corporation expressly reserves the right to make technical
modifications, even without notice, which improve the performance or safety
standards of its machines.
î‚„ The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson Corporation reserves the right
to change any portion of this information without notice.
Manufacturer’s
approval
This manual contains references to approved parts, attachments, and
modifications. The following definitions apply:
î‚„ Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.
î‚„ Approved modifications are those performed by an authorized Wacker
Neuson service center according to written instructions published by Wacker
Neuson.
î‚„ Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following
consequences:
î‚„ Serious injury hazards to the operator and persons in the work area
î‚„ 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.
Machine Item Number Revision
HP 252D 0620249 200 and above
Foreword
4 wc_tx001627gb.fm
William Lahner Paul Krause
Vice President of Engineering Manager, Product Engineering
WACKER NEUSON CORPORATION
2010_CE_HP252D_en.fm
EC DECLARATION OF CONFORMITY
WACKER NEUSON CORPORATION, N92W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA
hereby certifies that the construction equipment specified hereunder:
AUTHORIZED PERSON FOR TECHNICAL DOCUMENTS Axel Häret
WACKER NEUSON SE
Preußenstraße 41
80809 München
1. Category:
Heating Equipment
2. Machine function:
This machine is intended to be used as an air heater. In addition, when used with other Wacker Neuson accessories, this
machine can be used to thaw frozen ground, cure concrete, or prevent frost and freezing. An insulated blanket may be laid
over the hoses to increase efficiency.
3. Type / Model
Hydronic Air Heater HP 252D
4. Item number of equipment:
0620249
5.
This machinery fulfills the relevant provisions of Machinery Directive 2006/42/EC and is also produced in
accordance with these standards:
98/37/EC
EN 60204-1:2006
ISO 12100-1:2003
ISO 12100-2:2003
2006/95/EC
The original language of this EC Declaration of Conformity is American English.
22.09.10
Date
EC DECLARATION OF CONFORMITY
wc_bo5000189353_02TOC.fm 7
Table of ContentsHP 252D
Foreword 3
EC DECLARATION OF CONFORMITY 5
1 Safety Information 11
1.1 Signal Words Used in this Manual ..................................................... 11
1.2 Machine Description and Intended Use ............................................. 12
1.3 Safety Guidelines for Operating the Machine ..................................... 13
1.4 Service Safety .................................................................................... 15
1.5 Safety Guidelines for Operating Combustion Burners ....................... 17
1.6 Safety Guidelines for Towing the Machine ......................................... 18
2 Labels 20
2.1 Label Locations .................................................................................. 20
2.2 Label Meanings .................................................................................. 21
3 Lifting and Transporting 26
3.1 Lifting the Machine ............................................................................. 26
3.2 Preparing the Machine for Transport on a Truck or Trailer ................ 27
4 Operation 28
4.1 Control / Component Locations .......................................................... 28
4.2 Control / Component Descriptions ..................................................... 29
4.3 Control Panel ...................................................................................... 30
4.4 Control Panel Components ................................................................ 31
4.5 Valves ................................................................................................. 32
4.6 Preparing the Machine for First Use ................................................... 33
4.7 Sequence of Operation: Air Heating ................................................... 34
4.8 Sequence of Operation: Thawing, Curing, and Frost Prevention ....... 35
4.9 Recommended Fuel ........................................................................... 36
4.10 Positioning the Machine for Air Heating Applications ......................... 37
4.11 Positioning the Machine for Thawing, Curing, or Frost Prevention .... 38
4.12 Connecting the Diesel Fuel Supply .................................................... 40
4.13 Connecting the Electric Power ........................................................... 41
4.14 Pre-Starting Checks ........................................................................... 42
4.15 Unloading and Loading the Heat Exchangers .................................... 44
4.16 Positioning and Connecting the Heat Exchangers ............................. 46
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Table of ContentsHP 252D
4.17 Preheating the HTF and Initiating Flow of the HTF .............................48
4.18 Operating the Machine: Surface Heating Applications ........................51
4.19 Setting the Operating Temperature .....................................................53
4.20 Monitoring the Operating Parameters .................................................54
4.21 Stopping the Machine Temporarily ......................................................55
4.22 Emergency Shutdown Procedure ........................................................56
4.23 Rewinding the Hoses ..........................................................................57
4.24 Shutting Down and Packing Up the Machine ......................................59
4.25 Resetting a Low HTF Level Fault ........................................................60
4.26 Resetting the Burner Control ...............................................................63
4.27 Quick-Connect Coupling Usage and Care ..........................................64
4.28 Resetting the Snap Switch ..................................................................65
5 Accessories 66
5.1 Available Accessories .........................................................................66
5.2 Connecting a Booster Pump ...............................................................67
5.3 Heating Layout Using Four HX 60 Heat Exchangers ..........................68
5.4 Components ........................................................................................69
5.5 Heating Layout Using Eight HX 30 Heat Exchangers .........................70
5.6 Components ........................................................................................71
5.7 Heating Layout Using Sixteen HX 15 Heat Exchangers .....................72
5.8 Components ........................................................................................73
5.9 Curing Layout ......................................................................................74
5.10 Components for Curing .......................................................................75
5.11 Thawing Layout ...................................................................................76
5.12 Components for Thawing ....................................................................77
5.13 Frost Prevention Layout ......................................................................78
5.14 Components for Frost Prevention .......................................................79
6 Burner Setup 80
6.1 Factory Settings ..................................................................................80
6.2 Setting up the Burner ..........................................................................81
6.3 Removing and Installing the Burner ....................................................84
6.4 Adjusting the Burner Electrodes ..........................................................85
6.5 Replacing the Burner Nozzle ...............................................................86
6.6 Adjusting the Head ..............................................................................87
6.7 Adjusting the Burner Low-Fire Settings ...............................................88
6.8 Adjusting the Burner High-Fire Settings ..............................................90
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Table of ContentsHP 252D
7 Maintenance 93
7.1 Periodic Maintenance Schedule ......................................................... 93
7.2 Repairing a Hose ................................................................................ 94
7.3 Inspecting the HTF System and the Fuel System .............................. 96
7.4 Inspecting Electrical Cords ................................................................. 97
7.5 Filling the HTF Reservoir .................................................................... 98
7.6 Cleaning the HTF Strainer ................................................................ 101
7.7 Replacing the Fuel Filter .................................................................. 103
7.8 Lubricating the Hose Reel System ................................................... 104
7.9 Changing a Turbulator and Cleaning a Turbulator Tube .................. 105
7.10 Inspecting/Replacing the Rope Gasket ............................................ 107
7.11 Storing the Machine ......................................................................... 108
7.12 Preparing the Machine for Seasonal Operation ............................... 109
8 Troubleshooting 110
8.1 Troubleshooting the Machine ........................................................... 110
9 Technical Data 112
9.1 Machine ............................................................................................ 112
9.2 Trailer ............................................................................................... 113
9.3 Dimensions ....................................................................................... 114
9.4 Sound Measurements ...................................................................... 114
MSDS: Dowfrostâ„¢ HD 50 115
MSDS: Dowcalâ„¢ 20-G 123
Omron E5CN Temperature Controller 130
10 Schematics 132
10.1 Electrical Schematic - Sheet 1 ......................................................... 132
10.2 Electrical Schematic - Sheet 2 ......................................................... 133
10.3 Electrical Schematic Components .................................................... 134
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Table of ContentsHP 252D
HP 252D Safety Information
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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.
f 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.
f To avoid death or serious injury from this type of hazard, obey all safety mes-
sages that follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
f 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.
f To avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.
Safety Information HP 252D
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1.2 Machine Description and Intended Use
This machine is a hydronic air heater. The Wacker Neuson Hydronic Air Heaters
consist of trailer-mounted enclosures that house a hydronic heater, electric motors,
fixed pump(s) and plumbing, a diesel burner, a fuel tank, and a hose handling
system.
The hydronic heating system utilizes a burner that indirectly warms the HTF. The
warmed HTF is continuously circulated through a vented, closed loop hose system.
A centrifugal pump pushes the warmed HTF through heat exchangers via hoses.
The heat exchangers transfer the heat from the HTF into the air of the application
area. A low HTF level protection device shuts down the machine if the HTF level
drops below minimum operational capacity.
This machine is intended to be used as an air heater. In addition, when used with
other Wacker Neuson accessories, this machine can be used to thaw frozen
ground, cure concrete, or prevent frost and freezing. An insulated blanket may be
laid over the hoses to increase efficiency.
This machine has been designed and built strictly for the intended use(s) described
above. Using the machine for any other purpose could permanently damage the
machine or seriously injure the operator or other persons in the area. Machine
damage caused by misuse is not covered under warranty.
The following are some examples of misuse:
î‚„ Using the machine to heat anything other than what is stated above
î‚„ Using the machine to pump anything other than the factory recommended heat
transfer fluid
î‚„ Using the machine as a ladder, support, or work surface
î‚„ Using the machine to carry or transport passengers or equipment
î‚„ Using the machine to tow other machines
î‚„ Operating the machine outside of factory specifications
î‚„ Operating the machine in a manner inconsistent with all warnings found on the
machine and in the Operator’s Manual
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:
î‚„ Heat, noise, and exhaust from the engine or hydronic heater
î‚„ Burns from HTF or radiant heat from the hoses
î‚„ Fire hazards from improper refueling techniques
î‚„ Fuel and its fumes
î‚„ Personal injury from improper lifting of the trailer tongue
î‚„ Tripping hazards from the hoses
To protect yourself and others, make sure you thoroughly read and understand the
safety information presented in this manual before operating the machine.
HP 252D Safety Information
wc_si000531gb.fm 13
1.3 Safety Guidelines for Operating the Machine
Operator
training
Before operating the machine:
î‚„ Read and understand the operating instructions contained in all manuals
delivered with the machine.
î‚„ Familiarize yourself with the location and proper use of all controls and safety
devices.
î‚„ Contact Wacker Neuson Corporation for additional training if necessary.
When operating this machine:
î‚„ 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:
î‚„ have received instruction on how to properly use the machine
î‚„ are familiar with required safety devices
The machine must not be accessed or operated by:
î‚„ children
î‚„ people impaired by alcohol or drugs
Application
area
Be aware of the application area.
î‚„ Keep unauthorized personnel, children, and pets away from the machine.
î‚„ Remain aware of changing positions and the movement of other equipment and
personnel in the application area/job site.
Be aware of the application area.
î‚„ 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:
î‚„ All safety devices and guards are in place and in working order.
î‚„ All controls operate correctly.
 The machine is set up correctly according to the instructions in the Operator’s
Manual.
î‚„ The machine is clean.
 The machine’s labels are legible.
To ensure safe operation of the machine:
î‚„ Do not operate the machine if any safety devices or guards are missing or
inoperative.
î‚„ Do not modify or defeat the safety devices.
î‚„ Do not use accessories or attachments that are not approved by Wacker
Neuson Corporation.
Safety Information HP 252D
14 wc_si000531gb.fm
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:
î‚„ Do not operate a machine in need of repair.
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while operating this
machine:
î‚„ Close-fitting work clothes that do not hinder movement
î‚„ Safety glasses with side shields
î‚„ Hearing protection
î‚„ Safety-toed footwear
HP 252D Safety Information
wc_si000531gb.fm 15
1.4 Service Safety
Service
training
Before servicing or maintaining the machine:
î‚„ Read and understand the instructions contained in all manuals delivered with
the machine.
î‚„ Familiarize yourself with the location and proper use of all controls and safety
devices.
î‚„ Only trained personnel shall troubleshoot or repair problems occurring with the
machine.
î‚„ Contact Wacker Neuson Corporation for additional training if necessary.
When servicing or maintaining this machine:
î‚„ 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
Follow the precautions below when servicing or maintaining the machine.
î‚„ Read and understand the service procedures before performing any service to
the machine.
î‚„ All adjustments and repairs must be completed before operation. Do not
operate the machine with a known problem or deficiency.
î‚„ All repairs and adjustments shall be completed by a qualified technician.
î‚„ 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.
î‚„ Reinstall the safety devices and guards after repair and maintenance
procedures are complete.
Machine
modifications
When servicing or maintaining the machine:
î‚„ Use only accessories/attachments that are approved by Wacker Neuson
Corporation.
When servicing or maintaining the machine:
î‚„ Do not defeat safety devices.
î‚„ Do not modify the machine without the express written approval of Wacker
Neuson Corporation.
Replacing
parts and
labels
î‚„ Replace worn or damaged components.
î‚„ Replace all missing and hard-to-read labels.
î‚„ When replacing electrical components, use components that are identical in
rating and performance as the original components.
î‚„ 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.
Safety Information HP 252D
16 wc_si000531gb.fm
Lifting and
transporting
When lifting the machine:
î‚„ Make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices
are attached securely and have enough weight-bearing capacity to lift or hold
the machine safely. See chapter Technical Data.
î‚„ Remain aware of the location of other people when lifting the machine.
î‚„ Make sure the transporting vehicle has sufficient load capacity and platform size
to safely transport the machine. See chapter Technical Data.
To reduce the possibility of injury:
î‚„ Do not stand under the machine while it is being lifted or moved.
î‚„ Do not get onto the machine while it is being lifted or moved.
Cleaning
When cleaning and servicing the machine:
î‚„ Keep the machine clean and free of debris such as leaves, paper, cartons, etc.
î‚„ Keep the labels legible.
When cleaning the machine:
î‚„ Do not clean the machine while it is running.
î‚„ 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:
î‚„ Close-fitting work clothes that do not hinder movement
î‚„ Safety glasses with side shields
î‚„ Hearing protection
î‚„ Safety-toed footwear
In addition, before servicing or maintaining the machine:
î‚„ Tie back long hair.
î‚„ Remove all jewelry (including rings).
HP 252D Safety Information
wc_si000531gb.fm 17
1.5 Safety Guidelines for Operating Combustion Burners
When using the machine:
î‚„ Clean up any spilled fuel immediately.
î‚„ Replace the fuel tank cap after refueling the machine.
î‚„ Refill the fuel tank in a well-ventilated area.
î‚„ Shut down the generator, if equipped, when refueling.
When using the machine:
î‚„ Do not fill or drain the fuel tank near an open flame or while the machine is
running.
î‚„ Do not smoke when refueling the machine.
DANGER
Exhaust gas from the burner contains carbon monoxide, a deadly poison. Exposure
to carbon monoxide can kill you in minutes.
f Never run the machine indoors or in an enclosed area unless the machine is
vented properly.
Safety Information HP 252D
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1.6 Safety Guidelines for Towing the Machine
.
When towing the machine:
 Do not tow the machine if the towing vehicle’s hitch or the trailer’s coupler are
damaged.
 Do not tow the machine if any of the trailer’s lug nuts are missing.
 Do not tow the machine if the trailer’s tires have less than 1.5 mm (1/16 inch) of
tread.
 Do not tow the machine unless the trailer’s brakes are functioning properly.
 Do not exceed the trailer manufacturer’s speed limitations.
When towing the machine:
 Only tow the machine when the trailer’s lug nuts are properly torqued.
 Only tow the machine when the trailer’s tires are properly inflated.
î‚„ Only tow the machine when all trailer lights are functioning correctly.
 Only tow the machine when the trailer’s safety chains are connected to the
towing vehicle in a crisscross pattern.
î‚„ Maintain extra distance between the towing vehicle and other vehicles.
î‚„ Avoid soft shoulders, curbs, and sudden lane changes.
î‚„ Abide by all licensing requirements for your area.
If you have not driven a towing vehicle with trailer before, practice turning,
stopping, and backing up the towing vehicle with trailer in an area away from traffic.
Only drive the towing vehicle with trailer when you are confident in your ability to do
so.
WARNING
Risk of severe injury or death. Improper trailer condition and towing technique can
lead to an accident.
f Obey the trailer manufacturer’s instructions and the instructions below to reduce
the risk of an accident.
HP 252D Safety Information
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Notes
Labels HP 252D
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2 Labels
2.1 Label Locations
wc_gr007909
12
12
13
13
1212
14
15
15 154316
16
21
23
39 37 40
24
25
25
25
25
25
27
27
30
30
32
32
31
33
33
34
37
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Wacker Neuson HP252 User manual

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User manual

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