Wacker Neuson Pureheat Hydronic Air Heater Operator's Manual

OPERATOR’S MANUAL

0 1 7 1 9 4 2 E N

0171942en 001

0907

Hydronic Air Heater

Pureheat

One Year Limited Warranty

(see your distributor to file warranty claim)

Ground Heaters, Inc. warrants that the Products described in this Limited Warranty shall be free of defects in material and workmanship under normal use and service for a period of one year from the Ground Heaters, Inc. invoice date to Distributor or for a period of one year from Distributor’s invoice date to end-user, excluding pre-season orders which will have an effective warranty date of

November 15th. This Limited Warranty is expressly limited to crediting the purchase price of the defective Product or to repairing or replacing the defective Product, at the sole option of Ground

Heaters, Inc. This warranty shall not extend to any repair work performed by anyone other than

Ground Heaters, Inc. or an authorized representative of Ground Heaters, Inc. Such credit, repair or replacement shall be Ground Heaters, Inc.’s sole obligation and buyer’s exclusive remedy hereunder and shall be conditioned upon Ground Heaters, Inc.’s timely receipt of warranty claim of the alleged defect and, at Ground Heaters, Inc.’s option, return of such product to Ground Heaters,

Inc., FOB its Spring Lake, Michigan, facility. Any warranty claims received after 13 months from warranty effective date are not valid. This exclusive remedy shall not be deemed to have failed of its essential purpose provided Ground Heaters, Inc. is willing and able to repair or replace the defective Product or to credit the purchase price within 90 days of the date on which Ground

Heaters, Inc. confirms that such products are defective. Use of repair or replacement parts not manufactured by Ground Heaters, Inc. may void this warranty. Ground Heaters, Inc.’s liability hereunder shall be limited to the contract price of that portion of the Product on which such liability is based. The existence of a defect shall be determined by Ground Heaters, Inc. in its sole discretion.

GROUND HEATERS, INC. SHALL NOT BE RESPONSIBLE FOR ANY LABOR CHARGES OR

LOST HEAT TRANSFER FLUID IN CONNECTION WITH WARRANTY SERVICE. USE OF ANY

ANTI-FREEZE OR HEAT TRANSFER FLUID OTHER THAN GROUND HEATERS BRAND HEAT

TRANSFER FLUID VOIDS THIS WARRANTY IN ITS ENTIRETY.

THIS WARRANTY IS EXCLUSIVE. WARRANTIES OF MERCHANTABILITY AND FITNESS FOR

A PARTICULAR PURPOSE, AND WARRANTIES ARISING FROM A COURSE OF DEALING OR

USAGE OF TRADE, ARE SPECIFICALLY EXCLUDED, AND THERE ARE NO WARRANTIES

EXPRESSED OR IMPLIED OTHER THAN THE LIMITED WARRANTY EXPRESSLY SET FORTH

HEREIN.

GROUND HEATERS, INC. SHALL NOT BE LIABLE FOR INCIDENTAL, CONSEQUENTIAL,

SPECIAL OR OTHER DAMAGES, INCLUDING BUT NOT LIMITED TO DAMAGES FOR LOSS

OF PROFITS OR PRODUCTION, OR INJURY TO PERSON OR PROPERTY. WITHOUT

LIMITING THE GENERALITY OF THE FOREGOING, GROUND HEATERS, INC. SHALL NOT BE

LIABLE FOR ANY CLAIMS BASED ON THE CONDITION, USE OR OPERATION OF THE

PRODUCTS, WHETHER BASED ON CONTRACT, TORT OR OTHER THEORIES OF LAW,

INCLUDING WITHOUT LIMITATIONS, THEORIES OF NEGLIGENCE.

The “Products” covered by this Limited Warranty include all machines manufactured by Ground

Heaters, Inc. and sold in the ordinary course of business, and all accessories therefore, which are registered with Ground Heaters, Inc., except for the following components: Heat Transfer Hoses,

Tires, Generator Powerheads and Engines. These are considered to be wear items and/or are covered by warranties of the component manufacturer. NOTE: Failure to maintain proper inflation or operating tires at speeds or under loads in excess of those recommended in the operator’s manual may void the tire manufacturer’s warranty. Failure to fully pay for Product will void this

Limited Warranty.

No agent or employee of Ground Heaters, Inc. is authorized to modify, extend, or otherwise change this limited warranty.

Rev. 11-22-04 - kk

Technical Assistance

877-799-9600

This Pureheat

™

Hydronic Air Heater manual contains the following:

1. Pureheat™ Hydronic Air Heater Operator’s Manual

2. One Year Limited Warranty

3. Pump Manufacturer’s Manual

4. Burner Manufacturer's Manual

© 2006 Ground Heaters, Inc.

i

V. 2, Rev. 09/01/06

WARNING

LICENSED GAS TECHNICIAN REQUIRED.

NG/LP BURNER SETUP AND INSTALLATION, FUEL

SUPPLY CONNECTION, TEST FIRING AND BURNER

ADJUSTMENT MUST BE PERFORMED BY A LICENSED

PROFESSIONAL GAS TECHNICIAN AND MUST CONFORM

TO THE REQUIREMENTS OF ALL RELEVANT LOCAL,

STATE, PROVINCIAL AND FEDERAL AUTHORITIES.

Burner setup and installation, fuel supply connection, testfiring and burner adjustment must be performed by a licensed professional and must conform to the requirements of local, state and federal authorities. In the

Commonwealth of Massachusetts, gas piping shall be installed by a licensed plumber or gas fitter.

The licensed gas technician must use a manometer (to properly adjust gas pressure) and an electronic combustion analyzer (to properly adjust burner air intake and verify that proper combustion parameters have been achieved). The licensed gas technician must supply all fuel lines, fittings, regulators, etc. necessary to connect the Pureheat

TM

NG/LP burner to the fuel source at the correct pressure and flow.

FAILURE TO HEED THIS WARNING MAY RESULT IN

AN EXPLOSION AND/OR FIRE CAUSING

PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.


ii

V. 2, Rev. 09/01/06

WARNING: If the instructions in this manual are not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

• Do not store or use gasoline or other

flammable vapors and liquids in the vicinity of this or any other appliance.

• WHAT TO DO IF YOU SMELL GAS

- Do not try to light any appliance

- Do not touch any electrical switch; do not

use any phone in your building

- Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's instructions.

- If you cannot reach your gas supplier, call

the fire department

• Installation and service must be performed by

a qualified installer, service agency, or the gas supplier.

Operator Manual available in French language upon request. Call 877-799-9600.

Manuel de renseignements disponible en langue francaise sur demande.

Appellez le 877-799-9600.


iii

V. 2, Rev. 09/01/06

PUREHEAT™ HYDRONIC AIR HEATER OPERATOR’S MANUAL

TABLE OF CONTENTS

Page

Technical, Checklists, Warranty Information .................................................................... i

Warnings ..................................................................................................................................... ii,

Specifications ............................................................................................................................ ix

List of Abbreviations ................................................................................................................ x

INTRODUCTION

1.1 EXTERNAL FEATURES ................................................................................................... 1-2

1.2 INTERNAL COMPONENTS .............................................................................................. 1-3

1.2.1

1.2.2

Heater with Burner Options ......................................................................................... 1-3

Heater with Burner Detail ............................................................................................ 1-4

1.3 IDENTIFICATION .............................................................................................................. 1-6

1.4 SAFETY FEATURES......................................................................................................... 1-6

1.5 SAFETY PRECAUTIONS.................................................................................................. 1-6

1.5.1 Burner Setup, Installation and Adjustment Requirements .......................................... 1-7

1.5.2 Operators..................................................................................................................... 1-7

1.5.3 Safe 1-7

1.6 REPAIR PARTS AND ACCESSORIES ............................................................................ 1-8

1.7 MAINTENANCE................................................................................................................. 1-8

1.8 OBTAINING WARRANTY SERVICE ................................................................................ 1-8

START UP, OPERATION AND SHUTDOWN

2.1 CIRCULATION SYSTEM ADVISORY............................................................................... 2-1

2.1.1.1 HX200 Heat Xchangers™ ................................................................................... 2-1

2.1.1.2 HX200 Heat Xchangers™ with Optional Booster Pump ..................................... 2-1

2.1.1.3 HX100 Heat Xchangers™ ................................................................................... 2-1

2.1.1.4 HX100 Heat Xchangers™ with Booster Pump.................................................... 2-1

2.1.1.5 HX50 Heat Xchangers™ ..................................................................................... 2-2

2.1.1.6 HX50 Heat Xchangers™ with Booster Pump...................................................... 2-2

2.1.1.7 Maximum Heat Xchanger™ Connection Capability ............................................ 2-2

2.1.2 Optional 2-2

2.1.3 Circulation 2-2

2.1.4 Insulate 2-3

2.1.5 Circulation 2-3

2.2 PRE-START CHECKS ................................................................................................ 2-3

2.2.1 Positioning ................................................................................................................... 2-3

V. 2, Rev. 09/01/06

HX50 2-4 iv


PUREHEAT™ HYDRONIC AIR HEATER OPERATOR’SMANUAL

TABLE OF CONTENTS (continued)

2.2.5 Heat

Page

Transfer Fluid (HTF)............................................................................................ 2-4

2.2.6 Switch Positions........................................................................................................... 2-4

2.2.7 Deployment of Circulation Hoses or Option Heat Transfer Hose................................ 2-5

2.3 SETUP ............................................................................................................................. 2-5

2.4.1 Integrity Check............................................................................................................. 2-5

2.4.3 Initiating Flow through Heat Transfer Hose ................................................................. 2-6

2.5 OPERATING WITH OPTIONAL ACCESSORIES............................................................. 2-7

2.5.2 Using Five HHS3004 with Booster Pump for Curing and Frost Prevention Applications 2-7

2.6 MONITORING OPERATING PARAMETERS ................................................................... 2-8

2.7.1 Burner Shutdown ......................................................................................................... 2-9

2.7.2 Disconnecting Hoses from Heat Xchangers™ and Pureheat ..................................... 2-9

2.7.3 Rewinding the Circulation Hose .................................................................................. 2-9

2.8 CONNECTING/DISCONNECTING OPTIONAL BOOSTER PUMP.................................. 2-10

2.8.1 Connecting................................................................................................................... 2-10

2.8.2 Start Up........................................................................................................................ 2-11

2.8.3 Shutdown..................................................................................................................... 2-11

2.8.4 Disconnecting .............................................................................................................. 2-11

BURNER ADJUSTMENT AND SHUTDOWN

3.1 NATURAL GAS/LIQUID PROPANE VAPOR ................................................................... 3-1

3.1.1 Burner Adjustment ....................................................................................................... 3-1

3.1.1.1 Fuel Pressure Adjustment ................................................................................... 3-2

3.1.1.2 Air Setting and Adjustment .................................................................................. 3-2

3.1.1.3 O

2

Content Sampling ........................................................................................... 3-3

3.1.1.4 Smoke Spot Sampling ......................................................................................... 3-3

3.1.2 Burner Shutdown ......................................................................................................... 3-3

3.2.1 Burner Adjustment ....................................................................................................... 3-3

3.2.1.1 Fuel Pressure Adjustment ................................................................................... 3-4

3.2.1.2 Air Setting and Adjustment .................................................................................. 3-4

3.2.1.3 O

2

Content Sampling ........................................................................................... 3-4

3.2.1.4 Smoke Spot Sampling ......................................................................................... 3-4

3.2.2 Burner Shutdown ......................................................................................................... 3-5

© 2006 Ground Heaters, Inc. v

V. 2, Rev. 09/01/06



MAINTENANCE

Page

4.1 ADDING HEAT TRANSFER FLUID.................................................................................. 4-1

4.1.1 To Clear a “LOW LEVEL FAULT”................................................................................ 4-1

NG/LP Diesel/Fuel Oil .................................................................................... 4-2

4.2.1.1 Installation ........................................................................................................... 4-2

4.2.1.2 Setup ................................................................................................................... 4-3

4.2.2 From 4-3

4.2.2.1 Installation ........................................................................................................... 4-4

4.2.2.2 Setup ................................................................................................................... 4-4

4.3 HIGH ELEVATION OPERATIONS.................................................................................... 4-5

4.5 SUMMER STORAGE INSTRUCTIONS ............................................................................ 4-6

TRANSPORTING THE PUREHEAT™ HYDRONIC AIR HEATER

5.1 TOWING............................................................................................................................. 5-1

5.3 TRANSPORTING on a FLATBED .................................................................................... 5-1

5.4 COMMON MECHANICAL INSPECTIONS PRIOR TO TRANSPORTING ....................... 5-1

TROUBLESHOOTING

6.2 HTF LOW LEVEL FAULT AND LIGHTS .......................................................................... 6-3

6.2.1 Low Level Shutdown Device ....................................................................................... 6-3

6.2.2 Testing the Low Level Shutdown Device .................................................................... 6-3

6.3 BURNER CONTROL LOCKOUT ...................................................................................... 6-4

V. 2, Rev. 09/01/06 vi


PUREHEAT™ HYDRONIC AIR HEATER OPERATOR’SMANUAL


APPENDIX A

Page

PUREHEAT SCHEMATIC AND WIRING DIAGRAM SYMBOL LEGEND .................................A-1a

PUREHEAT SCHEMATIC AND WIRING DIAGRAM SYMBOL LEGEND .................................A-1b

PUREHEAT SCHEMATIC AND WIRING DIAGRAM SYMBOL LEGEND ................................. A-1c

PUREHEAT CONTROL PANEL EXTERIOR LAYOUT.................................................................A-2

PUREHEAT CONTROL PANEL DOOR INTERIOR LAYOUT......................................................A-4

PUREHEAT MAIN CONTROL PANEL - EXTERIOR COMPONENT FUNCTION

PUREHEAT MAIN CONTROL PANEL INTERIOR COMPONENT LAYOUT ...............................A-6

PUREHEAT MAIN CONTROL PANEL INTERIOR COMPONENT

PUREHEAT DIESEL BURNER CONTROL SEQUENCE OF OPERATION

PUREHEAT SCHEMATIC - AUXILIARY PUMP PANEL (P/N A109-199)..................................A-15

PUREHEAT REWIND MOTOR WIRING .....................................................................................A-17

HX200 HEAT XCHANGER™ WIRING DIAGRAM ......................................................................A-19

HX100 HEAT XCHANGER™ WIRING DIAGRAM ......................................................................A-20

HX50 HEAT XCHANGER™ WIRING DIAGRAM ........................................................................A-21

PUREHEAT TRAILER JUNCTION BOX AND BATTERY WIRING............................................A-22

PUREHEAT NG/LP BURNER COMPONENT IDENTIFICATION (P/N P100-673).....................A-24

PUREHEAT NG/LP BURNER (P/N P100-673)

GAS PRESSURE CHECKING AND ADJUSTING ................................................................ A-25

PUREHEAT DIESEL BURNER COMPONENT IDENTIFICATION (P/N P100-690).................. A-26

SUGGESTED METHOD FOR SECURING THE PUREHEAT ONTO A TRUCK BED ...............A-27

PUREHEAT HOSE REWIND PARTS IDENTIFICATION............................................................A-28

© 2006 Ground Heaters, Inc. vii

V. 2, Rev. 09/01/06



APPENDIX B

Page

PUREHEAT AIR AND SURFACE HEATING ACCESSORIES.....................................................B-1

BOOSTER PUMP TO PUREHEAT CONNECTING ......................................................................B-2

HX200 HEAT XCHANGER™ TO PUREHEAT CONNECTION LAYOUT ....................................B-3

HX100 HEAT XCHANGER™ TO PUREHEAT CONNECTION LAYOUT ....................................B-4

HX50 HEAT XCHANGER™ TO PUREHEAT CONNECTION LAYOUT ......................................B-5

PUREHEAT 18,000 SQ. FT THAW LAYOUT

(THREE HHS 3004’S AND THREE 4-PORT MANIFOLDS) .................................................B-6

PUREHEAT 30,000 SQ. FT CURE LAYOUT

(FIVE HHS 3004’S AND FIVE 4-PORT MANIFOLDS) .........................................................B-7

PUREHEAT 45,000 SQ. FT FROST PREVENTION LAYOUT

(FIVE HHS 3004'S AND FIVE 4-PORT MANIFOLDS)..........................................................B-8

PUREHEAT VALVE POSITIONS FOR ADDING HTF (MACHINE IN USE).................................B-9

PUREHEAT VALVE POSITIONS FOR ADDING HTF (MACHINE NOT IN USE) ......................B-10

PUREHEAT QUICK-CONNECT AND CAM-LOCK CARE AND MAINTENANCE.....................B-11

APPENDIX C

PUREHEAT APPLICATIONS AND CAPACITIES ....................................................................... C-1

V. 2, Rev. 09/01/06 viii


SPECIFICATIONS

PUREHEAT™ HYDRONIC AIR HEATER

OPERATOR’S MANUAL SPECIFICATIONS

Dimensions and Capacities

Length

Width

Height

Ground Clearance

Weight

Optional Diesel Fuel Tank

Weight with Optional Diesel Fuel Tank

172 in. (437 cm)

93 in. (236 cm)

93 in. (236 cm)

9 in. (23 cm)

7,155 lbs (3,248 kg)

435 US gallons (1,647 liters)

11,230 lbs (5,098 kg)

Heat Transfer Fluid

Pump, 1.5 hp Centrifugal

Circulation Hose

145 US gallons (549 liters)

Total: 1,000 ft (305 m) (see breakdown below)

1

Hose Reel

Hose Rewind

Circulation Loops

4 x 100 ft [30 m]

4 x 50 ft [15 m]

1

120 VAC, w/12 VDC clutch

5

Tires LT235/85R16

Tire Inflation

Hitch

80 psig (752 kPa) cold

3 in. Pintle or 2 5 /

16

in. Ball

Heat Exchangers

Lifting Bail

200,000 BTU/H (2,400 cfm)

100,000 BTU/H (1,315 cfm)

50,000 BTU/H (710 cfm)

Remote Manifold (not included with HX200 package)

Loading Ramp (not included with HX50 package)

On-Board Manifold (Supply/Return)

4

8

16

4

1

1

Standard

Performance (choice of fuels)

Burner Orifice (NG/LP Burner) 5/8 in

Propane, Input 860,000 BTU/H

Natural Gas, Input 860,000 BTU/H

Burner Nozzle (Diesel Burner) 5.0 60º A (solid)

860,000 BTU/H Diesel, Input

Efficiency 83%

Temperature Control Digital

Fuel Consumption During Burner Operation:

(Propane) 344 CFH

(Natural Gas) 860 CFH

Electrical Requirement

Normal Operating Temperature

(Diesel) 6.1 GPH

1 x 15 amp. and 1 x 20 amp. x 120 VAC

180ºF (82 ºC)

V. 2, Rev. 09/01/06 ix



LIST OF ABBREVIATIONS

The following is a list of abbreviations used throughout the Operator’s Manual:

Abbreviation/Symbol Term/Meaning

amp. ampere (measurement of electrical current) asl

BTU above sea level

British Thermal Unit (measurement of heat energy)

CFM Cubic Feet per Minute (measurement of air flow)

cm centimeter (1/100 th of a meter)

CSA Canadian Standards Association

°F degrees Fahrenheit (measurement of temperature)

ft foot/feet (measurement of length/distance) ft 2 square foot/square feet (measurement of area)

GFI Ground Fault Interrupt/interrupter (protection device)

GVWR Gross Vehicle Weight Rating

HHS Ground Heaters Hose Handling System

hr hour (measurement of time)

Hz Hertz (measurement of frequency)

ID measurement of Inner Diameter

in. inch/inches (measurement of length/distance)

kg kilogram (metric measurement of weight)

kW kilo-Watt (measurement of electrical power)

lb pound (measurement of weight)

LWCO Low Water Cut Off Device

m meter (metric measurement of length/distance)

MGV Main Gas Valve (NG / LP Fuel)

mm millimeter (1/1000 th of a meter)

NHTSA National Highway Transportation Safety Administration

psig pounds per square inch gauge (measurement of pressure)

Rev. Revision

USDOT United States Department of Transportation

V. Version

VAC Volts, Alternating Current

VDC Volts, Direct Current

V. 2, Rev. 09/01/06 x © 2006 Ground Heaters, Inc.

PUREHEAT™ HYDRONIC AIR HEATER OPERATOR’S MANUAL – SECTION 1

INTRODUCTION

The Pureheat™ Hydronic Air Heater provides temporary air heat, thaws frozen ground, cures concrete and provides frost prevention at ambient temperatures below 40°F (5°C). Ground Heaters, Inc.’s revolutionary technology enables construction activities to continue throughout the cold weather months.

The Pureheat™ Hydronic Air Heater is equipped with a 5-Port On-Board Manifold and 1,000 ft (396 m) of

1 in. (25 mm) ID Red Circulation Hose Assemblies with Quick-Connects (QCs). The standard equipment package includes the following lengths of Circulation Hoses: Two (2) 200 ft (61 m), Four (4) 100 ft. (30 m ),

Four (4) 50 ft (15 m) .

The optional diesel or gas Burner heats the Heat Transfer Fluid (HTF) to 180°F

(82°C). The HTF is continuously circulated through the Circulation Hoses in a vented, closed-loop system.

With standard equipment, the Pureheat:

(Refer to Appendixes B and C)

• Provides remote space heating for up to 1,200,000 ft 3 (48,235 m 3 ) of building space.

Using GHI’s optional Booster Pump and Auxiliary Pump Panel, Three (3) Hose Handling System 3004

(HHS3004) with Twelve (12) 750 ft (228 m) 5/8 in. ID Heat Transfer Hoses (HTH) and three 4-Port

Remote Manifolds, the Pureheat will:

• Thaw up to 18,000 ft 2 spacing.

(1,674 m

2

) of frozen ground per application using 24 in. (60 cm) hose

• Thaw up to 9,000 ft 2

(837 m

2

) 75% to 100% faster using 12 in. (30 cm) hose spacing

Using GHI’s optional Booster Pump and Auxiliary Pump Panel, Five (5) Hose Handling System 3004

(HHS3004) with Twenty (20) 750 ft (228 m) 5/8 in. ID Heat Transfer Hoses (HTH) and Five (5) 4-Port

Remote Manifolds, the Pureheat can:

• Cure all types of concrete placements, including slabs on grade, elevated slabs, tilt-up walls, poured walls, columns, footings, bridge decks, etc. up to 30,000 ft

2

) per application using 24 in. (60 cm) hose spacing.

(2,790 m

2

• Provides Frost Prevention up to 45,000 ft 2 spacing.

(4,186 m 2 ) per application using 36 in. (91 cm) hose

The Pureheat™ Hydronic Air Heater Model Pureheat:

• Heats workspace easily & economically:

• Input of 860,000 BTUH.

• Fuel flexible; choice of natural gas, propane or diesel.

• Takes only minutes to change over from one fuel to another.

• Provides pure, dry, hot air – no moisture added to workspace; prevents mold and mildew.

• Removes excess moisture – dry / warm air removes moisture from workspace and building materials.

• Provides pure, clean air – no combustion by-products in workspace.

• Is rental friendly – easy setup and uses only One (1) 15 amp. And One (1) 20 amp. 120 volts AC circuits.

V. 2, Rev. 09/01/06 © 2006 Ground Heaters, Inc.

1- 1


1. Adjustable 3 in. (76 mm) Pintle Style Hitch or 2

5

/

16

in. (59 mm) Ball

2. Lifting Bail

3. Door Tieback

4. Lockable Doors

5. Electric Brakes with Breakaway Switch

6. Performance Monitoring Light

7. 5-Port On-Board Manifold Door

8. Heavy Duty Jack-Stand

9. Heavy Duty Fenders

2

6

4

1

8

7

9

1-1

5

3

1- 2


V. 2, Rev. 09/01/06


1.2.1 Heater with Burner Options (Photo 1-2)

The following components are accessed via the side door:

1. Main Control Panel 10. Main Pump

2. Hydronic Heater and Expansion Tank (not shown) 11. Rewind Foot Pedal

3. Natural Gas (NG)/Liquid Propane (LP) Burner

4. NG/LP Gas Train

5. NG/LP Gas Pressure Regulator

6. NG/LP Main Gas Valve

7. NG/LP Secondary Gas Valve

8. NG/LP Pilot Gas Valve

12. Return Temperature Gauge

13. Pressure Gauge

14. Return Flow Indicator

15. Operator’s Manual Holder

16. Performance Monitoring Power Receptacle

17. Low Level Shutdown Device

9. Hose Reel with 1,000 ft (305 m) 1 in. ID 18. HTF Sight Gauge and Decal

Red Circulation Hoses with Quick-Connects (QCs) 19. Optional Auxiliary Pump Panel (not shown)

1

15

12

17

13 18

16

2 6 7

4

14

9

5

19

3

8

10

1-2 11


1- 3


1.2.2 Heater with Optional Burner Detail (Photos 1-3 and 1-4)

The following components are accessed via the Side Door:

1. Natural Gas (NG)/Liquid Propane (LP) Supply

Gas Connection

2. NG/LP Gas Pressure Regulator

3. NG/LP Main Gas Valve

4. NG/LP Secondary Gas Valve

5. NG/LP Pilot Gas Valve

6. NG/ LP Gas Burner

8. NG/LP Gas Train

9. NG/LP Burner Control (not shown)

10. Diesel Burner

11. Diesel Burner Control

12. Diesel Return Fuel Line and QC

13. Diesel Supply Fuel Line and QC

14. Diesel Fuel Filter and QC

2 3 4

8 11

10

12

1-3

1 6

5

1-4

14

13

1- 4


V. 2, Rev. 09/01/06


1.2.3 Inside

The following components are located inside the Rear Door: (Photo 1-5 through 1-8)

1. HX200 Heat Xchangers

TM

2. Cab Interior Light and Remote Manifold Storage Location – not shown)

3. Ramp Alignment Pins

4. Ramp Storage and Remote Manifold Storage (not shown)

2

4

1

1-5

1-6

HX50 (LOADED)

V. 2, Rev. 09/01/06

3

1-7

HX100 (LOADED)


1-8

HX200 (LOADED)

1- 5


1.3 IDENTIFICATION

The Pureheat™ Hydronic Air Heater serial number is located on the Main Control Panel. Always reference the Pureheat serial number when ordering parts or requesting technical assistance.

Pureheat™ Hydronic Air Heaters are safe, quality equipment, are NHTSA compliant, meet all state requirements, meet all Transport Canada requirements, and are CSA certified.

Specific safety features include:

1. Trailer Brakes: electric with breakaway switch (12 VDC).

2. Hydronic Heater: operates at zero (atmospheric) pressure.

3. Low Level Shutdown Device: turns off the Burner and Pumps if HTF level in the system drops below minimum operating level. Manual reset requirement prevents unsupervised Pump/Burner start up.

4. Ground Fault Interrupters (GFI): built into control panel to protect all circuits.

5. Circuit Overload Protection: built into Main Control Panel to protect all circuits and components.

6. Burner Flame Monitoring: Burner Control uses optic flame sensor to shut off Burner if flame fails to ignite or upon loss of flame. Manual reset requirement prevents unsupervised restart.

7. Pump Motor Overload Protection: internal thermal overload trip with automatic reset.

8. Burner Motor Overload Protection: internal thermal overload trip with manual reset (diesel Burner

Motor only) and internal thermal overload trip with automatic reset (NG/LP only).

9. Reflective Markers: enhance night identification.

10. Foot Pedal: for Hose Rewind system wired with low voltage (12 VDC) signal to protect personnel from shock hazard should the Foot Pedal become accidentally immersed in water.

11. Digital Temperature Control: fails safe (Burner OFF) upon loss of power or temperature sensor malfunction

12. System Over Temperature Backup Shutdown: Bi-metal snap disc will shut down the Burner Blower

Motor should HTF temperature exceed 200°F.

13. Natural Gas (NG) / Propane (LP) Burner: a. Ten (10) Second Pre-Purge Timer b. Automatic Burner Sequencing c. Flame Monitoring d. System Status Indication e. System / Self-Diagnostics f. Post-Purge Timer g. Pilot Valve / Ignition h. Infrared Flame Detector i. Air Flow Proving Switch

1.5 SAFETY PRECAUTIONS

Ground Heaters, Inc. develops and manufactures equipment that is safe to operate. However, an accident could occur if the Pureheat ™ Hydronic Air Heater is used improperly. Safe operation requires that all instructions and precautions be followed. Key safety precautions are posted on decals throughout the machine. Read and understand all material in this Operator’s Manual and on the decals posted on the Pureheat before attempting to operate it.

1- 6


V. 2, Rev. 09/01/06


1.5.1 Burner Setup, Installation and Adjustment Requirements

Licensed gas technician required. NG/LP Burner setup and installation, fuel supply connection, test firing and

Burner adjustment must be performed by a licensed professional gas technician and must conform to the requirements of all relevant local, state, provincial and federal authorities. The licensed gas technician must use Two (2) Manometers to properly adjust supply and manifold gas pressure. A Combustion Analyzer and

Smoke Spot Tester must be used to properly adjust Burner emissions and verify that proper combustion parameters (O

2

, Exhaust temperature and smoke) have been achieved. The licensed gas technician must supply all fuel lines, fittings, regulators, etc. necessary to connect the Pureheat NG/LP Burner to the fuel source at the correct pressure and volume.

NOTE: In the Commonwealth of Massachusetts, gas piping shall be installed by a licensed plumber or gas fitter.

Diesel Burner setup, installation and adjustment must be performed by a trained and knowledgeable

Diesel Burner technician. The Diesel Burner technician must use a Fuel Pressure Test Gauge to properly adjust the fuel pressure. A Combustion Analyzer and a Smoke Spot Tester must be used to properly adjust Burner emissions and to verify that proper combustion parameters (O smoke) have been achieved.

2

, Exhaust temperature and

1.5.2 Operators

There are no published standards or certification requirements for operating portable hydronic heating machines. The following criteria reflect the experience of Ground Heaters, Inc. and should be considered a guide, not a comprehensive requirement. The following operator characteristics will prevent accidents, facilitate satisfactory results, and ensure reliable service from the Pureheat™ Hydronic Air Heater.

1. Patience: Insures the system runs at optimum levels; leaks are found and fixed; valves are properly set; and switches are activated properly.

2. Good Hearing, Vision and Smell: Enables operator to assess equipment and detect potential malfunctions.

3. Self Respect: Dresses for the weather; wears eye protection and gloves; and does not take chances with personal safety. Do not operate the Pureheat while intoxicated or impaired by alcohol or other substances.

4. Careful and Responsible: Insures the machine is operating properly before leaving it unattended; keeps track of fluid levels; locks compartments; conducts operational checks at regular intervals; and ensures proper officials are notified of the machine’s use.

5. Above all, a Pureheat™ Air Heater operator reads and understands this Operator’s Manual and the decals posted on the machine.

! Failure to adhere to all safety precautions and recommendations may result in

damage to the Pureheat™ Air Heater™, damage to other property, personal injury, or possibly death.

1.5.3 Safe Operation and Maintenance

1. Read and understand all material in this Operator’s Manual and on the decals posted on the

Pureheat ™ Air Heater before attempting to operate it.

2. Keep unauthorized people, especially children, away from the Pureheat .

3. Keep guards in place. Do not disable safety features.

4. Keep safety and instruction decals clean and legible. Replace damaged decals.

5. Do not operate the Burner while the Pureheat ™ Hydronic Air Heater is in an enclosed, non-ventilated area. The Burner Exhaust contains carbon monoxide, a colorless, odorless and deadly gas.

Pureheat on firm/level ground and chock wheels before operating.

7. Do not smoke while refueling. Do not refuel near open flame or sparks.

8. Clean up fuel spills immediately.


1- 7


9. Do not transport people in or on the Pureheat ™ Hydronic Air Heater.

10. If the Pureheat starts to function improperly, turn OFF immediately and repair before restarting.

11. Always wear gloves when handling hot or cold components—especially the Circulation Hose. Never loosen or remove Circulation Hoses while a Pump or Burner is running or when the HTF temperature is above 120ºF (49°C).

12. Do not attempt tire repairs. Have a qualified tire dealer or repair service perform required tire maintenance.

13. Torque for wheel lug nuts should be set at 110 ft-lbs.

!

Failure to observe these warnings may result in injury or death.

1.6 REPAIR PARTS AND ACCESSORIES

Your Ground Heaters Distributor carries a complete line of parts and accessories needed for all repair or replacement requirements.

1.7 MAINTENANCE

All maintenance should be performed by a qualified service technician using the Operators Manual.

The following preventative maintenance should be performed once per year or every 1,500 hours, whichever comes first:

• Hydronic Heater and Burner cleaning and inspection (Refer to section 3 of the Service Manual.)

• Low Level Shutdown Device operation verification (Refer to Appendix A-18, Pureheat Safety

Controls Low Level Shutdown Device).

• Temperature Control accuracy and operation verification (refer to section 2.1.5 of the Service

Manual).

• Routine Trailer Axle maintenance (common mechanical experience).

1.8 OBTAINING WARRANTY SERVICE

Your satisfaction is important to your Ground Heaters Distributor as well as to Ground Heaters, Inc.

Warranty details are explained in the Ground Heaters, Inc. Statement of Warranty found on the reverse side of the Customer Delivery Checklist.

All warranty services must be completed by a certified Ground Heaters Distributor service technician. If your Distributor does not satisfactorily resolve the problem, please call Ground Heaters, Inc. at

877-799-9600 for assistance. You will need to provide the following information for assistance:

• Name, address and phone number

• Machine serial number

• Date of purchase

• Distributor name and address (location)

• Nature of problem

Thank you for purchasing a Pureheat™ Hydronic Air Heater. Both your Ground Heaters Distributor and

Ground Heaters, Inc. want to assist you in every way possible to ensure your complete satisfaction with your purchase.

1- 8


V. 2, Rev. 09/01/06

PUREHEAT™ HYDRONIC AIR HEATER OPERATOR’S MANUAL–SECTION 2

START UP, OPERATION AND SHUTDOWN

2.1 CIRCULATION SYSTEM ADVISORY

2.1.1 Standard Configuration Performance

2.1.1.1 HX200 Heat Xchangers™

A Pureheat™ Hydronic Air Heater equipped with HX200 Heat Xchangers

TM following system configurations:

should conform to the

• Connection of up to Four (4) HX200 Heat Xchangers m) from base unit.

TM utilizing any combination [50 ft (15 m),

100 ft (30 m) or 200 ft (61 m)] of Circulation Hoses. Maximum run should not exceed 200 ft (61

• The maximum vertical rise or drop from the Pureheat to each HX200 is 60 ft (18 m) one way from base unit.

2.1.1.2 HX200 Heat Xchangers™ with Optional Booster Pump

A Pureheat™ Hydronic Air Heater equipped with HX200 Heat Xchangers™, optional Booster Pump and

Auxiliary Pump Panel should conform to the following system configurations:

• Connection of up to Four (4) HX200 Heat Xchangers exceed 400 ft (122 m) from base unit.

TM

utilizing any combination [50 ft (15 m),

100 ft (30 m) or 200 ft (61 m)] of Circulation Hoses with a maximum overall horizontal run not to

• The maximum vertical rise or drop from the Pureheat to each HX200 is 100 ft (30 m) one way from base unit.


A Pureheat™ Air Heater equipped with HX100 Heat Xchangers

TM conform to the following system configurations:

and 4-Port Remote Manifolds should

• Connect the Four (4) 4-Port Remote Manifolds utilizing any combination [50 ft (15 m) or 100 ft (30 m)] of Circulation Hoses with a maximum overall horizontal run not to exceed 150 ft (45 m) for each 4-Port Remote Manifold.

• The maximum vertical rise or drop from the Pureheat to each Xchanger TM

Manifold is 60 ft (18 m) one way from base unit.

or 4-Port Remote

• Connect Two (2) HX100 Heat Xchangers

Xchangers

TM

.

TM to each of the Four (4) 4-Port Remote Manifolds utilizing the 40 ft (12 m) 5/8 in. ID Black Circulation Hoses mounted on the HX100 Heat

2.1.1.4 HX100 Heat Xchangers™ with Booster Pump

A Pureheat™ Hydronic Air Heater equipped with the HX100 Heat Xchangers™, 4-Port Remote

Manifolds, optional Booster Pump and Auxiliary Pump Panel should conform to the following system configurations:

• Connect the Four (4) 4-Port Remote Manifolds utilizing any combination [50 ft (15 m), 100 ft (30 m) or 200 ft (61 m)] of Circulation Hoses with a maximum overall horizontal run not to exceed 350 ft (106 m) for each 4-Port Remote Manifold.

• The maximum vertical rise or drop from the Pureheat to each Xchanger or 4-Port Remote


• Connect Two (2) HX100 Heat Xchangers

Xchangers

TM

.

TM to each of the Four (4) 4-Port Remote Manifolds utilizing the 40 ft (12 m) 5/8 in. ID Black Circulation Hoses mounted on the HX100 Heat


1



A Pureheat™ Hydronic Air Heater equipped with HX50 Heat Xchangers

TM should conform to the following system configurations:

and 4-Port Remote Manifolds

• Connect the Four (4) 4-Port Remote Manifolds utilizing any combination [50 ft (15 m) or 100 ft (30 m)] of Circulation Hoses with a maximum overall horizontal run not to exceed 150 ft

(45 m) for each 4-Port Remote Manifold.


Manifolds is 60 ft one way from base unit.

or 4-Port Remote

• Connect Four (4) HX50 Heat Xchangers

HX50 Heat Xchangers

TM

.

TM to each of the Four (4) 4-Port Remote

Manifolds utilizing the 40 ft (12 m) 1/2 in. ID Black Circulation Hoses mounted on the

2.1.1.6 HX50 Heat Xchangers™ with Booster Pump

A Pureheat™ Air Heater equipped with the HX50 Heat Xchangers™, 4-Port Remote Manifolds, optional

Booster Pump and Auxiliary Pump Panel should conform to the following system configurations:

• Connect the Four (4) 4-Port Remote Manifolds utilizing any combination [50 ft (15 m), 100 ft

(30 m) or 200 ft (61 m)] of Circulation Hoses with a maximum overall horizontal run not to exceed 350 ft (106 m) for each 4-Port Remote Manifold.



or 4-Port Remote

• Connect the Four (4) HX50 Heat Xchangers

HX50 Heat Xchangers

TM

.

TM to each of the Four (4) 4-Port Remote

Manifolds utilizing the 40 ft (12 m) 1/2 in. ID Black Circulation Hoses mounted on the

2.1.1.7 Maximum Heat Xchanger™ Connection Capability

Connecting the maximum number of Heat Xchangers™ will not increase the heat delivered to the space

(compared to above stated standard configurations) but will provide increased air circulation.

All Pureheat™ Hydronic Air Heaters are equipped with a 5-Port On-Board Manifold (Circulation Hoses connection points) capable of a maximum connection of five (5) HX200 Heat Xchangers™, ten (10)

HX100 Heat Xchangers™ with Five (5) 4-Port Remote Manifolds, and twenty (20) HX50 Heat

Xchangers™ with Five (5) 4-Port Remote Manifolds.

2.1.2 Optional Booster Pump

All Pureheat™ Hydronic Air Heaters are equipped to accept an optional Booster Pump which requires the use of an Auxiliary Pump Panel for electrical connection to provide safety shutdown of the optional

Booster Pump. (For setup instructions, refer to Section 2.8, CONNECTING/DISCONNECTING

OPTIONAL BOOSTER PUMP.)

2.1.3 Circulation Hose Limitations not create excessively long Circulation Hoses by connecting multiple (more than two) Circulation

Hoses in series. Multiple QCs cause a loss of working pressure and restrict flow.

• Regardless of length, no more than two (2) Supply Circulation Hoses should be connected in series;

• Regardless of length, no more than two (2) Return Circulation Hoses should be connected in series;

• Overall Supply and Return Circulation Hoses should be no more than a combined 400 ft (122 m) in length (with Main Pump);

• Overall Supply and Return Circulation Hoses should be no more than a combined 800 ft (244 m) in length (with optional Booster Pump);

2- 2


V. 2, Rev. 09/01/06


Any Circulation Hoses exposed to the outdoor elements should be insulated for maximum heat delivery into work space. Ground Heaters, Inc. recommends wrapping a cut-to-size Red Wave™ Blanket around exposed Circulation Hoses. Secure the wrapped blankets to minimize air infiltration and heat loss.

Contact your local Ground Heaters Distributor for additional system configuration advice.

2.1.5 Circulation Hose Protection

Do not drive any vehicles or equipment over the Circulation Hoses. If the Hoses must be deployed in high traffic areas, construct ramps or guards to protect from damage.

! HTF may discolor floor surface. Provide extra protection and care to circulation hoses when floor appearance is critical. Place hoses away from high traffic areas

whenever possible.

2.2 PRE-START CHECKS

2.2.1 Positioning

1. Position the Pureheat’s 5-Port On-Board Manifold as close as possible to the space to be heated.

Circulation Hoses can then easily enter and exit the structure.

! The Pureheat must be positioned a minimum of 12 ft (3.6 m) from fuel source or

combustible materials.

2. Chock the wheels to prevent accidental rolling.

3. Use the Heavy Duty Jack-Stand to position the machine as level as possible.

2.2.2 Unloading HX200 Heat Xchangers

TM

1. OPEN the Rear Doors and remove the aluminum Ramp from its storage location above Xchangers TM .

2. Position the Ramp onto the Ramp

Alignment Pins to unload either the left side or the right side HX200s. (Photo 2-1)

NOTE: Each HX200 Heat Xchanger TM is equipped with wheels and fold-out handles.

3. Position the HX200s inside the building per your heating plan. (Refer to Appendix C-1,

Pureheat APPLICATION LAYOUTS.)

NOTE: Each HX200 Heat Xchanger TM must be connected to a separate 15 amp. 120 volts

AC 60 Hz electrical circuit. Use 12-3 extension cords of no more than 100 ft (30 m) in length.

2-1

4. Momentarily turn the BLOWER Switch ON to test Blower operation then turn the BLOWER Switch

OFF.


3


2.2.3 Unloading HX100 Heat Xchangers TM

1. OPEN the Rear Doors and remove the aluminum Ramp from the storage location above Xchangers.

2. Position the Ramp onto the Ramp Alignment Pins to unload either the left side, right side or the middle section HX100s. (Photo 2-2)

NOTE: Each HX100 Heat Xchanger TM is equipped with wheels, Lifting Bail and Lift-Up Handle.

3. Position the HX100s inside the building per your heating plan. (Refer to Appendix C-1, PUREHEAT

APPLICATION LAYOUTS.)

NOTE: Each HX100 Heat Xchanger TM must be connected to a separate 15 amp. 120 volts AC 60 Hz electrical circuit. Use 12-3 gauge extension cords of no more than 100 ft (30 m) in length.

2-2

4. Momentarily turn the Fan Switch ON to test Fan operation then turn the Fan Switch OFF.

2.2.4 Unloading HX50 Heat Xchangers

TM

1. OPEN the Rear Doors and unload the HX50s. (Photo 2-3)

NOTE: Each HX50 Heat Xchanger TM

Handles. The HX50 Heat Xchangers can be lifted by one individual.

is equipped with a Lifting Bail and

TM weigh approximately 70 lbs and

2. Position the HX50s inside the building per your heating plan. (Refer to

Appendix C-1, PUREHEAT APPLICATION LAYOUTS.)

NOTE: Each HX50 Heat Xchanger TM must be connected to a separate 15 amp.

120 volts AC 60 Hz electrical circuit. Use 12-3 gauge extension cords of no more than 100 ft (30 m) in length.

3. Momentarily turn the Fan Switch ON to test Fan operation then turn the

Fan Switch OFF.

2.2.5 Heat Transfer Fluid (HTF)

OPEN the Side Doors and Latch them to the Door Tiebacks

2-3

1. Verify Heat Transfer Fluid (HTF) level is between MIN and MAX lines on the Sight

Gauge Decal located on expansion tank above Hydronic Heater. (Photo 2-4) If fluid level is not above MIN level, refer to Section 4.1, ADDING HEAT TRANSFER FLUID, to correct before attempting to start the Burner or HTF Pump.

! If HTF temperatures are below -15ºF (-26ºC), pre-heat the HTF and

Pump housing before turning the Pump ON.

Positions

(Refer to Appendix A-2.)

Verify the MAIN BREAKER 1, MAIN BREAKER 2, PUMP, BURNER, CAB LIGHT and

HOSE REWIND Switches are in the OFF position on the Main Control Panel.

2-4

2- 4


V. 2, Rev. 09/01/06


2.2.7 Deployment of Circulation Hoses or Option Heat Transfer Hose

(Applies to Pureheat and Hose Handling Systems HHS3004)

The Hose Reel contains Ten (10) 1 in. ID Red Circulation Hoses with QCs [Four (4) at 50 ft (15 m), Four

(4) at 100 ft (30 m), and Two (2) at 200 ft (61 m)].

1. Release the Hose Reel Brake by turning the Brake T-handle counterclockwise

2. Remove the 1 in. ID Red Circulation Hoses with QCs or 5/8 in. ID Black Heat Transfer Hose Loops

(HHS3004) from the Hose Reel. Disconnect each hose Quick-Connect as it is removed from the

Hose Reel.

3. Select the shortest 1 in. ID Red Circulation Hoses and route, one at a time, to provide a supply and return connection to each Heat Xchanger

Board Manifold.

TM

or 4-Port Remote Manifold (if applicable) and 5-Port On-

4. Connect Circulation Hoses to the respective Heat Xchanger TM or 4-Port Remote Manifold (if applicable) Supply and Return connections.

Support the QC on the HX200 Xchanger

TM

with one hand when making these connections to insure good connection. Ensure hoses lay on top of HX200 Heat Xchanger TM once connection is made to avoid HTF restrictions.

5. The HX50 and the HX100 series Heat

Xchangers

Valve #2

TM are equipped with 40 ft (12 m) of ½ in or 5/8 in. ID Black Circulation Hoses permanently mounted and will connect to the 4-Port Remote

Manifolds. Four (4) HX50 or Two (2) HX100 can be connected per 4-Port Remote Manifold).

1. Connect the Main Control Panel Pigtail marked

MAIN POWER 1 to an extension cord connected to one 15 amp 120 volts AC 60 Hz electrical power circuit. Connect the Main Control Panel Pigtail marked MAIN POWER 2 Twist-Lock Male cord end to a Twist-Lock Female cord end extension cord connected to one 20 amp 120 volts AC 60 Hz electrical power circuit. Use only heavy-duty 10-3 extension cords of no more than 100 ft (30 m) in length.

2. Turn the MAIN BREAKER 1 and MAIN BREAKER

2 Switches ON, verify the following: a. LINE 1 and 2 GFI’s remain reset and Amber

Indicator Lights are OFF. b. LOW LEVEL FAULT light is ON for fifteen seconds and then turns OFF. c. Temperature Control (TC) displays HTF temperature in red and desired temperature

(set point) in green numbers.

2-5

Valve #1

Valve #3

Valve #4

Verify all hose, fittings, and pipe connections are not leaking.

V. 2, Rev. 09/01/06

2-6


5


1. Use the UP/DOWN arrow keys to adjust the temperature set-point on the TC to 70°F (21°C). (Refer to

Appendixes A-2 and A-3.)

2. Turn the BURNER Switch ON, then verify the following: a. The Burner Motor starts (after a five second delay) and fires fifteen seconds later. If the Burner fails to start, refer to Appendixes A-12 and A-13. b. The Burner runs clean, quiet and with no visible smoke. If the Burner operation is in question, a qualified service technician should check Burner settings and emissions.

NOTE: Section 4.3, BURNER COMBUSTION VERIFICATION AND ADJUSTMENT, provides detailed

instructions for testing Burner emissions and settings.

2.4.3 Initiating Flow through Heat Transfer Hose

(Refer to Appendix B-1.)

1. Position the following valves as directed below:

a. OPEN the Suction Valve #3. (Photo 2-6)

b. Verify Cross-Connect Valve #5 is OPEN. (Photo 2-13)

c. Verify Return Valve #2 is fully CLOSED. (Photo 2-5)

2. Turn the PUMP Switch ON at the Main Control Panel until the Pump Motor has reached full RPM. The

Dashboard Pressure Gauge will read an approximate 50 psig. Slowly OPEN Return Valve #2, lowering operating pressure, to a minimum of 30 psig on the Dashboard Pressure Gauge for optimum flow rate.

(Photo 2-8)

! If ambient temperatures are below -

15ºF (-26ºC), you must pre-heat the

Pump before turning the Pump ON.

3. Turn each Heat Xchanger™ BLOWER or FAN

Switch ON and verify the thermostat is at the desired set point temperature. Output air temperature will increase as the system warms up.

NOTE: Blowers will not run if the Heat Xchanger™

thermostats are set too low.

2-7

4. Periodically verify proper system operation using the dashboard gauges. Adjust Return Valve #2 so that the

Dashboard Pressure Gauge maintains 30 psig. Min. The Return

Flow Indicator should spin. The HTF return temperature should read approximately 40º to 50ºF (22º to 28ºC) less than the supply temperature (red numbers on the Main Control Panel). (Photo 2-7 and 2-8)

5. Set the TC to temperature required for application.

NOTE: Always set the TC to 180°F (82°C) for thawing, frost prevention and air heating applications. Concrete curing applications

usually require temperature settings below 180ºF (82ºC).

2-8

2- 6


V. 2, Rev. 09/01/06


2.5 OPERATING WITH OPTIONAL ACCESSORIES

The Pureheat has the capability to operate with up to Twenty (20) 750 ft (228 m) Accessory Hose Loops using One (1) Booster Pump, Five (5) Hose Handling Systems 3004 (HHS3004), Five (5) 4-Port Remote

Manifolds and One (1) Auxiliary Pump Panel.

2.5.1 Using Three HHS3004 with Booster Pump for Thawing Applications

(Refer to Appendix B-6.)

Thawing applications require the use of Three (3) HHS3004s with Twelve (12) 750 ft (228 m) Accessory

Hose Loops of 5/8 in. ID Heat Transfer Hose (HTH), One (1) optional Booster Pump, Three (3) 4-Port

Remote Manifolds and One (1) Auxiliary Pump Panel.

1. Install the optional Booster Pump and Auxiliary Pump Panel as directed in Section 2.8,

CONNECTING/DISCONNECTING OPTIONAL BOOSTER PUMP.

2. Place the Three (3) HHS3004s and Three (3) 4-Port Remote Manifolds spaced appropriately on the jobsite for thawing application.

3. Connect the Three (3) 4-Port Remote Manifolds to the 5-Port On-Board Manifold as directed in Step

2.2.7, Deployment of Circulation Hoses.

4. Connect the Accessory Hose Loop 1 Female QC to one of the available 4-Port Remote Manifold

Discharge Male QCs.

5. Remove the Accessory Hose Loop 1 from the HHS3004 Reel and place at job site for thawing application. The QCs joining Accessory Hose Loop 1 and Accessory Hose Loop 2 will be exposed when nearing the end of Accessory Hose Loop 1.

6. Once the QCs have been exposed, separate Accessory Hose Loop 1 and Accessory Hose Loop 2.

Connect the Accessory Hose Loop 1 Male QC to one of the available 4-Port Remote Manifold Return

Female QCs.

7. Connect the Accessory Hose Loop 2 Female QC to one of the remaining 4-Port Remote Manifold

Discharge Male QCs.

8. Remove the Accessory Hose Loop 2 from the HHS Reel and place at job site for thawing application.

The QCs joining Accessory Hose Loop 2 and Accessory Hose Loop 3 will be exposed when nearing the end of Accessory Hose Loop 2.

9. Once the QCs have been exposed, separate Accessory Hose Loop 2 and Accessory Hose Loop 3

QCs. Connect the Accessory Hose Loop 2 Male QC to one of the available 4-Port Remote Manifold

Return Female QCs.

10. Repeat Step 4 through Step 9 for the remaining Accessory Hose Loop 3 and Accessory Hose Loop 4 of the HHS3004.

11. Repeat Step 4 through Step 10 for the remaining Two (2) HHS3004s.

12. Power up the Main Control Panel as directed in Section 2.3, INITIAL POWER UP and start the optional Booster Pump after starting the Main Pump.

! The Booster Pump must be connected to the Auxiliary Pump Panel to maintain low

HTF level protection. Operating the Booster Pump without low HTF level protection could lead to complete loss of system HTF and HTF Pump failure.

2.5.2 Using Five HHS3004 with Booster Pump for Curing and Frost Prevention Applications

(Refer to Appendix B-7 and B-8.)

Curing and Frost Prevention applications require the use of Five (5) HHS3004 with Twenty (20) 750 ft

(228 m) Accessory Hose Loops of 5/8 in. ID Heat Transfer Hose (HTH), One (1) optional Booster Pump,

Five (5) 4-Port Remote Manifolds and One (1) Auxiliary Pump Panel.

1. Install the optional Booster Pump and Auxiliary Pump Panel as directed in Section 2.8,

CONNECTING/DISCONNECTING OPTIONAL BOOSTER PUMP.


7


2. Place the Five (5) HHS3004 and Five (5) 4-Port Remote Manifolds spaced appropriately on the jobsite for thawing application.

3. Connect the five (5) 4-Port Remote Manifolds to the 5-Port On-Board Manifold as directed in Step

2.2.7, Deployment of Circulation Hoses.

4. Connect the Accessory Hose Loop 1 Female QC to one of the available 4-Port Remote Manifold

Discharge Male QCs.

5. Remove the Accessory Hose Loop 1 from the HHS3004 Reel and place at job site for thawing application. The QCs joining Accessory Hose Loop 1 and Accessory Hose Loop 2 will be exposed when nearing the end of Accessory Hose Loop 1.



Female QCs.

7. Connect the Accessory Hose Loop 2 Female QC to one of the remaining 4-Port Remote Manifold

Discharge Male QCs.

8. Remove the Accessory Hose Loop 2 from the HHS Reel and place at job site for thawing application.

The QCs joining Accessory Hose Loop 2 and Accessory Hose Loop 3 will be exposed when nearing the end of Accessory Hose Loop 2.



Female QCs.

10. Repeat Step 4 through Step 9 for the remaining Accessory Hose Loop 3 and Accessory Hose Loop 4 of the HHS3004.

11. Repeat Step 4 through Step 10 for the remaining Four (4) HHS3004s.

12. Power up the Main Control Panel as directed in Section 2.3, INITIAL POWER UP and start the optional Booster Pump after starting the Main Pump in Step 2.4.3.

! The Booster Pump must be connected to the Auxiliary Pump Panel to maintain low

HTF level protection. Operating the Booster Pump without low HTF level protection could lead to complete loss of system HTF and HTF Pump failure.

2.6 MONITORING OPERATING PARAMETERS

The following parameters should be monitored regularly:

1. Fuel Tank Level: Keep track of fuel consumption to plan refueling schedule.

2. HTF Level: Should remain between MIN and MAX lines on the HTF Sight Gauge Decal. (Photo 2-6)

3. HTF Return Temperature(s): During a thaw application, the return temperatures will drop close to the surface temperature before rising rapidly to approximately 100ºF (38ºC). Return temperatures will rise slowly to an approximate 140ºF (60ºC), as the thaw nears completion. During curing applications, the return temperatures should average 5º to 20ºF (3º to 11ºC) above the concrete surface temperature.

During a frost prevention application, the return temperatures will drop close to the surface temperature before rising rapidly to approximately 140°F (60°C). During air heating applications, the return temperatures should be approximately 40ºF (22ºC) below the supply temperature.

4. HTF Supply Pressure: During air heat, thawing, curing and frost prevention applications, the operating supply pressures should be 30 to 50 psig (207 kPa to 345 kPa).

5. Plumbing and Fitting Leaks Always check for leaks during each monitoring period.

2- 8


V. 2, Rev. 09/01/06


1. Turn the BURNER Switch OFF and allow system cool down.

2. Continue running the Main Pump and optional Booster Pump (if applicable) for 15 to 20 minutes to cool the HTF to 120ºF (49ºC) or lower.

3. Turn the Main PUMP and BOOSTER PUMP (if applicable) Switch

OFF.

4. SHUT the Return Valve #2 and Suction Valve #3.

5. SHUT the Cam-Lock Suction Valve #6 and Cam-Lock Return Valve

#7 and Open Cross-Connect Valve #5 (if applicable).

2.7.2 Disconnecting Hoses from Heat Xchangers™ and Pureheat

1. Disconnect the Supply and Return Hose Sets from the 5-Port On-

Board Manifold and the Heat Xchangers™ or 4-Port Remote Manifold (if applicable).

2-9

2. HX50 and HX100 series 1/2 in. ID X 40 ft. Black Hose Assemblies with

QCs wind onto the back of the Heat Xchanger™. (Photo 2-9)

2.7.3 Rewinding the Circulation Hose

1. Fully release Hose Reel Brake (Photo 2-10) by turning the Brake Thandle counterclockwise. Attach the female end of 200 ft Circulation

Hose to the Hose Reel Rewinding Hook (Photo 2-11). Rewind the longest hose lengths first.

2. Turn ON the HOSE REWIND Switch.

3. Rinse QC in a bucket of water to remove any dirt before connecting onto hose reel. (Refer to Appendix B-11 PUREHEAT SAFTEY CONTROLS

QUICK CONNECT AND CAM-LOCK CARE AND MAINTENANCE.

4. Remove the Foot Pedal from storage location and position to allow control of rewind operation. The Foot Pedal should be placed on a piece of plywood or other material to keep it dry.

5. Turn the REWIND MOTOR Switch ON at the Main Control Panel.

2-10

! Always wear gloves to protect hands while rewinding circulation hoses.

6. Depress the Foot Pedal to begin rewinding, and guide the hose evenly onto the Hose Reel. HX200

7. Sequentially connect additional 1 in. ID Red Hose

Assemblies with QC's (200 ft, 100 ft and 50 ft). HX100

2-11

! Rewind the final 10 ft (3 m) of each 1 in.

ID Circulation Hose by hand to prevent

damaging a fitting or hose connection.

HX50

Support Bar

8. Set the Hose Reel Brake by turning the Brake Thandle clockwise when all of the Supply and

2-12

Return Hose Sets have been rewound on the Hose Reel and turn the HOSE REWIND Switch OFF.


9


9. Return Foot Pedal to storage location.

2.7.4 Completing Unit Shutdown

1. Retrieve and reload the Heat Xchangers™ into the trailer. Stow ramp, latch and lock the Rear Doors to secure Heat Xchangers™.

NOTE: If loading a different series of Heat Xchangers™ into the P 1260, refer to Photo 2-12 for proper

positioning of the Heat Xchanger™ Storage Area Cross-Support Bar.

2. Disconnect the optional Booster Pump and Auxiliary Pump Panel as directed in Step 2.8.4.

3. Disconnect fuel supply line(s). NG or LP disconnection requires a qualified technician.

4. Turn the CAB LIGHT, HOSE REWIND, PUMP, BURNER, HTF FILL, MAIN BREAKER 1 and MAIN

BREAKER 2 Switches OFF.

5. Disconnect and remove the power cords; Latch and Lock all remaining Doors.

2.8 CONNECTING/DISCONNECTING OPTIONAL BOOSTER PUMP

(Refer to Appendix A-15 and B-2.)

2.8.1 Connecting

1. Install / connect Auxiliary Pump Panel to the Main Control Panel (Refer to Appendix A-15 and B-2).

NOTE: The Auxiliary Pump Panel ensures that the optional Booster Pump will shutdown if a LOW LEVEL

FAULT condition exists.

2. Place the optional Booster Pump within 6 ft (2 m) of the 5-Port On-Board Manifold.

3. Remove the Suction Cam-Lock Leader Hose, Return Cam-Lock Leader Hose and the Power Cord stowed in the interior of the Booster Pump enclosure.

4. Ensure that Suction Valve #6 and Return Valve #7 are SHUT and LOCKED. (Photo 2-13)

5. Ensure the Auxiliary Pump Panel BREAKER Switch is OFF.

6. Ensure the Main PUMP Switch is OFF at the Main

Control Panel.

7. Remove the Protective Caps from the 5-Port On-

Board Manifold and remove the Cam-Lock Protective

Caps of the Cam-Lock Suction Valve #6 and the

Cam-Lock Return Valve #7.

8. Connect the Booster Pump Suction Cam-Lock Leader

Hose to the Cam-Lock Suction Valve #6 Cam-Lock and connect the optional Booster Pump Return Cam-

Lock Leader Hose to the Cam-Lock Return Valve #7.

!

DO NOT CONNECT THE OPTIONAL BOOSTER

PUMP SUCTION LEADER HOSE AND RETURN

LEADER HOSE WITH THE MAIN PUMP ON.

VERIFY SYSTEM PRESSURE IS AT ZERO (0)

PSIG. PRIOR TO CONNECTION.

Valve #7

Valve #5

9. UNLOCK and OPEN Suction Valve #6 and Return

Valve #7. Shut the Cross-Connect Valve #5.

(Photo 2-13)

2-13

10. Plug the Booster Pump power cord into the Auxiliary Pump Panel Female Pigtail.

Valve #6

2- 10


V. 2, Rev. 09/01/06


11. Connect a heavy duty 10-3 extension cord of no more than 20 ft (6 m) in length into the Auxiliary

Pump Panel Male Pigtail.

12. Connect a 20 amp. 120 volts AC 60 Hz electrical circuit supply (not the same circuit used for the

Pureheat) to the Auxiliary Pump Panel.

NOTE: The Booster Pump should only be started after the Pureheat has been set up and is ready for use.

The Booster Pump will only operate when the Main PUMP Switch is turned ON at the Main Control

Panel. (Refer to Section 2.4, START UP.)

1. Verify Cam-Lock Suction Valve #6 and Cam-Lock Return Valve #7 are in the OPEN position. Verify

Cross-Connect Valve #5 is in the SHUT position. (Photo 2-13).

2. Turn the BURNER Switch ON at the Main Control Panel.

3. Turn the Main PUMP Switch ON at the Main Control Panel.

4. Turn the Auxiliary Pump Panel BREAKER Switch ON.

2.8.3. Shutdown

1. Turn the BURNER Switch OFF.

2. Continue to operate the Main Pump and optional Booster Pump until the HTF has cooled below

120ºF (49ºC).

3. Turn the Main PUMP Switch OFF at the Main Control Panel.

4. Turn the Auxiliary Pump Panel BREAKER Switch OFF.

5. SHUT and LOCK Cam-Lock Suction Valve #6 and Cam-Lock Return Valve #7 and replace the Cam-

Lock Protective Caps. OPEN Cross-Connect Valve #5. (Photo 2-13)

! DO NOT DISCONNECT THE OPTIONAL BOOSTER PUMP SUCTION LEADER HOSE AND

RETURN LEADER HOSE UNTIL HTF HAS SUFFICIENTLY COOLED AND SYSTEM

PRESSURE IS AT ZERO (0) PSIG.

2.8.4 Disconnecting

1. Disconnect the optional Booster Pump Suction Cam-Lock Leader Hose from the Cam-Lock Suction

Valve #6 and connect the Protective Cap at the 5-Port On-Board Manifold.

2. Disconnect the optional Booster Pump Return Cam-Lock Leader Hose from the Cam-Lock Return

Valve #7 and connect the Protective Cap at the 5-Port On-Board Manifold.

3. Connect the Protective Cap on the optional Booster Pump Suction Cam-Lock Leader Hose and

Return Cam-Lock Leader Hose.

4. Disconnect the Booster Pump Power Cord and extension cord. Stow the Booster Pump Power Cord,

Suction Cam-Lock Leader Hose and Return Cam-Lock Leader Hose neatly in the Booster Pump enclosure.

! Verify that Drain Valve #1, Return Valve #2, and Suction Valve #3 are SHUT. Fill Valve

#4, Cam-Lock Suction Valve #6 and Cam-Lock Return Valve #7 must locked SHUT.

Cross-Connect Valve #5 is OPEN. Verify that the Male and Female Cam-Lock fittings on Cam-Lock Suction Valve #6 and Cam-Lock Return Valve #7 are plugged and capped. (Refer to Photos 2-7, 2-8 and 2-13)


11

V. 2, Rev. 09/01/06


BURNER ADJUSTMENT AND SHUTDOWN

The Pureheat™ Hydronic Air Heater can be operated on natural gas (NG), liquid propane vapor (LP) or diesel/fuel oil (OIL). (Refer to Appendix A-24 or A-25 for Burner component identification)

NOTE: All Burners on Pureheat™ are initially calibrated (adjusted) by test firing at Ground Heaters, Inc.’s factory located 600 ft (180 m) above sea level (asl) using NG/LP or a 70/30 blend of#2 and #1 (K1) diesel along with additives.

For NG and LP Burners: The air and/or gas settings are returned to “zero” after factory test firing.

A CERTIFIED AND LICENSED GAS TECHNICIAN MUST RECALIBRATE THE BURNER AIR AND

FUEL SETTINGS TO OBTAIN PROPER COMBUSTION AT YOUR WORK SITE.

1. Burner setup and installation, fuel supply connection, test-firing and Burner adjustment must be performed by a licensed professional and must conform to the requirements of local, state and federal authorities. In the Commonwealth of Massachusetts, gas piping shall be installed

by a licensed plumber or gas fitter.

2. All gas and propane connections must be leak tested prior to placing into service.

4. All NG/LP Burners are test fired at Ground Heaters, Inc.'s factory prior to shipment.

To ensure proper Burner performance and to avoid machine downtime due to heater sooting, Burner combustion verification and adjustment must be performed:

• before starting at a new job site

• before operating at elevations 1,000 ft (305 m) above or below the last adjustment

• after any Burner maintenance has been performed

• after changing fuel from NG to LP or LP to NG

• after removing oil Burner and installing gas Burner

• after removing gas Burner and installing oil Burner

• if Burner performance is in question for any reason

A Combustion Analyzer, Smoke True Spot Tester, Fuel Pressure Test Kit (oil), Low and High range

Manometers (NG/LP) and common hand tools will be required.

3.1 NATURAL GAS/LIQUID PROPANE

Before beginning these steps, it is assumed that the NG/LP Burner and gas train have been installed per

Section 4.2.2.

NOTE: The use of a high quality combustion analyzer and two manometers, one with a range of 0 to 15 in. water column [WC] and one with a range of 0 to 30 in. WC is mandatory. All adjustments must be accomplished by a licensed professional and must conform to the requirements of local, state and federal codes and authorities.

Use air damper settings and fuel pressure adjustments to obtain an Exhaust O smoke spot value of 1 or less. Maintaining O

2

2

value of 3 to 5% and a

in the 3 to 5% range assures that there are no unburned hydrocarbons remaining in the exhaust. Unburned hydrocarbons cause soot production.

If the above values cannot be obtained by adjusting the Burner air dampers alone, it may be necessary to reduce the firing rate (lower fuel pressure). This is especially true at elevations above 3,000 ft (914 m).


1


3.1.1.1 Fuel Pressure Adjustment

1. Ensure that the fuel supply source is OFF.

2. Ensure that the Main Gas Supply Ball Valve is SHUT.

3. Remove the ¼ in. pressure tap plug located in the gas train inlet ball valve body (opposite of the pilot gas cock).

4. Install a ¼ in. petcock and pipe adapter in the location of the pipe plug to facilitate connecting the 0 to

30 in. WC Manometer. Ensure the petcock is SHUT. Do not use pipe dope on this joint.

5. Remove the ¼ in. pressure tap plug located at the end of the “T” fitting just below the gas train union.

6. Install an adapter in the location of the pipe plug to facilitate connecting the 0 to 15 in. WC

Manometer for manifold pressure adjustment. Ensure the petcock is SHUT. Do not use pipe dope on this joint.

7. Loosen the air dampers locking screws enough to provide movement for adjustment. Open the top damper 45% and fully shut the bottom damper. (Refer to Appendix A-24)

8. Turn on the main gas supply.

9. Crack open the installed petcock of the supply line slowly while continuously monitoring gas pressure.

Immediately shut the petcock if the gas pressure climbs past 14 in. WC. Contact your fuel supplier for gas pressure adjustment of no more than 12 to 14 in. WC before proceeding with further adjustment.

10. Once a maximum gas supply pressure of 12 to 14 in. WC has been verified; open the Main Gas

Supply Ball Valve.

11. Remove the protective cap from the Manifold Gas Pressure Regulator to access the regulator adjusting stem.

12. Using a screwdriver, adjust the Manifold Gas Pressure Regulator stem until it is no more than ¼ in. below the threaded opening if using LP or no more than ½ in. below the threaded opening if using

NG. This will avoid over-firing upon initial start up.

13. Open the gas manifold valve.

14. Turn MAIN BREAKER 1 and MAIN BREAKER 2 Switches ON. Allow a 15 second time delay for the low heat transfer fluid (HTF) system to recycle and clear.

15. Ensure that the digital temperature control’s green numbers (temperature set-point) are at least 10º to

20ºF (5º to 11ºC) degrees higher than the red numbers (actual HTF temperature).

16. Turn the BURNER Switch ON.

17. After a 15 second pre-purge, the Burner will begin the ignition sequence; the pilot gas valve will open followed 15 seconds later by the main gas valves (MGV’s).

18. Once the MGV’s open, monitor the manometer connected to the manifold pressure tap and adjust the manifold regulator stem until the following values are obtained: 1.6 to 2.0 in. WC (LP);

2.5 to 3.0 in. WC (NG).

NOTE: Turn the manifold regulator stem clockwise to increase manifold pressure; turn the stem counterclockwise to reduce the manifold pressure.

19. Once the appropriate fuel pressure is set, proceed with air setting and adjustment.

3.1.1.2 Air Setting and Adjustment

Top or bottom air dampers may be opened or closed in amounts sufficient to adjust exhaust 0

2 to 5% using a combustion analyzer.

levels to 3

3- 2


V. 2, Rev. 09/01/06


3.1.1.3 O

2

Content Sampling

1. Follow the combustion analyzer manufacturer’s instructions for pre-purge and exhaust sampling.

2. Sample the exhaust gas by inserting the combustion analyzer sampling probe into the chimney access hole provided through the exhaust guard. The probe must be greater than 5 in. (127 mm) in length for an accurate sampling. Exhaust O

2 soot production.

content must be 3 to 4% for optimum performance and minimum

3. Several samples should be taken as the heater warms. The final sample should be taken just before the heater reaches 180ºF (82.2ºC).

3.1.1.4 Smoke Spot Sampling

1. Follow the smoke spot tester manufacturer’s instructions for accurate exhaust sampling.

2. Start the Burner by turning the BURNER Switch ON. The Burner will start and begin a 45 second prepurge followed by the ignition sequence

3. Sample the Burner exhaust for smoke by inserting the smoke spot sampling probe into the chimney access hole provided through the exhaust guard. The probe must be greater than 5 in. (127 mm) in length for an accurate sampling. Smoke spot production must be 2 or less.


NOTE: Higher O

2

percentage (excess air settings) lowers soot production but raises stack temperature and reduces efficiency. Lower O lowers stack temperature but may cause soot build-up. A Burner optimized for clean and efficient operation will have O

2

2

percentage (inadequate air settings) increases efficiency and

levels of 3 to 4% and a smoke spot value of 1 or less.

5. Loosen the air dampers locking screws enough to provide movement for adjustment. Open the top damper 45%, and fully shut the bottom damper. (Refer to Appendix A-24)

6.. Adjust the air dampers until combustion parameters fall within the above outlined values.

7. Lock the air dampers in place by tightening the locking screws.

Shutdown

1. Shut down the Burner by turning the BURNER Switch OFF.

2. Turn MAIN BREAKER 1 and MAIN BREAKER 2 Switches OFF.

3. Shut the Main Gas Supply Ball Valve. Remove the manometers, petcocks and adapters, and reinstall pipe plugs (use pipe dope).

NOTE: Should the Burner fail to respond during any of the air adjustments or if the fuel pressure cannot be adjusted or drifts, discontinue Burner setup and contact your Pureheat™ Distributor.

Before beginning these steps, it is assumed that the optional diesel Burner has been installed per Section

4.2.1.

NOTE: The use of a high quality combustion analyzer and fuel pressure test gauge is mandatory. All adjustments must be accomplished by an experienced fuel oil Burner professional and must conform to the requirements of local, state and federal codes and authorities.


3


Use air band and shutter settings and fuel pressure adjustments to obtain an Exhaust O and a smoke spot value of 1 or less. Maintaining O

2

2

value of 3 to 4%

in the 3 to 4% range assures that there are no unburned hydrocarbons remaining in the exhaust. Unburned hydrocarbons cause soot production.

If the above values cannot be obtained by adjusting the Burner air band and shutters alone, it may be necessary to reduce the firing rate (lower fuel pressure and/or install a smaller nozzle). This is especially true at elevations above 3,000 ft (914 m).

3.2.1.1. Fuel Pressure Adjustment

1. Disconnect the fuel Quick-Connects.

2. Remove the ¼ in. pressure tap plug located on the top of the Burner fuel pump.

3. Install an adapter to facilitate using a 0 to 300 psi pressure test gauge. Do not use pipe dope.

4. Connect the fuel Quick-Connects.

5. Turn the BURNER Switch ON.

6. The Burner will begin a 15 second pre-purge. Monitor the fuel pressure during the pre-purge and make adjustments using the fuel pressure adjusting screw. (Refer to Appendix A-26)

7. Turn the adjusting screw clockwise to increase fuel pressure or counter clockwise to decrease fuel pressure until it is stable at 150 psig.

8. Once the fuel pressure is set, proceed with air setting and adjustment.

3.2.1.2 Air Setting and Adjustment

Air Band and Shutter may be opened or closed in amounts sufficient to adjust exhaust 0

2 sampled using a combustion analyzer. (Refer to Appendix A-26)

levels as

3.2.1.3 O

2

Content Sampling

1. Follow the combustion analyzer manufacturer’s instructions for pre-purge and exhaust sampling.

2. Sample the exhaust gas by inserting the combustion analyzer sampling probe into the chimney access hole provided through the exhaust guard. The probe must be greater than 5 in. (127 mm) in length for an accurate sampling. Exhaust O

2 minimum soot production.

content must be 3 to 4% for optimum performance and


3.2.1.4 Smoke Spot Sampling

1. Follow the smoke spot tester manufacturer’s instructions for accurate exhaust sampling.

2. Sample the Burner exhaust for smoke by inserting the smoke spot sampling probe into the chimney access hole provided through the exhaust guard. The probe must be greater than 5 in. (127 mm) in length for an accurate sampling. Smoke spot production must be 2 or less.


NOTE: Higher O

2

percentage (excess air settings) lowers soot production but raises stack temperature and reduces efficiency. Lower O lowers stack temperature but may cause soot build-up. A Burner optimized for clean and efficient operation will have O

2

2

percentage (inadequate air settings) increases efficiency and

levels of 3 to 4% and a smoke spot value of 1 or less.

3- 4

4. Loosen the air band and shutter locking screws enough to provide movement for adjustment. (Refer to Appendix A-26)

5. Start the Burner by turning the BURNER Switch ON. The Burner will start and begin a 15 second pre-purge followed by the ignition sequence.


V. 2, Rev. 09/01/06


6. Once the Burner lights, sample the exhaust. Adjust the air band and shutter until combustion parameters fall within the above outlined values.

7. Lock the air band and shutter in place by tightening the locking screws.

! Do not exceed 150 psi fuel pressure

Do not set below 125 psi fuel pressure

1. Shut down the Burner by turning the BURNER Switch OFF.

2. Turn both MAIN BREAKERS OFF.

3. Separate the fuel Quick-Connects and remove the fuel pressure gauge. Reinstall the pressure tap plug.

4. Reconnect the fuel Quick-Connects.

NOTE: You may need to install a smaller nozzle at high elevations or if the ambient temperature falls below

10ºF (-12ºC). The table below shows the approximate firing rate at various fuel pressures with the

5.0 GPH nozzle:

Fuel

Pressure

Firing

Rate psi GPH

125 - 5.59

130 -

5.92

150 -


5


MAINTENANCE

The Pureheat™ Hydronic Air Heater must be operated only with Ground Heaters Heat Transfer Fluid

(HTF).

The standard Pureheat™ contains 145 US gallons (535 liters) of HTF for normal operation. Ground

Heaters, Inc. recommends that the HTF be replaced every three years to ensure that the corrosion inhibitors are sufficiently active to protect the system components.

4.1 ADDING HEAT TRANSFER FLUID

(Refer to Appendix B-10)

NOTE: Shut down all pumps (including optional Booster Pump). (If using optional Booster Pump, refer to Section 2.3.7, Optional Booster Pump.)

4.1.1 To Clear a “LOW LEVEL FAULT”

1. Place an open container of HTF close to the manifold area to facilitate filling. The container must be close enough to allow the 16 ft (4.9 m) fill hose to reach the bottom of the container.

2. Power up the Pureheat™ as directed in Section

2.4, START UP.

3. Ensure that the PUMP and BURNER Switches are OFF.

4. Ensure that a least one section of circulation hose is connected to the supply and return manifolds to complete a circulation loop.

5. Verify that valve #3 is shut.

4-1

6. Verify that valves #2 and #5 are open.

7. Pull out the fill hose (attached to valve #4). Clean the exterior and remove the fill hose dust cap.

8. Remove the locking pin from fill valve #4.

9. Direct the open end of the fill hose into the opening of the HTF container.

10. Momentarily open fill valve #4 until HTF is observed running out of the fill hose. This will “prime” the fill hose.

11. Quickly close fill valve #4 to avoid over filling the HTF container.

12. Cover the open end of the fill hose to retain HTF after priming.

NOTE: If the HTF container height is such that it will not allow gravity flow from the Pureheat™ fill hose, use a separate container with an opening low enough to facilitate priming the fill hose using the method described.

13. Insert the fill hose into the HTF container, ensuring that the hose is not sealed against any interior surface of the container.

14. Open fill valve #4. Immediately lift and hold the HTF FILL Switch to begin filling. (Photo 4-1)

15. Continue filling using the HTF FILL Switch until fluid is observed in the bottom of the sight gauge.

16. The LOW LEVEL RESET button may now be pressed to clear the low level shutdown condition. It is not necessary to stop the filling process during this step. (Refer to Appendix B-10)


4- 1


17. After the Low Level Shutdown device has cycled through a 15 second self test, the low level condition will clear.

18. The PUMP Switch may now be turned ON, and the HTF FILL Switch released to finish filling.

19. Continue filling until the HTF level is between the MIN and MAX as observed in the HTF sight gauge.

Do not over fill.

20. Once adequate HTF levels are verified in the Sight Gauge, remove the Fill Hose from the HTF container but continue running the HTF pump. Elevate and outstretch the Fill Hose to clear excess fluid from the hose.

21. Close fill valve #4 and insert the locking pin. Open Pump Suction Valve #3.

22. Clean the Fill Hose exterior and replace the dust cap. Stow the hose neatly in-between the HTF

Pump and the Supply/Return manifold rack.

NOTE: HTF Low Level Shutdown Device red (Low Water) light will blink for 15 seconds while device performs self-diagnostic tests. After 15 seconds the red light will go out and the green light will stay on, signaling the unit is ready to operate. The red LOW LEVEL FAULT light on the control

panel will also go out.

4.2 BURNER INSTALLATION/CHANGEOVER

4.2.1 From NG/LP to Diesel/Fuel Oil

1. Burner setup and installation, fuel supply connection, test-firing and Burner adjustment should be performed by an experience fuel oil Burner professional and must conform to the requirements of local, state and federal authorities.

2. Main heater unit (trailer) must not be installed within 12 ft (3.6 m) of combustible materials.

3. To ensure proper Burner performance and to avoid machine downtime due to heater sooting, Burner combustion verification and adjustment must be performed:

• Before starting at a new job site.

• Before operating at altitudes 1,000 ft (305 m) above or below the last adjustment.

• After any Burner maintenance has been performed.

1

• After installing any Burner, even if it had been previously used and calibrated.

• If Burner performance is in question for any reason.

4. A Combustion Analyzer, Smoke True Spot Tester and common hand tools will be required.

4.2.1.1 Installation (Photo 4-2)

2

3

NOTE: All CF800 oil Burners are shipped by Ground Heaters,

Inc. with the proper nozzle (5.0 GPH 60º solid) installed

and the fuel pressure set at 150 psi.

4-2

1. Slide the flange gasket over the Burner air tube and align the gasket with the mounting flange holes.

1. Burner Mounting Flange

2. Burner Air Tube

3. Burner Fuel Pump

2. Install the ½ in. insulation and the Burner mounting plate for the oil Burner (supplied when you purchase an oil Burner) on the hydronic heater.

3. Insert the Burner air tube into the hydronic heater and install the four bolts which have been supplied.

4- 2


V. 2, Rev. 09/01/06


4. Using the supplied 1¼ in. x 5 /

16

in. bolts, washers and nuts, install the Burner support bracket on the trailer floor below the Burner. Extend the adjusting rod such that the round pad firmly contacts the underside of the blower housing on the Burner. Tighten the jam nut to keep the support rod from backing off.

5. Attach the 3-pin Quick-Connect Fuel Line power cord leading from the Main Control Panel to the mating part located just below the Honeywell controller on the Burner.

6. Connect the Pigtails for the Burner Inline Fuel Heater. The Male portion is attached to the Burner and the female portion is attached to the Main Control Panel.

7. Route the Supply and Return Fuel Lines from the Fuel Tank through the 5 in. (127 mm) square access hole in the trailer floor below the Burner.

8. Using the Quick-Connect and hose barb supplied with the Oil Burner, attach the Supply Fuel Line to the Fuel Filter on the Burner.

9. Attach the Return Fuel Line to the return hose Quick-Connect and hose barb on the Burner.

4.2.1.2 Setup

1. Set the Burner Air Band at 6 and Air Shutter at 6. These initial air settings will be fine tuned later.

2. With fuel in the remote tank, power up the Pureheat™ control panel as directed in Section 2.4,

START UP.

3. After the low level device runs through its self diagnostic cycle, the Burner should pre-purge and then light. The oil primary control on the Burner may have to be re-set several times for the initial start up to purge air out of the fuel supply line.

4. Follow procedures in Sections 3.2.1.1 through 3.2.1.4 to complete Burner adjustment.

4.2.2 From Diesel/Fuel Oil to NG/LP

1. Burner setup and installation, fuel supply connection, test-firing and Burner adjustment should be performed by a licensed professional and must conform to the requirements of local, state and federal authorities.

2. All gas and propane connections must be leak tested prior to placing into service.

3. Main heater unit (trailer) must not be installed within 12 ft (3.6 m) of combustible materials.

4. All gas Burners are test fired at Ground Heaters, Inc.'s factory prior to shipment.

5. To ensure proper Burner performance and to avoid machine downtime due to heater sooting, Burner combustion verification and adjustment must be performed:

• Before starting at a new job site.

• Before operating at altitudes 1,000 ft (305 m) above or below the last adjustment.

• After any Burner maintenance has been performed.

• After installing any Burner, even if it had been previously used and calibrated.

• If Burner performance is in question for any reason.

6. A Combustion Analyzer, Smoke True Spot Tester and common hand tools will be required.

!

Do not exceed 14 in. water column gas supply pressure. Excessive pressure will damage the gas train components.

NG: Do not exceed 3.0 in. water column manifold pressure, as this will over-fire the heater and cause damage.

LP: Do not exceed 2.0 in. water column manifold pressure, as this will over-fire the heater and cause damage.

4- 3



4.2.2.1 Installation

(Refer to Appendix A-24)

1. Remove the trailer enclosure lower panel located below the trailer's left side door adjacent to the fender (to provide unrestricted access to the Burner mounting plate on the Pureheat™ Hydronic Air

Heater). (Photo 4-3)

2. Verify that the gasket is properly positioned on the mounting flange and Burner blast tube.

3. Insert the blast tube into the hydronic heater Burner mounting plate and attach with the four bolts which have been supplied. The Burner should be oriented with the Power Flame Model JR30A-12 label oriented right side up.

4-3

4. Using the supplied 1¼ in. x 5 /

16

in. bolts, washers and nuts, install the Burner support bracket on the trailer floor below the Burner. Extend the adjusting rod such that the square pad firmly contacts the Burner support flange. Tighten the jam nut to keep the support rod from backing off.

5. Reinstall the enclosure panel next to the fender.

6. Attach the 3-pin Quick-Connect Burner power cord leading from the Main Control Panel to the connection socket located just behind the blue Honeywell™ Burner control.

7. Attach the gas train at the pipe union (secure to gas train mounting bracket), with the horizontal portion of the gas train extending toward the tongue of the trailer. Do not use pipe dope on this joint.

8. Attach the 2-pin Quick-Connect power cord leading from the Burner control to the electrical junction box mounted on the gas train.

9. Connect the 90º end of the braided pilot gas line to the fitting provided on the left side of the gas train. do not use pipe dope on this joint.

10. Verify that the two ball valves and the pilot valve on the gas train are turned OFF.

11. Attach the 36 in. x ¼ in. poly vent hose to the main gas pressure regulator vent and route it outside through the 5 in. (127 mm) square access panel in the floor.

12. Attach the 17 in. x ¼ in. poly vent hose to the pilot pressure regulator and route it outside through a slot in the trailer floor along the left side of the trailer.

13. Attach the NG or LP gas supply line to the main gas inlet fitting at the left side of the gas train.

This gas line should enter the trailer through the 5 in. (127 mm) square access panel in the floor of the trailer.

4.2.2.2 Setup

1. Open the top Burner air inlet damper 100 percent. The bottom air inlet damper should be completely closed. This initial setting will be fine tuned later.

2. Follow procedures located in Sections 3.1.1.1 through 3.1.1.4 to complete Burner adjustment.

!

Do not turn on the gas at this time.

NOTE: The gas supply line must be sized such that it is capable of providing a minimum of 860 CFH NG

(or 344 CFH LP vapor) at 5 to 14 in. water column pressure.

4- 4


V. 2, Rev. 09/01/06


1. The following procedures are recommended when operating the Pureheat™ at altitudes higher than

5,000 ft (1,524 m) asl. These procedures keep the Pureheat™ running smoothly and prevent the possibility of premature soot build-up inside the hydronic heater fire tubes. ALL PROCEDURES

LISTED BELOW SHOULD BE PERFORMED BY CERTIFIED PERSONNEL AT YOUR GROUND

HEATERS DISTRIBUTOR.

2. When operating the Pureheat™ at high altitudes, the hydronic heater should be checked every 500 hours for sooting or other combustion abnormalities. Combustion Analyzer and Smoke Spot Tester must be used for this test.

3. In addition to air adjustments, fuel pressure may be reduced to a lower pressure. To decrease fuel burning rate, refer to Section 3, BURNER ADJUSTMENT AND SHUTDOWN for fuel pressure adjustment instructions.

NOTE: Always verify Burner exhaust O

2

and smoke levels after completing any adjustments to fuel pressure as directed in Section 3.1.1, Gas Burner Adjustment or 3.2.1, Diesel Burner Adjustment.

1. Pureheat™ Hydronic Air Heaters are typically used outdoors, in cold weather.

! Care must be taken in selecting a fuel blend which will work properly in your jobsite conditions.

2. Diesel fuel will thicken (gel) at low temperatures. Gelling (also known as waxing) may cause the

Burner not to light and/or fuel pump damage.

Contact for diesel fuel vary from terminal to terminal. Some fuel suppliers may add products such as

ValveTect to prevent gelling or Diesel 911 after gelling has occurred. Your fuel supplier should supply this information and make recommendations for the selection and use of such products.

4. If ambient temperatures are such that your fuel supplier cannot insure the fuel will not gel, K1

Kerosene or #1 diesel fuel (dyed K1 for off-road use) must be added by ratio until gelling does not occur.

5. Refer to the Fuel Blend Guide, below; consult your fuel supplier for assistance in calibrating these values to your fuel.

DIESEL FUEL SELECTION

Low overnight ambient air temperatures can cause diesel fuels to gel.

Gelled fuel will cause the Burner not to light and/or fuel pump damage.

ALWAYS USE THE PROPER FUEL

LOWEST EXPECTED

AMBIENT AIR TEMPERATURE

PROPER

FUEL

5ºF AND BELOW

5ºF TO 25ºF

ABOVE 25ºF

100% #1 DIESEL

OR

100% K-1 KEROSENE

50% #2 DIESEL

+ BLEND

50% #1 DIESEL

WINTER BLEND DIESEL

Require your fuel supplier to guarantee that the fuel supplied will not gel at the lowest temperature which will be experienced at your work site.

4- 5



4.5 SUMMER STORAGE INSTRUCTIONS

1. Allow the heater to cool sufficiently. Cover the chimney and the Burner with plastic wrap or other waterproof material. This will prevent corrosive moisture build-up and blockages caused by animal nests. Burners not installed should be stored in a cool, dry place.

2. Remove emergency break-away battery and store the battery in a cool, dry place. Connect the battery to a trickle charger once every 30 days to maintain full charge.

3. Perform a thorough inspection for leaks, and correct. Double-check that all valves are shut.

4. Ensure all manifold Quick-Connect covers are in place and secured.

5. Shut and lock all doors.

6. Protect the tires from direct sunlight if stored outdoors.

NOTE: Do not drain the HTF. The heater and plumbing must remain flooded with HTF to prevent corrosion (rusting).

(Refer to Section 3 of the Service Manual for detailed instructions.)

1. Remove all waterproof wrapping or covering from the chimney and Burner.

2. Test and reinstall emergency break-away battery.

3. Remove the Flue Access Door to inspect the Hydronic Heater Interior and fire tubes. Clean out any soot or flaked material. Remount the Flue Access Door.

For Oil Burners: Remove the Burner electrode assembly. Replace the nozzle with an exact replacement. Adjust or replace the electrodes as necessary.

4. Remove the Burner to inspect and clean the flame head.

5. Replace fuel filter element.

6. Reinstall the electrode assembly and verify the “Z” distance is correctly set.

7. Remount Burner using a new Burner mounting gasket.

8. Adjust Burner settings as directed in Section 3, BURNER ADJUSTMENT AND SHUTDOWN.

9. Verify HTF level.

4- 6


V. 2, Rev. 09/01/06


TRANSPORTING THE PUREHEAT TM HYDRONIC AIR HEATER

This section describes the three basic methods of Pureheat

TM associated precautions.

Hydronic Air Heater transport and

5.1 TOWING

Pureheat

TM

is easily towed by a vehicle rated to tow up to 8,500 lbs (3,855 kg) (HX Package) or

11,300 lbs (5125 kg) for the fuel tank package. The tow vehicle must be fitted with a Class V or above hitch. (Photo 5-1)

The Pureheat TM has a tongue weight of 895 to 1,446 lbs (405 - 657 kg) depending on configuration.

Towing vehicle must be equipped with an electric brake system controller.

NOTE: A trailer plug wiring decal is located on the inside frame wall across from the trailer junction box.

(Refer to Appendix A-22 and Appendix A-23)

5-1

!

The Pureheat TM is equipped with a lifting bail. The lifting bail has multiple holes to provide balance with various configurations.

A qualified rigger should set up and perform all rigging.

5.3 TRANSPORTING on a FLATBED

Pureheat TM may be loaded onto a 98 in. (250 cm) or wider flatbed using common-sized loading ramps and docks. The Pureheat


TM

should be chained down to the flatbed trailer.

5.4 COMMON MECHANICAL INSPECTIONS PRIOR TO TRANSPORTING

1. Trailer lights, brakes, wiring and wheel bearing inspection.

2. Tires inflated to proper pressure and free of defects.

3. Plumbing, internal and field hose integrity check.

4. Lug nuts torque value is as directed on wheel decal. (Photo 5-2)

6

8

4

1

2

3

7

5

!

WARNING

FAILURE TO FOLLOW THESE INSTRUCTIONS

MAY RESULT IN WHEEL LOSS WHICH CAN

CAUSE INJURY OR DEATH !

TORQUE WHEEL NUTS TO 90–120 LB- FT

BEFORE FIRST ROAD USE. RETORQUE TO

90–120 LB-FT AFTER 10, 25 AND 50 MILES.

CHECK PERIODICALLY THEREAFTER .

5-2

!

WARNING

FAILURE TO FOLLOW THESE INSTRUCTIONS

MAY RESULT IN WHEEL LOSS WHICH CAN

CAUSE INJURY OR DEATH!

TORQUE WHEEL NUTS TO 90–120 LB-FT

BEFORE FIRST ROAD USE. RETORQUE TO

90–120 LB-FT AFTER 10, 25 AND 50 MILES.

CHECK PERIODICALLY THEREAFTER.

Torque the wheel lug nuts sequentially as shown.

Torque to the values listed on the

Warning decal located on the wheel.

5-1



TROUBLESHOOTING

(Contact your local Ground Heaters Distributor for situations not covered in this section.)

NOTE: Discontinue troubleshooting activities and shut down the Pureheat™ Hydronic Air Heater if one of the following occurs:

1. One of the GFIs trips and will not remain reset.

2. An electric motor "hums" but does not turn.

3. The Burner Safety will not reset when the MANUAL RESET button is pushed.

4. Dark smoke emits from the hydronic heater exhaust.

Once the Pureheat™ is shut down; call your local Ground Heaters Distributor for assistance.

Symptom

Heat transfer fluid pump will not start.

Heat transfer fluid pump turns but does not start.

Heat transfer fluid pump turns but trips breaker.

Burner motor will not start.

Possible Cause Corrective Action

• Verify both MAIN BREAKERS are ON.

• Verify both GFIs are reset.

No power due to incorrect switch position or protective function.

• Verify LOW LEVEL FAULT light is not lit.

Motor internal overload is tripped.

• Verify HTF level is between MIN and MAX.

• Allow motor to cool; it will reset automatically.

• Have an electrician verify voltage at control panel is 110 volts (min.) while attempting to start pump motor.

Low voltage caused by inadequate power supply; poor quality; or excessively long extension cords.

• Ensure power cords are at least 10 gauge wires and ≤ 100 ft (30.5 m) in length.

• Verify power cords are supplied by separate 20 amp 120 volts AC 60 Hz electrical power circuits.

HTF too cold (-20ºF [-28.9ºC]). • Warm HTF pump.

HTF too cold. • Warm HTF pump.

Low Voltage.

Pump pressure below 30 psi.

Insufficient power supply.

Power supply sufficient but no power to burner motor.

Refer To

Appendix

A-2

Section 2

- - - - - - -

- - - - - - -

• Correct low voltage.

• Throttle valve #2.

• Have an electrician verify voltage at burner motor is 110 volts (min.) while attempting to start burner motor.

• Ensure power cords are at least 10 gauge wires and ≤ 100 ft (30.5 m) in length.


• Call your Ground Heaters Distributor.

- - - - - - -

- - - - - - -

Section 2.4

- - - - - - -

- - - - - - -


6- 1


Symptom Possible Cause

• Verify HTF level is between MIN and MAX level.

• Verify LOW LEVEL SHUTDOWN DEVICE is RESET.

Corrective Action

• Verify both MAIN BREAKERS are ON.

• Verify both GFIs are reset.

• Verify LOW LEVEL FAULT light is not lit.

Burner motor will not start

( . . .continued)

Improper switch position or protective function action.

Burner safety trips (no flame).

Burner Safety is tripped as indicated by DIAGNOSTIC light on burner control.

• Reset burner safety.

No fuel.

• Verify fuel supply is adequate.

• Verify both fuel line Quick-Connects are connected (oil burner).

Insufficient voltage for ignition.

• Have an electrician verify voltage at control panel is 110 volts (min.) while attempting to start burner.

• Ensure power cords are at least 10 gauge wire and ≤ 100 ft (30.5 m) in length.


Refer To

Appendix

A-2

Section 2

Appendix

A-18

Appendix

A-10 or A-13

- - - - - - -

Section

4.2.1.1

- - - - - - -

Burner safety trips

(flame occurs).

Control not sensing flame. • Call your Ground Heaters Distributor. - - - - - - -

Heat exchanger blower will not start.

• No electrical power.

• Thermostat or speed selector setting incorrect.

• Verify 120 volts AC to heat exchanger.

• Set thermostat above room temperature.

• Set speed selector to desired fan speed.

- - - - - - -

Hoses will not rewind.

Brake not fully released.

Rewind motor is too cold

(rewind motor may not start if below 0ºF [-18 °C]).

• Fully release hose reel brake.

• Warm rewind motor.

Section

2.6.3

- - - - - - -

Faulty foot pedal. • Call your Ground Heaters Distributor. - - - - - - -

If problem is not resolved by performing the above steps, call your Ground Heaters Distributor for assistance.

6- 2


V. 2, Rev. 09/01/06


6.2 HTF LOW LEVEL FAULT AND LIGHTS


Perform the following when HTF LOW LEVEL FAULT light (refer to control panel) is it: (Photo 6-1)

1. Turn BURNER, PUMP and REWIND MOTOR switches OFF.

2. Locate and correct cause of low HTF condition (i.e. fix the leak).

3. Restore HTF level to normal operating level per Section 4.1, ADDING HEAT TRANSFER FLUID.

4. Depress MANUAL RESET button to clear low level condition. Reset will complete in 15 seconds.

NOTE: Call your Ground Heaters Distributor if HTF level is between MIN and MAX and:

• Low Level Shutdown device will not reset;

• LOW LEVEL FAULT light (refer to control panel) remains on after depressing the Low level

Shutdown device RESET button; or

• Burner control locks out the burner and will not remain reset.

6.2.1 Low Level Shutdown Device

The LOW LEVEL FAULT light is activated for 15 seconds after initial power up and then goes out.

Reset is accomplished by pressing the RESET button for 1 to 2 seconds or by momentarily shutting

OFF BREAKER 1.

6.2.2 Testing the Low Level Shutdown Device

Power up the main control panel by following the steps outlined in Section 2.4, START UP.

Observe the LOW WATER and POWER lights on the bottom of the Low Level Shutdown Device.

Ensure that the Green POWER light is ON and the

Red LOW WATER light is OFF.

6-1

LOW LEVEL FAULT

Press and hold the TEST button while monitoring the red LOW WATER light.

The red LOW WATER light will flash 10 times followed by the main control panel LOW WATER light will be on.

The green POWER light and the LOW WATER light will both be ON.

Verify that the LOW LEVEL FAULT light is ON at the main control panel.

Turn the PUMP and the BURNER switches ON one at a time at the main control panel to verify that the

PUMP AND BURNER ARE NOT OPERATIONAL.

RESET

Turn the PUMP and BURNER switches OFF.

Momentarily press the RESET button. The LOW WATER and POWER lights will flash simultaneously 4 times and the POWER light will return to normal operating mode. The LOW WATER light will continue to flash an additional 14 times and return to normal operating mode. The POWER light will be ON, the LOW

WATER light will be OFF and the LOW LEVEL FAULT light at the main control panel will be OFF.

Turn the burner switch ON and the burner will start after a five second delay. After the burner starts, turn the BURNER switch OFF.

Turn the pump switch ON and the pump will start immediately. Turn the PUMP switch OFF.

If the test does not conform to the instructions and results as outlined above, call your Ground Heaters distributor.


6- 3


6.3 BURNER CONTROL LOCKOUT

(Refer to Appendix A-13 or A-8 through A-14)

6.3.1 Gas Burner Control

The POWER light will illuminate only during the heating cycle. After flame is established, the POWER,

PILOT, MAIN and FLAME lights should all be illuminated.

If flame failure of any nature is sensed during the start up or heating cycle, the control will stop all burner function and begin Lockout mode.

• ALARM light will illuminate

• PILOT, FLAME and MAIN lights will go out.

Momentarily press the RESET button to clear the lockout condition.

6.3.2 Oil Burner Control

The DIAGNOSTIC light (green LED) will illuminate during the heating cycle after the 15 second pre-purge time has elapsed and flame has been established.

If flame failure is sensed during the start up or heating cycle, the control will stop all burner function and begin one of three protective modes:

The DIAGNOSTIC light will flash in two second intervals while attempting three automatic restarts. If the flame fails after three successive attempts, the control will go into Lockout mode.

The DIAGNOSTIC light will flash in one-half second intervals.

The RESET button must be momentarily pressed to clear the lockout and attempt a burner restart.

After three attempts to manually clear the lockout mode, the control will begin Restricted Lockout mode.

3. Restricted Lockout Mode

The DIAGNOSTIC light will flash in one-half second intervals.

The RESET button must be pressed and held for 30 seconds or until the DIAGNOSTIC light comes on for two seconds and then goes out.

The control will return to Restricted Lockout mode with each flame failure until one successful heating cycle has occurred.

6- 4


V. 2, Rev. 09/01/06

SCHEMATIC AND WIRING DIAGRAM SYMBOL LEGEND

PUSH BUTTON SWITCH, MOMENTARY, NORMALLY OPEN: A momentary push button switch that CLOSES on activation (makes contact when pushed) such as the LOW OIL PRESSURE OVERRIDE Switch

PUSH BUTTON SWITCH: A two position push button switch such as the EMERGENCY STOP Switch

PRESSURE SWITCH, MAKES ON RISE: A pressure operated switch that CLOSES (makes contact) on an increase in pressure.

THERMOSTAT, MAKES ON RISE: A temperature operated switch that CLOSES (makes contact) on an increase in temperature

THERMOSTAT, BREAKS ON RISE: A temperature operated switch that OPENS (discontinues contact) on an increase in temperature

GROUND: May be used to show a frame (chassis) ground or a neutral connection.

NORMALLY CLOSED CONTACTS (N.C.): Relay contacts that are SHUT (making contact) when the relay coil is not powered or energized.

NORMALLY OPEN CONTACTS (N.O.) : Relay contacts that are OPEN (not making contact) when the relay coil is not powered or energized.

TOGGLE SWITCH, TWO POSITION: An ON – OFF – ON bat handled switch such as the REWIND CLUTCH switch.

TOGGLE SWITCH: An OFF or ON bat handled switch such as the BURNER switch.

MOMENTARY TOGGLE SWITCH: A bat handled switch that automatically returns to the OFF position when released.

THERMAL FUSE: A fuse, motor overload or other heat reactive protective switch

RESISTIVE LOAD: Relay coils, resistance heaters, resistors.

V. 2, Rev. 09/01/06

SNAP DISC, MAKES ON RISE, AUTO RESET: A bi-metal disc that CLOSES a switch should the temperature of the media it is sensing reach the set point (usually fixed). The Switch will return to its normal position after the temperature drops to a pre-determined level.

SNAP DISC, BREAKS ON RISE, MANUAL RESET: A bi-metal disc that OPENS a switch should the temperature of the media it is sensing reach the set point (usually fixed). The Switch can be reset only after after the temperature drops to a pre-determined level.

This type of switch is commonly used as a high limit.

SNAP DISC, OPENS ON RISE, AUTO RESET: A bi-metal disc that OPENS a switch should the temperature of the media it is sensing reach the set point (usually fixed). The Switch will return to its “normal” position after the temperature drops to a pre-determined level.

This type of switch is commonly used as a high limit.


A – 1a


xx

1

BLK

RED

WHT

1

1

1

TERMINAL STRIP CONNECTION POINT: Provides a transitional connection from Main Control Panel internal wiring and Main Control

Panel exterior wiring. Note: Terminal strip connection point numbers are the same as the wires attached

TERMINAL IDENTIFIER: Identifies specific terminals on components with labeled terminals.

WIRE COLOR DESIGNATION: Identifies wire colors.

COLOR AND WIRE NUMBER DESIGNATIONS: Identifies wires by number and color to simplify troubleshooting.

CONNECTION POINT: A general connection point symbol used primarily on schematics to represent common connections such as wire nuts, lug screws or piggy-backed disconnects.

0 CR-1 1 GENERIC LOAD: Relays, Motors and electrically operated valves etc.

YELLOW WIRE NUT: Used to connect several wires. It is larger than the common orange wire nut and typically used with up to six 16 –

18 gauge wires.

ORANGE WIRE NUT: Used to connect two or more 16 – 18 gauge wires.

WIRE CAGES: Used to connect up to five 16 – 18 gauge wires.

DUPLEX OUTLET: A receptacle used to plug in various loads such as a strobe light, Pump Pack or small resistance heaters..

1

5

2

3

4

ROTARY SWITCH: A common selector switch for various functions such as multi speed motors.

WIRE JUMP: Used to show wires that are adjacent but are not connected to each other.

A – 1b

CONNECTION POINT: Used to show wires that are connected to each other by common means such as a lug, wire nut or crimp-on connector.

© 2006

Ground Heaters, Inc.

V. 2, Rev. 09/01/06


CAPACITOR: Used to add starting torque and efficiency to single phase electric motors.

Capacitors are rated by Microfarad (µf or mfd) and volts i.e.: 10 µf 370V = Ten Microfarads x Three Hundred Seventy Volts.

FNM-3

FUSE: Single use glass or fiber case fuses commonly used in electrical circuitry.

Their capacity is listed in the type number of the fuse i.e FNM-3 is a fuse with a Three Amp rating.

STEP DOWN TRANSFORMER: Used in GHI equipment to reduce 120 Volts AC to 12.6 Volts AC.

IGN. TRANS.

IGNITION TRANSFORMER: Increases 120 Volts AC up to 30,000 Volts to generate the high energy spark required to ignite fuel.

CB-2

20A

LINE

MAGNETIC CIRCUIT BREAKER: Trips when the electrical energy level through the breaker generates electromagnetic force in amounts sufficient to activate a mechanical (electromagnetic) device to force the Switch OPEN.

LOAD

CB-2

20A

LINE

OR

CB-2

20A

LINE

THERMAL CIRCUIT BREAKERS: Trips when the electrical energy level through the breaker generates heat in amounts sufficient to activate a thermo-mechanical (Bi-Metal) device to force the Switch OPEN.

LOAD LOAD

V. 2, Rev. 09/01/06

BATTERY: Typically 12 Volts DC batteries are used to start Generators or to provide power for Electric Trailer Brakes.

COMMON WIRE COLORS

BLK = BLACK

RED = RED

WHT = WHITE

GRN = GREEN

BLU = BLUE

YEL = YELLOW

ORG = ORANGE

VIO = VIOLET

BRN = BROWN

PNK = PINK

© 2006

Ground Heaters, Inc.

A – 1c

PUREHEAT CONTROL PANEL EXTERIOR LAYOUT

MAIN

BREAKER 1 o

ON OFF

0 0 0 0

HOURS

0 0

LINE1GFI

BURNER

FAULT

LOW LEVEL

FAULT

WARNING

REFER TO OPERATOR

MANUAL

TO CLEAR

FAULTS

ON ON ON

FUJI

ELECTRIC

C1 C2

AL

1

AL

2

AL

3

PV

F

SV

PXR-4

TEMPERATURE

CONTROL

ON ON

OFF

HTF FILL

OFF

PUMP

OFF

BURNER

OFF

HOSE

REWIND

OFF

CAB

LIGHT

MAIN

BREAKER 2 o

ON OFF

LINE 2 GFI

A - 2


V. 2, Rev. 09/01/06

PUREHEAT TEMPERATURE CONTROL

A HEATING DEMAND INDICATOR

B PROCESS VALUE (HTF TEMPERATURE)

C SET-POINT VALUE (DESIRED TEMPERATURE)

D

E

-

+

NOT USED

DISPLAY DURING THERMOCOUPLE

(SENSOR) CONNECTION LOSS

DECREASE TEMPERATURE

INCREASE TEMPERATURE

B

C

A

FUJI

MODEL PXR-4

FUJI

ELECTRIC

C1 C2 AL1 AL2 AL3

F

PV

SV

SEL

PXR-4

D + -

E

FUJI

ELECTRIC

C1 C2 AL1 AL2 AL3

F

PV

SV

SEL

FUJI

ELECTRIC

C1 C2 AL1 AL2 AL3

F

PV

SV

SEL

WIRE #1,1 120 VOLTS

WIRE #2,2 NEUTRAL

4

5

6

FUJI TEMPERATURE

CONTROL WIRING

1 7 13

2 14

3

8

9 15

10

11

12

16

17

18

WIRE #1 120 VOLTS

WIRE #22 TO RELAY COIL CR2

THERMOCOUPLE + (BLUE)

THERMOCOUPLE – (RED)

V. 2, Rev. 09/01/06


A - 3

PUREHEAT CONTROL PANEL DOOR INTERIOR LAYOUT

2

27

BURNER

FAULT LIGHT

HTF FILL

SW.

1,1

9,9

PUMP

SW.

19

9

BURNER

SW.

14

HOSE REWIND

SW.

18

CAB LIGHT

SW.

1,1

21 15 5

2

20

LOW LEVEL

FAULT LIGHT 1,1

2

4

5

6

1

2

3

TEMPERATURE

CONTROL

17

18

15

16

13

14

7

8

9

10

11

12

1

22

BLU

RED

1

LINE 1 GFI

2

MAIN

BREAKER 1

L3

2, 2

13

WIRE NUMBERS SHOWN IN BOLD

MAIN

BREAKER 2

L4

26

LINE 2 GFI

17

L3 N1

HOURS

L4 N2

L1 L2

G G

A - 4


V. 2, Rev. 09/01/06

PUREHEAT MAIN CONTROL PANEL

EXTERIOR COMPONENT FUNCTION AND IDENTIFICATION

DOOR COMPONENTS

BREAKER 1 CURVE 10 15 AMP. (P/N E100-354):

Provides ON and OFF power control and circuit protection for electrical circuit one.

BREAKER 2 CURVE 10 20 AMP. (P/N E100-123):

Provides ON and OFF power control and circuit protection for electrical circuit two.

LINE 1 GFI (P/N E100-093):

A Ground Fault Circuit Interrupter (GFI) which provides operator protection for electrical circuit one.

LINE 2 GFI (P/N E100-093):

A Ground Fault Circuit Interrupter (GFI) which provides operator protection for electrical circuit two.

HOUR METER (P/N E100-096):

A meter to record total hours of use. The Hour Meter functions only when the BURNER Switch is turned ON and does not reflect actual burner run time.

TEMPERATURE CONTROL (P/N E100-084):

Provides ON and OFF control of the Burner based on set-point (desired temperature) as well as primary high and low temperature limit functions. The digital display panel indicates the Heat Transfer Fluid (HTF) temperature in red, the set-point (desired temperature) in green and output indication (demand for heat) by illuminating the C1 light in the upper left of the display panel. Set-point is adjusted using the UP and DOWN arrow Keys located below the display panel.

BURNER FAULT LAMP (P/N E100-353):

Indicates the Burner Control has sensed flame failure and has entered BURNER FAULT mode. All Burner functions are disabled during

BURNER FAULT mode except for the Inline Fuel Heater (oil burner only) which is powered directly by the BURNER Switch.

LOW LEVEL FAULT LAMP (P/N E100-353):

Indicates that the Low Level Shut Down Device sensed an HTF loss and has entered LOW LEVEL FAULT mode. All Burner and Pump functions are disabled except for the Inline Fuel Heater (oil burner only) which is powered directly by the BURNER Switch.

HTF FILL SWITCH (P/N E100-230):

Used to operate the Pump during a LOW LEVEL FAULT to effect re-filling of HTF.

PUMP SWITCH (P/N E100-101):

Provides operation and control of the HTF Pump.

BURNER SWITCH (P/N E100-101):

Provides ON or OFF power control to the Burner.

REWIND MOTOR SWITCH (P/N E100-101):

Provides ON or OFF power control to the Rewind Motor.

CAB LIGHT SWITCH (P/N E100-101):

Provides ON or OFF power control to the Interior Cab Light.

V. 2, Rev. 09/01/06


A - 5

A - 6


INTERIOR COMPONENT LAYOUT

25

18

1

1

1

FUSE 2 3AG 5.0-SB

P/N E100-356

7

8

9

10

25

4

5

6

2

2

2

2

3

17

18

24

26

L2

N2

L1

N1

14

15

16

11

12

13

FUSE 1 FNM-3 P/N E100-357

23

1

2

6

26

2

CR4

3

16

5

9

13 10 27

COM COIL

CR3

NO

COIL NC

24 3

2 4 3

6

12 11

8 7

22

CR2

2

1

0

2 4

19 1

3

6 8 7

21 1 20

4

0

CR1

2

1

CR 1&2 RELAY, 120VAC, FLANGE MOUNT, 30A

CR- 4 RELAY, 120VAC, 30A, 1 ½ HP

CR- 3 RELAY, 12VAC, FLANGE MOUNT, 25A

TRANSFORMER, 80VA, 120/240:12.6

RECTIFIER, BRIDGE, FULL WAVE, 25A, 200V

3 27 13 10

WIRE NUMBERS

SHOWN IN BOLD

24,24

8

6

25

RECTIFIER

24

Jumper 26

Blank

Blank

Jumper 26

23

CR3

T1

P/N E100-205

P/N E100-359

P/N E100-382

P/N E100-220

P/N E100-225

24

18

2

Blank

Blank

18

2


V. 2, Rev. 09/01/06


INTERIOR COMPONENT FUNCTION AND IDENTIFICATION

PANEL INTERIOR COMPONENTS

CR-1 RELAY (P/N E100-205):

Relay CR-1 is controlled by the Low Level Shutdown Device contacts C - B (NO) (normally open). Relay CR-1 contacts 8 – 7 (N.C.)

(normally closed) control the 120V power to the LOW LEVEL FAULT light. CR-1 relay contacts 6 – 8 (N.O.) control the 120V power to the BURNER switch.

CR-2 RELAY (P/N E100-205):

Relay CR-2 is controlled by the normally open (NO) contacts 14 – 15 of the FUJI Temperature Control. Relay CR-2 contacts 6 – 8 (N.O.) are connected in parallel to the 3T & T connections on the Burner Control. Opening and closing relay contacts 6 – 8 will initiate or terminate the heating cycle.

CR-3 RELAY (P/N E100-382):

Relay CR-3 is controlled by the internal alarm contacts of the burner control (diesel burner) or by Relay CR-5 contacts COM and NO (LP/

NG burner). The Relay CR-3 controls 120V power to the Accessories Power Receptacle via contacts COM and NC. The BURNER FAULT light is controlled by Relay CR-3 contacts COM and NO. 120V power to the Relay CR-3 COM is controlled by Relay CR-1 contacts 6 – 8 via the BURNER switch.

CR-4 RELAY (P/N E100-359):

Relay CR-4 Operating Coil is energized (powered) by the PUMP switch. Relay CR-4contacts 2 – 3 (N.O.) control the 120V power to the

HTF Pump.

CR-5 RELAY (P/N E100-383): (LP/NG burner only)

Relay CR-5 is controlled by the burner control’s alarm contacts..

Relay CR-5 contacts COM – N.O. close during a burner fault to power the Relay CR-3 12 volt DC coil. Relay CR-5 is located beneath the

Burner Control.

T-1 TRANSFORMER (P/N E100-220):

Reduces 120 volts AC current to approximately 12.6 volts AC current.

RECTIFIER (P/N E100-225):

Converts 12.6 volts AC current to 12.6 volts DC current as an operator safety feature of the rewind circuit.

FUSE 1 TYPE FNM-3 (P/N E100-356):

Provides circuit protection for the Rewind Motor and the line voltage portion of the Rewind Circuit.

FUSE 2 TYPE 3AG, 5.0 SB (P/N E100-357):

Provides circuit protection for the low voltage portion of the Rewind Circuit.

TERMINAL STRIP:

A transitional connection point between control panel interior and exterior components.

Numbered connection points share the same number as the wire connected to them.

V. 2, Rev. 09/01/06


A - 7

A - 8

PUREHEAT WIRING SCHEMATIC

CIRCUIT 1

(SHEET 1)

11

11

LINE

CB-1

15A

LOAD

LINE

L3

L1

+120VAC

GFCI-1

N1

N1

GFCI-1

LINE

LOAD

GROUND FAULT INDICATOR LAMP

ILLUMINATES DURING GROUND FAULT

HTF FILL SW.

LOAD

1

1

1

BLK

1

1

1

4

CR-1

2

19

FU-1

FNM-3

18

BLK

6

25

25

FU-2

3AG 5.0 SB

RED

23

RED

7

18

18

WHT

2

2

9

9

A

B

C

PUMP SW.

AUX PUMP CABLE

15

9 5 CR-4 6

WHT 2

2

15

15

REWIND MOTOR

1/6 HP 2.1A

MTR-2

2

WHT

WHT

WHT

2

2

2

2

2

120V

5

TX-1

8 11

12V

26

1

12

GRN

24

RED

24

COIL

12VAC

12VDC

CR3 COIL

10

BLU

10

RECTIFIER

P/N E100-218

6

BLU

25

RED

6

6

BLK

COM

FOOT SW.

N.O

7

WHT

7

7

WHT

REWIND CLUTCH

3.9A, 12V DC

8

BLK

8


V. 2, Rev. 09/01/06


(SHEET 2)

CIRCUIT 1 WITH DIESEL BURNER

1

BLK

1

1

1

1

1

ORG C

1

LOW LEVEL

B

RED

4

4

BLK

8

CR1-1

7

BLK

BLK

8

CR1-1

6

21 13

COM

CR3

NO

NC

BURNER SW.

14

14

TS1

BLK 14

13

WHT

200 º F.

MANUAL RESET

BI-METAL DISC

13

13

6

CR2

8

11

BURNER

CABLE

PIN-A (BLK)

13

13

11

(PNK) PIN-F (RED)

1 12

7

TX-1

120V

12V 12

24

COIL

12VAC

12VDC

CR3 COIL

10

25

FU-2

3AG 5.0 SB

12

10

25

PIN-E (ORG)

PIN-D (BLU)

PIN C (WHT/BLK)

PIN-G (GRN)

RED

4

20

27

3

13

11

12

10

25

0 CR1 1

LOW LEVEL FAULT LAMP

R

BURNER FAULT LAMP

R

RECEPTACLE

+

HOUR METER

-

25 WATT (.2 A)

FUEL PRE-HEATER

L1

LIMIT

T

BURNER

CONTROL

3T

ALARM

C+

L2

L2

L2

L2

IG BLU WHT

BM ORG

BURNER MOTOR

4.8

FLA.

WHT

CV VIO

BURNER

CABLE

PIN-B (WHT)

IGN. TRANS.

WHT 2

WHT 2

2

WHT 2

2

WHT 2

WHT 2

WHT

2

2

2

N

2

OIL VALVE

CAD CELL

BURNER

GROUND

1

1

1

BLK

BLK

CAB LIGHT SW.

5

22

CAB LIGHT

W

2

WHT 2

0 CR2 1 WHT

2

2

1

1

BLK

THERMOCOUPLE,

TYPE T

BLU

RED

14

17

18

5

DIGITAL

TEMPERATURE

CONTROL

15

6

2

2

WHT 2

V. 2, Rev. 09/01/06


A - 9

PUREHEAT SAFETY CONTROLS

DIESEL BURNER WIRING

13

MAIN CONTROL PANEL TERMINAL STRIP

2 25 10 12 11 GND

BURNER

CABLE

BLK

13

WHT

2

WHT/BLK

25

BLU

10

ORG

12

RED

11

GRN

GND

SEVEN PIN CONNECTOR (FEMALE)

A B C D E F G

SEVEN PIN CONNECTOR (MALE)

BLK

13

WHT

2

WHT/BLK

25

BLU

10

ORG

12

RED

11

GRN

GND

BURNER

PIGTAIL

CABLE

BLK

13

WHT/BLK

25

BLU

10

WHT

2

WHT

WHT

WHT

WHT

INLINE

FUEL

HEATER

BURNER

MOTOR

FUEL

SHUT-OFF

VALVE

IGNITION

WHT

WHT

WHT

WHT

BLK

BLK

RED

ORG

VIO

BLU/WHT

BURNER CONTROL

(P/N P100-206)

GRN

GND

ALARM

ALARM

L-2

L-2

L-2

L-2

L-1

LIMIT

BURNER

VALVE

IGN

BURNER CONTROL

(P/N P100-206)

3T

T

1

2

C+ C-

YEL

CAD

CELL

YEL

RED

11

ORG

12

A - 10


V. 2, Rev. 09/01/06

1

1

1

1

1

BLK

1

1

ORG C

LOW LEVEL

H

BLK 8

CR1-1

7


(SHEET 3)

CIRCUIT 1 WITH NP/LP BURNER

4

RED

BLK 8

21

BLK

BURNER SW.

6

14

14

TS1

BLK 14

13

WHT

200 º F.

MANUAL RESET

BI-METAL DISC

13

13

6

CR2

8

12

12

12

TX-1

120V

7 12V 12

24

COIL

12VAC

12VDC

CR3 COIL

10

25

FU-2

3AG 5.0 SB

13

13

11

11

11

4

COM

CR3

NO

NC

BURNER

CABLE

PIN-A (BLK)

PIN-F (RED)

PIN-E (ORG)

4

RED

10

PIN-D (BLU)

AIR PRESS SW.

10

25 PIN C (WHT/BLK)

PIN-G (GRN)

25

BURNER

GROUND

20

27

3

13

13

11

12

N

0 CR-1 1

LOW LEVEL FAULT LAMP

R

BURNER FAULT LAMP

R

RECEPTACLE

WHT 2

2

WHT 2

WHT 2

2

WHT 2

2

HOUR METER

+

WHT 2

2

5 L2

6

10

7

COM

BURNER

CONTROL

4

CR5

NO

8

3

ALARM

F G

9

BURNER

CABLE

PIN-B (WHT)

IGN. TRANS.

WHT

BURNER MOTOR

5.6

FLA.

WHT

PILOT GAS VALVE

RED

MAIN GAS VALVE

WHT

2

2

2

AUX GAS VALVE

WHT

IR FLAME SENSOR

1

1

1

1

BLK

BLK

1 BLK

CAB LIGHT SW.

5

THERMOCOUPLE,

TYPE T

BLU

RED

18

5

14

17

15

DIGITAL

TEMPERATURE

CONTROL

6

22

COIL

CR5

COIL WHT

CAB LIGHT

W WHT 2

2

1 CR2 0 WHT 2

2

WHT 2

V. 2, Rev. 09/01/06


A - 11

PUREHEAT DIESEL BURNER CONTROL

SEQUENCE OF OPERATION AND LOCKOUT

NORMAL SEQUENCE OF OPERATION:

Assuming a normal power up has been completed per Section 2 of this manual, the BURNER Switch is turned ON, the In-Line

Fuel Heater is energized and begins to warm the fuel in the Nozzle Assembly Tube. With a demand for heat, output contacts 14

& 15 of the Temperature Control (TC) will close completing a circuit from L1 to the Burner Control Relay Coil (CR-2). Burner

Control Relay (CR-2) normally open contacts 6 - 8 will CLOSE completing a circuit between 3T & T of the burner control.

The Burner Control initiates a 5 second self diagnostic test followed by a non-adjustable 15 second valve on-delay period called

Pre-purge. During the Pre-purge cycle, both the Ignition Transformer and Burner Blower Motor are energized but fuel is not allowed to flow past the Fuel Shut-off Valve. Once the pre-purge cycle is complete, the Fuel Shut-off Valve Solenoid Coil is energized by the Burner Control and fuel flow is initiated to the Burner Nozzle. Once fuel flow has begun, a 10 second trial for ignition period begins. During trial for ignition, the Ignition Transformer remains energized for an additional 10 seconds, this is known as ignition carryover. Once flame is established and proven by a Cad Cell resistance value of more than 300 but less than 1600 Ohms, the Ignition and the ten second trial for ignition time has elapsed, the Ignition Transformer is de-energized for the duration of the heating cycle. Once the demand for heat has been satisfied, output contacts 14 & 15 of the TC OPEN breaking the circuit to Burner Control Relay Coil CR-2. The now de-energized relay will OPEN Relay CR-2 contacts 6 - 8 breaking the circuit at 3T to T of the Burner Control. The Burner Control will shut off the fuel supply to the burner nozzle by deenergizing the Fuel Shut-off Valve Solenoid coil. The Burner Blower Motor will continue to run for 15 seconds (post-purge cycle). The amount of time allowed for pre-purge depends on the Off-delay Dip Switch setting. Ground Heaters, Inc. recommends the factory setting of 15 seconds off-delay. Several delay settings are available as detailed on the front of the burner control.

BURNER FAULT:

If the Cad Cell senses an absent or unstable flame at any time during the heating cycle, the Burner Control immediately shuts down all Burner functions and enters one of three protective modes (BURNER FAULT). BURNER FAULT is identified by the

Diagnostic Light (see photo below) and indicated by illuminating the BURNER FAULT Light (main control panel) simultaneously.

The three BURNER FAULT or Lockout modes are described in detail below.

1. RECYCLE MODE:

The DIAGNOSTIC Light will flash in two second intervals while attempting three automatic restarts. If the flame fails after three successive attempts, the control will enter Lockout Mode.

2. LOCKOUT MODE:

The DIAGNOSTIC Light will flash in ½ second intervals. The RESET button must be momentarily pressed to clear the Lockout and attempt a Burner restart. After the third attempt to manually clear the Lockout mode, the Burner Control will begin

Restricted Lockout Mode.

3. RESTRICTED LOCKOUT MODE:

The DIAGNOSTIC Light will flash in ½ second intervals. The RESET button must be pressed and held until the DIAGNOSTIC

Light comes on momentarily and then goes out. The Burner Control will return to Restricted Lockout Mode with each flame failure until one successful heating cycle has occurred.

A - 12

DIAGNOSTIC LIGHT

RESET BUTTON

OFF DELAY DIP

SWITCHES

ALARM

(BURNER FAULT)

CONNECTIONS


V. 2, Rev. 09/01/06


NG/LP BURNER WIRING DIAGRAM

V. 2, Rev. 09/01/06

13

MAIN CONTROL PANEL TERMINAL STRIP

2 25 10 12 11 GND

Honeywell

BURNER CONTROL

GAS TRAIN

MAIN

GAS

VALVE

BLK

BLK

BLK

AUX

GAS

VALVE

BLK

ORG WHT

BURNER

CABLE

BLK

13

WHT

2

WHT/BLK

25

BLU

10

ORG

12

RED

11

GRN

GND

SEVEN PIN CONNECTOR (FEMALE)

A B C D E F G

SEVEN PIN CONNECTOR (MALE)

BLK

13

WHT

2

WHT/BLK

25

BLU

10

ORG

12

RED

11

GRN

GND

BURNER

PIGTAIL CABLE

WHT 2

BLK 13

RED 11

GRN - GND

BLU 10

WHT/BLK 25

ORG 12

PILOT GAS

VALVE

BLOWER

MOTOR

IGNITION

TRANS

POWER

PILOT

FLAME

MAIN

ALARM

RESET

NG/LP BURNER

CONTROL

P/N P100-338

6

AIR PRESSURE

2 3

7

8

9

10

F

3

4

G

L2

5

COIL

COIL

COM

NO

2 PIN GAS TRAIN CABLE

BURNER

CONTROL

SUB-BASE

GAS BURNER

CONTROL

P/N P100-338

UV

FLAME

SENSOR


A - 13

20

21

22

17

18

19

14

15

16 l2

13


BURNER CONTROL OVERVIEW

Mounting Screw

Honeywel l

BURNER CONTROL

Dust Cover: Remove to access the Purge

Timer or to mount the S7800 Keyboard Display

Module (Available through Honeywell, Inc.)

Status Panel: Indicator lights illuminate to show the Burner

Operation Status.

Reset Button: Press and release to clear Burner ALARM condition

POWER

PILOT

FLAME

MAIN

ALARM

RESET

Mounting Screw

Flame Amplifier

Honeywel l

BURNER CONTROL

POWER

PILOT

FLAME

MAIN

ALARM

RESET

Flame Amplifier (*p/n P100-368): Boosts the signal from the Ultra Violet (UV) Flame

Detector, the Flame Detector monitors the Pilot

Flame and allows Main Gas Valve operation provided the Pilot Flame remains stable. To remove the Flame Amplifier, carefully pry the

Amplifier away from the Main Control using the slot provided.

Dust Cover: Removed to access the Purge Timer or to mount the S7800

Keyboard Display Module.

Honeywel l

BURNER CONTROL

Honeywel l

BURNER CONTROL

SCROLL MODE

SAVE

Honeywel l

BURNER CONTROL

Purge Timer

(p/n P100-369):

A fixed 30 second timer for the Pre-Purge cycle of the Burner.

SCROLL MODE

SAVE

S7800A KEYBOARD DISPLAY MODULE:

The S7800 Keyboard Display Module (shown powered) is a tool to aid in the diagnosis of

Burner malfunctions and is available through

Honeywell, Inc.

POWER

PILOT

FLAME

MAIN

ALARM

RESET

A – 13a


V. 2, Rev. 09/01/06

Honeywel l

BURNER CONTROL


SEQUENCE OF OPERATION

POWER

PILOT

FLAME

MAIN

ALARM

RESET

1

POWER

PILOT

FLAME

MAIN

ALARM

30 SECOND

PRE-PURGE

RESET

BURNER SWITCH ON

2

POWER

PILOT

FLAME

MAIN

ALARM

1-3 SECONDS

RESET

PILOT GAS VALVE

POWERED

3

POWER

PILOT

FLAME

MAIN

ALARM

RESET

PILOT FLAME

DETECTED

15 SECOND

FLAME CHECK

4

POWER

PILOT

FLAME

MAIN

ALARM

RESET

MAIN GAS VALVES

POWERED, NORMAL HEAT

CYCLE IN PROGRESS

V. 2, Rev. 09/01/06

POWER

PILOT

FLAME

MAIN

ALARM

RESET

BURNER CONTROL IS IN ALARM MODE,

PRESS AND RELEASE RESET BUTTON


POWER

PILOT

FLAME

MAIN

ALARM

RESET

FLAME INDICATOR LAMP ILLUMINATES

AFTER BURNER SWITCH IS TURNED ON

BUT THE BURNER DOES NOT START:

FLAME AMPLIFIER FAILURE

UV FLAME SENSOR FAILURE

MOISTURE IN BURNER CONTROL

A – 13b

+120VAC

L2

LINE

CB-2

20A

L4

LOAD

LINE GFCI-2

26

LOAD

26

26


CIRCUIT 2

N2

H

2

CR-4

GROUND FAULT

INDICATOR LAMP

3

LOW LEVEL

LOGIC N

16

GFCI-2 LINE

PUMP MOTOR

15.8A 1.5 HP

PUMP

17

WHT

LOAD

17

17

17

WHT 17

A - 14


V. 2, Rev. 09/01/06

PUREHEAT SCHEMATIC – AUXILIARY PUMP PANEL

(P/N A109-199)

Auxiliary

Pump

Panel o

BOOSTER PUMP

20A Power IN

OUT TO

PUMP

Aux. Pump

Cable

BOOSTER PUMP AND AUXILIARY PUMP PANEL INTERNAL SCHEMATIC

CONNECT TO:

120V 20A 60Hz POWER

SUPPLY

(GFCI PROTECTED)

AUX PUMP PANEL

L3

GND

N3

LINE

CB-3

20A

LOAD

5 CRX-1 6

5

AUX PUMP PANEL

CABLE CONNECTION

PIN A BLK

PIN B WHT

PIN C GRN

A

2

B

C

11

2

CRX-1

3

12

BOOSTER PUMP

CONNECTION

AUX PUMP CABLE

BOOSTER PUMP

BLK

93

GRN

WHT

N3

MTR1

V. 2, Rev. 09/01/06


A - 15

PUREHEAT CIRCULATION - BOOSTER PUMP MOTOR WIRING

WIRE COLORS

BLK = BLACK

RED = RED

WHT = WHITE

GRN = GREEN

BLU = BLUE

YEL = YELLOW

W/y = WHITE W/

YELLOW TRACE

PUMP CABLE

WHT

BLK

GRN

17

16

GND

YEL

ORG

BLK

BLU

WHT BRN BRN BRN W/y

WHITE WITH

YELLOW TRACE

(X2)

4 3 1 2 J J J

A - 16

CIRCULATION - BOOSTER PUMP ASSY.

1.5 HP 15.8 FLA 18.8 SFA

P/N M100-647


V. 2, Rev. 09/01/06

V. 2, Rev. 09/01/06

PUREHEAT REWIND MOTOR WIRING

BLK

WHT

GND

DAYTON

GEAR MOTOR

1/6 th

HP 120 v. 60 Hz

P/N E100-212

BLK

BRN

ORG

RED

WHT

YEL

BLK

BLK

CAPACITOR

10 µƒ

330V

BISON

GEAR MOTOR

1/6 th

HP 120 v. 60 Hz

P/N E100-212

BLK

WHT

BLK

BRN

ORG

RED

WHT

YEL

BLK

BLK

CAPACITOR

10

µƒ

330V

GND


A - 17

RED

4

GRN

ORG

1

BLK

26

WHT

17

C

H

B

W

N


LOW LEVEL SHUTDOWN DEVICE

(P/N E100-198)

NOTE: CONTROL IS SHOWN IN A NON-POWERED STATE

LOW LEVEL

LOW LEVEL SHUTDOWN DEVICE CONTROLS

AND INDICATOR LIGHTS LOCATION ON THE

BOTTOM OF THE DEVICE.

POWER

TEST

LOW WATER

RESET

REFER TO SECTION

5.2.1.2 FOR

DETAILED TESTING

INSTRUCTIONS

BLK

HYDRONIC

HEATER SHELL

LOW LEVEL

SENSOR

A - 18

FUSE 3

2 AMP

TO RELAY COILS K-1 & K-2

110 VOLTS FROM CIRCUIT 1

LOW LEVEL DEVICE INTERNAL SCHEMATIC

RED

4

ORG

1

BLK

26

WHT

17

B

W

C

H

RESET

N

SENSOR

(PROBE)

N.O.

N.C.

PROBE

CONNECTION

TEST

LOW LEVEL

LOGIC MODULE

GREEN LED

RED LED

110 VOLTS FROM CIRCUIT 2

WIRE COLORS

BLK = BLACK

WHT = WHITE

RED = RED

BLU = BLUE

ORG = ORANGE

GRN = GREEN


V. 2, Rev. 09/01/06

L-1 BLK

HX200 HEAT XCHANGER

™

WIRING DIAGRAM

THERMOSTAT

P/N M100-740

T-1 BLK

OFF

RED LO

BLUE MEDIUM

BLK HI

3

2

4

ROTARY SWITCH

P/N E100-334

1

5

BLOWER

MOTOR

E100-349 BRN BRN

370V

15 mfd

P/N E100-646

CAPACITOR

P/N E100-335

RECESSED PLUG

BLOWER WHEEL

P/N F109-008

WIRE COLORS

BLK = BLACK

RED = RED

WHT = WHITE

GRN = GREEN

BLU = BLUE

BRN = BROWN

V. 2, Rev. 09/01/06


A - 19

L-1 BLK


™

WIRING DIAGRAM

THERMOSTAT

P/N M100-773

T-1 YEL

TOGGLE SWITCH

P/N E100-101

RED LO BLU MED BLK HI

BLOWER

MOTOR

F109-167

370V

7.5 mfd

P/N M100-769

CAPACITOR

P/N E100-335

RECESSED PLUG

FAN BLADE M100-772

A - 20

WIRE COLORS

BLK = BLACK

RED = RED

WHT = WHITE

GRN = GREEN

BLU = BLUE

BRN = BROWN

YEL = YELLOW

PURP = PURPLE


V. 2, Rev. 09/01/06

L-1 BLK


™

WIRING DIAGRAM

THERMOSTAT

P/N M100-773

T-1 BLK

TOGGLE SWITCH

P/N E100-101

BLK

BLOWER

MOTOR

E100-378

P/N E100-335

RECESSED PLUG

FAN BLADE M100-771

V. 2, Rev. 09/01/06

WIRE COLORS

BLK = BLACK

RED = RED

WHT = WHITE

GRN = GREEN

BLU = BLUE

BRN = BROWN


A - 21

PUREHEAT TRAILER JUNCTION BOX AND BATTERY WIRING

TRAILER WIRE COLORS

BLK = BLACK - NOT USED

RED = RED - LEFT TURN

WHT = WHITE - NEGATIVE/GROUND

GRN = GREEN - RUNNING LIGHTS

BLU = BLUE - BRAKES

YEL = YELLOW - NOT USED

BRN = BROWN - RIGHT TURN

BATTERY WIRE COLORS

BLK = BLACK - VEHICLE 12 VOLTS DC


GRN = GREEN - TRAILER BATTERY

7-WAY PLUG WIRING COLORS





BLU = BLUE - BRAKES



TOW VEHICLE

NOT

USED

BLU.

YEL

BLU

BRN

GRN

RED

BLK

WHT

BRN.

GRN.

BREAK-AWAY

SWITCH

RED

YEL.

YEL

BLK

BLU

BRN

GRN

RED

WHT

BLK.

WHT.

WHT

TRAILER

WHT

BLK

BLK

BATT CABLE

GRN

WHT

BLK

WHT

RED

+ -

BATTERY

12 Volt DC

RED

BATTERY

CHARGER

BATTERY BOX

A - 22


V. 2, Rev. 09/01/06

7-WAY PLUG WIRING COLORS





BLU = BLUE - BRAKES



PUREHEAT TRAILER WIRING

BATTERY WIRE COLORS



GRN = GREEN - TRAILER BATTERY

TRAILER WIRE COLORS

BLK = BLACK - NOT USED




BLU = BLUE - BRAKES



B

C D E C

A

GRN

GRN

GRN

A

GRN

B

GRN

F

ELECTRIC BRAKES

GRN

GRN

GRN

A

A

GRN

GRN

B

A LIGHT, 2 BULB RED (P/N E100-131)

B LIGHT, 2 BULB AMBER (P/N E100-132)

C LIGHT, STOP-TURN (P/N E100-342)

D 3 LIGHT COMBO (P/N E100-022)

E LICENSE PLATE LIGHT (P/N E100-491)

F MINI LIGHT, AMBER (P/N E100-133)

BLU

WHT

BRN

GRN

RED

F

B

V. 2, Rev. 09/01/06


A - 23

A - 24

PUREHEAT NG/LP BURNER COMPONENT IDENTIFICATION

(P/N P100-673)

E

A

F

G

B

I

J

C D

M

H

K L

N

O

W

V U

F

G

D

E

A

B

C

J

K

H

I

REGULATOR DUST CAP

MANIFOLD GAS PRESSURE REGULATOR (P/N P100-342)

MAIN GAS VALVE (P/N P100-340)

AUX GAS VALVE (P/N P100-341)

1/16" MALE PIN PLUG (P/N100-341)

GAS SUPPLY INLET VALVE

GAS SUPPLY PRESSURE TEST PORT

MAIN GAS SUPPLY CONNECTION POINT

PILOT GAS LINE (P/N F100-130)

PILOT GAS SUPPLY VALVE

BURNER BLOWER MOTOR (P/N P100-333)

T

HONEYWELL

POWER

PILOT

FLAME

MAIN

ALARM

RESET

S R Q

P

Q

N

O

L

M

T

U

R

S

V

BURNER BLOWER WHEEL (P/N P100-334)

MANIFOLD GAS SHUT-OFF VALVE

AIR DAMPERS

GAS TRAIN UNION

PRESSURE TEST PORT w/ 9/16" ORIFICE & SPRING

BURNER CONTROL (P/N P100-338)

AIR PROVING PRESSURE SWITCH (P/N P100-335)

I.R. PILOT FLAME SENSOR (P/N P100-354)

PILOT GAS TRAIN UNION

PILOT GAS VALVE (P/N P100-353)

PILOT GAS REGULATOR (P/N P100-336)

P


V. 2, Rev. 09/01/06

PUREHEAT NG/LP BURNER

(P/N P100-673)

GAS PRESSURE CHECKING AND ADJUSTING

REMOVE THE GAS REGULATOR ADJUSTMENT COVER.

INSERT A SCREWDRIVER INTO THE ADJUSTMENT STEM.

TURN CLOCKWISE TO INCREASE PRESSURE.

TURN COUNTER CLOCKWISE TO DECREASE PRESSURE.

INSTALL A PETCOCK AND 0-30"

MANOMETER ADAPTER

FITTING IN THE PLACE OF THE

SUPPLY PRESSURE TAP PLUG.

SUPPLY GAS PRESSURE FOR

LP/NG IS 5 - 14"

2

3

4

5

6

7 8

9

10

11

12

13

0

15

Inches Water Column

PILOT GAS PRESSURE TAP

PILOT GAS PRESSUREIS PRE-SET TO 4.0 in WC

USE A MANOMETER TO MEASURE GAS PRESSURE

2

3

4

5

6

7 8

9

10

11

12

13

0

15

Inches Water Column

HONEYWELL

POWER

PILOT

FLAME

MAIN

ALARM

RESET

REMOVE THE PIPE PLUG AND

CONNECT A 0-15" (LOW

PRESSURE) MANOMETER

HERE TO READ MANIFOLD

PRESSURE

2

3

4

5

6

7 8

9

10

11

12

13

0

Inches Water Column

15

V. 2, Rev. 09/01/06

GAS SUPPLY PRESSURE

5 in WC MINIMUM

14 in WC MAXIMUM

LP 1.4-1.6 in. WC MAX NG 2.5-3.0 in. WC MAX

GAS MANIFOLD PRESSURE


A - 25

PUREHEAT DIESEL BURNER COMPONENT IDENTIFICATION

(P/N P100-690)

D

A

B

BECKETT

CF 800

E

F

C

ALARM

ALARM

T

T

G

A - 26

50

75

10

0

125

150

175

200

225

25

0

0 – 300 PSI TEST GAUGE

(P/N P100-072)

S

FUEL PRESSURE

TEST PORT

INCREASE

FUEL PRESSURE

ADJUSTING SCREW

A FUEL SHUT OFF VALVE (P/N P100-306)

B IGNITION TRANSFORMER (P/N P100-355)

C BURNER CONTROL (P/N P100-206)

D FUEL PUMP (P/N P100-359)

E BLOWER WHEEL (P/N P100-356)

F FUEL PUMP DRIVE COUPLER (P/N P100-273

G BURNER MOTOR (P/N P100-356)

BURNER NOZZLE

5.0 60 º A

(P/N P100-408)

ELECTRODE

REPLACEMENT KIT

(P/N P100-307)

INLINE FUEL HEATER

(P/N P100-251)

FUEL SYSTEM

BLEEDER PORT


NOZZLE ASSEMBLY

V. 2, Rev. 09/01/06

SUGGESTED METHOD FOR SECURING THE PUREHEAT ONTO A TRUCK BED

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

V. 2, Rev. 09/01/06


A - 27

PUREHEAT HOSE REWIND PARTS IDENTIFICATION

A - 28

A

B

C

D

E

F

G

G

H

E

F

I

C

D

A

B

GEAR MOTOR (P/N E100-212)

MOTOR SHAFT ADAPTER (P/N F102-026)

KEY, ¼ X ¼ X 1¾ (P/N M100-730)

RETAINING RING (P/N M100-707)

BRAKE ASSEMBLY (P/N A103-205)

CLUTCH DRIVE SPROCKET (P/N F109-041)

12 VOLT CLUTCH (P/N M100-108)

ROLLER CHAIN, #35, 231 PITCHES (P/N M100-372)

DRIVE SPROCKET (P/N M100-659)

H

I


V. 2, Rev. 09/01/06

PUREHEAT AIR AND SURFACE HEATING ACCESSORIES

BOOSTER PUMP HHS 3004

(P/N G109-014)

AUXILIARY PUMP PANEL

Auxiliary

Pump

Panel o

(P/N A109-199)

HX200 Heat Xchanger™

(P/N G302-009)

HOSE ASSY. W/ QC SET

1 IN. I.D. RED

50 FT LENGTH (P/N A109-136)

100 FT LENGTH (P/N A109-137)

200 FT LENGTH (P/N A109-138)

4 PORT REMOTE MANIFOLD

(P/N G109-005)


(P/N G109-009)


V. 2, Rev. 09/01/06

(P/N G109-007)


(P/N G109-006)

B - 1

BOOSTER PUMP TO PUREHEAT CONNECTING

SUPPLY MANIFOLD

1.

ENSURE VALVES 5,6 AND 7 ARE SHUT.

REMOVE THE CAPS AND PLUGS FROM THE PUREHEAT

BOOSTER PUMP CONNECTION POINTS AND THE

BOOSTER PUMP HOSE ENDS.

SHUT

7

SHUT

6

SHUT

B - 2

HTF SUPPLY - FLOW DIRECTION

HTF RETURN - FLOW DIRECTION

2.

JOIN BOOSTER PUMP AND PUREHEAT CAM-LOCKS

(REFER TO PAGE B-8)

OPEN VALVES 6 & 7 (VALVE 5 REMAINS SHUT)

CHECK FOR HTF LEAKS.

3.

CONNECT POWER SUPPLY TO AUX PUMP PANEL.

CONNECT BOOSTER PUMP TO AUX PUMP PANEL.

JOIN AUX PUMP CABLES.

SUPPLY MANIFOLD

MAIN CONTROL PANEL

OPEN

7

OPEN

6

5

SHUT

Auxiliary

Pump

Panel o

OUT to Pump

20A Power IN


Aux. Pump Cable

V. 2, Rev. 09/01/06


™

TO PUREHEAT CONNECTION LAYOUT

OPEN

RETURN MANIFOLD

F

2

FILL HOSE DUST CAP

FILL HOSE

SUPPLY MANIFOLD

4

OPEN

MAIN

PUMP

SHUT

3

PRESSURE

GAUGE

PSI



SHUT

7

5

OPEN

SHUT

6

CHECK

VALVE

V. 2, Rev. 09/01/06

HX200

(P/N G109-005)

HX200

(P/N G109-005)

HX200

(P/N G109-005)


HX200

(P/N G109-005)

B - 3


™

TO PUREHEAT CONNECTION LAYOUT

FILL HOSE DUST CAP

FILL HOSE

OPEN 2

4

OPEN

RETURN MANIFOLD

SUPPLY MANIFOLD

F

MAIN

PUMP

SHUT

3

PRESSURE

GAUGE

PSI



SHUT

7

5

OPEN

6

SHUT

CHECK

VALVE

FOUR PORT

MANIFOLD 1

FOUR PORT

MANIFOLD 2

FOUR PORT

MANIFOLD 3

FOUR PORT

MANIFOLD 4

B - 4


V. 2, Rev. 09/01/06

HX50 HEAT XCHANGER TO PUREHEAT CONNECTION LAYOUT

FILL HOSE DUST CAP

FILL HOSE

OPEN 2

4

OPEN

RETURN MANIFOLD

SUPPLY MANIFOLD

SHUT

F

MAIN

PUMP

3

PRESSURE

GAUGE

PSI



SHUT

7

5

OPEN

6

SHUT

CHECK

VALVE

FOUR PORT

MANIFOLD 1

FOUR PORT

MANIFOLD 2

FOUR PORT

MANIFOLD 3

FOUR PORT

MANIFOLD 4

FOUR PORT

MANIFOLD 5

V. 2, Rev. 09/01/06


B - 5

PUREHEAT 18,000 SQ. FT THAW LAYOUT

(THREE HHS 3004'S AND THREE 4-PORT MANIFOLDS)

FILL HOSE DUST CAP

FILL HOSE

OPEN 2

RETURN MANIFOLD

F

SUPPLY MANIFOLD

4

OPEN

MAIN

PUMP

SHUT

3

PRESSURE

GAUGE

PSI



OPEN

7

OPEN

6

5

SHUT

CHECK

VALVE

B - 6


V. 2, Rev. 09/01/06

PUREHEAT 30,000 SQ. FT CURE LAYOUT

(FIVE HHS 3004'S AND FIVE 4-PORT MANIFOLDS)

FILL HOSE DUST CAP

FILL HOSE

OPEN 2

RETURN MANIFOLD

F

SUPPLY MANIFOLD

4

OPEN

MAIN

PUMP

SHUT

3

PRESSURE

GAUGE

PSI



OPEN

7

OPEN

6

5

SHUT

CHECK

VALVE

V. 2, Rev. 09/01/06


B - 7

PUREHEAT 45,000 SQ. FT FROST PREVENTION LAYOUT

(FIVE HHS 3004'S AND FIVE 4-PORT MANIFOLDS)



OPEN

FILL HOSE DUST CAP

2

FILL HOSE

3

OPEN SUCTION VALVE

SHUT

HTF FILL

VALVE

RETURN MANIFOLD 4

F

RETURN HTF

THERMOMETER SUPPLY MANIFOLD

MAIN

PUMP

PRESSURE

GAUGE

PSI

CHECK

VALVE

OPEN

7

OPEN

6

5

SHUT

B - 8


V. 2, Rev. 09/01/06

PUREHEAT VALVE POSITIONS FOR ADDING HTF

(Machine in use)

3



OPEN 2

FILL HOSE

RETURN MANIFOLD 4

F

RETURN HTF

THERMOMETER SUPPLY MANIFOLD

SHUT SUCTION VALVE

OPEN

HTF FILL

VALVE

MAIN

PUMP

PRESSURE

GAUGE

HTF

PSI

CHECK

VALVE

7

SHUT

5

OPEN

SHUT

6

1. Power up the PureHeat as described in section 2 of this manual.

2. Place the container of HTF near the access doors for the Hose Reel and the Main Control Panel.

3. Remove the Fill Hose from its storage location below the hose reel.

4. Clean the exterior of the Fill Hose and place the open end in the container of HTF.

5. It may be necessary to fill (prime) the Fill Hose prior to insertion into the HTF container.

This is accomplished by first lowering the hose near ground elevation and momentarily opening Valve #4 until HTF has filled the hose.

6. SHUT Pump Suction Valve #3

7. Pull the locking pin from Valve #4, pull the locking collar toward the handle and OPEN valve #4

8. If the LOW HTF LEVEL light is lit, push and hold the HTF FILL switch to operate the Pump.

If the LOW HTF LEVEL light is NOT lit, you may turn the pump switch ON to begin filling.

9. Continue filling until the HTF is observed in-between the LOW and HIGH marks adjacent to the HTF Sight Gauge. (photo 2-4, page 2.4)

10. Once filling is complete, pull the Fill Hose out of the HTF container with the Main Pump running to effect emptying the Fill Hose.

11. Shut Valve #4, ensure the locking collar slides toward the valve stem to the locked position, place the locking pin into the hole provided.

12. Turn the Pump Switch OFF.

13. Wipe down the fill hose and store it neatly below the Hose Reel.

14. Open Pump Suction Valve #3, check for leaks.

V. 2, Rev. 09/01/06


B - 9

PUREHEAT VALVE POSITIONS FOR ADDING HTF

(Machine not in use)

4

3

SHUT SUCTION VALVE

OPEN

HTF FILL

VALVE

RETURN MANIFOLD

2 OPEN

F

FILL HOSE

HTF

SUPPLY MANIFOLD

MAIN

PUMP

PSI

PRESSURE

GAUGE

CHECK

VALVE

SHUT

7

5

OPEN

SHUT

6

1. Power up the PureHeat as described in section 2 of this manual.

2. Attach a hose equipped with Quick-Connect fittings to the Supply and Return Manifold in order to provide a complete fluid path prior to adding HTF.

3. Place the container of HTF near the access doors for the Hose Reel and the Main Control Panel.

4. Remove the Fill Hose from its storage location below the hose reel and clean the exterior.

5. Prime the Fill Hose prior to insertion into the HTF container by lowering the hose near ground elevation, pull the locking pin out of Valve #4, slide the locking collar toward the handle, open the valve partially until HTF is observed filling the hose.

6. SHUT Pump Suction Valve #3

7. Attach a hose equipped with Quick-Connect fittings to the Supply and Return Manifold in order to provide a complete fluid path prior to adding HTF.

8. Pull the locking pin from Valve #4, pull the locking collar toward the handle, (unless it was done at step 5) OPEN valve #4.

9. If the LOW HTF LEVEL light IS ON, push and hold the HTF FILL switch to operate the Pump.

10. If the LOW HTF LEVEL light is NOT ON, you may turn the pump switch ON to begin filling.

11. Continue filling until the HTF is observed in-between the LOW and HIGH marks adjacent to the HTF Sight Gauge. (photo 2-4, page 2.4)

12. Once filling is complete, pull the Fill Hose out of the HTF container with the Main Pump running to effect emptying the Fill Hose.

13. Shut Valve #4, ensure the locking collar slides toward the valve stem to the locked position, place the locking pin into the hole provided.

14. Turn the Pump Switch OFF.

15. Wipe down the fill hose and store it neatly below the Hose Reel.

16. Open Pump Suction Valve #3, check for leaks.

B - 10


V. 2, Rev. 09/01/06

PUREHEAT QUICK-CONNECT AND CAM-LOCK CARE AND MAINTENANCE

ALWAYS:

Keep connection devices free of sand and dirt.

Rinse in clear water before and after each use.

Inspect seals and gaskets before and after each use.

Reinstall caps or protective covers after each use.

1

RINSE

NEVER:

Drop onto a hard surface such as concrete.

Drive over with any size vehicle.

Attempt to use damaged connection devices.

Attempt to use when contaminated with soil, vegetation or any petroleum product.

Attempt to use with damaged or worn seals or gaskets.

Lubricate with petroleum products.

2

PUSH LOCKING

RING BACK

3

INSERT MALE

QUICK-CONNECT,

RELEASE LOCKING RING

MALE QUICK CONNECT

(P/N M100-258)

MALE QUICK CONNECT

(P/N M100-258)

FEMALE QUICK CONNECT

(P/N M100-259)

Unlock the Cam-Lock by swinging the locking arms outward. Insert the male fitting and lock by simultaneously swinging the arms inward as shown.

VITON GASKET

P/N P100-352

FEMALE CAM-LOCK

P/N M100-728

MALE CAM-LOCK

P/N M100-700

V. 2, Rev. 09/01/06


B - 11

C - 1

HX200

PUREHEAT APPLICATIONS AND CAPACITIES

(See Appendix pages B-1 – B-10 for accessories connecting)

HX100 HX50

THAWING

N/A

PUREHEAT, FIVE HX200 or, EIGHT HX100 or,

TWENTY HX50 HEAT XCHANGERS™

CURING

N/A

FROST PREVENTION

N/A

AIR HEATING

Up to: 1,200.00 ft 3 (with Propane Fuel @ .6 BTU per ft 3 )

PUREHEAT, ONE Booster Pump, 3 HHS3004,

THREE Four Port Manifolds

( TWELVE 750 FT HOSE LOOPS)

THAWING

Up to: 18,000 ft 2 @ 24 in hose spacing

CURING




HTF SUPPLY

HTF RETURN

PUREHEAT, ONE Booster Pump, FIVE HHS3004,

FIVE Four Port Manifolds

(TWENTY 750 FT HOSE LOOPS)

THAWING

Up to: 30,000 ft 2 @24 in hose spacing

CURING

Up to:30,000 ft 2 @ 24 in hose spacing




V. 2, Rev. 09/01/06

Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90

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 Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21

Wacker Neuson Pureheat Hydronic Air Heater Operator's Manual

OPERATOR’S MANUAL

0171942en 001

0907

Hydronic Air Heater

Pureheat

One Year Limited Warranty

(see your distributor to file warranty claim)

Technical Assistance

877-799-9600

This Pureheat

Hydronic Air Heater manual contains the following:

1. Pureheat™ Hydronic Air Heater Operator’s Manual

2. One Year Limited Warranty

3. Pump Manufacturer’s Manual

4. Burner Manufacturer's Manual

WARNING

LICENSED GAS TECHNICIAN REQUIRED.

NG/LP BURNER SETUP AND INSTALLATION, FUEL

SUPPLY CONNECTION, TEST FIRING AND BURNER

ADJUSTMENT MUST BE PERFORMED BY A LICENSED

PROFESSIONAL GAS TECHNICIAN AND MUST CONFORM

TO THE REQUIREMENTS OF ALL RELEVANT LOCAL,

STATE, PROVINCIAL AND FEDERAL AUTHORITIES.

Burner setup and installation, fuel supply connection, testfiring and burner adjustment must be performed by a licensed professional and must conform to the requirements of local, state and federal authorities. In the

Commonwealth of Massachusetts, gas piping shall be installed by a licensed plumber or gas fitter.

NG/LP burner to the fuel source at the correct pressure and flow.

FAILURE TO HEED THIS WARNING MAY RESULT IN

AN EXPLOSION AND/OR FIRE CAUSING

PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING: If the instructions in this manual are not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

• Do not store or use gasoline or other

flammable vapors and liquids in the vicinity of this or any other appliance.

• WHAT TO DO IF YOU SMELL GAS

- Do not try to light any appliance

- Do not touch any electrical switch; do not

use any phone in your building

- Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's instructions.

- If you cannot reach your gas supplier, call

the fire department

• Installation and service must be performed by

a qualified installer, service agency, or the gas supplier.

DIESEL FUEL SELECTION

WARNING

SCHEMATIC AND WIRING DIAGRAM SYMBOL LEGEND

SCHEMATIC AND WIRING DIAGRAM SYMBOL LEGEND

SCHEMATIC AND WIRING DIAGRAM SYMBOL LEGEND

COMMON WIRE COLORS

BLK = BLACK

RED = RED

WHT = WHITE

GRN = GREEN

BLU = BLUE

YEL = YELLOW

ORG = ORANGE

VIO = VIOLET

BRN = BROWN

PNK = PINK

PUREHEAT CONTROL PANEL EXTERIOR LAYOUT

PUREHEAT TEMPERATURE CONTROL

PUREHEAT CONTROL PANEL DOOR INTERIOR LAYOUT

PUREHEAT MAIN CONTROL PANEL

EXTERIOR COMPONENT FUNCTION AND IDENTIFICATION

PUREHEAT MAIN CONTROL PANEL

INTERIOR COMPONENT LAYOUT

PUREHEAT MAIN CONTROL PANEL

INTERIOR COMPONENT FUNCTION AND IDENTIFICATION

PUREHEAT WIRING SCHEMATIC

CIRCUIT 1

PUREHEAT WIRING SCHEMATIC

CIRCUIT 1 WITH DIESEL BURNER

+

PUREHEAT SAFETY CONTROLS

DIESEL BURNER WIRING

PUREHEAT WIRING SCHEMATIC

CIRCUIT 1 WITH NP/LP BURNER

+

PUREHEAT DIESEL BURNER CONTROL

SEQUENCE OF OPERATION AND LOCKOUT