Wacker Neuson HDR155 Operator's Manual
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Wacker Neuson HDR155 Operator's Manual

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Document
Date
Revision
Language
Operator's Manual
Direct-Fired Air Heater
HDR155
HDR155
5200009218
0419
05
EN
5 2 0 0 0 0 9 2 1 8

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Summary of Contents for Wacker Neuson HDR155

  • Page 1 Operator’s Manual Direct-Fired Air Heater HDR155 Type HDR155 Document 5200009218 0419 Date Revision Language 5 2 0 0 0 0 9 2 1 8...
  • Page 2 Copyright notice © Copyright 2019 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 Expectations This manual provides information and procedures to safely operate and main- tain the above Wacker Neuson model(s). For your own safety and to reduce the information in risk of injury, carefully read, understand, and observe all instructions described this manual in this manual.
  • Page 6 Foreword HDR 155 wc_tx003204gb.fm...

  • Page 7: Table Of Contents

    HDR 155 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 Operating Combustion Burners ....... 14 Service Safety ..................15 Safety Guidelines for Lifting and Transporting the Machine ....
  • Page 8 Table of Contents HDR 155 Adjusting the Air Damper ..............39 Checking and Adjusting the Fuel Pressure .........40 Maintenance Periodic Maintenance Schedule ............42 Inspecting and Cleaning the Machine ..........43 Removing the Access Panel ...............45 Replacing the Fuel Heater Filter ............46 Inspecting and Cleaning the Cadmium (CAD) Cell ......47 Inspecting the Flame Head ..............48 Inspecting the Electrical Connections ..........48 Long Term Storage ................49...

  • Page 9: Safety Information

    HDR 155 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 155 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 HDR 155 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 155 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

    ■ Maintenance items that can be performed by the operator are listed in this manual. Other repairs should be performed by a qualified technician. Repairs can be hazardous if not performed correctly. Contact your Wacker Neuson dealer service department for additional information or for repairs to your machine.

  • Page 16: Safety Guidelines For Lifting And Transporting The Machine

    Safety Information HDR 155 When cleaning the machine: ■ Do not clean the machine while it is running. ■ Never use gasoline or other types of fuels or flammable solvents to clean the machine. Fumes from fuels and solvents can become explosive. ■...

  • Page 17: Labels

    HDR 155 Labels Labels Label Locations wc_gr010203 wc_si000733gb.fm...

  • Page 18: Label Meanings

    Labels HDR 155 Label Meanings WARNING Hot surface NOTICE Lifting point 136 kg ( 3 00 LB) 5200012779 WARNING! Electric shock hazard. Disconnect power before servicing. Read Operator’s Manual. CAUTION This machine uses diesel fuel. wc_si000733gb.fm...
  • Page 19 HDR 155 Labels Tie-down point. 113726 113726 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 20 Labels HDR 155 WARNING Read and understand the supplied Opera-  tor's Manual before operating this machine. The requirements of local authorities hav-  ing jurisdiction shall be followed. Do not use heater in close proximity of  combustible surfaces or materials. Ensure fresh air supply to space where ...
  • Page 21 HDR 155 Labels CAUTION CAUTION ATTENTION Burn hazard. The front of the machine gets very hot during operation. Do not touch the 10 10˚ ˚ front of the machine when adjusting. 5200012778 wc_si000733gb.fm...

  • Page 22: Lifting And Transporting

    Lifting and Transporting HDR 155 Lifting and Transporting Requirements Transport vehicle capable of carrying 180 lbs (81.6 kg) Crane or lift capable of carrying 180 lbs (81.6 kg) NOTICES Do not tow this machine. Do not route tie-down straps or chains over the top of the machine. Fuel may leak from the fuel tank cap during transport.

  • Page 23: Operation

    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 24: Parts Included

    Operation HDR 155 Parts Included wc_gr010574 Ref. Qty. Description Ref. Qty. Description Bolt Washer Washer Bolt with washer Lock nut Assembly diagram Allen-head screw Front guard Lock washer Lift bar Washer Handle Screw Wheel Locking pin Foot suport Washer Axle Hexagonal bolt Floor guard Wing nut...

  • Page 25: Assembling The Machine

    HDR 155 Operation Assembling the Machine Requirements Standard tools Extra person 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 (S) using the bolts (A), washers (B), and lock nuts (C). 2.

  • Page 26: Control / Component Locations

    Operation HDR 155 Control / Component Locations RESET wc_gr009909 Description Description Combustion chamber Drain plug Upper guard Fuel pump Lifting device Fuel filter Burner (flame head) Lower (floor) guard Transport handle Power cord Fuel tank cap Power indicator Fuel tank Thermostat receptacle Support Operation mode switch...

  • Page 27: Adjusting The Heater Output Angle

    HDR 155 Operation Adjusting the Heater Output Angle Requirement Heater on a level surface. CAUTION Pinch hazard. Several areas of the machine present pinching hazards if not properly alligned and secured. Be sure to align and secure the machine properly when adjusting. CAUTION Burn hazard.

  • Page 28: 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 29 HDR 155 Operation Continued from the previous page. Requirements Position the machine: So that burner exhaust will not enter nearby structures. So that the machine does not block traffic. So that the machine is not close to any combustibles or flammable vapor. So that the machine is not exposed to high levels of dust or airborne debris.

  • Page 30: Electrical And Grounding

    Operation HDR 155 Electrical and Grounding WARNING Fire and electric shock hazards. The use of an innappropriate 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 31: Recommended Fuels And Fuel Blending Guide

    HDR 155 Operation Recommended Fuels and Fuel Blending Guide 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 Blend Guide Lowest expected ambient Generator-powered Shore-powered...

  • Page 32: Starting The Machine In Extremely Cold Weather

    Operation HDR 155 4.10 Starting the Machine in Extremely Cold Weather Cold weather In temperatures below 32°F (0°C), it may be necessary to preheat the fuel inside the fuel filter canister. The fuel filter canister is equipped with a low-wattage heating element specially designed for this purpose.

  • Page 33: Starting The Machine

    HDR 155 Operation 4.11 Starting the Machine Requirements Machine properly positioned 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 To start the machine, follow the procedure below.

  • Page 34: Stopping

    To clear a burner lock-out, press and hold the burner fault lamp / reset button until the lamp goes out. Power The power indicator (g) illuminates if the supply power is present. indicator See Basic Troubleshooting or contact Wacker Neuson for additional help if necessary. wc_tx003206gb.fm...

  • Page 35: 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 36: Burner Setup

    Burner Setup HDR 155 Burner Setup Removing and Installing the Burner Assembly Requirements Machine shut down and cool 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 37: Setting Up The Burner

    HDR 155 Burner Setup Setting Up the Burner Factory settings Machine Nozzle size Fuel pressure Air damper HDR 155 0.85 (80ºW) gph Checking and Adjusting the Electrodes Requirements Machine shut down Power disconnected Burner cool When to Inspect the electrodes on your machine every two weeks or after every 50 hours of inspect operation.

  • Page 38: Replacing The Burner Nozzle

    Burner Setup HDR 155 Replacing the Burner Nozzle When Replace the burner nozzle annually, or if it is damaged. Requirements Machine shut down and cool to the touch 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.

  • Page 39: Adjusting The Air Damper

    HDR 155 Burner Setup Adjusting the Air Damper When Adjust the air damper when burner performance is in question. Factory Air damper: 2 settings Note: This parameter is factory-set. Effects The air setting has the following effects on combustion. Higher O percentage (excess air settings) lowers soot production but raises stack temperature and reduces efficiency: lean mixture.

  • Page 40: Checking And Adjusting The Fuel Pressure

    Burner Setup HDR 155 Checking and Adjusting the Fuel Pressure When Check the fuel pressure if the machine emits smoke during operation. Requirements Machine shut down and cool to the touch Power disconnected Fuel pressure gauge Background The information below will show you how to check the fuel pressure on your machine.
  • Page 41 HDR 155 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_gr010095 NOTICE: Do not adjust the fuel pressure to a setting outside the operational parameters.

  • Page 42: Maintenance

    Maintenance HDR 155 Maintenance Periodic Maintenance Schedule Interval* (Hours of service) Daily 2 Weeks 6 Months Yearly Task (50) (1000) (1200) Inspect and clean the machine. Inspect the fuel hoses. Check fuel level and pressure. Clean the fuel filter. Inspect electrical components.

  • Page 43: Inspecting And Cleaning The Machine

    HDR 155 Maintenance Inspecting and Cleaning the Machine When Every 50 hours or as needed. Requirements Machine shut down 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. Do not use flammable materials or solvents to clean the machine.
  • Page 44 Maintenance HDR 155 Procedure Perform the procedure below to clean the interior components of the machine. 1. Remove the access cover. See topic Removing the Access Panel. 2. Use compressed air to clean the enclosure and ventilator (b). 3. Inspect and clean the high-tension connnectors and wires (d). Replace any damaged or worn components.

  • Page 45: Removing The Access Panel

    HDR 155 Maintenance Removing the Access Panel Requirements Machine shut down and cool 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 46: Replacing The Fuel Heater Filter

    Maintenance HDR 155 Replacing the Fuel Heater Filter Requirement Machine shut down and cool CAUTION Hot surface hazard. The external surface of the fuel filter canister may be hot. Allow the machine to cool before servicing. WARNING Hot fluids. The fuel inside the fuel filter canister may be hot. Wear safety glasses.

  • Page 47: Inspecting And Cleaning The Cadmium (Cad) Cell

    HDR 155 Maintenance Inspecting and Cleaning the Cadmium (CAD) Cell Requirements Machine shut down and cool to the touch 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 48: Inspecting The Flame Head

    Maintenance HDR 155 Inspecting the Flame Head Requirements Machine shut down and cool to the touch 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 the flame head prior to the first seasonal use, during regular maintenance, and as needed.

  • Page 49: Long Term Storage

    HDR 155 Maintenance Long Term Storage Introduction Extended storage of equipment requires preventative maintenance. Performing these steps helps to preserve machine components and ensures the machine will be ready for future use. While not all of these steps necessarily apply to this machine, the basic procedures remain the same.

  • Page 50: Basic Troubleshooting

    Note: The following symptoms and remedies are some of the more common issues that have arisen during the history of these machines. These do not represent all the possibilities. If you need advanced troubleshooting assistance, please contact Wacker Neuson Product Support. Problem Cause...
  • Page 51 HDR 155 Basic Troubleshooting Problem Cause Remedy Motor starts, heater emits Air supply is insufficient Make sure air inlet and out- smoke let are unobstructed. Check setting of combus- tion air flap. Clean burner disc. Air supply is overly suffi- Check setting of combus- cient tion air flap.

  • Page 52: Technical Data

    Technical Data HDR 155 Technical Data Machine Model HDR 155 - 5200007530 Units Max. heat output BTU/h 154,000 Fuel pressure Fuel consumption gal/h (L/h) 1.1 (4.16) Power supply F/V/Hz 1/120/60 Power consumption Fuel tank capacity gal/L 17.17 (65) Noise level at 1m Weight lb(kg) 180 (81.6)

  • Page 53: Schematics

    HDR 155 Schematics Schematics HDR 155 wc_gr012088 Description Description Fuse Control Overheat thermostat Remote thermostat plug Solenoid valve Control box CAD cell Heated fuel filter Capacitor Tip switch Fan motor Reset switch Electric pilot lamp — — Wire Colors Black Yellow Orange Green...
  • Page 55 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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