Wacker Neuson Cub 200 Operator`s manual

0170893en
006
0809
Indirect-fired Air
Heaters
Cub 200/300/300 HD
OPERATOR’S MANUAL
0
1
7
0
8
9
3
E
N
Foreword
1
Foreword
WARNING
CALIFORNIA
Proposition 65 Warning:
Engine exhaust, some of its constituents, and certain vehicle
components, contain or emit chemicals known to the State of
California to cause cancer and birth defects or other reproductive
harm.
This manual provides information and procedures to safely operate
and maintain this Wacker Neuson 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 Neuson
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 Neuson
Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Neuson Corporation
reserves the right to change any portion of this information without
notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2009 by Wacker Neuson Corporation.
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by Wacker
Neuson 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.
wcghi_tx000001gb diesel.fm
3
Foreword
Notes:
wcghi_tx000001gb diesel.fm
4
Table of Contents
1.
Foreword
3
2.
Safety Information
7
2.1
2.2
2.3
2.4
2.5
3.
Operation
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
4.
Operating Safety .................................................................................. 7
Operator Safety while using Combustion Burners ............................... 8
Service Safety ...................................................................................... 8
Label Locations .................................................................................. 10
Label Descriptions .............................................................................. 11
15
System Description ............................................................................ 15
Installing the Lift Brackets .................................................................. 15
System Component Locations ........................................................... 16
Mounting the Handle and Base Assembly ......................................... 17
Machine Location ............................................................................... 18
Suggested Venting ............................................................................. 18
Connecting Power to the Machine ..................................................... 20
Preliminary Checks ............................................................................ 20
Control Panel ...................................................................................... 21
Starting the Machine .......................................................................... 22
Starting the Machine in (Extreme) Cold Weather ............................... 23
Shutting Down the Machine ............................................................... 24
Using the Remote Thermostat ........................................................... 25
Maintenance
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
27
Periodic Maintenance Schedule ......................................................... 27
Removing and Installing the Burner Assembly ................................... 28
Replacing the Burner Nozzle .............................................................. 30
Replacing the Fuel Filter .................................................................... 31
Inspecting and Aligning the Burner Electrodes .................................. 32
Inspecting and Cleaning the Cadmium (CAD) Cell ............................ 33
Checking and Adjusting the Fuel Pressure ........................................ 34
Cleaning the Fan Blades and Motor ................................................... 36
Cleaning the Interior Shell .................................................................. 37
Inspecting the Flame Head ................................................................ 38
ghi_bo0170893en_006TOC.fm
5
Table of Contents
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
5.
Inspecting the Electrical Connections .................................................39
Fuel Blend Guide .................................................................................39
Transporting ........................................................................................40
List of Abbreviations ............................................................................41
Troubleshooting ...................................................................................42
Cub 200/300 Wiring Schematic ...........................................................44
Cub 300 HD Wiring Schematic ............................................................44
Schematic Legend ...............................................................................45
Technical Data
5.1
47
Machine Technical Data ......................................................................47
ghi_bo0170893en_006TOC.fm
6
Cub 200/300/300 HD
2
Safety Information
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.
DANGER
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
WARNING
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
CAUTION
NOTICE: Used without the safety alert symbol, NOTICE indicates a
situation which, if not avoided, could result in property damage.
Note: Contains additional information important to a procedure.
2.1
Operating Safety
WARNING
Familiarity and proper training are required for the safe operation of
equipment! Equipment operated improperly or by untrained personnel
can be dangerous! Read the operating instructions contained in this
manual and familiarize yourself with the location and proper use of all
controls. Inexperienced operators should receive instruction from
someone familiar with the equipment before being allowed to operate
the machine.
2.1.1
Be sure the machine is on a firm, level surface and will not tip, roll,
slide, or fall while operating.
2.1.2
NEVER start a machine in need of repair.
wcghi_si000212gb.fm
7
Safety Information
Cub 200/300/300 HD
2.1.3
Keep unauthorized personnel, children, and pets away from the
machine.
2.1.4
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.
2.1.5
NEVER run the machine indoors or in an enclosed area unless
adequate ventilation, through such items as exhaust fans or hoses, is
provided and if local and national codes permit. Exhaust from the
burner contains poisonous carbon monoxide gas. Exposure to carbon
monoxide can cause loss of consciousness and may lead to death.
2.1.6
Do not smoke while operating the machine.
2.1.7
NEVER run the machine in areas that contain flammable objects,
fuels, or products that produce flammable vapors.
2.1.8
NEVER connect ductwork between the exhaust outlet port and the
supply air inlet port.
2.1.9
NEVER block the air inlet or outlet.
2.1.10 The installation of this machine must be in accordance with the
regulations put forth by all governing bodies having jurisdiction
including the Canadian Standard B139.
2.2
Operator Safety while using Combustion Burners
2.2.1
Refill the fuel tank in a well-ventilated area.
2.2.2
Replace the fuel tank cap after refueling.
2.2.3
DO NOT spill fuel when refueling the machine. Clean up spilled fuel
immediately.
2.2.4
DO NOT smoke when refueling machine.
2.2.5
DO NOT refuel a hot or running machine.
2.2.6
The machine must be installed by qualified personnel who have read
and understand all supplied manuals and instructions.
2.2.7
When operating the machine indoors, install a carbon monoxide
detector in the work area according to the detector manufacturer’s
instructions.
2.2.8
2.3
Service Safety
WARNING
wcghi_si000212gb.fm
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.
8
Cub 200/300/300 HD
Safety Information
2.3.1
ALWAYS replace the safety devices and guards after repairs and
maintenance.
2.3.2
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.
2.3.3
ALWAYS make sure slings, chains, hooks, ramps, jacks, and other
types of lifting devices are attached securely and have enough weightbearing capacity to lift or hold the machine safely. Always remain
aware of the location of other people in the area when lifting the
machine.
2.3.4
ALWAYS replace or repair electrical components with components
that are identical in rating and performance as the original component.
2.3.5
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.
2.3.6
Always wear protective epuipment when servicing the machine. Some
machine components may be hot and contain hot fluids.
2.3.7
Notes:
wcghi_si000212gb.fm
9
Safety Information
2.4
Cub 200/300/300 HD
Label Locations
wcghi_si000212gb.fm
10
Cub 200/300/300 HD
2.5
Ref.
Safety Information
Label Descriptions
Label
Label Text
1
Danger! Hazardous voltage. Do not operate without this cover in place. Disconnect
and lock out power source before opening
panel. Could cause severe injury or death.
2
Warning: Blower can automatically start
which can cause serious injury. Disconnect
power source before servicing.
3
WARNING
Warning: Blower can automatically start
which can cause serious injury. Disconnect
power source before servicing.
177370
WARNUNG
ADVERTENCIA
AVERTIS
SEMENT
wcghi_si000212gb.fm
11
Safety Information
Ref.
Label
Cub 200/300/300 HD
Label Text
4
Using a heater indoors can kill you in minutes. Heater exhaust contains carbon monoxide. This is a poison you cannot see or
smell. During indoor operation, vent
exhaust gas outdoors. Refer to Operator's
Manual.
5
Warning: Electric shock hazard.
Disconnect power before servicing.
Read Operator’s Manual.
6
Danger: To avoid injury from moving parts,
shut off the equipment before removing this
cover.
DANGER
TO AVOID INJURY FROM
MOVING PARTS, SHUT OFF
THE EQUIPMENT BEFORE
REMOVING THIS COVER.
7
CAUTION
D
DIESEL
VORSICHT
PRECAUCION
PRECAUCION
Hot surface hazard!
8
9
Caution: This machine uses diesel fuel.
CAUTION
Caution: Lift point.
Attach lifting device in this location.
VORSICHT
PRECAUCION
PRECAUTION
wcghi_si000212gb.fm
12
Cub 200/300/300 HD
Ref.
Label
Safety Information
Label Text
10
Diesel fuel blend guide. This label indicates
the recommended fuel blending values for
diesel fuel usage.
11
Tie-down point.
12
Machine rating label: This label indicates
rating information for the machine.
13
Weight/mass label: This label indicates the
total weight of the machine, including the
trailer and a full fuel tank.
14
Model and serial number label: This label
shows the model name and the serial number for the heat exchanger on your
machine.
wcghi_si000212gb.fm
13
Safety Information
Ref.
Label
Cub 200/300/300 HD
Label Text
15
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
be available should the nameplate become
lost or damaged. When ordering parts or
requesting service information, you will
always be asked to specify the model number, item number, revision number, and
serial number of the unit.
16
Schematic label. This label, located behind
the control panel, shows the electrical
schematic for the machine.
17
Installation and instruction label. This label
shows installation and operation instructions for the unit.
18
Center of gravity.
wcghi_si000212gb.fm
14
Cub 200/300/300 HD
3
Operation
Operation
3.1
System Description
The Cub series Air Heater machines are indirect-fired air heaters. The
Cub series Air Heater machines incorporate aluminized steel shells
and heat exchangers. The machines run on three fuel options: diesel,
Kerosene, or winter blend diesel (winter blend diesel is treated with
anti-gelling conditioners for use in cold weather). The fuel is consumed
in a closed combustion chamber. The exhaust gasses must be vented
outdoors through a vent pipe. The clean, dry hot air is recirculated by
means of an enclosed blower.
The Cub series Air Heater machines are intended to heat air on
construction sites and in other rugged environments. Do not use the
machines for any other purpose.
3.2
Installing the Lift Brackets
See graphic ghi_gr005931
Before attempting to lift the Cub 200 and 300 models, the lift brackets
must be installed.
3.2.1
Remove the machine from the crate.
3.2.2
Intstall the four lift brackets (a) as shown using the supplied bolts and
washers.
wcghi_tx000720gb.fm
15
Operation
3.3
Cub 200/300/300 HD
System Component Locations
Ref
wcghi_tx000720gb.fm
Component
Ref
Component
1
Fuel tank
2
Air outlet
3
Flue collar (vent)
4
Burner access panel
5
Handle (and base)
6
Control panel
7
Blower
8
Fuel oil filter
9
Lifting device
10
Duct adapter
16
Cub 200/300/300 HD
3.4
Operation
Mounting the Handle and Base Assembly
See graphics: wcghi_003991 and ghi_gr005319
The Cub series Air Heater machines are shipped partially assembled.
Before operating either machine, use the following procedure to mount
the handles and base assembly. This assembly includes the handle,
base support, and wheels with axles.
Note: There are pre-drilled bolt holes for all the components installed
within this procedure.
Note: The Cub 300 HD requires that only the handle be attached.
Refer to the procedure below to install the handle.
3.4.1
Attach the axles to the sides of the fuel tank using the supplied bolts
and washers.
3.4.2
Install the wheels using a rubber mallet to secure them to the axle
ends.
3.4.3
Attach the base support to the rear of the fuel tank using the supplied
bolts and washers.
3.4.4
Attach the handle to the machine using the supplied bolts (and
washers, if applicable).
wcghi_tx000720gb.fm
17
Operation
3.5
Cub 200/300/300 HD
Machine Location
The Air Heater machines may be located outdoors or in any
environment that requires heating. When locating a machine within the
area to be heated, the exhaust gases must be vented to the outdoors.
The machines must be installed:
•
By qualified personnel who have read and understood all
supplied instructions.
•
On a flat, firm surface.
•
With the following minimum clearances:
• 3.05 m (10 ft.) to front.
• 0.61 m (2 ft.) to rear.
• 0.61 m (2 ft.) to sides.
• 1.52 m (5 ft.) to top.
• 0.915 m (3 ft.) to flue pipe.
3.6
Suggested Venting
See Graphic: wcghi_gr003990
WARNING
Exhaust gas from this machine CAN KILL YOU IN MINUTES. The
exhaust contains carbon monoxide, a deadly poison you can not see
or smell. This machine must be properly vented to reduce the risk of
carbon monoxide poisoning.
When installing vents:
wcghi_tx000720gb.fm
•
Adhere to all local and national codes.
•
Consult all appropriate governing bodies or local contractor for
venting and fresh air requirements.
•
Place the machine in a manner that avoids excessive vent bends
(elbows), and long horizontal runs.
•
Keep air inlets and outlets free from obstruction.
•
Route the venting pipes in a manner that avoids any flammable
material.
•
Route the venting pipes in a manner that avoids contact with
humans.
18
Cub 200/300/300 HD
WARNING
Exhaust gas from this machine CAN KILL YOU IN MINUTES. The
exhaust contains carbon monoxide, a deadly poison you can not see
or smell. This machine must be properly vented to reduce the risk of
carbon monoxide poisoning.
•
wcghi_tx000720gb.fm
Operation
The above venting diagram shows suggested venting layouts
only. Consult all appropriate governing bodies or local contractor
for venting and fresh air requirements.
19
Operation
3.7
Cub 200/300/300 HD
Connecting Power to the Machine
WARNING
Fire and electric shock hazard. High voltage can cause severe injury
or death. This unit must be electrically grounded. Do NOT use
adapters.
The Air Heater machines come equipped with power cords. Connect
the power cord to a grounded outlet rated for 115V, 60 Hz, 15A.
3.8
Preliminary Checks
Before starting the machine, check the following:
wcghi_tx000720gb.fm
•
Fuel supply on diesel burning machines. See Fuel Blend Guide.
•
Position of power switch. It must be in the Off (“O”) position.
•
Power supply. The machine must be connected to a 115V 60Hz
power supply.
•
Machine location. Ensure that the machine is properly located
according to the Machine Location guidelines in this manual.
•
Remote thermostat connection. If the remote thermostat will not
be used, the remote thermostat receptacle cover must be
installed.
20
Cub 200/300/300 HD
3.9
Ref
Operation
Control Panel
Component
Function
a
Remote thermostat
receptacle
The remote thermostat receptacle (shown with protective
cap installed) is used for connecting an optional remote
thermostat
b
Burner fault lamp and reset
button (dual function).
The dual function burner fault lamp and reset button:
•
illuminates red when the burner has
faulted.
•
resets the machine when pressed.
c
Power switch
The power switch provides power to the machine.
d
Power cord
The power cord provides a means of connecting the
machine to a 115V 60 Hz receptacle.
e
Power indicator lamp
The power indicator lamp illuminates green when the power
cord is connected to a 115V 60 Hz receptacle.
wcghi_tx000720gb.fm
21
Operation
Cub 200/300/300 HD
3.10 Starting the Machine
3.10.1 Perform the necessary preliminary checks. See section Preliminary
Checks.
3.10.2 If using the remote thermostat, connect it to the control panel at the
remote thermostat receptacle. Place the remote thermostat in the area
to be heated. Set it to the desired temperature.
Note: If the ambient temperature is below 32°F (0°C), it may be
necessary to preheat the fuel. See section Preheating the Fuel Filter
and Nozzle Heater.
3.10.3 Move the power switch to the On “I” position.
wcghi_tx000720gb.fm
•
The blower will turn on immediately.
•
The burner will go through a prepurge cycle and then light.
•
The burner will continue to fire until the temperature of the space
being heated reaches the temperature set by the thermostat. At
that time, the burner shuts down but the blower will remain on.
•
If not using the remote thermostat, the blower will continue to
operate until shutdown.
22
Cub 200/300/300 HD
Operation
3.11 Starting the Machine in (Extreme) Cold Weather
In temperatures below 32°F (0°C), it may be necessary to preheat the
fuel inside the fuel filter canister. The fuel filter and nozzle contain lowwattage heating elements that are controlled by a thermostat and are
specifically designed for this purpose.
Hot surface hazard.
The external surface of the fuel filter may be hot.
CAUTION
•
Wear safety gloves when handling the fuel filter.
Note: Excess heating may increase the need for maintenance. See
sections “Replacing the Fuel Filter” and “Replacing the Burner Nozzle”.
To preheat the fuel, carry out the following procedure.
3.11.1
Connect power to the machine. See section Connecting Power to the
Machine.
3.11.2
Wait 20-30 minutes—longer for colder temperatures.
3.11.3
Start the machine. See section Starting the Machine.
Note: In extreme wind, the machine may need to be temporarily
blocked from the wind in order to start.
3.11.4
If the burner does not start on the first attempt, allow the power-on
sequence to cycle again (see 3.10.3).
3.11.5
If, after the second power-on sequence completes, the machine will
not fire, move the power switch to the off position.
3.11.6
Wait another 20-30 minutes and attempt to start the machine again.
wcghi_tx000720gb.fm
23
Operation
Cub 200/300/300 HD
3.12 Shutting Down the Machine
WARNING
Electric shock and cutting injury hazard! At temperatures above 104°F
(40°C), electric power is available at the supply blower even with the
operation mode switch in the OFF position. Always remove all power
to the machine before servicing it.
3.12.1 Move the power switch to the Off (“O”) position.
Note: The burner will shut down; however, the fan will continue to
operate for approximately two minutes to allow the combustion
chamber to cool.
3.12.2 When the blower has shut off automatically, disconnect the power
supply cord.
3.12.3 Disconnect the remote thermostat and re-install the receptacle cover.
wcghi_tx000720gb.fm
24
Cub 200/300/300 HD
Operation
3.13 Using the Remote Thermostat
See Graphic: wcghi_gr004009
In order for the machine to function, the remote thermostat (b) or the
receptacle cover (a) must be installed into the control panel. To use the
remote thermostat:
3.13.1
Plug (c) the remote thermostat into the control panel.
3.13.2
Set the sensor end within the space to be heated.
3.13.3
Adjust the temperature setting with dial (d).
wcghi_tx000720gb.fm
25
Operation
Cub 200/300/300 HD
Notes:
wcghi_tx000720gb.fm
26
Cub 200/300/300 HD
4
Maintenance
Maintenance
4.1
Periodic Maintenance Schedule
Prior to first
seasonal use
As needed or
during regular
maintenance
Every 1200
hours
or yearly
Replace the burner nozzle
„
„
Replace the fuel filter
„
„
Inspect the burner electrodes
„
Inspect and clean the Cadmium (CAD)
cell.
„
„
„
Check the fuel pressure
„
„
Clean the fan blades and motor
„
„
„
Clean the interior shell
„
„
„
Inspect the flame head
„
„
Inspect all electrical connections
„
„
wcghi_tx000721gb.fm
27
„
Maintenance
4.2
Cub 200/300/300 HD
Removing and Installing the Burner Assembly
See graphic: wcghi_gr004015
Before performing any maintenance on the burner assembly, it must
be removed from the machine. To remove or install the burner
assembly perform the following procedure:
Removal:
4.2.1
Shut down the machine and allow it to cool.
4.2.2
Disconnect the power cord from the power source.
4.2.3
Remove the two bolts (a) and open the access panel.
4.2.4
Remove the screw (d) to disconnect the ground wire (c) from the
burner assembly.
4.2.5
Rotate the burner assembly (b) counter-clockwise and remove it from
the flame head and air tube assembly (e).
4.2.6
Perform the required maintenance.
Note: Refer the maintenance procedures in this manual.
4.2.7
Re-install the burner assembly. Refer to the steps below to install the
burner assembly.
Installation:
4.2.8
Place the burner assembly into the flame head and air tube assembly
(e).
4.2.9
Rotate the burner assembly clockwise to lock it into place.
4.2.10 Install the ground wire (c) using the screw (d).
4.2.11 Close the access panel and re-install the two bolts (a) that secure the
panel.
wcghi_tx000721gb.fm
28
Cub 200/300/300 HD
wcghi_tx000721gb.fm
Maintenance
29
Maintenance
4.3
Cub 200/300/300 HD
Replacing the Burner Nozzle
See Graphic: wcghi_gr004016
To replace the burner nozzle, carry out the following procedure:
Removal:
4.3.1
Remove the burner. See section Removing and Installing the Burner
Assembly.
4.3.2
Place an adjustable wrench on the large fitting (1) on the nozzle base
(3).
4.3.3
Place another adjustable wrench on the nozzle (2).
4.3.4
Rotate the nozzle counter-clockwise and remove it from the assembly.
Installation:
4.3.5
Install the new nozzle (2) onto the nozzle base (3).
4.3.6
Tighten the nozzle (2) using an adjustable wrench. Rotate the wrench
clockwise.
4.3.7
Re-install the burner assembly. See section Removing and Installing
the Burner Assembly.
wcghi_tx000721gb.fm
30
Cub 200/300/300 HD
4.4
Maintenance
Replacing the Fuel Filter
See Graphic: wcghi_gr004019
Hot surface hazard.
The external surface of the fuel filter may be hot.
CAUTION
•
Allow the machine to cool before servicing.
•
Wear safety gloves.
Hot fluids.
The fuel inside the filter canister may be hot.
WARNING
•
Allow the machine to cool before servicing.
•
Wear safety glasses.
To replace the fuel filter (b), carry out the following procedure.
Removal:
4.4.1
Shut down the machine and allow it to cool.
4.4.2
Remove all power from the machine (unplug).
4.4.3
Remove the screw (a) that secures the cover to the housing.
4.4.4
Remove the filter (b).
Installation:
4.4.1
Install the new filter (b).
4.4.2
Inspect the rubber gasket (c) for damage.
4.4.3
Install the cover and the screw (a).
wcghi_tx000721gb.fm
31
Maintenance
4.5
Cub 200/300/300 HD
Inspecting and Aligning the Burner Electrodes
See graphic: wcghi_gr004020
To inspect and align the burner electrodes, carry out the following
procedure.
Inspection:
4.5.1
Remove the burner assembly. See section Removing and Installing
the Burner Assembly.
4.5.2
Inspect the electrodes for the following:
•
Wear. Be sure to inspect the ends of the electrodes for
pitting. Replace any worn electrodes. See section
“Replacement or Alignment”.
•
Straightness. Replace any bent or broken electrodes.
See section “Replacement or Alignment”.
•
Corrosion and/or cleanliness. Clean the electrodes with a soft dry
cloth or replace if necessary. See section “Replacement or
Alignment”.
•
Correct alignment. Align the electrodes as shown.
Replacement or Alignment:
4.5.3
Loosen the screw (1).
4.5.4
Align the electrode as shown or remove if necessary.
4.5.5
Install a new electrode if necessary.
4.5.6
Tighten the screw (1).
4.5.7
Verify the electrodes are correctly aligned.
4.5.8
Reinstall the burner. See section Removing and Installing the Burner
Assembly.
wcghi_tx000721gb.fm
32
Cub 200/300/300 HD
4.6
Maintenance
Inspecting and Cleaning the Cadmium (CAD) Cell
See Graphic: wcghi_gr004021
To inspect and clean the CAD cell, carry out the following procedure.
4.6.1
Remove the burner assembly. See section Removing and Installing
the Burner Assembly.
4.6.2
Twist and pull out the plastic protective holder (1) off the base of the
burner assembly. The CAD cell is inside this plastic holder.
4.6.3
Inspect the CAD cell for the following:
•
4.6.4
Cleanliness. Be sure the cell is free of debris or soot.
Clean the cell if necessary.
NOTICE: Do NOT use solvents or liquids to clean the CAD cell. Use a
soft dry cloth to clean the CAD cell.
4.6.5
Reinstall the plastic protective holder (1) onto the base of the burner
assembly.
4.6.6
Reinstall the burner assembly. See section Removing and Installing
the Burner Assembly.
wcghi_tx000721gb.fm
33
Maintenance
4.7
Cub 200/300/300 HD
Checking and Adjusting the Fuel Pressure
See Graphic: wcghi_gr004025
To check the fuel pressure a pressure gauge is needed. To check and/
or adjust the fuel pressure, carry out the following procedure:
4.7.1
Shut down the machine and allow it to cool.
4.7.2
Disconnect the power cord from the power source.
4.7.3
Remove the two bolts (a) and open the access panel.
4.7.4
Remove the threaded plug (b) from the pressure test port using an
allen wrench. Set the plug in a safe location to be re-installed later.
4.7.5
Install a pressure gauge with adapter in the pressure test port (c).
4.7.6
Start the machine. See section Starting the Machine.
4.7.7
With the machine running, verify the fuel pressure setting. For the
correct settings, refer to the Technical Data charts in this manual.
4.7.8
Shut down the machine. See section Shutting Down the Machine.
4.7.9
Adjust the fuel pressure if necessary using the adjusting screw (e) and
re-check the settings. Repeat steps 6-8 to re-check the settings.
Do not adjust the fuel pressure to a setting outside the safe operational
parameters.
4.7.10 Remove the pressure gauge (d) from the pressure test port (c).
4.7.11 Re-install the threaded plug (b) into the pressure test port (c).
4.7.12 Close the access panel and re-install the two bolts (a) that secure the
panel.
wcghi_tx000721gb.fm
34
Cub 200/300/300 HD
wcghi_tx000721gb.fm
Maintenance
35
Maintenance
4.8
Cub 200/300/300 HD
Cleaning the Fan Blades and Motor
See graphic: wcghi_gr004030
To clean the fan blades and motor, carry out the following procedure:
4.8.1
Shut down the machine and allow it to cool.
4.8.2
Disconnect the power cord from the power source.
4.8.3
Remove the fan guard. There are four screws that secure the guard.
4.8.4
Remove the six bolts that secure the top portion of the shell.
4.8.5
Remove the top shell to access the interior of the machine.
4.8.6
Inspect and, if necessary, clean the motor using compressed air.
4.8.7
Clean the fan blades using a brush.
4.8.8
Re-install the top shell using the six bolts.
4.8.9
Re-install the fan guard.
wcghi_tx000721gb.fm
36
Cub 200/300/300 HD
4.9
Maintenance
Cleaning the Interior Shell
See graphic: wcghi_gr004029
To clean the interior shell, carry out the following procedure:
4.9.1
Shut down the machine and allow it to cool.
4.9.2
Disconnect the power cord from the power source.
4.9.3
Remove the fan guard. There are four screws that secure the guard.
4.9.4
Remove the six bolts that secure the top portion of the shell.
4.9.5
Remove the top shell to access the interior of the machine.
4.9.6
Inspect and, if necessary, clean the interior shell using compressed air.
4.9.7
Re-install the top shell using the six bolts.
4.9.8
Re-install the fan guard.
wcghi_tx000721gb.fm
37
Maintenance
Cub 200/300/300 HD
4.10 Inspecting the Flame Head
See Graphic: wcghi_gr004028
To inspect the flame head, carry out the following procedure:
4.10.1 Remove the burner assembly. See section Removing and Installing
the Burner Assembly.
4.10.2 Mark the location of the air lock sleeve (c) with a pencil.
4.10.3 Loosen the wing nut (b).
4.10.4 Loosen the four screws (a) that secure the flame head (d).
4.10.5 Turn the flame head (d) counter-clockwise and remove.
4.10.6 Inspect the flame head (d) for the following:
•
Wear. Replace if necessary.
•
Cleanliness. Clean the flame head if necessary.
•
Thermal stress. Replace if necessary.
4.10.7 Re-install the flame head (d).
4.10.8 Position the air lock sleeve (c) at the marked location.
4.10.9 Tighten the wing nut (b).
4.10.10 Tighten the four screws (a).
4.10.11 Re-install the burner assembly. See section Removing and Installing
the Burner Assembly.
wcghi_tx000721gb.fm
38
Cub 200/300/300 HD
Maintenance
4.11 Inspecting the Electrical Connections
After disconnecting the power cord, check all electrical connections for
the following:
•
Proper connections. Be sure that all connections are complete and
tight.
•
Corrosion. Clean or replace if necessary.
•
Damaged wires/connectors. Replace if necessary.
•
Proper ground.
4.12 Fuel Blend Guide
Fuel Blend Guide
Temperature Range
Fuel Blend
15° to 30°F
80% #2 : 20% #1
0° to 15°F
70% #2 : 30% #1
–15° to 0°F
50% #2 : 50% #1
below –15°F
30% #2 : 70% #1
wcghi_tx000721gb.fm
39
Maintenance
Cub 200/300/300 HD
4.13 Transporting
Cub series Air Heater machines must be supported by use of blocks
during transport. NOTICE: DO NOT strap or chain down the unit with
the foot or wheels in contact with the transporter.
wcghi_tx000721gb.fm
•
Openings or the entire unit should be covered during transport to
avoid road debris and clutter.
•
Take care when placing straps on areas which are painted red.
Use corner protectors and never use chains.
•
Excessive loading on the foot, wheels, and axle will cause
permanent damage
•
The foot and wheels are for moving by hand and for parking only.
•
This unit is not designed to be towed with any vehicle.
•
All venting external to the machine must be removed prior to
transporting.
•
Only qualified riggers should attempt aerial lifting.
40
Cub 200/300/300 HD
Maintenance
4.14 List of Abbreviations
Amp
ampere (unit of electrical current)
asl
above sea level
BTU
British Thermal Unit
°C
Celsius (metric unit of temperature)
°F
Fahrenheit (unit of temperature)
ft2
square foot/square feet (measurement of area)
ft.lbs.
foot pounds (unit of torque)
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 unit of heat energy)
kPal
kilo-Pascals (metric unit of pressure)
kW
kilo-Watt (unit of electrical power)
lb.
pound
m
meter
mm
millimeter (1/1000 of a meter)
psig
pounds per square inch gauge (unit of pressure)
VAC
Volts, Alternating Current
VDC
Volts, Direct Current
VFD
Variable Frequency Drive
HTF
Heat Transfer Fluid
wcghi_tx000721gb.fm
41
Maintenance
Cub 200/300/300 HD
4.15 Troubleshooting
Note: The following symptoms and remedies are some of the more
common issues that have arisen during the history of these machines.
These do not represent all the possibilities. If you need advanced
troubleshooting assistance, please contact Wacker Neuson Product
Support.
Symptom
Possible Causes
Remedy
The burner does not start
• The remote thermostat
or thermostat plug is not
inserted correctly.
• Faulty cable or power
supply
• The over temperature
limit has tripped
• The burner is in lock-out
mode.
• Insert the remote
thermostat or thermostat
plug.
• Check cable and power
supply
• Press the reset button.
The burner starts, the flame
does not ignite, the unit
locks out
•
•
•
•
No fuel
Worn burner nozzle
Faulty electrodes
Cad cell detecting
external light.
• Cad cell defective
• Burner control defective
•
•
•
•
The burner starts, flame
ignites, but the unit locks
out
•
•
•
•
•
• Increase fuel pressure
• Replace burner nozzle
• Re-adjust air lock setting
The burner ignites but the
performance is poor
• Worn burner nozzle
• Clogged fuel filter
• Air leaks in the fuel lines
Incorrect fuel pressure
Worn burner nozzle
Incorrect air lock setting
Cad cell defective
Burner control defective
Fill fuel tank
Replace burner nozzle
Replace electrodes
Check the Cad cell
enclosure
• Replace burner nozzle
• Replace the fuel filter
• Inspect the lines for
leaks; replace if
necessary
• Insufficient oil pressure
Black smoke from vent pipe
• Insufficient combustion
air
• Insufficient ventilation air
• Remove any
obstructions from the air
inlet and outlet areas.
The machine stops due to
pressure switch fault
• Overheat condition
• Faulty pressure switch
• Contact Wacker Neuson
Product Support
wcghi_tx000721gb.fm
42
Cub 200/300/300 HD
Maintenance
Notes:
wcghi_tx000721gb.fm
43
Maintenance
Cub 200/300/300 HD
4.16 Cub 200/300 Wiring Schematic
4.17 Cub 300 HD Wiring Schematic
wcghi_tx000721gb.fm
44
Cub 200/300/300 HD
Maintenance
4.18 Schematic Legend
Ref.
wcghi_tx000721gb.fm
Description
Ref.
Description
a
Fuel solenoid valve
i
Pressure switch
b
Photo cell
j
Push button reset light
c
Fuse
k
Heated filter
d
ON-OFF switch
l
Relay
e
Motor
m
Temperature limit control
f
Power light
n
Capacitor
g
Remote thermostat
o
Air temperature switch
h
Transformer
p
Nozzle preheater
45
Maintenance
wcghi_tx000721gb.fm
Cub 200/300/300 HD
46
Cub 200/300/300 HD
5
Technical Data
Technical Data
5.1
Machine Technical Data
Item Number
Model
0620204
0620262
Cub 200
0620233
Cub 300
0620253
Cub 300 HD
Units
Heat input
BTU/hr
180,000
289,000
289,000
Heat output
BTU/hr
147,000
232,000
232,000
1300
2600
2600
4.85 (1.28)
7.72 (2.04)
7.72 (2.04)
1.5-80
1.35-80
81.5
80
80
73
71
73.9 (at 3 m)
115/60
115/60
115/60
12
14
116.1 (256)
264(583)
Air flow
Fuel consumption
Fuel nozzle size
Efficiency
Noise level at 2 m
cfm
L (gal)/hr
gal/hr-deg 1.00-60
%
dB (A)
Power requirement
VAC/Hz
Electrical current
Ampere 7
Weight (no fuel)
kg (lb) 79.4 (175)
Height
cm (in.)
78.7 (31)
116.8 (46)
130.8(51.5)
Length
cm (in.)
139.7 (55)
172.7 (68)
228.3(89.9)
Width
cm (in.)
61 (24)
69.9 (27.5)
97.5(38.4)
Flue diameter
cm (in.)
15.2 (6)
15.2 (6)
15.2 (6)
100 (26.42)
138.9 (36.7)
232.8(61.5)
175
175
218
2
3
5
Fuel tank capacity
Fuel pressure
Air lock setting
wcghi_td000213gb.fm
L (gal)
psi
number
47
Technical Data
wcghi_td000213gb.fm
Cub 200/300/300 HD
48
Wacker Neuson SE
·
Preußenstraße 41
· D-80809 München
· Tel.: +49-(0)89-3 54 02-0 · Fax: +49 - (0)89-3 54 02-390
Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · 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 Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
Tel: (852) 3605 5360, Fax: (852) 2758 0032