Operator’s Manual Indirect-Fired Air Heaters HI400HD D HI400HD G Type HI400HD D, HI400HD G Document 5000192824 Date 0419 Revision 12 Language EN 5 0 0 0 1 9 2 8 2 4
Copyright notice © Copyright 2019 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.
CALIFORNIA Proposition 65 Warning CALIFORNIA Proposition 65 Warning WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. WARNING Cancer and Reproductive Harm www.P65Warnings.ca.gov.
CALIFORNIA Proposition 65 Warning Proposition 65 Warning Notes 4 wc_tx004643en.
HI400HD D / HD G 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 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.
Foreword HI400HD D / HD G 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. Operate the machine only as specified in Machine Description and Intended Use. SAVE THESE INSTRUCTIONS—This manual contains important instructions for the machine models below.
HI400HD D / HD G Expectations for information in this manual Manufacturer’s approval Foreword 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.
Foreword HI400HD D / HD G 8 ghi_tx001460gb_FM10.
Table of Contents HI400HD D / HD G CALIFORNIA Proposition 65 Warning Foreword 1 Safety Information 1.1 1.2 1.3 1.4 1.5 1.6 2 13 Signal Words Used in this Manual ..................................................... 13 Machine Description and Intended Use ............................................. 14 Operating Safety ................................................................................ 15 Safety Guidelines for Gas-Fired Machines .........................................
Table of Contents 4.21 4.22 4.23 4.24 4.25 4.26 4.27 4.28 4.29 5 Available Accessories .........................................................................58 59 Removing the Access Cover ...............................................................59 Removing and Installing the Burner ....................................................60 Setting up the Burner ..........................................................................61 Adjusting the Gas Pressure (G Models) .......................
Table of Contents HI400HD D / HD G 9 Technical Data 9.1 84 Machine .............................................................................................. 84 10 Schematics 10.1 10.2 10.3 10.4 10.5 10.6 86 HI400HD D ......................................................................................... 86 Components ....................................................................................... 87 HI400HD G (2014) .......................................................................
Table of Contents HI400HD D / HD G 12 wc_bo5000192824_11TOC.
HI400HD D / HD G 1 1.1 Safety Information Safety Information 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. ► Obey all safety messages that follow this symbol.
Safety Information 1.2 HI400HD D / HD G Machine Description and Intended Use Machine description The HI Heater is an indirect-fired air heater. Depending on the model, the machine operates either on diesel fuel (oil) or natural gas / Liquid Propane (LP).
HI400HD D / HD G 1.3 Safety Information Operating Safety Operator training 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.
Safety Information HI400HD D / HD G ■ Do not operate a machine in need of repair. Personal Protective Equipment (PPE) 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 Machine condition Only operate the machine when: ■ ■ ■ ■ The heat exchanger is in proper working order.
HI400HD D / HD G 1.4 Safety Information Safety Guidelines for Gas-Fired Machines WARNING Gas leaks can cause explosions or fire. Follow the steps below if you smell gas. ► Open windows. ► Do not touch electrical switches. ► Extinguish open flames. ► Immediately call your gas supplier. WARNING Risk of explosion, fire, property damage, asphyxiation, death, or carbon monoxide poisoning. ► Read and follow the instructions below regarding proper gas supply and preparation of the machine.
Safety Information 1.5 HI400HD D / HD G 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).
HI400HD D / HD G 1.6 Safety Information Service Safety Service training Before servicing or maintaining the machine: ■ Read and understand the instructions contained in all manuals delivered with the machine. ■ Familiarize yourself with the location and proper use of all controls and safety devices. ■ Only trained personnel shall troubleshoot or repair problems occurring with the machine. ■ Contact Wacker Neuson for additional training if necessary.
Safety Information Personal Protective Equipment (PPE) HI400HD D / HD G 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). After use ■ Stop the engine when the machine is not being operated.
HI400HD D / HD G 2 2.1 Labels Labels Label Locations—HI400 HD D j x g b a c p q f h o c d e f wc_gr011675 ghi_si000469gb_FM10.
Labels 2.2 HI400HD D / HD G Label Locations—HI400 HD G j x g b g s c t c p u h m q c e f w wc_gr011676 22 ghi_si000469gb_FM10.
HI400HD D / HD G 2.3 Labels Label Meanings a CAUTION This machine uses diesel fuel. b NOTICE Lifting point c Tie-down point. f WARNING Hot surface g WARNING Entanglement hazard. Rotating machinery. Do not reach inside machine when engine is running. h WARNING 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. ghi_si000469gb_FM10.
Labels HI400HD D / HD G j WARNING Electric shock hazard. Disconnect power before servicing. Read Operator’s Manual. 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.
HI400HD D / HD G Labels r Gas shut-off valve s Gas selector valve Propane Gas Position Natural Gas Position Lock valve in position after selection. t Electrical grounding instructions. w General usage warnings ghi_si000469gb_FM10.
Labels HI400HD D / HD G x — Hose assembly specification — Gas type label Natural Gas Propane Gas WARNING Explosion and fire hazard. Read the Operator’s Manual for more information. 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.
HI400HD D / HD G Labels — ghi_si000469gb_FM10.
Lifting and Transporting 3 HI400HD D / HD G Lifting and Transporting Requirements ■ Transport vehicle capable of carrying 1000 lbs (454 kg) ■ Crane or lift capable of carrying 1000 lbs (454 kg) Background NOTICE: These machines are NOT designed to be towed with any vehicle. WARNING Crushing hazard. ► Only qualified riggers should attempt aerial lifting of this machine. Guidelines Follow the guidelines below when lifting and transporting this machine.
HI400HD D / HD G 4 4.1 Operation Operation Preparing the 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.
Operation 4.3 HI400HD D / HD G Installing the Front Duct Adapter Overview 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. Duct adapter varieties Your machine is supplied with either a one-way, two-way, or three-way front duct adapter depending on the specific model.
HI400HD D / HD G 4.4 Operation Blower Duct Heater Option Overview An optional 10 cm (4 in.) duct for preheating air drawn into the combustion blower can be installed. This accessory is recommended for use in extremely cold temperatures. Note: The installation instructions below are provided for your convenience. Refer to the complete instruction sheet packaged with the blower duct kit. Prerequisites ■ Blower duct kit (includes 10 cm (4 in.
Operation 4.5 HI400HD D / HD G Installing the Rear Duct Adapter (Optional) Overview The optional rear duct adapter is shipped loose and must be installed before operating the machine. Procedure Perform 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.
HI400HD D / HD G 4.6 Operation Control and Component Locations HI400HD G a k Machine components Ref. Description Ref. a Exhaust flue g Access cover b Control panel h Fuel filter (D units) c Manual transport handle i Gas train (G units only) d Fuel fill location (D units only) j Fork pockets e Lift brackets k Manual holder f Air inlet and fan guard — — ghi_tx001462gb_FM10.
Operation 4.7 HI400HD D / HD G Adjusting the Handle Height Overview Your machine is equipped with a manual transport handle. The handle height can be adjusted to suit the operator’s preference. Procedure Perform the procedure below to adjust the handle height. 1. Loosen, but do not remove, the two adjusting knobs (a) on the handle. b a 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.
HI400HD D / HD G 4.8 Operation Positioning the Machine DANGER Carbon monoxide. Exhaust gas from the burner contains carbon monoxide, a deadly poison. Exposure to carbon monoxide can kill you in minutes. ► Never run the machine indoors or in an enclosed area unless the machine is vented properly according to local and national codes. WARNING Fire hazard. Restricting air flow through the machine during operation can cause a fire due to overheating components.
Operation 4.9 HI400HD D / HD G Electrical and Grounding WARNING Fire and electric shock hazards. The use of an innappropriate power supply, or undersized extension cords, can lead to fire and electric shock. Fire and electric shock can cause severe injury. ► Before use, ensure that the machine is properly connected to an appropriate power source and grounded per the requirements provided below. ► Do not use undersized extension cords.
HI400HD D / HD G 4.10 Operation Control Panel—Oil Burner (D Models) RESET 0 Control panel components Symbols and meanings Ref. Description Ref. Description a Operating status indicator and reset button (dual function) d Firing mode switch (High-fire or low-fire) b Mode switch (on-off-on) See topic Starting the Machine. e Power indicator c Remote thermostat receptacle f Power cord Symbol Meaning/function Symbol RESET Push the button to reset the machine when a burner fault occurs.
Operation 4.11 HI400HD D / HD G Recommended Fuels and Fuel Blending Guide 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.
HI400HD D / HD G 4.13 Operation Control Panel—Gas Burner (G Models) RESET Control panel components Symbols and meanings Ref. Description Ref. Description a Operating status indicator and reset button (dual function) e Power indicator b Mode switch (on-off-on) See topic Starting the Machine.
Operation 4.14 HI400HD D / HD G Gas Installation and Setup (G models) WARNING Extreme explosion and fire hazards. ► Only a licensed, professional gas technician shall perform installation, fuel supply connection, setup, adjustment, and testing of gas lines. ► Never use open flames to detect gas leaks. Natural gas 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.
HI400HD D / HD G 4.15 Operation Connecting the Gas Line (G models) Overview The HI400HD-G heater includes a 3/4" NPT shutoff valve and inlet (a) on the gas safety valve/pressure regulator body. The gas supply line connects to the inlet. a wc_gr015340 WARNING Extreme fire and explosion hazard! ► Only a licensed, professional gas technician shall perform installation, fuel supply connection, setup, adjustment, and testing of gas lines.
Operation 4.16 HI400HD D / HD G Setting the Gas Selector Valve (G models) Overview 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. Procedure Perform the procedure below to change the type of gas. 1. Ensure that the gas shutoff valve is closed. 2. Loosen the screw (a) on the gas selector valve. a wc_gr015341 3. Turn the handle to the desired position.
HI400HD D / HD G 4.17 Operation Venting the Machine DANGER Asphyxiation hazard. Exhaust gas from the burner contains carbon monoxide, a deadly poison. Exposure to carbon monoxide can kill you in minutes. ► Never run the machine indoors or in an enclosed area unless the machine is vented properly according to local and national codes. Overview The exhaust from indirect-fired heaters must be vented to a chimney or an exhaust duct.
Operation HI400HD D / HD G Note: The above venting diagram shows suggested venting layouts only. Consult all appropriate governing bodies or local contractor for venting and fresh air requirements. 44 ghi_tx001462gb_FM10.
HI400HD D / HD G 4.18 Operation Flex Ducting Options Refer to the chart below for the maximum allowable return and supply duct lengths for your machine. NOTICE: Do not exceed the maximum total lengths specified in the chart. Exceeding these lengths, or blocking any of the duct openings, constricts the air flow through the machine and may cause a high-temperature shut-down fault.
Operation 4.19 HI400HD D / HD G Ducting Guidelines Duct Types Use appropriate type (Heat range) and length of duct. Use Black or Gray duct for supply air. Use Yellow duct for return air only. CAUTION Use of Yellow duct (rated for 200°F MAX) for supply ducting (required rating 280°F) can result in damage to the duct or unplanned shutdown if the ducting fails. ► Do not use Yellow duct for supply ducting. Yellow duct is for RETURN DUCTING ONLY.
HI400HD D / HD G Operation Avoid any sharp bends from the supply outlet. Use a stand to keep the duct level for a distance of 3–6 ft away from the machine. wc_gr013132 If additional ducting for a machine with more than one supply adapter is not available, change the adapter arrangement or use one adapter and leave the other adapters open.
Operation 4.20 HI400HD D / HD G Installing the Remote Thermostat or Receptacle Cap Requirements ■ Remote thermostat, or ■ Thermostat receptacle cap Background 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.
HI400HD D / HD G 4.21 Operation Connecting Power to the Machine Requirements ■ 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. ► Do not use under-sized extension cords. Extension cords Restrictions for extension cords: ■ Use only 3-wire type extension cords with heavy-duty plugs.
Operation 4.22 HI400HD D / HD G Before Starting Requirements ■ Machine properly positioned ■ Power connected to the machine Checks Before starting the machine, check the following items: Result 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.
HI400HD D / HD G 4.23 Operation Cold Weather Start-Up Background 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. ► Wear safety gloves when handling the fuel filter.
Operation 4.24 HI400HD D / HD G Starting the Machine (D models) Requirements ■ Machine properly positioned ■ Power connected ■ Pre-starting checks completed Procedure Perform the procedure below to start the machine. 1. Select an operation mode. a. Continuous heat mode (I) b. thermostat mode (II) c RESET 0 wc_gr007276 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.
HI400HD D / HD G 4.25 Operation Starting the Machine (G models) Requirements ■ Machine properly positioned ■ Power connected ■ Pre-starting checks completed Procedure Perform the procedure below to start the machine. 1. Select an operation mode (b). a. Continuous heat mode (I) b. thermostat mode (II) RESET 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.
Operation 4.26 HI400HD D / HD G High and Low Voltage Protection (G Models) Serial Number Range 20105810 and higher Introduction Your machine is equipped with a control board that offers high and low voltage protection. This enhanced control board controls burner operation when the voltage drops or spikes for prolonged periods. If you wish to install this enhanced control board on a machine outside the serial number range listed above, contact Wacker Neuson.
HI400HD D / HD G 4.27 Operation Stopping Procedure Perform 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. ► Remove all electric power to the machine before servicing the machine. 1. Turn the operation mode switch to the OFF (O) position (c). c Shutdown sequence The following sequence of events will occur after turning the machine off. 1. The burner will shut down. 2.
Operation 4.28 HI400HD D / HD G Installing and Using the Remote Thermostat Requirements ■ Remote thermostat ■ Pre-starting checks complete Procedure Perform 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).
HI400HD D / HD G 4.29 Operation Operating at High Elevations (D models) Background If using the machine at or above elevations of 1524 m (5000 ft) asl (above sea level), a high elevation kit, periodic monitoring, and additional maintenance are necessary to preserve the machine’s systems. The following procedures will ensure that the machine runs smoothly and that premature soot build-up will be reduced. Guidelines Use the guidelines below to ensure efficient operation of the machine.
Accessories 5 5.1 HI400HD D / HD G Accessories Available Accessories Introduction Wacker Neuson Corporation offers many optional accessories for this machine. These accessories are described below. Contact 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.
HI400HD D / HD G 6 6.1 Setting up the Burner Setting up the Burner Removing the Access Cover Requirements ■ Machine shut down and cooled ■ Machine properly positioned CAUTION Hot surface hazard. The machine surfaces may be hot. ► Allow the machine to cool for a minimum of ten minutes before touching it. Overview Your machine is equipped with a removable access cover.
Setting up the Burner 6.2 HI400HD D / HD G Removing and Installing the Burner Note: Although an oil-burning machine (D model) is shown in the photos below, the procedure for removing the burner assembly on a gas-burning machine (G model) is similar. Requirements ■ Machine shut down and cooled ■ Machine properly positioned CAUTION Hot surface hazard. The machine surfaces may be hot. ► Allow the machine to cool for a minimum of ten minutes before touching it.
HI400HD D / HD G 6.3 Setting up the Burner Setting up the Burner Factory settings Background Machine Nozzle size Burner pressure in WC Fuel pressure psi bar HI400 HD D 2.00 (80W) gph Stage I: 160 Stage II: 217 Stage I: 11 Stage II: 15 HI400 HD G 3 x 2.8 mm (12 X 0.11 in.) — — NG LP Air damper setting — 6.40 (1600 Pa) 1.5 6.52 (1630 Pa) 3 The burner consists of several different components and subsystems.
Setting up the Burner HI400HD D / HD G (See topic Checking/Adjusting the Gas Pressure.) 8. Conduct a smoke spot test. Follow the smoke spot tester manufacturer’s instructions and the general guidelines below. 5/16 in. dia. (8 mm) 18 in. (450 mm) 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). 9. Analyze the combustion.
HI400HD D / HD G 6.4 Setting up the Burner Adjusting the Gas Pressure (G Models) Prerequisites ■ ■ ■ ■ ■ ■ Procedure 1. Verify that the machine is shut down, stopped, and connected to electrical power (115V 60 Hz). Machine is stopped Hex key set Yellow Jacket® gas pressure test kit (0–15 in. w.c. manometer) Flat-head screwdriver Phillips-head screwdriver Small adjustable wrench 2. Close the gas valve (a) on the inlet to the gas train. a wc_gr015323 3. Connect the manometer to the machine. 4.
Setting up the Burner HI400HD D / HD G Continued from the previous page. 6. Remove the pressure test port plug (c) located on the bottom of the gas valve. c wc_gr015325 7. Thread the manometer barbed adapter fitting into the test port plug location. wc_gr015326 8. Connect the manometer (d) to the barbed adapter fitting. d wc_gr015327 This procedure continues on the next page. 64 ghi_tx001464gb_FM10.
HI400HD D / HD G Setting up the Burner Continued from the previous page. 9. Position the gas selector valve for the fuel being used: ■ In line for natural gas (e) ■ 90° for liquid propane (LP) (f) f e e wc_gr015328 10.Open the gas supply valve (g). g wc_gr015329 11.Start the machine (h). h wc_gr015331 This procedure continues on the next page. ghi_tx001464gb_FM10.
Setting up the Burner HI400HD D / HD G Continued from the previous page. 12.When the gas valve opens, adjust the gas pressure to: ■ 6.4 in. w.c. for natural gas ■ 6.52 in. w.c. for liquid propane (LP) Note: Turning the Maxitrol regulator (j) adjusting screw clockwise increases the pressure. Turning the Maxitrol regulator adjusting screw counterclockwise reduces the pressure. j wc_gr015330 13.Observe a few burner cycles to ensure the gas pressure is set properly. 14.After the pressure is set: a.
HI400HD D / HD G 6.5 Setting up the Burner Inspecting the Oil Burner Electrodes (D models) Requirements ■ Machine shut down ■ Power disconnected ■ Burner cool When to inspect 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. Procedure Remove the burner assembly and inspect the condition of the electrode tips (a).
Setting up the Burner 6.6 HI400HD D / HD G Checking and Changing the Burner Nozzle (D models) Requirements ■ Machine shut down and cool to the touch ■ Machine properly positioned CAUTION Hot surface hazard. The machine surfaces may be hot. ► Allow the machine to cool for a minimum of ten minutes before touching it. When Removing the nozzle Replace the burner nozzle annually, or if it is damaged. Perform the procedure below to replace the burner nozzle. 1. Remove the burner.
HI400HD D / HD G 6.7 Setting up the Burner Checking and Adjusting the Air Damper Background The air damper setting can affect burner performance especially at high altitudes. Check and adjust the air damper when the burner performance is poor. Procedure Perform the procedure below to check and adjust the air damper setting. 1. The air damper (a) is located beneath the fan guard. a Shown with baffle removed for clarity wc_gr011997 2. To adjust the air damper, move the lever left to close (O).
Setting up the Burner 6.8 HI400HD D / HD G Checking and Adjusting the Fuel Pressure Requirements ■ 300-psi (20 bar) fuel pressure gauge with long tube ■ G 1/8-in. threaded adapter (British Standard Pipe) Background Incorrect fuel pressure will result in poor heater performance. Note: The fuel pressure differs between the low fire mode (stage I) and the high fire mode (stage II). Therefore, the fuel pressure must be checked in both low fire mode and the high fire mode.
HI400HD D / HD G Setting up the Burner Continued from the previous page. 3. Install the G 1/8-in. adapter (d) into the pressure port. Install a tube onto the adapter. The tube (e) must be long enough to reach outside of the heater. Install a 300-psig (20 bar) pressure gauge (f) onto the tube. e a d f b e wc_gr012098 4. Close the access cover (a). WARNING High voltage, cutting, and hot surface hazards exist inside the machine. High voltage can cause severe injury or death.
Setting up the Burner HI400HD D / HD G Continued from the previous page. Adjusting fuel pressure The pump has two adjustment screws; one for low fuel pressure (g) and one for high fuel pressure (h). If the fuel pressure does not equal the recommended pressure, it will need to be adjusted. h g wc_gr012099 NOTICE: Do not adjust the fuel pressure to a setting outside the safe operational parameters. WARNING Cutting hazard. ► Disconnect the power source before adjusting the fuel pressure. 1.
HI400HD D / HD G 7 7.1 Maintenance Maintenance Periodic Maintenance Schedule Interval* (hours of service) Daily 2 Weeks 6 Months Yearly Task --- (50) (1000) (1200) 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 the heat exchanger. Inspect electrical components.
Maintenance 7.2 HI400HD D / HD G Inspecting the Heat Exchanger Introduction The heat exchanger consists of the combustion chamber and an outer shell. As intake air flows over the hot combustion chamber, it collects heat. The heated intake air is then blown out of the supply ducts. Reasons for inspection A cracked or damaged heat exchanger is hazardous! Poisonous carbon monoxide gas can escape from the heat exchanger and enter the clean air stream.
HI400HD D / HD G Maintenance Continued from the previous page. Access procedure Perform the procedure below to access the heat exchanger. 1. Remove the access cover (a). d a c c b e wc_gr008462 2. Remove the cover (d). (See topic Cleaning the Interior Shell.) 3. Remove the screws (b) securing the burner tube assembly (c), and remove the burner tube assembly from the heat exchanger. 4. Remove the bolts that secure the heat exchanger (e) to the lower shell. 5.
Maintenance HI400HD D / HD G Continued from the previous page. Inspection procedure Perform the procedure below to inspect the heat exchanger. 1. Using a strong light and inspection mirror, inspect the outer shell of the combustion chamber for cracks or separations. 2. Inspect welded areas. 3. Use the light and mirror to examine the interior of the combustion chamber for cracks or separations. Also, inspect the burner tube assembly mounting surface (f) for damage. g f wc_gr008463 4.
HI400HD D / HD G 7.3 Maintenance Changing the Fuel Heater Filter (D models) Prerequisites ■ Machine shut down ■ Burner cool CAUTION Hot surface hazard. The external surface of the fuel filter canister may be hot. ► Allow the machine to cool before servicing. WARNING Hot fluids. The fuel inside the fuel filter canister may be hot. ► Wear hand and eye protection when doing this procedure. Procedure Perform the procedure below to change the fuel heater filter. 1.
Maintenance 7.4 HI400HD D / HD G Inspecting and Cleaning the Cadmium (CAD) Cell Requirements ■ Machine shut down and cool to the touch ■ Machine properly positioned CAUTION Hot surface hazard. The machine surfaces may be hot. ► Allow the machine to cool for a minimum of ten minutes before touching it. When Inspect and clean the CAD cell as needed, or while performing other scheduled maintenance procedures. Perform the procedure below to inspect and clean the CAD cell. 1. Remove the access cover. 2.
HI400HD D / HD G 7.5 Maintenance Cleaning the Fan Blades and Motor Prerequisites ■ 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. ► Remove all electric power to the machine before performing this procedure. CAUTION Hot surface hazard. The machine surfaces may be hot. ► Allow the machine to cool for a minimum of ten minutes before touching it.
Maintenance 7.6 HI400HD D / HD G Cleaning the Interior Shell Prerequisites ■ Machine shut down and cool to the touch ■ Power source disconnected CAUTION Hot surface hazard. The machine surfaces may be hot. ► Allow the machine to cool for a minimum of ten minutes before touching it. When Clean the interior shell prior to the first seasonal use, every 1200 hours or annually, or as needed. Procedure Perform the procedure below to clean the interior shell. 1. Remove the fan guard.
HI400HD D / HD G 7.8 Maintenance Inspecting the Flame Head Prerequisites ■ Machine shut down and cool to the touch ■ Machine properly positioned CAUTION Hot surface hazard. The machine surfaces may be hot. ► Allow the machine to cool for a minimum of ten minutes before touching it. When Inspect the flame head prior to the first seasonal use, during regular maintenance, and as needed. Procedure Perform the procedure below to inspect the flame head (b). 1. Remove the access panel.
Maintenance 7.9 HI400HD D / HD G 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. 7.10 Cleaning the Machine Requirements ■ Machine shut down ■ Machine cool General cleaning Clean the following areas to ensure proper operation.
HI400HD D / HD G 8 8.
Technical Data 9 HI400HD D / HD G Technical Data 9.1 Machine Model HI400HD D HI400HD G Units Gross burner heat input BTU/hr (kW) 412,682 (120.8) NG: 380,548 (111.4) LP: 334,700 (98) Net heat output BTU/hr (kW) 341,288 (99.9) NG: 329,174 (96.4) LP: 289,515 (84.8) 3015 3015 L/hr (gph) 11.2 (2.97) — m3/hr (cfh) L/hr (gph) — 10.1 (355.97) 13.8 (3.65) Fuel nozzle size L/hr (gph) 7.6 (2.0) (80W) — Fuel nozzle size mm (in.) — 3 x 2.8 (12 x 0.11) 82.7 82.
HI400HD D / HD G Technical Data Notes wc_td000604gb_FM10.
Schematics HI400HD D/ HD G 10 Schematics HI400HD D 14 11 YL/GN BR BK GY BR 19 BK WH 6 BR 5 BK BK WH BK BR 2 BU BK 1 22 2 16 6 RD RD WH 20 BU WH WH 21 WH BK YL/GN BK 3 13 N BK WH 12 L 18 5 WH 10.1 BK BK WH BK WH RD RD WH 24 8 WH BK BK RD BK WH BK BK WH 17 RD 15 WH WH BK 9 4 RD RD WH RD WH BK WH RD 10 BK BK BK RD WH YL GY BU BK 25 WH BK wc_gr011974 86 wc_tx003752gb_FM10.
HI400HD D/ HD G 10.2 Schematics Components No. Description No. Description 1 Line fuse 14 Pre-heated filter plug 2 Overheat thermostat 15 Summer/winter switch 3 Solenoid valve 16 Overheat safety thermostat 4 CAD cell 17 Low fire/high fire power switch 5 Capacitor 18 Preheated nozzle 6 Fan motor 19 Control board heater 7 Electric pilot lamp 20 Starter capacitor 8 Transformer H.V.
Schematics 10.3 HI400HD D/ HD G HI400HD G (2014) 5 BR YL/GN BU 20 17 7 5 BK WH BK BK 6 WH WH WH 2 19 23 16 WH BK 1 RD WH BK RD WH 11 1 7 BK BK WH 24 YL/GN WH BK YL/GN BK 4 13 N L WH BK BK YL/GN 3 WH YL/GN YL/GN 8 WH BK BK BK 1 18 WH WH BK WH BK RD RD 15 BK BK RD WH BK 9 12 RD WH WH RD RD 10 BK BK RD 21 WH YL GY BU BK 22 WH wc_gr011975 88 wc_tx003752gb_FM10.
HI400HD D/ HD G 10.4 Schematics Components (2014) No. Description No. Description 1 Line fuse 13 Burner motor 2 Burner thermostat 15 Summer/winter switch 3 Solenoid valve 16 Overheat safety thermostat 4 Gas train 17 Fan thermostat 5 Capacitor 18 Flame lamp 6 Fan motor 19 Control board heater 7 Electric pilot lamp 20 Pressure switch heater 8 Transformer H.V.
Schematics 10.5 HI400HD D/ HD G HI400HD G (2015) 5 BR YL/GN BU 20 17 7 5 WH 6 BK WH BK BK WH RD 2 19 23 16 WH BK 1 WH 7 WH BK RD WH 11 1 BK BK WH 24 YL/GN WH BK YL/GN BK 4 13 N L WH BK BK YL/GN 3 YL/GN YL/GN 8 WH BK BK WH BK 1 18 WH WH BK WH BK RD RD 15 BK BK RD WH BK 9 12 RD WH WH RD RD 10 BK BK RD 21 WH YL GY BU BK 22 WH wc_gr011975 90 wc_tx003752gb_FM10.
HI400HD D/ HD G 10.6 Schematics Components (2015) No. Description No. Description 1 Line fuse 13 Burner motor 2 Burner thermostat — — 3 Solenoid valve 15 Mode switch, ON/Thermostat 4 Gas train 16 Overheat safety thermostat 5 Capacitor 17 Fan thermostat 6 Fan motor 18 Flame lamp 7 Electric pilot lamp — — 8 Transformer H.V.
Important: For spare parts information, please see your Wacker Neuson Dealer, or visit the Wacker Neuson website at http://www.wackerneuson.com/. Wichtig! Informationen über Ersatzteile erhalten Sie von Ihrem Wacker Neuson Händler oder besuchen Sie die Wacker Neuson Website unter http://www.wackerneuson.com/. Important : Pour des informations sur les pièces détachées, merci de consulter votre distributeur Wacker Neuson, ou de visiter le site Internet de Wacker Neuson sur http://www.wackerneuson.com/.
