Hotsy 9452, Operator'S Manual

Page 1: ...8 914 365 0 M 12 21 18 9452 9462 Hot Water Gas Fired Burner Modules Operator s Manual MODELS 9452 1 103 906 0 9462 1 103 908 0 For the Dealer nearest you consult our web page at www kaercher us com ...

Page 2: ...2 GF 9452 9462 Operator s Manual 8 914 365 0 M Machine Data Label ...

Page 3: ...General Cleaning Techniques 16 Shutting Down And Clean Up 17 Basic Facts 18 Maintenance Preventative Maintenance 20 Winterizing Procedure 20 Heating Coils 20 Gas Valve Regulator Adjustment 20 Pressure Relief Valve 21 Gas Pressure Requirements 21 Burner Features 21 Oil Change Record 23 Troubleshooting 24 Parts 9452 Left 28 9452 Right 29 Parts 9452 30 Burner 9452 32 9462 Left 34 9462 Right 35 Parts ...

Page 4: ...contains preventive main tenance to keep the machine and its components in good working condition They are listed in this general order Preventative Maintenance Winterizing Procedure Heating Coils Gas Valve Regulator Adjustment Pressure Relief Valve Gas Pressure Requirements Burner Features Oil Change Record Troubleshooting The PARTS LIST section contains assembled parts illustrations and correspo...

Page 5: ...ds its contents SAVE THESE INSTRUCTIONS This manual should be considered a permanent part of the machine and should remain with it if machine is resold When ordering parts please specify model and serial number Use only identical replacement parts This machine is to be used only by trained opera tors IMPORTANT SAFETY INFORMATION WARNING When using this machine basic precautions should always be fo...

Page 6: ...ipment can produce a high pressure stream of fluid that can pierce skin and its underlying tissues leading to serious injury and possible ampu tation AVERTISSEMENT Le jet de liquide haute pression de la laveuse à pression attaché à cet équipement peut percer la peau et ses tissus sous jacents causant ainsi des blessures graves et possiblement une amputation 7 High pressure developed by this machin...

Page 7: ...any changes made to our standard machines or any components not purchased from us 23 Do not overreach or stand on unstable support Keep good footing and balance at all times 24 When making repairs disconnect from electrical source and shut off gas valve 25 Turn burner off and cool to 100 F before turning machine off 26 Extinguish any open flame and test all joints with a soap solution If odor pers...

Page 8: ...k Size Machine Weight Shipping Weight Machine Dimensions 9452 3200 PSI 120V 1 Amps Natural Gas LP Optional 540 000 BTU Hr Max 10 470 Lbs 500 Lbs L 32 5 X W 25 X H 50 5 9462 3200 PSI 120V 1 Amps Natural Gas LP Optional 920 000 BTU Hr Max 12 880 Lbs 935 Lbs L 40 5 X W 32 X H 65 GF 9452 9462 Operator s Manual 8 914 365 0 M ...

Page 9: ...entification GF 9452 9462 Operator s Manual 8 914 365 0 M Fresh Water Inlet Flow Switch Power Cord Gas Valve Fuel Supply Inlet Relief Valve High Pressure Outlet For Detail See Control Box Illus Burner Exhaust Vent Burner Switch ...

Page 10: ...AUST FANS Gas Codes Confer with local gas company and with proper municipal officials regarding any specific code or regu lations governing the installation The installation must conform to local codes Electrical The machine when installed must be electrically grounded in accordance with local codes Check for proper power supply using a volt meter check the serial plate for the correct requirement...

Page 11: ...c gravity of 6 and a pressure loss of 5 w c i Numbers are for straight schedule 40 pipe fittings further reduce capacity Propane Length of Pipe ft Iron Pipe Size 1 2 3 4 10 3339 6982 20 2295 4799 30 1843 3854 40 1577 3298 50 1398 2923 60 1267 2649 70 1165 2437 80 1084 2267 90 1017 2127 100 961 2009 150 772 1613 200 660 1381 250 585 1224 300 530 1109 350 488 1020 400 454 949 450 426 890 500 402 84 ...

Page 12: ...hange the vent requirement for compliance with local building codes Draft Diverter The draft diverter shall be installed at least three 3 feet above the heating coil The diverter serves to sever the chimney effect created in all sections of furnace pipe posi tioned below to enhance the draft through the burner It also helps prevent freezing of the coil due to wind chill factors Optional When a roo...

Page 13: ... outlined in current American Standard ANSI Z223 1 National Fuel Gas Code or National Standard of Canada CSA 149 1 and CSA 149 2 Installation Code for Gas Burning Appliances Warning Check List 1 Installation or servicing of gas appliances and controls must only be performed by qualified personnel After installation or servicing test manual valve operating valves pressure regu lation and automatic ...

Page 14: ...propane tanks large enough according to rating to prevent freezing Have gas lines been checked for gas leaks Have gas lines been checked with local codes Have all operators using this machine been instructed properly have they read the manual Has machine been installed according to operator s manual instructions FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions e...

Page 15: ...ompanying pressure washer and burner module to appropriate power supply STEP 5 Assemble spray gun to high pressure outlet hose Attach desired nozzle to end of wand and secure it in place STEP 3 Connect high pressure hose from attached pressure washer not included to burner module STEP 6 Turn on burner switch Pilot ignition will begin to spark Confirm pilot light ignition if unsuc cessful turn of s...

Page 16: ...e extreme caution as pressure washer may remove the loose paint from the surface Keep the spray nozzle a safe distance from the surface you plan to clean High pressure wash a small area then check the surface for damage If no damage is found continue to pressure washing CAUTION Never use Bleach chlorine products and other corrosive chemicals Liquids containing solvents i e paint thinners gasoline ...

Page 17: ...t hose in clean bucket of water and run for a few minutes until steady stream of clean water is evident STEP 4 Open spray gun to relieve remaining pressure STEP 2 Turn burner switch Off and continue spraying water until temperature reaches 100 STEP 3 Turn water off GF 9452 9462 Operator s Manual 8 914 365 0 M ...

Page 18: ... 2 563 3 39 B T U Per Lb Vapor 21 663 21 3 9 B T U Per Gallon Liquid 91 74 1 3 93 Cubic Feet Per Lb Liquid 8 607 7 53 Cubic Feet Per Gallon Liquid 3 45 31 9 Octane Number 125 1 Molecular Weight 44 09 58 12 To calculate running cost 1 cubic Ft 1 000 B T U 100 cubic Ft Therm Therm Hour 50 Therm Example Using natural gas 400 000 BTU Machine 400 cubic feet 4 Therms hour 4 x 50 2 00 hour to run GF 9452...

Page 19: ...the lower levels it is expressed in water column inches i e 1 w c i Higher pressures are expressed in terms of the force exerted against a square inch of area For example 125 lbs per square inch 125 psi 1 Water Column Inch 50 Oz Sq In 11 Water Column Inches 4 Lb Sq In 1 Lb Sq In 2 04 Mercury 1 Std Atmosphere 14 73 Lbs Sq In 11 Water Column Inches 6 35 Oz Sq In 1 Lb Sq In 27 71 Water Column Inches ...

Page 20: ...rner compartment with a drop light or flashlight If no leaks are visible then water dripping from coil is from condensation in the flue gases when the burner is on Condensation from Heating Coil When cold water is being pumped into the water heater coils and the burner is on condensation will form on the coil and drip down into the burner compartment giving the appearance of a leaking coil particu...

Page 21: ...re washer Propane Cylinder Capacity An important consideration with propane systems is the capacity of the supply cylinder relative to the needs of the burner The burner operates on propane as a gas As gas is used from the propane cylinder the liquid in the cylinder boils to maintain gas pressure This boiling process cools the liquid and in a heavy continuous demand situation the liquid temperatur...

Page 22: ...ainte nance Regular preventative maintenance will add many hours to the life of your pressure washer Perform maintenance more often under severe conditions GF 9452 9462 Operator s Manual 8 914 365 0 M MAINTENANCE SCHEDULE Remove Burner Soot From Heating Coil Annually Descale Coil Annually more often if required Replace Quick Connects Annually Clean Water and Detergent Screen Filter Weekly Clean Fl...

Page 23: ... Change Record GF 9452 9462 Operator s Manual 8 914 365 0 M Date Oil Changed Month Day Year Estimated Operating Hours Since Last Oil Change Date Oil Changed Month Day Year Estimated Operating Hours Since Last Oil Change ...

Page 24: ...m is turned on 2 With gas on and system sparking probe terminals PV and 24V GND If pilot gas does not flow with 24 volts at these terminals replace gas valve 3 Probe terminals PV and MV PV If 24 volts not present replace ignition control box HAVE PILOT GAS NO SPARK A Defective ignitor sensor and or its wiring Set test meter to ohm scale 1 Disconnect the wire from the IGN terminal on the ignition c...

Page 25: ...ain burner should turn on If it does not replace the ignition control unit SHORT CYCLING OF MAIN BURNER MAIN BURNER TURNS OFF BEFORE THE BURNER SWITCH OR FLOW SWITCH IS TURNED OFF Draft condition pulls flame away from ignitor sensor rod Check the thermostat by bypassing at terminals P1 and 1 Set thermostat high With main burner on observe the pilot flame impingement on the ignitor sensor Faulty th...

Page 26: ...26 Notes GF 9452 9462 Operator s Manual 8 914 365 0 M ...

Page 27: ...27 Parts Parts 1 103 906 0 1 103 908 0 9452 9462 GF 9452 9462 Operator s Manual 8 914 365 0 M ...

Page 28: ...28 9452 Left 28 41 10 5 6 4 37 19 26 9 7 8 5 2 3 22 29 36 35 32 31 33 38 42 43 21 27 24 24 GF 9452 9462 Operator s Manual 8 914 365 0 M ...

Page 29: ... 8 914 365 0 M 9452 Right 30 12 11 10 13 25 20 14 15 18 44 16 17 12 1 See Control Box Illus For Detail 23 40 39 51 34 49 50 47 45 46 47 48 50 Location Of 1st Serial Plate Location Of 2nd Serial Plate Underside Corner Of Burner Platform ...

Page 30: ...T 115V 15A 19 8 706 226 0 1 CROSS 1 2 20 8 706 548 0 1 GROMMET 2 1 8 X 2 7 8 X 7 16 21 9 802 047 0 1 ADAPTER 1 2 HEX 22 8 911 621 0 1 MOUNT PLUMBING 23 8 900 898 0 1 LABEL CONTROL PANEL 24 8 706 294 0 2 BUSHING 1 2 X 3 8 STEEL 25 9 802 775 0 2 NUT 1 4 FLANGE ZN 26 8 902 433 0 1 VALVE SAFETY RELIEF VSP 27 9 802 802 0 2 WASHER 1 4 FLAT 28 9 802 700 0 2 BOLT 1 4 X 3 4 NC HH 29 9 802 718 0 1 U BOLT 5 ...

Page 31: ... SERVICE CORD 45 9 800 013 0 1 LABEL INDOOR USE 46 9 800 034 0 1 LABEL CLEAR LEXAN 47 9 800 021 0 2 LABEL HOT WATER OUTLET 48 8 900 858 0 1 LABEL NATURAL GAS INLET NG ONLY 8 940 281 0 1 LABEL LP GAS FUEL WARNING LP ONLY 49 8 901 191 0 1 LABEL CAUTION GROUNDING 50 8 719 946 0 2 HANGER HOSE 51 8 718 945 0 1 SCREW 14 TEK ...

Page 32: ...32 Burner 9452 GF 9452 9462 Operator s Manual 8 914 365 0 M H O N E Y W E L L L O H I 11 28 10 3 9 8 11 5 7 6 4 2 13 1 16 17 12 21 18 9 15 20 23 25 14 24 22 19 17 17 26 27 28 ...

Page 33: ... 90 10 8 718 050 0 1 VALVE NATURAL GAS 8 718 048 0 1 VALVE PROPANE 11 8 706 323 0 2 UNION 1 BLACK PIPE 12 8 911 615 0 1 MOUNT BURNER GAS 24 13 9 802 778 0 1 NUT 5 16 FLANGE WHIZ LOC NC 14 9 802 159 0 1 CONNECTOR 1 4 X 1 4 MPT 15 9 802 016 0 1 BUSHING 16 9 802 713 0 1 BOLT 5 16 X 1 1 2 NC HH 17 8 718 980 0 7 WASHER 5 16 FLAT PLATED 18 8 719 957 0 1 BRACKET PILOT LIGHT 19 9 803 610 0 1 PILOT 20 9 80...

Page 34: ...34 9462 Left 28 42 10 5 3 4 40 24 30 26 9 7 8 5 2 22 29 39 38 35 32 33 41 6 57 27 34 21 31 31 GF 9452 9462 Operator s Manual 8 914 365 0 M ...

Page 35: ...2 Right 12 11 10 13 25 20 14 15 18 44 16 17 12 1 See Control Box Illus For Detail 23 19 59 56 55 54 45 47 46 48 47 58 43 43 Reversed View 50 51 52 53 50 37 49 Location Of 2nd Serial Plate Underside Corner Of Burner Platform Location Of 1st Serial Plate ...

Page 36: ...8 8 717 010 0 1 CORDSET 115V 15A 19 9 802 781 0 3 NUT 3 8 20 8 706 548 0 2 GROMMET 2 1 8 X 2 7 8 X 7 16 21 9 802 802 0 2 WASHER 1 4 FLAT 22 8 911 621 0 1 MOUNT PLUMBING 23 8 900 898 0 1 LABEL CONTROL PANEL 24 8 706 226 0 1 CROSS 1 2 25 79 802 775 0 2 NUT 1 4 FLANGE ZN 26 8 902 433 0 1 VALVE SAFETY RELIEF VSP 27 9 802 047 0 1 ADAPTER 1 2 HEX 28 9 802 700 0 2 BOLT 1 4 X 3 4 NC HH 29 9 802 718 0 2 U ...

Page 37: ...TURAL GAS OUTLET NG ONLY 8 940 281 0 1 LABEL LP GAS FUEL WARNING LP ONLY 49 9 802 799 0 2 SCREW 14 X 1 TEK BLK ZINC 50 8 719 946 0 2 HANGER HOSE 51 8 718 945 0 1 SCREW 14 TEK 52 8 716 460 0 1 LUG GROUNDING 53 8 901 191 0 1 LABEL CAUTION GROUNDING 54 8 911 626 0 2 BRACKET LIFT 55 9 803 551 0 8 SCREW 5 16 X 3 4 WHIZ 56 9 802 778 0 8 NUT 5 16 WHIZ LOC 57 8 717 451 0 96 INSULATION 1 2 58 9 800 016 0 1...

Page 38: ...38 Burner 9462 GF 9452 9462 Operator s Manual 8 914 365 0 M 1 17 2 16 12 9 13 10 3 4 12 6 11 5 4 6 8 3 10 15 7 26 25 23 24 22 20 19 18 21 14 ...

Page 39: ...NIPPLE 1 X 4 BLACK PIPE 10 9 802 026 0 2 ELBOW 1 BLACK 90 11 8 706 098 0 1 NIPPLE 1 X 12 BLACK PIPE 12 8 706 019 0 2 NIPPLE 1 X 5 BLACK PIPE 13 8 706 323 0 1 UNION 1 BLACK PIPE 14 9 802 911 0 18 TUBING 1 4 ALUMINUM 15 8 718 048 0 1 VALVE PROPANE LP OPTION 8 718 050 0 1 VALVE 1 NATURAL GAS 24V LARGE NATURAL GAS MODEL 16 8 706 021 0 1 NIPPLE 1 X 11 BLACK PIPE 17 8 911 625 0 1 MOUNT BURNER 18 8 719 9...

Page 40: ... 8 NUT 1 4 FLANGE ZN 10 9 802 525 0 3 LOCKNUT 1 2 11 8 718 936 0 8 SCREW 8X 1 2 PHILLIPS ZINC PLATED 12 9 802 553 0 1 TRANSFORMER MICRON 120 240V 24V 050KVA 9 803 977 0 1 FUSE 2 1 2 AMP 250V FNM2 1 2 8 933 007 0 2 FUSE KTK R1 600V MIDGET FUSE 13 9 803 613 0 1 IGNITION ELECTRONIC CTRL 14 9 802 514 0 3 STRAIN RELIEF STRT LQ TITE 15 9 802 771 0 4 SCREW 10 32 X 3 4 16 9 804 567 0 4 NUT 10 32 ESNA 17 9...

Page 41: ...41 GF 9452 9462 Operator s Manual 8 914 365 0 M Electrical Wiring Diagram B B OR B ...

Page 42: ...8 914 365 0 Printed in U S A ...