Procom PCK110VT, PCK160VT, PCK175VT, PCK220VT 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.

Never use heater in living or sleeping areas. Heater is suitable for outdoor use and for use on com-

bustible oors.

PORTABLE FORCED AIR HEATERS

KEROSENE/DIESEL HEATER WITH BUILT-IN THERMOSTAT

OWNER’S MANUAL

PCK110VT - ADJUSTABLE 80-110,000 BTU/HR

PCK160VT - ADJUSTABLE 110-160,000 BTU/HR PCK175VT - ADJUSTABLE 125-175,000 BTU/HR PCK220VT - ADJUSTABLE 160-220,000 BTU/HR

Questions, problems, missing parts? Before returning to your retailer, call

our customer service department at 1-866-573-0674, 7:30 am - 4:15 pm CST,

Monday through Friday or email customerservice@usaprocom.com

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160108-01B2

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.

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 mini-

mum of 25 feet (762 cm) 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 frequency 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.

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.

SAFETY

TABLE OF CONTENTS

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

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

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

Product Identication and 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 ......................................... 9

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

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

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

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

Parts ........................................................ 19

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

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

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3160108-01B

SAFETY

UNPACKING

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 3 ft2 (2800 cm2) opening of fresh, outside air for each 100,000 Btu/Hr (30 kw) 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.

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 10 feet (304.8 cm). It is further recommended that these enclosure materials 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

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 1-866-573-0674 for replacement

parts before returning to dealer.

ASSEMBLY

WIRE GUARD

All Models

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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160108-01B4

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 x 1.5 (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

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5160108-01B

PRODUCT IDENTIFICATION AND 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

English Warnings Label 160110-01

French Warnings Label 160110-02

Spanish Warnings Label 160110-03

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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160108-01B6

SPECIFICATIONS

VENTILATION

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)

FUELS

• 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.

PCK110VT PCK160VT PCK175VT PCK220VT

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 5.5 gal/20.8 L 10 gal/37.9 L 10 gal/37.9 L 14 gal/53 L

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

Pump Pressure 6.9 PSI (hot) 6.7 PSI (hot) 6.8 PSI (hot) 8.4 PSI (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 3400 RPM 3400 RPM 3400 RPM 3400 RPM

Motor 1/4 hp 1/4 hp 1/4 hp 1/4 hp

Shipping Weight 42 lbs/19 kg 71 lbs/32.2 kg 71 lbs/32.2 kg 77 lbs/35 kg

Heater Weight without

Fuel (approx)

36 lbs/16.3 kg

60.5 lbs/27.4 kg 60.5 lbs/27.4 kg 66 lbs/29.9 kg

WARNING: 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 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:

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.

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7160108-01B

ASSEMBLED IN THE USA BY:

ASSEMBLE AUX ETATS-UNIS PAR: ENSAMBLADA EN LOS EE.UU.POR:

PROCOM HEATING, INC. 2800 GRIFFIN DRIVE BOWLING GREEN, KY 42101

THERMOSTAT MODE

MODE/RESET

PUMP PRESSURE

STAND BY

ON/STOP

TEMPERATURE

MANUAL MODE

MODE MANUEL/MODO MANUAL

MODE/REINITIALISATION

MARCHE/ARRET

MODE THERMOSTAT

THERMOSTATO MODO

MODO/RESTABLECER

ENCENDER/APAGAR

TEMPERATURA

160167-02

PRESSION DE LA POMPE PRESION DE BOMBA

ADJUST

AJUSTE

IMPORTANT: Review and understand the warnings in the Safety section, page 2. 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 crankcases, naphtha, paint thinners, alcohol or other ammable fuels.

4. Plug heater’s power cord into approved, grounded, three-wire extension cord. Extension cord must be at least 6 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.

6. Push ON/STOP button to ON. An alarm will sound and the display will start countdown to ignition. The heater will start and pump pressure will be displayed for 6 seconds.

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

Note: When operating in Thermostat

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

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

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 by 3° F, the heater will ignite. If the thermostat set temperature is lower than surrounding air temperature, the heater will not ignite. Heater output will adjust automatically to maintain set temperature.

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.

2. Push MODE/RESET button to restart

heater.

OPERATION

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

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.

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160108-01B8

Ground Wire (#10 AWG Stranded-Copper)

Copper

or Brass Grounding Point

Figure 6 - Typical Generator Grounding

Method (Generator construction may

vary from that shown)

PREVENTATIVE MAINTENANCE SCHEDULE

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

or hot. Severe burns and electrical shock can occur.

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

STORING, TRANSPORTING OR SHIPPING

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.

measure in this range heater should not be

plugged into generator. Refer to Operation, page 7, for starting, stop-

ping 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.

Item How Often How To

Fuel tank Clean every season or as needed. See Storing, Transporting, or

Shipping, above.

Air output and lint lters

Replace every 500 hours of operation or once a year.

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

Air intake lter Wash and dry with soap and water every 500

hours of operation or as needed.

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

Fuel lter Clean twice a heating season or as needed. See Fuel Filter, page 14.

Fan blades Clean every season or as needed. See Fan, page 13. Motor Not required/permanently lubricated.

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9160108-01B

TROUBLESHOOTING

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

or hot. Severe burns and electrical shock can occur.

WARNING: High voltage! Unplug heater before servicing.

DISPLAY POSSIBLE CAUSE REMEDY

Display shows

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

1. Control remembers codes from prior operation.

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

heater.

Display is off. 1. No power to heater (All LED’s

are off).

2. Bad electrical connection between control and power cord.

1. Check power cord connec-

tions.

2. Unplug heater. Check all electrical connections (see Wiring Diagram, page 18).

Display shows room tem-

perature.

1. Thermostat setting is too low. 1. Adjust thermostat to a higher

setting by pressing button or change to MANUAL MODE by pressing the MODE/RESET button.

Display shows C1 High

Voltage.

1. Supply voltage is above 135

volts. Generator out of regulation.

1. Confirm supply voltage is below 135 volts.

Display shows C2 Low

Voltage.

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

inadequate gauge.

1. Confirm supply voltage is above 95 volts. See extension cord requirements on page 7.

Display shows C8 Te m perature over 100°F.

1. Room or ambient temperature exceeds 100°F.

1. Operate heater in a cooler environment.

Display shows C9 Low

Pressure.

1. Bad electrical connection between motor and power cord.

2. Motor locked-fan obstructed.

3. Motor locked-pump obstructed.

4. Motor defective.

1. Unplug heater. Check all electrical connections (see Wiring Diagram, page 18).

2. Unplug heater. Clear fan obstruction.

3. Service pump (see page 17).

Unplug heater. Replace motor.

FAULT CONDITION

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

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160108-01B10

TROUBLESHOOTING

WARNING: High voltage! Unplug heater before servicing.

FAULT CONDITION

Motor starts and runs but heater does not ignite.

DISPLAY POSSIBLE CAUSE REMEDY

Display shows C9 Low

Pressure.

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. Cannot adjust to specication.

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 10-20 in-lbs.

3. Unplug heater. Replace pump output lter. See Pump Pres-

sure Adjustment page 14.

4. Adjust pump pressure to specication. See Pump Pres- sure Adjustment, page 14.

5. Service pump, see page 17.

Display shows C3 No Ignition.

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.

1. Fill Tank. See Fuels, page 6.

Restart heater.

2. Drain and flush 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.

6. 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.

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11160108-01B

TROUBLESHOOTING

WARNING: High voltage! Unplug heater before servicing.

FAULT CONDITION

Heater ignites but control assembly shuts heater off before running out

of fuel.

DISPLAY POSSIBLE CAUSE REMEDY

Display shows C4 Flame Extinguished.

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. Fill tank. See Fuels, page 6.

Restart heater

2. Drain and flush 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.

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

7. Clean photocell lens.

8. Replace photocell.

Display shows C5 Improper Flame.

1. Pump pressure too high.

2. Heater inlet or outlet is cov-

ered and unit is not getting

enough air for combustion.

3. Fan set screw is loose.

1. See Pump Pressure Adjust- ment, 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.

Display shows C6 Flame Change.

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

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

2. Drain and flush 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.

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160108-01B12

TROUBLESHOOTING

DISPLAY POSSIBLE CAUSE REMEDY

Display shows C7 Control button stuck.

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

2. Defective control assembly.

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.

Display shows C8 Te m perature Over 100°F.

1. Room or ambient temperature exceeds 100°F.

1. Operate heater in a cooler environment.

Display shows C9 Low Pressure (Setting 5).

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. Cannot adjust to specification. Pump lters are dirty.

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

1. Unplug heater. Check air

lines and fittings of leaks.

Correct all leaks.

2. Unplug heater. Check pump cover for leaks. Tighten pump cover screws to 10-20 in-lbs.

3. Unplug heater Replace pump output lter. See Pump Rotor, page 17.

4. Adjust pump pressure to specication. See Pump Pres- sure Adjustment, page 14.

5. Replace pump filters. See

page 13.

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

WARNING: High voltage! Unplug heater before servicing.

FAULT CONDITION

(Continued) Heater ignites but control assembly shuts heater off before

running out of fuel.

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13160108-01B

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).

1. 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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160108-01B14

ASSEMBLED IN THE USA BY:

ASSEMBLE AUX ETATS-UNIS PAR: ENSAMBLADA EN LOS EE.UU.POR:

PROCOM HEATING, INC. 2800 GRIFFIN DRIVE BOWLING GREEN, KY 42101

THERMOSTAT MODE

MODE/RESET

PUMP PRESSURE

STAND BY

ON/STOP

TEMPERATURE

MANUAL MODE

MODE MANUEL/MODO MANUAL

MODE/REINITIALISATION

MARCHE/ARRET

MODE THERMOSTAT

THERMOSTATO MODO

MODO/RESTABLECER

ENCENDER/APAGAR

TEMPERATURA

160167-02

PRESSION DE LA POMPE PRESION DE BOMBA

ADJUST

AJUSTE

SERVICE PROCEDURES

PUMP PRESSURE

ADJUSTMENT (USING

EXTERNAL GAUGE)

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. DO NOT OVERTIGHTEN ADJUSTMENT SCREW. Service pump if pressure can not be adjusted to proper setting (see Figure 12).

6. Remove pressure gauge. Replace pressure gauge plug in lter end cover.

Figure 11 - Pressure Gauge Plug

Removal

Pressure Gauge Plug

Relief Valve

LED Display

Pressure Gauge

Figure 12 - Adjusting Pump Pressure

Using External Gauge

Figure 13 - Adjusting Pump Pressure

Using Built-In Gauge

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 14 - Fuel Filter Removal

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.

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.

4. 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. DO NOT OVERTIGHTEN ADJUSTMENT SCREW. Service pump if pressure can not be adjusted to proper setting (see Figure 12).

PUMP PRESSURE ADJUSTMENT

(USING BUILT-IN GAUGE)

1. This heater continuously monitors pump pressure with a built-in pressure sensor.

2. When the heater starts, pump pressure will be displayed for 6 seconds.

3. To display the pump pressure while operating, operate the heater for 2 minutes, set

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15160108-01B

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 15).

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

Photocell Bracket

Ignitor

Ignitor Screw/ Washer Assembly

Nozzle Adapter Bracket

Ignitor Element

Combustion Chamber

Nozzle Adapter Bracket Opening

Figure 16 - Ignitor SP002-01

Replacement

Figure 15 - 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

3. Pull upper fuel line off fuel lter neck (see Figure 14, page 14).

4. Carefully pry bushing, fuel lter, and lower fuel line out of fuel tank (see Figure 14,

page 14).

5. Wash fuel lter with clean fuel and replace

in tank.

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

7. Replace side cover.

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 Figure 14).

4. Disconnect ignitor wires from ignition control assembly (see Figure 15). 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 15).

6. Remove combustion chamber. Stand combustion chamber on end with nozzle adapter bracket on top (see Figure 16).

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160108-01B16

Figure 17 - 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 17).

4. Turn nozzle assembly 1/4 turn to left and pull toward motor to remove (see Figure

18).

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 19).

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 nozz l e se ats. Tig h t e n 1/3 tur n mo re u s i n g 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 18).

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 18 - Removing Nozzle/Adapter

Assembly

Nozzle/ Adapter Assembly

Combustion Chamber

Figure 19 - 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 Ig- nitor, page 15.

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 19).

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 15.

SERVICE PROCEDURES

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17160108-01B

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.

3. Remove fuse from fuse clips (see Figure

20).

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 20 - 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 21).

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 22).

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

8. Install insert and rotor.

9. Check gap on rotor. Adjust to

0.076/0.101 mm (0.003"/0.004") if needed (see Figure 22).

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 21 - 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 22 - Gap Adjusting Screw

Locations

Sandpaper

Figure 23 - 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 23).

15. Reinstall insert and rotor.

16. Perform steps 10 through 12.

SERVICE PROCEDURES

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160108-01B18

WIRING DIAGRAM

ST002-01

AIR GAUGE KIT

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

thread.

ST001-01

IGNITION CONTROL ASSEMBLY/

PHOTOCELL TESTER

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

ACCESSORIES

Purchase these accessories from your local dealer. If they can not supply these accessories, contact ProCom Heating, Inc. at 1-866-573-0674 for information. You can also write to the address listed on the back page of this manual.

TECHNICAL SERVICE

You may have further questions about installation, operation, or troubleshooting. If so, contact ProCom Heating, Inc. at 1-866-573-0674. When calling, please have your model and serial numbers of your heater ready.

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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19160108-01B

PARTS

WHEEL AND HANDLES

ITEM PART # 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 0.5 1

MODELS PCK160VT PCK175VT PCK220VT

MODEL

PCK110VT

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160108-01B20

PARTS

MODELS PCK110VT, PCK160VT, PCK175VT AND PCK220VT

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21160108-01B

ITEM 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 6 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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160108-01B22

PHOTOCELL ASSEMBLY

ITEM PART # DESCRIPTION QTY

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

ITEM PART # DESCRIPTION QTY

1 160001-01 Motor 1 2 160023-01 Rotor Insert 1 3 160003-01 Pump Rotor 1 4 160006-01 Pump Body 1

5 160088-01 Screw, 10-32 x .62 2 6 160007-01 Pump Cover 1 7 160009-01 Lint Filter 1 8 160008-01 Output Filter Assembly 1 9 160010-01 Intake Filter 1

10 160057-01 Filter End Cover 1

11 160106-01 Adjusting Screw 1 12 160024-01 Pipe Plug 1 13 160090-01 Screw, 10-32 x 1.0 3 14 160089-01 Screw, 10-32 x 1.12 6

15 160029-01 90° Nylon Elbow 1 16 160004-01 Pump Blade 4

PARTS

MOTOR AND PUMP ASSEMBLY

MODELS PCK110VT, PCK160VT, PCK175VT AND PCK220VT

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23160108-01B

PARTS

NOZZLE ASSEMBLY

MODELS PCK110VT, PCK160VT, PCK175VT AND PCK220VT

ITEM PART # 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 Nozzle Assembly 1 7 160040-20 Nozzle Assembly 1 7 160040-39 Nozzle Assembly 1 7 160040-41 Nozzle 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

REPLACEMENT PARTS

Contact authorized dealers of this product. If they can’t supply original replacement parts, call ProCom Heating, Inc. toll free at 1-866-573-6074 for referral information.

When calling have ready:

• Your name

• Your address

• Model and serial number of your heater

• How heater was malfunctioning

• Type of gas used (Propane/LP or Natural gas/NG) and Propane/LP tank size

• Purchase date

• Place of purchase

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

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

PARTS UNDER WARRANTY

PARTS NOT UNDER WARRANTY

Contact authorized dealers of this product. If they can’t supply original replacement part(s) call ProCom Heating, Inc. toll free at 1-866-573-6074 for referral information.

When calling have ready:

• Model and serial number of your heater

• The replacement part number

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.

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.

160108-01

Rev. B

08/13

ProCom Heating, Inc. Bowling Green, KY 42101 www.usaprocom.com 1-866-573-0674

+ 56 hidden pages

Procom PCK110VT, PCK160VT, PCK175VT, PCK220VT Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual