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Drash D-1000B Operation & Maintenance Manual

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OPERATIONS & MAINTENANCE MANUAL
33 Kings Highway, Orangeburg, NY 10962
DHS Manual Part Number: 1006395
Revision Date: 01 APRIL 2010
D-1000B HEATER
Outdoor Use Only
ISO 9001: 2000 Registered
Quality Management System
Phone: 845-359-6066
Fax: 845-365-2114
Hotline: 800-977-3647
Web: www.drash.com
Email:
drash@drash.com

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  • Page 1 D-1000B HEATER Outdoor Use Only OPERATIONS & MAINTENANCE MANUAL ISO 9001: 2000 Registered Quality Management System 33 Kings Highway, Orangeburg, NY 10962 Phone: 845-359-6066 Fax: 845-365-2114 Hotline: 800-977-3647 DHS Manual Part Number: 1006395 Web: www.drash.com Revision Date: 01 APRIL 2010 Email: drash@drash.com...
  • Page 2 Revision History Date Revision Description 03/31/10 1002811 Original Issue. Revised Manual Part Number. Revised Section 1, General, Section 4, 01 APR 10 1006395 Operations, Section 5, Maintenance, and Repair Procedures, and Section 8, Illustrated Parts Breakdown (Rev B). This manual contains privileged and confidential information proprietary to DHS Systems, LLC and is intended solely for use by its customers.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS GENERAL..............................1-1 Scope ..............................1-1 Receipt of the D-1000B Heater ......................1-1 Equipment Description ........................1-1 Major Components ..........................1-3 1.4.1 Shell............................1-3 1.4.2 Fuel Tank........................... 1-3 1.4.3 Combustion Chamber........................ 1-3 1.4.4 Burner Head ..........................1-3 1.4.5 Electric Motor..........................
  • Page 4 Fuel Pump Assembly Exploded View ....................8-3 Pre-Heated Fuel Filter Exploded View....................8-4 Control Panel Assembly Exploded View.................... 8-5 Parts List for Exploded View of D-1000B Heater................8-6 Heater Sub-Assembly, Skid Body and Heater................. 8-10 Skid Body Assembly, Heater D-1000B .................... 8-11 D-1000B Heater Accessories......................

  • Page 5: General

    100,000 BTUs/hr of dry, clean heat at a rate of 880 CFMs. The heater includes an electronic control system that monitors for high-heat conditions and flameout, and operates on 120V, 60Hz. The D-1000B heater is a compact and mobile, indirect fuel fired air heater which burns JP8 and Diesel fuel. The heater contains a stainless steel dual Combustion Chamber, a Fuel Pump and an Electric Motor.
  • Page 6 Skid Body Control Panel Power Cord Fuel Cap / Tank Accessory Bag Compartment Figure 1-2 - D-1000B Heater GENERAL DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.

  • Page 7: Major Components

    1.4.3 Combustion Chamber The D-1000B has a dual combustion chamber made of stainless steel and is fully welded to provide clean warm air. The heater is equipped with fifteen seconds pre-ventilation cycle to “clean” the combustion chamber. After switching the heater off, a post ventilation time is electronically set by a control flame box to lower the combustion chamber temperature.

  • Page 8: Performance

    A pre-heated fuel filter allows heater to work continuously in extreme low temperatures. When operating the D-1000B heater, the noise level when measured at a distance of 3 feet (0.92 meters) from the control panel is 76dB. With the remote thermostat / CO detector attached, the heater may be operated remotely from within the shelter. The D-1000B has a fuel consumption rate of 0.81 US Gallon per hour (3.07 liters per hour), approximately 12 hrs of continuous run-time...

  • Page 9: Safety

    Operations & Maintenance SAFETY Scope This chapter contains general information for the safe operation and maintenance of the D-1000B heater. The cautions and warnings point out known conditions that are potentially hazardous. However, no manual can cover every possible situation. If in doubt, contact DHS.

  • Page 10: Heater

    2.4.2 Safety Protections The D-1000B heater has the following safety devices installed:  Flame Detector Safety Shut-off Switch: In case of the flame extinguishing, the safety shut-off switch will cut in and stop the heater; at the same time the reset button will illuminate (See Figure 4-1, Item #1).

  • Page 11: Storage & Transport

    JP8 or Diesel fuel. Before the D-1000B heater is transported or placed in storage, the heater must be totally cooled off. Before moving the heater, the heater’s power switch must be in the OFF (0) position and unplugged. Ensure the following equipment is installed and attached to the heater before transporting or storing.
  • Page 12 D-1000B Heater Operations & Maintenance THIS PAGE INTENTIONALLY LEFT BLANK STORAGE & TRANSPORT DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.

  • Page 13: Operations

    The following chapter contains general information for operating the D-1000B heater. Control Panel Operation of the D-1000B heater requires the usage of the control panel shown in Figure 4.1 Figure 4-1 - Control Panel Layout Table 4-1 – Control Panel...

  • Page 14: Start Up Procedures For Cold Weather Operations

    D-1000B Heater Operations & Maintenance Start up procedures for Normal Operation (Cont) NOTE When the heater is started for the first time or is started after the fuel tank has been completely emptied, the flow of fuel to the burner may be impaired by air in the system.

  • Page 15: Shut Down Procedure

    DO NOT USE GASOLINE. USING ANY UNAPPROVED FUELS FOR THE HEATER COULD RESULT IN DAMAGE TO THE HEATER, VOID WARRANTY AND / OR PERSONAL INJURY. Ensure the power switch is in the OFF (0) position. It is recommended to allow 5 minutes for the D-1000B heater to cool before refueling.
  • Page 16 D-1000B Heater Operations & Maintenance THIS PAGE INTENTIONALLY LEFT BLANK OPERATIONS DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.

  • Page 17: Maintenance, And Repair Procedures

    This chapter contains general information for operator-level, qualified personnel. A qualified person is one who is familiar with this manual, the operation of the D-1000B heater; the hazard involved in its operation and maintenance, and has been certified by the DHS Training Program. This chapter also describes the procedures for both periodic and daily maintenance.

  • Page 18: Annual Maintenance

    D-1000B Heater Operations & Maintenance 5.2.4 Annual Maintenance  Check all nuts, bolts, fittings, and connections for looseness. Tighten as required.  Clean or replace the fuel filter.  Drain and flush the fuel tank.  Remove burner assembly, clean, and adjust electrode setting.

  • Page 19: Removal And Installation Electric Motor Assembly

    D-1000B Heater Operations & Maintenance NOTE! In the following Repair Procedures, the numbers in parentheses refer to item numbers listed in Chapter 8, Illustrated Parts Breakdown diagram on page 8-1 or otherwise noted. 5.4.2 Removal and Installation Electric Motor Assembly 5.4.2.1...
  • Page 20 D-1000B Heater Operations & Maintenance Electric Motor Removal Procedures (Cont) 11. Slide the plastic cover off the capacitor (11) and disconnect two female terminal couplers. (See Figure 5-3). 12. Using a 13mm socket wrench, loosen and remove the mount nut and lock washer; remove capacitor (11).
  • Page 21 D-1000B Heater Operations & Maintenance IMPORTANT! Fan blade must be positioned correctly on the electric motor shaft to ensure correct balance of the fan. 11. Using a 4mm Allen wrench, tighten set screw (92) to secure the fan blade (15) in place.

  • Page 22: Removal And Installation Of The Condenser (Capacitor)

    D-1000B Heater Operations & Maintenance 5.4.3 Removal and Installation of the Condenser (Capacitor) 5.4.3.1 Removal procedures: 1. Disconnect power cord from the power source. Allow heater to cool. 2. Using an 8mm nut driver, remove two middle screws from the maintenance access panel (7) and loosen four corner screws (78).

  • Page 23: Removal And Installation Of Fuel Filter

    D-1000B Heater Operations & Maintenance 5.4.4 Removal and Installation of Fuel Filter 5.4.4.1 Removal procedures: 1. Disconnect power cord from the power source. Allow heater to cool. 2. Using a 19mm open end wrench, loosen and remove pre-heat probe from bottom of fuel filter assembly 3.

  • Page 24: Removal And Installation Of Fuel Pump Assembly

    D-1000B Heater Operations & Maintenance 5.4.5 Removal and Installation of Fuel Pump Assembly 5.4.5.1 Removal Procedures: 1. Disconnect power cord from power source and allow heater to cool. 2. Remove four quick release pins and remove top cover (see Figure 5-1).

  • Page 25: Removal, Inspection And Installation Of Electric Motor / Fuel Pump Coupling

    D-1000B Heater Operations & Maintenance 22A Return to Tank 22B Supply from Fuel Filter 22B Fuel Supply 22A Fuel Return Figure 5-6 – Fuel Pump 5.4.6 Removal, Inspection and Installation of Electric Motor / Fuel Pump Coupling 5.4.6.1 Removal Procedures;...
  • Page 26 D-1000B Heater Operations & Maintenance 5.4.6.2 Inspection Procedures: 1. Remove the fuel pump plastic coupler (74) (see Figure 5-6). 2. Inspect the plastic coupler (74) for wear, cracks, chips or any other defects to render unserviceable condition. 3. Replace or install (if required) the plastic coupler (74) by aligning flat of shaft with tab inside the coupler.

  • Page 27: Removal And Installation Of Fuel Solenoid

    D-1000B Heater Operations & Maintenance 5.4.7 Removal and Installation of Fuel Solenoid 5.4.7.1 Removal Procedures: 1. Disconnect power cord and allow heater to cool. 2. Using an 8mm nut driver, remove two middle screws from the maintenance access panel (7) and loosen four corner screws (78).

  • Page 28: Removal And Installation Of Fuel Nozzle

    D-1000B Heater Operations & Maintenance 5.4.8 Removal and Installation of Fuel Nozzle 5.4.8.1 Removal procedures: 1. Disconnect power cord from power source and allow heater to cool. 2. Remove four quick release pins and remove top cover (see Figure 5-1).
  • Page 29 D-1000B Heater Operations & Maintenance Fuel Nozzle Installation Procedures (Cont) 7. Reconnect ground wire (103) to the terminal lug (94) on combustion head (40). 8. Install heat shield (05). Using an 8mm nut driver install and tighten six screws (79) and two sheet metal screws (78) to secure heat shield.

  • Page 30: Removal, Installation And Gap Adjustment Procedures For Ignition Electrodes

    D-1000B Heater Operations & Maintenance 5.4.9 Removal, Installation and Gap Adjustment Procedures for Ignition Electrodes 5.4.9.1 Electrode Removal procedures: 1. Disconnect power cord from power source and allow heater to cool. 2. Remove four quick release pins and remove top cover (see Figure 5-1).

  • Page 31: Removal And Installation Of The Ignition Control Assembly

    D-1000B Heater Operations & Maintenance 5.4.10 Removal and Installation of the Ignition Control Assembly 5.4.10.1 Removal procedures: 1. Disconnect power cord from power source and allow heater to cool. 2. Remove four quick release pins and remove top cover (see Figure 5-1).

  • Page 32: Removal And Installation Of H.t. Ignition Cables

    D-1000B Heater Operations & Maintenance 5.4.10.2 Installation procedures: 1. Install new ignition control assembly (53) onto control panel assembly (29). 2. Using a Phillips head screwdriver, install and tighten two screws (88) securing ignition control assembly (53) to control panel assembly (29).

  • Page 33: Removal And Installation Of The Photocell

    D-1000B Heater Operations & Maintenance 5.4.12 Removal and Installation of the Photocell 5.4.12.1 Removal procedures: 1. Disconnect power cord from power source and allow heater to cool. 2. Remove four quick release pins and remove top cover (see Figure 5-1).

  • Page 34: Removal And Installation Of The Pressure Switch

    D-1000B Heater Operations & Maintenance Installation of Photocell procedures (Cont) 4. Slide control panel assembly (29) back into base (30). Ensure that electrical wires do not get pinched when sliding control panel assembly into base. 5. Using a Phillip head screwdriver, install and tighten two screws (81) securing control panel assembly (29) to base.
  • Page 35 D-1000B Heater Operations & Maintenance 5.4.13.2 Installation procedures: 1. Install new pressure switch (43). 2. Using a Philips head screwdriver, install and tighten two screws (100) through bracket (99) securing pressure switch (43). 3. Connect two silicone hoses (31) (see Figure 5-13) to the side of the pressure switch (43).
  • Page 36 D-1000B Heater Operations & Maintenance THIS PAGE INTENTIONALLY LEFT BLANK MAINTENANCE, and REPAIR PROCEDURES 5-20 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.

  • Page 37: Test Procedures

    D-1000B Heater Operations & Maintenance TEST PROCEDURES Maintenance Repair Test Procedures 1. Remove all protective fabric covers and accessories bag (if attached) from heater. 2. Install exhaust stack. 3. Add fuel if needed. 4. Connect power cord to power source.

  • Page 38: Fuel Pressure Test

    D-1000B Heater Operations & Maintenance Handle Filter Paper Filter Paper Slot Knurled Knob Sampling Tube Figure 6-1 - Smoke Tester Table 6-1 - Smoke Spot SMOKE SPOT COLOR CAUSE Light Gray Smoke Good – no adjustment required Yellow or Blue Smoke...
  • Page 39 D-1000B Heater Operations & Maintenance NOTE Always start adjustments low and then increase 10. Disconnect pressure gauge hose by pushing down on the black tab at the M10 MNPT elbow and pulling hose out. There may be pressure and or fuel still in the hose; use caution and have a rag or container to collect fuel.
  • Page 40 D-1000B Heater Operations & Maintenance Remove Plug From “P” Port for Test Elbow Connection Adjustment Screw Plug Clockwise to Increase Counter- Clockwise to Decrease Figure 6-2 - Pressure Gauge Tester TEST PROCEDURES DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.

  • Page 41: Troubleshooting

    Tools, equipment, clothing and This section provides a systematic approach to locating and your body must stay clear of correcting malfunctions of the D-1000B heater. rotating parts and electrical The section is arranged according to the symptoms of the connectors.
  • Page 42 D-1000B Heater Operations & Maintenance CORRECTIVE ACTION SYMPTOM / FAULT CAUSE  Check connection of H.T. Ignition Cables to electrodes  Check electrodes setting  Ignition Control Assembly defective  Check electrodes for cleanliness  Replace Ignition Control Assembly Pressure Switch defective Replace Pressure Switch ...

  • Page 43: Illustrated Parts Breakdown

    From Fuel Pump to Burner Head Return From Fuel Pump to Tank Figure 8-1 - D-1000B Heater Detail ILLUSTRATED PARTS BREAKDOWN DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.

  • Page 44: Burner Head And Nozzle Assembly Exploded View

    D-1000B Heater Operations & Maintenance Burner Head and Nozzle Assembly Exploded View To Ground Terminal Board Figure 8-2 – Burner Head and Nozzle Assembly Detail ILLUSTRATED PARTS BREAKDOWN DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.

  • Page 45: Fuel Pump Assembly Exploded View

    D-1000B Heater Operations & Maintenance Fuel Pump Assembly Exploded View 22A Return to Tank 22B Supply from Fuel Filter 22B Fuel Supply 22A Fuel Return Figure 8-3 – Fuel Pump Assembly Detail ILLUSTRATED PARTS BREAKDOWN DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.

  • Page 46: Pre-Heated Fuel Filter Exploded View

    D-1000B Heater Operations & Maintenance Pre-Heated Fuel Filter Exploded View Figure 8-4 – Pre-Heated Fuel Filter Assembly Detail ILLUSTRATED PARTS BREAKDOWN DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.

  • Page 47: Control Panel Assembly Exploded View

    D-1000B Heater Operations & Maintenance Control Panel Assembly Exploded View Figure 8-5 – Control Panel Assembly Detail ILLUSTRATED PARTS BREAKDOWN DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.

  • Page 48: Parts List For Exploded View Of D-1000B Heater

    D-1000B Heater Operations & Maintenance Parts List for Exploded View of D-1000B Heater Table 8-6 – Parts List ITEM DHS PN DHS PART DESCRIPTION Qty. 1003778 Outlet Duct 1003779 Stack, Exhaust 1003780 Support, Combustion Chamber 1003781 Chamber, Combustion 1003782 Shield, Upper Heat...
  • Page 49 D-1000B Heater Operations & Maintenance Parts List for Exploded View of D-1000B Heater Continued: Table 8-6 – Parts List (Cont) ITEM DHS PN DHS PART DESCRIPTION Qty. 1003803 Cap, Fuel w/level indicator 1008418 Plug, Drain M16 x 1.5 1008419 O-ring Ø16mm x 2,62mm...
  • Page 50 D-1000B Heater Operations & Maintenance Parts List for Exploded View of D-1000B Heater Continued: Table 8-6 – Parts List (Cont) ITEM DHS PN DHS PART DESCRIPTION Qty. 1003831 Light, Power Indicating 1003832 Cord, Power 1003833 Cap, w/lanyard 1003834 Plug, Thermostat (remote)
  • Page 51 D-1000B Heater Operations & Maintenance Parts List for Exploded View of D-1000B Heater Continued: Table 8-6 – Parts List (Cont) ITEM DHS PN DHS PART DESCRIPTION Qty. Screw, Hex Hd w/Washer, Tapping #10 x ½”L, 18- T270040 8 SS 1004133...

  • Page 52: Heater Sub-Assembly, Skid Body And Heater

    Figure 8-7 – Heater, Skid Body and Heater Sub-Assembly Detail ITEM DHS PN DHS PART DESCRIPTION Qty. 1002814 Heater, D-1000B, BTU 100,000 1002815 Skid Body Assembly, Heater, D-1000B 1002774 Heater, D-1000B, BM2 1002777 Cover, Top, Heater D-1000B 1002806 Pin, Quick Release, 6”L RD300145 Washer, Flat, ¼”, 18-8 SS...

  • Page 53: Skid Body Assembly, Heater D-1000B

    D-1000B Heater Operations & Maintenance Skid Body Assembly, Heater D-1000B Figure 8-8 – Skid-Body Assembly Detail ITEM DHS PN DHS PART DESCRIPTION Qty. 1002778 Base, Heater D-1000B, Plastic 1002807 Strip, Wear, Alum, 2 “ Wide x 42.5” Long 1004781 Screw, Cap Flat Hd, ¼”-20 x ¾”L, 18-8 SS 1002808 Rod, Carbon Steel, ½”OD x 20-1/2”L...

  • Page 54: D-1000B Heater Accessories

    D-1000B Heater Operations & Maintenance D-1000B Heater Accessories Figure 8-9 – Heater Accessories Details ITEM DHS PN DHS PART DESCRIPTION Qty. 1003581 Heater Sub Assembly, Skid Body & Heater T295157G Cap, Duct, 12.5” dia, Fabric, Green Duct Assembly, Heater Return, 12” dia x 15’ L,...

  • Page 55: Wiring Schematic

    D-1000B Heater Operations & Maintenance 8.10 Wiring Schematic Figure 8-10 – Wiring Schematic ILLUSTRATED PARTS BREAKDOWN 8-13 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.
  • Page 56 D-1000B Heater Operations & Maintenance Wiring Schematic (Cont) Table 8-10 – Wiring Schematic Key CODE Control Box Room Thermostat Plug Electric Pilot Lamp Fuse Overheat Thermostat Solenoid Valve Control Transformer H.V. Photocell Condenser Fan Motor Fuse Transformer Air Pressure Switch...

  • Page 57: Warranty

    DHS SYSTEMS LLC LIMITED WARRANTY  DHS Systems LLC provides a limited warranty that all DRASH (Deployable Rapid Assembly Shelter) products shall be free from defects in materials and workmanship for the period of time shown in the Warranty Schedule below.

  • Page 58: Equipment And/Or Documentation Feedback Form

    PUBLICATION TITLE PUBLICATION DATE OPERATIONS AND MAINTENANCE MANUAL for the DRASH D-1000B HEATER 01 APRIL 2010 DRASH D-1000B Heater Serial Number MANUAL P/N: 1006395 BE EXACT PIN-POINT WHERE IT IS USE THIS SPACE TO DESCRIBE WHAT IS WRONG AND WHAT SHOULD BE DONE ABOUT IT:...
  • Page 59 D-1000B Heater Operations & Maintenance (fold) Return Address: Place Stamp Here DHS Logistics 33 Kings Highway Orangeburg, New York 10962 (fold) WARRANTY DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.

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