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E 2200 E 3000ES

1. wc 01007817 4 Position the HEAT XCHANGERS within the space to be heated 5 Connect the HEAT XCHANGER supply hoses a to the HTF supply line b 6 Connect the HEAT XCHANGER return hoses c to the accessory HTF return port d On E 3000ES machines use a 1 2 connector 9 7 Insulate the supply and return hoses 8 Close the Pump Pack HTF supply valves f 9 Connect the HEAT XCHANGERS to the appropriate electrical sources NOTICE Only turn on the pumps when the HEAT XCHANGERS are connected Turning on the pumps when the HEAT XCHANGERS are not connected will cause excess system pressure which will damage the pumps 10 Start the parent machine Operate the parent machine with the temperature controller set to 80 C 180 F 11 Turn on the HEAT XCHANGERS and adjust their thermostats as desired Resu
2. wc 01007818 Position the HEAT XCHANGERS within the space to be heated Connect the 1 2 adapters a to the supply lines b Connect the HEAT XCHANGER supply hoses e to the 1 2 adapters a Connect the HEAT XCHANGER HTF return hoses f to 2 1 adapters c Close the Pump Pack HTF supply valves h ON O Ff Insulate the supply and return hoses 10 Connect the HEAT XCHANGERS to the appropriate electrical sources NOTICE Only turn on the pumps when the HEAT XCHANGERS are connected Turning on the pumps when the HEAT XCHANGERS are not connected will cause excess system pressure which will damage the pumps 11 Start the parent machine Operate the parent machine with the temperature controller set to 80 C 12 Turn on the HEAT XCHANGERS and adjust their thermostats as desired Result The HEAT XCHANGERS have now been connected WACKER wc tx001668g
3. EMERGENCY SHUTDOWN PROCEDURE WARNING ON BREAKER 1 ON or LL m o OFF a HOURS E L J LINE 1 GFI LINE 2 GFI FTS N DANGER HAZARDOUS VOLTAGE Do not operate without this cover in place Disconnect and lock out power source before opening panel Could cause severe injury or death BURNER LOW LEVEL FAULT FAULT REFER TO OPERATOR MANUAL TO CLEAR T FAULTS PEE TEMPERATURE HTF FILL CONTROL ON ON ON ON ON OFF OFF OFF OFF OFF PUMP 1 PUMP 2 BURNER REWIND LIGHT pf L oe wc 1008054 WACKER un NEUSON 32 _tx001667gb f 2200 3000 5 Operation 4 4 Control Panel Components Temperature controller Allows the user to control the HTF target application temperature Shows the actual temperature of the HTF Cab light ON OFF switch Switches electric power ON and OFF to the cab light Hose rewind ON OFF switch owitches electric power ON and OFF to the hose rewind motor Burner ON OFF switch Switches electric power ON and OFF to the burner Pump 2 ON OFF switch owitches electric power ON and OFF to Pump 2 Pump 1 ON OFF switch Switches electric power ON and OFF to Pump 1 HTF fill switch This momentary switch bypasses the low level shut down device and provides power to the pumps It is used when filling
4. ghi gr006489 v 76 wc tx001668gb fm 2200 3000 5 Burner Setup 6 Burner Setup Firing rate Fuel pressure Air band Adjusting L hr gph bar psi setting settings Background Fuel Tools required Mandates wc tx001669gb fm Vi 68 1 80 135 70 B 1240180 1 10 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 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 C Generator powered Shore powered 50 50 blend of 2 diesel 100 1 diesel plus and 1 diesel plus additives additives OR Below 5 15 OR 100 K1 kerosene 50 50 blend 2 diesel and plus additives K1 kerosene plus additives 70 30 blend of 2 diesel and 1 diesel plus additives OR to 25 15 to 4 70 30 blend of 2 diesel and K1 kerosene plus additives Above 25 4 Winter blend diesel The following tools are required to adjust the burner a High quality combustion analyzer Smoke spot tester Fuel pressure test gauge General hand tools Adjustm
5. 29 4 Operation 30 4 1 Control Component Locations 30 4 2 Control Component Descriptions 31 4 3 COOOL VS 32 4 4 Control Panel Components 33 4 5 Pumps Gauges and Valves 2 34 4 6 Preparing the Machine for First Use 35 4 7 General Sequence of Operation 2 2 36 4 8 Recommended nennen nennen nnns 37 4 9 Positioning the Machine qe 38 4 10 Pre Starting Checks 40 4 11 Connecting Power to the Machine 2 42 4 12 Starting and Stopping the Generator 43 4 13 Preheating the HTF nennen 44 4 14 Initiating HIF Flow 45 4 15 Setting the Operating Temperature 47 4 16 Positioning the Hoses and Operating the Machine 48 4 17 Monitoring the Operating Parameters 50 WACKER wc bo0192779en 001TOC fm 5 NEUSON 2200 3000 5 wW NEUSON 4 18 Stopping the Machine Temporarily 51 4 19 Pe WINGIG NG TAO SCS TO 52 4 20 Shutting Down Packing Up the Machine 54 4
6. BURNER wc_gr008064 wc 1007892 4 Move the hose rewind ON OFF switch d to the ON position Note 7he rewind motor will start but will not rotate the hose reel until the clutch 15 engaged 5 Press down on the foot pedal to engage the clutch The hose reel will rotate 6 Guide hose loop 2 evenly onto the hose reel as it rotates This procedure continues on the next page i WACKER ve tx Ww NEUSON 52 _tx001667gb f 2200 3000 5 Operation Result wc tx001667gb fm Continued from the previous page NOTICE Disengage the clutch release the foot pedal before reaching the hose end Failure to do so may damage the machine 7 Release the foot pedal to disengage the clutch approximately six feet from the end of the hose 8 Manually wind the remainder of the hose onto the reel 9 Move Pump 2 ON OFF switch to the OFF position 10 Connect hose loop 1 to hose loop 2 a SESS SW TI OFF BURNER wc gr007803 wc 0008065 11 Move Pump 1 ON OFF switch e to the ON position 12 Rewind hose loop 1 as you did hose loop 2 13 Pump 1 ON OFF switch to the OFF position 14 Engage the hose reel brake by turning the T handle a clockwise 15 Return the foot pedal to its storage location 16 Move the burner ON OFF switch f to the OFF position The hoses are now wound onto the hose reel and your machine is ready to be placed into storage See topic Storing the Machine
7. Juv 0 1 00063 00065 00223 N0023 00119 TAGOW S3 YIVA 38n 1 VH3dW3 L MOT Lac Cd gt es EW IW 9O 19 Suv3ddv 1950 NWYON ovu avad 5 938ACN N3389 ONIHSV 14 NID38 TIM W38NfN Q3AV 1dSKH SI 291 3SV4 TH JHL C 10H SSd ud JHL JO 3HL dY L N33u5 3HL SONO dY L OH SS3ud Suv3ddv 1950 NMWHON MOT38 SCIND SANOdSJYYOD ONIHSV 14 NID38 TIM Q3AV IdSH SI 1 AS IdS SIT NJAM ASV TH JHL ILUNA SSd ud JOWA SHLTLNA dvb SYSEWWAN N3399 3HL IONO TUNN A aad vadas avc SS3ud 8 o inna SdVaddV 1950 MAHON odz va noHs N3aso ONIHSV 14 NID38 TIM Q3AV 1dSKH SI 291 3SV3 HW JHL IUNN SSd ud JHL 3O INWA HL FIOM dv N33W9 HL IONO dY L SS3ud ONILSRfP QOIOV 1 1 MOT 122 gb fm wc tx001673 Fuji Temperature Controller Fuji Temperature Controller High Temperature Limit Adjusting 012 sjepou Jeeg 081 00063 00065 00223 N0023 00113 TAGOW A8 S3fYIVA SHYNLVaAdWAL H9IH Suv3ddv AV1dSIC MAHON OMLQV3G INOHKS W38ACN N33995 ONIHSV 14 NID38 TIM Q3AV laSK SI 207 N3HM 3S V3 TH JHL IUNN C 1OH S SSdud JHL JO ANTWA HHL
8. D MSSR Operation E 2200 E 3000ES 4 20 Shutting Down and Packing Up the Machine Shutting Perform the procedure below to shut down the machine d m 1 Move the burner ON OFF switch a to the OFF position wc gr008066 2 Move the pump ON OFF switches 6 and to the OFF position 3 Turn off all accessories if applicable 4 Rewind the hoses See topic Rewinding the Hoses 5 Move the circuit breaker ON OFF switches e to the OFF position wc gr008067 The machine is now shut down and ready to be packed up Packing up Perform the following procedure to pack up the machine the machine 1 Disconnect and store all accessories 2 Disconnect power from the machine 3 Close and lock all doors The machine is now ready to be stored W NEG AMT 54 wc tx001667gb fm 2200 3000 5 Operation 4 21 Resetting a Low HIF Level Fault Requirements Genuine Wacker Neuson Heat Transfer Fluid Power connected to the machine NOTICE Use only factory recommended Heat Transfer Fluid HTF Failure to do so may damage the machine Background The HTF reservoir includes a sensor that will trigger the low level shut down device to stop the machine s function if the HTF falls below the minimum operational capacity During a low HTF level condition the following occur he control panel low level fault light illuminates Power is disconnected from the burner Power is disconnected
9. Machine cool Procedure Follow the procedure below to clean change the turbulator tubes 1 Allow the machine to cool WARNING Burn hazard The hydronic heater is very hot when the machine is operating When hot it can cause severe burns gt Allow the machine to cool before performing this procedure 2 Remove the nuts a that secure the flue box door ghi gr005628 ghi gr005627 3 Open the flue box door b NOTICE f the door panel insulation does not open with the door carefully remove it from where it is caught on the bolts c Inspect all panels for damaged insulation Replace all damaged panels 4 Locate the turbulators housed in the burner tubes ghi gr005629 5 Remove the turbulators d by pulling the turbulator tab Replace any turbulator that is badly eroded 6 Clean each burner tube with a bottle brush 7 Vacuum out each burner tube WACKER un p wy NEUSON 102 _tx001670gb f 2200 3000 5 Maintenance 8 Remove the exhaust stack e both inner and outer panels wc gr008079 9 Vacuum out the exhaust ducting f and the heater 10 Reinstall the exhaust stack 11 Reassemble the machine Result The procedure is now complete wc tx001670gb fm 103 Maintenance E 2200 E 3000ES 7 10 Inspecting Replacing the Rope Gasket Requirements Integrity inspection AN Replace the rope gasket Machine shut down Machine cool Follow the
10. LOW WATER red e lights will blink for fifteen seconds while the low level shut down device performs a self diagnostic test wm After 15 seconds the LOW WATER light will go out the POWER light will stay on The low HTF level indicator will go out Power will be returned to the pump circuit Power will be returned to the burner circuit This procedure continues on the next page Ww NEG CON 56 wc tx001667gb fm 2200 3000 5 Operation Continued from the previous page 2 Move the fill valve 3 to the CLOSED position and insert the pin wc 01007810 3 Move the operation valve 2 to the OPEN position 4 Clean the fill hose and cap the fill hose if a cap is provided 5 Return the fill hose to its storage location under the hose reel Result The machine is now ready for operation wc tx001667gb fm 57 Ww MEGCON Operation E 2200 E 3000 5 4 22 Quick Connect Coupling Usage and Care CAUTION Burn hazard The hoses and components of the plumbing system may be very hot Hot hoses and hot plumbing components may cause severe burns gt Wear gloves when handling hot hoses and plumbing components Precautions Do not join or separate quick connect couplings when the pressure gauge indicates the lines are pressurized Do not join or separate quick connect couplings when the HTF temperature is above 48 C 120 F Do use damaged quick connect couplings Do not u
11. The HTF temperature is below 26 C 15 F The hose reel brake is not Fully release the hose reel fully released brake The motor temperature is below nominal value lt 18 C 0 F Warm the enclosure by run ning the burner with all doors closed or warm the enclosure using an exter nal heat source The foot pedal switch has Replace the foot pedal failed switch The operation valve is not Verify that the operation fully open valve is fully open Warm the HTF and hoses before starting machine see topic Preheating the HTF in this manual The HTF temperature is below 26 C 15 F The strainer basket is clogged Clean the strainer basket see topic Cleaning the HTF Strainer Hose loops not seperated Separate the hose loops WACKER 109 NEUSON wW Technical Data E 2200 E 3000ES 9 Technical Data 9 1 E2200 Item No Item No Item No Item No 0620176 0620215 0620216 0620226 Weight no fuel no genera 2139 4715 tor Weight full fuel no genera kg Ib 2618 5772 tor rom _ Wem wT 2 265 Bumermakemode Becket AFGGHIO6 4 Fuel input KW hr 7 BTU hr 252 000 i BTU hr 220 000 Heater efficiency foo d 204 409 2200 4400 MEOSGN 110 wc td000422gb fm 2200 3000 5 Technical Data 9 2 E 3000ES Item No Item No 0620967 0620968 oem me em Wem a _ 2 265 Burner make model Beok
12. a T YILIN MnOH d 3 3 Po 1 ONIMI 3SOH Ind St fo SS HO al Ro 775 77 75 PE 1 g a a a 7 P pee x 8 c6 N UNE Md DRE M L 4 N H T 22 22 Linv4 p 6 J Linv4 14A31 MOT 41735 zo dH ec vii 57 HO x 820 di as 9 a ot 22 dH ZI amp Ho 7 9 S L9 eS 2 dWnd amp U Iz ANY IN3AOA ug HO 02 T13A31 MOT 04 Se Ne ME ee ee un 61 MOVd 2 318VN3 SdWNd jsvud gi ZHO9 2 02 072 Ove E d 9 9 eV z 980 2 T3431 MOI ond ie J 0 2VAOZI Lk AN LV INNT WO3J LN LN ZN QVAOZ I 2 021 1 zi WACKER NEUSON 2200 3000 5 Schematics 10 2 Electrical Schematic Components Use the following table of symbols for the schematics found throughout this chapter ee _____ Circuit breaker 1 Ground Fault Circuit Interrupt 1 Hose rewind Off On switch HOSE REWIND io Rewind motor Pump motor Burner motor Rewind transformer To line 30 To line 29 FISW1 Foot switch 1 Solenoid 1 rewind clutch 7 K3 Relay coil wc tx001672gb fm 1 25 M MEOSGR Sche
13. first use 1 Make sure all loose packaging materials 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 WACKER wc tx001667gb fm 35 VY EU SON Operation E 2200 E 3000 5 47 General Sequence of Operation Follow the sequence of operation below Refer to the specific topic for details When Where See m C 1 Check HTF level HTF level 11 Check HTF level Before leaving for the job site 4 410 Or when at the job site before 2 Check fuel level daily operation 4 10 3 Position the machine At the job site 4 9 4 Connect power 4 11 5 Perform Pre Starting checks 4 7 Preheat the HTF if necessary and 13 4 14 initiate HTF flow 8 Set the operating temperature 4 415 9 Unwind and position the hoses 4 16 10 Monitor the operating parameters 4 17 11 Rewind the hoses 4 19 12 Stop the machine 4 18 13 Shut down and pack up the machine 4 20 4 WACKER Wed i NEUSON 36 _tx001667gb f 2200
14. Checks Before starting the machine check the following items Fuel System Fuel sight gauge valve a gt Check that the fuel sight gauge valve is open Fuel sight gauge b gt Check that there is fuel in the tank Suction valve 2 Checkthat suction valve 2 is opened HTF fill valve 3 gt Check that HTF fill valve 3 is closed and locked with the locking pin wc gr007784 NOTICE The HTF fill valve must remain closed and locked during normal operation An open HTF fill valve will cause HTF leakage MEOSGN 40 wc tx001667gb fm 2200 3000 5 Operation HTF sight gauge c gt Check that the HTF level is within the operating range NOTICE Starting the machine with low HTF will damage the pumps HTF Hose connections e gt Check that all HTF hose quick connects are secure Hydronic heater f gt Inspect for signs of exhaust leaks See topic nspecting Replacing the Rope Gasket wc gr008059 Result The machine is ready to have power applied Wc tx001667gb fm 41 Operation E 2200 E 3000 5 4 11 Connecting Power to the Machine Prerequisites Power source Machine properly positioned 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 Donotuse under sized extension cords Extens
15. DOWFROST HD 50 Heat Transfer Fluid Dyed COMPANY IDENTIFICATION The Dow Chemical Company 2030 Willard H Dow Center Midland MI 48674 USA Customer Information Number 800 258 2436 EMERGENCY TELEPHONE NUMBER 24 Hour Emergency Contact 989 636 4400 Local Emergency Contact 989 636 4400 2 Hazards Identification Emergency Overview Color Yellow Physical State Liquid Odor Characteristic Hazards of product No significant immediate hazards for emergency response are known OSHA Hazard Communication Standard This product is not a Hazardous Chemical as defined by the OSHA Hazard Communication Standard 29 1910 1200 Potential Health Effects Eye Contact May cause slight temporary eye irritation Corneal injury is unlikely Skin Contact Prolonged contact is essentially nonirritating to skin Repeated contact may cause flaking and softening of skin Skin Absorption Prolonged skin contact is unlikely to result in absorption of harmful amounts Inhalation At room temperature exposure to vapor is minimal due to low volatility Mist may cause irritation of upper respiratory tract nose and throat amp TM Trademark of The Dow Chemical Company Dow or an affiliated company of Dow Page 1 of 7 MSDS Dowfrost 50 Product Name DOWFROST HD 50 Heat Transfer Fluid Dyed Issue Date 12 10 2007 Ingestion Very low toxicity if swallowed Harmful effects not anticipated from swallowing small am
16. HTF system Inspect all hoses and couplings for wear or damage Replace damaged hoses and cou plings Clean the HTF strainer basket Fuel system Replace the fuel filter element With machine Perform the procedures below with the machine powered up powered up tem Task Burner m Verify fuel pump pressure m Verify burner combustion MEOSGN 1 06 wc tx001670gb fm 2200 3000 5 Maintenance Notes we_tx001670gb f 107 WAKER Troubleshooting E 2200 E 3000ES 8 Troubleshooting 8 1 Troubleshooting the Machine The burner does not start Improper switch position or Verify that the breaker is protective function action ON Verify that the HTF level is within range and low level shutdown device is reset low level indicator light must be OFF The burner primary control Reset the burner control is in lockout mode The over temperature limit Reset the thermal switch has tripped The burner starts the flame There is no fuel Fill fuel tank des ot The burner nozzle is dam Replace the burner nozzle aged or worn The electrodes are defec Replace the electrodes tive The cadmium cell is mal Replace the cadmium cell functioning The burner primary control Replace the burner primary is malfunctioning control The burner starts and the The fuel pressure is set Adjust the fuel pressure flame ignites but does not incorrectly The burner nozzle is dam Replace the burner nozzle aged
17. 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 WACKER 3 VM NEUSON Foreword MEGCON 4 wc tx001665gb fm 2200 3000 5 Table of Contents Foreword 3 1 Safety Information 9 1 1 Signal Words Used in this Manual 9 1 2 Machine Description and Intended Use _ 10 1 3 Safety Guidelines for Operating the Machine 11 1 4 SEMIC ondimentum scum UN 13 1 5 Safety Guidelines for Operating Combustion Burners 15 1 6 Safety Guidelines for Operating Gensets 16 1 7 Safety Guidelines for Towing the Machine 18 2 Labels 20 2 1 d 20 2 2 WIC AMINO 22 3 Lifting and Transporting 27 3 1 LUG TAS 27 3 2 Preparing the Machine for Transport on a Truck or Trailer 28 3 3 Before Towing
18. up and out of the burner This procedure continues on the next page WACKER Ww NEUSON 80 tx001669gb f 2200 3000 5 Burner Setup Installation wc tx001669gb fm Continued from the previous page 7 Use the measurements below to properly set the electrode tips ghi gr005523 Ret Description Gapdistance Electrode tip to electrode tip 5 32 in 4 mm Nozzle center to electrode tip 5 16 in 7 5 mm Nozzle end to electrode tip end 1 16 in 1 5 mm Follow the procedure below to install the burner nozzle 1 Thread the new burner nozzle into the burner tube Note Do not use thread sealant on the threads 2 Position the electrode nozzle assembly d into the burner AE e lt YY ya v X gr r e W x wc 07008112 wc 01008113 3 Connect the wiring 4 Close the igniter cover and secure it with tabs c This procedure continues on the next page D MSSR Burner Setup E 2200 E 3000ES Continued from the previous page 5 Install the splined knob b Note Handle the knurled knob with care It is easily damaged ghi_gr005524 6 Install the copper fuel line a between the fuel pump and the burner housing Result The electrodes have now been checked adjusted MEGCON 82 wc tx001669gb fm 2200 3000 5 Burner Setup 6 2 Prerequisites Removal wc tx001669gb fm Repla
19. wc tx001667gb fm 45 Ww NEG MIS Operation E 2200 E 3000ES Continued from the previous page NOTICE Operate only pump 1 when both hose loops are connected together Turning on pump 1 and pump 2 with the hoses connected together may cause pump damage 4 Connect hose loop 1 female QC f to the supply port male QC 5 Connect hose loop 2 male QC g to the return port female QC 5 e f wc gr007797 wc 1008063 6 Move pump 1 ON OFF switch b4 to the ON position The HTF will flow through both loops 7 Verify rising pressure by checking the pump 1 pressure gauge h and the flow indicator i wc gr007798 wc gr007799 NOTICE f the HTF reaches 170 psi 11 7 bar after only a second or two of oper ation there is a problem Shut down the machine and rectify the problem before continuing Once flow is established pressure should be 125 140 psi 8 6 9 6 bar When the HTF is warm operating pressure should be 90 110 psi 6 2 7 6 bar 8 Check the HTF flow indicator f The flow indicator should be spinning If it is not there is a problem Shut down the machine and rectify the problem before continuing Result The HTF is now flowing The hoses may now be unwound and positioned WACKER oe Ww NEUSON 46 tx001667gb f 2200 3000 5 Operation 4 15 Setting the Operating Temperature Operating Once the HTF is preheated set the temperature control
20. 12 18 in 15 cm 6 in Accelerated thaw Up to 50 faster than contractor s thaw Result The machine is now operating Monitor the operating parameters while the machine is operating See topic Monitoring the Operating Parameters we_tx001667gb fm 49 Ww MEOCON Operation E 2200 E 3000ES 4 17 Monitoring the Operating Parameters Background Monitor the machine while it is operating to ensure safe and efficient operation Parameters Monitor the following parameters every 8 24 hours Parameter NO Fuel level Add fuel as needed HTF level Add HTF as needed HTF operating pressure HTF return temperature otrobe light 4 WACKER M NEUSON Operating pressure 90 110 psi If operating pressure is higher than 110 psi check for kinked hoses If operating pressure is less that 90 psi check HTF level The HTF return temperature tells you how much heat is being transferred It can also tell you when a thawing process is complete as very little heat will be transferred at that point Consult Wacker Neuson Product Support for detailed information Flashing strobe signifies that all systems are OK 50 wc tx001667gb fm 2200 3000 5 Operation 4 18 Stopping the Machine Temporarily Precautions Stopping the machine Restarting the machine Result wc tx001667gb fm NOTICE This procedure is to be used for stopping the machine temporarily for routine maintenance such as refueling or reposi
21. 21 Resetting a Low HTF Level Fault 55 4 22 Quick Connect Coupling Usage and Care 58 4 23 Resetting the Snap Switch 59 4 24 Burner Controller Periods and Modes 60 Accessories 65 5 1 Avalla ble ACCESSONOS M eR 65 5 2 Connecting the HX 200 or HX 60 HEAT XCHANGER 66 5 9 Connecting the HX 100 or HX 30 HEAT XCHANGER 68 5 4 Connecting the HX 50 or HX 15 HEAT XCHANGERH M 70 5 5 Combining the Machine with One HHS and One DPP 72 5 6 Combining the Machine with Two HHS and Two DPP E 2200 only 74 D Mounting the Auxiliary Pump Panel 2 76 Burner Setup 77 6 1 Adjusting the Burner Electrodes 0 80 6 2 Replacing the Burner Nozzle 83 6 3 Setting the Z Distance on V1 Style Heads 86 6 4 Adjusting the Air Settings 88 6 5 Setting the Fuel Pressure 89 Maintenance 91 7 1 Periodic Maintenance Schedule 91 7 2 mis GING A FIO SE 92 fo Inspecting the HTF System and the Fuel System 94 7 4 Inspecting Electrical 95 7 5 the MTP Reservo EET
22. 96 7 6 cleaning MEET 98 7 7 Replacing the Fuel Filter 100 7 8 Lubricating the Hose Reel System 101 7 9 Cleaning the Turbulators and the Exhaust Ducting 102 7 10 Inspecting Replacing the Rope Gasket 104 7 11 SLOMMG Me 105 7 12 Preparing the Machine for Seasonal Operation 106 WACKER 6 wc bo0192779en 001TOC fm Table of Contents 2200 3000 5 Table of Contents 8 Troubleshooting 108 8 1 Troubleshooting the Machine 108 9 Technical Data 110 9 1 E 2200 e 110 9 2 zc 111 9 3 112 9 4 DIERON 113 MSDS Dowfrost HD 50 114 Fuji Temperature Controller 121 10 Schematics 124 10 1 Electrical SCEMA 124 10 2 Electrical Schematic Components 125 103 Bulther System OI OBI 128 10 4 Circulation System Circuit 129 10 5 Rewind System Circuit 2 130 wc_bo0192779en_001TOC fm 7 WACKER NEUSON 2200 3000 5 Table of Contents NEG 8 wc_bo0192779en_001TOC fm 2200 3000 5 Safety Information 1 Safety Information 11 Signal Words Used in this Manual A A A A wc_si000540gb fm This manual contains DANGER WARNING CAUTION NOTICE and N
23. Circuit 115 VAC 60HZ CB1 L 1 L2 N L3 BLK 4 ie WH mm 20A u ee ia ei i 3 Q Dm a a a a ee 1 BLK N WHT 2 H LOW LEVEL N E ORG RED m 2 6 iC 0 1 4 FL i Eo Heisse PL1 K2 1 17 2 5 C EAF LOW LEVEL FAULT K2 O N 6 16 4 2 T 8 DUPLEX 2 BURNER FAULT 2 HOUR METER IGNITION TRANSFORMER TO LINE 24 BURNER MOTOR 1 9FLA 15 1 7HP TP 16 TO LINE 24 OIL VALVE 17 18 4 fee _ ee TEMPERATURE CONTROLLER 2 18 i J ghi_gr005711 WACKER 128 wc_tx001672gb fm NEUSON 2200 3000 5 Schematics 10 4 Circulation System Circuit 115 VAC 60HZ 1 L1 L2 N 13 BLK y X WH mm 20A e e eee ee c c c C e o c c c i cm coo 1 TEL Q NUN ee ee ee ee E 1 eS 2 dine BLK H Low LEVEL N WHT 1 ORG RED 10 o 2 4 0 1 2 L Lo PL1 5 d 4 K2 ie T N p 5 E LOW LEVEL FAULT PUMP K2 2 1 6 16 23 24 56FLA
24. ENGAGE NA DISENGAGE DISENGAGE BRAKE BEFORE REVANDING APPROXIMATELY 3 4 GALLONS U S IS REPRESENTED BY EACH INCH OF FUEL OBSERVED IN THE FUEL GAUGE STROBE wc_si000541gb fm 23 between the flue box and the heater vessel for visual signs of combustion gas leakage Replace the gasket with part number P100 312 when needed per the service manual Approximately 3 4 gallons U S is represented by each inch of fuel observed in the fuel gauge Heat Transfer Fluid level This label indicates the minimum and maximum level for the Heat Transfer Fluid This label is located adjacent to a sight gauge on the Heat Trans fer Fluid reservoir Plug in the strobe light to this side of the receptacle WACKER M NEUSON Labels E 2200 E 3000 5 611 Plug in the Pump Pack to this side of the receptacle 614 615 WARNING HEAS OPERATOR S MANIM Read Operator s Manual before operating EXHAUST GAS IS DEADLY machine Exhaust gas is deadly Operate a machine only in well ventilated area Do not e operate machine indoors 623 WARNING A WARNING Lugnuts factory torqued to 110 ft lbs Verify EACIORVIOROUED IO lugnuts are properly torqued before 110 LB FT VERIFY LUGNUTS ARE transporting Failure to heed above warning PROPERLY TORQUED BEFORE TRANSPORTING could result in wheel loss which can cause Failure to heed above warning could result Inju ry or death wheel loss which cause injury
25. Information relating to this product Additional transportation system information can be obtained through an authorized sales or customer service representative 1116 the responsibility of the transporting organization to follow all applicable laws regulations and rules relating to the transportation of the material Page 5 of 7 MSDS Dowfrost 50 Product DOWFROST HD 50 Heat Transfer Fluid Dyed Issue Date 12 10 2007 15 Regulatory Information OSHA Hazard Communication Standard This product is not a Hazardous Chemical as defined by the OSHA Hazard Communication Standard 29 CFR 1910 1200 Superfund Amendments and Reauthorization Act of 1986 Title Ill Emergency Planning and Community Right to Know Act of 1986 Sections 311 and 312 Immediate Acute Health Hazard No Delayed Chronic Health Hazard No Fire Hazard No Reactive Hazard No Sudden Release of Pressure Hazard No Superfund Amendments and Reauthorization Act of 1986 Title Ill Emergency Planning and Community Right to Know Act of 1986 Section 313 To the best of our knowledge this product does not contain chemicals at levels which require reporting under this statute Pennsylvania Worker and Community Right To Know Act Pennsylvania Hazardous Substances List and or Pennsylvania Environmental Hazardous Substance List The following product components are cited in the Pennsylvania Hazardous Substance List and or the Pennsylvania Environmental Sub
26. N3349 JHL 3ONO dY L ANY 554 Suv3ddv 145 MAHON MOT38 JHL OL SANOdSJYYOD ONIHSV 14 NID38 TIM Q3AV 185 SIH AS GSAV1dSI SIT N3HM 3573199 AHL SSdud ANTWA SHL ALIN 1 SYSEWNN N3399 JHL IONO dvb TUNN av CNV SS3ud o Suv3ddv AV IdSK MAHON odz 5 Nass ONIHSV 14 NID38 TIM 8 1 SI 201 N3HM ASV 134 TUNN SSd ud JHL JO INWA N33u9 JHL IONO CNV SS3ud ONILSNPAV 34NLY43dW3L HDIH 123 gb fm wc tx001673 2200 3000 5 Schematics 10 Schematics 10 1 Electrical Schematic gb fm N N E T 27980026 1u6 gt lt 81 OL 81 3NH Ol E 7 1 Zz eee i 6 5 in avo uo m iy n LZ THOM BV 21112 m 43T1031N02 Si dMd31 g e d Ce SS gi ze ii 3 3ATVA 110 OL 0g E STI n LL 034 c 4 b dL 9S OL dH ps gg 762 INN OL vld 9 3NH OL 62 znd a308 H3WHOJSNYHL QNIM3H __ i 0235 WASS sz 5 NOILIND 4 7 01 17 JS 07 er dH 9 1 O SWN oe e N 9 uO HO 82 l 2117 92
27. Notes Ww MEOSGN 90 wc tx001669gb fm 2200 3000 5 Maintenance 7 Maintenance 7 1 Periodic Maintenance Schedule The table below lists basic machine maintenance Tasks designated with check marks may be performed by the operator Tasks designated with square bullet points require special training and equipment Refer to the generator manufacturer s operation manual for generator maintenance procedures Interval hours of service 2 Week Yearly Task 50 1200 quick connect couplings Inspect hoses and connectors Inspect electrical cords connections Check adjust burner air setting Check HTF level Fill if necessary Check adjust fuel pressure Glean HTF strainer o Lubricate hose reel chain hose reel chain Lubricate hose reel chain Lubricate hose reel bearings Clean turbulator tubes Test the burner exhaust As needed or upon changing job sites adjust the settings Use whichever comes first calendar time or service hours we_tx001670gb fm 91 M MEOCON Maintenance E 2200 E 3000ES 7 2 Repairing a Hose Requirements Hose nipple wo hose ferrules Hose crimping tool part number 0169002 Procedure Follow the procedure below to repair a damaged hose 1 Shut down the machine and allow the Heat Transfer Fluid HTF to cool 2 Locate the damaged portion of the hose and clamp locking pliers on either side of the damaged portion 3 Cut away the damaged
28. 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 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 back long hair Remove all jewelry including rings wu WACKER wo si m NEUSON 14 _si000540gb f 2200 3000 5 Safety Information 1 5 Safety Guidelines for Operating Combustion Burners wc_si000540gb fm 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 Shut down the generator if equipped when refueling When using the machine DANGER Exhaust gas from the burner contains carbon monoxide a deadly poison Exposure to carbon monoxide can kill you in minutes gt Never run the machine indoors or in an enclosed area unless the machine is vented properly Do not fill or drain the fuel tank near an open flame or while the machine is running Do not smoke when refueling the machine lt p WACKER NEUSON Safety Information E 2200 E 3000ES 1 6 Safety Guidelines
29. damage 2 Inspect hydronic heater and associated plumbing for leaks and or damage 3 Repair replace any damaged components 4 Repair any leaks Fuel System 1 Inspect all fuel hoses and connections for leaks and or damage 2 Inspect the fuel filter and associated fuel hoses for leaks and or damage 3 Repair replace any damaged hoses pipes or connectors 4 Repair any leaks Fuel tank 1 Inspect all fuel hoses running into and out of the fuel tank for leaks and or dam age 2 Repair replace any damaged hoses pipes or connectors 3 Repair any leaks WACKER 94 we_tx001670gb tm 2200 3000 5 Maintenance 7 4 Inspecting Electrical Cords Requirements Procedure wc tx001670gb fm Machine stopped Circuit breaker off All power disconnected from machine Open all access doors and remove all access covers Inspect control panel and associated electrical cords for wear and or damage Inspect pump and associated electrical cords for wear and or damage Inspect hose reel and associated electrical cords for wear and or damage Inspect burner and associated electrical cords for wear and or damage Repair replace any worn or damaged cords Refer to your Parts Book for replacement parts WACKER 95 M NEUSON Maintenance E 2200 E 3000ES 7 5 Filling the HTF Reservoir Requirements a Genuine Wacker Neuson Heat Transfer Fluid Machine is on a level surface NOTICE Use only factor
30. from any source other than ourselves If you have obtained an M SDS from another source or if you are not sure that the M SDS you have is current please contact us for the most current version Page 7 of 7 Fuji Temperature Controller Fuji Temperature Controller Fuji Temperature Controller Hysteresis differential Adjusting 5 Jeeg nov 01 1eeueung 0009 0022S N0023 00113 TAGOW SNIVA OviLN3uaaia SISSHALSAH dq3aNaWWooag Suvdddv AVIdSIC MAHON OMLOV3WGIDOHS N3389 ONIHSV 1H NID38 TIM JHL SSd d JHL 3O INVA 3HL SOML av L N3349 JHL 3ONO Suv4dddv AV IdSK MAHON MO 138 3HLOL SCINOdSd3HHOO ONIHSV 15 NID38 TIM Q3AV IdSK SI SAH JHL ILINN SS3 ud JAVA LINDA Xd V3d3H 92 SYSGNNN N3399 JHL IONO TUNN av 8 Suv4dddv AV IdSK MAHON odz Qva 5 3WNnN N3389 ONIHSV 14 NID38 TIM JHL ILINN SS3 ud JHL 3O JHL FOMU av L N3349 JHL SONO dY L ONILSNPGV GYILNIJY34410 SIS3H31SAH v YXd GSAV1dSId SI 301 3SV3 134 ANY 553 Q3AV 1dSId SI d N3HM 3Sv3 134 554 4 Q3AYV 1950 SI 301 N3HM 3573199 553 121 gb fm wc tx001673 Fuji Temperature Controller Fuji Temperature Controller Low Temperature Limit Adjusting 0S
31. from the pumps Turn off the 1 Move the burner ON OFF switch a to the OFF position LA burner and the pumps ON OFF OFF OFF PUMP 1 PUMP 2 BURNER wc_gr008066 2 Move the pump ON OFF switches b4 and to the OFF position Fill the HTF 1 Move the operation valve 2 to the CLOSED position reservoir wc gr007807 wc gr008071 2 Remove the pin and move the fill valve 3 to the OPEN position 3 Remove the fill hose c from its storage location under the hose reel Remove the cap from the hose if a cap is provided Clean the fill hose if necessary This procedure continues on the next page wc tx001667gb fm 55 Ww WACKER NEUSON Operation Prepare machine for operation E 2200 E 3000ES Continued from the previous page 4 Place the open end of the fill hose into a container of HTF 5 Move and hold the bypass switch x in the ON position HTF will begin to flow When the HTF level is between the minimum and maximum marks on the sightglass a Pull the fill hose from the HTF supply b Release the bypass switch NOTICE Do not overfill the HTF reservoir LOW LEVEL FAULT OFF TEMPERATURE wc 01008068 After filling the HTF reservoir perform the procedure below to prepare the machine for operation 1 Press and release the RESET button d on the low level shut down device gho_gr006391 The following will occur a POWER green f and
32. machine without the express written approval of Wacker Neuson Corporation Replace worn or damaged components Replace all missing and hard to read labels a When replacing electrical components use components that are identical in rating and performance as the original components 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 WACKER 13 VM NEUSON Safety Information E 2200 E 3000ES Lifting and transporting Cleaning Personal Protective Equipment PPE 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 chapter 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 chapter 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 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
33. or death 624 Tie down location marker 625 WARNING A WARNING Jack should not be deployed for truck bed Jack Should NOT be Deployed for Truck Bed Transport transport P roperly suppo rt tong ue with wood Properly Support Tongue with Wood Block and Retract block and retract jack befo re tig htening Jack Before Tightening Chains or Straps Jack is not designed to take loads that ratcheting straps or load binded chains or straps Jack IS not desig ned to take chains can deliver Use jack for raising lowering trailer tongue only Failure to heed above warning could result in damage to personal property or cause serious injury or death loads that ratcheting straps or load binded chains can deliver Use jack for raising or lowering trailer tongue only Failure to heed these warnings could result in damage to personal property or cause serious injury or death MEOSGN 24 wc si000541gb fm 2200 3000 5 DIESEL FUEL SELECTION Low ambient teeuperatercs cower to Gertie turi wel cause Durar igeition tahere tee pump damage ALWAYS USE THE PROPER FUEL FOR THE APPLICATION LOWEST EXPECTED GENERATOR SHORE AMBIENT TEMPERATURE POWERED POWERED 25 80 0E ND 7 T4 100 t DIESE DES K UI nostr wi uel AND BELOW x gt HE noin ni FF TO n DESA fi WESEL KAOSE mus 5 um ADOIUNT 5 ELA EINE Require your ve 1
34. portion of the hose a using a utility knife or similar tool ghi gr005622 ghi gr005623 4 Install a ferrule b on each end of the freshly cut hose 5 nsert a nipple c into one of the ferrules NOTICE Do not use petroleum to lubricate the nipple If lubrication is needed use HTF ghi gr005624 ghi gr005625 6 Insert the free end of the nipple into the second ferrule Be sure to push each end of each hose to the lip of the nipple This procedure continues on the next page MEOSGN 92 wc tx001670gb fm 2200 3000 5 Maintenance Continued from the previous page 7 Use a Wacker Neuson brand hose crimper e to crimp both ferrules ghi_gr005626 8 Rotate the hose 90 degrees and crimp both ferrules again The procedure is now complete WACKER wc_tx001670gb fm 93 NEU lt Maintenance E 2200 E 3000ES 7 3 Inspecting the HTF System and the Fuel System Requirements Machine shut down Burner cool HTF System Hoses 1 Rotate the hose reel brake T handle counterclockwise to release the brake 2 Unwind all the hose off the reel Inspect the hose for leaks and or damage 3 Repair any leaks and repair replace any damaged hoses See topic Repairing a Hose 4 Turn on the machine and rewind the hose onto the reel 5 Engage the brake by turning the T handle clockwise Pump motor and hydronic heater 1 Inspect the pumps and motor assemblies and associated plumbing for leaks and or
35. pressure to drop to 0 psig Disconnect loop 1 from loop 2 we_gr007803 we 07007800 6 Connect loop 1 male quick connect to the return port NEG 48 wc tx001667gb fm 2200 3000 5 Operation 7 Connect loop 2 female quick connect to the supply port e 8 Unwind loop 2 from the hose reel and position it within the application area Use caution when nearing the end of the hose loop so that the hose loop is not damaged due to over spinning of the hose reel 9 Turn the hose reel brake T handle clockwise b to engage the brake 10 Move pump 1 and pump 2 ON OFF switches to the ON position 11 Set the temperature controller to the appropriate temperature for the application See topic Setting the Operating Temperature Hose spacing Refer to the table below for the appropriate hose spacing specifications To increase heat penetration cover the hoses with a plastic vapor barrier and two layers of insulated blankets For concrete curing cover the concrete with plastic place the hoses on top of the plastic then cover the hoses with two layers of insulated blankets wc 1007802 Distance Application Description 91 5 cm 36 in Frost prevention Prevents frost in the application area 61 cm 24 in Allows concrete to cure 46 61 cm Excavation thaw Partially thaws the ground for excavation 18 24 in 30 5 46 cm Contractor s thaw Completely thaws the ground for site work
36. than the machine itself or Wacker Neuson accessory machines as instructed in the Operator s Manual a Using the machine as a ladder support or work surface a Using the machine to carry or transport passengers or equipment Using the machine to tow other machines Operating the generator if equipped in a manner that is inconsistent with all federal state and local codes and regulations Operating the machine outside of factory specifications Operating the machine in a manner inconsistent with all warnings found on the machine and in the Operator s Manual This machine has been designed and built in accordance with the latest global safety standards It has been carefully engineered to eliminate hazards as far as practicable and to increase operator safety through protective guards and labeling However some risks may remain even after protective measures have been taken They are called residual risks On this machine they may include exposure to Heat noise and exhaust from the engine or hydronic heater Burns from HTF or radiant heat from the hoses a Fire hazards from improper refueling techniques Fuel and its fumes wu WACKER wo si m NEUSON 10 _si000540gb f 2200 3000 5 Safety Information Personal injury from improper lifting of the trailer tongue ripping hazards from the hoses To protect yourself and others make sure you thoroughly read and understand the safety informatio
37. the HTF reservoir after a low level fault Low level fault indicator Illuminates to indicate a low HTF level condition Burner fault indicator Illuminates to indicate a burner fault condition Line 1 GFCI Provides protection for the operator Thermal switch snap switch Disconnects power to the burner circuit in the event of an over temperature condition This switch opens at 70 C This switch must be manually reset m n HTF low level reset switch Pressing this switch resets the low level module is located inside the shut down device auxiliary control panel Wc tx001667gb fm 33 M MEOCON Operation 2200 3000 5 4 5 Pumps Gauges and Valves A wc 01007816 Gauges Ret Description Ret Description Return Pump b Loop t retumtow temperature g c Loop 2 retum fow temperature h Auxillary retur flow indicator Loop 1 supply flow pressure Auxiliary return flow temperature 1 3000 5 Loop 2 supply flow pressure Valves Pump suction valve Pump Pack supply not Ee on E 3000ES 3 HTF fill valve WACKER W NEUSON 34 wc tx001667gb fm 2200 3000 5 Operation 46 Preparing the Machine for First Use Preparing for prepare your machine for first use
38. the supply tank through the return bypass port of the fuel pump This process purges air from the fuel lines Power is sent to the electrodes and any residual fuel is burned off Fresh air fills the combustion chamber m he valve on delay period starts Valve on The valve on delay period lasts 15 seconds It is enabled turned on or delay off with DIP switch 3 When enabled m Power is sent to the burner motor fuel pump m Power is sent to the electrodes m he fuel shut off valve is energized opens and fuel flows to the noz zle after the valve on delay times out WACKER NEUSON 60 _tx001667gb f E 2200 E 3000 5 Non fault modes wc tx001667gb fm Trial for ignition Carry over Burner motor off delay Operation The trial for ignition period immediately follows the valve on delay period During this period The fuel shut off valve is opened energized Pressurized fuel atomizes at the burner nozzle The atomized fuel is vaporized and ignited by the electrodes The burner fires and the flame is monitored by the cad cell If flame is not detected m he burner controller enters lockout mode m Power is disconnected from the fuel shut off valve electrodes and the burner motor m he indicator light flashes The ignition carry over period starts as soon as the flame is established During this cycle The fuel shut off valve is open energized Pressurized fuel atomizes a
39. tires are properly inflated a Only tow the machine when all trailer lights are functioning correctly a Only tow the machine when the trailer s safety chains are connected to the towing vehicle in a crisscross pattern a Maintain extra distance between the towing vehicle and other vehicles Avoid soft shoulders curbs and sudden lane changes wm Abide by all licensing requirements for your area If you have not driven a towing vehicle with trailer before practice turning stopping and backing up the towing vehicle with trailer in an area away from traffic Only drive the towing vehicle with trailer when you are confident in your ability to do SO wu WACKER wo si m NEUSON 18 _si000540gb f 2200 3000 5 Safety Information Notes we_si000540gb fm 19 Wy Labels E 2200 3000ES 2 Labels 2 1 Label Locations 636 m m lt a li VACKER IESUS WACKER 613 MEUSON 612 wc_gr008049 WACKER u NEUSON 20 si000541gb f 2200 3000 5 Labels D 609 i a 603 wc 07008050 WACKER we_si000541gb f 21 NEUSON Labels E 2200 E 3000 5 2 2 Label Meanings Plug Side Colors used on vehicle may not match those used on trailer 601 Refer to back of connection box for further ES connection details 4 Black Running Lights Green R
40. to start operate and stop the genset before starting it a Obtain the proper training for operating the genset Do not allow untrained personnel to operate or service the genset Check the fuel lines and the fuel tank for leaks and cracks before starting the engine Clean the genset of any spilled fuel Do not start the engine if fuel has spilled or a fuel odor is present Keep the area around the exhaust pipe free of flammable materials Do not smoke while operating the genset Keep sparks flames electrical arcs and other sources of ignition far away from the genset 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 wu WACKER wo si m NEUSON 16 _si000540gb f 2200 3000 5 Safety Information Refueling safety Maintenance guidelines wc_si000540gb fm Do not overload the genset The total amperage of the tools and equipment attached to the genset must not exceed the load rating of the genset Do not operate the genset with wet hands Do not remove the radiator cap when the genset is running or is hot When adding fuel to the fuel tank Do not smoke Do not refuel a hot or running engine When adding fuel to the fuel tank Keep sparks flames electrical arcs and other sources of ignition far away from the genset Refill the fuel tank only in a we
41. tube Result The Z distance has now been set Continue by setting the head position adjusting plate Set the head Perform the procedure below to set the head position adjusting plate osition P 1 Loosen the hex head screw b wc gr008106 2 Loosen the splined nut a Do not loosen acorn nut c 3 Move the nozzle assembly until the burner reference indicator d lines up with the number listed in the Factory Settings chart in topic Burner Setup 4 Tighten both the hex head screw and the splined nut 5 Mark x the head position adjusting plate for future reference wc tx001669gb fm 87 ww MEGCON Burner Setup E 2200 E 3000ES 6 4 Adjusting the Air Settings Background Effects Procedure Result There are two parts to adjusting the air setting 1 air band and 2 air shutter Adjust the air band to make large adjustments Adjust the air shutter to make small adjustments The air setting has the following effects on combustion Higher Oo percentage excess air settings lowers soot production but raises stack temperature and reduces efficiency lean mixture Lower percentage inadequate air settings increases efficiency and lowers stack temperature but may cause soot build up rich mixture Follow the procedure below to adjust the air settings 1 Initial setting of the air damper should be performed with the machine shut down 2 Loosen the air band locking screw a and the air shut
42. 0 Page 6 of 7 MSDS Dowfrost 50 Product Name DOWFROST HD 50 Heat Transfer Fluid Dyed Issue Date 12 10 2007 Most recent revision s are noted by the bold double bars in left hand margin throughout this document Legend Action Level A value set by OSHA that is lower than the PEL which will trigger the need for activities such as exposure monitoring and medical surveillance if exceeded The Dow Chemical Company urges each customer or recipient of this M SDS to study it carefully and consult appropriate expertise as necessary or appropriate to become aware of and understand the data contained in this M SDS and any hazards associated with the product The information herein is provided in good faith and believed to be accurate as of the effective date shown above However no warranty express or implied is given Regulatory requirements are subject to change and may differ between various locations It is the buyer s user s responsibility to ensure that his activities comply with all federal state provincial or local laws The information presented here pertains only to the product as shipped Since conditions for use of the product are not under the control of the manufacturer it is the buyer s user s duty to determine the conditions necessary for the safe use of this product Due to the proliferation of sources for information such as manufacturer specific M SDSs we are not and cannot be responsible for M SDSs obtained
43. 0 Rabbit gt 10 000 mg kg Sensitization Skin For the major component s Did not cause allergic skin reactions when tested in humans Repeated Dose Toxicity In rare cases repeated excessive exposure to propylene glycol may cause central nervous system effects Chronic Toxicity and Carcinogenicity Similar formulations did not cause cancer in laboratory animals Developmental Toxicity For the major component s Did not cause birth defects or any other fetal effects in laboratory animals Reproductive Toxicity For the major component s In animal studies did not interfere with reproduction In animal studies did not interfere with fertility Genetic Toxicology In vitro genetic toxicity studies were negative For the major component s Animal genetic toxicity studies were negative Page 4 of 7 MSDS Dowfrost 50 Product Name DOWFROST HD 50 Heat Transfer Fluid Dyed Issue Date 12 10 2007 12 Ecological Information CHEMICAL FATE Movement amp Partitioning For the major component s Bioconcentration potential is low BCF less than 100 or log Pow less than 3 Potential for mobility in soil is very high Koc between 0 and 50 Persistence and Degradability For the major component s Material is readily biodegradable Passes OECD test s for ready biodegradability ECOTOXICITY For the major component s Material is practically non toxic to aquatic organisms on an acute basis LC50 EC5
44. 0 gt 100 mg L in the most sensitive species tested 13 Disposal Considerations DO NOT DUMP INTO ANY SEWERS ON THE GROUND OR INTO ANY BODY OF WATER All disposal practices must be in compliance with all Federal State Provincial and local laws and regulations Regulations may vary in different locations Waste characterizations and compliance with applicable laws are the responsibility solely of the waste generator DOW HAS NO CONTROL OVER THE MANAGEMENT PRACTICES OR MANUFACTURING PROCESSES OF PARTIES HANDLING OR USING THIS MATERIAL THE INFORMATION PRESENTED HERE PERTAINS ONLY TO THE PRODUCT AS SHIPPED IN ITS INTENDED CONDITION AS DESCRIBED IN MSDS SECTION Composition Information FOR UNUSED amp UNCONTAMINATED PRODUCT the preferred options include sending to a licensed permitted Recycler Reclaimer Incinerator or other thermal destruction device As a service to its customers Dow can provide names of information resources to help identify waste management companies and other facilities which recycle reprocess or manage chemicals or plastics and that manage used drums Telephone Dow s Customer Information Group at 1 800 258 2436 or 1 989 832 1556 U S or 1 800 331 6451 Canada for further details 14 Transport Information DOT Non Bulk NOT REGULATED DOT Bulk NOT REGULATED IMDG NOT REGULATED ICAO IATA NOT REGULATED This information is not intended to convey all specific regulatory or operational requirements
45. 0 2007 7 Handling and Storage Handling General Handling No special precautions required Spills of these organic materials on hot fibrous insulations may lead to lowering of the autoignition temperatures possibly resulting in soontaneous combustion See Section 8 EXPOSURE CONTROLS AND PERSONAL PROTECTION Storage Do not store in Galvanized steel Opened or unlabeled containers Store in the following material s Carbon steel Stainless steel Store in original unopened container See Section 10 for more specific information Additional storage and handling information on this product may be obtained by calling your Dow sales or customer service contact 8 Exposure Controls Personal Protection Exposure Limits Component List Type Value Propylene glycol WEEL TWA 10 mg m3 Aerosol Personal Protection Eye Face Protection Use safety glasses Skin Protection Wear clean body covering clothing Hand protection Use gloves chemically resistant to this material when prolonged or frequently repeated contact could occur Examples of preferred glove barrier materials include Butyl rubber Natural rubber latex Neoprene Nitrile outadiene rubber nitrile or NBR Polyethylene Ethyl vinyl alcohol laminate EVAL Polyvinyl alcohol PVA Polyvinyl chloride PVC or vinyl NOTICE The selection of a specific glove for a particular application and duration of use in a workplace should also take into account
46. 0 Quarames thal Ihe fue suppded mI ge at the temperature whith will be esperiesced M your wort Im ums ADNE me 627 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 bo heed above warning could result in damage to personal property or cause serious injury or death 635 CAUTION DO NOT USE ETHER OR OTHER START HELPERS ON GENERATOR ENGINE Failure to heed the above warning may cause irreparable damage and void engine warranty 168574 636 WARNING READ OPERATOR MANUAL FOLLOW USE AND MAINTENANCE GUIDELINES AS RECOMMENDED BY GENERATOR MANUFACTURER AND ENGINE MANUFACTURER Failure to do so may cause irreparable damage and void engine or generator warranty 168575 637 WARNING Attach Chains or Straps ONLY to Axles and Designed 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 639 wc si000541gb fm 25 Labels Fuel blend guide This label indicates the proper fuel blending requirements based upon power source and ambient temperature ranges Consult the Operator s Manual for more information WARNING Attach chains or straps only to axles and designated tie down points Never run Straps across any surface on
47. 1008072 2 Connect the DIN leader from the main control panel to the corresponding DIN leader on the APP 3 Connect a properly rated extension cord p to the power cord q on the APP 4 Connect the Pump Pack power cord s to the APP power adapter r Operating 1 Start the parent machine Turn on the burner and the pumps 2 Place the ON OFF switch of the APP in the ON position Start the pumps of both DPPs one at a time 4 Monitor the HTF flows pressures and temperature as the machine operates wc tx001668gb fm 75 WACKER NEUSON Accessories E 2200 E 3000ES 5 7 Mounting the Auxiliary Pump Panel Requirments Machine shut down Power disconnected a Auxiliary Pump Panel Background The Wacker Neuson Auxiliary Pump Panel APP is an electrical device that communicates with the main machine s systems to provide protection for any additional Pump Packs that are connected to the machine If the machine experiences a low level fault condition the APP will cut off power to the external components This power cut off protects the pumps from damage Guidelines Follow the guidelines below when mounting the APP Refer to the diagram below a Install the APP inside the machine near the main control panel a a Install APP using included hardware b REAR VIEW SIDE VIEW
48. 3000 5 Operation 4 8 Recommended Fuel 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 Generator powered Shore powered 50 50 blend of 2 diesel 100 1 diesel plus and 1 diesel plus additives additives OR Below 5 15 OR 10096 K1 kerosene 50 50 blend 2 diesel and plus additives K1 kerosene plus additives 70 30 blend of 22 diesel and 1 diesel plus additives 5 to 25 15 to 4 OR 70 30 blend of 42 diesel and K1 kerosene plus additives Above 25 4 Winter blend diesel wc tx001667gb fm 37 W MEOSGR Operation 2200 3000ES 490 Positioning the Machine DANGER Asphyxiation hazard Exhaust gas from the burner contains carbon monoxide a deadly poison you can not see or smell Exposure to carbon monoxide can kill you in minutes gt Position the machine so that burner exhaust will not enter any nearby structures WARNING Fire hazard Do not move the machine while it is running gt Shut down the machine before moving or repositioning it WARNING Fire hazard Machines positioned on a hill or an incline may slide break away or roll over gt Do not position the machine on a hill or an incline CO Alarms Because this machine produces carbon monoxide CO Wacker Neuson recommends that CO alarm
49. HS in a secure location Connect HHS hose loop 2 2 to the other discharge port 92 of the DPP iN WACKER NEUSON 12 wc_tx001668gb fm 2200 3000 5 Accessories Electrical Make the following electrical connections connections Connect the power cord from the DPP e to the auxiliary receptacle labeled PUMP b wc gr008081 Operating 1 Start the parent machine Turn on the buner and the pumps 2 Start the pumps of the DPP one at a time c 3 Monitor the HTF flows pressures and temperature as the machine operates wc tx001668gb fm 73 VW MEOSGR Accessories E 2200 E 3000ES 5 6 Combining the Machine with Two HHS and Two DPP 2200 only Requirements Machine stopped Two Hose Handling Systems HHS Two Dual Pump Packs DPP Two 2 1 adapters One Auxiliary Pump Panel APP See topic Mounting the Auxiliary Pump Panel Procedure Perform the procedure below to connect two HHS and two DPP to the machine 4 Unwind and position the hose of the parent machine as normal x wc gr008082 5 Connect both 2 1 adapters a4 and a to the return ports b 6 Position the Hose Handling Systems an
50. Hydronic Surface Heater E 2200 3000 5 0192779 001 1210 0 9 7 7 9 1 2 Copyright notice Trademarks Manufacturer Original instructions 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 Wacker Neuson Corporation represents an infringement of valid copyrights Violators will be prosecuted 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 This Operator s Manual presents the original instructions The original language of this Operator s Manual is American English Foreword Machines covered by this manual Machine documentation Expectations for information in this manual Manufacturer s approval wc tx001665gb fm Foreword This manual covers machines with the following item numbers E 2200 0620176 105 and above E 2200 0620215 105 and above Keep a copy of the Operator s Manual with the machine at all t
51. LL OVERRIDE 1 2 y llli Off On ee 1 25SF 1 MOMENTARY ghi gr005662 Wc 1x001672gb fm 129 Schematics E 2200 E 3000ES 10 5 Rewind System Circuit 115 VAC 60HZ CB1 L1 L2 N HOSE REWIND 21 FU1 Off On 1 29 15 2 REWIND MOTOR 22 e 2 1FLA 1 6 FNM3 0 lecce 4 23 LL s T 24 __ FU2 TOLINE 14 21 RED 14 TO LINE 16 25 4 26 1 sis 0 4 27 emai 5 REWIND CLUTCH N ghi_gr005710 NEU CON 1 3 0 wc tx001672gb fm Wacker Neuson SE gt PreuBenstraBe 41 D 80809 M nchen gt Tel 49 0 89 3 5402 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 amp 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
52. OTE 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 DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury gt To avoid death or serious injury from this type of hazard obey all safety mes sages that follow this signal word WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury gt 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 gt To avoid possible minor or moderate injury from this type of hazard obey all safety messages 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 WACKER 9 M NEUSON Safety Information E 2200 E 3000ES 1 2 Machine Description and Intended Use This machine is a hydronic surface heater The Wacker Neuson Hydronic Surface Heaters consist of trailer mounted enclosures that house an optional diesel gene
53. Point Closed Cup Not applicable water boils off Flammable Limits In Air Lower 2 6 V Literature Propylene glycol Page 3 of 7 MSDS Dowfrost 50 Product Name DOWFROST HD 50 Heat Transfer Fluid Dyed Issue Date 12 10 2007 Upper 12 5 V Literature Propylene glycol Autoignition Temperature 371 700 Literature Propylene glycol Vapor Pressure 15 5 mmHg 20 Literature Boiling Point 760 mmHg 104 C 219 F Literature Vapor Density air 1 gt 1 0 Literature Specific Gravity H20 1 1 06 20 C 20 Literature Freezing Point 33 8 28 8 Literature Melting Point Not applicable to liquids Solubility in Water by 100 Literature weight pH 9 5 Literature Kinematic Viscosity 6 3 cSt Literature 10 Stability and Reactivity Stability Instability Thermally stable at recommended temperatures and pressures Conditions to Avoid Some components of this product can decompose at elevated temperatures Generation of gas during decomposition can cause pressure in closed systems Incompatible Materials Avoid contact with Strong acids Strong bases Strong oxidizers Hazardous Polymerization Will not occur Thermal Decomposition Decomposition products depend upon temperature air supply and the presence of other materials 11 Toxicological Information Acute Toxicity Ingestion I LD50 Rat female 20 300 mg kg Skin Absorption For similar material s LD5
54. a Truck or Trailer Requirements A Checklist Machine stopped See topic Shutting Down and Packing Up the Machine m Flatbed truck or trailer capable of supporting the machine s weight a Chains hooks or straps capable of supporting the machine s weight WARNING Crushing hazard Improperly securing the machine can lead to a crushing hazard Useonly the designated tie down points to secure the machine to a truck or trailer Before transporting the machine check the following items Machine O Check that the hoses are completely wound on the hose reel and that all hose ends are secured O Check that all accessories are securely stored within the machine O Check that all doors and access panels of the machine are closed O Check that all electrical supplies are disconnected from the machine For machines with external fuel supplies check that all fuel supplies are disconnected from the machine Loading and transporting equipment O Check that the transport vehicle or trailer can support the weight of the machine O Check that the transport vehicle or trailer is wide enough to support the machine O Check that the wheels of the transport vehicle or trailer are chocked during the loading process Check that the transport vehicle or trailer is clean and free of grease oil ice and other loose material L1 If the machine is mounted to a trailer check that a transport block piece of wood or other simila
55. age D WACKER NEUSON 78 _tx001669gb f 2200 3000 5 Burner Setup Continued from the previous page 9 Analyze the combustion Follow the combustion analyzer manufacturer s instructions and the general guidelines below ghi_gr006183 Use the access hole in the exhaust stack several samples as the heater warms the final sample just before the heater reaches 71 C 160 10 Re adjust the air setting s if necessary until the smoke spot test and combustion analysis are within the following parameters O content 4 6 Smoke spot 1 or less Result You have now set up the burner wc tx001669gb fm 79 Ww MEOSGR Burner Setup E 2200 E 3000ES 6 1 Adjusting the Burner Electrodes Requirements Procedure Power supplies disconnected Measuring device Follow the procedure below to check the electrodes 1 Shut down the machine and disconnect the power supplies 2 Remove the copper fuel line a between the fuel pump and the burner housing Note Only remove the fuel fitting closest to the burner housing ghi 9005524 3 Remove the splined nut b that is seated against the escutcheon plate NOTICE Handle the splined nut with care It is easily damaged 4 Loosen tabs c and hinge back the igniter cover a wc 01008113 wc 01008112 5 Disconnect the wiring to the electrode assembly 6 Maneuver the electrode nozzle assembly d
56. all relevant workplace factors such as but not limited to Other chemicals which may be handled physical requirements cut puncture protection dexterity thermal protection potential body reactions to glove materials as well as the instructions specifications provided by the glove supplier Respiratory Protection Respiratory protection should be worn when there is a potential to exceed the exposure limit requirements or guidelines If there are no applicable exposure limit requirements or guidelines wear respiratory protection when adverse effects such as respiratory irritation or discomfort have been experienced or where indicated by your risk assessment process In misty atmospheres use an approved particulate respirator The following should be effective types of air purifying respirators Organic vapor cartridge with a particulate pre filter Ingestion Use good personal hygiene Do not consume or store food in the work area Wash hands before smoking or eating Engineering Controls Ventilation Use local exhaust ventilation or other engineering controls to maintain airborne levels below exposure limit requirements or guidelines If there are no applicable exposure limit requirements or guidelines general ventilation should be sufficient for most operations Local exhaust ventilation may be necessary for some operations 9 Physical and Chemical Properties Physical State Liquid Color Yellow Odor Characteristic Flash
57. b fm 71 NEUSON Accessories E 2200 E 3000ES 5 5 Combining the Machine with One HHS and One DPP Requirements Machine stopped Hose Handling System HHS Dual Pump Pack DPP Procedure Perform the procedure below to connect an HHS and a DPP to the machine 1 Unwind and position the hose of the parent machine as normal x 2 Position the HHS and the DPP e near the machine E 3000ES wc gr007819 3 Connect the DPP supply hose a to accessory supply valve 1 Then open accessory supply valve 1 HHS Hose 1 Connect HHS hose loop 1 f4 to the accessory return line On E 3000ES Loop 1 machines use a 2 1 adapter h 2 Unwind HHS hose loop 1 and position it within the application area 3 Disconnect HHS hose loop 1 from HHS hose loop 2 4 Connect 5 hose loop 1 f4 to a discharge port g4 of the DPP HHS Hose 1 Connect HHS hose loop 2 f2 to the other accessory return line lt 2 Continue to unwind HHS hose loop 2 and place HHS hose loop 2 within the application area 3 Remove hose loop 2 from the HHS and store the H
58. ce flammable vapors Only operate the machine when m All safety devices and guards in place and in working order All controls operate correctly machine is set up correctly according to the instructions in the Operator s Manual he machine is clean machines labels are legible To ensure safe operation of the machine WACKER 11 VM NEUSON Safety Information E 2200 E 3000ES Do operate the machine if any safety devices or guards are missing or inoperative Do modify or defeat the safety devices Only use accessories or attachments that are approved by Wacker Neuson Corporation safe When operating this machine operating Remain aware of the machine s moving parts Keep hands feet and loose practices clothing away from the machine s moving parts When operating this machine Do not operate a machine in need of repair Personal Wear the following Personal Protective Equipment PPE while operating this Protective machine oben a Close fitting work clothes that do not hinder movement Safety glasses with side shields Hearing protection Safety toed footwear w MEOSGN 1 2 wc si000540gb fm 2200 3000 5 Safety Information 1 4 Service Safety Service training Precautions Machine modifications Replacing parts and labels wc_si000540gb fm Before servicing or maintaining the machine Read and understand the inst
59. cing the Burner Nozzle Power supplies disconnected Machine cool Follow the procedure below to remove the burner nozzle 1 Disconnect the power supplies 2 Remove the copper fuel line a between the fuel pump and the burner housing ghi gr005524 3 Remove the splined knob b that is seated against the escutcheon plate Note Handle the splined knob with care It is easily damaged 4 Loosen tabs c and hinge back the igniter cover wc gr008113 wc gr008112 5 Disconnect the preheater wiring 6 Maneuver the electrode nozzle assembly d up and out of the burner This procedure continues on the next page D MSSR Burner Setup E 2200 E 3000ES Installation Continued from the previous page 7 Unscrew the burner nozzle e from the burner tube wc 01008114 The procedure to remove the burner nozzle is now complete Follow the procedure below to install the burner nozzle 1 Thread the new burner nozzle into the burner tube Note Do not use thread sealant on the threads 2 Position the electrode nozzle assembly d into the burner e P P ee ii PAP S E PCT v e wc gr008112 wc gr008113 3 Connect the wiring 4 Close the igniter cover and secure it with tabs c This procedure continues on the next page WACKER oe NEUSON 84 _tx001669gb f 2200 3000 5 Burner Setup Continued from the previous page 5 Install the splin
60. d the Dual Pump Packs near the machine 7 Connect the DPP1 supply hose c to accessory supply valve 1 Then open accessory supply valve 1 HHS 1 Hose Loop 1 Connect HHS hose loop 1 h4 to adapter Unwind the HHS hose loop 1 and position it within the application area Disconnect HHS hose loop 1 from HHS hose loop 2 A N gt Connect HHS hose loop 1 to a discharge port g4 of the DPP1 HHS 1 Hose 1 Connect HHS hose loop 2 to adapter Loop 2 Continue to unwind HHS hose loop 2 and place HHS hose loop 2 within the application area WACKER Ww NEUSON 74 tx001668gb f 2200 3000 5 Accessories 3 Remove hose loop 2 from the HHS and store the HHS in a secure location 4 Connect HHS hose loop 2 hg to discharge port 95 of DPP1 DPP 2 and Connect the hoses from HHS 2 to the machine and to DPP 2 in the same manner HHS 2 as connecting DPP 1 Electrical Make the following electrical connections connections 1 Connect the power cord from the DPP1 m to the auxiliary receptacle labeled PUMP PACK wc
61. ed knob b Note Handle the knurled knob with care It is easily damaged ghi_gr005524 6 Install the copper fuel line a between the fuel pump and the burner housing Result The burner nozzle has now been replaced WACKER wc tx001669gb f 85 NEUSON Burner Setup E 2200 E 3000ES 6 3 Setting the 2 Distance on V1 Style Heads Requirements Burner removed from the machine 501 gauge or straight edge and measuring device Preliminary Follow the procedure below to set the Z distance on V1 style heads 1 Remove the burner from the machine 2 Disconnect the copper fuel line from the nozzle assembly 3 Loosen the splined nut a wc 01008105 4 Loosen the hex head screw b 5 Loosen the acorn nut c 6 Move the head adjusting plate until 0 lines up with the indicator d on the housing Tighten the hex head screw b 7 Set the Z distance See below Z distance Perform the procedure below to measure the Z distance 1 Place a straight edge x on the end of the air tube wc gr008103 2 Adjust the nozzle assembly until the distance between the end of the head y and end of the air tube is 1 3 4 inches 44 mm 3 Tighten the acorn nut This procedure continues on the next page cd WACKER 9 W NEUS ON 86 c_tx001669gb f 2200 3000 5 Burner Setup Continued from the previous page 4 Tighten the hex head screw 5 Tighten the splined nut 6 Reconnect the oil connector
62. el expansion 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 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 Shut and lock all doors 4 If the machine has a trailer protect the trailer tires from direct sun light 5 When removing from storage the machine must be prepared for operation See wc tx001670gb fm topic Preparing the Machine for Seasonal Operation 105 v WACKER NEUSON Maintenance E 2200 E 3000ES 7 12 Preparing the Machine for Seasonal Operation Background After removing the machine from long term storage it must be prepared for operation Perform the procedures below before each seasonal use Before Perform the procedures below before you power up the machine powering up machine Clean all outside surfaces Heater and burner m Remove protective coverings from chimney and burner Remove any carbon buildup from the heater and burner assemblies Replace the burner nozzle Verify burner electrode position Controls and wiring Inspect all wires for damage corrosion or wear Replace damaged wiring Inspect all electrical components for damage corrosion or wear Replace damaged electrical components
63. ents must be made so that the machine conforms to the requirements of local state and federal codes and authorities m Adjustments shall be made at the job site This procedure continues on the next page WACKER 17 M NEUSON Burner Setup E 2200 E 3000ES Continued from the previous page When Adjust the burner Before operating the machine at elevations 305 m 1 000 ft above or below the location of the previous adjustments Before starting at a new job site a After any burner maintenance or repair has been performed f burner performance is in question Procedure Follow the procedure below to set up the burner Shut down the machine Set the burner electrodes See topic 6 1 Adjusting the Burner Electrodes Check the burner nozzle See topic 6 2 Replacing the Burner Nozzle Check set the z distance See topic 6 3 Setting the Z Distance Set the air settings See topic 6 4 Adjusting the Air Settings Start the machine and the burner Check set the fuel pressure See topic 6 5 Setting the Fuel Pressure Conduct a smoke spot test Follow the smoke spot tester manufacturer s instructions and the general guidelines below ghi_gr006184 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 This procedure continues on the next p
64. er controller will enter the startup mode as soon as there is a call for heat This mode consists of the following periods Safety Valve on delay Trial for ignition Carry over The run mode starts and continues once the ignition carry over period has elapsed During this mode m he fuel shut off valve is open energized m Pressurized fuel atomizes at the burner nozzle m he flame is monitored by the cad cell Once the setpoint is reached call for heat satisfied The output contacts of the temperature control open inter rupting the circuit between terminal and The fuel shut off valve is closed de energized The burner motor runs for the selected burner motor off delay time period then turns off The burner controller returns to the idle mode If the flame is lost during the run mode m he burner controller enters the recycle mode The burner will enter the recycle mode when the burner stops firing due to loss of flame During the recycle mode m he diagnostic light on the burner controller will flash in two second intervals m he burner will attempt to automatically restart m Flame must be detected during each restart attempt If no flame is detected the burner controller goes into burner fault lockout mode m The burner controller will wait 60 seconds between restart attempts m After three restart attempts in which the call for heat is not satisfied the burner controller will go in
65. eration valve 2 to the OPEN position 3 Move the fill valve 3 to the CLOSED position and insert the pin 4 Clean the fill hose and cap the fill hose if a cap is provided 5 Return the fill hose to its storage location under the hose reel Result The machine is now ready for operation Ww WACKER NEUSON wc tx001670gb fm 97 Maintenance E 2200 E 3000ES 7 6 Cleaning the HTF Strainer Requirements Machine shut down m Source of clean warm water Removal Perform the procedure below to clean the HTF strainer Note n the interests of environmental protection place a plastic sheet and a container under the machine to collect any liquid which drains off Dispose of this liquid in accordance with local environmental protection laws 1 Loosen but do not remove the top screw a Note here is a second screw b under the canister c Hold this screw while loosening the screw a wc gr007694 2 lap on screw a with a hammer to release the gasket seal 3 Remove the canister c by removing screw a support the canister while doing so 4 Dispose of the HTF that remains in the canister 5 Remove the gasket d from the canister Repl v ace it if it is damaged Cw EU gr007695 6 Remove the strainer basket e from the canister wc gr007696 7 Rinse the strainer basket and the canister with clean warm water This procedure continues on the next page MEGCON 98 wc
66. ett AFGGH106 4 Fuel input KW hr 7 BTU hr 252 000 omm BTU hr 220 000 Hewerefieny 278 557 3 000 6 000 3000 5 wc td000422gb fm 111 wW MEOSGR Technical Data E 2200 E 3000ES 9 3 Trailer Number Model e cRmx _ LRD Tire pressure 0 000 Tire pressure 0 000 4 5 65 7 5 110 Lug nut torque m ft lbs 149 110 149 110 GVWR kg Ib 2878 6345 2994 6600 Gross Vehicle Weight Rating Hitch type 2 in Ball 2 5 16 in ball or pintle 000 000 Electric E 3000ES 4 WACKER x M NEUSON 112 _td000422gb f 2200 3000 5 9 4 Dimensions wc td000422gb fm Technical Data cm in 429 169 165 72 gt 223 88 No E Lj 808 4 113 w ghi_gr005645 WACKER NEUSON MSDS Dowfrost 50 MSDS Dowfrost HD 50 gt Material Safety Data Sheet 5 The Dow Chemical Company Product Name DOWFROST HD 50 Heat Transfer Fluid Dyed Issue Date 12 10 2007 Print Date 01 Sep 2010 The Dow Chemical Company encourages and expects you to read and understand the entire M SDS as there is important information throughout the document We expect you to follow the precautions identified in this document unless your use conditions would necessitate other appropriate methods or actions 1 Product and Company Identification Product Name
67. for Operating Gensets A A A Before operating the genset Running the genset DANGER gt Carbon monoxide Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide CO This is a poison you cannot see or smell If you can smell the generator exhaust you are breathing CO But even if you cannot smell the exhaust you could be breathing CO WARNING Electrocution hazard Generators present special hazards during operation and servicing These include the risk of electrocution or severe electrical shock Failure to follow the safety information below can result in severe injury or death gt Read and follow the safety instructions in this Operator s Manual gt Contact the genset manufacturer for additional information regarding the genset WARNING Internal combustion engines present special hazards during operation and fueling Failure to follow the warnings and safety instructions could result in severe injury or death gt Read and follow the safety instructions in this Operator s Manual gt Contact the genset manufacturer for additional information regarding the genset This machine is built with user safety in mind however like any electrical device it can present serious hazards if improperly operated and serviced Follow instructions carefully Should questions arise during operation or service of this equipment contact your Wacker Neuson dealer Know how
68. h each unsuccessful burner restart until a successful heating cycle has occurred DIAGNOSTIC LIGHT ON FLAME OFF NO FLAME FLASHING 2 SEC ON RECYCLE SEC ON LOCKOUT PUSH RED BUTTON TO RESET FROM LOCKOUT z z o o 124512 3 30SEC 2MIN 4 8 ENABLED DISABLED ALARM ghi gr006221 63 WACKER wc tx001667gb fm NEUSON Operation 2200 3000 5 Notes Ww NEG CON 64 wc tx001667gb fm 2200 3000 5 Accessories 5 Accessories 5 1 Available Accessories Configurations wc tx001668gb fm To increase the machine s capabilities and capacities the following Wacker Neuson accessories are available ghi gr006475 Ref Descripion Descrpion a Hose Handling System 53002 f 1 2 Adapter HEAT XCHANGER HX 50 2 1 Adapter HEATXCHANGER 100 h Accessory hoses various lengths HEAT XCHANGER HX 200 Single SPP or Dual Pump Pack DPP Insulation blanket Auxiliary Pump Panel APP power adapter These accessories allow the following application configurations Combining your parent machine with Heat XCHANGERS allows it to heat air Combining your parent machine with a DPP and HHS increases the ground heating thawi
69. ight Hand Turn Stop Brown Left Hand Turn Stop Red Electric Brake Ground Blue White Back Up Yellow Refer to back of connection box cover for further connection details 602 Stop Do not reset until HTF leak is repaired and DO NOT RESET HTF level is restored ANT Red LOW LEVEL FAULT light on control panel indicates HTF is below the minimum nn operating level Follow procedure below to rectify the fault 3 ADD HTF TO MIN LEVEL ON 1 Shut off burner switch and pump ane switch es 5 TURN ON BURNER SWITCH 2 Find and repair the leak TURN ON PUMP S ONE AT A 3 Add HTF to reservoir up to MIN level on HTF sight gauge RESET 4 Press manual reset button below 5 Turn on burner switch 6 After burner ignites turn on pump s one at a time 603 To prevent loss of Heat Transfer Fluid the fill AWARNNG i WARNING valve must remain LOCKED SHUT closed To prevent loss of Heat Transfer Fluid Fill valve must remain LOCKED SHUT at all times except as directed by the Operator s Manual at all times except as directed in the Operator s Manual MEOSGN 22 wc si000541gb fm 2200 3000 5 Labels Regularly inspect the rope gasket located CAUTION REGULARLY INSPECT ROPE GASKET BETWEEN FLUE BOX AND HEATER VESSEL FOR VISUAL SIGNS OF COMBUSTION GAS LEAKAGE REPLACE GASKET WITH GHI P100 312 PER GROUND HEATERS SERVICE MANUAL 168493 BRAKE
70. imes Use the separate Parts Book supplied with the machine to order replacement parts Ifyou are missing any of these documents please contact Wacker Neuson Corporation to order a replacement or visit www wackerneuson com m When ordering parts or requesting service information be prepared to provide the machine model number item number revision number and serial number This manual provides information and procedures to safely operate and maintain the above Wacker Neuson model s For your own safety and to reduce the risk of injury carefully read understand and observe all instructions described in this manual Wacker Neuson Corporation expressly reserves the right to make technical modifications even without notice which improve the performance or safety standards of its machines m 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 This manual contains references to approved parts attachments and modifications The following definitions apply Approved parts or attachments are those either manufactured or provided by Wacker Neuson Approved modifications are those performed by an authorized Wacker Neuson service center according to written instructions published by Wacker Neuson Unapproved parts attachments and modifications are those that do not
71. ion Restrictions for extension cords 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 a 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 Procedure Follow the procedure below to connect power to the machine 1 Move both circuit breaker switches a and b to the OFF position wc gr006372 2 Connect the main power cords c to a properly rated power source or to the generator if included Result Power has now been connected The machine is ready for pre starting checks MEGCON 42 wc tx001667gb fm 2200 3000 5 Operation 4 12 Starting and Stopping the Generator Background Starting Stopping wc tx001667gb fm Only general starting and stopping procedures for the generator are included in this manual See the generator manufacturer s operation manual for detailed procedures Perform the procedure below to start the generator 1 Move the circuit breaker switches on the genset to the OFF position 2 Prime the fuel system if needed The fuel system will need to be primed if Fuel system has run dry Fuel system has been drained he fuel filter has been changed he genset has not been run for several weeks gt To prime the fuel system Press and hold the control switch in the Stop Prime position The fuel pump will start
72. k that all lug nuts are in place and are properly torqued Check the tread wear of the tires O Check that the tires are inflated to the proper pressure Trailer operation O Check that the directional and running lights on the trailer function correctly O Check that the safety chains of the trailer are connected to the towing vehicle using a crisscross pattern O Check that the trailer s breakaway cable is attached to the towing vehicle O Check the operation of the trailer brakes by braking the towing vehicle at a slow speed Both the vehicle and the trailer must brake smoothly If the trailer pushes check the fluid level in the surge brakes or the operation of the electric brakes lt p WACKER NEUSON Operation E 2200 E 3000 5 4 Operation 41 Control Component Locations e e Ground i Heater Thaw Frozen Ground Cure Concrete Meat Air wc_gr008060 WACKER 30 we_tx001667gb fm NEUSON 2200 3000 5 Operation 4 2 Control Component Descriptions Ret Description Ret Descriptor Liting vail optiona lowlevishudowndewos b m Temperature pressure gauge _ Exhaust stack p Hydronic heater flue box e Reier Pump i w Rwiffer Generator v Fuel supy ine Wc tx001667gb fm 31 M MEOCON Operation 2200 3000 5 4 3 Control Panel BREAKER 2
73. ler to the operating temperature temperature Use the chart below as a guide Operation type Recommended Temperature Setting Ground thawing 80 C 180 F Concrete curing 7 C 20 F above the desired temperature of the concrete Air heating 80 C 180 F we_tx001667gb fm 47 M MEGCON Operation 2200 3000ES 4 16 Positioning the Hoses and Operating the Machine Prerequisites Pre Starting checks completed See topic Pre Starting Checks a HTF preheated See topic Preheating the HTF and topic Initiating HTF Flow CAUTION Hoses may be very hot You may be burned if proper precautions are not taken gt Wear hand protection when handling hoses and hot components NOTICE This machine uses two hose loops during operation curing thawing heating The hose loops must be disconnected from each other before operating the machine Do not turn on both pumps with the hoses connected to each other Unwind Perform the procedure below to unwind and position the hoses the Note Unwind hose loop 1 with pump 1 turned 1 Close the cross connect valve 4 wc 01007815 wc 01007801 2 Turn the hose reel brake T handle counterclockwise a to release the brake 3 Unwind hose loop 1 position hose loop 1 in the application area while unwinding until the quick connect coupling that connects loop 1 with loop 2 is exposed Then turn off pump 1 4 Allow the
74. ll ventilated area Reinstall the fuel tank cap after refueling Only a trained technician should attempt to repair the genset Test procedures which require that the generator be running must be performed using extreme caution Make sure clothing and shoes are dry stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles when servicing the genset Engine antifreeze is toxic to humans and animals Clean up spills and dispose of used engine antifreeze in accordance with local environmental regulations uw WACKER H WY NEUSON Safety Information E 2200 E 3000ES 1 7 Safety Guidelines for Towing the Machine WARNING Risk of severe injury or death Improper trailer condition and towing technique can lead to an accident gt Obey the trailer manufacturer s instructions and the instructions below to reduce the risk of an accident When towing the machine Do not tow the machine if the towing vehicle s hitch or the trailer s coupler are damaged a Do not tow the machine if any of the trailer s lug nuts are missing Do not tow the machine if the trailer s tires have less than 1 5 mm 1 16 inch of tread Do not tow the machine unless the trailer s brakes are functioning properly Do not exceed the trailer manufacturer s speed limitations When towing the machine a Only tow the machine when the trailer s lug nuts are properly torqued a Only tow the machine when the trailer s
75. lt The HEAT XCHANGERS have now been connected 69 D WACKER NEUSON wc tx001668gb fm Accessories E 2200 E 3000ES 5 4 Connecting the HX 50 or HX 15 HEAT XCHANGER Requirements Limitations Procedure Machine stopped One HEAT XCHANGER HX 50 or HX 15 Hose For runs longer than 12 m 40 ft 2 pieces of 5 8 in ID with quick connect fittings Maximum run horizontal distance from HX to machine 228 m 750 ft Maximum rise vertical distance of HX above machine 76 m 250 ft a Maximum run at maximum rise 215 m 707 ft Note The farther an HX is positioned from the parent machine the more heat will be lost through the hose This may affect HX performance 0 76 m 250 ft 0 215 m 707 ft 0 228 m 750 ft wc gr008096 NOTICE Disconnect both surface heating hose loops before connecting the HEAT XCHANGERS The HEAT XCHANGERS require all HTF flow from both pumps to perform at their rated capacity Perform the procedure below to connect the HEAT XCHANGER to the machine 1 Stop the parent machine temporarily 2 Disconnect both surface heating hose loops from the machine before connecting the HEAT XCHANGERS This procedure continues on the next page WACKER NEUSON 70 _tx001668gb f 2200 3000 5 Accessories Continued from the previous page 3 Close valve 4
76. matics w Symbol LOW LEVEL LOW LEVEL BLK Low level shut down device power connection terminals WHT LOW LEVEL Low level shut down device normally open contacts Pumps enable Pump pack Relay coil K1 Relay normally open contacts K1 K2 K2 Relay normally closed contacts ay ica K2 K2 Relay normally open contacts K2 Ip e Relay coil CRX1 CRX1 CRX1 Relay normally open contacts 7 CRX1 E PL1 Pilot light 1 Low level fault oy PL2 Pilot light 2 Burner fault DUPLEX Duplex receptacle HOUR Hour meter METER Burner controller primary control n a n a K1 WACKER NEUSON 2200 3000 5 wc tx001672gb fm 2200 3000 5 Schematics Symbol Ret Description A SOL 2 Solenoid 2 Oil valve SOL 2 T CtypeT Thermocouple Type T TEMP Temp temperature controller CONTROLLER m CAB LIGHT Cab light Off On switch 7 14 15 8 6 CONTROLLER Circuit breaker 2 Ground Fault Circuit Interrupt 2 Pump 2 Off On switch Pump 1 Off On switch T Se DE HTR1 Heater fuel prewarmer HTR1 wq OVERRIDE LOW LEVEL Low level shut down device a OVERRIDE momentary override Off On MOMENTARY switch BURNER BURNER Burner Off On switch REWIND wc tx001672gb fm 1 27 W MEOSGR Schematics E 2200 E 3000ES 10 3 Burner System
77. n presented in this manual before operating the machine 1 3 Safety Guidelines for Operating the Machine Operator training Operator qualifications Application area Safety devices controls and attachments wc si000540gb fm 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 trained personnel are permitted to start operate and shut down the machine They also must meet the following qualifications have received instruction on how to properly use the machine a are familiar with required safety devices The machine must not be accessed or operated by a children people impaired by alcohol or drugs 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 Do not operate the machine in areas that contain flammable objects fuels or products that produ
78. nce occurs a The burner motor starts after a 5 second delay b The burner fires after a 15 second delay c he burner will operate with little or no visible exhaust smoke until the HTF reaches the set point temperature at which time the burner will stop firing d The burner will re fire if the set point temperature is increased or the temperature of the HTF falls below 100 F 38 Note The temperature of the HTF is displayed c in red TEMPERATURE CONTROL wc 1008062 Result When the temperature controller displays 100 0 c the HTF is preheated NEUSON 44 2200 3000 5 Operation 4 14 Initiating HTF Flow Prerequisites Heat Transfer Fluid HTF preheated See topic Preheating the HTF protection CAUTION Burn hazard The hoses and components of the plumbing system may be very hot Hot hoses and hot plumbing components may cause severe burns gt Wear hand protection when handling hot hoses or hot plumbing components Note f you are using accessories see Chapter Accessories Procedure Follow the procedure below to initiate HTF flow 1 Verify that the operation valve 2 is in the OPEN position wc 1007786 wc 01007815 2 Verify that the fill valve 3 is the CLOSED position Lock it in the closed position with the locking pin 3 Close the cross connect valve 4 This procedure continues on the next page
79. ng and curing capacities of the parent machine Covering the heat transfer hoses with insulation blankets increases heat retention and penetration he 1 2 and 2 1 adapters and accessory hoses allow the accessories to be properly connected to your parent machine For compatibility and configuration information continue reading gt WACKER 65 VM NEUSON Accessories E 2200 E 3000ES 5 2 Connecting the HX 200 or HX 60 HEAT XCHANGER Requirements Limitations Procedure Machine stopped One HEAT XCHANGER HX 60 or HX 200 Hose 2 pieces of 5 8 in ID or 1 in ID with quick connect fittings m Maximum run horizontal distance from HX to machine 228 m 750 ft Maximum rise vertical distance of HX above machine 76 m 250 ft Maximum run at maximum rise 215 m 707 ft Note he farther the HX is positioned from the parent machine the more heat will be lost through the hose This may affect HX performance 0 76 m 250 ft 0 215 m 707 ft 0 228 m 750 ft wc gr008096 NOTICE Disconnect both surface heating hose loops before connecting the HEAT XCHANGER The HEAT XCHANGER requires all HTF flow from both pumps to perform at its rated capacity Perform the procedure below to connect the HEAT XCHANGER to the machine 1 Stop the parent machine temporarily 2 Disconnect both surface heating hose loops from the machine before connecting the HEAT XCHANGER This pr
80. ocedure continues on the next page WACKER NEUSON 66 _tx001668gb f 2200 3000 5 Accessories Continued from the previous page 3 Open valve 4 EL TII HX 60 HX 200 wc gr007814 4 Position the HEAT XCHANGER within the space to be heated 5 Connect the HEAT XCHANGER supply hose a to the HTF supply line b 6 Connect the HEAT XCHANGER HTF return hose to the accessory HTF return port d 7 Insulate the supply and return hoses 8 Close the Pump Pack HTF supply valves f 9 Connect the HEAT XCHANGER to the appropriate electrical source NOTICE Only turn on the pumps when the HEAT XCHANGER is connected Turning on the pumps when the HEAT XCHANGER is not connected will cause excess system pressure which will damage the pumps 10 Start the parent machine Operate the parent machine with the temperature controller set to 80 C 11 Turn on
81. or worn The air damper is set incor Adjust the air damper rectly The cadmium cell is mal Replace the cadmium cell functioning The burner primary control Replace the burner primary is malfunctioning control Combustion is poor or There is a lack of fresh air Ensure there is an ade noisy to burner quate air supply MEOSGN 108 wc tx001671gb fm 2200 3000 5 Troubleshooting Thaw progress is below capacity Pump will not start Hose rewind does not work Pump is noisy and HTF flow is below nominal value wc tx001671gb fm The insulation is insuffi Add additional insulation cient blankets The moisture is insufficient Verify that there is standing water on job site There is no vapor barrier Lay down vapor barrier The HTF is not flowing Verify that the pump pres sure is nominal and hoses are not restricted The temperature control is not set properly oet the temperature control to optimum setting This setting depends on environ mental conditions at the job site The soil conditions are not as expected Re evaluate thawing plan based on job site condi tions There is no power Verify that the breaker switch is ON Verify that the HTF level is within range and low level cutoff control is reset low level indicator light must be OFF Warm the HTF and hoses before turning on the pumps see topic Preheat ing the Heat Transfer Fluid HTF in this manual
82. ounts Effects of Repeated Exposure In rare cases repeated excessive exposure to propylene glycol may cause central nervous system effects 3 Composition Information Component CAS Amount Propylene glycol 57 55 6 gt 48 0 lt 54 0 Water 7732 18 5 lt 50 0 Dipotassium hydrogen phosphate 7758 11 4 lt 3 0 4 First aid measures Eye Contact Flush eyes thoroughly with water for several minutes Remove contact lenses after the initial 1 2 minutes and continue flushing for several additional minutes If effects occur consult a physician preferably an ophthalmologist Skin Contact Wash skin with plenty of water Inhalation Move person to fresh air if effects occur consult a physician Ingestion No emergency medical treatment necessary Notes to Physician No specific antidote Treatment of exposure should be directed at the control of symptoms and the clinical condition of the patient 9 Fire Fighting Measures Extinguishing Media To extinguish combustible residues of this product use water fog carbon dioxide dry chemical or foam Fire Fighting Procedures Keep people away Isolate fire and deny unnecessary entry Use water spray to cool fire exposed containers and fire affected zone until fire is out and danger of reignition has passed To extinguish combustible residues of this product use water fog carbon dioxide dry chemical or foam Special Protective Equipment for Firefighters Wear posi
83. procedure below to confirm the integrity of the flue box rope gasket 1 Allow the machine to cool WARNING Burn hazard The hydronic heater is very hot when the machine is operating When hot it can cause severe burns gt Allow the machine to cool before performing this procedure 2 Inspect the area around the flue box door a for the following signs of leakage White or brown residue is visible Rope gasket is protruding from flue box Bubbles are visible on the black painted surface NOTICE f any of these symptoms exist investigate and repair the source ghi 07006509 Follow the procedure below to replace the rope gasket 1 Remove the nuts b that secure the flue box door and remove the door E ghi 97006510 ghi gr006511 2 Remove the old gasket c and replace with a new one Note You may need to use a tool such as a screwariver to remove the gasket The procedure is now complete Re assemble the machine WACKER un p NEUSON 104 _tx001670gb f 2200 3000 5 Maintenance 7 11 Storing the Machine Short term 1 storage 2 3 4 5 6 Long term 1 storage Fill the HTF reservoir if it is low Stop the machine See topic Shutting Down and Packing Up the Machine Remove and store any accessories Allow the heater to cool sufficiently Verify that all control switches are in the OFF position Fill the fuel tank if it is low Allow space in the fuel tank for fu
84. r material is available to support the trailer tongue during transporting Do not use the machine s jack stand to support the trailer tongue during transporting O Check that any ramps used in the loading process Can support the weight of the machine clean and free of grease oil ice and other loose material securely connected to the transport vehicle or trailer m of sufficient length to keep the loading angle 15 or less In addition O Check that the loading area is flat and the ground is stable O Check the overall height of the machine once loaded Plan your travel route so there will be adequate clearance for overpasses road signs buildings etc Check local regulations regarding transporting and obey these regulations k WACKER NEUSON 28 _tx001666gb f 2200 3000 5 Lifting and Transporting 3 3 Before Towing Checklist wc tx001666gb fm Before towing the machine check the licensing requirements for trailers in your area Also check the following items Hitch and coupler Check that the towing vehicle and hitch have a rating equal to or greater than the GVWR of the machine See Technical Data O Check that the hitch of the towing vehicle and coupler of the trailer are compatible O Check the condition of both the coupler and hitch O Check that all fasteners on the coupler are secure Check that the coupler has fresh grease applied to it Wheels Chec
85. rator a hydronic heater electric motors fixed pump s and plumbing a diesel or gas burner a fuel tank and a hose handling system The hydronic heating system utilizes a burner that indirectly warms the Heat Transfer Fluid HTF The warmed HTF is continuously circulated through vented closed loop hose system A positive displacement pump pushes the warmed HTF through the hose system thereby radiating and transferring the heat to the required application area An insulated blanket may be laid over the hoses to increase efficiency The low HTF level protection device shuts down the machine if the HTF level drops below minimum operational capacity This machine is intended to be used as a surface heater in order to thaw frozen ground to cure concrete or to prevent frost and freezing In addition when used with other Wacker Neuson accessories this machine can be used to heat air This machine has been designed and built strictly for the intended use s described above Using the machine for any other purpose could permanently damage the machine or seriously injure the operator or other persons in the area Machine damage caused by misuse is not covered under warranty The following are some examples of misuse a Using the machine to heat anything other than what is stated above Using the machine to pump anything other than the factory recommended heat transfer fluid Using the generator if equipped to power anything other
86. ructions contained in all manuals delivered with the machine Familiarize yourself with the location and proper use of all controls and safety devices a Only trained personnel shall 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 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 a Remain aware of the machine s moving parts Keep hands feet and loose clothing away from the machine s moving parts Reinstall the safety devices and guards after repair and maintenance procedures are complete When servicing or maintaining the machine Use only accessories attachments that are approved by Wacker Neuson Corporation When servicing or maintaining the machine Do not defeat safety devices Do not modify the
87. s be installed in all structures in close proximity to the machine CO alarms provide an extra measure of protection against this poison that you cannot see or smell Install battery operated CO alarms or plug in CO alarms with battery backup according to the manufacturer s instructions CO alarms should be certified to the requirements of the latest safety standards UL 2034 IAS 6 96 or CSA 6 19 01 Test the CO alarm batteries monthly Requirements Position the machine So that burner exhaust will not enter nearby structures So that the machine does not block traffic a So that the machine is not close to any combustible material So that all of the machine s access doors panels may be accessed that HTF hoses do not pose tripping hazards and so the HTF hoses cannot be damaged by machines or other equipment on the job site Procedure This procedure continues on the next page 4 WACKER M NEUSON 38 x0016679b 2200 3000 5 Operation Continued from the previous page Perform the following procedure to position the machine 1 Place the machine near the application area a on solid stable and level ground wc 07008055 2 For machines with trailers install chocks b under the wheels Result The machine is now properly positioned WACKER M NEUSON wc tx001667gb fm 39 Operation E 2200 E 3000 5 4 10 Pre Starting Checks Prerequisites Machine properly positioned
88. se dirty or contaminated quick connect couplings Do not lubricate quick connect couplings Usage Follow the instructions below when using the quick connect couplings 1 Clean both the male and female b couplings before and after each use 2 Push and hold the locking collar c on the female coupling b down 3 Insert the male coupling a 4 Release the locking collar to lock Cleaning Follow the instructions below when cleaning the quick connect couplings Instructions 1 Rinse each coupling with clean water before and after each use Note Be sure that each coupling is free of dirt and debris 2 Inspect seals and gaskets before and after each use 3 Install caps or protective covers after each use ghi_gr005291 s WACKER M NEUSON 58 _tx0016679b 2200 3000 5 Operation 4 23 Resetting the Snap Switch Background The thermal overload switch snap switch opens when the temperature of the Heat Transfer Fluid HTF reaches 88 190 F When the snap switch opens electric power is disconnected from the burner The snap switch must be manually reset to reconnect power to the burner NOTICE lf the snap switch opens locate and resolve the reason why it opened before using the machine WARNING Burn hazard Hot piping and hot HTF can cause burns gt Allow the machine to cool before attempting to reset the snap swi
89. stance List and are present at levels which require reporting Component CAS Amount Propylene glycol 5 55 6 gt 48 0 54 0 Pennsylvania Worker and Community Right To Know Act Pennsylvania Special Hazardous Substances List To the best of our knowledge this product does not contain chemicals at levels which require reporting under this statute California Proposition 65 Safe Drinking Water and Toxic Enforcement Act of 1986 This product contains no listed substances known to the State of California to cause cancer birth defects or other reproductive harm at levels which would require a warning under the statute Toxic Substances Control Act TSCA All components of this product are on the TSCA Inventory or are exempt from TSCA Inventory requirements under 40 CFR 720 30 CEPA Domestic Substances List DSL This product contains one or more substances which are not listed on the Canadian Domestic Substances List DSL Contact your Dow representative for more information 16 Other Information Hazard Rating System NFPA Health Fire Reactivity 0 0 0 Recommended Uses and Restrictions Intended as a heat transfer fluid for closed loop systems Dow recommends that you use this product in a manner consistent with the listed use If your intended use is not consistent with Dow s stated use please contact Dow s Customer Information Group Revision Identification Number 50551 1001 Issue Date 12 10 2007 Version 3
90. t the burner nozzle The atomized fuel is ignited by the electrodes The electrodes stay powered for up to 30 seconds after flame is sensed Once the carry over period has expired m he ignition transformer is shut off m he burner controller enters the run mode If the flame is lost m f the lockout time has not expired the burner controller returns to trial for ignition period f the lockout time has expired the burner controller enters the recy cle mode The burner motor off delay period starts immediately after the setpoint is reached i e the call for heat has been satisfied The time of this period is set by the DIP switches DIP switches 1 and 2 in the down position 3 in the up position During this period m The fuel shut off valve is closed de energized m he burner motor runs until the burner motor off delay expires then the burner motor turns off m he burner controller returns to the idle mode The burner non fault modes are described below Mode Functional description The burner controller will enter the idle mode if m At power up the internal conditions are correct and the cad cell senses no light m he cad cell senses light during the safety period m he call for heat has been satisfied During this mode m he burner controller powers no outputs WACKER 61 M NEUSON Operation E 2200 E 3000ES Mode Functional description Startup The burn
91. tap the bolt b with a hammer to break the seal between the gasket e and the housing g 4 Remove the bolt b and gasket d 5 Remove the filter housing cap c and gasket e 6 Pull the fuel filter element f out of the housing Perform the procedure below to install the new fuel filter 1 Remove any remaining gasket material from the filter housing cap or the housing 2 Place the new fuel filter element f with exposed screen portion facing up into the housing g Place the new gasket e on the top lip of the housing Slide the new gasket d on the bolt b Reinstall the filter housing cap c to the housing g with bolt b o A Reconnect the fuel line at the quick connect fitting a The fuel filter has now been changed MEOSGN 1 00 wc tx001670gb fm 2200 3000 5 Maintenance 7 8 Lubricating the Hose Reel System Requirements Machine shut down Machine cool Procedure Perform the procedure below to lubricate the hose reel system 1 Disconnect electric power from the machine 2 Apply low temperature bearing grease with several pumps from a grease gun to each bearing a wc gr007823 3 Lightly apply a low temperature lubricating oil to the chain b Result The hose reel system has now been lubricated wc tx001670gb fm 101 Ww MEOSGR Maintenance E 2200 E 3000ES 7 9 Cleaning the Turbulators and the Exhaust Ducting Requirements Machine shut down
92. tch Procedure Perform the procedure below to reset the snap switch 1 Locate the snap switch a on top of the hydronic heater wc gr007878 2 Press the reset button Result The snap switch has now been reset wc tx001667gb fm 59 M MEOSGR Operation 2200 3000ES 4 24 Burner Controller Periods and Modes 2 Period Call for heat Call for heat satisfied ghi_gr006220 Periods The burner controller has several periods it sequences through during normal operation These periods are described below Action or Function Power up As soon as power is supplied to the burner controller it conducts an internal safety check If all internal conditions are OK the burner controller enters the idle mode and will remain there until there is a call for heat or power is disconnected Safety When the setpoint of the temperature controller is set at a temperature 5 seconds higher than that of the heat transfer fluid the output contacts of the temperature controller close completing a circuit between terminal T and 3T of the burner controller This is the call for heat The burner controller initiates the safety period If flame or light is detected the burner controller remains in the idle mode and no other functions take place If flame or light is not detected after 5 seconds Power is sent to the burner motor fuel pump Fuel is pumped from the supply tank and returned to
93. ter locking screw b i ghi gr006189 3 Using the band position pointer c to determine position move the air band to a higher number to increase air volume Turn it to a lower number to decrease air volume 4 Using the shutter position pointer d to determine position move the air shutter to a higher number on the shutter position pointer to increase air volume Turn it to a lower number to decrease air volume 5 After the air settings have been made tighten the band locking screw a and the shutter locking screw b You have now adjusted the air settings NEUSON NEGSON 88 wc tx001669gb fm 2200 3000 5 Burner Setup 6 5 Setting the Fuel Pressure Requirements Pressure gauge See Factory Settings chart in topic Burner Setup for fuel pressure reading Procedure Follow the procedure below to check and adjust the fuel pressure 1 Shut down the machine 2 Remove the bleeder valve a from the fuel pump ghi gr006188 3 Insert the gauge in place of the bleeder valve 4 f your machine has a generator start it 5 Move the Burner ON OFF switch to the ON position The burner will go through a pre purge cycle Monitor and make adjustments during the pre purge cycle 6 Turn the adjusting screw b clockwise to increase fuel pressure counterclockwise to decrease fuel pressure Result The fuel pressure has now been adjusted Wc tx001669gb fm 89 Ww Burner Setup E 2200 E 3000ES
94. the HEAT XCHANGER and adjust its thermostat as desired Result The HEAT XCHANGER has now been connected and is operating WACKER wc tx001668gb fm 67 NEUSON Accessories E 2200 E 3000ES 5 3 Connecting the HX 100 or HX 30 HEAT XCHANGER Requirements Limitations Procedure Machine stopped One HEAT XCHANGER HX 100 or HX 30 Hose For runs longer than 12 m 40 ft 2 pieces of 5 8 in ID with quick connect fittings Maximum run horizontal distance from HX to machine 228 m 750 ft Maximum rise vertical distance of HX above machine 76 m 250 ft a Maximum run at maximum rise 215 m 707 ft Note The farther an HX is positioned from the parent machine the more heat will be lost through the hose This may affect HX performance 0 76 m 250 ft 0 215 m 707 ft 0 228 m 750 ft wc gr008096 NOTICE Disconnect both surface heating hose loops before connecting the HEAT XCHANGERS The HEAT XCHANGERS require all HTF flow from both pumps to perform at their rated capacity Perform the procedure below to connect the HEAT XCHANGER to the machine 1 Stop the parent machine temporarily 2 Disconnect both surface heating hose loops from the machine before connecting the HEAT XCHANGERS This procedure continues on the next page WACKER NEUSON 68 _tx001668gb f 2200 3000 5 Accessories Continued from the previous page 3 Close valve 4
95. this machine which is painted red Failure to heed above warning could result in damage to personal property or cause serious injury or death Do not use ether or other start helpers on generator engine Failure to heed the above warning may cause irreparable damage and void engine warranty Read Operator s Manual Follow use and maintenance guidelines as recommended by generator manufacturer and engine manufacturer Failure to do so may cause irreparable damage and void engine or generator warranty 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 Burner setup This label indicates important setup information for the burner WACKER M NEUSON Labels E 2200 E 3000ES CAUTION Hot surface hazard WARNING Hand entanglement hazard Moving parts can crush and cut Do not operate with guard removed HTF MSDS label This label is the Material Safety Data Sheet for the HTF installed in the factory THIS HEATER OPERATES AT ZERO ATMOSPHERIC PRESSURE AND IS NOT SUBJECT TO REGULATIONS APPLICABLE TO PRESSURIZED BOILERS 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 sho
96. tioning hoses Do not use this pro cedure for any other purpose Follow the procedure below to stop the machine temporarily 1 Move the burner ON OFF switch a to the OFF position wc 1008084 2 Allow the burner to complete the burner motor off delay period 3 Move the pump ON OFF switches b and c to the OFF position 4 Turn off all accessories if applicable Your machine is now stopped Perform the necessary task s refueling repositioning hoses etc Follow the procedure below to restart the machine 1 Move the burner ON OFF switch a to the ON position 2 Wait until the burner fires 3 Move the pump ON OFF switches b and c to the ON position 4 Start accessories if applicable Your machine has resumed operating WACKER 51 VM NEUSON Operation 2200 3000 5 4 19 Rewinding the Hoses Requirements All accessories off if applicable Machine turned on CAUTION Hot surface hazard Hoses may be very hot Wear hand protection while handling hoses Procedure Perform the procedure below to rewind the hose Note Having warm HTF circulate through the hose will aid in rewinding of the hose Rewind the hoses with the burner firing 1 Turn the T handle a counterclockwise to unlock the hose reel wc 1007885 wc gr007886 2 Remove the foot pedal b and place it on a firm flat and dry surface 3 Move Pump 2 ON OFF switch c to the ON position
97. tive pressure self contained breathing apparatus SCBA and protective fire fighting clothing includes fire fighting helmet coat trousers boots and gloves If protective equipment is not available or not used fight fire from a protected location or safe distance Unusual Fire and Explosion Hazards This material will not burn until the water has evaporated Residue can burn Hazardous Combustion Products Under fire conditions some components of this product may decompose The smoke may contain unidentified toxic and or irritating compounds Combustion products may include and are not limited to Carbon monoxide Carbon dioxide 6 Accidental Release Measures Steps to be Taken if Material is Released or Spilled Small spills Absorb with materials such as Cat litter Sawdust Vermiculite Zorb all amp Collect in suitable and properly labeled containers Large spills Dike area to contain spill See Section 13 Disposal Considerations for additional information Personal Precautions Keep unnecessary and unprotected personnel from entering the area Use appropriate safety equipment For additional information refer to Section 8 Exposure Controls and Personal Protection Environmental Precautions Prevent from entering into soil ditches sewers waterways and or groundwater See Section 12 Ecological Information Page 2 of 7 MSDS Dowfrost 50 Product DOWFROST HD 50 Heat Transfer Fluid Dyed Issue Date 12 1
98. to burner fault lockout mode m lf the call for heat is satisfied the recycle counter resets This procedure continues on the next page WACKER M NEUSON 62 wc tx001667gb fm 2200 3000 5 Continued from the previous page Fault modes Operation The burner controller fault modes are described below Lockout Restricted lockout The burner will enter the lockout mode after three unsuccessful attempts to re light the flame During the lockout mode The burner will not fire m he diagnostic light on the burner controller will flash in half second intervals m he burner fault light on the control panel will illuminate To clear the lockout fault so a restart can be attempted press and release the reset button Note After the third attempt to manually clear the lockout fault the burner controller will enter the restricted lockout mode The burner will enter the restricted lockout mode after three unsuccessful attempts to manually reset the lockout fault During the restricted lockout mode m he burner will not fire m he diagnostic light on the burner controller will flash in half second intervals m he burner fault light on the control panel will illuminate To clear the restricted lockout fault so a restart can be attempted press and hold approximately 30 45 seconds the reset button until the diagnostic light flashes once Note The burner will return to the lockout mode wit
99. two seconds after the control switch is initially placed in the Stop Prime position Continue holding the control switch for at least one minute wc gr007811 3 Press and hold the control switch in the Start Preheat position The genset will first preheat for up to 15 seconds depending on how cold it is Then the starter will engage and the engine will start NOTICE not crank the engine for more than 30 seconds at a time Wait at least two minutes before cranking the engine again Perform the procedure below to stop the genset 1 Move the generator circuit breakers to the OFF position 2 Allow the genset to run two minutes to cool down 3 Press the control switch to the Stop Prime position lt p WACKER NEUSON Operation 2200 3000 5 4 13 Preheating the HTF NOTICE Starting the machine with frozen or partially frozen Heat Transfer Fluid HTF will permanently damage the pumps Preheat the HTF when ambient air temperature is below 26 C 15 F Prerequisites HTF reservoir full a Machine powered up Procedure Follow the procedure below to preheat the HTF 1 Use the up and down arrows a on the temperature controller to set the HTF temperature to 100 F 38 C This is the set point temperature BURNER wince i mp Se TEMPERATURE wc 01008061 ghi gr006377 2 Move the burner ON OFF switch b to the ON position The following seque
100. tx001670gb fm 2200 3000 5 Maintenance Installation Result wc_tx001670gb fm Continued from the previous page 1 Inspect the strainer gasket f and replace it if it is damaged 7 T Pw gt pes 9704 by 2 wc 01007697 wc 97007698 2 ensure strainer gasket f placement install the canister b over the strainer basket 91007695 007694 4 Install the strainer housing including strainer basket into the machine using the screw a and screw b The HTF strainer is now clean and ready for operation WACKER 99 NEUSON Maintenance E 2200 E 3000ES 7 7 Replacing the Fuel Filter Requirements Removal Installation Result a Machine shut down New fuel filter element and gasket kit NOTICE Do not remove the fuel filter assembly from the machine unless the filter housing cap needs to be replaced To remove the fuel filter element carry out the following procedure Note n the interests of environmental protection place a plastic sheet and a con tainer under the machine to collect any liquid which drains off Dispose of this liquid in accordance with local environmental protection laws 1 Disconnect the fuel line at the quick connect fitting a e om wc gr008078 2 Loosen do not remove at this time the bolt b that secures the filter housing cap c 3 Hold the filter housing g and lightly
101. uld 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 WACKER we Ww NEUSON 26 _si000541gb f 2200 3000 5 Lifting and Transporting 3 Lifting and Transporting 3 1 Lifting the Machine Requirements Procedure wc tx001666gb fm wm Lifting device crane or hoist capable of supporting the machine s weight wm Lifting hooks and chains capable of supporting the machine s weight Machine stopped cooled and accessories removed See section Shutting Down and Packing Up the Machine WARNING Crushing hazard You may be crushed if the lifting devices fail gt Never stand under or get onto the machine while it is being lifted or moved Useonly the designated lifting points to lift the machine Perform the procedure below to lift the machine 1 Only those machines fitted with optional lifting bails may be lifted with a crane Attach the lifting hook and chain from the crane to one of the lifting eyes a on the machine wc gr008053 2 Lift the machine a short distance 3 Check for stability If necessary lower the machine and reposition it Only continue lifting when the machine is stable 4 Continue lifting the machine as necessary WACKER 27 NEUSON Lifting and Transporting E 2200 E 3000ES 3 2 Preparing the Machine for Transport on
102. y recommended Heat Transfer Fluid HTF Failure to comply may damage the machine Background procedure for routine filling of the HTF reservoir differs slightly from that when a low level fault is encountered If your machine has experienced a low level fault see topic Hesetting a Low HTF Level Fault Fill the HTF 1 Remove the pin and move the fill valve 3 to the OPEN position reservoir wc gr007807 2 Move the operation valve 2 to the CLOSED position 3 Remove the fill hose from its storage location under the hose reel Remove the cap from the hose if a cap is provided 4 Place the open end of the fill hose into a container of HTF This procedure continues on the next page NEG AMT 96 wc tx001670gb fm 2200 3000 5 Maintenance Continued from the previous page Fill the HTF 5 Move and hold the bypass switch x in the ON position HTF will begin to flow reservoir When the HTF is level is between the minimum and maximum marks on the sightglass c a Pull the fill hose from the HTF supply b Release the bypass switch NOTICE Do not overfill the HTF reservoir Doing so may damage the machine MAX T uM TEMPERATURE MIN wc 01008068 wc gr008120 Prepare After filling the HTF reservoir perform the procedure below to prepare the machine machine for operation operation 1 Press the low level shut down reset button a if the red LED b is lit wc gr008077 wc gr007810 2 Move the op

E 2200 E 3000ES

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