Wacker Neuson HDR115 Operator's Manual
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Wacker Neuson HDR115 Operator's Manual

Wacker Neuson HDR115 Operator's Manual

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Type
Document
Date
Revision
Language
Operator's Manual
Direct-Fired Air Heater
HDR115
HDR115
5100020937
1017
03
EN
5 1 0 0 0 2 0 9 3 7

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Summary of Contents for Wacker Neuson HDR115

  • Page 1 Operator’s Manual Direct-Fired Air Heater HDR115 HDR115 Type Document 5100020937 1017 Date Revision Language 5 1 0 0 0 2 0 9 3 7...
  • Page 2 Copyright notice © Copyright 2017 by Wacker Neuson Production Americas LLC All rights, including copying and distribution rights, are reserved. This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Production Americas LLC.

  • Page 3: Foreword

    THE INSTALLATION OF THE UNIT SHALL BE IN ACCORDANCE WITH THE REGULATIONS OF THE AUTHORITIES HAVING JURISDICTION. In addition, as a standard practice for installation, Wacker Neuson recommends referencing the current issue of CSA B139, Installation Code for Oil Burning Equipment in Canada and NFPA 31 Standard for the Installation of Oil-Burning Equipment in the USA.
  • Page 4 SAVE THESE INSTRUCTIONS—This manual contains important instructions for the machine model below. These instructions have been written expressly by Wacker Neuson Production Americas LLC and must be followed during installation, operation, and maintenance of the machine. This manual covers the machine with the following item number:...
  • Page 5 Americas LLC will be referred to as Wacker Neuson. ■ Keep a copy of the Operator’s Manual with the machine at all times. ■ For spare parts information, please see your Wacker Neuson Dealer, or visit the Wacker Neuson website at http://www.wackerneuson.com/.
  • Page 6 Foreword HDR 115 wc_tx004151gb_FM10.fm...

  • Page 7: Table Of Contents

    HDR 115 Table of Contents Foreword Safety Information Signal Words Used in this Manual ............9 Machine Description and Intended Use ..........10 Safety Guidelines for Operating the Machine ........11 Safety Guidelines for Lifting the Machine ........... 13 Safety Guidelines for Operating Combustion Burners ....... 14 Service Safety ..................

  • Page 8: 10 Schematics

    Table of Contents HDR 115 Burner Setup Removing and Installing the Burner Assembly ........40 Setting up the Burner ................41 Checking and Adjusting the Electrodes ..........41 Inspecting and Replacing the Burner Nozzle ........42 Adjusting the Air Damper ..............43 Checking and Adjusting the Fuel Pressure .........44 Maintenance Periodic Maintenance Schedule ............46 Inspecting and Cleaning the Machine ..........47...

  • Page 9: Safety Information

    HDR 115 Safety Information Safety Information Signal Words Used in this Manual This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE signal words which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol.

  • Page 10: Machine Description And Intended Use

    HDR 115 Machine Description and Intended Use This machine is a direct-fired heater. The Wacker Neuson direct-fired heater operates on diesel fuel, which is consumed in a closed combustion chamber. The machine consists of a stainless steel combustion chamber, blower, single-stage burner, high-temperature shut-down device, and a fuel tank.

  • Page 11: Safety Guidelines For Operating The Machine

    ■ Familiarize yourself with the location and proper use of all controls and safety devices. ■ Contact Wacker Neuson for additional training if necessary. When operating this machine: ■ Do not allow improperly trained people to operate the machine. People operating the machine must be familiar with the potential risks and hazards associated with it.
  • Page 12 ■ Do not operate the machine if any safety devices or guards are missing or inoperative. ■ Do not modify or defeat the safety devices. ■ Only use accessories or attachments that are approved by Wacker Neuson. Safe When operating this machine: operating ■...

  • Page 13: Safety Guidelines For Lifting The Machine

    HDR 115 Safety Information Personal Wear the following Personal Protective Equipment (PPE) while operating this Protective machine: Equipment ■ Close-fitting work clothes that do not hinder movement (PPE) ■ Safety glasses with side shields ■ Hearing protection ■ Safety-toed footwear General Follow the guidelines below when placing the machine in the workspace.

  • Page 14: Safety Guidelines For Operating Combustion Burners

    Safety Information HDR 115 Safety Guidelines for Operating Combustion Burners When using the machine: ■ Clean up any spilled fuel immediately. ■ Replace the fuel tank cap after refueling the machine. ■ Refill the fuel tank in a well-ventilated area. ■...

  • Page 15: Service Safety

    Machine When servicing or maintaining the machine: modifications ■ Use only accessories/attachments that are approved by Wacker Neuson. When servicing or maintaining the machine: ■ Do not defeat safety devices. ■ Do not modify the machine without the express written approval of Wacker Neuson.
  • Page 16 Safety Information HDR 115 ■ When replacing electrical components, use components that are identical in rating and performance to the original components. ■ When replacement parts are required for this machine, use only Wacker Neuson replacement parts or those parts equivalent to the original in all types of specifications, such as physical dimensions, type, strength, and material.
  • Page 17 HDR 115 Safety Information Notes wc_si000963gb_FM10.fm...

  • Page 18: Labels

    Labels HDR 115 Labels Label Locations wc_gr013182 wc_si000964gb_FM10.fm...

  • Page 19: Label Meanings

    HDR 115 Labels Label Meanings WARNING WARNING WARNING Hot surface ADVERTENCIA ADVERTENCIA AVERTISSEMENT AVERTISSEMENT 5100015212 NOTICE Lifting point 78 kg 175 LB 5100019484 WARNING Electric shock hazard. Read Operator’s Manual for instructions. CAUTION This machine uses diesel fuel. CAUTION ATENCIÓN ATTENTION DIESEL 116679...
  • Page 20 Labels HDR 115 DANGER Asphyxiation hazard. Using this machine indoors CAN KILL YOU IN MINUTES. Burner exhaust and generator exhaust (if the machine is equipped with a generator) contains carbon monoxide. This is a poison you cannot see or smell. Never use inside an enclosed area even if doors and windows are open.
  • Page 21 HDR 115 Labels WARNING ■ Read and understand the supplied Operator's Manual before operating this machine. ■ The requirements of local authorities having jurisdiction shall be followed. ■ Do not use heater in close proximity of combustible surfaces or materials. ■...
  • Page 22 Labels HDR 115 CAUTION 10° Burn hazard. The front of the machine gets CAUTION ATENCIÓN ATTENTION very hot during operation. Do not touch the front of the machine when adjusting. 5100019485 WARNING ADVERTENCIA AVERTISSEMENT Restablecimiento después Réinitialisation Après Verrouillage Resetting From Restricted de una restricción o bloqueo Restreint Ou Complet or Hard Lockout...

  • Page 23: Lifting And Transporting

    HDR 115 Lifting and Transporting Lifting and Transporting Lifting the Machine ■ Lifting equipment (crane, hoist, or fork truck) capable of supporting the Requirements machine’s weight ■ Lifting devices (hooks, chains, and shackles) capable of supporting the machine’s weight ■ Machine unplugged Lifting the Perform the procedure below to lift this machine.

  • Page 24: Transporting The Machine

    Lifting and Transporting HDR 115 Transporting the Machine WARNING Fire hazard. Fuel is flammable and may ignite. ► Drain the fuel tank before transporting the machine. ■ Transport vehicle capable of supporting this machine Requirements ■ Machine unplugged Transporting Perform the procedure below to transport the machine to and from the job site. the machine 1.

  • Page 25: Machine Setup

    1. Make sure all loose packaging materials have been removed from the machine. 2. Check the machine and its components for damage. If there is visible damage, do not operate the machine! Contact your Wacker Neuson dealer immediately for assistance.

  • Page 26: Recommended Fuels

    Machine Setup HDR 115 Recommended Fuels Low ambient temperatures cause diesel fuels to gel. Gelled fuels will cause burner ignition failure and/or burner fuel pump damage. Always use the proper fuel for the conditions. Fuel Guide Lowest expected ambient temperature Fuel Type °F (°C) 15 to 25 (-10 to -4)

  • Page 27: Refueling The Machine

    HDR 115 Machine Setup Refueling the Machine ■ Machine shut down Requirements ■ Engine cool ■ Machine/fuel tank level with the ground ■ Fresh, clean fuel supply Procedure Perform the procedure below to refuel the machine. WARNING Fire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause severe burns.

  • Page 28: Assembling The Machine

    Machine Setup HDR 115 Assembling the Machine ■ Standard tools Requirements ■ Assistant or a lifting device capable of supporting the weight of the machine Procedure Perform the procedure below to assemble the machine. 1. Install the handle (q) using the screws (r). 2.

  • Page 29: Adjusting The Floor Guard

    HDR 115 Machine Setup Adjusting the Floor Guard Background The floor guard is slid back during shipping and must be slid out before use. WARNING Fire hazard. Exposure to heat due to the floor guard being improperly positioned may cause damage or burning to items under or around the heater. ►...

  • Page 30: Control / Component Locations

    Machine Setup HDR 115 Control / Component Locations wc_gr013062 Ref. Description Ref. Description Combustion chamber Reset button and reset lamp Burner Control switch Nozzle Remote thermostat connection port Solenoid valve Power indicator lamp Diesel pump Power cord Motor Adjustment handle Fuel cap Fuel filter Drain plug...

  • Page 31: Positioning The Machine

    ► Do not operate the machine near flammable vapors, fuels, or combustibles. CO Alarms Because this machine produces carbon monoxide (CO), Wacker Neuson recommends that CO alarms be installed in all structures in close proximity to the machine. CO alarms provide an extra measure of protection against this poison that you cannot see or smell.
  • Page 32 Machine Setup HDR 115 Continued from the previous page. Requirements Position the machine so that: ■ The machine is on a flat, firm surface. ■ Burner exhaust will not enter nearby structures. ■ The machine does not block traffic. ■ The machine is not close to any combustibles or flammable vapor. ■...

  • Page 33: Adjusting The Heater Output Angle

    HDR 115 Machine Setup Adjusting the Heater Output Angle Requirement Heater properly positioned CAUTION Pinch hazard. Several areas of the machine present pinching hazards if not properly aligned and secured. ► Be sure to align and secure the machine properly when adjusting. CAUTION Burn hazard.

  • Page 34: Electrical And Grounding

    Machine Setup HDR 115 Electrical and Grounding WARNING Fire and electric shock hazards. The use of an inappropriate power supply, or undersized extension cords, can lead to fire and electric shock. Fire and electric shock can cause severe injury. ► Before use, ensure that the machine is properly connected to an appropriate power source and grounded per the requirements provided below.

  • Page 35: Operating Status Indicators

    The burner lock-out must be cleared before machine operation can resume. ► To clear a burner lock-out, press and hold the reset lamp/reset button until the lamp goes out. See the chapter Troubleshooting or contact Wacker Neuson for additional help if necessary. wc_tx004174gb_Fm10.fm...

  • Page 36: Operation

    Operation HDR 115 Operation DANGER Carbon monoxide. Using the machine indoors CAN KILL YOU IN MINUTES. Exhaust gas contains carbon monoxide (CO). This is a deadly poison you cannot see or smell. If you can smell the exhaust, you are breathing CO. Even if you cannot smell the exhaust, you could be breathing CO.

  • Page 37: Starting The Machine

    HDR 115 Operation Starting the Machine ■ Machine properly positioned Requirements ■ Power connected ■ Pre-starting checks completed WARNING Burn hazard. The external surface of the machine and fuel filter may be hot. ► Wear safety gloves when handling the machine components. Procedure Perform the procedure below to start the machine.

  • Page 38: Stopping

    Operation HDR 115 Stopping Procedure Perform the procedure below to stop the machine. WARNING Electric shock hazard. Electric power is still active in the blower even when the machine is turned OFF. ► Remove all electric power to the machine before servicing the machine. 1.

  • Page 39: Installing And Using The Remote Thermostat

    Edison plug-style connection for use with commonly available thermostats. This adapter can be purchased using Wacker Neuson part #5200007098. NOTICE: The thermostat adapter is designed for use ONLY with a thermostat. To avoid damaging the machine, do not plug any other equipment into the thermostat adapter.

  • Page 40: Burner Setup

    Burner Setup HDR 115 Burner Setup Removing and Installing the Burner Assembly ■ Machine shut down and cool Requirements ■ Machine properly positioned CAUTION Hot surface hazard. The machine surfaces may be hot. ► Allow the machine to cool for a minimum of ten minutes before touching it. Procedure Before performing any maintenance on the burner assembly, it must be removed from the machine.

  • Page 41: Setting Up The Burner

    HDR 115 Burner Setup Setting up the Burner Factory settings Machine Nozzle size Fuel pressure Air damper 11.4 0.126 in. (3.2 mm) HDR 115 0.65 (80ºW) gph Checking and Adjusting the Electrodes ■ Machine shut down Requirements ■ Power disconnected ■...

  • Page 42: Inspecting And Replacing The Burner Nozzle

    Burner Setup HDR 115 Inspecting and Replacing the Burner Nozzle When Replace the burner nozzle annually or if it is damaged. ■ Machine shut down and cool to the touch Requirements ■ Machine properly positioned CAUTION Hot surface hazard. The machine surfaces may be hot. ►...

  • Page 43: Adjusting The Air Damper

    HDR 115 Burner Setup Adjusting the Air Damper When Adjust the air damper when burner performance is in question. Factory Air damper: 0.126 in (3.2 mm) settings Note: This parameter is factory-set. Effects The air setting has the following effects on combustion. ■...

  • Page 44: Checking And Adjusting The Fuel Pressure

    Burner Setup HDR 115 Checking and Adjusting the Fuel Pressure When Check the fuel pressure if the machine emits smoke during operation. ■ Machine shut down and cool to the touch Requirements ■ Hex key wrench ■ Fuel pressure gauge Background The information below will show you how to check the fuel pressure on your machine.
  • Page 45 HDR 115 Burner Setup Continued from the previous page. 7. Adjust the fuel pressure using the adjusting screw (d). ■ Clockwise increases fuel pressure ■ Counter-clockwise decreases fuel pressure wc_gr013183 NOTICE: Do not adjust the fuel pressure to a setting outside the operational parameters.

  • Page 46: Maintenance

    Maintenance HDR 115 Maintenance Periodic Maintenance Schedule Interval* (Hours of service) Daily 6 Months Yearly Task (1000) (1200) Inspect and clean the   machine.  Inspect the fuel hoses.  Check fuel level. Inspect electrical  components.  Inspect the CAD cell. ...

  • Page 47: Inspecting And Cleaning The Machine

    HDR 115 Maintenance Inspecting and Cleaning the Machine When Every 50 hours or as needed. ■ Machine shut down Requirements ■ Machine cool ■ Machine properly positioned DANGER Fire and explosion hazard. Residue from flammable materials such as solvents or gasoline could ignite and cause a fire or an explosion.
  • Page 48 Maintenance HDR 115 Continued from the previous page. The following internal components of the machine require regular cleaning to maintain optimum performance.  Enclosure (all areas must be free of dirt and debris)  Ventilator (b)  High-tension connectors (c) ...

  • Page 49: Removing The Access Panel

    HDR 115 Maintenance Removing the Access Panel ■ Machine shut down and cool Requirements ■ Machine properly positioned CAUTION Hot surface hazard. The machine surfaces may be hot. ► Allow the machine to cool for a minimum of ten minutes before touching it. Overview Your machine is equipped with removable access panels.

  • Page 50: Inspecting And Cleaning The Cadmium (Cad) Cell

    Maintenance HDR 115 Inspecting and Cleaning the Cadmium (CAD) Cell ■ Machine shut down and cool to the touch Requirements ■ Machine properly positioned CAUTION Hot surface hazard. The machine surfaces may be hot. ► Allow the machine to cool for a minimum of ten minutes before touching it. When Inspect and clean the CAD cell as needed, or while performing other scheduled maintenance procedures.

  • Page 51: Inspecting The Electrical Connections

    HDR 115 Maintenance Inspecting the Electrical Connections After disconnecting the power cord, check all electrical connections for the following: ■ Proper connections. Be sure that all connections are complete and tight. ■ Corrosion. Clean or replace if necessary. ■ Damaged wires/connectors. Replace if necessary. ■...

  • Page 52: Troubleshooting

    Troubleshooting HDR 115 Troubleshooting Problem Cause Remedy ■ ■ Motor does not start, no Electrical current is not Check the electrical present supply connection. ignition ■ Check proper positioning and functioning of switch. ■ Check fuse. ■ ■ Control setting is below Check setting of heater ambient temperature control.
  • Page 53 HDR 115 Troubleshooting Problem Cause Remedy ■ ■ Motor starts, heater emits Air supply is insufficient Make sure air inlet and outlet are unobstructed. smoke ■ Check setting of the air damper. ■ ■ Air supply is overly Check setting of sufficient the air damper.

  • Page 54: Technical Data

    Technical Data HDR 115 Technical Data Machine Model HDR 115 Units Max. heat output BTU/h 115,250 Fuel pressure Fuel consumption gal/h (L/h) 0.85 (3.2) V/Ø Power supply 120/1/60 Power consumption Current consumption 2.15 Run time (estimate) Fuel tank capacity gal/L 11.35 (43) Noise level at 1m Weight...

  • Page 55: Schematics

    HDR 115 Schematics 10 Schematics 10.1 HDR 115 BRAHMA TGRD71 CSA RL+LL wc_gr013086 110V/1PH/ 60Hz Description Description Control box Fuse Room thermostat plug Control switch Overheat thermostat Power indicator lamp Solenoid valve Heated filter (optional) CAD cell Reset button Capacitor Reset lamp Burner motor Electrodes...
  • Page 57 Wacker Neuson Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI. 53051 Tel.: (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong. Tel: (852) 3605 5360, Fax: (852) 2758 0032...

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