Wacker Neuson BP45 User manual

Operator’s Manual

Booster Pump

BP45

Type BP45

Document 5000184176

Date 1115

Revision 04

Language EN

5000184176

Copyright notice

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.

BP 1 Table of Contents

3

1. Foreword 5

2. Safety Information 7

2.1 Operating Safety .................................................................................. 8

2.2 Maintenance Safety .............................................................................. 9

2.3 Label Locations .................................................................................. 10

2.4 Safety and Operating Labels .............................................................. 10

3. Operation 13

3.1 System Description ............................................................................ 13

3.2 System Component Locations ........................................................... 13

3.3 Control Panel Information ................................................................... 14

3.4 Positioning the Machine ..................................................................... 14

3.5 Preliminary Checks ............................................................................ 14

3.6 Connecting the BP to the Hydronic Air Heater Machine .................... 15

3.7 Connecting Power to the Machine ..................................................... 16

3.8 Starting the Machine .......................................................................... 17

3.9 Shutting Down the Machine ............................................................... 17

4. Maintenance 19

4.1 Periodic Maintenance Schedule ......................................................... 19

4.2 Lifting, Transporting, and Storing the Machine ................................... 20

5. Technical Data 21

5.1 Booster Pump ..................................................................................... 21

6. Appendix A A1

6.1 Heat Transfer Fluid Material Data Safety Sheet .................................A1

Table of Contents BP 1

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Foreword

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1. Foreword

This manual provides information and procedures to safely operate

and maintain this Wacker model. For your own safety and protection

from injury, carefully read, understand and observe the safety

instructions described in this manual.

Keep this manual or a copy of it with the machine. If you lose this

manual or need an additional copy, please contact Wacker

Corporation. This machine is built with user safety in mind; however,

it can present hazards if improperly operated and serviced. Follow

operating instructions carefully! If you have questions about operating

or servicing this equipment, please contact Wacker Corporation.

The information contained in this manual was based on machines in

production at the time of publication. Wacker Corporation reserves the

right to change any portion of this information without notice.

.

Any type of reproduction or distribution not authorized by Wacker

Corporation represents an infringement of valid copyrights and will be

prosecuted. We expressly reserve the right to make technical

modifications, even without due notice, which aim at improving our

machines or their safety standards.

Foreword

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BP 1 Safety Information

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2. Safety Information

This manual contains DANGER, WARNING, CAUTION, NOTICE and

NOTE callouts which must be followed to reduce the possibility of

personal injury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this

symbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, will

result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, could

result in minor or moderate injury.

NOTICE: Used without the safety alert symbol, NOTICE indicates a

hazardous situation which, if not avoided, could result in property

damage.

Note: Contains additional information important to a procedure.

DANGER

WARNING

CAUTION

Safety Information BP 1

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2.1 Operating Safety

Familiarity and proper training are required for the safe operation of

this machine. Machines operated improperly or by untrained personnel

can be dangerous. Read the operating instructions contained in both

this manual and the OEM manuals included with this machine.

Familiarize yourself with the location and proper use of all controls.

Inexperienced operators should receive instruction from someone

familiar with the machine before being allowed to operate it.

NEVER use the Booster Pump machine to transfer any substance

other than Ground Heaters Heat Transfer Fluid (HTF). Doing so could

result in personal injury, death, explosion, or damage to the machine.

2.1.1 NEVER use this machine with anything other than the intended

complementary Hydronic Air Heater machine.

2.1.2 NEVER start a machine in need of repair.

2.1.3 NEVER transport people in or on the machine.

2.1.4 NEVER run the machine in areas that contain flammable objects,

fuels, or products that produce flammable vapors.

2.1.5 Keep unauthorized personnel, children, and pets away from the

machine.

2.1.6 ALWAYS be sure the machine is on a firm, level surface and will not

tip, roll, slide, or fall while operating.

2.1.7 ALWAYS operate machine with all safety devices and guards in place

and in working order. DO NOT modify or defeat safety devices. DO

NOT operate machine if any safety devices or guards are missing or

inoperative.

2.1.8 ALWAYS wear gloves when handling hoses and hot components.

WARNING

BP 1 Safety Information

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2.2 Maintenance Safety

HIGH VOLTAGE! This unit uses high voltage circuits capable of

causing serious injury or death. Only a qualified electrician should

troubleshoot or repair electrical problems occurring with this

equipment.

2.2.1 DO NOT use gasoline or other types of fuels or flammable solvents to

clean parts, especially in enclosed areas. Fumes from fuels and

solvents can become explosive.

2.2.2 ALWAYS replace the safety devices and guards after repairs and

maintenance.

2.2.3 ALWAYS keep the machine clean and labels legible. Replace all

missing and hard-to-read labels. Labels provide important operating

instructions and warn of dangers and hazards.

2.2.4 ALWAYS 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. Always remain

aware of the location of other people in the area when lifting the

machine.

2.2.5 ALWAYS replace or repair electrical components with components

that are identical in rating and performance as the original component.

2.2.6 ALWAYS connect the safety chains.

WARNING

Safety Information BP 1

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2.3 Label Locations

2.4 Safety and Operating Labels

Ref. Label Meaning/Label text

1

2 Two persons are required to lift the

machine.

3 Weight/mass label:

This label indicates the total weight of the

machine.

4 Consult Operator’s Manual!

ghi_gr004922

123 4

5

6

79

8

Booster Pump

LBS

KG

135

65

173283

BP 1 Safety Information

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5 Wear eye protection!

6 Hot surface hazard!

7 Wear safety gloves!

8 Machine rating label:

This label indicates rating information for

the machine.

9 Booster Pump usage guide:

This label illustrates BP connection

configurations.

Ref. Label Meaning/Label text

BPCE 2.21 224.2 230/50/1 1x10

MODEL LTR/s kpa V/Hz/ A

Safety Information BP 1

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BP 1 Operation

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3. Operation

3.1 System Description

The Booster Pump (BP) is a safe and durable machine designed to

expand the capacity and functions of your Hydronic Air Heater

machine.

The BP consists of two six-foot hoses and one positive displacement

pump encased in a durable enclosure.

Each BP is designed to automatically shut down if the complementary

Hydronic Air Heater machine experiences a low level fault.

3.2 System Component Locations

Ref. Description Ref. Description

a Booster pump enclosure d Hose

b Electrical cord e Cam lock coupling

c Booster pump f Electrical plug

a

ghi_gr004937

b

d

c

e

f

Operation BP 1

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3.3 Control Panel Information

The Booster Pump is controlled through the complementary Hydronic

Air Heater machine. Refer to the Operator’s Manual for your Hydronic

Air Heater for more information.

3.4 Positioning the Machine

Normal positioning and setup is as follows:

3.4.1 Position the machine on firm, dry, and level ground adjacent to your

Hydronic Air Heater machine.

Note: Position the machine within six feet of your Hydronic Air Heater

machine to allow the hoses to be connected properly.

3.5 Preliminary Checks

Before starting the machine, check the following:

• Location—see section Positioning the Machine.

• Control switches—all must be in the OFF position.

• Electrical connection—verify that the electrical plug is connected

to the Hydronic Air Heater control panel receptacle. See section

Connecting Power to the Machine.

• Hose connections—verify all hose connections are secured.

BP 1 Operation

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3.6 Connecting the BP to the Hydronic Air Heater Machine

NOTICE: NEVER use this machine with anything other than the

intended complementary Hydronic Air Heater machine.

To connect the BP to your Hydronic Air Heater machine, carry out the

following procedure:

3.6.1 Position the machine. See section Positioning the Machine.

3.6.2 Move the handles for valves (a), (b), and (c) on the Hydronic Air Heater

machine to the CLOSED position.

3.6.3 Remove all caps and plugs from the connection couplings on the BP

and the Hydronic Air Heater machine.

3.6.4 Connect the BP supply (g) and return (h) leader hoses to the HTF

supply and return couplings on the Hydronic Air Heater machine.

3.6.5 Move the handles for valves (a) and (c) to the OPEN position.

Note: Verify that all hose connections are secured before connecting

power to the machine.

3.6.6 Verify that valves (d) and (e) are OPEN and that valve (f) is CLOSED.

3.6.7 Connect power to the machine. See section Connecting Power to the

Machine.

F

PSI

a

h

g

d e

f

c

b

ghi_gr004939

Operation BP 1

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3.7 Connecting Power to the Machine

NOTICE: NEVER connect the machine to an external power source.

The machine MUST be connected to the accessory power receptacle

on the control panel of the complementary Hydronic Air Heater

machine.

To connect power to the machine, carry out the following procedure:

3.7.1 Perform the necessary preliminary checks. Refer to section

Preliminary Checks.

3.7.2 Position the machine. See section Positioning the Machine.

3.7.3 Verify that the BP is properly connected to the Hydronic Air Heater

machine. Refer to section Connecting the BP to the Hydronic Air

Heater Machine.

3.7.4 Connect the power cord to the accessory power receptacle on your

Hydronic Air Heater machine.

ghi_gr004938

BP 1 Operation

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3.8 Starting the Machine

NEVER use the Booster Pump machine to transfer any substance

other than Ground Heaters Heat Transfer Fluid (HTF). Doing so could

result in personal injury, death, explosion, or damage to the machine.

Note: The BP machine is not designed to operate independently. Each

machine must be used in combination with a Hydronic Air Heater

machine.

3.8.1 Perform the necessary preliminary checks. See section Preliminary

Checks.

3.8.2 Start the Hydronic Air Heater machine. Refer to the Operator’s

Manual.

3.8.3 Warm the HTF. Refer to your Hydronic Air Heater Operator’s Manual.

3.8.4 Move the pump two (2) ON/OFF switch to the ON position.

3.8.5 Continue with normal operating procedures for the Hydronic Air Heater

machine. Refer to the Operator’s Manual.

3.9 Shutting Down the Machine

3.9.1 Move the pump two (2) ON/OFF switch to the OFF position.

3.9.2 Allow the hoses and couplings to cool for a minimum of ten minutes.

3.9.3 Disconnect all hoses from the BP machine.

WARNING

Operation BP 1

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Notes:

BP 1 Maintenance

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4. Maintenance

4.1 Periodic Maintenance Schedule

Before

and

after

each

use

Every

1200

hours

or

yearly

Inspect power cord for wear and damage.



Inspect all power connectors for wear and damage.



Inspect all hoses and connections for wear and damage.



Clean the enclosure.



Maintenance BP 1

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4.2 Lifting, Transporting, and Storing the Machine

Two persons are required to manually lift the machine.

Lifting The Machine

The machine may be lifted using the following methods:

• using a properly rated forklift

• manual lift—requires two persons

4.2.1 To lift the machine using a forklift, insert the forks at the indicated

locations.

Transporting the Machine

4.2.2 During transportation, the machine must be properly secured using

chains, hooks, straps, or other securing mechanisms.

Storing the Machine

4.2.3 Store the machine in a dry location away from any heat sources.

WARNING

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Wacker Neuson BP45 User manual

Wacker Neuson BP45 User manual

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