Wacker Neuson HI 110HD D, HI 200D, HI 110D, HI 300HD D, HI 200HD D Operator's Manual

Operator’s Manual

Indirect-Fired Air Heaters

HI 110D / HI 110HD D
HI 200D / HI 200HD D

HI 300D / HI 300HD D

EN

5000192822 06 0614

5000192822

Copyright
notice

© Copyright 2014 by Wacker Neuson Production Americas LLC

All rights, including copying and distribution rights, are reserved.

This publication may be photocopied by the original purchaser of the machine. Any
other type of reproduction is prohibited without express written permission from
Wacker Neuson Production Americas LLC.

Any type of reproduction or distribution not authorized by Wacker Neuson Production
Americas LLC represents an infringement of valid copyrights. Violators will be
prosecuted.

Trademarks

Manufacturer

All trademarks referenced in this manual are the property of their respective owners.

Wacker Neuson Production Americas LLC

N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.

Tel: [phone] · Fax: [phone] · Tel: [phone]

www.wackerneuson.com

Original
instructions

This Operator’s Manual presents the original instructions. The original language of this
Operator’s Manual is American English.

Foreword

Foreword

This heater is designed and approved for use as a construction heater in
accordance with the applicable standards of CSA. CHECK WITH YOUR LOCAL
FIRE SAFETY AUTHORITY IF YOU HAVE QUESTIONS ABOUT APPLICATIONS.

Other standards govern the use of fuel gases and heat producing products in
specific applications. Your local authority can advise you about these.

THE INSTALLATION OF THE UNIT SHALL BE IN ACCORDANCE WITH THE
REGULATIONS OF THE AUTHORITIES HAVING JURISDICTION.

SAVE THESE INSTRUCTIONS—This manual contains important instructions for
the machine models below. These instructions have been written expressly by
Wacker Neuson Production Americas LLC and must be followed during installation,
operation, and maintenance of the machines.

Machines
covered by
this manual

This manual covers machines with the following item numbers:

Machine Item Number Machine Item Number

HI 110 D 0620915 HI 300 D 0620866

HI 110 HD 0620864 HI 300 HD D 0620867

HI 200 D 0620865, 5200011877

HI 200 HD 0620916, 5200011878

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Machine
identification

Serial number
(S/N)

ghi_tx001445gb.fm 3

A nameplate listing the model number, item number, revision number, and serial
number is attached to this machine. The location of the nameplate is shown above.

For future reference, record the serial number in the space provided below. You will
need the serial number when requesting parts or service for this machine.

Foreword

Serial Number:

Machine
documentation

Expectations
for
information in
this manual

 From this point forward in this documentation, Wacker Neuson Production

Americas LLC will be referred to as Wacker Neuson.

 Keep a copy of the Operator’s Manual with the machine at all times.
 Use the separate Parts Book supplied with the machine to order replacement

parts.

 Refer to the separate Repair Manual for detailed instructions on servicing and

repairing the machine.

 If you are missing any of these documents, please contact Wacker Neuson to

order a replacement or visit www.wackerneuson.com.

 When ordering parts or requesting service information, be prepared to provide

the machine model number, item number, revision number, and serial number.

 This manual provides information and procedures to safely operate and

maintain the above Wacker Neuson model(s). For your own safety and to
reduce the risk of injury, carefully read, understand, and observe all instructions
described in this manual.

 Wacker Neuson expressly reserves the right to make technical modifications,

even without notice, which improve the performance or safety standards of its
machines.

 The information contained in this manual is based on machines manufactured

up until the time of publication. Wacker Neuson reserves the right to change
any portion of this information without notice.

 The illustrations, parts, and procedures in this manual refer to Wacker Neuson

factory-installed components. Your machine may vary depending on the
requirements of your specific region.

Manufacturer’s
approval

This manual contains references to approved parts, attachments, and
modifications. The following definitions apply:

 Approved parts or attachments are those either manufactured or provided by

Wacker Neuson.

 Approved modifications are those performed by an authorized Wacker

Neuson service center according to written instructions published by Wacker
Neuson.

 Unapproved parts, attachments, and modifications are those that do not

meet the approved criteria.

Unapproved parts, attachments, or modifications may have the following
consequences:

 Serious injury hazards to the operator and persons in the work area
 Permanent damage to the machine which will not be covered under warranty

Contact your Wacker Neuson dealer immediately if you have questions about
approved or unapproved parts, attachments, or modifications.

4 ghi_tx001445gb.fm

HI 110 / 200 / 300

Table of Contents

Foreword 3

1 Safety Information 7

1.1 Signal Words Found in this Manual ...................................................... 7

1.2 Machine Description and Intended Use ............................................... 8

1.3 Operating Safety .................................................................................. 9

1.4 Safety Guidelines for Operating Combustion Burners ....................... 10

1.5 Service Safety .................................................................................... 11

2 Labels 13

2.1 Label Locations .................................................................................. 13

2.2 Label Meanings .................................................................................. 15

3 Lifting and Transporting 19

3.1 Lifting and Transporting the Machine ................................................. 19

4 Operation 20

4.1 Installing the Lift Brackets (if equipped) ............................................. 20

4.2 Installing the Wheels and Handle ....................................................... 21

4.3 Controls and Service Locations .......................................................... 22

4.4 Control Panel ...................................................................................... 24

4.5 Recommended Fuels and Fuel Blending Guide ................................. 25

4.6 Inspecting the Fuel Hose .................................................................... 26

4.7 Positioning the Machine ..................................................................... 27

4.8 Suggested Venting ............................................................................. 28

4.9 Installing the Heater Duct ................................................................... 30

4.10 Flex Ducting Options .......................................................................... 31

4.11 Connecting Power to the Machine ..................................................... 32

4.12 Pre-Starting Checks ........................................................................... 33

4.13 Starting the Machine .......................................................................... 34

4.14 Starting the Machine in Extremely Cold Weather ............................... 35

4.15 Stopping the Machine ......................................................................... 36

4.16 Burner Faults ...................................................................................... 37

4.17 Installing and Using the Remote Thermostat ..................................... 38

5 Accessories 39

5.1 Available Accessories ........................................................................ 39

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5

Table of Contents

HI 110 / 200 / 300

6 Burner Setup 40

6.1 Removing the Access Panel ...............................................................40

6.2 Removing and Installing the Burner Assembly ....................................41

6.3 Setting Up the Burner ..........................................................................42

6.4 Checking the Oil Burner Electrodes ....................................................44

6.5 Checking/Changing the Burner Nozzle ...............................................45

6.6 Adjusting the Fuel Pressure ................................................................46

6.7 Setting the Air Band ............................................................................47

7 Maintenance 48

7.1 Periodic Maintenance Schedule ..........................................................48

7.2 Inspecting the Heat Exchanger ...........................................................49

7.3 Changing the Fuel Heater Filter ..........................................................52

7.4 Inspecting and Cleaning the Cadmium (CAD) Cell .............................53

7.5 Cleaning the Fan Blades and Motor ....................................................54

7.6 Cleaning the Interior Shell ...................................................................55

7.7 Inspecting the Flame Head .................................................................56

7.8 Inspecting the Electrical Connections .................................................57

7.9 Cleaning the Machine ..........................................................................58

8 Basic Troubleshooting 59

9 Technical Data 60

9.1 Machine ...............................................................................................60

9.2 Dimensions - HI110D, HI110HD D ......................................................61

9.3 Dimensions - HI200D, HI200HD D ......................................................62

9.4 Dimensions - HI300D, HI300HD D ......................................................62

10 Schematics 64

10.1 Electrical Schematic - HI 110 D, HI 110 HDD .....................................64

10.2 Electrical Schematic - HI 200 D ...........................................................65

10.3 Electrical Schematic - HI 200 HDD .....................................................66

10.4 Electrical Schematic - HI 300 D ...........................................................67

10.5 Electrical Schematic - HI 300 HDD .....................................................68

6

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HI 110 / 200 / 300 Safety Information

1 Safety Information

1.1 Signal Words Found in this Manual

This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE
signal words which must be followed to reduce the possibility of personal injury,
damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potential personal hazards.
f Obey all safety messages that follow this symbol.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.

To avoid death or serious injury from this type of hazard, obey all safety messages that

f

follow this signal word.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

f

To avoid possible death or serious injury from this type of hazard, obey all safety mes­sages that follow this signal word.

CAUTION!

CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.

To avoid possible minor or moderate injury from this type of hazard, obey all safety mes-

f

sages that follow this signal word.

NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.

Note: A Note contains additional information important to a procedure.

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Safety Information HI 110 / 200 / 300

1.2 Machine Description and Intended Use

Machine
description

Intended use

The HI Heater is an indirect-fired air heater that operates on diesel fuel. The
machine consists of the following components:

 Stainless steel combustion chamber and heat exchanger
 Blower
 Single-stage burner
 High-temperature shut-down device
 Fuel tank

Fuel is consumed in a closed combustion chamber. Room air or outside air
(depending on the application) is pulled into the machine where it is heated. This
clean, dry, hot air is then blown into the space to be heated by the blower. Access
to the blower assembly is protected by a guard fitted on the air inlet.

The HI Heater is intended to provide heat on outdoor or indoor construction sites (if
properly vented) and in other rugged applications.

This machine has been designed and built strictly for the intended use described
above. Using the machine for any other purpose could permanently damage the
machine or seriously injure the operator or other persons on the work site. Machine
damage caused by misuse is not covered under warranty.

Do not use this machine indoors without proper exhaust venting designed for
indoor use which meets all applicable regulations.

Optional
accessories

This machine has been designed and built in accordance with the latest global
safety standards. It has been carefully engineered to eliminate hazards as far as
practicable and to increase operator safety through protective guards and labeling.
However, some risks may remain even after protective measures have been taken.
They are called residual risks. On this machine, they may include exposure to:

 exhaust emissions
 hot surfaces such as exhaust vents and fuel heater
 fuel and fuel fumes when refueling
 high voltages and arc flash

To protect yourself and others, make sure you thoroughly read and understand the
safety information presented in this manual before operating the machine.

Wacker Neuson Corporation offers many optional accessories for the machine.
These accessories include the following:

 Remote thermostat
 Duct adapters (various sizes, available as kits, or individual ducts at lengths of

25 ft. or more).

 Exhaust vents and elbows

Contact your Wacker Neuson dealer for more information.

8 ghi_si000463gb.fm

HI 110 / 200 / 300 Safety Information

1.3 Operating Safety

Operator
training

Machine
condition

Before operating the machine:

 Read and understand the operating instructions contained in all manuals

delivered with the machine.

 Familiarize yourself with the location and proper use of all controls and safety

devices.

 Contact Wacker Neuson for additional training if necessary.

When operating this machine:

 Do not allow improperly trained people to operate the machine. People

operating the machine must be familiar with the potential risks and hazards
associated with it.

Only operate the machine when:

 The heat exchanger is in proper working order.
 All safety devices and guards are in place and in working order.
 All controls operate correctly.
 The machine is set up correctly according to the instructions in the Operator’s

Manual.

 The machine is clean.
 The machine’s labels are legible.

When operating the machine:

 Do not modify or defeat the safety devices.
 Do not use worn electrical cords.
 Do not use faulty fuel supplies.

Guidelines for
operator

When operating the machine:

 Remain aware of the machine’s moving parts. Keep hands, feet, and loose

clothing away from the machine’s moving parts.

 Wear protective clothing appropriate to the job site when operating the machine.
 Wear safety glasses.

When operating the machine:

 Do not operate a machine in need of repair.
 Do not smoke near the machine.
 Do not block the air inlet or outlet during machine operation.

Personal
Protective
Equipment
(PPE)

ghi_si000463gb.fm 9

Wear the following Personal Protective Equipment (PPE) while operating this
machine:

 Close-fitting work clothes that do not hinder movement
 Safety glasses with side shields
 Hearing protection
 Safety-toed footwear

Safety Information HI 110 / 200 / 300

Machine
installation
guidelines

Work space

As a recommended installation practice, refer to the current issue of CSA B139,
Installation Code for Oil Burning Equipment in Canada and NFPA 31 Standard for
the Installation of Oil-Burning Equipment in the USA;

 Never operate the machine in immediate proximity to flammable materials.

Minimum distances are specified in the Operation chapter under Positioning the
Machine.

 A rough estimate of opening required for each gallon (US) of capacity is one

square foot for indirect-fired heater

When operating the machine:

 Position the machine on a firm, noncombustible, level surface.
 Keep the area immediately surrounding and underneath the machine clean,

neat, and free of debris and combustible materials.

 Keep the area above the machine clear of debris that could fall on the machine.
 Store the machine properly when it is not being used.
 Keep unauthorized personnel, children, and pets away from the machine.

When operating the machine:

 Do not connect ductwork between the exhaust outlet port and the supply air inlet

port.

 Never operate the machine in areas that contain flammable objects, fuels, or

products that produce flammable vapors.

 Do not position the electrical cords under the machine or over the top of the

machine.

1.4 Safety Guidelines for Operating Combustion Burners

When using the machine:

 Clean up any spilled fuel immediately.
 Replace the fuel tank cap after refueling the machine.
 Refill the fuel tank in a well-ventilated area.
 Make sure you have proper certification or licensing required by the locality,

state, or province in which the machine is being installed to work with Liquid
Petroleum (LP).

When using the machine:

DANGER

Exhaust gas from the burner contains carbon monoxide, a deadly poison. Exposure
to carbon monoxide can kill you in minutes.

f Never run the machine indoors or in an enclosed area unless the machine is

vented properly according to local and national codes.

 Do not fill or drain the fuel tank near an open flame, while smoking, or while the

machine is running.

 Do not smoke when refueling the machine.

10 ghi_si000463gb.fm

HI 110 / 200 / 300 Safety Information

1.5 Service Safety

Licensing/
training/

Cleaning

Maintenance
guidelines

 Only trained personnel should troubleshoot or repair electrical problems

occurring with the machine.

When cleaning and servicing the machine:

 Keep the area around the burner free of debris such as leaves, paper, cartons,

etc.

 Keep the machine clean and labels legible.

When cleaning the machine:

 Do not clean the machine while it is running.
 Never use gasoline or other types of fuels or flammable solvents to clean parts.

Fumes from fuels and solvents can become explosive.

When maintaining the machine:

 Keep the fuel lines in good condition and properly connected.
 Allow the burner to cool before maintaining the machine.
 Re-install the safety devices and guards after repairs and maintenance.
 Keep all electrical cords away from heat, oil, vibrating surfaces, and sharp

edges.

 Inspect all electrical cords before each use and replace damaged cords.

Replacing
parts and
labels

Accessories,
safety devices
and
modifications

Personal
Protective
Equipment
(PPE)

When maintaining the machine:

 When replacement parts are required for this machine, use only Wacker

Neuson replacement parts or those parts equivalent to the original in all types of
specifications, such as physical dimensions, type, strength, and material.

 Replace worn or damaged components.
 Replace all missing and hard-to-read labels.
 Replace or repair electrical components with components that are identical in

rating and performance as the original component.

When using the machine:

 Use only accessories/attachments that are recommended by

Wacker Neuson Corporation.

When using the machine:

 Never operate the machine if any safety devices or guards are missing or

inoperative.

 Do not defeat safety devices.
 Do not modify the machine without the express written approval of the

manufacturer.

Wear the following Personal Protective Equipment (PPE) while servicing or
maintaining this machine:

 Close-fitting work clothes that do not hinder movement
 Safety glasses with side shields

ghi_si000463gb.fm 11

Safety Information HI 110 / 200 / 300

 Hearing protection
 Safety-toed footwear

In addition, before servicing or maintaining the machine:

 Tie back long hair.
 Remove all jewelry (including rings).

12 ghi_si000463gb.fm

HI 110 / 200 / 300 Labels

2 Labels

2.1 Label Locations

(4)

J

H

D G

A

B

G

B

P

K

E

H
L

N

C

F

HI 110

C

A

A

H

D

G

B

G

B

J

(4)

C

P

E

HI 200

L

N

K
H

C

AF

wc_gr009251

ghi_si000464gb.fm 13

Labels HI 110 / 200 / 300

(4)

A

H

G

D

B

G

B

J

P

L

E

N

K

C

H

C

AF

HI 300

D

G H

A

B

J

(4)

B

P

E

H
K

L

C

F

HI 300 HD

A

N

C

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14 ghi_si000464gb.fm

HI 110 / 200 / 300 Labels

2.2 Label Meanings

1

A WARNING

Hot surface hazard!

B WARNING

Entanglement hazard. Rotating machinery.
Do not reach inside machine when engine is
running.

C NOTICE

Lifting point

D

WARNING!
Electric shock hazard.
Disconnect power before servicing.
Read Operator’s Manual.

ECAUTION

This machine uses diesel fuel.

F Tie-down point

ghi_si000464gb.fm 15

Labels HI 110 / 200 / 300

G

DANGER
Using a heater indoors can kill you in
minutes. Heater exhaust contains
carbon monoxide. This is a poison
you cannot see or smell. During
indoor operation, vent exhaust gas
outdoors. Refer to Operator's
Manual.

HCAUTION

Hot while in operation. Do not touch. Keep
children, clothing, and combustibles away.

J Safety instruction label for diesel fuelled

heaters

K A nameplate listing the model number, item

number, revision number, and serial number
is attached to each unit. Please record the
information found on this plate so it will be
available should the nameplate become lost
or damaged. When ordering parts or
requesting service information, you will
always be asked to specify the model
number, item number, revision number, and
serial number of the unit.

L Heater rating plate

16 ghi_si000464gb.fm

HI 110 / 200 / 300 Labels

M WARNING

Licensed gas technician required.

Natural gas / liquid propane burner setup and
installation, fuel supply connection, test
firing, and burner adjustment MUST be
performed by a LICENSED professional gas
technician and must conform to the
requirements of all relevant local, state,
provincial, and Federal authorities.

Failure to heed this warning may result in an
explosion and/or fire causing property
damage, personal injury, or death.

N Creating Green Environments

This product may help you earn credits
toward LEED® EQ 3.1 and 3.2 certification.

P DIRECTIONS FOR OPERATION:

1. Connect the machine to 120V power sup­ply using a 12/3 x 50 foot max. 10/13 x
100 foot max. extension cord.

2. Wait 20-30 minutes to allow the oil filter to
pre-heat the fuel.

3. Turn the machine on:

a. Continuous heat mode (I) or
thermostat mode (II)
b. If available, select high or low fire
mode.

4. To turn off, switch to (0) position.

— WARNING

If three consecutive attempts to reset the
machine are unsuccessful, then troubleshoot
the heating system for the root cause(s) of
the lockout.

 Make necessary repairs or adjustments to

ensure a safe start condition.

 Ensure that the heat exchanger is free of

oil and oil vapors before starting or reset­ting the burner.

ghi_si000464gb.fm 17

Labels HI 110 / 200 / 300

— Fork lift pocket

18 ghi_si000464gb.fm

HI 110 / 200 / 300 Lifting and Transporting

3 Lifting and Transporting

3.1 Lifting and Transporting the Machine

Requirements

Background

Guidelines

 Transport vehicle capable of carrying 1000 lbs (454 kg)
 Crane or lift capable of carrying 1000 lbs (454 kg)

NOTICE: These machines are NOT designed to be towed with any vehicle.

WARNING

Crushing hazard.
f Only qualified riggers should attempt aerial lifting of this machine.

Follow the guidelines below when lifting and transporting this machine.



Remove all venting from the machine prior to lifting/transporting.



Cover all openings on the machine to avoid infiltration from road debris and dust.



Except for the HI 300HD, use all four lifting points on the sides of the machine
when using an aerial lifting rig.

 When using an aerial lifting rig on the HI 300HD, use the designated lifting point

on top of the machine.



HI 300HD only: Use the designated fork pockets when transporting the machine
with a fork lift.



Use the manual transport handle when relocating the machine within the job site.

 When tying down the machine, route tie-down straps or chains through the

lower frame only.

NOTICE: Do not route tie-down straps or chains over the top of the machine.
Doing so will damage the machine. Use only the designated tie-down locations.

ghi_tx001446gb.fm 19

Operation HI 110 / 200 / 300

4 Operation

4.1 Installing the Lift Brackets (if equipped)

Before attempting to lift the machine, the lift brackets must be installed.

1. Remove the machine from the crate.

2. Intstall the four lift brackets

(a) as shown using the supplied bolts and washers.

20 ghi_tx001447gb.fm

HI 110 / 200 / 300 Operation

4.2 Installing the Wheels and Handle

Overview

Installing the
axle and
wheels

The axle, wheels, handle, and stand are shipped loose with the machine and must
be assembled before operation.

There are pre-drilled holes for all of the components to be assembled. Bolts,
washers, and nuts are provided.

Follow the procedure below to install the axle and wheels.

1. Lift the machine using appropriate lifting gear.

WARNING

Crushing hazard.

f Refer to chapter Lifting the Machine for instructions on proper lifting techniques.

2. Attach the two axle mounting brackets (a) to the sides of the fuel tank.

f

c

d

Atttaching the
handle and
stand

Result

e

g

b

a

wc_gr007779

3. Insert the ends of the axle (b) through the axle mounting brackets.

4. Place a wheel (c) and flat washer (d) on each end of the axle as shown.

5. Insert hitch pins (e) into the holes at each end of the axle to secure the wheels.

A

6. Align the holes in the handle (f) and stand (g) with the holes on the fuel tank
flange as shown.

7. Attach the handle and base support with bolts, washers, and nuts.

The machine has now been assembled. Lower the machine and proceed.

ghi_tx001447gb.fm 21