Wacker Neuson HI 400 HD D, Operator'S Manual

Page 1: ...0192824 001 1110 0 1 9 2 8 2 4 Operator s Manual Indirect Fired Air Heaters HI 400 HD D HI 400 HD G...

Page 2: ...distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights Violators will be prosecuted Trademarks All trademarks referenced in this manual are the propert...

Page 3: ...oss 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 prov...

Page 4: ...tice 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 Corpora...

Page 5: ...3 Installing the Front Duct Adapter 20 4 4 Installing the Rear Duct Adapter optional 21 4 5 Control Component Locations 22 4 6 Adjusting the Handle Height 23 4 7 Positioning the Machine 24 4 8 Control...

Page 6: ...ng the Burner Nozzle D models 49 6 5 Adjusting the Burner Air Damper Setting 50 6 6 Adjusting the Fuel Pressure D models 51 7 Maintenance 53 7 1 Periodic Maintenance Schedule 53 7 2 Changing the Fuel...

Page 7: ...al 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 ser...

Page 8: ...ntly 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...

Page 9: ...ctions in the Operator s 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...

Page 10: ...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...

Page 11: ...ate 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 wh...

Page 12: ...machine clean and 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 parts Fumes from fuels...

Page 13: ...he machine Use only accessories attachments that are recommended by Wacker Neuson Corporation When using the machine Never operate the machine if any safety devices or guards are missing or inoperativ...

Page 14: ...Labels HI 400HD D HD G 14 ghi_si000469gb fm 2 Labels 2 1 Label Locations ghi_gr007391 A C H F 4 O J B E R P K M D G Q K...

Page 15: ...surface B WARNING Entanglement hazard Rotating machinery Do not reach inside machine when engine is running C NOTICE Lifting point D WARNING Electric shock hazard Disconnect power before servicing Rea...

Page 16: ...l for diesel fuelled heaters K A nameplate listing the model number item number revision number and serial number is attached to each unit Please record the information found on this plate so it will...

Page 17: ...ustment MUST be performed by a LICENSED professional gas technician and must conform to the requirements of all relevant local state provincial and Federal authorities Failure to heed this warning may...

Page 18: ...Cover all openings on the machine to avoid infiltration from road debris and dust When using an aerial lifting rig use the designated lifting point on top of the machine Use the designated fork pocket...

Page 19: ...parts not already attached 5 Add fluids as needed and applicable including fuel engine oil and battery acid 6 Move the machine to its operating location 4 2 Installing the Axle and Wheels Overview Th...

Page 20: ...g screw c to disconnect the bracket from the machine shell 2 Remove the screw fastening the thermostat probe to the disposable bracket and discard the bracket Temporarily rest the thermostat probe ins...

Page 21: ...ting knobs a on the handle 2 Grasp the handgrips b and slide the handle down to the lowest detent position in the handle slots 3 Pull the handle away from the fan guard f 4 Remove the fan guard There...

Page 22: ...cations Machine components a Ref Description Ref Description a Exhaust flue f Air inlet and fan guard b Control panel g Access panel c Manual transport handle h Fuel filter D units d Fuel fill locatio...

Page 23: ...d to suit the operator s preference Procedure Follow the procedure below to adjust the handle height 1 Loosen but do not remove the two adjusting knobs a on the handle 2 Grasp the handgrips b and slid...

Page 24: ...ns The machine must be located a safe distance from any other structures vehicles materials or other combustible surfaces The following proximity restrictions apply for all machine installations 20 ft...

Page 25: ...th of extension cord usage per circuit is 30 m 100 ft Use 12 gauge extension cords for lengths up to 15 m 50 ft Use 10 gauge extension cords for lengths up to 30 m 100 ft Grounding requirements Electr...

Page 26: ...itch on off on See topic Starting the Machine e Power indicator c Remote thermostat receptacle f Power cord Symbol Meaning function Symbol Meaning function Push the button to reset the machine when a...

Page 27: ...ect the fuel hose assembly each time before operating the heater Replacement hose Replace a damaged hose assembly with an equivalent as specified on the machine label Fuel Blend Guide Lowest expected...

Page 28: ...function d Burner indicator b Mode switch on off on See topic Starting the Machine e Power indicator c Remote thermostat receptacle f Power cord Symbol Meaning function Symbol Meaning function Push th...

Page 29: ...capacity of gas cylinders shall be properly dimensioned according to the gas flow in Technical Data The cylinder supply system shall be arranged to provide for vapor withdrawal from the operating cyl...

Page 30: ...gulator ensures a steady flow of LP to the burner A regulator is especially valuable when the gas supply pressure is inconsistent Note Gas piping pressure regulators and fittings are not included with...

Page 31: ...to convert the machine from natural gas to LP as job site conditions require Procedure To change the type of gas follow the procedure below 1 Remove the gas type label a from the handle on the gas sel...

Page 32: ...ve vent bends elbows and long horizontal runs Keep air inlets and outlets free from obstruction Ensure that there are no bulky objects or sheets covers near or on the machine Route the venting pipes i...

Page 33: ...D D HD G Operation ghi_tx001462gb fm 33 Note The above venting diagram shows suggested venting layouts only Consult all appropriate governing bodies or local contractor for venting and fresh air requi...

Page 34: ...ve the static air pressure limits specified in Technical Data Requirements Machine shut down and cooled Machine properly positioned Procedure To install the ducts carry out the following procedure 1 O...

Page 35: ...ing the receptacle make sure the cover is securely locked in place when a remote thermostat is not installed To install the remote thermostat remove the cap insert the plug into the receptacle and loc...

Page 36: ...rify that the operation mode switch is in the OFF 0 position 2 Connect the main power cord cord to a properly rated power source Note If the ambient temperature is below freezing wait 10 30 minutes be...

Page 37: ...30 minutes longer for colder temperatures 3 Start the machine See topic Starting the Machine Note In extreme wind the machine may need to be temporarily blocked from the wind in order to start Troubl...

Page 38: ...s supply lines if applicable have been properly installed Check that all valves are in the proper operating position Operation mode switch Check that the operation mode switch is in the OFF position M...

Page 39: ...er blower will start Nozzle heater Note The burner may not fire immediately on startup if the nozzle is cold An addi tional heater warms the nozzle to the required operating temperature After you sele...

Page 40: ...r will start firing In applications in which the thermostat receptacle plug is being used the burner will fire continuously In applications in which the remote thermostat is being used the burner will...

Page 41: ...hine is operating The lamp is green during normal operation Burner fault A burner fault occurs if the burner does not fire upon startup The lamp will turn red The lamp will also turn red if the burner...

Page 42: ...below to install and use the remote thermostat 1 Remove the thermostat receptacle plug a from the control panel receptacle 2 Connect the remote thermostat b to the control panel receptacle c 3 Set th...

Page 43: ...can be purchased and installed as needed Item Description Purpose Remote thermostat Allows the user to remotely control the target temperature Exhaust pipe An insulated exhaust pipe that offers a meth...

Page 44: ...c motor and fuel pump Procedure Follow the procedure below to remove the access panel 1 Shut down the machine and allow it to cool 2 Disconnect the power cord from the power source 3 Remove the four s...

Page 45: ...the access panel See topic Removing the Access Panel 4 Remove the screw d to disconnect the ground wire c from the burner assembly b 5 Rotate the burner assembly counter clockwise and remove it from t...

Page 46: ...new job site After any burner maintenance or repair has been performed If burner performance is in question Procedure Follow the procedure below to set up the burner 1 Shut down the machine 2 Set the...

Page 47: ...the combustion analyzer manufacturer s instructions and the general guidelines below Use the access hole in the exhaust stack Take several samples as the heater warms Take the final sample just before...

Page 48: ...eration The condition of the electrodes will drastically affect your machine s ability to fire efficiently Procedure Remove the burner assembly and inspect the condition of the electrode tips a Refer...

Page 49: ...ssembly 2 Place an adjustable wrench on the large fitting a on the nozzle base c 3 Place another adjustable wrench on the nozzle b 4 Rotate the nozzle counter clockwise and remove it from the assembly...

Page 50: ...and adjust the burner air damper setting 1 Shut down the machine and allow it to cool 2 Disconnect the power cord from the power source 3 The burner air damper a is located beneath the fan guard 4 To...

Page 51: ...herefore both pressures must be checked When to check Check the fuel pressure if the machine emits smoke during operation Procedure To check and or adjust the fuel pressure carry out the following pro...

Page 52: ...section Stopping the Machine Adjusting fuel pressure 10 Adjust the fuel pressure if necessary The pump has two adjustment screws one for low fuel pressure d and one for high fuel pressure e Adjust th...

Page 53: ...the interior shell Clean and check adjust burner electrode settings Inspect electrical components Inspect the blower motor and belts Replace the belt if necessary Replace the burner nozzle Replace the...

Page 54: ...ures the cover to the housing a 3 Remove the filter b 4 Inspect the O ring c Replace it if it is cracked damaged or deformed 5 Install the new filter 6 Reinstall the cover Result The procedure to repl...

Page 55: ...e Access Panel 2 Twist and pull out the plastic protective holder 1 off the base of the burner assembly The CAD cell 2 is inside this plastic holder 3 Inspect the CAD cell for cleanliness Be sure the...

Page 56: ...cure the fan guard 2 Remove the the access panel g See topic Removing the Access Panel 3 Inspect and if necessary clean the motors m using compressed air 4 Clean the fan blades using a stiff brush 5 R...

Page 57: ...opic Removing the Access Panel 3 Unscrew and remove the four lift bracket screws a Carefully raise and maneuver the lift bracket b away from the machine shell cover c resting it on the rear frame as s...

Page 58: ...oving the Access Panel 2 Remove the burner assembly a See topic Removing and Installing the Burner Assembly 3 The flame head is attached to the burner assembly Inspect the flame head for the following...

Page 59: ...lace if necessary Proper ground 7 8 General Cleaning Guidelines Prerequisites Machine shut down Machine cool General cleaning Clean the following areas to ensure proper operation Item Method task Burn...

Page 60: ...gph gallons per hour unit of liquid flow GFI Ground Fault Interrupt er protection device Hz Hertz unit of frequency ID inner diameter in inch kg kilogram kilo cal kilo calorie 1000 calories metric un...

Page 61: ...e Faulty electrodes Cad cell detecting external light Cad cell defective Burner control defective Fill fuel tank Replace burner nozzle Replace electrodes Check the Cad cell enclosure The burner starts...

Page 62: ...iciency 82 7 82 8 Noise level at 1 m dB A 76 74 Power requirement VAC Hz 120 60 120 60 Electrical current Ampere 15 15 Weight no fuel kg lb 206 8 456 225 4 497 Height mm in 1308 51 5 1105 43 5 Length...

Page 63: ...chematics 10 1 HI 400HD D Oil Burning 9 4 10 8 17 23 19 18 6 3 13 20 22 5 12 14 15 1 7 21 5 2 11 1 WH BK BK RD RD RD BR BK BK BK BK BU BK WH WH WH BK BK BK BK BK BU RD RD RD RD BR BR BK BK BK BN BU WH...

Page 64: ...apacitor 17 Low fire high fire power switch 6 Fan motor 18 Preheated nozzle 7 Electric pilot lamp 19 Control board heater 8 Transformer H V 20 Starter capacitor 9 Room thermostat plug 21 Solenoid valv...

Page 65: ...0 3 HI 400HD G Gas Burning ghi_gr007400 wc_gr007400 15 9 12 10 8 18 19 20 21 3 6 13 16 17 4 1 7 11 5 5 5 2 1 WH WH WH BK BK BK RD BK RD RD RD WH BK BK BK BK BK BK RD RD BN WH WH WH WH WH BK BK BK BK B...

Page 66: ...verheat safety thermostat 5 Capacitor 17 Fan thermostat 6 Fan motor 18 Flame lamp 7 Electric pilot lamp 19 Control board heater 8 Transformer H V 20 Pressure switch heater 9 Room thermostat plug 21 Ga...

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Page 68: ...390 Wacker Neuson Corporation N92W15000 Anthony Ave Menomonee Falls WI 53051 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Neuson Limited Room 1701 03 1717 20 17 F Tower 1 Grand Century Pl...