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Wacker Neuson E 1250 Operator's Manual
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Wacker Neuson E 1250 Operator's Manual

Wacker Neuson E 1250 Operator's Manual

Hydronic surface heater
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Operator's Manual
Hydronic Surface Heater
E 1250
5200016690
01
0115
5
2
0
0
0
1
6
6
9
0

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Summary of Contents for Wacker Neuson E 1250

  • Page 1 Operator’s Manual Hydronic Surface Heater E 1250 5200016690 0115...
  • Page 2 Copyright notice © Copyright 2015 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 Hydronic Surface Heater Foreword Foreword THIS HEATER IS SUITABLE FOR OUTDOOR USE ONLY. WARNING FAILURE TO COMPLY WITH THE PRECAUTIONS AND INSTRUCTIONS PROVIDED WITH THIS HEATER CAN RESULT IN DEATH, SERIOUS BODILY INJURY AND PROPERTY LOSS OR DAMAGE FROM HAZARDS OF FIRE, BURN, ASPHYXIATION, CARBON MONOXIDE POISONING, AND / OR ELECTRICAL SHOCK.
  • Page 4 Canadian Electrical Code Part I, CSA C22.1, Electrical Code. READ AND SAVE THESE INSTRUCTIONS—This manual contains important instructions for the machine models below. These instructions have been written expressly by Wacker Neuson Production Americas LLC and must be followed during installation, operation, and maintenance of the machines. Machine...
  • Page 5 The information contained in this manual is based on machines manufactured up until the time of publication. Wacker Neuson reserves the right to change any portion of this information without notice. The illustrations, parts, and procedures in this manual refer to Wacker Neuson factory-installed components.
  • Page 6 Serious injury hazards to the operator and persons in the work area Permanent damage to the machine which will not be covered under warranty Contact your Wacker Neuson dealer immediately if you have questions about approved or unapproved parts, attachments, or modifications.
  • Page 7 Hydronic Surface Heater Table of Contents Foreword Safety Information Signal Words Used in this Manual ............. 11 Machine Description and Intended Use ..........12 Safety Guidelines for Operating the Machine ........13 Safety Guidelines for Lifting and Transporting the Machine ....15 Safety Guidelines for Towing the Machine .........
  • Page 8 Table of Contents Hydronic Surface Heater 4.15 Connecting Power to the Machine ............52 4.16 Starting the Generator Engine ............53 4.17 Starting the Machine ................54 4.18 Unwinding and Positioning the Hoses ..........56 4.19 Hose Spacing Guidelines ..............57 4.20 Operating the Machine ...............
  • Page 9 Hydronic Surface Heater Table of Contents Removing the Combustion Head ............89 Adjusting the Ionization Probe and the Electrode ......90 Changing the Burner Orifice ............... 91 Checking the Burner Air Damper Setting ........... 92 Adjusting the Head Setting ..............93 Checking the Supply Gas Pressure ...........
  • Page 10 Table of Contents Hydronic Surface Heater 12 Schematics 12.1 Electrical Wiring Diagram ..............140 12.2 Wiring Diagram Components ............141 wc_bo5200016690_01TOC.fm...
  • Page 11 Hydronic Surface Heater 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 12 In addition, when used with other Wacker Neuson accessories, this machine can be used to heat air. This machine has been designed and built strictly for the intended use(s) described above.
  • Page 13 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 14 Do not modify or defeat the safety devices. Only use accessories or attachments that are approved by Wacker Neuson. Do not start the machine unless all cleanout doors are secured in place. Do not attempt to start the machine when excess oil has accumulated, when machine is full of vapor, or when the combustion chamber is very hot.
  • Page 15 Hydronic Surface Heater Safety Information Safety Guidelines for Lifting and Transporting the Machine When lifting the machine: Make sure slings, chains, hooks, ramps, jacks, forklifts, cranes, hoists, and any other type of lifting device used is attached securely and has enough weight- bearing capacity to lift or hold the machine safely.
  • Page 16 Safety Information Hydronic Surface Heater Safety Guidelines for Towing the Machine WARNING Risk of severe injury or death. Improper trailer condition and towing technique can lead to an accident. Obey the trailer manufacturer’s instructions and the instructions below to reduce the risk of an accident.
  • Page 17 Hydronic Surface Heater Safety Information Safety Guidelines for Operating Combustion Burners When using the machine: Make sure you have proper certification or licensing required by the locality, state, or province in which the machine is being installed to connect natural gas or LP.
  • Page 18 If you believe your trailer has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Wacker Neuson. If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in a group of trailers, it may order a recall and remedy campaign.
  • Page 19 Follow instructions carefully. Should questions arise during operation or service of this equipment, contact your Wacker Neuson dealer. General Keep a multi-class, type ABC or equivalent fire extinguisher at hand when using precautions the genset.
  • Page 20 Safety Information Hydronic Surface Heater Running the Do not start the engine if fuel has spilled or a fuel odor is present. genset Keep the area around the exhaust pipe free of flammable materials. Do not smoke while operating the genset. Keep sparks, flames, electrical arcs, and other sources of ignition far away from the genset.
  • Page 21 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 22 Safety Information Hydronic Surface Heater 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. Cleaning When cleaning and servicing the machine: Keep the machine clean and free of debris such as leaves, paper, cartons, etc.
  • Page 23 Hydronic Surface Heater Labels Labels wc_gr011817 wc_si000843gb.fm...
  • Page 24 Labels Hydronic Surface Heater Label Meanings WARNING WARNING Never operate in an explosive atmosphere or near flammable vapors, fuels Never operate in an explosive environment or combustibles. Explosion or fire may occur. Risk of severe injury or death. ADVERTENCIA Nunca opere en un atmósfera explosiva o cerca de los vapores inflamables, or near flammable vapors, fuels, or combus- gasolina o combustibles.
  • Page 25 Hydronic Surface Heater Labels Heat Transfer Fluid level. This label indicates the minimum and maximum levels for the Heat Transfer Fluid. This label is located adjacent to the sight gauge on the Heat Transfer Fluid reservoir. 172365 Forklift lift point 183236 WARNING Hot surface...
  • Page 26 Labels Hydronic Surface Heater WARNING WARNING Hot surface hazard. ADVERTENCIA Wear hand protection. AVERTISSEMENT Wear eye protection. 173199 Weight/mass label 3775 1712 5200018780 CAUTION This machine uses diesel fuel. CAUTION CAUTION Lug nuts must be tightened to 110ft.lbs. Wheel nuts must be tightened to 110 ft. lbs. ATENCIÓN Tuercas de las ruedas tienen que ser apretadas a 110 pies-lb.
  • Page 27 Hydronic Surface Heater Labels CAUTION! Pressurized contents. Do not open when hot! WARNING WARNING WARNUNG WARNUNG ADVERTENCIA ADVERTENCIA AVERTISSEMENT AVERTISSEMENT 110164 110164 Notification of National Association of Trailer Manufacturers (NATM) compliance Emergency stop 155460 WARNING Hot surface Lifting point wc_si000843gb.fm...
  • Page 28 Labels Hydronic Surface Heater WARNING WARNING Do not engage trailer jack while transporting ADVERTENCIA the machine. AVERTISSEMENT Read the Operator’s Manual for further instructions. 173200 Uncoupling will cause trailer to come loose from tow vehicle. 1. CHECK the pintle LOAD RATING is same or great than ring LOAD RATING. 2.
  • Page 29 Hydronic Surface Heater Labels WARNING WARNING ADVERTENCIA ADVERTENCIA AVERTISSEMENT AVERTISSEMENT Lights can prevent trailer from being Lights can prevent trailer from being Las luces pueden evitar que otros vehículos Las luces pueden evitar que otros vehículos Des feux peuvent empêcher la remorque d'être Des feux peuvent empêcher la remorque d'être hit by other vehicles.
  • Page 30 Labels Hydronic Surface Heater To start the machine (I): 1. Check the level of the Heat Transfer Fluid. Also check the level of fuel in the diesel fuel tank. 2. Connect the machine to the electric power source. 3. Move the circuit breaker switch to the ON position. Also press the ON/OFF switch.
  • Page 31 Hydronic Surface Heater Labels Heater rating plate: This plate displays important technical information relating to the setup and operation of the machine. — WARNING Licensed gas technician required. Natural gas / liquid propane 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...
  • Page 32 Lifting and Transporting Hydronic Surface Heater Lifting and Transporting Preparing the Machine for Transport on a Truck or Trailer Requirements Machine stopped. Flatbed truck or trailer capable of supporting the machine’s weight. Chains, hooks, or straps capable of supporting the machine’s weight. WARNING Crushing hazard.
  • Page 33 Hydronic Surface Heater Lifting and Transporting Transporting the Machine on a Truck or Trailer WARNING Crushing hazard. Improperly securing the machine can lead to a crushing hazard. Use only the designated tie-down points to secure the machine. NOTICE: Do not run chains or straps across any painted surface. The machine may be damaged by chaines or straps.
  • Page 34 Lifting and Transporting Hydronic Surface Heater Before Towing Checklist Before towing the machine, check the licensing requirements for trailers in your area. Also check the following items: Hitch and coupler Check that the towing vehicle and hitch have a rating equal to or greater than the GVWR of the machine.
  • Page 35 Hydronic Surface Heater Lifting and Transporting Lifting the Machine Requirements Properly-rated lifting equipment (crane or hoist) Machine stopped All doors and access covers closed and secured WARNING Crushing hazard. You may be crushed if the lifting devices fail. Never stand under, or get onto, the machine while it is being lifted or moved. Use only the designated lifting points to lift the machine.
  • Page 36 Lifting and Transporting Hydronic Surface Heater Testing the Breakaway System (Electric Brakes) Requirements Voltmeter Battery charger or backup battery (charged) When Test the breakaway system: Before towing Monthly if the machine is not in service Procedure Perform the following procedure to test the breakaway system. NOTICE: Disconnect the trailer wiring plug from the tow vehicle before testing.
  • Page 37 Hydronic Surface Heater Lifting and Transporting Continued from the previous page. 5. If the brakes did not function, check the voltage of the breakaway battery. To do a. Remove the cover of the battery box. b. Remove the wires connected to the breakaway battery (d). c.
  • Page 38 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 39 Hydronic Surface Heater Operation General Sequence of Operation Follow the sequence of operation below. Refer to the specific topic for details. Task When/Where See Topic Before leaving for the job site. 4.10 1. Check HTF level. Or, when at the job site before —...
  • Page 40 Operation Hydronic Surface Heater External Components wc_gr011924 Note: Graphic is representative only. Your machine may vary. Ref. Description Ref. Description Trailer with safety chains Trailer Hose reel access door Burner access door Control panel access Trailer tongue bracket Accessory hose manifold Air intake grate Fuel fill port Strobe light...
  • Page 41 Hydronic Surface Heater Operation Internal Components-Burner Access Door wc_gr011925 Note: Graphic is representative only. Your machine may vary. Ref. Description Ref. Description Fuel fill HTF temperature probe Fuel tank HTF sight gauge Fuel filter Hydronic heater Burner — — wc_tx003584gb.fm...
  • Page 42 Operation Hydronic Surface Heater Internal Components-Rear Access Doors wc_gr011926 Note: Graphic is representative only. Your machine may vary. Ref. Description Ref. Description Door prop rod HTF accessory supply Hose reel and HTF hose HTF accessory return Main control panel Accessory power receptacle Main power receptacle Generator control panel HTF flow indicator...
  • Page 43 Hydronic Surface Heater Operation Main Control Panel Components wc_gr011562 Description Main Function(s) Main power switch Switches power on and off Control display Displays status message Instructs the user on machine operation See Control Display Screen Status indicator Shows overall status of the machine as follows: Red - Fault Yellow - Warning (preheating) Green - OK...
  • Page 44 Operation Hydronic Surface Heater Generator Control Panel Components wc_gr011570 Description Function Engine control Controls engine starting and stopping procedures. Allows the user to select auto start mode. Refer to user manual for control. Control switch Controls power to the engine starter solenoid. Allows the user to prime the fuel system.
  • Page 45 Hydronic Surface Heater Operation Control Display Screen WACKER NEUSON [MODEL] HYDRONIC CONTROL SETPOINT ( F): SUPPLY ( F): 63 Return- F 0.0 PSI 0.0 GPM Power: Fuel: 80.0 GAL/100% Volts: Burner: Heat Call: OFF Pump: Faults: NONE wc_gr011618 Ref. Description...
  • Page 46 Operation Hydronic Surface Heater 4.10 Checking the HTF Level When Before leaving for the job site, or Before beginning operation at the job site. NOTICE: Running the machine with low HTF will damage the pumps. Requirements The machine is level. The machine is cool.
  • Page 47 Hydronic Surface Heater Operation 4.11 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 48 Operation Hydronic Surface Heater 4.12 Refueling the Machine Requirements Machine shut down Machine level with the ground Diesel fuel supply CAUTION Fire and health hazard. Fuel expands when heated. Expanding fuel in a overly-full tank can lead to spills and leaks. Do not overfill the fuel tank.
  • Page 49 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 50 Operation Hydronic Surface Heater Continued from the previous page. Requirements Position the machine: On solid, stable, and level ground. So that 1 ft. (305 mm) clearance is maintained on all sides during operation. So that the air intake on the machine are not obstructed during operation. So that proper ventilation is maintained during operation.
  • Page 51 Hydronic Surface Heater Operation 4.14 Before Starting the Machine WARNING Personal injury hazard. Failure to follow the listed procedures may cause injury to personnel or damage to the machine. Make sure that all persons setting up the machine are certified or fully trained on the installation of the machine.
  • Page 52 Operation Hydronic Surface Heater 4.15 Connecting Power to the Machine Prerequisites Power source Machine properly positioned WARNING Fire hazard and electric shock hazard. The use of under-sized extension cords can lead to fire and electric shock. Fire and electric shock can cause severe injury. Do not use under-sized extension cords.
  • Page 53 Hydronic Surface Heater Operation 4.16 Starting the Generator Engine Requirements Machine positioned Prestarting checks complete Powering Perform the procedure below to start the engine. 1. Move the circuit breaker (a) to the ON position. wc_gr011573 Priming NOTICE: The fuel system will need to be primed if: Fuel system has run dry Fuel system has been drained The fuel filter has been changed...
  • Page 54 2. Move the Main Power switch (a) to the ON position. The control display (b) indicates that power is ON. The status indicator light flashes green. All other functions are be disabled. WACKER NEUSON [MODEL] HYDRONIC CONTROL SETPOINT ( F): SUPPLY ( F): 63 Return- F 0.0 PSI 0.0 Flow...
  • Page 55 F (10 ° ° The control display indicates that the pump is on. The return, pressure, and flow parameters display current values. WACKER NEUSON [MODEL] HYDRONIC CONTROL SETPOINT ( F): SUPPLY ( F): 18O 18O 120 Return- F 140 PSI 2.0 Flow...
  • Page 56 Operation Hydronic Surface Heater 4.18 Unwinding and Positioning the Hoses Requirements HTF preheated if applicable HTF flow initiated CAUTION Burn hazard. The hoses and components of the plumbing system may be very hot. Hot hoses and hot plumbing components may cause severe burns. Wear hand protection when handling hot hoses and plumbing components.
  • Page 57 When laying hose in the application area, the space between individual lines of hose significantly affects the progress of the application. Although it is impossible to predict the ambient conditions for each job site, Wacker Neuson recommends observing the following guidelines to maximize efficiency.
  • Page 58 The HTF return temperature tells you how much heat is being transferred. It can also tell you when a thawing process is complete, as very little heat will be transferred at that point. Consult Wacker Neuson Product Support for detailed information. Strobe light Flashing green strobe signifies that all systems are OK.
  • Page 59 Hydronic Surface Heater Operation 4.21 Rewinding the Hoses Requirements All accessories off—if applicable Machine main power on Insulation blankets removed—if applicable CAUTION Burn hazard. The hoses and components of the plumbing system may be very hot. Hot hoses and hot plumbing components may cause severe burns. Wear hand protection when handling hot hoses and plumbing components.
  • Page 60 Operation Hydronic Surface Heater 4.22 Stopping Perform the procedure below to stop the machine. 1. Turn off any external pumps, hose handling systems, or other accessories if applicable. 2. Set the pump (e) and burner (c) switch to the OFF position. wc_gr011592 wc_gr011593 3.
  • Page 61 Hydronic Surface Heater Operation 4.23 Stopping the Engine Stopping Perform the procedure below to stop the engine. 1. Press the STOP push-button (c) on the engine control. wc_gr012533 wc_gr012534 2. After the engine has stopped, set the circuit breaker (a) to the OFF position. wc_tx003584gb.fm...
  • Page 62 Operation Hydronic Surface Heater 4.24 Quick-Connect Coupling Usage and Care CAUTION Burn hazard. The hoses and components of the plumbing system may be very hot. Hot hoses and hot plumbing components may cause severe burns. Wear hand protection when handling hot hoses and plumbing components. Precautions Do not join or separate quick-connect couplings when the pressure gauge indicates the lines are pressurized.
  • Page 63 Operation 4.25 Filling the HTF (Low Level Fault Condition) Requirements Genuine Wacker Neuson Heat Transfer Fluid, or Dowfrost HD 50 Heat Transfer Fluid An assistant NOTICE: Use only factory-recommended Heat Transfer Fluid (HTF). Failure to do so may damage the machine.
  • Page 64 Operation Hydronic Surface Heater Continued from the previous page. 5. Hold the reset switch (e) down while pushing up on the temperature switch (d). The pump will activate and begin filling the HTF reservoir. wc_gr012391 6. Release the switches when the pump stops. The float switch has activated signalling the reservoir is mostly full.
  • Page 65 Hydronic Surface Heater Operation 4.26 Options Menu Background The controller includes an options menu on which the user can adjust functional parameters, screen brightness and contrast, and view run timers. The machine must be shut down in order to access this menu. CUSTOMER OPTIONS Parameters Display...
  • Page 66 Operation Hydronic Surface Heater Accessing the To acces the options menu, the machine must be shut down according the options menu instructions in this manual. See Stopping. Follow the procedure below. NOTICE: Do not use the customer options menu unless you have the proper training on machine function, parameters, and setup.
  • Page 67 Hydronic Surface Heater Accessories Accessories To expand the machine’s capabilities and capacities, the following Wacker Neuson accessories can be purchased at your local Wacker Neuson dealer. Basic machines are not compatible with accessories. Contact your local Wacker Neuson dealer to determine the capabilities of your machine.
  • Page 68 Accessories Hydronic Surface Heater Hose Handling Systems Add a Hose Handling System (and a Pump Pack) to Hydronic Heater models to thaw even more faster, or increase size of area for frost prevention or concrete curing. Available in several sizes, all units are equipped with Heat Transfer Hose filled with Heat Transfer Fluid, quick-connect brass fittings, and electric foot pedal rewind system.
  • Page 69 + adapter (6600) (9900) Air Heat The standard Hydronic Heater can be combined with Wacker Neuson accessories Conversion to convert the target application to air heat. The typical configurations are shown below; however, these do not represent all possible configurations. Contact Wacker Neuson for more information.
  • Page 70 Accessories Hydronic Surface Heater Expansion Diagram - 1 X HHS1101 + 1 X SPP (U.S. only) NOTICE: Shut down the machine before connecting accessories. wc_gr011776 Ref. Description Ref. Description Hydronic Surface Heater HHS hose Hose Handling System (HHS) Accessory connection manifold Single Pump Pack (SPP) Main hose connection manifold Main hose...
  • Page 71 Hydronic Surface Heater Accessories Expansion Diagram - 1 X HHS2202 (702) + 1 X DPP + Adapter NOTICE: Shut down the machine before connecting accessories wc_gr011777 Ref. Description Ref. Description Hydronic Surface Heater HHS hose (loop 2) Hose Handling System (HHS) Accessory connection manifold Dual Pump Pack (DPP) Main hose connection manifold...
  • Page 72 Accessories Hydronic Surface Heater Connecting Two HX 50 (HX 15) Heat Exchangers Requirements Machine stopped Two HX 50 or HX 15 Heat Exchangers One 2-1 adapter One 1-2 adapter Limitations Maximum run (horizontal distance from HX to machine): 228 m (750 ft) Maximum rise (vertical distance of HX above machine): 76 m (250 ft) Maximum run at maximum rise: 215 m (707 ft) Note: The farther the HX is positioned from the parent machine, the more heat will...
  • Page 73 Hydronic Surface Heater Accessories Connecting a HX 100 (HX 30) Heat Exchanger Requirements Machine stopped One HX 100 or HX 30 Heat Exchanger Limitations Maximum run (horizontal distance from HX to machine): 228 m (750 ft) Maximum rise (vertical distance of HX above machine): 76 m (250 ft) Maximum run at maximum rise: 215 m (707 ft) Note: The farther the HX is positioned from the parent machine, the more heat will be lost through the hose.
  • Page 74 Burner Setup Hydronic Surface Heater Burner Setup Factory settings Firing rate Fuel pressure Air band Head Nozzle size L/hr (gph) bar (psi) setting shutter — 0.85 60° A 12.1 (175) Setting up the Burner Background The burner consists of several different components and subsystems. Each of these components or subsystems must be operating correctly for the burner to function properly.
  • Page 75 Hydronic Surface Heater Burner Setup Continued from the previous page. When Adjust the burner: Before operating the machine at elevations 305 m (1,000 ft) above or below the location of the previous adjustments Before starting at a new job site After any burner maintenance or repair has been performed If burner performance is in question Procedure...
  • Page 76 Burner Setup Hydronic Surface Heater Continued from the previous page. 9. Analyze the combustion. Follow the combustion analyzer manufacturer’s instructions and the general guidelines below. Use the access hole in the exhaust stack. Take several samples as the heater warms. Take the final sample just before the heater reaches 71°C (160°F).
  • Page 77 Hydronic Surface Heater Burner Setup Setting/Checking the Electrodes Requirements Power supplies disconnected Measuring device Procedure Perform the procedure below to check the electrodes. 1. Disconnect the power supplies feeding the machine. 2. Loosen the copper fuel line (a) between the fuel pump and the burner housing. wc_gr008521 3.
  • Page 78 Burner Setup Hydronic Surface Heater Continued from the previous page. 7. Remove the turbulator assembly (f) from the nozzle assembly. wc_gr008520 8. Use the measurements below to properly set the electrodes. Ref. Description Gap distance Electrode tip to electrode tip 5/32 in.
  • Page 79 Hydronic Surface Heater Burner Setup Checking/Replacing the Burner Nozzle Requirements Power supplies disconnected Machine cool Procedure Perform the procedure below to replace the burner nozzle. 1. Disconnect the power supplies feeding the machine. 2. Loosen the copper fuel line (a) from the burner housing. wc_gr008521 3.
  • Page 80 Burner Setup Hydronic Surface Heater Continued from the previous page. 7. Remove the turbulator assembly (e) from the nozzle/electrode assembly. wc_gr005544 wc_gr008520 8. Unscrew the burner nozzle from the burner tube and install a new burner nozzle. Note: Do not use thread sealant on the threads of the nozzle. 9.
  • Page 81 Hydronic Surface Heater Burner Setup Setting the “Z” Distance Requirements Burner removed from the machine T501 gauge or measuring device Procedure Follow the procedure below to set the “Z” distance on “L” heads. 1. Remove the burner from the machine. 2.
  • Page 82 Burner Setup Hydronic Surface Heater Adjusting the Air Settings Factory Air band: 2 settings Air shutter: 4 These settings are initial settings only. Adjust the air settings as necessary to obtain the proper smoke spot and combustion analysis values. Background There are two parts to adjusting the air setting: 1) air band;...
  • Page 83 Hydronic Surface Heater Burner Setup Setting the Fuel Pressure Factory Factory settings: setting “L” head: 175 psig (12.1 bar) Procedure Follow the procedure below to check and adjust the fuel pressure. 1. Shut down the machine. 2. Remove the bleeder valve (a) from the fuel pump. 3.
  • Page 84 Burner Setup Hydronic Surface Heater Removing the Burner Requirements Power supplies disconnected Machine cool Procedure Perform the procedure below to remove the burner. 1. Disconnect the power supplies. 2. Disconnect fuel lines (a) at the quick-connects. wc_gr008524 3. Remove the primary control (b) to expose the wiring. Label all the wires to assist in reconnecting.
  • Page 85 Hydronic Surface Heater Burner Setup Installing the Burner Requirements Power supplies disconnected Machine cool Procedure Perform the procedure below to install the burner. 1. Position the burner inside the machine and secure it to the hydronic heater. wc_gr008524 2. Connect fuel lines (a) at the quick-connects. 3.
  • Page 86 Burner Setup—Gas E1250 Burner Setup—Gas Factory Settings - NG/LP Parameter Air damper setting Combustion head setting Gas manifold pressure (in. w.c.) Orifice (mm) / Diaphragm 2.0 / B5 1.3 / B16 wc_tx003588gb.fm...
  • Page 87 E1250 Burner Setup—Gas Setting up the Burner Background The burner consists of several different components and subsystems. Each of these components or subsystems must be operating correctly for the burner to function properly. Tools required The following tools are required to adjust the burner: High-quality combustion analyzer Smoke spot tester Fuel pressure test gauge...
  • Page 88 Burner Setup—Gas E1250 Continued from the previous page. Smoke spot testing guidelines wc_gr012400 Use the access hole in the exhaust stack. Several samples should be taken as the heater warms. The final sample should be taken just before the heater reaches 71°C (160°F). 10.Analyze the combustion.
  • Page 89 E1250 Burner Setup—Gas Removing the Combustion Head Requirements Machine shut down Burner cool Procedure Perform the procedure below to remove the combustion head assembly. 1. Open the access door and locate the burner. 2. Remove the burner cover. 3. Remove nut (a) and open the burner. wc_gr012411 wc_gr012412 4.
  • Page 90 Burner Setup—Gas E1250 Adjusting the Ionization Probe and the Electrode Requirements Machine shut down Burner cool Procedure Perform the procedure below to adjust both the ionizatIon probe and the electrode. 1. Shut down the machine and allow it to cool. 2.
  • Page 91 E1250 Burner Setup—Gas Changing the Burner Orifice Requirements Machine shut down Machine cool Procedure Perform the procedure below to change the burner orifice. 1. Shut down the machine and allow it to cool. 2. Remove the combustion head assembly (a). See topic Removing the Combustion Head Assembly.
  • Page 92 Burner Setup—Gas E1250 Checking the Burner Air Damper Setting Requirements Machine shut down Burner cool Procedure Follow the procedure below to check the air damper setting. Note: This procedure must be performed at each new job site. The proper setting depends on environmental conditions at the job site.
  • Page 93 E1250 Burner Setup—Gas Adjusting the Head Setting Requirements Machine shut down Machine cool Procedure Perform the procedure below to adjust the head setting. 1. Open the access doors and locate the burner. 2. Remove the burner assembly cover. 3. Remove nut (a) and open the burner. wc_gr012411 wc_gr012412 4.
  • Page 94 Burner Setup—Gas E1250 Checking the Supply Gas Pressure Requirements Machine shut down Supply gas turned off Manometer Nipple Checking Perform the procedure below to check and adjust the supply gas pressure. pressure 1. Shut down the machine and allow it to cool. 2.
  • Page 95 E1250 Burner Setup—Gas Changing the Burner from Natural Gas Burning to LP Burning Requirements Machine shut down Machine cool Background The burner is set up at the factory to burn natural gas (NG). By changing the burner orifice and adding an air restricting washer, the burner can burn LP gas. A kit is included with new machines with the appropriate orifice and the air restricting washer.
  • Page 96 General Maintenance Hydronic Surface Heater General Maintenance WARNING A poorly maintained machine can malfunction, causing injuries or permanent damage to the machine. Keep the machine in safe operating condition by performing periodic mainte- nance and making repairs as needed. Preparing for Maintenance Do not perform even routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut down.
  • Page 97 Hydronic Surface Heater General Maintenance Periodic Maintenance Schedule The table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment. Refer to the generator manufacturer’s operation manual for generator maintenance procedures.
  • Page 98 General Maintenance Hydronic Surface Heater Cleaning the Machine When As needed Suggested Compressed air cleaning Clean water supply materials Mild detergent Clean, dry cloths NOTICE: Do not use a pressure washer to clean this machine. Pressurized water can severely damage the generator and sensitive electronic components. Cleaning the Clean the interior of the machine.
  • Page 99 Hydronic Surface Heater General Maintenance Maintaining the Trailer Tires Keep tires inflated to the proper pressure as shown on the tire sidewall. Check tread periodically for wear. Replace tires as required. Wheels Check that lug nuts holding wheels are tight. Replace any missing lug nuts immediately.
  • Page 100 Repairing a Hose Requirements Hose nipple Two hose ferrules Hose crimping tool, Wacker Neuson part number 5000169002 Procedure Follow the procedure below to repair a damaged hose. 1. Shut down the machine and allow the Heat Transfer Fluid (HTF) to cool.
  • Page 101 Hydronic Surface Heater General Maintenance Continued from the previous page. 7. Use a Wacker Neuson brand hose crimper (e) to crimp both ferrules. 8. Rotate the hose 90 degrees and crimp both ferrules again. The procedure is now complete. wc_tx003589gb.fm...
  • Page 102 General Maintenance Hydronic Surface Heater Cleaning the HTF Strainer Requirements Machine shut down Source of clean, warm water Removal Perform the procedure below to clean the HTF strainer. Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid which drains off.
  • Page 103 Hydronic Surface Heater General Maintenance Continued from the previous page. Installation 1. Inspect the strainer gasket (f) and replace it if it is damaged. 2. To ensure strainer gasket (f) placement, install the canister (b) over the strainer basket (c). 3.
  • Page 104 General Maintenance Hydronic Surface Heater Replacing the Fuel Filter Element When Every 1000 hours of operation or yearly. Requirements Machine shut down New filter element and gasket set Procedure Follow the procedure below to replace the fuel filter element. 1. Turn off the main power. 2.
  • Page 105 Hydronic Surface Heater General Maintenance Lubricating the Hose Reel System Requirements Machine shut down Machine cool Procedure Perform the procedure below to lubricate the hose reel system. 1. Disconnect electric power from the machine. 2. Apply low temperature bearing grease, with several pumps from a grease gun, to each bearing (a).
  • Page 106 General Maintenance Hydronic Surface Heater 8.10 Cleaning the Turbulator Tubes When Every 1000 hours of operation or once every year. Requirements Machine shut down Machine cool Lever WARNING Burn hazard. The hydronic heater is very hot when the machine is operating. When hot it can cause severe burns.
  • Page 107 Hydronic Surface Heater General Maintenance Continued from the previous page. 5. Place a lever (large flat screwdriver) under the turbulator retentainer (e) and pry it out of the flue box. wc_gr011719 wc_gr011720 6. Locate the turbulators (f) housed in the tubes. 7.
  • Page 108 General Maintenance Hydronic Surface Heater 8.11 Storage Introduction Extended storage of equipment requires preventive 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 109 Hydronic Surface Heater General Maintenance 8.12 Preparing the Machine for Seasonal Operation Background After removing the machine from long-term storage, it must be prepared for operation. Perform the procedures below before each seasonal use. Before Perform the procedures below before you power up the machine. powering up machine Item...
  • Page 110 General Maintenance Hydronic Surface Heater 8.13 Machine Disposal / Decommissioning Introduction This machine must be properly decommissioned at the end of its service life. Responsible disposal of recyclable components, such as plastic and metal, ensures that these materials can be reused—conserving landfill space and valuable natural resources.
  • Page 111 Kubota Genset Genset Maintenance Genset Maintenance The engine maintenance schedule(s) in this chapter are reproduced from the engine owner’s manual. For additional information, see the engine owner’s manual. 770013 wc_tx003650gb.fm...
  • Page 112 Genset Maintenance Kubota Genset The viscosity of the engine oil is an important factor when determining the correct engine oil to use in your machine. Use an engine oil of appropriate viscosity based on the expected outside air temperature. See the table below. WARNING Most used liquids from this machine such as oil, gasoline, grease, etc., contain small amounts of materials that can cause cancer and other health problems if...
  • Page 113 E 1100 Troubleshooting 10 Troubleshooting 10.1 Troubleshooting the Machine Problem / Symptom Reason Remedy The burner does not start. Improper switch position or Verify that the breaker is protective function action. ON. Verify that the HTF level is within range and low level shutdown device is reset (low level indicator light must be OFF).
  • Page 114 Troubleshooting E 1100 Problem / Symptom Reason Remedy Thaw progress is below The insulation is insuffi- Add additional insulation capacity. cient. blankets. The moisture is insufficient. Verify that there is standing water on job site. There is no vapor barrier. Lay down vapor barrier.
  • Page 115 E 1100 Troubleshooting Problem / Symptom Reason Remedy Pump is noisy and HTF flow The suction valve is not fully Verify that the suction valve is below nominal value. open. is fully open. The HTF temperature is Warm the HTF and hoses below -26°C (-15°F).
  • Page 116 MSDS: Dowfrost™ HD 50 MSDS: Dowfrost HD 50 Material Safety Data Sheet The Dow Chemical Company Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 Print Date: 18 Aug 2011 The Dow Chemical Company encourages and expects you to read and understand the entire (M)SDS, as there is important information throughout the document.
  • Page 117 MSDS: Dowfrost™ HD 50 Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 Inhalation: At room temperature, exposure to vapor is minimal due to low volatility. Mist may cause irritation of upper respiratory tract (nose and throat). Ingestion: Very low toxicity if swallowed.
  • Page 118 MSDS: Dowfrost™ HD 50 Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 Personal Precautions: Keep unnecessary and unprotected personnel from entering the area. Use appropriate safety equipment. For additional information, refer to Section 8, Exposure Controls and Personal Protection.
  • Page 119 MSDS: Dowfrost™ HD 50 Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 Physical and Chemical Properties Physical State Liquid. Color Yellow to green Odor Characteristic Odor Threshold No test data available Flash Point - Closed Cup Not applicable, Water boils off Flammability (solid, gas) Not applicable to liquids...
  • Page 120 MSDS: Dowfrost™ HD 50 Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 Eye damage/eye irritation May cause slight temporary eye irritation. Corneal injury is unlikely. Skin corrosion/irritation Prolonged contact is essentially nonirritating to skin. Repeated contact may cause flaking and softening of skin.
  • Page 121 MSDS: Dowfrost™ HD 50 Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 Transport Information DOT Non-Bulk NOT REGULATED DOT Bulk NOT REGULATED IMDG NOT REGULATED ICAO/IATA NOT REGULATED This information is not intended to convey all specific regulatory or operational requirements/information relating to this product.
  • Page 122 MSDS: Dowfrost™ HD 50 Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 All components of this product are on the TSCA Inventory or are exempt from TSCA Inventory requirements under 40 CFR 720.30 CEPA - Domestic Substances List (DSL) This product contains one or more substances which are not listed on the Canadian Domestic Substances List (DSL).
  • Page 123 Tire Safety Information Tire Safety Information Introduction to Tire Safety Information Federal Regulation 49 CFR 575 requires trailer manufacturers to include certain tire information in the owner’s manuals for the trailers they manufacture. This regulation requires that the information be in the English language. This chapter includes all the information required by Federal Regulation 49 CFR 575.
  • Page 124 Tire Safety Information 1. T AFETY NFORMATION This portion of the - Trailer . Section 1.1 contains Tow Vehicle . Section 1.2 contains Section 1.3 contains a Glossary of Tire Terminology -technical terms. Section 1.4 contains information from the NHTSA brochure entitled “Tire Safety – Everything Rides On It”. This brochure This brochure, as well as the preceding subsections, describes the following items;...
  • Page 125 Tire Safety Information Excessive loads and/or underinflation cause tire overloading and, as a result, abnormal tire flexing occurs. This situation can generate an excessive amount of heat within the tire. Excessive heat may lead to tire failure. It is the air pressure that enables a tire to support the load, so proper inflation is critical.
  • Page 126 Tire Safety Information Bead The part of the tire that is made of steel wires, wrapped or reinforced by ply cords and that is shaped to fit the rim. Bead separation This is the breakdown of the bond between components in the bead. Bias ply tire A pneumatic tire in which the ply cords that extend to the beads are laid at alternate angles substantially less than 90 degrees to the centerline of the tread.
  • Page 127 Tire Safety Information Intended outboard sidewall The sidewall that contains a white-wall, bears white lettering or bears manufacturer, brand, and/or model name molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward facing sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a vehicle.
  • Page 128 Tire Safety Information A layer of rubber-coated parallel cords. Ply separation A parting of rubber compound between adjacent plies. Pneumatic tire A mechanical device made of rubber, chemicals, fabric and steel or other materials, that, when mounted on an automotive wheel, provides the traction and contains the gas or fluid that sustains the load. Production options weight The combined weight of those installed regular production options weighing over 2.3 kilograms (5 lbs.) in excess of those standard items which they replace, not previously considered in curb weight or accessory...
  • Page 129 Tire Safety Information Tread rib A tread section running circumferentially around a tire. Tread separation Pulling away of the tread from the tire carcass. Treadwear indicators (TWI) The projections within the principal grooves designed to give a visual indication of the degrees of wear of the tread.
  • Page 130 Tire Safety Information Use this information to make tire safety a regular part of your vehicle maintenance routine. Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure.
  • Page 131 Tire Safety Information 1.5.4. S TEPS FOR AINTAINING ROPER RESSURE Step 1: Locate the recommended tire pressure on the vehicle's tire information placard, certification label, or in the owner's manual. Step 2: Record the tire pressure of all tires. Step 3: If the tire pressure is too high in any of the tires, slowly release air by gently pressing on the tire valve stem with the edge of your tire gauge until you get to the correct pressure.
  • Page 132 Tire Safety Information 1.5.9.1. Information on Passenger Vehicle Tires Please refer to the diagram below. The "P" indicates the tire is for passenger vehicles. Next number This three-digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge. In general, the larger the number, the wider the tire.
  • Page 133 Tire Safety Information Letter Rating Speed Rating 99 mph 106 mph 112 mph 118 mph 124 mph 130 mph 149 mph 168* mph 186* mph * For tires with a maximum speed capability over 149 mph, tire manufacturers sometimes use the letters ZR. For those with a maximum speed capability over 186 mph, tire manufacturers always use the letters ZR.
  • Page 134 Tire Safety Information Please refer to the following diagram. Tires for light trucks have other markings besides those found on the sidewalls of passenger tires. The "LT" indicates the tire is for light trucks or trailers. An "ST" is an indication the tire is for trailer use only. Max.
  • Page 135 E1250 Technical Data 11 Technical Data 11.1 Machine Model Units E 1250B-D E 1250B-G Length x width x height 116 x 76 x 68 (mm) (2946 x 1930 x 1727) Operating weight (full fuel) lb (kg) 3175 (1440) — Assembled weight (no fuel) lb (kg) 2730 (1238) Shipping weight no trailer (no fuel)
  • Page 136 Technical Data E1250 Model Units E 1250B-D E 1250B-G Burner nozzle — 0.75, 60° A — Burner air shutter / band 8 / 2 — Fuel consumption (no generator) gal/hr (L/hr) 1.00 (3.8) — Fuel tank volume gal (L) 71 (269) —...
  • Page 137 E1250 Technical Data 11.2 Dimensions—E1250 in. (mm) 68 (1727) 76 (1930) 116 (2946) wc_gr012443 wc_td000637gb.fm...
  • Page 138 Technical Data E1250 wc_td000637gb.fm...
  • Page 139 E1250 Schematics 12 Schematics This page is intentionally left blank. wc_tx003592gb.fm...
  • Page 140 Schematics E1250 12.1 Electrical Wiring Diagram SNAP DISC SENSOR SENSOR LIMIT wc_gr012466 wc_tx003592gb.fm...
  • Page 141 E1250 Schematics 12.2 Wiring Diagram Components Ref. Description Snap disc Thermister 1 Thermister 2 Low limit switch Pump motor Rewind motor Foot switch Pressure sensor Flow sensor Main control panel Rewind clutch Strobe light Emergency stop switch Main power plug Burner controller Fuel level sensor Diesel burner (Beckett)
  • Page 142 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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