Wacker Neuson Pureheat User manual

Type
User manual
Operator’s Manual
Hydronic Air Heater
Pureheat
®
Type
Pureheat
®
Document 5000188851
Date
1215
Revision 03
Language
EN
5000188851
Copyright notice
© Copyright 2015 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 Operators Manual presents the original instructions. The original
language of this Operator’s Manual is American English.
Pureheat Foreword
wc_tx002088gb.fm 3
Foreword
This heater is designed and approved for use as a construction heater in
accordance with Standard ANSI Z83.7–CSGA 2.14. CHECK WITH YOUR LOCAL
FIRE SAFETY AUTHORITY IF YOU HAVE QUESTIONS ABOUT APPLICATIONS.
Other 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
Risk of personal injury or machine damage from improper use.
f Before using the machine, read and understand all instructions and follow them
carefully.
f The manufacturer is not responsible for damages to goods or persons due to
improper use of this machine.
WARNING
Failure to comply with the precautions and instructions provided with this machine
can result in death, serious injury, and property loss or damage from fire, explosion,
burns, asphyxiation, carbon monoxide poisoning, and/or electric shock.
f Before using the machine, read and understand all precautions and instructions
that have been provided. Follow them carefully.
f Only persons who can understand and follow the precautions and instructions
should use or service this machine.
f Contact the manufacturer if you need assistance with operating the machine or
need replacement manuals or labels.
WARNING
Work site fire, burn, inhalation, and explosion hazards.
f Keep solid combustibles, such as building materials, paper, or cardboard at a
safe distance away from the machine as recommended by the instructions.
f Never use this machine in spaces which do or may contain volatile or airborne
combustibles, or products such as gasoline, solvents, paint thinner, dust parti-
cles, or unknown chemicals.
WARNING
Not for use in homes or recreational vehicles. Installing this machine in a home or
RV may result in fire, explosion, property damage, personal injury, or death.
f Operate the machine only for applications specified in Machine Description and
Intended Use.
Foreword Pureheat
4 wc_tx002088gb.fm
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.
Machines
covered by
this manual
This manual covers machines with the following item numbers:
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 below.
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
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.
Use the separate Parts Book supplied with the machine to order replacement
parts.
If you are missing either of these documents, please contact Wacker Neuson to
order a replacement or visit www.wackerneuson.com.
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
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.
Machine Item Number Revision
Pureheat 50000620245 112 and above
Pureheat 50000620246 111 and above
wc_gr009934
Serial Number:
Pureheat Foreword
wc_tx002088gb.fm 5
Wacker Neuson expressly reserves the right to make technical modifications,
even without notice, which improve the performance or safety standards of its
machines.
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.
Manufacturer’s
approval
This manual contains references to approved parts, attachments, and
modifications. The following definitions apply:
Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.
Approved modifications are those performed by an authorized Wacker
Neuson service center according to written instructions published by Wacker
Neuson.
Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following
consequences:
Serious injury hazards to the operator and persons in the work area
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 Pureheat
6 wc_tx002088gb.fm
Table of Contents
Pureheat
®
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7
Foreword 3
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 Lifting the Machine ........................................... 16
1.6 Safety Guidelines for Operating Combustion Burners ....................... 17
1.7 Safety Guidelines for Towing the Machine ......................................... 18
1.8 Reporting Safety Defects ................................................................... 19
2 Labels 20
2.1 Label Locations .................................................................................. 20
2.2 Label Meanings .................................................................................. 21
3 Lifting and Transporting 34
3.1 Lifting the Machine ............................................................................. 34
3.2 Preparing the Machine for Transport on a Truck or Trailer ................ 36
3.3 Transporting the Machine on a Flatbed .............................................. 37
3.4 Before Towing Checklist ..................................................................... 38
3.5 Towing the Machine ........................................................................... 39
3.6 Testing the Breakaway System (Electric Brakes) .............................. 40
4 Operation 42
4.1 Control / Component Locations .......................................................... 42
4.2 Control / Component Descriptions ..................................................... 43
4.3 Control Panel ...................................................................................... 44
4.4 Control Panel Components ................................................................ 45
4.5 Valves ................................................................................................. 46
4.6 Preparing the Machine for First Use ................................................... 47
4.7 Sequence of Operation: Air Heating ................................................... 47
4.8 Sequence of Operation: Thawing, Curing, and Frost Prevention ....... 48
4.9 Recommended Fuel ........................................................................... 49
4.10 Positioning the Machine for Air Heating Applications ......................... 50
4.11 Positioning the Machine for Thawing, Curing, or Frost Prevention .... 52
4.12 Connecting the Diesel Fuel Supply .................................................... 54
4.13 Connecting the Electric Power ........................................................... 55
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Pureheat
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8
4.14 Pre-Starting Checks ............................................................................56
4.15 Loading and Unloading the Heat Exchangers .....................................58
4.16 Positioning and Connecting the Heat Exchangers ..............................62
4.17 Preheating the HTF .............................................................................64
4.18 Operating the Machine: Surface Heating Applications ........................66
4.19 Setting the Operating Temperature .....................................................68
4.20 Monitoring the Operating Parameters .................................................69
4.21 Rewinding the Hoses ..........................................................................70
4.22 Stopping and Packing Up the Machine ...............................................72
4.23 Resetting a Low HTF Level Fault ........................................................73
4.24 Quick-Connect Coupling Usage and Care ..........................................76
4.25 Resetting the Snap Switch ..................................................................77
4.26 Operating States of the Beckett Burner Controller ..............................78
4.27 Periods of the Gas Burner Controller ..................................................82
5 Accessories 84
5.1 Available Accessories .........................................................................84
5.2 Connecting a Booster Pump ...............................................................85
5.3 Heating Layout Using Four HX 200 Heat Exchangers ........................86
5.4 Components ........................................................................................87
5.5 Heating Layout Using Eight HX 100 Heat Exchangers .......................88
5.6 Components ........................................................................................89
5.7 Heating Layout Using Sixteen HX 50 Heat Exchangers .....................90
5.8 Components ........................................................................................91
5.9 Curing Layout ......................................................................................92
5.10 Components for Curing .......................................................................93
5.11 Thawing Layout ...................................................................................94
5.12 Components for Thawing ....................................................................95
5.13 Frost Prevention Layout ......................................................................96
5.14 Components for Frost Prevention .......................................................97
6 Burner Setup—Oil 98
6.1 Factory Settings ..................................................................................98
6.2 Setting up the Burner ..........................................................................98
6.3 Setting/Checking the Electrodes .......................................................100
6.4 Replacing the Burner Nozzle .............................................................102
6.5 Setting the “Z” Distance and Head Position ......................................104
6.6 Adjusting the Air Settings ..................................................................106
6.7 Adjusting the Fuel Pressure—Oil Burner ..........................................107
Table of Contents
Pureheat
®
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9
7 Burner Setup—Gas 108
7.1 Factory Settings ............................................................................... 108
7.2 Setting up the Burner ....................................................................... 108
7.3 Adjusting the Fuel Pressure ............................................................. 110
8 Maintenance 113
8.1 Periodic Maintenance Schedule ....................................................... 113
8.2 Repairing a Hose .............................................................................. 114
8.3 Inspecting the HTF System .............................................................. 116
8.4 Inspecting Electrical Cords ............................................................... 117
8.5 Filling the HTF Reservoir .................................................................. 118
8.6 Replacing the Fuel Filter .................................................................. 121
8.7 Lubricating the Hose Reel System ................................................... 122
8.8 Changing a Turbulator and Cleaning a Turbulator Tube .................. 123
8.9 Inspecting/Replacing the Rope Gasket ............................................ 125
8.10 Cleaning the Flame Sensor .............................................................. 127
8.11 Cleaning the Flame Head ................................................................. 128
8.12 Storing the Machine ......................................................................... 130
8.13 Preparing the Machine for Seasonal Operation ............................... 131
8.14 Removing the Oil Burner .................................................................. 132
8.15 Installing the NG/LP Burner .............................................................. 133
8.16 Removing the NG/LP Burner ............................................................ 135
8.17 Installing the Oil Burner .................................................................... 137
9 Troubleshooting 138
9.1 Troubleshooting Machine Performance ........................................... 138
9.2 Troubleshooting Oil Burners ............................................................. 140
9.3 Troubleshooting Gas Burners .......................................................... 141
9.4 Fault Codes of the Honeywell Burner Controller .............................. 142
10 Technical Data 148
10.1 Machine ............................................................................................ 148
10.2 Trailer ............................................................................................... 149
10.3 Dimensions ....................................................................................... 150
MSDS: Dowfrost HD 50 151
Fuji Temperature Controller 158
Table of Contents
Pureheat
®
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Tire Safety Information 161
11 Schematics 174
11.1 Electrical Schematic - Sheet 1 Oil Burners .....................................174
11.2 Electrical Schematic - Sheet 2 Oil Burners .....................................175
11.3 Electrical Schematic - Sheet 1 Gas Burners ...................................176
11.4 Electrical Schematic - Sheet 2 Gas Burners ...................................177
11.5 Electrical Schematic Components .....................................................178
11.6 Gas Train Schematic .........................................................................182
11.7 Gas Train — Components .................................................................182
11.8 Wiring Diagram — Gas Burner Controller .........................................183
11.9 Trailer Plug — Wiring Diagram ..........................................................184
11.10 Trailer Junction Box — Wiring Diagram ............................................185
11.11 Trailer Lights and Brakes — Wiring Diagram ....................................186
11.12 Trailer Lights and Brakes — Components ........................................187
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Pureheat 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.
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
messages 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.
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Safety Information Pureheat
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:
Using the machine to heat anything other than what is stated above
Using the machine to pump anything other than the factory recommended heat
transfer fluid
Using the machine as a ladder, support, or work surface
Using the machine to carry or transport passengers or equipment
Using the machine to tow other machines
Operating the machine outside of factory specifications
Operating the machine in a manner inconsistent with all warnings found on the
machine and in the Operators 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:
Heat, noise, and exhaust from the engine or hydronic heater
Burns from HTF or radiant heat from the hoses
Fire hazards from improper refueling techniques
Fuel and its fumes
Personal injury from improper lifting of the trailer tongue
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.
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Pureheat Safety Information
1.3 Safety Guidelines for Operating the Machine
Operator
training
Before operating the machine:
Read and understand the operating instructions contained in all manuals
delivered with the machine.
Familiarize yourself with the location and proper use of all controls and safety
devices.
Contact Wacker Neuson for additional training if necessary.
When operating this machine:
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:
have received instruction on how to properly use the machine
are familiar with required safety devices
The machine must not be accessed or operated by:
children
people impaired by alcohol or drugs
Application
area
Be aware of the application area.
Keep unauthorized personnel, children, and pets away from the machine.
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.
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:
All safety devices and guards are in place and in working order.
All controls operate correctly.
The machine is set up correctly according to the instructions in the Operator’s
Manual.
The machine is clean.
The machine’s labels are legible.
To ensure safe operation of the machine:
Do not operate the machine if any safety devices or guards are missing or
inoperative.
Do not modify or defeat the safety devices.
Only use accessories or attachments that are approved by Wacker Neuson.
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Safety Information Pureheat
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:
Do not operate a machine in need of repair.
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while operating this
machine:
Close-fitting work clothes that do not hinder movement
Safety glasses with side shields
Hearing protection
Safety-toed footwear
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15
Pureheat Safety Information
1.4 Service Safety
Service
training
Before servicing or maintaining the machine:
Read and understand the instructions contained in all manuals delivered with
the machine.
Familiarize yourself with the location and proper use of all controls and safety
devices.
Only trained personnel shall troubleshoot or repair problems occurring with the
machine.
Contact Wacker Neuson for additional training if necessary.
When servicing or maintaining this machine:
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.
Read and understand the service procedures before performing any service to
the machine.
All adjustments and repairs must be completed before operating the machine.
Do not operate the machine with a known problem or deficiency.
All repairs and adjustments shall be completed by a qualified technician.
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.
Reinstall the safety devices and guards after repair and maintenance
procedures are complete.
Machine
modifications
When servicing or maintaining the machine:
Use only accessories/attachments that are approved by Wacker Neuson.
When servicing or maintaining the machine:
Do not defeat safety devices.
Do not modify the machine without the express written approval of Wacker
Neuson.
Replacing
parts and
labels
Replace worn or damaged components.
Replace all missing and hard-to-read labels.
When replacing electrical components, use components that are identical in
rating and performance to the original components.
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.
Cleaning
When cleaning and servicing the machine:
Keep the machine clean and free of debris such as leaves, paper, cartons, etc.
Keep the labels legible.
wc_si000662gb.fm
16
Safety Information Pureheat
When cleaning the machine:
Do not clean the machine while it is running.
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:
Close-fitting work clothes that do not hinder movement
Safety glasses with side shields
Hearing protection
Safety-toed footwear
In addition, before servicing or maintaining the machine:
Tie back long hair.
Remove all jewelry (including rings).
1.5 Safety Guidelines for Lifting the Machine
When lifting the machine:
Make sure slings, chains, hooks, ramps, jacks, forklifts, cranes, hoists, and any
other type of lifting device used is attached securely and has enough weight-
bearing capacity to lift or hold the machine safely. See section Technical Data
for machine weight.
Remain aware of the location of other people when lifting the machine.
Only use the lifting points and tie-downs described in the Operators Manual.
Make sure the transporting vehicle has sufficient load capacity and platform size
to safely transport the machine.
To reduce the possibility of injury:
Do not stand under the machine while it is being lifted or moved.
Do not get onto the machine while it is being lifted or moved.
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Pureheat Safety Information
1.6 Safety Guidelines for Operating Combustion Burners
When using the machine:
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.
Clean up any spilled fuel immediately.
Replace the fuel tank cap after refueling the machine.
Refill the fuel tank in a well-ventilated area.
When using the machine:
Do not fill or drain the fuel tank near an open flame, while smoking, or while the
machine is running.
Do not smoke when refueling the machine.
Do not smoke when connecting natural gas or LP.
Note: Some machines may not be capable of supporting natural gas or LP. Please
see the burner manufacturer’s literature for more information.
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.
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18
Safety Information Pureheat
1.7 Safety Guidelines for Towing the Machine
When towing the machine:
Do not tow the machine if the towing vehicle’s hitch or the trailers coupler are
damaged.
Do not tow the machine if any of the trailers lug nuts are missing.
Do not tow the machine if the trailers tires have less than 1.5 mm (1/16 inch) of
tread.
Do not tow the machine unless the trailers brakes are functioning properly.
Do not exceed the trailer manufacturers 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.
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.
Maintain extra distance between the towing vehicle and other vehicles.
Avoid soft shoulders, curbs, and sudden lane changes
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.
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Pureheat Safety Information
1.8 Reporting Safety Defects
If you believe your trailer has a defect which could cause a crash or could cause
injury or death, you should immediately inform the National Highway Traffic Safety
Administration (NHTSA) in addition to notifying Wacker Neuson.
If NHTSA receives similar complaints, it may open an investigation; and if it finds
that a safety defect exists in a group of trailers, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in individual problems
between you, your dealer, or Wacker Neuson.
To contact NHTSA, you may either contact the Vehicle Safety Hotline toll-free at
1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.safercar.gov; or write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain other information about your motor vehicle safety from
http://www.safercar.gov
Labels Pureheat
20 wc_si000663gb.fm
2 Labels
2.1 Label Locations
wc_gr0089884
23
39
41
42
40
38
19
18
38
32
36
34
21
35
37
17
14
27
25
15
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Wacker Neuson Pureheat User manual

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User manual

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