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Drash D-1000B Operation & Maintenance Manual

Outdoor use only
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OPERATIONS & MAINTENANCE MANUAL
33 Kings Highway, Orangeburg, NY 10962
DHS Manual Part Number: 1002811
Original Issue: 31 MARCH 2009
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: 1002811 Web: www.drash.com Original Issue: 31 MARCH 2009 Email: drash@drash.com...
  • Page 2 Revision History Date Revision Description 03/31/09 1002811 Original Issue. This manual contains privileged and confidential information proprietary to DHS Systems, LLC and is intended solely for use by its customers. No portion of this document may be reproduced for release to a third party without written consent of DHS Systems, LLC.

  • 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..........................1-3 1.4.6 Control System ..........................
  • 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

    THIS EQUIPMENT IS INTENDED FOR OUTDOOR USE ONLY The D-1000B model is a compact and mobile, indirect fuel fired air heater that uses 120 volts, 60 Hz input power which burns JP8, Diesel #1 and Diesel #2 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

    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 ten seconds pre-ventilation cycle to “clean” the combustion chamber once the heater is turned off;...

  • Page 8: Performance

    3’ (Ft) 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 (GPH), approximately 12 hrs of continuous run-time without refueling.

  • 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

    Diesel fuel and or JP8. 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 (O) 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 100V-60Hz Figure 4-1 - Control Panel Layout 1 – Reset Button - Press the reset button to reset the lock-out condition.

  • Page 14: Start Up Procedures For Cold Weather Operations

    D-1000B Heater Operations & Maintenance Start Up Procedures for Cold Weather Operations 1. Connect heater to a 120V 60Hz grounded power supply for 15 minutes to pre-heat fuel filter. 2. Remove protective covers from each end and check for debris.

  • Page 15: Filling The Fuel Tank

    DO NOT USE GASOLINE. USING ANY UNAPPROVED FUELS FOR THE HEATER COULD RESULT IN DAMAGE TO THE HEATER AND / OR PERSONAL INJURY. Ensure the power switch is in the OFF (O) 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 Figure 5-3 - Capacitor Wire Connections 5.4.2.2 Installation procedures: 1. Place serviceable electric motor (10) onto the motor assembly plate (12) and reinstall four mounting screws (79) and four spring washers (80). Using a 8mm nut driver tighten hardware.

  • Page 21: Removal And Installation Of The Condenser (Capacitor)

    D-1000B Heater Operations & Maintenance Electric Motor Installation Procedures Continued 13. Connect the electric motor wire harness’ three wires; black wire (#9), tan wire (#10) on the terminal board (47), the yellow and green stripe ground wire on the small terminal board (46).

  • Page 22: Removal And Installation Of Fuel Filter

    D-1000B Heater Operations & Maintenance 5.4.3.2 Installation procedures: 1. Install capacitor (11) onto the electric motor (10). 2. Using a 13mm socket wrench, install lock washer and nut. Tighten hardware. 3. Reconnect the two female terminal couplers and slide plastic cover over terminals.

  • Page 23: Removal And Installation Of Fuel Pump Assembly

    D-1000B Heater Operations & Maintenance Fuel Filter Installation Procedures Continued: 6. Wipe up any fuel spills. 7. Connect heater to a power supply. 8. Test heater in accordance with operations manual (see Chapter 6) and check for fuel leaks. 5.4.5 Removal and Installation of Fuel Pump Assembly 5.4.5.1...

  • Page 24: Removal, Inspection And Installation Of Electric Motor / Fuel Pump Coupling

    D-1000B Heater Operations & Maintenance Figure 5-6 – Fuel Pump 5.4.6 Removal, Inspection and Installation of Electric Motor / Fuel Pump Coupling 5.4.6.1 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 D-1000B Heater Operations & Maintenance Installation of Electric Motor / Fuel Pump Coupling Continued 3. Using a 13mm open end wrench, connect and tighten the fuel feed hose (65) from the burner head (61) to fuel pump (70). 4. Using a 15mm open end wrench, connect and tighten the fuel supply line (18) from the fuel filter and fuel return line (22B) to the fuel tank at the fuel pump.

  • Page 26: 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 27: 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 28: Removal And Installation Of Ignition & Control Components

    D-1000B Heater Operations & Maintenance 5.4.9 Removal and Installation of Ignition & Control Components 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 29: Removal And Installation Of The Transformer And High Temp (H.t.) Leads

    D-1000B Heater Operations & Maintenance 5.4.10 Removal and Installation of the Transformer and High Temp (H.T.) Leads 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 30 D-1000B Heater Operations & Maintenance 5.4.10.2 Installation procedures: 1. Secure new transformer (50) onto Control Panel Assembly (29) with two screws (88). 2. Feed two red electrode wires (64) up through lower heat shield (6) and connect onto back of electrodes (63).

  • Page 31: Removal And Installation Of The Photocell

    D-1000B Heater Operations & Maintenance 5.4.11 Removal and Installation of the Photocell 5.4.11.1 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 D-1000B Heater Operations & Maintenance Installation of the Photocell Continued IMPORTANT If you do not hear it click you must adjust the holder (67). Clear part of bulb should always face up when inserting into Burner Flange (61). 4. Attach Control Panel Assembly (29) to Heater base (30) using two screws (81).

  • Page 33: Test Procedures

    D-1000B Heater Operations & Maintenance TEST PROCEDURES Maintenance Repair Test Procedures 1. Remove all fabric covers and accessories bag (if attached) from heater. 2. Install exhaust Stack. 3. Add fuel; run heater outdoors in accordance to start up procedures for ten minutes.

  • Page 34: Fuel Pressure Test

    D-1000B Heater Operations & Maintenance Handle Filter Paper Filter Paper Slot Knurled Knob Sampling Tube Figure 6-1 - Smoke Tester SMOKE SPOT COLOR CAUSE Light Gray Smoke Good – no adjustment required Yellow or Blue Smoke Contaminated or Bad Fuel White Smoke Excessive Air Flow;...
  • Page 35 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 36 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 37: 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 38 D-1000B Heater Operations & Maintenance CORRECTIVE ACTION SYMPTOM / FAULT CAUSE  Check connection of H.T. Leads to electrodes and transformer  Check electrodes setting  Electric igniter defective  Check electrodes for cleanliness  Replace H.T. transformer Air Pressure Switch defective Replace Air Pressure Switch ...

  • Page 39: 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 40: 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 41: Fuel Pump Assembly Exploded View

    D-1000B Heater Operations & Maintenance Fuel Pump Assembly Exploded View 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 42: Pre-Heated Fuel Filter Exploded View

    D-1000B Heater Operations & Maintenance Pre-Heated Fuel Filter Exploded View Figure 8-4 – Pre-Heated Fuel Filter 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 43: 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 44: Parts List For Exploded View Of D-1000B Heater

    D-1000B Heater Operations & Maintenance Parts List for Exploded View of D-1000B Heater ITEM DHS PN DHS PART DESCRIPTION Qty. 1003778 Outlet Duct 1003779 Stack, Exhaust 1003780 Support, Combustion Chamber 1003781 Chamber, Combustion 1003782 Shield, Upper Heat 1003783 Shield, Lower Heat...
  • Page 45 D-1000B Heater Operations & Maintenance Parts List for Exploded View of D-1000B Heater Continued: ITEM DHS PN DHS PART DESCRIPTION Qty. 1003804 Plug, Drain M30 x 1.5 1003805 O-ring Ø30mm x 2,62mm 1003806 Assembly, Panel Control 1003807 Base 1003808 Tube, Silicone Ø5x900mm 1003809 Fitting, Connector Straight, 1/8"...
  • Page 46 D-1000B Heater Operations & Maintenance Parts List for Exploded View of D-1000B Heater Continued: ITEM DHS PN DHS PART DESCRIPTION Qty. 1003831 Light, Power Indicating 1003832 Cord, Power 1003833 Cap, w/lanyard 1003834 Plug, Thermostat (remote) 1003835 Switch, Power, 3-Position 1003836 Nozzle 0.60GPH 80°...
  • Page 47 D-1000B Heater Operations & Maintenance Parts List for Exploded View of D-1000B Heater Continued: ITEM DHS PN DHS PART DESCRIPTION Qty. Screw, Hex Hd w/Washer, Tapping #10 x ½”L, 18- T270040 8 SS 1004133 Screw, Cap Flange Hex Hd, M5 x 14mm...

  • Page 48: 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 49: 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 42-1/2” 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 50: 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, 12-1/2”dia, Fabric, Green Duct Assembly, Heater Return, 12”dia x 15’L...

  • Page 51: 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 52: Equipment And/Or Documentation Feedback Form

    PUBLICATION TITLE PUBLICATION DATE OPERATIONS AND MAINTENANCE MANUAL for the DRASH D-1000B HEATER 31 MARCH 2009 DHS D-1000B Heater Serial Number MANUAL P/N: 1002811 BE EXACT PIN-POINT WHERE IT IS USE THIS SPACE TO DESCRIBE WHAT IS WRONG AND WHAT SHOULD BE DONE ABOUT IT:...
  • Page 53 D-1000B Heater Operations & Maintenance (fold) Return Address: Place Stamp Here DHS Logistics 33 Kings Highway Orangeburg, NY 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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