Wacker Neuson HI400HDD User manual

Type
User manual

This manual is also suitable for

Operator’s Manual
Indirect-Fired Air Heaters
HI400HD D
HI400HD G
Type HI400HD D, HI400HD G
Document 5000192824
Date 1115
Revision 10
Language EN
5000192824
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.
HI400HD D / HD G Foreword
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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.
Before using the machine, read and understand all instructions and follow them
carefully.
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.
Before using the machine, read and understand all precautions and instructions
that have been provided. Follow them carefully.
Only persons who can understand and follow the precautions and instructions
should use or service this machine.
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.
Keep solid combustibles, such as building materials, paper, or cardboard at a
safe distance away from the machine.
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.
Operate the machine only as specified in Machine Description and Intended
Use.
Foreword HI400HD D / HD G
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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.
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 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
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.
For spare parts information, please see your Wacker Neuson Dealer, or visit
the Wacker Neuson website at http://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.
Machine Item Number Revisions
HI400HD D 5000620868 105-999
HI400HD G 5000620701 105-999
wc_gr010608
Serial Number:
HI400HD D / HD G Foreword
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Expectations
for
information in
this manual
This manual provides information and procedures to safely operate and main-
tain 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.
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.
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:
Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.
Approved modifications are those performed by an authorized Wacker Neu-
son service center according to written instructions published by Wacker Neu-
son.
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 HI400HD D / HD G
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HI400HD D / HD G
Table of Contents
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 Operating Safety ................................................................................ 13
1.4 Safety Guidelines for Gas-Fired Machines ......................................... 15
1.5 Safety Guidelines for Operating Combustion Burners ....................... 16
1.6 Service Safety .................................................................................... 17
2 Labels 19
2.1 Label Locations—HI400 HD D ........................................................... 19
2.2 Label Locations—HI400 HD G ........................................................... 20
2.3 Label Meanings .................................................................................. 21
3 Lifting and Transporting 26
4 Operation 27
4.1 Preparing the Machine for First Use ................................................... 27
4.2 Installing the Axle and Wheels ........................................................... 27
4.3 Installing the Front Duct Adapter ........................................................ 28
4.4 Blower Duct Heater Option ................................................................. 29
4.5 Installing the Rear Duct Adapter (Optional) ........................................ 30
4.6 Control and Component Locations ..................................................... 31
4.7 Adjusting the Handle Height ............................................................... 32
4.8 Positioning the Machine ..................................................................... 33
4.9 Electrical and Grounding .................................................................... 34
4.10 Control Panel—Oil Burner (D Models) ............................................... 35
4.11 Recommended Fuels and Fuel Blending Guide ................................. 36
4.12 Inspecting the Fuel Hose .................................................................... 36
4.13 Control Panel—Gas Burner (G Models) ............................................. 37
4.14 Gas Installation and Setup (G models) .............................................. 38
4.15 Connecting the Gas Line (G models) ................................................. 39
4.16 Setting the Gas Selector Valve (G models) ........................................ 40
4.17 Venting the Machine ........................................................................... 41
4.18 Flex Ducting Options .......................................................................... 43
4.19 Ducting Guidelines ............................................................................. 44
4.20 Installing the Remote Thermostat or Receptacle Cap ........................ 46
4.21 Connecting Power to the Machine ..................................................... 47
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HI400HD D / HD G
Table of Contents
4.22 Before Starting ....................................................................................48
4.23 Cold Weather Start-Up ........................................................................49
4.24 Starting the Machine (D models) .........................................................50
4.25 Starting the Machine (G models) .........................................................51
4.26 High and Low Voltage Protection (G Models) .....................................52
4.27 Stopping ..............................................................................................53
4.28 Installing and Using the Remote Thermostat ......................................54
4.29 Operating at High Elevations (D models) ............................................55
5 Accessories 56
5.1 Available Accessories .........................................................................56
6 Setting up the Burner 57
6.1 Removing the Access Cover ...............................................................57
6.2 Removing and Installing the Burner ....................................................58
6.3 Setting up the Burner ..........................................................................59
6.4 Adjusting the Gas Pressure (G Models) ..............................................61
6.5 Inspecting the Oil Burner Electrodes (D models) ................................62
6.6 Checking/Changing the Burner Nozzle (D models) .............................63
6.7 Checking and Adjusting the Air Damper .............................................64
6.8 Checking and Adjusting the Fuel Pressure .........................................65
7 Maintenance 68
7.1 Periodic Maintenance Schedule ..........................................................68
7.2 Inspecting the Heat Exchanger ...........................................................69
7.3 Changing the Fuel Heater Filter (D models) ........................................72
7.4 Inspecting and Cleaning the Cadmium (CAD) Cell .............................73
7.5 Cleaning the Fan Blades and Motor ....................................................74
7.6 Cleaning the Interior Shell ...................................................................75
7.7 Inspecting the Flame Head .................................................................76
7.8 Inspecting the Electrical Connections .................................................77
7.9 Cleaning the Machine ..........................................................................77
8 Basic Troubleshooting 78
8.1 Basic Troubleshooting .........................................................................78
9 Technical Data 79
9.1 Machine ...............................................................................................79
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HI400HD D / HD G
Table of Contents
10 Schematics 81
10.1 HI400HD D ......................................................................................... 81
10.2 Components ....................................................................................... 82
10.3 HI400HD G (2014) ............................................................................. 83
10.4 Components (2014) ............................................................................ 84
10.5 HI400HD G (2015) ............................................................................. 85
10.6 Components (2015) ............................................................................ 86
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HI400HD D / HD G
Table of Contents
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11
HI400HD D/ HD G 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.
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.
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.
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.
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 HI400HD D/ HD G
1.2 Machine Description and Intended Use
Machine
description
The HI Heater is an indirect-fired air heater. Depending on the model, the machine
operates either on diesel fuel (oil) or natural gas / Liquid Propane (LP). The
machine consists of the following components:
Stainless steel combustion chamber and heat exchanger
Blower
Two-stage burner (oil model)
High-temperature shut-down device
Fuel tank (oil model)
Gas selector valve (gas model)
High and low voltage control (gas model)
Fuel is consumed in a closed combustion chamber. Room air or outside air
(depending on the application) is pulled into the machine where it is heated. This
clean, dry, hot air is then blown by the blower into the space to be heated . Access
to the blower assembly is protected by a guard fitted on the air inlet.
Intended use
The HI Heater is intended to provide heat on outdoor or indoor construction sites (if
properly vented) and in other rugged applications.
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.
Do not use this machine indoors without proper exhaust venting designed for
indoor use which meets all applicable regulations.
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:
exhaust emissions
hot surfaces such as exhaust vents and fuel heater
fuel and fuel fumes when refueling
high voltages and arc flash
To protect yourself and others, make sure you thoroughly read and understand the
safety information presented in this manual before operating the machine.
Optional
accessories
Wacker Neuson Corporation offers many optional accessories for the machine.
These accessories include the following:
Remote thermostat
Duct adapters (various sizes, available as kits, or individual ducts at 25 ft.
lengths).
Exhaust vents and elbows
Contact your Wacker Neuson dealer for more information.
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HI400HD D/ HD G Safety Information
1.3 Operating Safety
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.
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.
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 HI400HD D/ HD G
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
Machine
condition
Only operate the machine when:
The heat exchanger is in proper working order.
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 Operators
Manual.
The machine is clean.
The machine’s labels are legible.
When operating the machine:
Do not modify or defeat the safety devices.
Do not use worn electrical cords.
Do not use faulty fuel supplies.
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HI400HD D/ HD G Safety Information
1.4 Safety Guidelines for Gas-Fired Machines
Proper gas supply must be provided to the inlet of the machine. Refer to the rating
plate for the correct gas supply pressure.
Gas pressure above the maximum specified on the rating plate can cause fire or
explosions, leading to serious injury, death, or property loss.
Gas pressure below the minimum specified on the rating plate may cause
improper combustion, leading to asphyxiation or carbon monoxide poisoning.
Before operating the machine, read and follow all instructions in the Operation
chapter. Important points to note are:
Position the machine correctly before each use.
Provide proper venting for both indoor and outdoor use.
Do not operate the machine with exterior panels removed.
Disconnect all electrical power from the machine before opening doors or
removing panels.
Check the gas lines and connections for leaks.
WARNING
Gas leaks can cause explosions or fire. Follow the steps below if you smell gas.
Open windows.
Do not touch electrical switches.
Extinguish open flames.
Immediately call your gas supplier.
WARNING
Risk of explosion, fire, property damage, asphyxiation, death, or carbon monoxide
poisoning.
Read and follow the instructions below regarding proper gas supply and
preparation of the machine.
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Safety Information HI400HD D/ HD G
1.5 Safety Guidelines for Operating Combustion Burners
When using the machine:
Clean up any spilled fuel immediately.
Replace the fuel tank cap after refueling the machine.
Refill the fuel tank in a well-ventilated area.
Make sure you have proper certification or licensing required by the locality,
state, or province in which the machine is being installed to work with natural
gas or Liquid Petroleum (LP).
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.
DANGER
Exhaust gas from the burner (and generator, if equipped) contains carbon
monoxide, a deadly poison. Exposure to carbon monoxide can kill you in minutes.
Never run the machine indoors or in an enclosed area unless the machine is
vented properly according to local and national codes.
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HI400HD D/ HD G Safety Information
1.6 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 operation. 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.
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.
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.
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18
Safety Information HI400HD D/ HD G
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).
After Use
Stop the engine when the machine is not being operated.
Close the fuel valve on engines equipped with one when the machine is not
being operated.
Ensure that the machine will not tip over, roll, slide, or fall when not being
operated.
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.
Licensing/
training
Only qualified personnel who possess the proper certification or license
required by the locality, state, or province in which the machine is being installed
are allowed to make connections to natural gas or LP.
Only trained personnel should troubleshoot or repair electrical problems
occurring with the machine.
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HI400HD D / HD G Labels
2 Labels
2.1 Label Locations—HI400 HD D
a
c
f
h o f
q e
c
d
p
b
g
x
j
wc_gr011675
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20
Labels HI400HD D / HD G
2.2 Label Locations—HI400 HD G
fmh
w
b
g
g
s
c
c u q e
cpt
xj
wc_gr011676
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Wacker Neuson HI400HDD User manual

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User manual
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