Procom PCK110VT Owner's Manual

IMPORTANT: Read and understand this manual before assembling, starting or servicing heater. Improper use of heater can cause serious injury. Keep this manual for future reference.

HEATER SIZES:

110,000, 160,000, 175,000 AND 220,000 BTU/HR

KEROSENE/DIESEL HEATER WITH BUILT-IN THERMOSTAT

PORTABLE FORCED AIR HEATERS

OWNER’S MANUAL

Never use heater

in living or

sleeping areas.

Heater is suitable

for outdoor use

and for use on

combustible

oors.

TABLE OF CONTENTS

Safety .................................................................. 2

Unpacking............................................................ 3

Assembly ............................................................. 3

Product Identication & Label Locations ............. 5

Specications ...................................................... 6

Fuels .................................................................... 6

Ventilation ............................................................ 6

Operation ............................................................. 7

Operation with Portable Generator ...................... 8

Storing, Transporting or Shipping ........................ 8

Preventative Maintenance Schedule ................... 8

Troubleshooting ................................................. 12

Service Procedures ........................................... 13

Wiring Diagram .................................................. 18

Technical Service............................................... 18

Accessories ....................................................... 18

Illustrated Parts Lists ......................................... 19

Replacement Parts ............................................ 23

Warranty ............................................................ 24

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160108-012

d) During fueling, all fuel lines and fuel-

line connections shall be inspected for leaks. Any leaks shall be repaired prior to returning the heater to service.

e) At no time shall more than one day's

supply of heater fuel be stored inside a building in the vicinity of the heater. Bulk fuel storage shall be outside the structure.

f) All fuel storage shall be located a

minimum of 762 cm (25 feet) from heaters, torches, welding equipment and similar sources of ignition (exception: fuel reservoir integral with heater unit or any authorized auxiliary tank connected to heater unit).

g) Whenever possible, fuel storage

shall be conned to areas where oor

penetrations do not permit fuel to drip

onto or be ignited by a re at lower

elevation.

h) Fuel storage shall be in accordance

with the authority having jurisdiction.

3. Use only the electrical voltage and fre-

quency specied on model plate.

4. Heater is suitable for outdoor use.

5. Heater must be grounded. Use only a properly grounded three-wire extension cord. Plug into grounded outlet only.

6. Use only in areas free of ammable vapors or high dust content.

7. Minimum clearance from any combustible materials: 8 feet (244 cm) from hot air outlet, 6 feet (183 cm) from top, and 4 feet (120 cm) from sides and inlet.

8. Locate heater on a stable and level surface while hot or operating or a re may

occur.

9. Heater is acceptable for use on ooring

such as wood (a combustible material).

10. Use only in well vented areas. Before using heater, provide at least a 2800 square cm (three-square-foot) opening of fresh, outside air for each 30 kw (100,000 Btu/ Hr) of rating.

11. Keep children and animals away from heater at all times.

12. Never start heater when combustion chamber is hot or if fuel has accumulated in combustion chamber.

13. This heater is equipped with a thermostat. Heater may start at anytime.

WARNING: This product contains and/or generates chemicals known to the State of California to cause cancer or birth defects or other reproductive harm.

IMPORTANT: Read this owner’s manual carefully and completely before trying to assemble, operate or service this heater. Improper use of this heater can cause serious injury or death from burns, fire, explosion, electrical shock and carbon monoxide poisoning.

DANGER: Carbon monoxide

poisoning may lead to death!

Carbon Monoxide Poisoning: Early signs

of carbon monoxide poisoning resemble the

u, with headaches, dizziness and/or nausea.

If you have these signs, the heater may not be working properly. Get fresh air at once! Have heater serviced. Some people are more affected by carbon monoxide than others. These include pregnant women, persons with heart or lung disease or anemia, those

under the inuence of alcohol and those at

high altitudes. Make certain you read and understand all

warnings. Keep this manual for reference. It is your guide to safe and proper operation of this heater.

1. Use only kerosene, #1/#2 diesel/fuel oil,

JET A or JP-8 fuels to avoid risk of re or

explosion. Never use gasoline, oil from crank cases, naphtha, paint thinners,

alcohol or other highly ammable fuels.

2. Fueling a) Personnel involved with fueling shall

be qualied and thoroughly familiar

with the manufacturer's instructions and applicable regulations regarding the safe fueling of heating units.

b) Only the type of fuel specied on the

heater's data plate shall be used.

c) All ame shall be extinguished and the

heater allowed to cool, prior to fueling.

SAFETY

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160108-01 3

SAFETY

Continued

1. Remove all packing items applied to heater for shipment.

2. Remove all items from carton.

3. Check items for any shipping damage. If heater is damaged call ProCom Heating, Inc. at 1-877-886-5989 for replacement parts before returning to dealer.

UNPACKING

14. Never leave a heater plugged in without adult supervision if children or animals are likely to be present.

15. Use caution when moving or storing heater when fuel tank contains fuel. Fuel spillage can occur.

16. Use heater only in accordance with local ordinances and codes. Canadian residents should refer to CSA standard

B139, Installation Code for Oil Burning Equipment for recommended installation

practice.

17. Never use gasoline, crankcase drainings, naphtha, paint thinners, alcohol or other

highly ammable fuels.

18. Never use heater where gasoline, paint

thinner or other highly ammable vapors

are present.

19. Never use heater in living or sleeping areas.

20. Never move, handle, refuel or service a hot, operating or plugged-in heater.

21. Never attach duct work to front or rear of heater.

22. Heaters used in the vicinity of tarpaulins, canvas or similar enclosure materials shall be located a safe distance from such materials. The recommended minimum safe distance is 304.8 cm (10 feet). It is further recommended that these enclosure ma-

terials be of a re retardant nature. These

enclosure materials shall be securely fastened to prevent them from igniting or from upsetting the heater due to wind action.

23. Unplug heater when not in use.

24. Never block air inlet (rear) or air outlet (front) of heater.

25. Warning to New York City Residents

For Use Only At Construction Sites in

accordance with applicable NYC codes.

26. Never use external fuel sources or tanks

that are not specically designed for use

with this heater.

Figure 1 - Wire Guard moved to locked position

ASSEMBLY

WIRE GUARD

All Models

1. Grasp Wire Guard from top of shell and pull towards front of heater until it locks into place in slots on both sides of upper shell.

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160108-014

WHEEL ASSEMBLY

Models 160, 175 and 220

1. Slide Axle (A) through holes in wheel support frame.

2. Slide Wheel Spacer (B), then wheel (D) (concave side facing outward) onto axle.

3. Attach Acorn Nut (C) nger tight to end of axle.

4. Repeat steps 2 and 3 for opposite side, then tighten nuts with adjustable wrench.

Axle (A)

Acorn Nut (C)

Wheel (D)

Spacer (B)

Figure 2 - Wheel Assembly, 160, 175 and 220 models

HANDLE ASSEMBLY

Models 160, 175 and 220

1. Slide rear handle (E) onto Wheel Support Frame. Insert Screws (G) from rear and attach lock nuts (F).

2. Place Front Handle (I) under ange of fuel tank and insert 4 screws (J)from top of

ange through holes in ange into holes in handle. Attach Lock Nuts (H) and tighten.

Rear Handle (E)

Screw, 10-24 x1.5 (G)

Lock Nut 10-24 (F)

Screw 1/4-20 x 1.75" (J)

Front Handle (I)

Figure 3 - Handle Assembly, 160, 175 and 220 models

ASSEMBLY

Continued

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160108-01 5

PRODUCT IDENTIFICATION & LABEL LOCATIONS

Fueling Label

Part No. 160168-01

Control Label

Part No. 160167-02

CSA Label (Rating Plate)

Part No. 160111-04, 110 model Part No. 160112-02, 160 model Part No. 160112-03, 175 model Part No. 160112-05, 220 model

Operating Label

Part No. 160173-01

Operating Codes Label

Part No. 160174-01

Maintenance Label

Part No. 160175-01

Caution Label

Part No. 160172-01

Figure 4 - Product Identication & Label Locations

Warnings Label

Part No. 160110-01

NY, MA and CA Information Label

Part No. 160169-01

All Models Right Side

(220 Model Shown)

All Models Left Side

(110 Model Shown)

Front Handle

(160, 175 &

220 models)

Hot Air Outlet

Control Panel

Rear Handle

(160, 175 &

220 models)

Wire Guard

Top Handle

(110 model)

Fuel Tank

Cold Air Inlet

Power Cord

Fuel Cap

Fuel Gauge

Hot Air Outlet

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160108-016

SPECIFICATIONS

WARNING: Provide a fresh air opening of at least three square feet (2,800 square cm) for each 100,000 BTU/HR rating. Provide extra fresh air if more heaters are being used. The minimum ventilation requirements must be followed to avoid risks associated with carbon monoxide poisoning. Make certain these requirements are met prior to operating heater.

Example: A 220,000 Btu/Hr (64.5 kw) heater requires one of the following:

• a two-car garage door [16 feet (4.88 meter)

opening] raised 5" (12.7 cm)

• a single-car garage door [9 feet (2.74 meter) opening] raised 9" (22.9 cm)

• two, 30" (76.2 cm) windows raised 16"

(40.6 cm)

WARNING: Use only kerosene, #1/#2 diesel/fuel oil, JET A or JP-8 fuels to avoid risk of fire or explosion. Never use gasoline, oil drained from crankcases, naphtha, paint thinners, alcohol or other highly

ammable fuels.

Use only kerosene, #1/#2 diesel*/fuel oil, JET A, JP-8 fuels. Heavier fuels such as No. 2 fuel oil, No. 2 diesel fuel may also be used but will result in:

• noticeable odor

• additional fuel lter maintenance

* Use of #2 diesel/fuel oil in extreme cold

temperatures may require nontoxic anti-icer additives.

Do not use fuels heavier than No. 2 grade or heavy oils such as oil drained from crankcases. These heavy oils will not ignite properly and will contaminate the heater.

IMPORTANT: Use a KEROSENE ONLY (blue) or DIESEL ONLY (yellow) storage container.

Be sure storage container is clean. Foreign matter such as rust, dirt or water will cause the ignition control assembly to shut down heater. Foreign matter may also require heater's fuel system to be frequently cleaned.

FUELS

VENTILATION

110 Model 160 Model 175 Model 220 Model

Output Rating

80K-110K 110K-160K 125K-175K 160K-220K

Fuel (all models)

Use only kerosene, #1/#2 diesel*/fuel oil, JET A or JP-8 fuels

Fuel Tank Capacity (gal/liter)

5.5 / 20.8 10 / 37.9 10 / 37.9 14 / 53

Fuel Consumption 0.82 / 3.1 1.19 / 4.5 1.3 / 4.9 1.64 / 6.2 (gal/liter per hr.)

Pump Pressure (PSI) 6.9 (hot) 6.7 (hot) 6.8 (hot) 8.4 (hot) Electric Requirements

120 V/60 HZ 120 V/60 HZ 120 V/60 HZ 120 V/60 HZ

Amperage (Normal Run) 2.9 3.2 3.4 4.6

Typical Motor Speed (RPM)

3400 3400 3400 3400 Motor Horsepower 1/4 1/4 1/4 1/4 Shipping Weight (lbs / kg) 42 /19 71 /32.2 71 / 32.2 77 / 35 Heater Weight without 36 / 16.3 60.5 / 27.4 60.5 / 27.4 66 / 29.9

Fuel (approx) (lbs / kg)

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160108-01 7

IMPORTANT: Review and understand the warnings in the Safety section, pages 2 and 3. They are needed to safely operate this heater. Follow all local ordinances and codes when using this heater.

TO START HEATER

1. Follow all ventilation and safety information.

2. Locate heater to provide maximum circulation of the heated air. Follow all location requirements noted in Safety, pages 2 and 3.

3. Fill fuel tank with fuel and attach fuel cap. Use only kerosene, #1/#2 diesel/fuel oil,

JET A or JP-8 fuels to avoid risk of re or

explosion. Never use gasoline, oil drained from crank cases, naphtha, paint thinners,

alcohol or other ammable fuels.

Plug heater’s power cord into approved, grounded, three-wire extension cord. Extension cord must be at least six feet (1.8 m) long.

Extension Cord Size Requirement

• 6 to 10 feet (1.8 to 3 m) long, use 18

AWG (0.75 mm2) rated cord

• 11 to 100 feet (3.3 to 30.5 m) long, use

16 AWG (1.0 mm2) rated cord

• 101 to 200 feet (30.8 to 61 m) long, use

14 AWG (1.5 mm2) rated cord

5. Plug extension cord into standard 120 volt/60 hertz, 3-prong grounded outlet.

Push ON/STOP button to ON. Alarm will sound and display will start countdown to ignition. 6

seconds after motor startup, LED will display.

7. Push MODE/RESET button to select desired operating mode.

Please Note: When operating in Ther-

mostat Mode, press the MODE/RESET button once to change to Manual Mode. When operating in Manual Mode, Press the MODE/RESET button twice within 5 seconds to change to Thermostat Mode.

Manual Mode LED On: Adjust output to

disired setting. Press to raise the BTU output. Press to lower the BTU output.

Please Note: After startup, heater BTU

output can be immediately adjusted, but adjustments will not take effect for 2 minutes. This allows the heater to stabilize.

Thermostat Mode LED On: Adjust ther-

mostat by pressing to change set point higher. Press to change set point lower. If thermostat set temperature is higher than the surrounding air temperature, heater should ignite immediately. If heater thermostat set temperature is lower than surrounding air temperature, heater will not ignite.

OPERATION

WARNING: This heater is equipped with a thermostat. Heater may start at any time.

TO STOP HEATER

1. Push ON/STOP button to stop heater.

2. Unplug heater when not in use.

TO RESET HEATER

1. Wait two minutes before restarting.

Push MODE/RESET button to restart heater.

Fault Codes

This heater will display fault codes whenever there is a control shutdown. See Trouble- shooting, pages 9 - 12, before attempting to rectify any problems with your heater.

LED display will show surrounding temperature

unless up and down arrow keys are pressed. After pressing these keys, display shows set

point temperature for ve seconds and then will

change back to display surrounding temperature. Exposure to direct sunlight or extreme cold may affect temperature reading and/or thermostat operation.

This thermostat will store the last set point even if power is removed. Unit will maintain this set point until a new set point is entered.

Figure 5 - Controls Display

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160108-018

FUEL

Ground Wire (#10 AWG Stranded-Copper)

Copper or Brass Grounding Point

Figure 6 - Typical Generator Grounding

Method (Generator construction may

vary from that shown)

STORING, TRANSPORTING OR SHIPPING

WARNING: Never service heater while it is plugged in, operating

or hot. Severe burns and electrical shock can occur.

How To

See Storing, Transporting, or Shipping, above

See Air Output, Air Intake and Lint Filters, page 13

See Fuel Filter, page 14

See Fan, page 13

Item

Fuel tank

Air output and lint filters

Air intake filter

Fuel filter

Fan blades Motor

How Often

Clean every season or as needed

Replace every 500 hours of operation or once a year

Wash and dry with soap and water every 500 hours of operation or as needed

Clean twice a heating season or as needed

Clean every season or as needed Not required/permanently lubricated

OPERATION WITH PORTABLE GENERATOR

Alternator

Ground Lug

WARNING: Before operating heater or any appliance from a portable generator, verify that generator has been properly connected to earth ground. Improper grounding or failure to ground generator can result in electrocution if a ground fault occurs. Refer to owner’s manual supplied by generator manufacturer for proper grounding procedures.

Operating voltage range of heater is 95 to 135 Volts. Prior to plugging heater into generator

output voltage should be veried (if generator

is equipped with automatic idle feature, output voltage should be measured with generator running at full speed). If voltage does not

measure in this range heater should not be plugged into generator.

Refer to Operation, page 7, for starting, stopping and resetting heater procedures.

Note: If shipping, transport companies require fuel tanks to be empty.

1. Remove excess fuel from tank using a siphon pump. Drain remaining fuel through

ller neck by tipping heater to the rear.

2. If any debris is noted in old fuel, add 1 or 2 quarts of clean kerosene to tank, stir and drain again. This will prevent excess debris

from clogging lters during future use.

3. Properly dispose of old and dirty fuel. Check with local automotive service stations that recycle oil.

4. If storing, store heater in dry place. Make sure storage place is free of dust and corrosive fumes.

IMPORTANT: Do not store kerosene over summer months for use during next heating season. Using old fuel could damage heater.

PREVENTATIVE MAINTENANCE SCHEDULE

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160108-01 9

TROUBLESHOOTING

WARNING: Never service heater while it is plugged in, operating

or hot. Severe burns and electrical shock can occur.

POSSIBLE CAUSE

1. Control remembers Codes from prior operation

1. No power to heater (All

LED's are off)

2. Bad electrical connection between control and power cord

1. Thermostat setting is too low.

1. Supply voltage is above 135 volts

Generator out of regulation

1. Supply voltage is below 95 volts. Poor supply circuit or extension cord too long or inadequate gauge.

1. Room or ambient temperature exceeds 100°F

1. Bad electrical connection between motor and power cord.

2. Motor locked-fan obstructed

Motor locked-pump obstructed

4. Motor defective

REMEDY

1. Press MODE/RESET button to clear Code and restart heater.

1. Check power cord connections.

2. Unplug heater. Check all electrical connections. (see wiring diagram, page 18)

1. Adjust thermostat to a higher setting by pressing button or change to MAN-

UAL MODE by pressing the

MODE/RESET button

1. Conrm supply voltage is

below 135 volts.

1. Conrm supply voltage is

above 95 volts. See extension cord requirements on page 7.

1. Operate heater in a cooler environment.

1. Unplug heater. Check all electrical connections. (See wiring diagram, page 18)

2. Unplug heater. Clear fan obstruction.

3. Service pump (See page

17)

4. Unplug heater. Replace motor.

DISPLAY

Display shows

C1,C2,C3,C4,C5,C6, C7,C8 or C9

Display is Off

Display shows room temperature

Display shows C1 High Voltage

Display shows C2 Low Voltage

Display shows C8 Temperature over 100°F

Display shows C9 Low Pressure

WARNING: High voltage!

Unplug heater before servicing.

FAULT CONDITION

Motor does not start after heater is plugged in and ON/STOP button is ON.

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160108-0110

POSSIBLE CAUSE

1. Air line or tting leaking.

2. Pump cover leaking Pump cover screws loose

3. Pump cover gasket leaking

Pump output lter clogged

4. Pump pressure is low

5. Pump pressure is low. Can-

not adjust to specication

1. No fuel in fuel tank

2. Water in fuel tank

3. Pump pressure incorrect

4. Dirty Fuel Filter

5. Obstruction in Nozzle

6. Bad electrical connection between ignitor and control

7. Blown control fuse

8. Defective ignitor

9. Defective ignition control assembly

REMEDY

1. Unplug heater. Check air

lines and ttings for leaks.

Correct all leaks.

2. Unplug heater.Check pump cover for leaks. Tighten pump cover screws to 1020 in-lbs.

Unplug heater. Replace pump

output lter. See Pump Pressure Adjustment page 14.

Adjust pump pressure to

specication. See Pump Pressure Adjustment, page 14.

5. Service pump, see page 17.

1. Fill Tank. See Fuels, page

6. Restart heater.

2. Drain and ush fuel tank

with kerosene. See Storing, Transporting or Shipping,

page 8.

3. See Pump Pressure Adjust- ment, page 14.

4. See Fuel Filter, page 14.

5. See Nozzle Assembly, page 16.

Check electrical connections. See Wiring Diagram, page 18.

7. Replace control fuse, see page 17.

8. Replace ignitor and control

fuse, see pages 14 & 17.

9. Replace ignition control assembly

DISPLAY

Display shows C9 Low Pressure

Display shows C3 No Ignition

TROUBLESHOOTING

Continued

FAULT CONDITION

Motor starts and runs but heater does not ignite.

WARNING: High voltage!

Unplug heater before servicing.

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160108-01 11

POSSIBLE CAUSE

1. Not enough fuel in tank to maintain combustion

2. Water in fuel tank

3. Pump pressure incorrect

4. Dirty fuel lter

5. Obstruction in nozzle

6. Photocell assembly not properly installed

7. Dirty photocell lens

8. Defective photocell

1. Pump pressure too high

2. Heater inlet or outlet is covered and unit is not getting enough air for combustion

3. Fan set screw is loose

1. Heater inlet suddenly blocked by debris.

2. Water in fuel tank

3. Dirty fuel lter

4. Obstruction in nozzle

5. Fan set screw is loose

REMEDY

1. Fill tank. See Fuels, page 6. Restart heater.

2. Drain and ush fuel tank

with kerosene. See Storing, Transporting or Shipping, page 8.

3. See Pump Pressure Adjustment, page 14.

4. See Fuel Filter, page 14.

5. See Nozzle Assembly, page 16.

6. Make sure photocell boot is fully seated in bracket.

7. Clean photocell lens.

8. Replace photocell.

1. See Pump Pressure Adjustment, page 14.

2. Unplug heater. Remove obstructions or loose material from heater inlet or outlet.

3. Tighten fan set screw to 40-50 in-lbs. See service procedures on page 13.

1. Unplug heater. Remove obstructions or loose material from heater inlet.

2. Drain and ush fuel tank

with kerosene. See Storing, Transporting or Shipping, page 8.

3. See Fuel Filter, page 14.

4. See Nozzle Assembly, page 16.

5. Tighten fan set screw to 40-50 in-lbs. See service procedures on page 13.

DISPLAY

Display shows C4 Flame Extinguished

Display shows C5 Improper Flame

Display shows C6 Flame Change

TROUBLESHOOTING

Continued

FAULT CONDITION

Heater ignites but control assembly shuts heater off before running out of fuel.

WARNING: High voltage!

Unplug heater before servicing.

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160108-0112

REMEDY

1. Unplug heater. Depress and release each control button several times to check operation. Every button should click every time it is depressed.

2. Replace control assembly.

1. Operate heater in a cooler environment.

1. Unplug heater. Check air

lines and ttings of leaks.

Correct all leaks.

2. Unplug heater. Check pump cover for leaks. Tighten pump cover screws to 1020 in-lbs.

3. Unplug heater Replace pump output filter. See Pump Maintenance, page

17.

4. Adjust pump pressure to specification. See Pump Pressure Adjustment, page

14.

5. Replace pump lters. See

page 13.

6. Adjust pump rotor gap or replace pump rotor and blades. See page 17.

POSSIBLE CAUSE

1. One or more of the control buttons is depressed continuously (stuck).

2. Defective control assembly

1. Room or ambient temperature exceeds 100°F

1. Air line or tting leaking

2. Pump cover leaking. Pump cover screws loose

3. Pump cover gasket leaking.

Pump output lter clogged

4. Pump pressure is low

5. Pump pressure is low. Can-

not adjust to specication. Pump lters are dirty.

6. Pump pressure is low, pump has excessive wear or improper adjustment

DISPLAY

Display shows C7 Control Button Stuck

Display shows C8 Temperature Over 100°F

Display shows C9 Low Pres- sure (Setting 5)

TROUBLESHOOTING

Continued

FAULT CONDITION

(Continued) Heater ignites but control assembly shuts heater off before running out of fuel.

WARNING: High voltage!

Unplug heater before servicing.

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160108-01 13

Figure 7 - Upper Shell Removal,

Motor Shaft

Setscrew

Figure 8 - Fan, Motor Shaft, and

Setscrew Location

Motor Shaft

Back of Flat on Motor Shaft

1.82"

Motor

Shaft

Length

Fan

Setscrew Touching Back of Flat on Motor Shaft

Figure 9 - Fan Cross Section

Fan

Motor

SERVICE PROCEDURES

WARNING: To avoid risk of burn and electrical shock, never attempt to service heater while it is plugged in, operating, or hot.

UPPER SHELL REMOVAL

1. Remove screws along each side of heater using 5/16" nut-driver. These screws attach upper and lower shells together. See Figure 7.

2. Lift upper shell off.

3. Remove fan guard.

FAN

IMPORTANT: Remove fan from motor shaft before removing motor from heater. The weight of the motor resting on the fan could damage the fan pitch (see Figure 8).

Remove upper shell (see Figure 7).

2. The fan is located with the set screw in

contact with the back of at on motor as

shown in Figure 9.

3. Use 1/8" allen wrench to loosen setscrew

which holds fan to motor shaft (see Figure

8).

4. Slip fan off motor shaft.

5. Clean fan using a soft cloth moistened

with kerosene or solvent.

6. Dry fan thoroughly.

7. Place setscrew on flat of shaft.

Tighten setscrew firmly (40-50 inchpounds/4.5-5.6 n-m).

8. Replace fan guard and upper shell.

AIR OUTPUT, AIR INTAKE AND LINT FILTERS

Remove upper shell (see Figure 7).

2. Remove lter end cover screws using

5/16" nut-driver (see Figure 10).

3. Remove lter end cover.

4. Replace air output and lint lters.

5. Wash or replace air intake lter.

6. Replace lter end cover.

7. Replace fan guard and upper shell.

IMPORTANT: Do not oil lters.

Air Intake Filter

Lint Filter

Filter End Cover

Air Output Filter

Figure 10 - Air Output, Air Intake, and

Lint Filters

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160108-0114

SERVICE PROCEDURES

Continued

PUMP PRESSURE ADJUSTMENT

1. Remove pressure gauge plug from lter

end cover (see Figure 11).

2. Install 0-15 PSI pressure gauge.

3. Start heater (see Operation, page 7). Allow heater to reach operating temperature (approx. 10 minutes).

4. Set heater to MANUAL MODE, SETTING

5. This is the only setting that will allow pressure adjustment.

5. Adjust pressure. Turn relief valve to right to increase pressure. Turn relief valve to left to decrease pressure. See specications with Figure 12 for correct pressure for each model.

6. Remove pressure gauge. Replace pres-

sure gauge plug in lter end cover.

7. This heater continuously monitors pump pressure with a built-in pressure sensor. To display the pump pressure while oper-

ating, set the heater to MANUAL MODE,

SETTING 5, then press the MODE/RESET button once. Pump pressure will be displayed (example: "6.9") for 5 seconds.

Figure 11 - Pressure Gauge Plug

Removal

Pressure Gauge Plug

Pressure Gauge

Figure 12 - Adjusting Pump Pressure

Relief Valve

Pump

Model Pressure

110 6.9 PSI

160 6.7 PSI 175 6.8 PSI 220 8.4 PSI

Fuel Filter, Bushing, and

Lower Fuel Line

Upper Fuel

Line

Side Cover

Figure 13 - Fuel Filter Removal

IGNITOR

1. Remove upper shell and fan guard (See Upper Shell Removal, page 13).

2. Remove fan (see page 13).

3. Remove the control side cover with a 5/16" nut driver. On 160, 175 and 220 models, remove two wheel support bolts and nuts with a Phillips screwdriver and an adjustable wrench. Remove side cover (see Figures 13).

FUEL FILTER

1. Remove side cover screws using 5/16" nut-driver.

2. Remove side cover with a 5/16" nut driver. On 160, 175 and 220 models, remove two wheel support bolts and nuts with a Phillips screwdriver and an adjustable wrench..

3. Pull upper fuel line off fuel lter neck (see

Figure 13).

4. Carefully pry bushing, fuel filter, and lower fuel line out of fuel tank (see Figure

13).

5. Wash fuel lter with clean fuel and replace

in tank.

6. Attach upper fuel line to fuel lter neck.

7. Replace side cover.

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160108-01 15

4. Disconnect ignitor wires from ignition control assembly (see Figure 14). Pull the ignitor wires up through the hole in the lower shell.

5. Disconnect fuel line hose and air line hose. Remove photocell from photocell bracket (see Figure 14).

6. Remove combustion chamber. Stand combustion chamber on end with nozzle adapter bracket on top (see Figure 15).

7. Remove ignitor screw with a 1/4" nut driver. Carefully remove ignitor from nozzle adapter bracket.

CAUTION: Do not bend or strike

ignitor element. Handle with care.

8. Carefully remove replacement ignitor from packing.

9. Carefully guide ignitor into opening in nozzle adapter bracket. Do not strike ignitor element. Attach ignitor to nozzle adapter bracket with screw using a 1/4" nut driver. Torque 0.90 to 1.69 N-m (8 to 15 in-lbs) Do not over torque.

10. Replace combustion chamber.

11. Route the ignitor wires back down through the hole in the lower shell. Connect wires to the ignition control assembly (see Figure 14).

12. Replace fuse on ignition control assembly with the fuse provided with the SP002-01 Igniter Kit. See Ignition Control Assembly, page 17.

13. Replace control side cover.

14. Connect and route fuel line hose and air line hose to nozzle adapter assembly.

15. Replace photocell in photocell bracket.

16. Replace fan (see page 13).

17. Replace fan guard and upper shell (see page 13).

SERVICE PROCEDURES

Continued

Photocell Bracket

Ignitor

Ignitor Screw/ Washer Assembly

Nozzle Adapter Bracket

Ignitor Element

Combustion Chamber

Nozzle Adapter Bracket Opening

Figure 15 - Ignitor SP002-01

Replacement

Figure 14 - Disconnecting Ignitor Wires

from Ignition Control Assembly

Photocell Bracket

Air Line

Hose

Fuel Line

Hose

Combustion Chamber

Photocell Assembly

Ignitor

Nozzle Adapter Bracket

Ignition Control Assembly

Side Cover

Ignitor Wire

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160108-0116

SERVICE PROCEDURES

Continued

Figure 16 - Removing Air and Fuel Line

Hoses

Fuel Line

Hose

Air Line

Hose

Nozzle/ Adapter Assembly

Combustion Chamber

Photocell Bracket

Nozzle Adapter Bracket

NOZZLE ASSEMBLY

1. Remove upper shell (see Upper Shell

Removal, page 13).

2. Remove fan (see Fan, page 13).

3. Remove fuel and air line hoses from

nozzle assembly (see Figure 16).

4. Turn nozzle assembly 1/4 turn to left

and pull toward motor to remove (see Figure 17).

5. Place plastic hex-body into vise and lightly

tighten.

6. Carefully remove nozzle from the nozzle

adapter using 5/8" socket wrench (see Figure 18).

7. Blow compressed air through face of nozzle.

This will free any dirt in nozzle area.

8. Inspect nozzle sleeve for damage.

9. Replace nozzle into nozzle adapter until

nozzle seats. Tighten 1/3 turn more using 5/8" socket wrench 4.5 to 5.1 N-m (40 to 45 in-lbs). See Figure 18.

10. Attach nozzle assembly to burner strap

(see Figure 17).

11. Attach fuel and airline hoses to nozzle

assembly.

12. Replace fan (see Fan, page 13).

13. Replace fan guard and upper shell (see

Upper Shell Removal, page 13).

Figure 17 - Removing Nozzle/Adapter

Assembly

Nozzle/ Adapter Assembly

Combustion Chamber

Figure 18 - Nozzle and Nozzle Adapter

Nozzle Face

Nozzle

Nozzle Sleeve

Nozzle Adapter

Air Line

Fitting

Fuel Line

Fitting

(For 220 Model Only)

1. Remove combustion chamber and ignitor by following steps 1 through 7 under Ignitor, page 14.

2. Carefully place ignitor in a safe location.

3. Remove two nozzle adapter bracket screws.

4. Place hex-shaped aluminum nozzle adapter into vise (do not overtighten).

5. Carefully remove nozzle from nozzle adapter using 5/8" socket wrench (see Figure 18).

6. Blow compressed air through face of nozzle. This will remove any debris in nozzle.

7. Inspect nozzle seal for damage.

8. Replace nozzle into nozzle adapter until nozzle seats. Tighten 80-110 inch-pounds.

9. Attach nozzle adapter bracket to combustion chamber with two screws removed in step 3.

10. Repeat steps 9 through 16 under Ignitor, page 14.

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160108-01 17

SERVICE PROCEDURES

Continued

IGNITION CONTROL ASSEMBLY

WARNING: High voltage!

1. Unplug heater.

2. To expose the ignition control assembly, remove the control panel side cover screws using 5/16" nut-driver. On 160, 175 and 220 models, remove two wheel support bolts and nuts with a Phillips screwdriver and an adjustable wrench.

Remove fuse from fuse clips (see Figure 19).

4. Replace fuse with fuse of the same type and rating (7A, 125VP). Do not substitute a fuse with a higher current rating.

5. Replace control panel side cover.

Figure 19 - Replacing Fuse

Ignition Control Assembly

Fuse

PUMP ROTOR

(Procedure if Rotor is Binding)

1. Remove upper shell (see Upper Shell Removal, page 13).

2. Remove filter end cover screws using 5/16" nut driver (see Figure 20).

3. Remove filter end cover and air filters.

4. Remove pump plate screws using 5/16" nut-driver.

5. Remove pump plate.

6. Remove rotor, insert, and blades (see Figure 21).

7. Check for debris in pump. If debris is found, blow out with compressed air.

8. Install insert and rotor.

Check gap on rotor. Adjust to 0.076/0.101 mm (0.003"/0.004") if needed (see Figure 21).

Note: Rotate rotor one full turn to ensure

the gap is 0.076/0.101 mm (0.003"/0.004")

at tightest position. Adjust if needed.

Figure 20 - Rotor Location

Pump Plate

Insert

Rotor

Blade

Filter End Cover

Air Intake Filter

Air Output Filter

Gap Adjusting Screw

Rotor

Blade

0.003"/0.004" (0.076-0.101 mm) Gap Measured With Feeler Gauge

Gap Adjusting Screw

Figure 21 - Gap Adjusting Screw

Locations

Sandpaper

Figure 22 - Sanding Rotor

10. Install blades, pump plate, air filters, and filter end cover.

11. Replace fan guard and upper shell (see Upper Shell Removal, page 13).

12. Adjust pump pressure (see Pump Pres- sure Adjustment, page 14).

Note: If rotor is still binding, proceed as

follows.

13. Perform steps 1 through 6.

14. Place fine grade sandpaper (600 grit) on flat surface. Sand rotor lightly in “figure 8” motion four times (see Figure 22).

15. Reinstall insert and rotor.

16. Perform steps 10 through 12.

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160108-0118

WIRING DIAGRAM

AIR GAUGE KIT

For all models. Special tool to check pump pressure. 0-15 PSI gauge. 3/8" NPT pipe

thread.

IGNITION CONTROL ASSEMBLY/PHOTOCELL TESTER

Special tool used to test the ignition control assembly and photocell.

Purchase these accessories from your local dealer. If they can not supply these accessories, contact ProCom Heating, Inc. at 1-877-886-5989 for information. You can also write to the address listed on the back page of this manual.

ACCESSORIES

You may have further questions about installation, operation, or troubleshooting. If so, contact ProCom Heating, Inc. at 1-877-886-

5989. When calling please have your model and serial numbers of your heater ready.

TECHNICAL SERVICE

You can also visit ProCom Heating, Inc.’s web site at www.usaprocom.com.

Blue

main return

Heater Control Assmebly

Blue

White

Black

Ignitor

Red

Photocell

Ignitor IGN

Motor MTR

Neutral AC

Line (L1) AC

Motor MTR

Ignitor IGN

Ground

Green

motor

Yellow or White

Power Plug 120V/60Hz

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160108-01 19

PARTS

WHEEL AND HANDLES

KEY QTY QTY QTY QTY NO. PART NO. DESCRIPTION 110 160 175 220

1 160074-01 Rear Handle 1 1 1 2 160073-01 Front Handle 1 1 1 3 160072-01 Wheel Support Frame 2 2 2 4 160158-01 Support Bushing 2 2 2 5 160072-12 Fuel Tank Support Assembly 1 1 1 6 160072-13 Screw, M10-1.5 x 60 2 2 2 7 160129-01 Acorn Nut 2 2 2 8 160080-01 Wheel 2 2 2 9 160130-01 Wheel Spacer 2 2 2 10 160079-01 Axle 1 1 1 11 160062-01 Handle 1 12 160064-01 Front Handle Bracket 1 13 160064-02 Rear Handle Bracket 1 14 160083-01 Shell Heat Shield 1 15 160100-01 Screw, 10-16 x 2.0 1 16 160078-01 Screw, 10-16 x .5 1

160, 175, and 220 Models

110 Model

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160108-0120

PARTS

12 13

24 25

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160108-01 21

KEY QTY QTY QTY QTY NO. PART NO. DESCRIPTION 110 160 175 220

1 160075-01 Guard Wire 1 1 160075-02 Guard Wire 1 1 1 160075-03 Guard Wire 1 2 160101-01 Shell Screw 8 8 8 8 3 160050-01GY Upper Shell, Painted 1 3 160144-01GY Upper Shell, Painted 1 1 3 160147-01GY Upper Shell, Painted 1 4 160135-01 Combustion Chamber Assy. 1 4 160136-01 Combustion Chamber Assy. 1 4 160137-01 Combustion Chamber Assy. 1 4 160138-01 Combustion Chamber Assy. 1

5 160051-01GY Lower Shell, Painted 1 5 160145-01GY Lower Shell, Painted 1 1 5 160148-01GY Lower Shell, Painted 1

see detail, pg 23

Nozzle Bracket Assembly 7 160011-01 Fan 1 7 160058-01 Fan 1 1 1 8

see detail, pg 22

Motor/Pump Assembly 9

see detail, pg 22

Photocell/Bracket Assembly 10 160043-01 Motor Mounting Bracket 1 10 160043-02 Motor Mounting Bracket 1 1 1 11 160066-01 Fan Guard 1 11 160066-02 Fan Guard 1 1 1 12 160012-02 Fuel Filter 1 12 160012-01 Fuel Filter 1 1 1 13 160034-01 Fuel Tube Bushing 1 1 1 1 14 160060-01 Small Shell Bracket 2

14 160060-02 Large Shell Bracket 2 2 2

15 160020-03 Power Supply Cord 1 1 1 1 16 160013-01 Strain Relief Bushing 1 1 1 1 17 160056-01 Right Side Cover 1 17 160056-02 Right Side Cover 1 1 1 18 160087-01 Clip, Nut, #10, .08 Wall 6 6 6 6

19 160055-01 Left Side Cover 1 19 160055-02 Left Side Cover 1 1 1

20 160139-01GY Fuel Tank Assy., Small 1 20 160140-01GY Fuel Tank Assy., Medium 1 1

20 160141-01GY Fuel Tank Assy., Large 1

21 160005-01 Fuel Gauge 1 21 160005-02 Fuel Gauge 1 1 1 22 160037-04 Nylon Airline Tee 1 1 1 1 23 160171-01 Programmed Variable Control 1 23 160171-02 Programmed Variable Control 1 1 23 160171-03 Programmed Variable Control 1 24 160030-01 Vented Fuel Cap Assy. 1 1 1 1 25 160030-03 Vented Fuel Cap Gasket 1 1 1 1 26 160031-01 Plastic Filler Neck 1 1 1 1 27 160036-01 Filler Neck Gasket 1 1 1 1

Parts Available - Not Shown

160037-02 Airline Tubing 2 2 2 2

160039-01 Upper Fuel Line 1 1 1 1 160038-01 Lower Fuel Line 1 160038-02 Lower Fuel Line 1 1 1

160037-03 Control Airline 1 1 1 1

PARTS

This list contains replaceable parts used in your heater. When ordering parts, be sure to provide correct model and serial numbers (from model plate), and part number and description of desired part.

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160108-0122

PHOTOCELL ASSEMBLY

KEY QTY QTY QTY QTY NO. PART NO. DESCRIPTION 110 160 175 220

1 160041-03 Photocell Bracket 1 1 1 1 2 160092-02 Screw, 6-32 x .38 2 2 2 2 3 160016-01 Photocell Assembly 1 1 1 1

KEY QTY QTY QTY QTY NO. PART NO. DESCRIPTION 110 160 175 220

1 160001-01 Motor 1 1 1 1 2 160023-01 Rotor Insert 1 1 1 1 3 160003-01 Pump Rotor 1 1 1 1 4 160006-01 Pump Body 1 1 1 1 5 160088-01 Screw, 10-32 x .62 2 2 2 2 6 160007-01 Pump Cover 1 1 1 1

7 160009-01 Lint Filter 1 1 1 1

8 160008-01 Output Filter Assembly 1 1 1 1 9 160010-01 Intake Filter 1 1 1 1 10 160057-01 Filter End Cover 1 1 1 1 11 160106-01 Adjusting Screw 1 1 1 1 12 160024-01 Pipe Plug 1 1 1 1 13 160090-01 Screw, 10-32 x 1.0 3 3 3 3 14 160089-01 Screw, 10-32 x 1.12 6 6 6 6 15 160029-01 90° Nylon Elbow 1 1 1 1 16 160004-01 Pump Blade 4 4 4 4

PARTS

MOTOR AND PUMP ASSEMBLY

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160108-01 23

PARTS

NOZZLE ASSEMBLY

4 5

KEY QTY QTY QTY QTY NO. PART NO. DESCRIPTION 110 160 175 220

1 160086-01 Stainless Steel Retaining Ring 1 2 160042-01 Nozzle Adapter Bracket 1 1 1 2 160042-02 Nozzle Adapter Bracket 1 3 160102-01 Screw, 10-16 x .38 2 2 2 2 4 160002-01 Ignitor 1 1 1 1 5 160093-01 Belleville Washer 1 1 1 1 6 160092-01 Screw, 6-32 x .88 1 1 1 1

7 160040-32 Orice Assembly 1 7 160040-20 Orice Assembly 1 7 160040-39 Orice Assembly 1 7 160040-41 Orice Assembly 1

8 160077-01 Brass Barb Fitting 1 9 160028-01 Nozzle Adapter 1 1 1 9 160028-02 Nozzle Adapter 1 10 160077-02 Barb Fitting, 90° 1

Note: Use only original replacement parts. This will protect your warranty coverage for parts replaced under warranty.

PARTS UNDER WARRANTY

Contact authorized dealers of this product. If they can’t supply original replacement part(s), call ProCom Heating, Inc. at 1-877-886-5989.

When calling ProCom Heating, Inc., have ready:

• your name

• your address

• model and serial numbers of your heater

• how heater was malfunctioning

• purchase date

• place of purchase

Usually, we will ask you to return the part to the factory. You may be asked to supply proof of purchase.

PARTS NOT UNDER WARRANTY

Contact authorized dealers of this product. If they can’t supply original replacement part(s), contact ProCom Heating, Inc. at 1-877-886-

5989. When calling ProCom Heating, Inc., have

ready:

• model and serial number(s) of your

heater(s)

• the replacement part number

REPLACEMENT PARTS

PROCOM HEATING, INC. LIMITED WARRANTIES

New Products – Outdoor Heating

Standard Warranty: ProCom Heating, Inc. warrants this new product and any parts thereof to be free from

defects in material and workmanship for a period of one (1) year from the date of rst purchase from an

authorized dealer provided the product has been installed, maintained and operated in accordance with ProCom Heating, Inc.’s warnings and Instructions.

For products purchased for commercial, industrial or rental usage, this warranty is limited to 90 days from

the date of rst purchase.

Factory Reconditioned Products

Limited Warranty: ProCom Heating, Inc. warrants factory reconditioned products and any parts thereof

to be free from defects in material and workmanship for a period 30 days from the date of rst purchase

from an authorized dealer provided the product has been installed, maintained and operated in accordance with ProCom Heating, Inc.’s warnings and Instructions. No return will be authorized. Parts will be provided to repair the product.

Terms Common to All Warranties

The following terms apply to all of the above warranties: Always specify model number and serial number when contacting the manufacturer. To make a claim under

this warranty, the bill of sale or other proof of purchase must be presented. This warranty is extended only to the original retail purchaser when purchased from an authorized dealer,

and only when installed by a qualied installer in accordance with all local codes and instructions furnished

with this product. This warranty covers the cost of part(s) required to restore this product to proper operating condition and

an allowance for labor when provided by a ProCom Heating, Inc. Authorized Service Center or a provider approved by ProCom Heating, Inc. Warranty parts must be obtained through authorized dealers of this product and/or ProCom Heating, Inc. who will provide original factory replacement parts. Failure to use original factory replacement parts will void this warranty.

Traveling, handling, transportation, diagnostic, material, labor and incidental costs associated with warranty repairs, unless expressly covered by this warranty, are not reimbursable under this warranty and are the responsibility of the owner.

Excluded from this warranty are products or parts that fail or become damaged due to misuse, accidents, improper installation, lack of proper maintenance, tampering or alteration(s).

This is ProCom Heating, Inc.’s exclusive warranty, and to the full extent allowed by law; this express warranty excludes any and all other warranties, express or implied, written or verbal and limits the duration of any

and all implied warranties, including warranties of merchantability and tness for a particular purpose to one (1) year on new products and 30 days on factory reconditioned products from the date of rst purchase.

ProCom Heating, Inc. makes no other warranties regarding this product. ProCom Heating, Inc.’s liability is limited to the purchase price of the product and ProCom Heating, Inc.

shall not be liable for any other damages whatsoever under any circumstances including direct, indirect, incidental, or consequential damages.

Some States do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

This warranty gives you specic legal rights, and you may also have other rights which vary from state to state.

160108-01 Rev A 08/12

WARRANTY

KEEP THIS WARRANTY

Model (

located on product or identication tag

) _____________________________

Serial No. (

located on product or identication tag

) __________________________

Date Purchased __________________________

Keep receipt for warranty verication.

ProCom Heating, Inc.

2800 Grifn Drive

Bowling Green, KY 42101

+ 56 hidden pages

Procom PCK110VT Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual