Operator s Manual. Hydronic Air Heater. Arctic Bear XHD-NS en /

Transcription

1 Operator s Manual Hydronic Air Heater Arctic Bear XHD-NS E N en /

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3 Arctic Bear XHD Foreword Foreword Machines covered by this manual This manual covers machines with the following item numbers: Machine Item Number Arctic Bear XHD-NS Machine documentation 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 When ordering parts or requesting service information, be prepared to provide the machine model number, item number, revision number, and serial number. Expectations for information in this manual This manual provides information and procedures to safely operate and maintain the above Wacker Neuson model(s). For your own safety and to reduce the risk of injury, carefully read, understand, and observe all instructions described in this manual. Wacker Neuson 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. Copyright notice All rights, especially copying and distribution rights, are reserved. Copyright 2008 by Wacker Neuson Corporation. This publication may be reproduced through photocopying 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 Wacker Neuson Corporation represents an infringement of valid copyrights, and violators will be prosecuted. Trademarks All trademarks referenced in this manual are the property of their respective owners. ghi_tx000993gb.fm 3

4 Foreword E 350M ghi_tx000993gb.fm 4

5 Arctic Bear XHD-NS Table of Contents Foreword 3 1 Safety Information Callouts Found in this Manual Safety Guidelines for Operating the Machine Safety Guidelines for Servicing the Machine Safety Guidelines while Operating Internal Combustion Engines Safety Guidelines while Operating Combustion Burners Label Locations - Warning Labels Warning Labels Label Locations - Informational Labels Informational Labels Label Locations - Procedural Labels Procedural Labels Lifting, Transporting, and Storing Lifting the Machine Transporting the Machine on a Flat-Bed Truck Towing the Machine Storing the Machine Preparing the Machine for Seasonal Operation Operation Application Operation and Maintenance Locations - External Operation and Maintenance Locations - Internal Operation and Maintenance Locations - Internal (continued) Obtaining Power from the Machine Before Starting Recommended Fuels Control Panel - AC Control Panel - DC Positioning the Machine Installing the Heater Duct Starting the Machine (Quick Start Guide) ghi_bo en_000toc.fm 5

6 Table of Contents Arctic Bear XHD-NS 3.13 Monitoring the Operating Parameters Stopping the Machine During an Emergency Enabling the DC Circuit Starting the Generator Enabling the AC Circuit and Components Temperature Controller Shutting Down the Machine Accessories Available Accessories Removing and Installing a Duct Adapter Maintenance Periodic Maintenance Schedule Inspecting and Lubricating the Blower Bearings Cleaning the Blower Motor Inspecting the Blower Drive Belts Inspecting the Blower Drive Pulleys Testing the Burner Exhaust and Adjusting the Settings Removing and Installing the Combustion Head Assembly Replacing the Burner Nozzle Checking and Adjusting the Electrode Position Basic Troubleshooting Troubleshooting the Burner Troubleshooting the Generator Engine...66 ghi_bo en_000toc.fm 6

7 Arctic Bear XHD-NS Table of Contents 7 Electrical Schematics AC Circuit Wire Color Legend Schematic Legend - AC Circuit DC Circuit Schematic Legend - DC Circuit Technical Data Engine Machine Dimensions Lubrication ghi_bo en_000toc.fm 7

8 Table of Contents Arctic Bear XHD-NS ghi_bo en_000toc.fm 8

9 Arctic Bear XHD-NS 1 Safety Information 1.1 Callouts Found in this Manual Safety Information This is the safety alert symbol. It is used to alert you to potential personal hazards. 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. Obey all safety messages that follow this symbol to avoid injury or death. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. Obey all safety messages that follow this symbol to avoid possible injury or death. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Obey all safety messages that follow this symbol to avoid possible minor or moderate injury. NOTICE: Used without the safety alert symbol, NOTICE indicates a situation which, if not avoided, could result in property damage. Note: Contains additional information important to a procedure. ghi_si000290gb.fm 9

10 Safety Information Arctic Bear XHD-NS 1.2 Safety Guidelines for Operating the Machine 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 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. Application area Be aware of the application area. Keep unauthorized personnel, children, and pets away from the machine. Remain aware of changing positions and the movement of other equipment and personnel in the application area/job site. Be aware of the application area. Never operate the machine in areas that contain flammable objects, fuels, or products that produce flammable vapors. Safety devices, controls, and attachments 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. To ensure safe operation of the machine: Do not operate the machine if any safety devices or guards are missing or inoperative. Do not modify or defeat the safety devices. Do not use accessories or attachments that are not recommended by Wacker Neuson Corporation. Safe operating practices When operating this machine: Remain aware of the machine s moving parts. Keep hands, feet, and loose clothing away from the machine s moving parts. Wear protective clothing appropriate to the job site when operating the machine. Wear safety glasses when operating this machine. ghi_si000290gb.fm 10

11 Arctic Bear XHD-NS When operating this machine: Do not operate a machine in need of repair. Safety Information 1.3 Safety Guidelines for Servicing the Machine 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 should troubleshoot or repair problems occurring with the machine. Contact Wacker Neuson Corporation for additional training if necessary. When servicing or maintaining this machine: Do not allow improperly trained people to service or maintain the machine. Personnel servicing or maintaining the machine must be familiar with the associated potential risks and hazards. Precautions Safe servicing practices Machine modifications Follow the precautions below when servicing or maintaining the machine. Read and understand the service procedures before performing any service to the machine. All adjustments and repairs must be completed before operation. Do not operate the machine with a known problem or deficiency. All repairs and adjustments shall be completed by a qualified technician. Turn off the machine before performing maintenance or making repairs. When servicing and maintaining this machine: Remain aware of the machine s moving parts. Keep hands, feet, and loose clothing away from the machine s moving parts. Wear protective clothing appropriate to the job when servicing and maintaining the machine. Wear safety glasses when servicing and maintaining this machine. Re-install the safety devices and guards after repairs and maintenance. When servicing or maintaining the machine: Use only accessories/attachments that are recommended by Wacker Neuson Corporation. When servicing or maintaining the machine: Do not defeat safety devices. Do not modify the machine without the express written approval of Wacker Neuson Corporation. ghi_si000290gb.fm 11

12 Safety Information Arctic Bear XHD-NS Replacing parts and labels Lifting and transporting Replace worn or damaged components. Use only spare parts recommended by Wacker Neuson Corporation. Replace all missing and hard-to-read labels. When replacing electrical components, use components that are identical in rating and performance as the original components. When lifting the machine: Make sure slings, chains, hooks, ramps, jacks and other types of lifting devices are attached securely and have enough weight-bearing capacity to lift or hold the machine safely. See section Technical Data. Remain aware of the location of other people when lifting the machine. Make sure the transporting vehicle has sufficient load capacity and platform size to safely transport the machine. See section Technical Data. To reduce the possibility of injury: Do not stand under the machine while it is being lifted or moved. Do not get onto the machine while it is being lifted or moved. Cleaning When cleaning and servicing the machine: Keep the machine clean and free of debris such as leaves, paper, cartons, etc. Keep the labels legible. When cleaning the machine: Do not clean the machine while it is running. Never use gasoline or other types of fuels or flammable solvents to clean the machine. Fumes from fuels and solvents can become explosive. ghi_si000290gb.fm 12

13 Arctic Bear XHD-NS Safety Information 1.4 Safety Guidelines while Operating Internal Combustion Engines Running the engine When running the engine: Keep the area around exhaust pipe free of flammable materials. Check the fuel lines and the fuel tank for leaks and cracks before starting the engine. Do not run the machine if fuel leaks are present or the fuel lines are loose. Fueling the engine When running the engine: Engine exhaust CAN KILL YOU IN MINUTES. Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. Never run the machine indoors or in an enclosed area such as a deep trench unless adequate ventilation, through such items as exhaust fans or hoses, is provided. Do not smoke while operating the machine. Do not run the engine near open flames. Do not touch the engine or muffler while the engine is running or immediately after it has been turned off. Do not operate a machine when its fuel cap is loose or missing. When fueling the engine: Clean up any spilled fuel immediately. Refill the fuel tank in a well-ventilated area. Replace the fuel tank cap after refueling. When fueling the engine: Do not smoke. Do not refuel a hot or running engine. Do not refuel the engine near an open flame. ghi_si000290gb.fm 13

14 Safety Information Arctic Bear XHD-NS 1.5 Safety Guidelines while Operating Combustion Burners Burner safety When using the machine: Make sure you have proper certification or licensing required by the locality, state, or province in which the machine is being installed to connect natural gas or LP. Clean up any spilled fuel immediately. Replace the fuel tank cap after refueling the machine. Refill the fuel tank in a well-ventilated area. When using the machine: Burner exhaust CAN KILL YOU IN MINUTES. Burner exhaust contains carbon monoxide. This is a poison you cannot see or smell. Never run the machine indoors or in an enclosed area unless adequate ventilation, through such items as exhaust fans or hoses, is provided. 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. Do not smoke when connecting natural gas or LP. Note: Some machines may not be capable of supporting natural gas or LP. Please see the burner manufacturer s literature for more information. ghi_si000290gb.fm 14

15 Arctic Bear XHD-NS Notes: Safety Information ghi_si000290gb.fm 15

16 Safety Information 1.6 Label Locations - Warning Labels Arctic Bear XHD-NS ghi_si000290gb.fm 16

17 Arctic Bear XHD-NS 1.7 Warning Labels Safety Information Ref. Label Definition 1 Warning: Read Operator s Manual before operating machine. Exhaust gas is deadly. Operate machine only in well ventilated area. Do not operate machine indoors. 2 Warning: Lugnuts factory torqued to 110 ft.lbs. Verify lugnuts are properly torqued before transporting. Failure to heed above warning could result in wheel loss which can cause injury or death. 3 Warning: Attach chains or straps only to axles and designated tie down points. Never run straps across any surface on this machine which is painted red. Failure to heed above warning could result in damage to personal property or cause serious injury or death. 4 Danger: Hazardous voltage. Do not operate without (the control panel) cover in place. Disconnnect and lock out power source before opening panel. Failure to comply could cause severe injury or death. ghi_si000290gb.fm 17

18 Safety Information 1.8 Label Locations - Informational Labels Arctic Bear XHD-NS ghi_si000290gb.fm 18

19 Arctic Bear XHD-NS 1.9 Informational Labels Safety Information Ref. Label Definition 1 A nameplate listing the model number, item number, revision number, and serial number is attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to specify the model number, item number, revision number, and serial number of the unit. 2 Machine rating label: This label indicates rating information for the machine. 3 Auxiliary city power output (120 VAC, 15 A maximum). This label indicates the location and rating of the auxiliary power receptacle. 4 High limit safety shutdown (manual reset). This label informs the user of the location of the high temperature safety shutdown device (snap disc). This component must be manually reset when tripped. ghi_si000290gb.fm 19

20 Safety Information Arctic Bear XHD-NS Ref. Label Definition 5 Generator auxiliary power output (120VAC, 15A maximum). This label informs the user of the location and rating of the generator auxiliary power output receptacle. 6 Emergency Stop. This label informs the user of the location of the Emergency Stop switch. 7 Tie-down location marker. 8 Burner nozzle storage. This label indicates the location of the burner nozzle storage box. 9 Low sulfur diesel only. This label informs the user that the rear fuel tank is to be filled with low sulfur diesel only. ghi_si000290gb.fm 20

21 Arctic Bear XHD-NS Safety Information Ref. Label Definition 10 Maximum tongue weight, maximum GVRW. This label informs the user of the maximum wieght capacity of the trailer tongue and the maximum Gross Vehicle Weight Rating (designed weight capacity including, but not limited to, fuel and accessories). 11 Not for highway use. This label informs the user the user that this machine is not certified to be transported on any public highways. 12 This is a marketing or model name label. 13 This is a marketing or model name label. 14 This is a marketing or model name label. ghi_si000290gb.fm 21

22 Safety Information 1.10 Label Locations - Procedural Labels Arctic Bear XHD-NS 1.11 Procedural Labels Ref. Label Definition 1 Important: Allow blower to run after burner is shut down to cool heat exchanger until temperature control reads 37.7 C (100 F) or lower. Failure to do so could cause overheating and failure of critical components. 2 Diesel fuel selection: This label is a guide to selecting and blending diesel fuel with additives based on temperatures at the work site. 3 After burner shutdown, run blower until temperature controller reads 37.7 C (100 F) or lower. ghi_si000290gb.fm 22

23 Arctic Bear XHD-NS Safety Information Ref. Label Definition 4 This label is an operational guide for users. 5 This label is a guide for selecting burner nozzles and setting fuel pressures based on environmental conditions at the work site. ghi_si000290gb.fm 23

24 Safety Information Notes Arctic Bear XHD-NS ghi_si000290gb.fm 24

25 Arctic Bear XHD 2 Lifting, Transporting, and Storing 2.1 Lifting the Machine Lifting, Transporting, and Storing Prerequisites Lifting equipment (crane, hoist, or fork truck) capable of supporting 3500 kg (7700 lbs.) Lifting hooks, chains, and shackles capable of supporting 3500 kg (7700 lbs.) Machine stopped and cooled. See section Shutting Down the Machine. WARNING Crushing hazard. You may be crushed if the lifting devices fail. Never stand under, or get onto, the machine while it is being lifted or moved. Use only the designated lifting points to lift the machine. Procedure Follow the procedure below to lift the machine. 1. Attach the lifting equipment to all of the lifting eyes (a) on the machine using hooks, shackles, and chains OR insert the lifting forks at the labeled locations (b) and skip to step Attach the other end of the chains to the lifting equipment. 3. Lift the machine a small distance. 4. Check for stability. If necessary, lower the machine, reposition the lifting device, and lift the machine a small distance again. 5. Continue lifting the machine as necessary. ghi_tx000999gb.fm 25

26 Lifting, Transporting, and Storing 2.2 Transporting the Machine on a Flat-Bed Truck Arctic Bear XHD Prerequisites Lifting equipment (crane, hoist, or fork truck) capable of supporting 3500 kg (7700 lbs.) Lifting hooks and chains capable of supporting 3500 kg (7700 lbs.) Transportation equipment capable of supporting 3500 kg (7700 lbs.) Machine stopped and cooled. See section Shutting Down the Machine. WARNING Crushing hazard. You may be crushed if the lifting devices fail. Never stand under, or get onto, the machine while it is being lifted or moved. Use only the designated lifting points to lift the machine. Transporting the machine on a flat-bed Follow the procedure below to transport the machine: 1. If necessary, lift the machine onto the transportation mechanism. See section Lifting the Machine. 2. Secure the machine using properly rated straps, chains, or other mechanisms attached at the labeled tie-down locations. 3. Verify that all access doors and panels are properly secured. 4. Transport the machine as necessary. ghi_tx000999gb.fm 26

27 Arctic Bear XHD 2.3 Towing the Machine Lifting, Transporting, and Storing Prerequisites Transportation equipment capable of supporting 3500 kg (7700 lbs.) Machine stopped and cooled. See section Shutting Down the Machine. WARNING This machine is not USDOT certified. Do not tow this machine on any public roads. Towing the machine Follow the procedure below to tow the machine: 1. Attach the towing vehicle s hitch to the front (a) towing hitch on the machine. 2. Verify all access doors and panels are secured. 3. Secure any stored duct work. 4. Tow the machine as necessary. Note: Do not tow this machine on public roads. ghi_tx000999gb.fm 27

28 Lifting, Transporting, and Storing 2.4 Storing the Machine Arctic Bear XHD Short term storage Long-term storage 1. Shut down the machine. See section Shutting Down the Machine. 2. Remove and store any accessories. 3. Allow the heater to cool sufficiently. 4. Verify that all control switches are in the Off position. 5. If necessary, fill the fuel tank. 1. Fill fuel tank with stabilized fuel and operate the burner for at least fifteen minutes to ensure circulation through entire fuel system. Any brand of fuel stabilizer is acceptable. 2. Allow heater to cool sufficiently. Cover the chimney and the burner with plastic wrap or other waterproof material. This will prevent corrosive moisture build-up and blockages caused by animal nests. 3. If applicable, remove the break-away battery and store in a cool, dry place. Connect the battery to a trickle charger once every 30 days to maintain full charge. 4. Shut and lock all doors. 5. Cover the exhaust outlets with waterproof covering. 6. If applicable, protect the trailer tires from direct sun light. 7. When removing from storage, the machine must be prepared for operation. See section Preparing the Machine for Seasonal Operation. ghi_tx000999gb.fm 28

29 Arctic Bear XHD 2.5 Preparing the Machine for Seasonal Operation Lifting, Transporting, and Storing Prerequisites Background Machine removed from storage. After removing the machine from long-term storage, it must be prepared for operation. This page indicates the procedures that must be performed before each seasonal use. Machine Remove any protective coverings from the exhaust outlets. Clean all enclosures. Heater Remove any carbon buildup from the heater and burner assemblies. Replace the burner nozzle. See section Replacing the Burner Nozzle. Verify burner electrode position. See section Checking and Adjusting the Electrode Position. Verify fuel pump pressure. See section Testing the Burner Exhaust and Adjusting the Settings. Verify burner combustion quality. See section Testing the Burner Exhaust and Adjusting the Settings. Electrical Systems Inspect all wires for damage, corrosion, or wear. Replace if necessary. Inspect all controls for damage, corrosion, or wear. Replace if necessary. Verify that the intended power source is properly rated. See section Technical Data for power requirements. Fluid Systems Inspect all hoses and couplings for wear or damage. Replace if necessary. Replace the fuel filter element. See section Replacing the Fuel Filter. Your machine is now prepared for seasonal operation. Continue to section Positioning the Machine. ghi_tx000999gb.fm 29

30 Lifting, Transporting, and Storing Arctic Bear XHD ghi_tx000999gb.fm 30

31 Arctic Bear XHD-NS 3 Operation 3.1 Application Operation Intended Purpose System Components Description This machine is an extra-heavy-duty, Mobile Indirect-Fired Air Heater intended to provide temporary air heat on construction sites. Do not use this machine for any other purpose. The Mobile Indirect-Fired Air Heater machine consists of: Mounted trailer including a jack stand. Rear hitch for towing a smaller trailer. Heavy-duty stainless steel heat exchanger. Diesel burner. Dual fuel tank system to accomodate alternative fuel usage. LED running lights. 10 kw generator. The indirect-fired air heating system utilizes a diesel burner that indirectly warms the air. The air is heated through the use of a stainless steel heat exchanger. The warmed air is pushed out of the machine using an on-board blower. The 10 kw generator provides constant power to the machine during operation. The LED running lights are illuminated when the generator is running. ghi_tx001000gb.fm 31

32 Operation 3.2 Operation and Maintenance Locations - External Arctic Bear XHD-NS Ref. Description Ref. Description a Trailer hitch (pintle style) k Heater exhaust b Duct storage basket l Performance monitoring light c Burner access door m Running light d Lifting eyes n Surge brake e Cabin exhaust o Generator auxiliary power output f Fire extinguisher bracket p GFCI protected outlet (auxiliary city power output) g Fuel fill locations q Rear hitch h Side access door r Air output (duct adapter) i Tie-down location s Air intake j Jack stand t Trailer ghi_tx001000gb.fm 32

33 Arctic Bear XHD-NS 3.3 Operation and Maintenance Locations - Internal Operation Burner access door Ref. Description Ref. Description a Heat exchanger h Burner fuel pump b Burner fuel filter (with priming bulb i Burner head adjustment screw and water separator) c Snap disc switch j Burner ignition transformer d Burner fuel pressure gauge k Burner primary control e Burner l Burner blower motor f Generator fuel pump m Generator fuel filter (with water separator) g Air pressure differential switch (located behind item b) ghi_tx001000gb.fm 33

34 Operation Arctic Bear XHD-NS 3.4 Operation and Maintenance Locations - Internal (continued) Side access door Ref. Description Ref. Description a 120 VAC control panel (not shown) f Engine air filter b 12 VDC control panel (not shown) g Engine fuel filter c Generator h Engine radiator d Engine i Engine oil level indicator e Blower j Engine battery ghi_tx001000gb.fm 34

35 Arctic Bear XHD-NS 3.5 Obtaining Power from the Machine Operation Prerequisites Machine prepared for seasonal operation. See section Preparing the Machine for Seasonal Operation. Machine properly positioned. See section Positioning the Machine. Procedure To obtain power to the machine, carry out the following procedure: 1. Verify that all control switches are off. 2. Connect a properly rated connector to the generator auxiliary power output (a) on the side of the machine. See section Technical Data for power requirements. The procedure to obtain power from the machine is now complete. Continue to section Starting the Machine. ghi_tx001000gb.fm 35

36 Operation 3.6 Before Starting Arctic Bear XHD-NS Prerequisites Machine properly positioned. See section Positioning the Machine. Power connected to the machine (if using an external power source). See section Connecting External Power to the Machine. Checks Before starting the machine, check the following items: 1. Fuel verify that the tanks are filled with the correct types of fuels. See section Recommended Fuels. 2. Control switches all must be Off. 3. Duct adapters verify that the duct adapters are properly installed for the desired application. See chapter Accessories. 4. Duct work verify that the correct duct work has been properly connected to the machine. See section Installing the Heater Duct. ghi_tx001000gb.fm 36

37 Arctic Bear XHD-NS 3.7 Recommended Fuels Operation Background The fuel tank for the burner is separate from the fuel tank for the generator. The front fuel tank is to be used only for the burner and the rear fuel tank only for the generator. Precautions Always use diesel fuel. Always turn off the engine before fueling. Aways fuel the machine in a well-ventilated area. Do not smoke while fueling. Do not mix gasoline or alcohol with diesel fuel. Do not allow the fuel tank to empty. Air bubbles in the fuel lines may result. Fuel guidelines for generator Fuel guidelines for burner Refer to the guidelines below when choosing the type of fuel to use with your generator: Use the rear fuel tank. Only low-sulfur fuel can be used in this generator. Chemical additives may be used in cold temperatures to reduce gelling. Refer to the manufacturer s recommendations for blending instructions. Refer to the guidelines below when choosing the type of fuel to use with your burner: Use the front fuel tank. It is recommended to use #2 Diesel. Chemical additives may be used in cold temperatures to reduce gelling. Refer to the manufacturer s recommendations for blending instructions. ghi_tx001000gb.fm 37

38 Operation 3.8 Control Panel - AC Arctic Bear XHD-NS Ref. Description Function a Volt meter Displays the voltage output value of the generator. b Frequency meter Displays the frequency output value of the generator. c Blower On/Off switch Controls power to the blower. d Burner On/Off switch Controls power to the burner. e Temperature control - Allows the user to control the target application temperature. - Displays the setpoint and actual output air temperatures. f Burner breaker switch Provides power control and protection for the burner electrical circuit, temperature control, and Volt and frequency meters. g Main breaker switch Provides power control and protection for the AC electrical circuit. ghi_tx001000gb.fm 38

39 Arctic Bear XHD-NS 3.9 Control Panel - DC Operation Ref Description Function h Glow plug indicator light Indicates by illumination that power has been applied to the glow plug electrical circuit. i Hour meter Meters usage of the machine. j Low oil pressure override switch Provides an override for the generator s low oil pressure safety circuit in order to start the generator. k Ignition switch Allows the user to start the generator. See section Starting the Generator for more information l Exhaust fan breaker reset Provides circuit protection for the cabinet exhaust fan electrical circuit. m Main DC breaker reset Provides protection for the main DC circuit (including the starter motor on the generator). n Battery disconnect switch Allows the user to control power to the DC electrical circuit (disconnects the battery). ghi_tx001000gb.fm 39

40 Operation Arctic Bear XHD-NS 3.10 Positioning the Machine Prerequisites Machine prepared for seasonal operation. See section Preparing the Machine for Seasonal Operation. Guidelines Use the following guidelines when positioning the machine for normal operation: Place machine near application area. Install chocks under the wheels, if necessary. Level the machine using the trailer jack, if available. Place the machine on solid, stable ground. Note: The machine may be air lifted to the top of a structure for operation if necessary. Use the lifting point to do so. Your machine is now properly positioned. Continue to perform the Before Starting checks. ghi_tx001000gb.fm 40

41 Arctic Bear XHD-NS 3.11 Installing the Heater Duct Operation Prerequisites 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. Procedure 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. The procedure to install the heater duct is now complete. ghi_tx001000gb.fm 41

42 Operation 3.12 Starting the Machine (Quick Start Guide) Arctic Bear XHD-NS Prerequisites Before Starting checks completed Machine properly positioned. See section Positioning the Machine. Quick start guide To start the machine, follow these simplified steps: 1. Enable the DC circuit. See section Enabling the DC circuit. 2. Start the generator. See section Starting the Generator. 3. Enable the AC circuit and all machine components. See section Enabling the AC Circuit and Components. Your machine is now started. Be sure to continuously monitor the operating parameters during operation. See section Monitoring the Operating Parameters Monitoring the Operating Parameters Background Parameters During normal operation, the machine should be monitored to ensure maximum efficiency. The following parameters should be monitored every 8 24 hours: Parameter Fuel level (burner and generator) Burner operation Generator operation Temperature Nominal Value Maximum Not applicable; see section Testing the Burner Exhaust and Adjusting the Settings if performance is in question. Monitor the generator output and frequency on the control panel. Refer to the generator operator s manual for more information. Specific to needs in application area. ghi_tx001000gb.fm 42

43 Arctic Bear XHD-NS 3.14 Stopping the Machine During an Emergency Operation Background Stopping the machine This machine is equipped with an emergency stop pushbutton. When pressed, this pushbutton shuts down the machine and disconnects all power to the machine controls. To stop the machine and lock out all power to the controls during an emergency, carry out the following procedure: 1. Press the emergency stop pushbutton. Resetting the machine To reset the machine and unlock the power to the controls, carry out the following procedure: 1. Twist the pushbutton in a clockwise direction and pull out. Note: The pushbutton will lock into place when pulled out. 2. Continue with normal operation. See section Starting the Machine. ghi_tx001000gb.fm 43

44 Operation 3.15 Enabling the DC Circuit Arctic Bear XHD-NS Prerequisites Before Starting checks completed Machine properly positioned. See section Positioning the Machine. Enable the DC circuit Turn the battery disconnect switch (a) to the On position. The DC circuit is now enabled. Continue to section Start the Generator. ghi_tx001000gb.fm 44

45 Arctic Bear XHD-NS 3.16 Starting the Generator Operation Prerequisites Before Starting checks completed Machine properly positioned. See section Positioning the Machine. DC circuit enabled. See section Enabling the DC Circuit. Start the generator To start the generator, carry out the following procedure: 1. Turn and hold the ignition switch to GLOW PLUG (a). 2. When the Generator Glow Plug indicator light (b) illuminates (up to 20 seconds), release the ignition switch (returns to OFF). Note: If the glow plug Indicator light does not illuminate, release the ignition switch and repeat steps Simultaneously, press and hold the low oil pressure override button (c) and turn and hold the ignition switch (a) to START. c c ghi_gr Release the ignition switch (returns to RUN) when the generator engine has started. Continue to hold the low oil Pressure button (c). 5. Release the low oil pressure button (c) when the generator engine is running smoothly. The generator is now started. Continue to Enable the AC Circuit and Components. ghi_tx001000gb.fm 45

46 Operation 3.17 Enabling the AC Circuit and Components Arctic Bear XHD-NS Prerequisites Before Starting checks completed Machine properly positioned. See section Positioning the Machine. DC circuit enabled. See section Enabling the DC Circuit. Generator started. See section Starting the Generator. Enable the AC circuit To enable the AC circuit and start the machine components, carry out the following procedure: 1. Move the main breaker switch (a) to ON. 2. Move the burner breaker switch (b) to ON. Verify that the volt and frequency meters (c and d) are within nominal operational values. Enable the blower 3. Move the blower On/Off switch (e) to ON. WARNING Explosion hazard. If the blower is not operating properly, fumes inside the machine may cause an explosion resulting in death, severe injury, or damage to the machine. Stop immediately. See section Troubleshooting for more information. This procedure continues on the next page. ghi_tx001000gb.fm 46

47 Arctic Bear XHD-NS Enable the burner Continued from the previous page. Operation 4. Set the desired application temperature. Refer to section Temperature Controller for more information. 5. Move the burner On/Off switch (f) to ON. Note: The burner will perform a series of automated safety checks and will ignite after approximately 35 seconds. Your machine is now started Temperature Controller Controller Components Ref Item Description/Function a Set value display (SV) Displays the set value temperature. b Process value display (PV) Displays the discharge air temperature. c C1 indicator Indicates a call for heat. d Temperature unit indicator Indicates the units for the displayed values. e Down arrow Allows the user to decrease the SV. f Up arrow Allows the user to increase the SV. ghi_tx001000gb.fm 47

48 Operation Arctic Bear XHD-NS 3.19 Shutting Down the Machine WARNING Burner exhaust CAN KILL YOU IN MINUTES. Burner exhaust contains carbon monoxide. This is a poison you cannot see or smell. Wait five minutes or until the discharge air temperature (PV) is less than 49 C (100 F) before proceeding. CAUTION Hot surface hazards. Personal injury or damage to the machine may occur. The emergency stop switch is intended for use only in an emergency situation. Do not use the Emergency Stop switch to shut down the machine during normal operation. Shut down the machine components and AC circuit To shut down the machine components and the AC circuit during normal operation, carry out the following procedure: 1. Move the burner On/Off switch (a) to OFF. 2. Move the blower On/Off switch (b) to OFF after the discharge air temperature (PV) is less than 49 C (100 F). 3. Move the main breaker (c) and burner breaker (d) switches to OFF. This procedure continues on the next page. ghi_tx001000gb.fm 48

49 Arctic Bear XHD-NS Shut down the generator and DC circuit Continued from the previous page. Operation To shut down the generator and the DC circuit, carry out the following procedure: 1. Turn the ignition switch (e) to OFF. 2. Turn the battery disconnect switch (f) to OFF. The machine is now shut down. ghi_tx001000gb.fm 49

50 Operation Notes: Arctic Bear XHD-NS ghi_tx001000gb.fm 50

51 Arctic Bear XHD-NS 4 Accessories 4.1 Available Accessories Accessories Available accessories Configuration The following accessories are available at your local Wacker Neuson distributor: Ref. Duct adapter (diameter) Ref. Heater Duct (diameter X length) a 2 X 12 in d 12 in X 24 ft b 16 in e 16 in X 20 ft c 20 in f 20 in X 20 ft These accessories offer three options for configuring the duct work on the machine. See sections Removing and Installing a Duct Adapter and Connecting the Ductwork for more information. ghi_tx001001gb.fm 51

52 Accessories 4.2 Removing and Installing a Duct Adapter Arctic Bear XHD-NS Prerequisites Machine shut down and cooled. See section Shutting Down the Machine New duct adapter. See section Available Accessories. CAUTION Hot surface hazard. The duct adapter and associated panels may be very hot upon shutting down the machine. Allow the machine to cool before installing a different duct adapter. Procedure To install a duct adapter, carry out the following procedure: 1. Remove the 12 bolts (a) and the currently installed duct adapter (b). 2. Install a new duct adapter and replace the bolts (a). The procedure to remove and install a duct adapter is now complete. ghi_tx001001gb.fm 52

53 Arctic Bear XHD-NS 5 Maintenance 5.1 Periodic Maintenance Schedule Maintenance Interval* (hours of service) Daily 2 Week 6 Month Yearly Task --- (50) (1000) (1200) Machine Clean the air intake area with compressed air. Clean the machine interior. As needed Replace the external fuel filter for the generator (with water separator bowl). Replace the burner fuel filter (with priming bulb). Burner Test the burner exhaust and adjust the settings. As needed or upon changing job sites Replace the burner nozzle. Or as needed Generator (refer to the manufacturer s literature) Replace the engine fuel filter. Replace the air filter. Replace the engine oil. Blower Inspect/lubricate the blower bearings. Clean the blower motor. Inspect the blower drive belts. Inspect the blower drive pulleys. * Use whichever comes first ghi_tx001002gb.fm 53

54 Maintenance 5.2 Inspecting and Lubricating the Blower Bearings Arctic Bear XHD-NS Prerequisites Inspect and lubricate the drive bearings Machine shut down and cooled. See section Shutting Down the Machine. To inspect and lubricate the drive bearings, carry out the following procedure: 1. Remove the blower access cover (a). 2. Lubricate the pillow block bearings (b) on both ends of the drive shaft. Refer to section Technical Data for lubrication specifications. 3. Inspect the bearing set screws (d) for tightness. Tighten if necessary. The procedure to inspect and lubricate the blower bearings is now complete. ghi_tx001002gb.fm 54

55 Arctic Bear XHD-NS 5.3 Cleaning the Blower Motor Maintenance Prerequisites Clean the blower motor Machine shut down and cooled. See section Shutting Down the Machine. To clean the blower motor, carry out the following procedure: 1. Remove the blower access cover (a). 2. Use a dry cloth to clean the air intake grate (c) on the blower motor. The procedure to clean the blower motor is now complete. ghi_tx001002gb.fm 55

56 Maintenance 5.4 Inspecting the Blower Drive Belts Arctic Bear XHD-NS Prerequisites Check belts for tension and wear Machine shut down and cooled. See section Shutting Down the Machine. To check the belts for wear and proper tension, carry out the following procedure: 1. Remove the blower access cover (a). 2. Inspect the drive belts (e) for wear. Replace if necessary. 3. Measure the belt deflection. If necessary, adjust the tension using the L-shaped bolts (f). Note: The belt deflection measurement must be mm ( in). The procedure to check the belts for proper wear and tension is now complete. ghi_tx001002gb.fm 56

57 Arctic Bear XHD-NS 5.5 Inspecting the Blower Drive Pulleys Maintenance Prerequisites Check the pulleys for wear Machine shut down and cooled. See section Shutting Down the Machine. To check the pulleys for wear, carry out the following procedure: 1. Remove the blower access cover (a). 2. Remove tension from the drive belts using the L-shaped bolts (f). 3. Remove the drive belts from the pulleys. 4. Inspect the pulleys for wear. Refer to the graphic below. Replace if necessary. ghi_tx001002gb.fm 57

58 Maintenance Arctic Bear XHD-NS 5.6 Testing the Burner Exhaust and Adjusting the Settings Prerequisites Combustion analyzer Smoke spot tester Precautions All adjustments must be accomplished by a licensed professional. All adjustments must conform to local, state, and federal codes. All adjustments should be made on site. When to adjust Factory fuel type Adjusting fuel pressure Before operating at elevations 305 m (1,000 ft.) above or below the elevation of the previous work site. Before starting at a new work site. After any burner maintenance has been performed. When burner performance is in question for any reason. The burner on this machine was calibrated by test-firing for correct operation at Wacker Neuson Corporation located 180 m (600 ft.) above sea level using a 70/30% blend of #2 and #1 diesel fuel combined with an anti-gelling additive. Follow the procedure below to adjust fuel pressure. 1. Move the burner switch to the On position. 2. Turn the adjusting screw (a) clockwise to increase pressure, counter-clockwise to decrease pressure. 3. Verify the pressure setting on the fuel pressure gauge (b). Checking O 2 content Follow the procedure below to check the O 2 content. 1. Follow the combustion analyzer manufacturer s instructions for setup and exhaust sampling. 2. Insert the combustion analyzer s probe into the gas analyzer access hole located on the exhaust stack. Exhaust O 2 content must be 3 to 4% for optimum performance and minimum soot production. Several samples should be taken as the heater warms. The final sample should be taken just before the heater reaches 160 F. This procedure continues on the next page. ghi_tx001002gb.fm 58

59 Arctic Bear XHD-NS Smoke spot sampling Continued from the previous page. Follow the procedure below to take a smoke spot sample. Maintenance Note: Follow the smoke spot tester manufacturer s instructions for accurate exhaust sampling. When testing: Several samples should be taken as the heater warms. The final sample should be taken just before the heater reaches 160 F. Higher O 2 percentage (excess air settings) lowers soot production but raises stack temperature and reduces efficiency. Lower O 2 percentage (inadequate air settings) increases efficiency and lowers stack temperature but may cause soot build-up. A burner optimized for clean and efficient operation will have O 2 levels of 3 to 4% and a smoke spot value of 1 or less. 1. Loosen the air damper locking screws enough to provide movement for adjustment. 2. Move the burner switch to the On position. The burner will begin a 15-second pre-purge followed by the ignition sequence. 3. Once the burner lights, sample the exhaust. 4. Adjust the air damper until combustion parameters fall within the above outlined values. Contact Wacker Neuson Product Support for assistance. The procedures to analyze the combustion are now complete. ghi_tx001002gb.fm 59

60 Maintenance Arctic Bear XHD-NS 5.7 Removing and Installing the Combustion Head Assembly Prerequisites Machine shut down. See section Shutting Down the Machine. Burner cooled. Allow the machine to cool for a minimum of ten minutes. When to remove When replacing the burner nozzle. See section Changing the Burner Nozzle. When checking/adjusting the electrode position. See section Checking and Adjusting the Burner Electrodes. When replacing other burner parts that require the combustion head assembly to be removed. Removal To remove the combustion head, carry out the following procedure: 1. Remove the screw (a) that secures the ignition plate (b) to the top of the burner and swing the plate open. 2. Loosen the fuel line coupling (c) at the elbow fitting. Let the fitting fall away from the end of the tube. 3. Carefully lift and pull the combustion head assembly (d) out of the flame tube. The combustion head is now removed. This procedure continues on the next page. ghi_tx001002gb.fm 60

61 Arctic Bear XHD-NS Reinstallation Continued from the previous page. Maintenance To reinstall the combustion head assembly, carry out the following procedure: NOTICE: Do not force the combustion head assembly into the flame tube. Failure to comply may damage the assembly. 1. Carefully insert the combustion head assembly (d) into the flame tube. 2. Seat the oil tube bracket into the slot on the adjusting screw (e). 3. Reconnect the fuel line coupling (c) at the elbow. 4. Close the ignitor plate (b) and tighten the screw (a). The combustion head assembly is now reinstalled. ghi_tx001002gb.fm 61

62 Maintenance 5.8 Replacing the Burner Nozzle Arctic Bear XHD-NS Prerequisites Machine shut down. See section Shutting Down the Machine. Burner cooled. Allow the machine to cool for a minimum of ten minutes. Combustion head assembly removed. See section Removing and Installing the Combustion Head Assembly. When to replace Once per year, if necessary. When the burner is not firing. When the burner performance is in question for any reason. NOTICE: Improper handling of the burner parts may cause damage. Use caution when handling these parts. Procedure To replace the nozzle, carry out the following procedure: 5. Loosen the screw (a) and remove the flame retention ring (b). 6. Support the assembly with your hands and remove the nozzle (c). 7. Install and hand tighten a new nozzle (c). This procedure continues on the next page. ghi_tx001002gb.fm 62

63 Arctic Bear XHD-NS Continued from the previous page. Maintenance 8. Fully tighten the nozzle by placing a wrench on the nozzle adapter (d) and the nozzle (c). 9. Reinstall the flame retention ring (b) and tighten the screw (a). 10.Replace the combustion head assembly. See section Removing and Installing the Combustion Head Assembly. The procedure to replace the burner nozzle is now complete. ghi_tx001002gb.fm 63

64 Maintenance 5.9 Checking and Adjusting the Electrode Position Prerequisites Machine shut down and cooled. Arctic Bear XHD-NS Combustion head assembly removed. See section Removing and Installing the Combustion Head Assembly. When to adjust Checking Once per year, if necessary. When the burner is not firing properly. To check the electrode position, measure the following distances: between tips (a) electrode to nozzle (b) electrode tip to nozzle centerline (c) Refer to the table below for the correct dimensions. Adjusting Dimensions To adjust the electrodes, loosen the screw (d), move to the correct position, and tighten the screw. Refer to the tabel below for the correct dimensions: Ref Measurement a 3.18 mm (0.125 in) b mm ( in) c 6.35 mm (0.25 in.) ghi_tx001002gb.fm 64

65 Arctic Bear XHD-NS 6 Basic Troubleshooting 6.1 Troubleshooting the Burner Basic Troubleshooting Problem / Symptom Reason Remedy The burner does not start. Improper switch position. Verify the breaker is On The over-temperature limit has tripped. Allow the burner to cool. The burner starts; the flame does not ignite. The burner starts and the flame ignites, but the unit locks out. Combustion is poor or noisy. The wire and/or power supply is faulty. The burner primary control is in lockout mode. There is no fuel. The burner nozzle is damaged or worn. The electrodes are defective. The cadmium cell is defective. The burner primary control is defective. The fuel pressure is set incorrectly. The burner nozzle is damaged or worn. The air damper is set incorrectly. The cadmium cell is defective. The burner primary control is defective. There is a lack of fresh air to burner. Replace the faulty wire or power supply. Reset the burner control. Fill fuel tank. Replace the burner nozzle. Replace the electrodes. Replace the cadmium cell. Replace the burner primary control. Adjust the fuel pressure. Replace the burner nozzle. Adjust the air damper. Replace the cadmium cell. Replace the burner primary control. Ensure there is an adequate air supply. ghi_tx001003gb.fm 65

66 Basic Troubleshooting 6.2 Troubleshooting the Generator Engine Arctic Bear XHD-NS Refer to the operator s manual for the generator engine for more information. Problem / Symptom Reason Remedy Difficulty starting engine Fuel is thick and does not Check the fuel tank and fuel flow. filter. Air or water mixed in fuel system. Valve clearance is not as specified. Leaking valves. Fuel injection is not as specified. Engine oil becomes thick in cold weather and engine cranks slow. Low compression. Battery is discharged and the engine will not crank. Remove water, dirt and other impurities using kerosene. If air is in the fuel filter or injection lines, the fuel pump will not work properly. To attain proper fuel injection pressure, check carefully for loosened fuel line coupling, loose cap nut, etc. Loosen join bolt stop fuel filter and air vent screws of fuel injection pump to eliminate all the air in the fuel system. Adjust valve clearance to to mm ( to in.) when the engine is cold. Grind valve. Check injection timing. Change grade of oil according to the temperature. Check valves, rings, pistons and liner for wear. Replace with new parts if necessary. Charge battery. In winter, always remove battery from machine, charge fully and keep indoors. Install in the machine at time of use. ghi_tx001003gb.fm 66