Wacker Neuson BP45 User manual

Type
User manual
Operator’s Manual
Booster Pump
BP45
Type BP45
Document 5000184176
Date 1115
Revision 04
Language EN
5000184176
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 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
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
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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
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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.
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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

Type
User manual

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