Indirect-Fired Air Heaters
Operator’s Manual
HI 400 HD D
HI 400 HD G
0192824 001 1110
0192824
Copyright
notice
© Copyright 2010 by Wacker Neuson Corporation.
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 Corporation.
Any type of reproduction or distribution not authorized by W acker Neuson Corp oration
represents an infringement of valid copyrights. Violators will be prosecuted.
T ra d emarks
Manufacturer
All trademarks referenced in this manual are the property of their respective owners.
Wacker Neuson Corporation
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957
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 Standard ANSI Z83.7–CSGA 2.14. CHECK WITH YOUR LOCAL
FIRE SAFETY AUTHORITY IF YOU HA VE 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.
WARNING
Risk of personal injury or machine damage from improper use.
f Before using the machine, read and understand all instructions and follow them
carefully.
f The manufacturer is not responsible for damages to goods or persons due to
improper use of this machine.
WARNING
Failure to comply with the precautions and instructions provided with this machine
can result in death, serious injury, and property loss or damage from fire, explosion,
burns, asphyxiation, carbon monoxide poisoning, and/or electric shock.
f Before using the machine, read and understand all precautions and instructions
that have been provided. Follow them carefully.
f Only persons who can understand and follow the precautions and instructions
should use or service this machine.
f Contact the manufacturer if you need assistance with operating the machine or
need replacement manuals or labels.
WARNING
Work site fire, burn, inhalation, and explosion hazards.
f Keep solid combustibles, such as building materials, paper, or cardboard at a
safe distance away from the machine as recommended by the instructions.
f Never use this machine in spaces which do or may contain volatile or airborne
combustibles, or products such as gasoline, solvents, paint thinner, dust particles, or unknown chemicals.
WARNING
Not for use in homes or recreational vehicles. Installing this machine in a home or
RV may result in fire, explosion, property damage, personal injury, or death.
f Operate the machine only for applications specified in Machine Description and
Intended Use.
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Foreword
Machines
covered by
this manual
Machine
documentation
Expectations
for
information in
this manual
This manual covers machines with the following item numbers:
Machine Item Number
HI 400HD D 0620868
HI 400HD G 0620701
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.
If you are missing any of these documents, please contact Wacker Neuson
Corporation 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, underst and, and observe all instructions
described in this manual.
Wacker Neuson Corporation 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 Corporation reserves the right
to change any portion of this information without notice.
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 ser-
vice 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.
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HI 400HD D / HD G Table of Contents
Foreword 3
1 Safety Information 7
1.1 Signal Words Used in this Manual ....................................................... 7
1.2 Machine Description and Intended Use ............................................... 8
1.3 Operating Safety .................................................................................. 9
1.4 Safety Guidelines for Gas-Fired Machines ......................................... 10
1.5 Safety Guidelines for Operating Combustion Burners ....................... 11
1.6 Service Safety .................................................................................... 12
2 Labels 14
2.1 Label Locations .................................................................................. 14
2.2 Label Meanings .................................................................................. 15
3 Lifting and Transporting 18
3.1 Lifting and Transporting ...................................................................... 18
4 Operation 19
4.1 Preparing the Machine for First Use ................................................... 19
4.2 Installing the Axle and Wheels ........................................................... 19
4.3 Installing the Front Duct Adapter ........................................................ 20
4.4 Installing the Rear Duct Adapter (optional) ........................................ 21
4.5 Control / Component Locations .......................................................... 22
4.6 Adjusting the Handle Height ............................................................... 23
4.7 Positioning the Machine ..................................................................... 24
4.8 Control Panel—Oil Burner (D Models) ............................................... 26
4.9 Recommended Fuels and Fuel Blending Guide (D models) .............. 27
4.10 Inspecting the Fuel Hose .................................................................... 27
4.11 Control Panel—Gas Burner (G Models) ............................................. 28
4.12 Gas Installation and Setup (G models) .............................................. 29
4.13 Connecting the Gas Line (G models) ................................................. 30
4.14 Setting the Gas Selector Valve (G models) ........................................ 31
4.15 Suggested Venting ............................................................................. 32
4.16 Installing the Heater Duct ................................................................... 34
4.17 Installing the Remote Thermostat or Receptacle Cap ........................ 35
4.18 Connecting Power to the Machine (Preheating) ................................. 36
4.19 Starting the Machine in Extremely Cold Weather ............................... 37
4.20 Before Starting ................................................................................... 38
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Table of Contents HI 400HD D / HD G
4.21 Starting the Machine (D models) .........................................................39
4.22 Starting the Machine (G models) .........................................................40
4.23 Stopping ..............................................................................................41
4.24 Burner Fault .........................................................................................41
4.25 Installing and Using the Remote Thermostat ......................................42
5 Accessories 43
5.1 Available Accessories .........................................................................43
6 Burner Setup 44
6.1 Removing the Access Panel ...............................................................44
6.2 Removing and Installing the Burner ....................................................45
6.3 Inspecting the Oil Burner Electrodes (D models) ................................48
6.4 Checking/Changing the Burner Nozzle (D models) .............................49
6.5 Adjusting the Burner Air Damper Setting ............................................50
6.6 Adjusting the Fuel Pressure (D models) ..............................................51
7 Maintenance 53
7.1 Periodic Maintenance Schedule ..........................................................53
7.2 Changing the Fuel Heater Filter (D models) ........................................54
7.3 Inspecting and Cleaning the Cadmium (CAD) Cell .............................55
7.4 Cleaning the Fan Blades and Motor ....................................................56
7.5 Cleaning the Interior Shell ...................................................................57
7.6 Inspecting the Flame Head .................................................................58
7.7 Inspecting the Electrical Connections .................................................59
7.8 General Cleaning Guidelines ..............................................................59
8 Technical Data 62
8.1 Machine ...............................................................................................62
9 Schematics 63
9.1 HI 400HD D—Oil Burning ....................................................................63
9.2 Components—Oil Burning ...................................................................64
9.3 HI 400HD G—Gas Burning .................................................................65
9.4 Components—Gas Burning ................................................................66
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HI 400HD D / HD G Safety Information
1 Safety Information
1.1 Signal Words Used 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 400HD D / HD G
1.2 Machine Description and Intended Use
Machine
description
Intended use
The HI Heater is an indirect-fired air heater . Depen ding on the model, the ma chine
operates either on diesel fuel (oil) or natural gas / liquid propane (LP). The machine
consists of the following components:
Stainless steel combustion chamber and heat exchanger
Blower
Two-stage burner (oil model)
High-temperature shut-down device
Fuel tank (oil model)
Gas selector valve (gas model)
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 rema in even after protective measures have been t aken.
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 25 ft.
lengths).
Exhaust vents and elbows
Contact your Wacker Neuson dealer for more information.
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HI 400HD D / HD G 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 Corporation 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:
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
Personal
Protective
Equipment
(PPE)
Work space
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 th e job site whe n operating t he machine.
Wear safety glasses.
When operating the machine:
Do not operate a machine in need of repair.
Do not smoke near the machine.
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
Follow the guidelines below when placing the machine in the workspace.
Position the machine on a firm, noncombustible, level surface.
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Safety Information HI 400HD D / HD G
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.
Keep unauthorized personnel, children, and animals away from the machine.
Do not connect ductwork between the exhaust outlet port and the supply air inlet
port.
Do not position the electrical cords under the machine or over the top of the
machine.
While
operating the
machine
Inspect the machine before startup, and monitor it regularly during operation.
Never exceed the maximum heat output of the machine.
Never operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
After use
Disconnnect power from the machine.
Store the machine properly when it is not being used.
1.4 Safety Guidelines for Gas-Fired Machines
WARNING
Gas leaks can cause explosions or fire. Follow the steps below if you smell gas.
f Open windows.
f Do not touch electrical switches.
f Extinguish open flames.
f Immediately call your gas supplier.
WARNING
Risk of explosion, fire, property damage, asphyxiation, death, or carbon monoxide
poisoning.
f Read and follow the instructions below regarding proper gas supply and prepa-
ration of the machine.
Proper gas supply must be provided to the inlet of the machine. Refer to the rating
plate for the correct gas supply pressure.
Gas pressure above the maximum specified on the rating plate can cause fire or
explosions, leading to serious injury, death, or property loss.
Gas pressure below the minimum specified on the rating plate may cause
improper combustion, leading to asphyxiation or carbon monoxide poisoning.
Before operating the machine, read and follow all instructions in the Operation
chapter. Important points to note are:
Position the machine correctly before each use.
Provide proper venting for both indoor and outdoor use.
Do not operate the machine with exterior panels removed.
Disconnect all electrical power from the machine before opening doors or
removing panels.
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HI 400HD D / HD G Safety Information
1.5 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 natural
gas or Liquid Petroleum (LP).
When using the machine:
DANGER
Exhaust gas from the burner (and generator, if equipped) 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.
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Safety Information HI 400HD D / HD G
1.6 Service Safety
Personal
Protective
Equipment
(PPE)
Licensing/
training/
Cleaning
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
Hearing protection
Safety-toed footwear
In addition, before servicing or maintaining the machine:
Tie back long hair.
Remove all jewelry (including rings).
Only qualified personnel who possess the proper certification or license
required by the locality , stat e, or province in which the machine is being installed
are allowed to make connections to natural gas or LP.
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.
Maintenance
guidelines
Replacing
parts and
labels
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 part s.
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.
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.
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HI 400HD D / HD G Safety Information
Accessories,
safety devices
and
modifications
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.
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Labels HI 400HD D / HD G
2 Labels
2.1 Label Locations
J
P
R
K
B
A
O
D
G
Q
C
M
E
K
H
(4)
ghi_gr007391
F
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HI 400HD D / HD G Labels
2.2 Label Meanings
A WARNING!
Hot surface!
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.
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Labels HI 400HD D / HD G
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, re vision 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, ite m number , revision number, and serial
number of the unit.
May not be on your machine.
L Gas selector valve
Propane Gas Position
Natural Gas Position
Lock valve in position after selection.
M Heater rating plate
16 ghi_si000469gb.fm
HI 400HD D / HD G Labels
N WARNING
Licensed gas technician required.
Natural gas / liquid propane burne r 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.
O General usage warnings
P Hose assembly specification
Q Electrical grounding instructions
R Gas type label
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Lifting and Transporting HI 400HD D / HD G
3 Lifting and Transporting
3.1 Lifting and Transporting
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.
When using an aerial lifting rig, use the designated lifting point on top of the
machine.
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.
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HI 400HD D / HD G Operation
4 Operation
4.1 Preparing the Machine for First Use
Preparing for
first use
To prepare your machine for first use:
1. Make sure all loose packaging materials have been removed from the machine.
2. Check the machine and its components for damage. If there is visible damage,
do not operate the machine! Contact your Wacker Neuson dealer immediately
for assistance.
3. Take inventory of all items included with the machine and verify that all loose
components and fasteners are accounted for.
4. Attach component parts not already attached.
5. Add fluids as needed and applicable, including fuel, engine oil, and battery acid.
6. Move the machine to its operating location.
4.2 Installing the Axle and Wheels
Overview
Procedure
The axle and wheels are shipped loose with the machine and must be installed by
the customer.
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. Slide the axle (a) into the tube (b) beneath the trailer.
c
d
e
3. Place a wheel (c) and flat washer (d) on each end of the axle as shown.
4. Insert hitch pins (e) into the holes at each end of the axle to secure the wheels.
a b
wc_gr007904
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Operation HI 400HD D / HD G
4.3 Installing the Front Duct Adapter
Overview
Procedure
The front duct adapter provided with your machine is shipped loose and must be
installed before operating the machine. The thermostat probe must also be
installed on the inside of the duct adapter during this procedure.
Follow the procedure below to install the front duct adapter and thermostat probe.
1. The thermostat probe (a) is temporarily mounted on a disposable bracket (b)
inside the machine shell. Remove and set aside the mounting screw (c) to
disconnect the bracket from the machine shell.
c
e
b
d
a
a
wc_gr007766
2. Remove the screw fastening the thermostat probe to the disposable bracket,
and discard the bracket. Temporarily rest the thermostat probe inside the
machine shell.
Note: Do not discard the screw. It will be used to mount the thermostat probe.
3. Slide the edge of the duct adapter (d) beneath the edges of the upper and lower
machine shell.
4. Align the four threaded mounting holes (e) on the duct adapter with the
corresponding holes on the machine shell.
5. Use the screws (provided) to fasten the duct adapter to the machine shell.
6. Align the thermostat probe inside the duct adapter as shown. Fasten the
thermostat probe in place using the reserved bracket screw.
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HI 400HD D / HD G Operation
4.4 Installing the Rear Duct Adapter (optional)
Overview
Procedure
The optional rear duct adapter is shipped loose and must be installed before
operating the machine.
Follow the procedure below to install the rear duct adapter.
1. Loosen, but do not remove, the two adjusting knobs (a) on the handle.
2. Grasp the handgrips (b) and slide the handle down to the lowest detent position
in the handle slots.
3. Pull the handle away from the fan guard (f).
4. Remove the fan guard. There are four screws that secure the fan guard.
5. Align the four threaded mounting holes (e) on the duct adapter with the
corresponding holes on the machine shell.
6. Use the fan guard screws to fasten the duct adapter to the machine shell.
7. Slide the handle back to its original position and tighten the adjusting knobs.
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Operation HI 400HD D / HD G
4.5 Control / Component Locations
a
Machine
components
Ref Description Ref Description
a Exhaust flue f Air inlet and fan guard
b Control panel g Access panel
c Manual transport handle h Fuel filter (D units)
d Fuel fill location (D units only) i Gas train (G units only)
e Lift brackets j Fork pockets
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HI 400HD D / HD G Operation
4.6 Adjusting the Handle Height
Overview
Procedure
Your machine is equipped with a manual transport handle. The handle height can
be adjusted to suit the operator’s preference.
Follow the procedure below to adjust the handle height.
1. Loosen, but do not remove, the two adjusting knobs (a) on the handle.
b
a
wc_gr007767
2. Grasp the handgrips (b) and slide the handle up or down to one of the three
detent positions in the handle slots.
3. When the handle is in the desired position, tighten the two adjusting knobs.
a
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Operation HI 400HD D / HD G
4.7 Positioning 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.
Guidelines
Proximity
restrictions
Observe the following guidelines when positioning the machine for operation.
Installer must be familiar with all applicable laws, codes, regulations, or other
restrictions regarding installation of Indirect-fired (IDF) heaters.
Machine must be on flat, firm surface.
Installation must adhere to proximity restrictions.
Install wedge blocks under the wheels to prevent movement.
The machine must be located a safe distance from any other structures, vehicles,
materials or other combustible surfaces. The following proximity restrictions apply
for all machine installations.
20 ft. (6 m) to air outlet
3 ft. (1 m) to air inlet and sides
5 ft. (1.5 m) to top
20 ft (6 m) from outlet to external fuel container
Note: Graphic is representative only. Your machine may vary.
Electrical and Grounding Req ui rem en t s
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HI 400HD D / HD G Operation
WARNING
Fire hazard and electric shock hazards. The use of an inappropriate power supply, or undersized extension cords, can lead to fire and electric shock. Fire and
electric shock can cause severe injury.
f Before use, ensure that the machine is properly connected to an a ppropriate
power source and grounded per the requirements provided below.
f Do not use undersized extension cords.
Electrical
requirements
Grounding
requirements
Ensure that the machine is connected to a reliable, consistent source of electric
power.
The electric power source must be grounded per the requirements below and
connected to a freely accessible circuit breaker.
Ensure that extension cords (if used) are properly sized for the installation. Do
not use worn, bare, or frayed cords!
Restrictions for extension c ords:
Use only 3-wire type extension cords with heavy-duty plugs.
The maximum length of extension cord usage per circuit is 30 m (100 ft).
Use 12-gauge extension cords for lengths up to 15 m (50 ft).
Use 10-gauge extension cords for lengths up to 30 m (100 ft).
Electrical grounding must comply with the National Electric Code ANSI/NFP A 70
or the CSA C22.1 Canadian Electrical Code, Part 1.
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Operation HI 400HD D / HD G
4.8 Control Panel—Oil Burner (D Models)
Control panel
components
Symbols and
meanings
RESET
Ref Description Ref Description
a Burner fault lamp and reset
button (dual function)
b Mode switch (on-off-on)
See topic Starting the Machine
c Remote thermostat receptacle f Power cord
Symbol Meaning/function Symbol Meaning/function
Push the button to reset the
machine when a burner fault
RESET
occurs.
0
d Firing mode switch
(High-fire or low-fire)
e Power indicator
On
(Continuous heat mode)
See topic Starting the
Machine
On
(Remote thermostat mode)
See topic Starting the
Machine
Low-fire mode
See topic Recommended
Fuels
Power indicator — —
Remote thermostat
connection point
High-fire mode
See topic Recommended
Fuels
26 ghi_tx001462gb.fm
HI 400HD D / HD G Operation
4.9 Recommended Fuels and Fuel Blending Guide (D models)
Overview
Low ambient temperatures cause diesel fuels to gel. Gelled fuels will cause burner
ignition failure and/or burner fuel pump damage. Always use the proper fuel for the
conditions.
Fuel Blend Guide
Lowest expected ambient
temperature °F (°C)
Below 5 (-15)
5 to 25 (-15 to -4)
Above 25 (-4) Winter-blend diesel
Generator powered Shore powered
50-50 blend of #2 diesel
and #1 diesel, plus
additives
OR
50-50 blend #2 diesel and
K1 kerosene, plus
additives
70-30 blend of #2 diesel and #1 diesel, plus additives
70-30 blend of #2 diesel and K1 kerosene,
plus additives
100% #1 diesel plus
additives
OR
100% K1 kerosene,
plus additives
OR
Note: The burner on this machine was calib rated by test-firing for correct operation
at Wacker Neuson Corporation located 180 m (600 ft.) above sea level using #2
diesel fuel combined with an anti-gelling additive.
4.10 Inspecting the Fuel Hose
When
Replacement
hose
Visually inspect the fuel hose assembly each time before operating the heater.
WARNING
Fire and explosion hazards. A damaged hose may leak flammable fuel.
f Do not operate the heater if the hose has excessive abrasions, wear, or cuts.
Replace a damaged hose assembly with an equivalent as specified on the
machine label.
ghi_tx001462gb.fm 27
Operation HI 400HD D / HD G
4.11 Control Panel—Gas Burner (G Models)
Control panel
components
Symbols and
meanings
RESET
Ref Description Ref Description
a Burner fault lamp and reset
button (dual function)
b Mode switch (on-off-on)
See topic Starting the Machine
c Remote thermostat receptacle f Power cord
Symbol Meaning/function Symbol Meaning/function
Push the button to reset the
machine when a burner fault
RESET
occurs.
0
wc_gr007770
d Burner indicator
e Power indicator
On
(Continuous heat mode)
See topic Starting the
Machine
On
(Remote thermostat mode)
See topic Starting the
Machine
Power indicator — —
Remote thermostat
connection point
28 ghi_tx001462gb.fm
HI 400HD D / HD G Operation
4.12 Gas Installation and Setup (G models)
WARNING
Extreme explosion and fire hazards.
f Only a licensed, professional gas technician shall perform installation, fuel sup-
ply connection, setup, adjustment, and testing of gas lines.
f Never use open flames to detect gas leaks.
Natural gas
installation
requirements
Propane
installation
requirements
Natural gas installation must conform with local codes. In the absence of local
codes, the installation must conform with the National Fuel Gas Code ANSI
Z223.1/NFPA 54 and the Natural Gas and Propane Installation Code, CSA B149.1.
Follow the instructions below if equpping the machine for liquid propane (LP) gas.
The installation must conform with local codes. In the absence of local codes,
the installation must conform with the Standard for the Storage and Handling of
Liquefied Petroleum Gases, ANSI/NFPA 58 and the Natural Gas and Propane
Installation Code, CSA B149.1.
Heated air from the machine shall not be directed toward any propane gas
container within 6 m (20 feet)
Size and capacity of gas cylinders shall be properly dimensioned according to
the gas flow in Technical Data.
The cylinder supply system shall be arranged to provide for vapor withdrawal
from the operating cylinder.
After connecting the machine to the gas cylinder, open the supply tap and check
the supply pipe and fittings for gas leaks. Only use foam soap or an approved
leak detector.
The gas shall be turned off at the prop ane supply cylinder( s) when the mach ine
is not in use.
When the machine is to be stored indoors, the connection between the propane
supply cylinder(s) and the machine must be disconnected. Cylinder(s) must be
removed from the heater and stored in accordance with Standard for the
Storage and Handling of Liquefied Petroleum Gases, ANSI/NFPA 58 and CSA
B149.1, Natural Gas and Propane Installation Code.
ghi_tx001462gb.fm 29
Operation HI 400HD D / HD G
4.13 Connecting the Gas Line (G models)
Overview
The HI 400HD-G heater includes a 3/4” NPT inlet (a) on the gas safety valve /
pressure regulator body. The gas supply line connects to the inlet.
a
wc_gr007559
WARNING
Extreme fire and explosion hazard!
f Only a licensed, professional gas technician shall perform installation, fuel
supply connection, setup, adjustment, and testing of gas lines.
f All connections and settings must conform to relevant local, state, provincial,
and federal requirements.
Gas
pressures
Regulating LP
gas pressure
The table below lists the minimum and maximum gas supply pressures.
Fuel
Natural gas 7” w.c. 10” w.c.
Liquid propane (LP) 8” w.c. 13” w.c.
Minimum supply
pressure
Maximum supply
pressure
The installation of a secondary pressure regulator is strongly recommended when
using LP gas. A secondary pressure regulator ensures a steady flow of LP to the
burner. A regulator is especially valuable when the gas supply pressure is
inconsistent.
Note: Gas piping, pressure regulators, and fitti ngs are not included with this heate r
and must be provided by the customer.
30 ghi_tx001462gb.fm
HI 400HD D / HD G Operation
4.14 Setting the Gas Selector Valve (G models)
Overview
Procedure
Your machine is configured at the factory to operate on natural gas. The gas
selector valve on the gas train allows you to convert the machine from natural gas
to LP as job site conditions require.
To change the type of gas, follow the procedure below.
1. Remove the gas type label (a) from the handle on the gas selector valve (b).
b
a
c
ghi_gr007393
2. Loosen the screw (c) beneath the label.
3. Turn the handle to the desired position.
4. Tighten the screw.
5. Apply a new gas type label to the handle. (Extra labels are provided with the
machine.)
ghi_tx001462gb.fm 31
Operation HI 400HD D / HD G
4.15 Suggested Venting
DANGER
Asphyxiation hazard.
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.
When installing vents:
Do not use B-vent exhaust pipes to vent an oil burning machine. Contact
Wacker Neuson Product Support for recommended alternatives.
Adhere to all local and national codes.
Adhere to all fire prevention regulations.
Consult all appropriate governing bodies or local contractor for venting and
fresh air requirements. Make sure that the room or building to be heated has
sufficient ventilation to ensure that the machine has enough air to function
properly.
Position the machine in a manner that avoids excessive vent bends (elbows),
and long horizontal runs.
Keep air inlets and outlets free from obstruction. Ensure that there are no bulky
objects or sheets/covers near or on the machine.
Route the venting pipes in a manner that avoids flammable materials.
Route the venting pipes in a manner that avoids contact with people.
When the machine is connected to a flue pipe, the flue pipe shall terminate in a
vertical section at least two feet long. Sufficient draft shall be created to assure
safe and proper operation of the machine.
32 ghi_tx001462gb.fm
HI 400HD D / HD G Operation
Note: The above venting diagram shows suggested venting layouts only. Consult
all appropriate governing bodies or local contractor for venting and fresh air
requirements.
ghi_tx001462gb.fm 33
Operation HI 400HD D / HD G
4.16 Installing the Heater Duct
Overview
Requirements
Procedure
Optional ducts can be connected to the air outlet. This allows warm air to be evenly
distributed throughout the heating area.
NOTICE: When using ducts, observe the static air pressure limits specified in
Technical Data.
Machine shut down and cooled
Machine properly positioned
CAUTION
Hot surface hazard. The machine surfaces may be hot.
f Allow the machine to cool for a minimum of ten minutes before touching it.
To install the ducts, carry out the following procedure.
1. Open the clamps (a).
2. Slide the duct (b) onto the duct adapter (c).
3. Close the clamp to secure the duct in place.
34 ghi_tx001462gb.fm
HI 400HD D / HD G Operation
4.17 Installing the Remote Thermostat or Receptacle Cap
Requirements
Background
Remote thermostat, or
Thermostat receptacle cap
The control panel includes a receptacle for an optional remote thermostat (b). The
receptacle is protected by an attached cap (a) when not in use.
NOTICE: To avoid damaging or contaminating the receptacle, make sure the
cover is securely locked in place when a remote thermostat is not installed.
To install the remote thermostat, remove the cap, insert the plug into the receptacle
and lock the plug in place.
Operational
notes
When the mode switch is set to the upper (continuous heat) position, the heater
will operate without a remote thermostat.
When the mode switch is set to the lower (remote thermostat) position, the
heater will not operate unless a remote thermostat is p lugged into the receptacle
and the signal is read by the control board.
ghi_tx001462gb.fm 35
Operation HI 400HD D / HD G
4.18 Connecting Power to the Machine (Preheating)
Requirements
Extension
cords
Power source (115VAC)
Machine properly positioned
Operation mode switch in the OFF (0) position
]
WARNING
Fire hazard and electric shock hazard. The use of under-sized extension cords can
lead to fire and electric shock. Fire and electric shock can cause severe injury.
f Do not use under-sized extension cords.
Restrictions for extension cords:
Use only 3-wire type extension cords with heavy-duty plugs.
The maximum length of extension cord usage per circuit is 30 m (100 ft).
Use 12-gauge extension cords for lengths up to 15 m (50 ft).
Use 10-gauge extension cords for lengths up to 30 m (100 ft).
CAUTION
Burn hazard. The self-regulating fuel heater, located inside the fuel filter canister,
will initiate when power is connected to the machine. The surface of the fuel filter
canister may become very hot.
f Use caution when working with the fuel filter canister.
Procedure
Result
Perform the procedure below to connect power to the machine.
1. Verify that the operation mode switch is in the OFF (0) position.
2. Connect the main power cord cord to a properly-rated power source.
Note: If the ambient temperature is below freezing, wait 10–30 minutes be fore proceeding.
Power has now been connected. The machine is ready for pre-starting checks.
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HI 400HD D / HD G Operation
4.19 Starting the Machine in Extremely Cold Weather
Background
Preheating
the fuel
Troubleshooting
In temperatures below 32°F (0°C), it may be necessary to preheat the fuel inside
the fuel filter canister. The fuel filter canister is equipped with a low-wattage heating
element specially designed for this purpose.
Your machine is also equipped with a thermostatically controlled nozzle heater as
described below.
.
WARNING
Burn hazard. The external surface of the fuel filter may be hot.
f Wear safety gloves when handling the fuel filter.
Note: Excess heating may increase the need for maintenance. See topics
“Replacing the Fuel Filter” and “Replacing the Burner Nozzle”.
To preheat the fuel, carry out the following procedure.
1. Connect power to the machine. See topic Connecting Power to the Machine.
2. Wait 20-30 minutes—longer for colder temperatures.
3. Start the machine. See topic Starting the Machine.
Note: In extreme wind, the machine may need to be temporarily blocked from the
wind in order to start.
4. If the burner does not start on the first attempt, allow the power-on sequence to
cycle again.
Nozzle heater
5. If, after the second power-on sequence completes, the machine will not fire,
move the power switch to the OFF position.
6. Wait another 20-30 minutes and attempt to start the machine again.
The burner may not fire immediately on startup if the nozzle is cold. An additional
heater warms the nozzle to the required operating temperature.
Note: After you select the ON (heat) mode, the nozzle preheating sequence may
cause a delay of up to 6 minutes before the burner fires.
ghi_tx001462gb.fm 37
Operation HI 400HD D / HD G
4.20 Before Starting
Requirements
Checks
Machine properly positioned
Power connected to the machine
Before starting the machine, check the following items:
Item Task
Fuel sight gauge (if equipped) Check that the fuel tank is full (if applicable).
Fuel tank cap Check that the fuel tank cap (if applicable) is
secure.
Gas supply (if equipped) Check that the gas supply lines (if applicable)
have been properly installed.
Check that all valves are in the proper operating
position.
Operation mode switch Check that the operation mode switch is in the
OFF position.
Main control panel Check that proper power supplies have been
connected at the main control panel. See topic
Connecting Power to the Machine.
Remote thermostat (if installed) Check that the remote thermostat has been
correctly installed. See topic Installing the Remote
Thermostat or Thermostat Receptacle Plug.
Ducts and duct adapters Check that all ducts and duct adapters have been
properly installed. See topic Installing the Heater
Duct.
Result
The machine is ready to turn on.
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HI 400HD D / HD G Operation
4.21 Starting the Machine (D models)
Requirements
Procedure
Machine properly positioned
Power connected
Pre-starting checks completed
To start the machine, follow the procedure below.
1. Select an operation mode.
a.Continuous heat mode (I)
b.thermostat mode (II)
c
RESET
2. Select a firing mode (c).
a.If the need for heat is low, choose the LOW fire mode. Low fire mode allows
the heater to run at a lower fuel pressure with a lower burner firing rate. Less
heat is generated and the machine runs more economically as a result.
b.If the need for heat is high, choose the HIGH fire mode. High fire mode allows
the machine to operate at full capacity, generating maximum heat.
0
wc_gr007276
Operational
sequence
Nozzle heater
The following sequence of events will occur.
1. The burner blower will start.
Note: The burner may not fire immediately on startup if the nozzle is cold. An additional heater warms the nozzle to the required operating temperature. After you
select the ON (heat) mode, the nozzle preheating sequence may cause a delay of
up to 6 minutes before the burner fires.
2. The burner will start firing.
In applications in which the thermostat receptacle plug is being used, the
burner will fire continuously.
In applications in which the remote thermostat is being used, the burner will
fire until the air temperature of the application area reaches the target temperature set by the remote thermostat. At that time, the burner will shut off,
but the blower will continue to operate. When the air temperat ure of the application area falls below the target temperature set by the remote thermostat,
the burner will refire. The process continues as long as there is fuel for the
burner.
3. The main blower will start.
ghi_tx001462gb.fm 39
Operation HI 400HD D / HD G
4.22 Starting the Machine (G models)
Requirements
Procedure
Machine properly positioned
Power connected
Pre-starting checks completed
To start the machine, follow the procedure below.
1. Select an operation mode (b).
a.Continuous heat mode (I)
b.thermostat mode (II)
RESET
0
wc_gr007770
Operational
sequence
The following sequence of events will occur.
1. The blue light on the gas regulator will illuminate, indicating that gas is flowing.
2. The burner blower will start.
3. The burner will start firing.
In applications in which the thermostat receptacle plug is being used, the
burner will fire continuously.
In applications in which the remote thermostat is being used, the burner will
fire until the air temperature of the application area reaches the target temperature set by the remote thermostat. At that time, the burner will shut off,
but the blower will continue to operate. When the air temperature of the application area falls below the target temperature set by the remote thermostat,
the burner will refire. The process continues as long as there is fuel for the
burner.
4. The main blower will begin blowing warm air when the combustion chamber is
hot.
40 ghi_tx001462gb.fm
HI 400HD D / HD G Operation
4.23 Stopping
Procedure
Follow the procedure below to stop the machine.
WARNING
Electric shock hazard. Electric power is still active at the blower even when the
machine is turned OFF.
f Remove all electric power to the machine before servicing the machine.
1. Turn the operation mode switch to the OFF (0) position (c).
c
Shutdown
sequence
The following sequence of events will occur after turning the machine off.
1. The burner will shut down.
2. The blower will stop when the machine is sufficiently cool.
4.24 Burner Fault
Burner fault
The burner fault lamp / reset button (a) is illuminated while the machine is
operating. The lamp is green during normal operation.
A burner fault occurs if the burner does not fire upon startup. The lamp will turn red.
The lamp will also turn red if the burner goes out while the machine is operating.
To clear a burner fault, press and hold the burner fault lamp / reset button for
2–3 seconds until the lamp goes out.
Re-start the machine.
If the burner fault re-occurs, see Basic Troubleshooting.
a
RESET
0
wc_gr007620
ghi_tx001462gb.fm 41
Operation HI 400HD D / HD G
c
4.25 Installing and Using the Remote Thermostat
Requirements
Procedure
Remote thermostat
Pre-starting checks complete
Follow the procedure below to install and use the remote thermostat.
1. Remove the thermostat receptacle plug (a) from the control panel receptacle.
2. Connect the remote thermostat (b) to the control panel receptacle (c).
3. Set the sensor end (d) within the area to be heated.
4. Adjust the target temperature with the dial (e).
b
a
d
Result
e
wcghi_gr007373
The machine will now be controlled by the remote thermostat.
42 ghi_tx001462gb.fm
HI 400HD D / HD G Accessories
5 Accessories
5.1 Available Accessories
Introduction
Wacker Neuson Corporation offers many optional accessories for this machine.
These accessories are described below . Cont act your local Wacker Neuson dealer
or visit www.wackerneuson.com for ordering information.
Note: Depending on the specific machine model, your heater is equipped with one
of three available outlet adapters. All three outlet adapters are comp atible with your
machine and can be purchased and installed as needed.
Item Description/Purpose
Remote thermostat Allows the user to remotely control the target
temperature
Exhaust pipe An insulated exhaust pipe that offers a method of
directing exhaust away from the application area
Inlet and outlet covers Vinyl covers that protect the interior of the machine
from the elements during transport or storage
Duct adapters—various sizes Various sizes of detachable inlet and outlet adapters
Flexible ducts—various sizes Vinyl ducts that offer a method of directing inlet and
outlet air
Exhaust support bracket Bracket to support exhaust vents
Exhaust vent rain cap Metal cap to protect exhaust pipes from the elements
ghi_tx001463gb.fm 43
Burner Setup HI 400HD D / HD G
6 Burner Setup
6.1 Removing the Access Panel
Requirements
Overview
Procedure
Machine shut down and cooled
Machine properly positioned
Over
CAUTION
Hot surface hazard. The machine surfaces may be hot.
f Allow the machine to cool for a minimum of ten minutes before touching it.
Your machine is equipped with a removable access panel. The access panel must
be removed in order to maintain and repair certain machine components such as
the burner, electric motor, and fuel pump.
Follow the procedure below to remove the access panel.
1. Shut down the machine and allow it to cool.
2. Disconnect the power cord from the power source.
3. Remove the four screws that fasten the access panel (g).
g
wc_gr007394
4. Remove the access panel and set it aside.
5. Perform the required maintenance.
6. When maintenance is complete, reinstall the access panel and fasten it with the
screws.
44 ghi_tx001464gb.fm
HI 400HD D / HD G Burner Setup
6.2 Removing and Installing the Burner
Requirements
Procedure
Removal
Note: Although an oil burning machine (D model) is shown in t he photos below, the
procedure for removing the burner assembly on a gas burning machine (G model)
is similar.
Machine shut down and cooled
Machine properly positioned
CAUTION
Hot surface hazard. The machine surfaces may be hot.
f Allow the machine to cool for a minimum of ten minutes before touching it.
Before performing any maintenance on the burner assembly, it must be removed
from the machine. To remove or install the burner assembly perform the following
procedure.
1. Shut down the machine and allow it to cool.
2. Disconnect the power cord from the power source.
3. Remove the access panel. See topic Removing the Access Panel.
e
d
Installation
b
c
4. Remove the screw (d) to disconnect the ground wire (c) from the burner
assembly (b).
5. Rotate the burner assembly counter-clockwise and remove it from the flame
head and air tube assembly (e).
6. Perform the required maintenance.
Note: Refer to the maintenance procedures in this manual.
7. Reinstall the burner assembly. Refer to the steps below to install the burner
assembly.
1. Place the burner assembly into the flame head and air tube assembly.
2. Rotate the burner assembly clockwise to lock it into place.
3. Install the ground wire using the screw (d).
b
wc_gr007773
4. Reinstall the access panel.
Setting Up the Burner
ghi_tx001464gb.fm 45
Burner Setup HI 400HD D / HD G
Factory
settings
Machine Nozzle size Fuel pressure
psi bar NG LP
HI 400 HD D 2.00 (80W) gph Stage I: 160
Sta ge II: 217
HI 400 HD G 3 x 2.8 mm
(12 X 0.11 in.)
— — 6.40
Sta ge I: 11
Sta ge II: 15
Burner pressure
in WC
—1.5
(1600 Pa)
6.52
(1630 Pa)
Air
damper
setting
3
Background
Tools required
Mandates
When
The burner consists of several different components and subsystems. Each of these
components or subsystems must be operating correctly for the burner to function properly.
The following tools are required to adjust the burner:
High-quality combustion analyzer
Smoke spot tester
Fuel pressure test gauge
General hand tools
Adjustments made shall be done so that the machine conforms to the require-
ments of local, state, and federal codes and authorities.
Adjustments shall be made at the job site.
Adjust the burner:
Before operating the machine at elevations 305 m (1,000 ft) a bove or below the
location of where the last adjustments were made
Before starting at a new job site
After any burner maintenance or repair has been performed
If burner performance is in question
Procedure
Follow the procedure below to set up the burner.
1. Shut down the machine.
2. Set the burner electrodes.
(See topic Checking and Adjusting the Oil Burner Electrodes.)
3. Check the burner nozzle.
(See topic Checking/Changing the Burner Nozzle.)
4. Check and adjust the burner air damper if necessary.
(See topic Adjusting the Burner Air Damper Setting.)
5. Start the machine and the burner.
6. On D models only, check/set the fuel pressure.
(See topic Adjusting the Fuel Pressure.)
7. Conduct a smoke spot test. Follow the smoke spot tester manufacturer’s
instructions and the general guidelines below.
This procedure continues on the next page.
46 ghi_tx001464gb.fm
HI 400HD D / HD G Burner Setup
HI Heater
ghi_gr007395
Use the access hole in the exhaust stack.
Several samples should be taken as the heater warms.
The final sample should be taken just before the heater reaches 71°C (160°F).
8. Analyze the combustion. Follow the combustion analyzer manufacturer’s
instructions and the general guidelines below.
Result
Use the access hole in the exhaust stack.
Take several samples as the heater warms.
Take the final sample just before the heater reaches 71°C (160°F).
9. Re-adjust the air band, if necessary, until the smoke spot test and combustion
analysis are within the following parameters:
O
content: 3–5%
2
Smoke spot: less than 1
The burner has now been set.
ghi_tx001464gb.fm 47
Burner Setup HI 400HD D / HD G
6.3 Inspecting the Oil Burner Electrodes (D models)
Requirements
When to
inspect
Procedure
Machine shut down
Power disconnected
Burner cool
Inspect the electrodes on your machine every two weeks or after every 50 hours of
operation. The condition of the electrodes will drastically affect your machine’s
ability to fire efficiently.
Remove the burner assembly and inspect the condition of the electrode tips (a).
Refer to the table below to determine the condition of the electrode tips.
a
b
a
c
wc_gr007619
Condition Task
None; ok as-is
None; ok as-is
Replace
The electrodes should be replaced if they are worn or damaged. Contact your
Wacker Neuson dealer for replacement electrodes.
48 ghi_tx001464gb.fm
HI 400HD D / HD G Burner Setup
ghi_g
6.4 Checking/Changing the Burner Nozzle (D models)
Prerequisites
When
Removing the
nozzle
Installing the
nozzle
Machine shut down and cool to the touch
Machine properly positioned
CAUTION
Hot surface hazard. The machine surfaces may be hot.
f Allow the machine to cool for a minimum of ten minutes before touching it.
Replace the burner nozzle annually, or if it is damaged.
To replace the burner nozzle, carry out the following procedure.
1. Remove the burner. See topic Removing and Installing the Burner Assembly.
2. Place an adjustable wrench on the large fitting (a) on the nozzle base (c).
3. Place another adjustable wrench on the nozzle (b).
4. Rotate the nozzle counter-clockwise and remove it from the assembly.
5. Install the new nozzle (b) onto the nozzle base (c).
6. Tighten the nozzle (b) using an adjustable wrench. Rotate the wrench
clockwise.
7. Reinstall the burner assembly. See topic Removing and Installing the Burner
Assembly.
b
a
c
ghi_tx001464gb.fm 49
r007408
Burner Setup HI 400HD D / HD G
6.5 Adjusting the Burner Air Damper Setting
Requirements
Procedure
Machine shut down
Power disconnected
Perform the procedure below to check and adjust the burner air damper setting.
1. Shut down the machine and allow it to cool.
2. Disconnect the power cord from the power source.
3. The burner air damper (a) is located beneath the fan guard.
a
hi_gr007396
4. To adjust the burner air damper, move the lever (b) left or right to align with the
desired graduation (marking). See Technical Data.
Result
The burner air damper has now been adjusted.
50 ghi_tx001464gb.fm
HI 400HD D / HD G Burner Setup
6.6 Adjusting the Fuel Pressure (D models)
Requirements
Background
When to
check
Procedure
Machine shut down and cool to the touch
Power disconnected
Fuel pressure gauge
Flat-bladed screwdriver
The information below will show you how to check the fuel pressure on your
machine. Incorrect fuel pressure will result in too much fuel, or too little fuel, to be
supplied to the burner. This will cause the machine to smoke during operation.
Note: The fuel pressure differs when the burner is operating in Stage 1 (low fire
mode) and Stage 2 (high fire mode). Therefore, both pressures must be checked.
Check the fuel pressure if the machine emits smoke during operation.
To check and/or adjust the fuel pressure, carry out the following procedure.
1. Remove the access panel and locate the pump
(a)
. See topic Removing the
Access Panel.
2. Remove the threaded plug from the pressure test port (b) using a hex key
wrench. Set the plug in a safe location to be re-installed later.
d
b
Checking low
pressure
a
e
c
wc_gr007902
3. Install a pressure gauge with adapter (c) in the pressure test port.
4. Set the mode switch to low fire mode (I).
5. Start the machine. See topic Starting the Machine.
6. With the machine running, verify the low fuel pressure setting. For the correct
setting, refer to the Technical Data charts in this manual.
ghi_tx001464gb.fm 51
Burner Setup HI 400HD D / HD G
Checking high
pressure
Adjusting fuel
pressure
7. Set the mode switch to high fire mode (II). Wait approximately 30 seconds to
allow the burner to switch from Stage I to Stage II.
8. Verify the high pressure fuel pressure setting. For t he correct setting, refer to the
Technical Data charts in this manual.
9. Stop the machine. See section Stopping the Machine.
10.Adjust the fuel pressure if necessary. The pump has two adjustment screws;
one for low fuel pressure (d) and one for high fuel pressure (e). Adjust the fuel
pressure and repeat steps 5–8 to re-check the settings.
Note: Do not adjust the fuel pressure to a setting outside the safe operational
parameters.
11.Remove the pressure gauge from the pressure test port.
12.Re-install the threaded plug into the pressure test port.
13.Replace the access panel and re-install the screws that secure the panel.
52 ghi_tx001464gb.fm
HI 400HD D / HD G Maintenance
7 Maintenance
7.1 Periodic Maintenance Schedule
Interval*
(hours of service)
Daily 2 Weeks 6 Months Yearly
Task
Inspect the heater.
Inspect the hose assembly.
Check fuel level and
pressure.
Clean the machine.
Clean the fuel filter.
Clean the fan and the
interior shell.
Clean and check/adjust
burner electrode settings.
Inspect electrical
components.
Inspect the blower motor
and belts. Replace the belt
if necessary.
Replace the burner nozzle.
--- (50) (1000) (1200)
Replace the fuel heater
filter.
Maintain the heater
weldment.
Inspect and test the burner. As needed or upon changing job sites;
Inspect burner electrodes;
replace if necessary.
*
Use whichever comes first, calendar time or service hours.
ghi_tx001465gb.fm 53
see chapter Burner Setup.
As needed or upon changing job sites;
see chapter Burner Setup.
Maintenance HI 400HD D / HD G
7.2 Changing the Fuel Heater Filter (D models)
Prerequisites
Procedure
Machine shut down
Burner cool
CAUTION Hot surface hazard.
The external surface of the fuel filter canister may be hot.
f Allow the machine to cool before servicing.
WARNING Hot fluids.
The fuel inside the fuel filter canister may be hot.
f Wear safety glasses.
Follow the procedure below to change the fuel heater filter.
1. Shut down the machine and allow it to cool.
2. Remove the screw that secures the cover to the housing (a).
Result
wcgr007774
3. Remove the filter (b).
4. Inspect the O-ring (c). Replace it if it is cracked, damaged, or deformed.
5. Install the new filter.
6. Reinstall the cover.
The procedure to replace the fuel heater filter is now complete.
54 ghi_tx001465gb.fm
HI 400HD D / HD G Maintenance
0
7.3 Inspecting and Cleaning the Cadmium (CAD) Cell
Prerequisites
When
Machine shut down and cool to the touch
Machine properly positioned
CAUTION
Hot surface hazard. The machine surfaces may be hot.
f Allow the machine to cool for a minimum of ten minutes before touching it.
Inspect and clean the CAD cell as needed, or while performing other scheduled
maintenance procedures.
To inspect and clean the CAD cell, carry out the following procedure.
1. Remove the access panel. See topic Removing the Access Panel.
2. Twist and pull out the plastic protective holder
(1) off the base of the burner
assembly. The CAD cell (2) is inside this plastic holder.
1
2
1
ghi_gr00737
3. Inspect the CAD cell for cleanliness. Be sure the cell is free of debris or soot.
4. Clean the CAD cell if necessary.
NOTICE: Do NOT use solvents or liquids to clean the CAD cell. Use a soft dry
cloth to clean the CAD cell.
5. Reinstall the plastic protective holder onto the base of the burner assembly.
ghi_tx001465gb.fm 55
Maintenance HI 400HD D / HD G
7.4 Cleaning the Fan Blades and Motor
Prerequisites
When
Machine shut down and cool to the touch
Power source disconnected
WARNING
Electric shock hazard. Electric power is still active at the blower even when the
machine is turned OFF.
f Remove all electric power to the machine before performing this procedure.
CAUTION
Hot surface hazard. The machine surfaces may be hot.
f Allow the machine to cool for a minimum of ten minutes before touching it.
Clean the fan blades and motors prior to the first seasonal use, every 1200 hours
or annually, or as needed.
To clean the fan blades and motors, carry out the following procedure.
1. Remove the fan guard (f). There are four screws that secure the fan guard.
g
f
ghi_gr007398
2. Remove the the access panel (g). See topic Removing the Access Panel.
3. Inspect and, if necessary, clean the motors (m) using compressed air.
4. Clean the fan blades using a stiff brush.
5. Reinstall the internal access panel.
6. Reinstall the fan guard.
m
56 ghi_tx001465gb.fm
HI 400HD D / HD G Maintenance
7.5 Cleaning the Interior Shell
Prerequisites
When
Machine shut down and cool to the touch
Power source disconnected
CAUTION
Hot surface hazard. The machine surfaces may be hot.
f Allow the machine to cool for a minimum of ten minutes before touching it.
Clean the interior shell prior to the first seasonal use, every 1200 hours or annually,
or as needed.
To clean the interior shell, carry out the following procedure.
1. Remove the fan guard. See topic Cleaning the Fan Blades and Motor.
2. Remove the access panel. See topic Removing the Access Panel.
3. Unscrew and remove the four lift bracket screws (a). Carefully raise and
maneuver the lift bracket (b) away from the machine shell cover (c), resting it on
the rear frame as shown.
c
b
a
b
wc_gr007776
4. Remove the six mounting screws and lift the machine shell cover off the machine
5. Inspect and clean the interior shell using compressed air.
6. Re-install the machine shell cover.
7. Re-install the lift bracket.
8. Re-install the access cover.
9. Re-install the fan guard.
.
ghi_tx001465gb.fm 57
Maintenance HI 400HD D / HD G
7.6 Inspecting the Flame Head
Prerequisites
When
Procedure
Machine shut down and cool to the touch
Machine properly positioned
CAUTION
Hot surface hazard. The machine surfaces may be hot.
f Allow the machine to cool for a minimum of ten minutes before touching it.
Inspect the flame head prior to the first seasonal use, during regular maintenance,
and as needed.
To inspect the flame head (b), carry out the following procedure.
1. Remove the access panel. See topic Removing the Access Pan el.
2. Remove the burner assembly (a). See topic Removing and Installing the Burner
Assembly.
b
HI 400HD D
b
a
ghi_gr007412
b
HI 400HD G
3. The flame head is attached to the burner assembly. Inspect the flame head for
the following:
Wear. Replace if necessary.
Cleanliness. Clean the flame head if necessary.
Thermal stress. Replace if necessary.
4. Re-install the burner assembly. See topic Removing and Installing the Burner
Assembly.
58 ghi_tx001465gb.fm
HI 400HD D / HD G Maintenance
7.7 Inspecting the Electrical Connections
After disconnecting the power cord, check all electrical connections for the
following:
Proper connections. Be sure that all connections are complete and tight.
Corrosion. Clean or replace if necessary.
Damaged wires/connectors. Replace if necessary.
Proper ground.
7.8 General Cleaning Guidelines
Prerequisites
General
cleaning
Machine shut down
Machine cool
Clean the following areas to ensure proper operation.
Item Method/task
Burner Remove all dirt and debris. Ensure air intake area is unob-
structed.
Hoses, connectors,
and couplings
Trailer (if equipped) Clean with compressed air: 50 PSI maximu m .
Covers/machine exte-
rior
Air inlets/ouputs Remove all dirt and debris. Ensure air intake area is unob-
Wipe clean with cloth.
Wipe clean with cloth.
structed.
ghi_tx001465gb.fm 59
Maintenance HI 400HD D / HD G
List of Abbreviations
Amp ampere (unit of electrical current)
asl above sea level
BTU British Thermal Unit
°C Celsius (metric unit of temperature)
°F Fahrenheit (unit of temperature)
2
ft
ft.lbs. foot pounds (unit of torque)
gph gallons per hour (unit of liquid flow)
GFI Ground Fault Interrupt(er) (protection device)
Hz Hertz (unit of frequency)
ID inner diameter
in. inch
kg kilogram
kilo-cal kilo-calorie (1000 calories) (metric unit of heat energy)
kPal kilo-Pascals (metric unit of pressure)
kW kilo-Watt (unit of electrical power)
lb. pound
mmeter
square foot/square feet (measurement of area)
mm millimeter (1/1000 of a meter)
psig pounds per square inch gauge (unit of pressure)
VAC Volts, Alternating Current
VDC Volts, Direct Current
VFD Variable Frequency Drive
HTF Heat Transfer Fluid
60 ghi_tx001465gb.fm
HI 400HD D / HD G Basic Troubleshooting
8 Basic Troubleshooting
Note: The following symptoms and remedies are some of the more
common issues that have arisen during the history of these machines.
These do not represent all the possibilities. If you need advanced
troubleshooting assistance, please contact Wacker Neuson Product
Support.
Symptom Possible Causes Remedy
The burner does not start • The remote thermostat or
thermostat plug is not
inserted correctly.
• Faulty cable or power
supply
• The over temperature limit
has tripped
• The burner is in lock-out
mode.
The burner starts, the flame
does not ignite, the unit locks
out
• No fuel
• Worn burner nozzle
• Faulty electrodes
• Cad cell detecting external
light.
• Cad cell defective
• Burner control defe ctive
The burner starts, flame
ignites, but the unit locks out
• Incorrect fuel pressure
• Worn burner nozzle
• Incorrect air lock setting
• Cad cell defective
• Burner control defe ctive
• Insert the remote
thermostat or thermostat
plug.
• Check cable and power
supply
• Press the reset button.
• Fill fuel tank
• Replace burner nozzle
• Replace electrodes
• Check the Cad cell
enclosure
• Increase fuel pressure
• Replace burner nozzle
• Re-adjust air lock setting
The burner ignites but the
performance is poor
Black smoke from vent pipe • Insufficient combustion air
The machine stops due to
pressure switch fault
Note:
ghi_tx001466gb.fm 61
• Worn burner nozzle
• Clogged fuel filter
• Air leaks in the fuel lines
• Insufficient oil pressure
• Insufficient ventilation air
• Overheat condition
• Faulty pressure switch
• Incorrect nozzle
• Wrong fuel pressure
• Replace burner nozzle
• Replace the fuel filter
• Inspect the lines for leaks;
replace if necessary
• Remove any obstructions
from the air inlet and outlet
areas.
• Contact Wacker Neuson
Product Support
Technical Data HI 400HD D / HD G
9 Technical Data
9.1 Machine
Model
Units
Heat input BTU/hr 412,682 354,610
Heat output BTU/hr 341,288 293,617
Air flow cfm 3760 3821
Fuel consumption L (gal)/hr 11.2 (2.97) —
Fuel consumption
—Natural gas
—Liquid propane (LP)
Fuel nozzle size L/hr (gph) 7.6 (2.0) (80W) —
Fuel nozzle size mm (in.) — 3 x 2.8 (12 x 0.11)
Efficiency % 82.7 82.8
Noise level at 1 m dB (A) 76 74
Power requirement VAC/Hz 120/60 120/60
Electrical current Ampere 15 15
m
3
/hr
cfm
HI 400HD D HI 400HD G
—
10.1 (5.93)
3.8 (2.23)
Weight (no fuel) kg (lb) 206.8 (456) 225.4 (497)
Height mm (in.) 1308 (51.5) 1105 (43.5)
Length mm (in.) 2134 (84) 2134 (84)
Width mm (in.) 838 (33) 838 (33)
Flue diameter mm (in.) 152.4 (6) 152.4 (6)
Fuel tank capacity L (gal) 216.1 (57.1) —
Fuel pressure psi (bar) Stage I: 160 (11)
Stage II: 217 (15)
Fuel supply pressure
—Natural gas
—Liquid propane (LP)
Burner pressure
—Natural gas
—Liquid propane (LP)
Air damper setting number 1.5 3
Static air pressure limit WC (Pa) 0.60 (150)
WC (Pa)
— Min 7, Max 10
WC (Pa)
— 6.40 (1600)
—
Min 8, Max 13
6.52 (1630)
62 ghi_td000402gb.fm
HI 400HD D / HD G Schematics
10 Schematics
10.1 HI 400HD D—Oil Burning
18
16
RD
RD
21
BU
WH
BR
BK
13
5
WH
BK
11
3
BU
BR
WH
WH
12
14
2
1
WH
WH
7
BK
RD
RD
22
BK
BK
BK
20
BK
WH
WH
5
6
WH
BK
BU
BN
BK
19
23
WH
BK
BK
WH
15
8
17
RD
RD
4
9
10
RD
1
WH
WH
WH
BK
BK
BK
WH
BK
BU
BK
BR
ghi_tx001467gb.fm 63
wc_gr007399
Schematics HI 400HD D / HD G
10.2 Components—Oil Burning
No. Description No. Description
1 Fuse 13 Burner motor
2 Overheat thermostat 14 Pre-heated filter plug
3 Solenoid valve 15 Summer/ winter switch
4 CAD cell 16 Overheat safety thermostat
5 Capacitor 17 Low fire / high fire power
switch
6 Fan motor 18 Preheated nozzle
7 Electric pilot lamp 19 Control board heater
8 Transformer H.V. 20 Starter capacitor
9 Room thermostat plug 21 Solenoid valve
10 Control box 22 Fan thermostat
11 Air pressure switch 23 Pressure switch heater
12 Heated fuel filter — —
Wire Colors
BK Black RD Red YL Yellow OR Orange
GN Green TN Tan BR Brown PU Purple
BU Blue VIO Violet CL Clear SH Shield
PK Pink WH White GY Gray LB Lt. blue
64 ghi_tx001467gb.fm
HI 400HD D / HD G Schematics
10.3 HI 400HD G—Gas Burning
4
13
5
BN
WH
7
WH
2
RD
RD
11
BK
BK
WH
1
WH
WH
BK
BK
WH
WH
18
BK
BK
WH
RD
17
BK
16
BK
BK
BK
5
5
19 20 21
6
WH
WHWH
BKBK BK
8
YL/GN
3
WH
BK
BK
15
RD
BK
12
BK
BK
WH
WH
10
9
RD
RD
WH
BK
1
BK
BK
WH
BK
ghi_gr007400
wc_gr007400
ghi_tx001467gb.fm 65
Schematics HI 400HD D / HD G
10.4 Components—Gas Burning
No. Description No. Description
1 Fuse 12 Ionization probe
2 Burner thermostat 13 Burner motor
3 Solenoid valve 15 Summer/ winter switch
4 Gas train 16 Overheat safety thermostat
5 Capacitor 17 Fan thermostat
6 Fan motor 18 Flame lamp
7 Electric pilot lamp 19 Control board heater
8 Transformer H.V. 20 Pressure switch heater
9 Room thermostat plug 21 Gas valve heater
10 Control box 22 PTC resistor
11 Air pressure switch — —
Wire Colors
BK Black RD Red YL Yellow OR Orange
GN Green TN Tan BR Brown PU Purple
BU Blue VIO Violet CL Clear SH Shield
PK Pink WH White GY Gray LB Lt. blue
66 ghi_tx001467gb.fm
Wacker Neuson SE · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02-0 · Fax: +49 - (0)89-3 54 02-390
Wacker Neuson Corporation · N92W15000 Anthony Ave. · Menomonee Falls, WI 53051 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 ·Tel. : (800) 770-0957
Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
Tel: (852) 3605 5360, Fax: (852) 2758 0032
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