THERMOBILE AT 400, AT 500 US User Manual

THERMOBILE

Type.......................................................

Cap Max. Mj/h........................................

Cap Max. kW.........................................

/h...........................................

Airflow m

Volt/Hz/Amp...........................................

Prod. code.............................................

Fabr.year 0000

Made by THERMOBILE Ind. B.V. Breda, Holland

- 1 - - 2 -

A B

C DE

AT-400

000

00 0

000/00/0,00

00.000.000

Serial nr: 00.0000

G H I

R Q P NO M L K J

- 3 - - 4 -

AT400

AT500

A B C D

- 5 - - 6 -

2 40.020.943 - rev. 04 - 2011 AT 400 - 500-US series

- 7 - - 8 -

ABCDEF

- 9 - - 10 -

- 11 - - 12 -

AT 400 - 500-US series 40.020.943 - rev. 04 - 2011 3

B A

English.........................................................5

Français.....................................................19

Español......................................................35

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English

Contents

Safety instructions....................................... 5

Introduction................................................. 7

Preparations................................................ 8

Use............................................................ 10

Maintenance ..............................................11

Faults........................................................ 14

Spare parts................................................ 17

Technical information ................................ 17

Installing accessories................................ 17

Standards and guidelines.......................... 18

Preface

This manual contains instructions for use of the stationary used oil fired heaters as shown on the cover. The information in this manual is important for the correct and safe use of the heater.

Identification of the product (fig. 1)

The identification plate is attached to the side of the heater. The identification plate contains the following data: A Year of manufacture B Serial number C Production code D Voltage data E Air displacement F Capacity max (kW) G Capacity max (MJ/h) H Type of machine

Service and technical support

Please contact your dealer or the manufacturer for information about the heater. Make sure you have the following data at hand: type and serial number of the stationary used oil fired heater.

Warranty and liability

For warranty and liability, see general warranty regulations.

Environment

Note

The heater is made of various metals and synthetic materials. The heater also contains electronic parts, which must be treated as electronic waste. Please contact your dealer for further information.

1 SAFETY INSTRUCTIONS

1.1 Pictograms in this manual Caution

Indicates risk of damage to the appliance.

Warning

Indicates a dangerous situation, that can lead to death or serious injuries.

Warning

Always switch off power when performing maintenance or repairs on the hot air heater!

Hot

Some surfaces may be hot! Wait until these parts have sufficiently cooled down before performing maintenance.

Suggestions and tips to simplify the carrying out of the specified tasks or actions.

1.2 Pictograms on the stationary used oil fired heater (fig. 2)

A Warning for quantity of oil to be used

Instruction not to put the burner dish on a

cold surface B Overheating thermostat C Instruction for re-ignition. D Positions of the burner: low and high.

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1.3 Use this product for its intended use

The stationary used oil fired hot air heater has been designed for heating of workshops at mechanization companies, heating and frost protection of halls, transit sheds and warehouses and heating of garage workshops.

Caution

If the heater will be installed indoors, make sure that there is proper ventilation in the room. Make sure the flue gas can only flow to an outside source separate from the room.

1.4 General instructions Warning

• Make sure that the heater is

properly installed, adjusted and maintained.

• For all service and adjustments

contact qualified, competent and authorized persons.

• Do not make any modifications to

the heater without the prior written consent of the manufacturer.

• Make sure to always follow the

local standards and guidelines as well as the local requirements, concerning environmental quality, fuel, fire and electrical safety.

• Read this manual carefully

before using the heater.

• Keep this document with the

heater.

• Follow the described procedures.

• Never lean against the heater.

Warning

• Do not create a fire hazard by storing or using highly inflammable materials near the heater. Keep these materials at adequate distance from the heater:

- top and sides 6 inch (150

mm)

- front 35 inch (890 mm)

- back and flue 18 inch (460

mm)

• Make sure there is enough air for proper combustion.

• Make sure that the convector heater has cooled down sufficiently and that the plug has been removed from the socket before carrying out any repair or maintenance work.

1.5 Additional safety Warning

• Connect the heater only to a

120 V / 60 Hz power supply.

• Replace fuses only with identical

spares.

• The heater must be grounded.

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Warning

• Use only the following types of fuel:

• Automatic transmission oil

• Crankcase oil

•Diesel oil

• Hydraulic oil

• Domestic fuel oil

• Do not add the following materials to the used oil:

• Anti-freeze

• Carburettor cleaner

• Paint thinner

• Parts washer solvents

• Gasoline

• Transformer oil

• Oil additives

• Any other inappropriate or

hazardous material

• Do not fill the tank while the heater operates.

2 INTRODUCTION

2.1 Purpose

These stationary used oil fired heaters are direct fired heaters with thermal protection, heat exchanger, combustion air fan, flue stack connection with T-piece and draught regulator and hot air fan. The A T 500 is equipped with a connection for a room thermostat The hot air heaters have been tested at sea level at a temperature of 68 °F.

2.2 Working principle

The stationary used oil fired heater is equipped with three electric motors. The first electric motor drives a fuel pump, which extracts fuel from the fuel tank. The second electric motor drives the combustion air ventilator, which blows the combustion air into the combustion chamber. The third electic motor drives the hot air fan, which draws the surrounding air around the combustion chamber and heat exchanger. The hot air is blown into the space to be heated.

Diesel oil is poured manually on a burner dish, which is ignited with a burning paper pellet. As soon as the burner dish is at the right temperature, the pump thermostat activates the fuel pump; the control light flashes on. The fuel pump pumps the used oil onto the burner dish. The used oil evaporates due to the temperature of the burner dish. The gas vapour burns. A thermostat switches on the hot air fan motor to blow hot air into the space to be heated. The pump thermostat switches off the fuel pump when a failure causes the heater to overheat. The fuel pump is switched off when the heater is switched off. The hot air ventilator runs until the combustion air thermostat switches off the ventilator: this allows the heater to cool down. The maximum thermostat switches off the heater when the temperature gets too high. The fuel supply has an overflow that ensures that the used oil flows back into the fuel tank when the fuel pipe is blocked. The overflow protection switches off the fuel pump when the burner dish overflows.

2.3 Main components of the stationary used oil fired heater (fig. 3)

ACover B Combustion chamber C Heat exchanger D Maximum thermostat E Thermostats F T-piece with draught regulator G Hot air fan H Combustion air ventilator I Fill filter J Control panel K Fuel tank LDrain cock M Fuel filter N Fuel pump O Identification plate P Return line QDrawer R Fuel pipe S Fuel supply pipe

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2.4 Main components of the burner (fig. 4)

A Cover combustion chamber B Combustion chamber C Flame trap D Burner ring ESeal cord F Burner dish G Vaporiser H Bottom combustion chamber I Overflow protection JShovel

2.5 Control panel (fig. 6)

A Indicator light, yellow B Indicator light, red C Bolt fuel tank D Rocker switch:

- 0: The pump is switched off

- 1: The pump is in operation

- 2: High pump speed (only for AT 500)

2.6 Thermostat

The heater has the following thermostats:

• Pump thermostat

When the burner dish is sufficiently preheated, the fuel pump starts up.

• Hot air thermostat:

The thermostat starts the hot air fan when the heater reaches a certain temperature.

• Maximum thermostat

The thermostat stops the fuel pump when the hot air temperature gets too high.

2.7 Accessories

•Flue with rain cap

3 PREPARATIONS

3.1 Removing the packaging

1. Remove packaging from the hot air

heater

2. Remove packaging from the loose parts

in the combustion chamber.

3.2 Installation

1. Ensure that the heater is positioned horizontally.

2. Correctly attach the parts of the combustion chamber, see fig. 4.

3. Attach the various handles to the cover and the drawer, see fig. 3.

4. Push the tank bolt up, see fig. 5 (D).

5. Pull the fuel tank forward.

6. Fill the fuel tank through the tank filter with used oil, until the level of used oil is 1 inch below the top of the tank.

Caution

Only the following oil types may be used in the stationary used oil fired heaters:

• Automatic transmission oil

•Diesel oil

• Hydraulic oil

• Oil for household use

Note

• Install the equipment in the US according to the following publications of the National Fire Protection Association:

• NFPA #30: Flammable and

Combustible

• Liquids Code

• NFPA #31: Oil Burning

Equipment

• NFPA #88A: Parking

Structures

• NFPA #88B: Repair Garages

• NFPA #211: Chimneys,

Fireplaces and Vents

• Local codes may require that the heater is mounted at a minimum of 8 feet (2.4 m) off the ground. This is especially the case when there are possible combustible or flamable fumes in the room. Refer to NFPA #88B.

• Install the equipment in Canada according to the following standard: CSA B139, installation Code for Oil Burning Equipment.

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Place the heater on a location with respect to the following:

• Possibility of unobstructed, even heat distribution.

• Safe and easy access for servicing.

• Unobstructed passage for shop vehicles and equipment.

• Proper clearances for combustibles. Refer to the safety section.

• Adequate combustion air per local codes. The room must be ventilated to provide sufficient combustion-air. The maximum air

consumption is 12 USG/h (46 m h)

• Proper installation of the stack.

• The structure in which the heater is located requires the following minimum dimensions:

• height from the point of

location of the heater: 15 feet (4.5 m).

• length and width: 20 feet

(6 m).

• floor area: 400 square feet

(36 m

)

• Possibility to place the heater on a combustible flooring.

• If the heater is installed at an elevation, a permanent platform, including stairs and railings, must be provided to facilitate regular maintenance.

7. Close the fuel tank: Ensure that it is locked.

8. Ensure that the hot air can flow out freely.

9. Ensure that inflammable materials are at a sufficient distance from the heater, see

1.4.

10. Ensure there is sufficient ventilation: the maximum air consumption is 2650 ft

hour.

11. Check the floor surface: this needs to be at least 645 ft

12. Install the flue (18 ft and a rain cap).

13. Make sure the rocker switch is positioned at 0.

14. Check the supply voltage: see identification plate.

15. Place the plug in the socket.

3.3 Preparing for start-up

1. Switch the rocker switch to "0".

2. Only for the AT 400: Switch control (A) of the fuel pump to "low", see (fig. 5).

3. Drain possible water of condensation from the fuel tank, see fig. 3 (L).

4. Open the drawer: Push pedal (A) down and keep it down, lift safety (B) up, turn

control (C) left or right and let go of the pedal, see fig. 7. Pull drawer (D) forward.

5. Check whether the burner dish and the floor of the combustion chamber are clean and cold.

6. Clean the burner dish and the floor of the combustion chamber if necessary.

7. Pour 0.3 litre of diesel oil onto the burner dish, see fig. 4 (F).

Warning

Never pour diesel oil onto a hot burner dish. The burner dish must be cool!

8. Form a paper pellet and light it.

9. Drop the burning pellet on the burner dish.

10. Close the drawer.

1 1. Check through the upper cover that there

is no flame around the seal cord and between the bottom and the combustion chamber, see fig. 4.

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3.4 Starting up Warning

• Never pour diesel oil onto a hot

burner dish. The burner dish must be cool and clean!

• Do not start the heater if the fan

still runs. The heater is cooling down.

• Do not start the heater if excess

oil has accumulated in or near the heater.

Caution

Do not switch on the convector heater if there is no fuel, or if the connected fuel tank is empty.

Caution

Only the following oil types may be used in the stationary used oil fired heaters:

• Automatic transmission oil

• Crankcase oil

• Diesel oil

• Hydraulic oil

• Domestic fuel oil

1. Switch the rocker switch to "2", see fig. 6

(D). When the burner dish has reached the right temperature, the fuel pump starts running and the control light is on.

2. During the first 20 - 30 minutes the fuel

pump should have a low capacity.

For AT 400:

Position the rocker switch to "low", see fig. 5 (A).

For AT 500:

The yellow control light is on, see fig. 6 (A).

3. Set the pump regulator to high capacity if

maximum capacity is desired.

For AT 400:

Switch the rocker switch to "high", see fig. 5 (B).

For AT 500:

Switch the rocker switch to "2", see fig. 6 (D).The red control light is on, see fig.6(B).

4USE

4.1 During operation Caution

• Do not operate the heater in hot

weather to burn oil.

• Do not burn used oils other than

generated on the premiss of the owner, unless written authorization is obtained from the regulatory authority.

Hot

Do not touch the flue stack or blower outlet! The flue stack and blower outlet get hot during operation!

4.2 Switching off

Switch off heating:

1. Switch the rocker switch to "0".

The fuel pump stops running. The control light turns off.

Caution

After switching off the heater it will run for several minutes, until the fuel on the burner dish is used up. In the meantime the hot air fan and the distributor fan keep running. These fans cool the heater until it has sufficiently cooled down (after 10 to 30 minutes). Both fans will stop around the same time.

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5 MAINTENANCE

English

5.1 Maintenance table

Use the table in this booklet to record performed maintenance after each winter season.

Warning

For all service and adjustments contact qualified, competent and authorized persons.

Description Period

Every 12 hours

Clean the burner dish. X Drain (water of) condensation from the

fuel tank, when the waste oil contains water.

Clean the combustion chamber. X

Warning

Always clean the combustion chamber before starting the heater.

Hot

Do not touch the flue and air outlet! Wait until the flue and the air outlet have cooled down sufficiently before carrying out any maintenance.

Week-lyMonth-lyEvery

six months

Annually

Every two years

Clean the burner ring. X Clean the combustion chamber and the

vaporiser with a steel brush. Clean the combustion chamber and the

vaporiser with a steel brush. Clean the overflow pipe in the floor of

the combustion chamber. See fig. 4(I). Check the oil pipes for leakage. X Clean the fuel tank, the supply filter and

the fuel filter. The fuel tank can easily be removed.

Check the combustion air fan and clean if necessary.

Check the hot air fan and clean if necessary.

Clean the flue stack valve in the T-piece,

Dealer see fig. 8 (A). The recommended draught is 2 mmwk.

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Description Period

Every 12 hours

Check the seal between the bottom and

Week-lyMonth-lyEvery

six months

X the vaporiser for leakage. Adjust the pressure on the seal cord, or replace the seal.

Replace the seal cord in the bottom.

X Check the seal ring for leakage. Adjust the pressure on the seal cord in case of a leakage.

Clean the heat exchanger. X Clean the flue stack T-piece, see "clean-

ing the flue stack valve". Check the heater's wiring. X Clean the heat exchanger.

Take the heat exchanger apart for a good cleaning.

Annually

Every two years

Hot

Do not touch the flue stack or combustion chamber! Do not perform maintenance until the flue and combustion chamber have cooled down.

5.2 General Warning

Switch off the power supply before carrying out any repairs!

When the heater is stored long-term:

1. Switch off the heater.

2. Disconnect the power plug.

3. Clean the heater.

4. Use an oily cloth to clean the combustion

chamber, to protect the combustion chamber against corrosion.

Warning

Do not operate the heater in hot weather to burn oil.

5.3 Cleaning the combustion chamber(fig. 4)

1. Open the cover of the heater, see fig. 4

(A).

2. Remove the burner ring (D) with the hook

of the shovel (J).

3. Clean the burner ring with a steel brush.

4. Remove the burner dish (F) with the hook

of the shovel.

5. Clean the burner dish with a scraper.

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6. Clean the inner side of the combustion chamber (B) and the vaporiser (G) with the front of the shovel.

Note

• Used oils can contain heavy metallic compounds and foreign materials. These materials stay as a residu when burned. Therefore it is necessary to take care when using, cleaning and maintaining the heater.

• Wear protective gear when cleaning the inside of the heater:

• Respirator for fine particles

• Rubber gloves

• Safety goggles

• Protective clothing

• Ensure that the holes in the combustion chamber wall remain open for combustion air supply.

7. Remove any soot pieces from the floor of the combustion chamber.

8. Clean the inside of the pipe in the vaporiser with a small brush (diameter 4 mm).

9. Clean the fuel supply line (N) with a brush (inner diameter 0.33 in), see fig. 3.

10. Install all parts in reversed order.

5.4 Cleaning the heat exchanger (fig.

1. Disconnect the power connection from the heater.

2. Open the cover, see fig. 3 (A).

3. Unscrew the thermostat clamp (A).

4. Take the wiring off both thermostats (B).

5. Remove safety strip (C).

6. Remove safety strip (D).

7. Remove cover (E) from the heat exchanger.

8. Clean the inner side of the heat exchanger with a brush and vacuum cleaner.

9. Re-install the cover of the heat exchanger.

Always attach a new gasket (F) between the cover and the heat exchanger.

Install all parts in reversed order.

Apply the wiring of the thermostats according to the electrical circuit diagram. The thermostats are equal.

5.5 Taking t he heat exchanger apart

(fig. 9)

1. Disconnect the power connection from the heater.

2. Remove the T-piece (A) from the flue, see fig. 3 (F).

3. Remove the grate, see fig. 3 (A).

4. Unscrew the thermostat clamp (A).

5. Take the wiring off both thermostats (B).

6. Remove safety strip (C).

7. Remove safety strip (D).

8. Remove the fuel supply pipe, see fig. 3 (S).

9. Unscrew the overflow cup support and put the overflow protection on the floor of the heater.

10. Remove the combustion air fan (H) with motor support, see fig. 3.

11. Unscrew the back panel from the heater and turn it 180° to the fuel tank. Temporarily support the back panel in this position.

12. Remove the casing of the combustion air fan.

Warning

Do not change the position of the valve in the casing.

13. Unscrew the frame of the combustion chamber from the groundplate of the heater.

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14. Lift the combustion chamber with heat exchanger from the heater.

Do this with another person.

15. Unscrew the connection of the combustion chamber and the heat exchanger.

16. Remove the strip between the combustion chamber and the heat exchanger.

17. Pull the heat exchanger from the combustion chamber.

18. Remove upper and lower cover of the heat exchanger.

19. Clean the heat exchanger internally with a brush and remove dirt with a vacuum cleaner.

20. Re-install the upper and lower cover of the heat exchanger.

Always apply new gaskets between the upper and lower cover and the heat exchanger.

Re-install the heater in reversed order.

Apply the wiring of the thermostats according to the electrical circuit diagram. The thermostats are equal.

Reposition the bottom cover.

5.7 Removing the fuel tank (fig. 10)

1. Drain the fuel tank through the drain cock, see fig. 3 (L).

2. Push the tank bolt up, see fig. 10 (C).

3. Support the fuel tank with a woo den reel (A).

4. Remove the black knurled bolt (B) on the left and right side of the fuel tank.

5. Remove the fuel tank using both hands by grasping the bottom of the tank.

6. Remove the wooden reel.

7. Gently lower the fuel tank and take the fuel tank from the heater.

Remove the fuel tank with care: the fuel system is installed in the fuel tank.

Install the fuel tank in reversed order.

5.8 Adjusting the pressure of the seal

cord (fig. 11)

1. Open the control panel (A), see 3.3.

2. Unscrew nut (B).

3. Turn the bottom (C) of the vaporiser slightly up or down (depending on the situation).

4. Unscrew nut (B).

5. Push the control panel in the heater.

5.6 Cleaning the flue (fig. 8)

1. Remove the bottom cover (B) of the T-

Check whether the seal cord seals properly when the heater is running.

piece (A).

2. Clean the flue from top to bottom with a flue brush.

3. Check the connections for leakage.

4. Check the flue parts for rust.

Caution

Rust formation indicates that chlorine

6 FAULTS

Warning

For all service and adjustments contact qualified, competent and

authorized persons. containing materials have been burnt. Chlorine containing materials seriously damage the heater. This may void your warranty. Contact your dealer for instructions on how to test waste oil for chlorine.

Warning

Switch off the power supply before carrying out any repairs!

Ensure that the power is switched on, and the fuel tank is full, before you start troubleshooting.

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6.1 Troubleshooting table

Fault Cause Solution Action

The flame is extinguished immediately after ignition; the control light is off.

1 The heater has no volt-

age.

2 The fuel pump is not

switched on.

3 The motor and pump

are not functioning.

Check the electric connec-

User

tion. Position the switch to "1", see

User

fig. 5 (A). Dilute the waste oil with die-

User sel oil when the waste oil is too viscous.

Check the pump thermostat

Dealer and replace if necessary.

Check the overflow protec-

User tion switch by moving the overflow basin a few times from left to right.

Check whether the pump

User axis can be turned manually. Clean the pump if this is not possible.

Check the pump motor. Dealer

The flame is extinguished immediately after ignition; the control light is on.

4 The pump thermostat

has not reached the right temperature yet.

5 The maximum thermo-

stat is defective.

6 The overflow protection

is full of waste oil.

7 There is water or sedi-

ment in the fuel tank.

8 The fuel supply pipe is

blocked: The fuel flows back into the fuel tank through the return pipe.

Let the heater cool down.

User Restart the heater.

Replace the pump thermo-

Dealer stat.

Reset the thermostat. User Replace the thermostat. User Clean the overflow basin,

User burner dish and the bottom of the vaporiser.

Clean the fuel tank and the

User fuel filter, see fig. 3.

Clean the fuel supply pipe or

User replace if necessary.

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Fault Cause Solution Action

The flame is extinguished immediately after ignition; the control light is on.

The air combustion fan keeps running, while the hot air fan has stopped and the heater has cooled down.

There is soot formation in the combustion chamber and in the flue.

9 There is no proper flue

draught.

10 The combustion thermo-

stat is defective.

11 The combustion air fan

is not functioning.

12 There is insufficient sup-

ply of combustion air

Check whether the flue is fit-

User ted according to the description, see "flue".

Check the flue for leakage. User Clean the flue if necessary. User See faults: 3 and 4. Replace the combustion

User thermostat.

Check the motor and replace

Dealer if necessary.

Clean the holes in the vapor-

User iser.

Check the functioning of the

User combustion air fan.

There is leakage between the bottom of the control panel and the vaporiser.

The flame goes out directly after ignition.

13 The flue draught is too

high or irregular.

14 There is leakage

between the bottom of the control panel and the vaporiser.

15 The flue draught is too

low.

Position a flue stack valve,

Dealer see "flue". Adjust the flue to the right pressure, see § 5.3.

See faults: 9, 12, and 13. Adjust the pressure on the

User seal cord.

Replace the seal cord. User

Check all connections in the

User flue.

Check whether the draught

User regulator is off.

Check the flue for blockage. User Reduce the number of

User bends.

Heighten the flue. User

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Fault Cause Solution Action

The flame goes out directly after ignition.

The heater makes a humming sound.

The flue draught is too low.

16 There is too much diesel

oil at start up.

There is unburnt fuel on the burner dish.

Record the maintenance details in table A in the appendix of this manual.

7 SPARE PARTS

Before use we advise you to have spare parts in store, see table B in the appendix of this manual.

Isolate the flue outside the

User

building. Check the flue, see "flue". User Reduce the amount of diesel

User

oil. Low temperatures for single

User walled flue, for instance in case of frost. The sound will stop when the temperature rises.

See faults: 2, 11, 12, 13 and

14.

8 TECHNICAL INFORMATION

• See for technical specifications table C in the appendix of this manual.

9 INSTALLING ACCESSORIES

9.1 Flue (fig. 12)

The heater has a flue stack connection.

1. Push a T-piece (A) directly over the connection (B).

2. Push the flue pipe (C) on the T-piece.

3. Use three screws to screw the flue pipe to the T-piece.

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Caution

The flue must meet the following requirements.

• The flue must be pointed upwards.

• The flue (or any part of it) may not be positioned horizontally. A 45° angle is acceptable.

• It is not allowed to lenghten the flue connection horizontally.

• When a pipe is used under 45°, pipe pieces of at least 3.2 ft must be fitted in front of and at the back of the slanting pipe.

English

• The flue must stick out at least 1.6 ft above the apex of the building.

• Keep the vertical part at the back of the heater as long as possible before leading it outside through the wall.

4. Fit the following pipe pieces.

5. Place a cap (D) at the end of the flue.

9.2 Diameter flue

AT 400 AT 500

6 inch 8 inch

10 STANDARDS AND GUIDELINES

For the standards and guidelines, go to www.thermobile.nl.

18 40.020.943 - rev. 04 - 2011 AT 400 - 500-US series

+ 39 hidden pages

THERMOBILE AT 400, AT 500 US User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual