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2004 SAH 1250 Operators Manual

1. dmg RETURN MANIFOLD SUPPLY MANIFOLD CHECK VALVE Valve 6 Valve 5 OPEN SHUT Valve 7 OPEN Valve 4 SHUT MAIN CIRCULATION PUMP P N M100 647 Valve 3 OPEN S HYDRONIC HEATER PRESSURE GAUGE FLOW INDICATOR OPEN V 1 Rev 2 17 04 2004 Ground Heaters Inc 11 SAH 1250 VALVE POSITIONING FOR NORMAL OPERATION HX 200 HEAT EXCHANGER RETURN MANIFOLD SUPPLY MANIFOLD CHECK VALVE 5 4 Valve 5 MAIN CIRCULATION PUMP P N M100 647 Valve 3 OPEN PRESSURE GAUGE FLOW INDICATOR Valve 2 OPEN A 12 2004 Ground Heaters Inc BOOSTER PUMP CONNECTIONS WITH PROTECTIVE CAPS INSTAL
2. dVL 3ufissaud 5 AHL AHL YALAWONVI ANY MOOOLAd V TIVLSNI ASVAYOAG ASIMMOOTO YALNNOO NYNL ASVAYONI 3SIMMOO 19 WALS LNAWLSNPOV AHL V lt H3AOO SVS AHL 17 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAH 1250 DIESEL BURNER P N P100 690 COMPONENT IDENTIFICATION fir C 1 4303319 1304 MAYOS 55 1314 ASVAYONI 4195 0014 133HM 1531 1915 a E S 0 Ero p EEN v H D 9S8 00Ld N d p uu HOLON iHOdNOHO3NNOO 008 45 EE 1131238 3 VIN 91 waviv O 1 2 905 0014 19 4
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5. Nant L331 qaa 1 SHO IOO YA IIVH L 13A NYS LHM agd 97109 1 SYNLVININ NYS 681 0013 gina 1 pum AH3LlV8 N33H9 NHO IHC 3lIHM LHM NEN dqasn LON MOTI3A 134 ZI JT0IHIJA WER Es N3349 3lIHM 1HM pu 1491 Od SLIOA ZI 30709 2 AVM Z V 1 Rev 2 17 04 2004 Ground Heaters Inc SAH 1250 TRAILER JUNCTION BOX AND BATTERY WIRING SHO 1OO AVM Z EE Addliva dddVHl NYS ALIHM LHM cl SHO IOO NOLL NMOH8 Been 0351 LON MOTI3A TAA p 3 S3 Vu8 alld 3399 NYS GQNNOYD AAILVDAN ALIHM LHM L331 439 dau GASNLON SHO 1OO 3UIM H3 TIVH L SSS NOLL NMOH8 0351 LON MOTI3A TAA S3 Vu8 ani
6. 3 2 DIE SEL FUEC 3 2 1 sae mo mE 3 2 1 1 Fuel Pressure nennen nennen nnn nnns 3 2 1 2 Air Setting and Adusiment nennen nnne nnn 3 2 1 3 O Content RE o 3 2 1 4 Smoke Spot Sampling 3 2 2 2004 Ground Heaters Inc V 2 4 2 4 2 4 2 4 2 4 2 5 2 5 2 6 2 6 2 6 2 6 2 6 3 1 3 1 3 2 3 2 3 3 3 3 3 3 3 4 3 5 V 1 Rev 2 17 04 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL 6 Ground 153 inc NS Heaters TABLE OF CONTENTS continued Page MAINTENANCE 4 1 ADDING HEAT TRANSFER FLUID 4 1 4 1 1 To Clear LOW HTF LEVEL CGondrton 4 1 4 2 BURNER INSTALLATION CHANGEOVER 4 2 4 2 1 From NG LP to Diesel Fuel Ou 4 2 4 2 1 1 CANE 4 2 4 2 1 2 o EC 4 3 4 2 2 From Diesel Fuel Olto NG cti RUE ine Cte ode Costume ous 4 3 4 2 2 1 Jr M 4 4 4 2 2 2 vj 4 5 4 3 HIGH ELEVATION 4 5 4 4 HECOMMENDE
7. nnne nennen nennen 1 2 1 2 2 Rear tn E 1 3 1 3 EREECHEN 1 3 1 4 SAFETY FEATURES E 1 4 1 5 SAFETY EE 1 4 1 5 1 1 4 1 5 2 Safe Operation Mamtenance 1 5 1 6 REPAIR PARTS AND ACCESSORIES 1 5 1 7 ap hole 1 5 1 8 OBTAINING WARRANTY SERVICE 1 6 START UP OPERATION AND SHUTDOWN 2 1 SYSTEM CONFIRMATION ADVISORY 2 1 2 1 1 Standard Configuration 2 1 2 1 2 Booster Pump Option and 2 1 2 1 3 Hose Configuration Lummtatons 2 1 2 1 4 9162 1018 110 N 2 1 2 1 5 Ms late gt 2 1 2 2 CARE AND HANDLING OF HOSE QUICK CONNECTS CAM LOCKG 2 2 2 2 1 2 2 2 2 2 Quick Connects and CGam Locks 2 2 2 2 3 MVR dme pm 2 2 2 3 SETUP 2 2 2 3 1 OS MOMMA MT _ _______ ____ 2 2 2 3 2 Unloading HX 200 Heat 2 2 2 3 3 Heat Transfer Fluid HTF 2 3 2
8. 5 QOOM cLX8X8 NV ANONOL 0921 HVS AHL LYOddNS NOILOVO Q39HOHNI3H H3QN 19 LSNW 342018 LHOddflS 15 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAH 1250 GAS BURNER P N P100 673 COMPONENT IDENTIFICATION 9868 0014 HOLIMS HIV 96 001 YOSNAS 14 001 S 00ld GION3 OG SVO 1O lld gt dV L Q IOJINVIM NIVH L SVD p n p 3A1VA SV9 V 1 Rev 2 17 04 966 0014 N d dHOLV 938 SVD 1 Z 00Ld YAWYOASNVEL 00 33HM NOILONAL NIVEL SVO 75 00153 N d 3 VIN 2 91 LVE 00ld SVO xnv 0v 00Ld N d SVO NIYIN YOLOW H3MO 18 ONT 051 0013 N d SVS
9. L le L 12 LIC G G 2 6 6 LL L6 6 L6 8 LOC 202 LOC 202 cO 1230 yoop duis 9 910N 41915 4 9 Q V 1 Rev 2 17 04 2004 Ground Heaters Inc SAH 1250 DIESEL BURNER SCHEMATIC FROM LINE 17 120VAC LOWLEVEL SHUTDOWN 100 198 ORG B RED CONCERN 4 BLK H LOW LEVEL OVERRIDE SW BLK BLK CIRCULATION PUMP SW BLK CR2 BURNER SW TS 1 200 E100 143 8 LJ L1 LIMIT CAD CELL P100 253 WIRE COLORS YEL BLK BLACK 49 RED RED WHT WHITE BLUE OFANGE BURNER 100 206 PIN 1 8 10 BLU 1 2 5 NO THERMOCOUPLE m TYPE T RED 40 TEMP S CONTROL E100 084 CAB LIGHT SW V 1 Rev 2 17 04 2004 Ground Heaters Inc P 1 PIN 3 FROM LINE 17 N LOW LEVEL RELAY 100 205 WHT 0 LOW LEVEL LIGHT E100 353 WHT PUMP CONTACTOR E100 317 M1 WHT 9 HOUR METER E100 096 PRE HEATER P100 251 WHT e gt P 1 PIN 2 BLU IGN e BURNER MOTOR ORG e FUEL SHUTOFF VALVE BURNER CONTROL RELAY E100 205 2 0 4 CAB LIGHT 9 SAH 1250 NG LP BURNER SCHEMATIC FROM LINE 17 120VAC N
10. d 665 0014 H3INHOJSNVH L Q3 TIVISNI 1531 164 00 0 i 00 N d 1303 9068 0014 N d 330 LAHS Tana V 1 Rev 2 17 04 2004 Ground Heaters Inc A 18 SAH 1250 SAFETY CONTROLS NG LP BURNER CONTROL P N P100 338 TS ET BURNER CONTROL The POWER light will illuminate only during the heating cycle After flame is established the POWER PILOT MAIN and FLAME lights should all be illuminated If flame failure of any nature is sensed during the start up or heating cycle the control will stop all burner function and begin Lockout mode Lockout Mode ALARM light will illuminate PILOT FLAME and MAIN lights will go out Momentarily press the RESET button to clear the lockout condition gt lt WHT gt gt BLK gt lt GRN 1 WHT WHT BLK AIR SWITCH BURNER MOTOR IGNITER UV FLAME SENSOR WIRE COLORS BLK We BLK BLACK T ORG ORANGE WHT WHITE GRN BLU BLUE gt gt ORG ORANGE 1 2 17 04 2004 Ground Heaters Inc 19 SAH 1250 SAFETY CONTROLS DIESEL BURNER CONTROL P N P100 206 The Diagnostic light green LED will illuminate during the heating cycle after the 15 second pre purge time has elapsed and flame ha
11. the protective caps from the booster pump connection points on the SAH 1250 SU De XL od X I Connect the booster pump hoses to the SAH 1250 one at a time by removing the protective cap from the hose cam lock Take care not to spill the HTF contained in the booster pump and hose 8 Engage the hose cam lock into the appropriate cam lock on the SAH 1250 and LOCK into place by simultaneously swinging the cam lock handles to the LOCKED position Refer to Appendix A 14 SAH 1250 QUICK CONNECT AND CAM LOCK CARE AND MAINTENANCE 9 Repeat Step 6 for the remaining hose 10 UNLOCK and OPEN valves 6 and 7 11 Plug the booster pump power cord into the booster pump female pigtail provided Refer to booster pump control panel 12 Connect a heavy duty 10 3 extension cord of no more than 50 ft in length into the booster pump male pigtail provided Refer to booster pump control panel 13 Connect the extension cord to a 20 amp 120 volts AC 60 Hz electrical circuit not the same circuit used for the SAH 1250 NOTE The Booster Pump should only be started after the SAH 1250 has been set up and is ready for use The on board pump should be started prior to starting the booster pump The booster pump will only operate when the MAIN PUMP switch is turned ON Refer to main control panel Refer to Section 2 4 START UP for SAH 1250 start up instructions 2 3 5 2 Start Up 1 Turn the BOOSTER PUMP switch ON 2 SHUT
12. Nid m LHM penu 039 8 SYO IOO 2004 Ground Heaters Inc V 1 Rev 2 17 04 HX 200 HEAT EXCHANGER WIRING DIAGRAM NAXAOHH EE Nid m LHM o 039 OV IG SYO 100 67 0019 N d 9201 dH HOLON H3MO T18 Nu9 N N js L Ne 0344 N m lt gt 879 00 LN 3 MOT v 0013 N d MS HOLO313S 9334 440 979 00LW N d OWAOZE X AJAN SI YOLIOVdVO 0v4 00LIN N d JOH INOO 985 0015 3 IVIN 04554944 1 2 17 04 2004 Ground Heaters Inc A 10 SAH 1250 VALVE POSITIONING FOR OPTIONAL BOOSTER PUMP USE HX 200 HEAT EXCHANGER II BOOSTER PUMP FILL HOSE BOOSTER PUMP CONNECTIONS
13. Once the MGV s open monitor the manometer connected to the manifold pressure tap and adjust the manifold regulator stem until the following values are obtained 2 in WC LP 4 in WC NG Turn the manifold regulator stem clockwise to increase manifold pressure turn the stem counter clockwise to reduce the manifold pressure 19 Once the appropriate fuel pressure is set proceed with air setting and adjustment Air Setting and Adjustment Top or bottom air dampers may be opened or closed in amounts sufficient to adjust exhaust 0 levels to 4 6 using a combustion analyzer 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAHARA AIR MODEL 1250 OPERATOR S MANUAL SECTION 3 GR Ground se crus Heaters 3 1 1 3 Content Sampling 3 1 1 4 NOTE NOTE 1 2 Follow the combustion analyzer manufacturer s instructions for pre purge and exhaust sampling Sample the exhaust gas by inserting the combustion analyzer sampling probe into the chimney access hole provided through the exhaust guard The probe must be greater than 5 in 127 mm in length for an accurate sampling Exhaust O content must be 4 to 6 for optimum performance and minimum soot production Several samples should be taken as the heater warms The final sample should be taken just before the heater reaches 180 F 82 2 omoke Spot Sampling 1 2 Follow the smoke spot tester manufacturer s instructions for accur
14. RESET TEST we ae S a TEST BUTTON POWER WIRE COLORS BLK BLACK rc HED RED WHT WHITE EINEN GRN GREEN sw BLU BLUE Sj ORG ORANGE mew A 21 Ground 111 me SAHARA AIR HEATER 1250 OPERATOR S MANUAL 6 Heaters SPECIFICATIONS E SPECIFICATIONS Dimensions and Capacities Length 172 in 437 cm Width 92 in 234 cm Height 80 in 203 cm Weight 7 120 105 3 230 kg Hose 1 000 ft 305 m 200 ft 61 m 100 ft 31 m 50 ft 15 m Hose Reel Hose Rewind 120V AC w 12V DC clutch Circulation Loops Tires LT235 85R 16 Hitch 3 in Pintle or 2 5 16 in Bal Heat Exchangers 200 000 BTU H 2 670 4 Loading Ramp On Board Manifolds Lifting Bar Standard Normal Operating Temp 180 F 829C V 1 Rev 2 17 04 2004 Ground Heaters Inc B 1 SAH 1250 APPLICATION LAYOUTS Application Multi room single level building site Application Multi level building site V 1 Rev 2 17 04 2004 Ground Heaters Inc
15. Grou HOSE CAB PUMP BURNER REWIND LIGHT MINIMI TEMPERATURE LOWLEVEL OVERRIDE SW 2004 Ground Heaters Inc SAH 1250 CONTROL PANEL INTERIOR LAYOUT D 69 69 216 0019 N d YOLOVLNOO NOILVINOYIO SE 62 3l NHOJSNVH L 0 0013 ONIA M rl 9 0019 CHO 6c 0013 N d 1OHLNOO YANYNE edo 902 0019 E 0c 0013 AV 13H 13441 MOT HI L62 0013 N d GL 0O d1 end 02 0013 N d m CO 61 0013 2 20 1 9 1 0013N d SNA LN L1 LN 205 205 COE CLL 205
16. Ground inc Heaters Sahara Air Heater Model 1250 Operator s Manual Work in clean dry heat 0000000 Another innovative e EU heat solution e from Ground Heaters Inc US Ground Heaters Inc Place Serial 1271 Judson Road Number Label Here Spring Lake MI 49456 Phone 231 799 9600 Fax 231 799 9500 V 1 Rev 02 17 04 2004 Ground Heaters Inc www groundheaters com Ground i Heaters WARNING the instructions in this manual are not followed exactly a fire or explosion may result causing property damage personal injury or loss of life e Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance e WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department e Installation and service must be performed by a qualified installer service agency or the gas supplier Operator Manual available in French language upon request Call 231 799 9600 X204 Manuel de renseignements disponible en langue francaise sur demande Appellez le 231 799 9600 poste 204 2004 Ground Heaters Inc V 1 Rev 02 17 04 Ground jj j 24 Hour Heaters
17. LOW LEVEL RELAY E100 205 ORG B RED NOT USED lcu S LOW LEVEL LIGHT 100 353 H WHT ea LOW LEVEL OVERRIDE SW PUMP CONTACTOR E100 317 CIRCULATION PUMP SW M1 CR1 g WHT e HOUR METER E100 096 CR2 BURNER CONTROL RELAY 8 3 WHT __ P 1 PIN 3 8 n BURNER SW P 1 WHT gt gt TS 1 gt 8 PIN 2 i veveveveve 6 i e d WIRE COLORS ARPROVNG WHT WHT _ SW BLK BLACK e WHT WHT RED RED CN BURNER WHT WHITE m omm BL BLUE B U pee ORG ORANGE mu UV FLAME SENSOR N P 1 MAIN GV 1 PIN 1 MAIN GV 2 d d i 9 EE EE BURNER CONTROL RELAY 10 WHT 4 BLU WHT THERMOCOUPLE T RED WHT WHT 4 CAB LIGHT CAB LIGHT WHT 9 A 4 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAH 1250 CIRCUIT TWO WITH MAIN PUMP AND BOOSTER PUMP L2 120 N2 CIRCUIT ONE N L1 1 120VAC N1 1 a CIRCUIT TWO Se 1 ond 2 20 100 093 m a a 1 PUMP CONTACTOR PUMP MOTOR 1 5 HP 15 8 FLA 18 8 SFA M100 647 L1 111 LP CC 25 LOW LEVEL SHUTDOWN DEVICE WHT E100 198 GFI 1 20A E100 093 1 Pump Contactor REWIND MOTOR 1 6 HP 2 1A L 4 ix
18. SECTION 2 6 UNIT SHUTDOWN Burner Shutdown 1 2 3 4 Turn OFF the BURNER switch to allow system cool down Continue running the pump s for 15 to 20 minutes to cool the to 120 F 49 C or lower Turn OFF pump s SHUT valves 2 and 3 Disconnecting Hoses from Heat Exchangers and SAH 1 2 Hewinding the Circulation Hose 1 9 Disconnect the hose QC s from the manifold and heat exchangers Disconnect each section of hose QC s before rewinding onto the hose reel Fully release hose reel brake by turning the brake knob counterclockwise Turn ON the HOSE REWIND switch the female QC of the first hose in a bucket of water to remove before winding onto the hose reel Photo 2 5 Remove the foot pedal from storage location and position to allow control of rewind operation The foot pedal should be placed on a piece of plywood or other material to keep it dry Turn ON the REWIND MOTOR switch at the control panel Always wear gloves to protect hands while rewinding hose Depress the foot pedal to begin rewinding and guide the hose evenly onto the reel Sequentially connect additional hose QC s rinsing each QC in a bucket of water before connecting and continue rewinding Rewind the final 10 ft 3 m of hose by hand to prevent damaging a fitting or hose connection Set the hose reel brake by turning the brake knob clockwise and turn the HOSE REWIND switch OFF Retu
19. 100 212 5L1 gt T 1 TRANSFORMER 01 E100 220 H1 115 VAC H4 411 REWIND CLUTCH 3 9A 12VDC P N M100 108 T 1 d RECTIFIER a BLU E 9 x1 RED 4 102 FOOT SW Ges WHT M 1 PUMP CONTACTOR MAIN CONTROL PANEL BOOSTER PUMP 7 71 L 3 CIRCUIT 91 93 BOOSTER PUMP MOTOR 1 5 HP 15 8 FLA 18 8 SFA 100 647 8 gt lt lt CONNECT TO 120VAC 20 60 HZ GFI PROTECTED CIRCUIT V 1 Rev 2 17 04 2004 Ground Heaters Inc L 1 0013 ana 51 0013 ana LHD NYS c 1 0013 gina 8681 0019 LHOFT3WRLVINIIN Nao 261 0013 275 0013 15 2 m 16 00 1 STE 3ALW1d A 5 ziii C S3MVHgS 914193713 660 0014 OS8INOO 5 LC HOLIMS H3OHVHO A cv 0013 Adv 15 S3MVM8 1 N NYS 2 T t 151 0013 97109 T 261 0013 851 0013 ana 1 ERES NMOH8 aasN LON MOTI3A EE S35Vu8 anid SLHSIT N3du9
20. 3 4 Deployment of Circulation nnns 2 3 V 1 Rev 2 17 04 IV 2004 Ground Heaters Inc SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL Ground Heaters TABLE OF CONTENTS continued 2 3 5 Optional 2 3 5 1 2 3 5 2 2 3 5 3 wise m 2 3 5 4 BIG e elei I 2 4 STARTUP 2 5 MONITORING OPERATING 65 2 6 UNIT SHUTDOWN 2 6 1 BIST tree 2 6 2 Disconnecting Hoses from Heat Exchangers and 2 6 3 Rewinding the Circulation 2 6 4 Completing Unit Shutdown E BURNER ADJUSTMENT AND SHUTDOWN 3 1 NATURAL GAS LIQUID PROPANE 3 1 1 ETT m MET 3 1 1 1 Fuel Pressure E 3 1 1 2 Air Setting and esce iine a 3 1 1 3 Content 5 191 3 1 1 4 SMOKE Spot 3 1 2
21. BLACK BLK WHT 4 WHT 4 f x RED p WHT o 3 1 2 TETH WHITE 4 GREEN BLK L 1 BLUE rese T BLK BURNER YELLOW M RED CONTROL ORANGE P N P100 206 VIOLET i PURNER BLK ORG Js D 1 VALVE ri Se VIO E E VIO SI EN d M IGN INLINE FUEL HEATER IGNITION YEL YEL START HELPER BLU BLU 1 rRANSFORMER Cy 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAH 1250 SAFETY CONTROLS LOW WATER CUT OFF P N P100 198 NOTE CONTROL IS SHOWN IN NON POWERED STATE LOW WATER CUT OFF BASIC WIRING DIAGRAM GRN GRN RED Sg Bn BLU III 5 m LOW LEVEL SENSOR RESET BUTTON LOW WATER CUT OFF TO LOW LEVEL RELAY CR 1 RED 3 110 VOLTS FROM CIRCUIT 1 BLK 4L2 WHT 302 110 VOLTS FROM CIRCUIT 2 gt V 1 Rev 2 17 04 N O N C LOW LEVEL LOGIC 2004 Ground Heaters Inc FLOW LEVEL GREEN LED MODULE JD RED LED F LLCIW PROCEDURE DEL SHUT OFF BURNER cu AND Pian EeerCu e 4 FIND AND REPR LEN L ADD HTF TO Leg HTF Sur GAUGE LEVEL ex 5 TURN OM BURNER 4 BURNER arts UHN DN TIME ara MANUAL
22. Optional Booster Pump To Clear a LOW HTF LEVEL Condition 1 Place an open container of HTF close to the manifold area to facilitate filling The container must be close enough to allow the 16 ft 4 9 m fill hose to reach the bottom of the container 2 Power up the SAH 1250 as directed in Section 2 4 START UP Ensure that the PUMP and BURNER switches are OFF Ensure that a least one section of circulation hose is connected to the supply and return manifolds to complete a circulation loop p Verify that valve 3 is shut Verify that valves 2 and 5 are open Pull out the fill hose attached to valve 4 Clean the exterior and remove the fill hose dust cap Remove the locking pin from fill valve 4 Direct the open end of the fill hose into the opening of the HTF container I m 0 Momentarily open fill valve 4 until HTF is observed running out of the fill hose This will prime the fill hose 11 Quickly close fill valve 4 to avoid over filling the HTF container 12 Cover the open end of the fill hose to retain HTF after priming If the HTF container height is such that it will not allow gravity flow from the SAH 1250 fill hose use a separate container with an opening low enough to facilitate priming the fill hose using the method described 13 Insert the fill hose into the HTF container ensuring that the hose is not sealed against any interior surface of the container 14 Open fill valve 4 Immedi
23. SAH 1250 TRAILER WIRING teet A 6 SAH 1250 TRAILER JUNCTION BOX AND BATTERY A 7 SAH 1250 CIRCULATION BOOSTER PUMP MOTOR A 8 SAH 1250 REWIND MOTOR WIRING eene A 9 HX 200 HEAT EXCHANGER WIRING DIAGRAM A 10 SAH 1250 VALVE POSITIONING FOR OPTIONAL BOOSTER PUMP USE A 11 SAH 1250 VALVE POSITIONING FOR NORMAL OPERATION A 12 SAH 1250 VALVE POSITIONING FOR ADDING HTF A 13 SAH 1250 QUICK CONNECT AND CAM LOCK CARE AND MAINENTANCE A 14 SUGGESTED METHOD FOR SECURING THE SAH 1250 ONTO A TRUCK BED A 15 SAH 1250 GAS BURNER P N P100 673 COMPONENT IDENTIFICATION A 16 SAH 1250 GAS PRESSURE CHECKING AND ADJUSTING A 17 SAH 1250 DIESEL BURNER P N P100 690 COMPONENT IDENTIFICATION A 18 SAH 1250 SAFETY CONTROLS NG LP BURNER CONTROL P N P100 338 A 19 SAH 1250 SAFETY CONTROLS DIESEL BURNER CONTROL P N 100 206 A 20 SAH 1250 SAFETY CONTROLS LOW WATER CUT OFF P N 100 198 A 21 APPENDIX B SPECIEICATIONS B 1 APPENDIX C SAH 1250 APPLICATION LAYOUTS CA 2004 Ground Heaters Inc vii V 1 Rev 2 17 04 SA
24. below the burner so the doors can be later closed Use heavy duty 10 3 extension cords of no more than 50 ft in length each and attach the provided Velcro cord connectors to assure that the plugs do not separate Turn ON both MAIN BREAKERS Verify that both are not tripped LOW LEVEL light will come on for 15 seconds while the low level device cycles through a self test Verify that the temperature control green numbers is set to desired temperature usually 180 F 82 OPEN supply valve 3 and verify that valve 5 is OPEN Verify that valve 2 is fully closed Turn ON the PUMP switch Wait for the pump motor to spool up and attain full RPM The pressure gauge should read approximately 50 psi Slowly OPEN valve 2 wide enough to drop the pressure gauge needle to 30 psi Do not allow the pressure gauge to drop below 30 psi as this will cause the pump motor to draw excessive current If the pump fails to start and attain full RPM the supply voltage is too low Low voltage could cause the pump fuse located in the control panel to blow Have a licensed electrician check the circuits to verify that they can supply a minimum of 20 amps and that the voltage does not drop below 110 volts with the pump running Turn ON the BURNER switch After a pre purge the burner will light Refer to Section 3 BURNER ADJUSTMENT AND SHUTDOWN Turn ON the blower motor on each heat exchanger Slowly step through speeds 1 2 and 3 to avoid possibly
25. the reverse side of the Customer Delivery Checklist located directly behind Operator s Manual cover sheet All warranty services must be completed by a certified Ground Heaters Distributor service technician lf your Distributor does not satisfactorily resolve the problem please call Ground Heaters Inc at 231 799 9600 for assistance You will need to provide the following information for assistance Name address and phone number e Machine serial number Date of purchase e Distributor name and address location e Nature of problem Thank you for purchasing a Sahara Air Heater Both your Ground Heaters Distributor and Ground Heaters want to assist you in every way possible to ensure your complete satisfaction with your purchase 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 2 GR Ground 2 1 2 1 1 START UP OPERATION AND SHUTDOWN SYSTEM CONFIRMATION ADVISORY Standard Configuration Performance A Sahara Air Heater should conform to the following system configurations upto 5 heat exchangers located no higher than 60 ft 18 m above the SAH trailer and connected with any combination of the standard supplied hose lengths i e 50 100 and 200 ft 15 30 and 61 m A Sahara Air Heater equipped with the optional Booster Pump should conform to the following system configurations upto 5 heat exchangers located no higher th
26. 10 volts min while attempting to rt pump motor Heattransfer Low voltage caused by Start pump moto fluid pump inadequate power supply poor e Ensure power cords are at least 10 gauge turns but does quality or excessively long wire and lt 50 ft 15 3 m in length not start extension cords e Verify power cords are supplied by separate 20 amp 120 volts AC 60 Hz electrical power circuits e Have an electrician verify voltage at burner motor is 110 volts min while attempting to start burner motor e Ensure power cords are at least 10 gauge nsuticient power Supply wire and lt 50 ft 15 3 m in length Burner motor e Verify power cords are supplied by will not start separate 20 amp 120 volts AC 60 Hz electrical power circuits Power supply sufficient but no e Call your Ground Heaters Distributor power to burner motor V 1 Rev 2 17 04 2004 Ground Heaters Inc 6 1 SAHARA AIR MODEL 1250 OPERATOR S MANUAL SECTION 6 Ground inc Meaters Symptom Possible Cause Corrective Action e Verify both MAIN BREAKERS are ON e Verify both GFls are reset Appendix Burner motor will Improper switch position or e Verify HTF level is between MIN and not start protective function action MAX level and LOW HTF LEVEL light is continued not lit Appendix e Verify LOW WATER CUT OFF is RESET A 21 Burner Safety is tripped as indicated by DIAGNOSTIC light e
27. Air Heaters and Sahara Air accessories damaged by rough use or foreign particles will not be replaced under Ground Heaters 5 warranty SETUP Positioning 1 Position the right side of the SAH trailer as close as possible to the building to be heated but not closer than 12 ft 3 6 m Main heater unit trailer must not be positioned within 12 ft 3 6 m of fuel source or combustible materials 2 Position the SAH near a doorway or other opening in the building such that the circulation hoses can readily enter and exit the structure 3 Chock the wheels to prevent accidental rolling 4 Use the trailer jack to position the SAH as level as possible Unloading HX 200 Heat Exchangers 1 Remove the aluminum ramp from under the rear of the trailer Photos 2 1 and 2 2 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 2 GR Heaters 2 Open the rear doors and latch them to the trailer sides Attach the ramp to either side of the rear door NOTE Each heat exchanger must be connected to a separate 15 amp 120 volts AC 60 Hz 2 3 3 NOTE 2 3 4 opening and roll out the first two heat exchangers Move the ramp to the other side of the trailer and roll out the other two heat exchangers Photo 2 3 Position the heat exchangers inside the building per your heating plan Refer to Appendix C 1 SAH 1250 APPLICATION LAYOUTS electrical circuit to po
28. D FUELS eg 4 5 4 5 SUMMER STORAGE INGTRUCTIONG 4 6 4 6 PRE SEASON MAINTENANCE aaaaaaaaaaaaaaaaanaaaannnnnnnnnrrnnnrnrrrrrrrrrrrrrrnrrrrrnrrrrrrrrrrrrenn 4 6 TRANSPORTING THE SAH 1250 5 1 _ 5 1 5 2 CRANE and AIR LIFTING 5 1 5 3 TRANSPORTING FLATBED 5 1 5 4 COMMON MECHANICAL INSPECTIONS PRIOR TO TRANSPORTING 5 1 TROUBLESHOOTING 6 1 TROUBLESHOOTING CHART 6 1 6 2 IF LOW HTF LEVEL and LOW WATER LIGHTS ARE LIT 6 3 6 2 1 Low Level Shutdown 6 3 6 3 BURNER CONTROL LOCKOUT 6 3 6 3 1 Burner 6 3 6 3 2 6 3 V 1 Rev 2 17 04 vi 2004 Ground Heaters Inc TM i Ground p ARA AIR HEATER MODEL 1250 OPERATOR S MANUAL 68 TABLE OF CONTENTS continued Page APPENDIX A SAH 1250 CONTROL PANEL EXTERIOR LAYOUT 1 SAH 1250 CONTROL PANEL INTERIOR LAYOUT A 2 SAH 1250 DIESEL BURNER SCHEMATIC 00 0 3 SAH 1250 NG LP BURNER SCHEMATIC 0 4 SAH 1250 CIRCUIT TWO WITH MAIN PUMP AND BOOSTER A 5
29. EMENTS OF LOCAL STATE AND FEDERAL AUTHORITIES All gas and propane connections must be leak tested prior to placing into service Main heater unit trailer must not be installed within 12 ft 3 6 m of combustible materials All gas burners are test fired at Ground Heaters Inc s factory prior to shipment Ground Heaters technicians have installed an ie in orifice This orifice is suitable for burning both NG and LP fuels and does not need to be changed in the field combustion verification and adjustment must be performed e before operating at elevations 1 000 ft 305 m above or below the last adjustment e before starting at a new job site e after any burner maintenance has been performed e after changing fuel type NG LP to 2 fuel oil etc e if burner performance is in question for any reason A Combustion Analyzer Smoke True Spot Tester and common hand tools will be required NATURAL GAS LIQUID PROPANE VAPOR Burner Adjustment Before beginning these steps it is assumed that the NG LP burner and gas train have been installed per Section 4 2 BURNER INSTALLATION CHANGEOVER The use of a high quality combustion analyzer and two manometers 0 to 15 in water column WC and 0 to 30 in WC is mandatory adjustments must be accomplished by a licensed authorities Use air damper settings and fuel pressure adjustments to obtain an Exhaust value of 4 to 6 and a smoke spot value of 1 or less Maintaining i
30. HARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 1 555 me INTRODUCTION The Sahara Air Heater SAH Model 1250 provides temporary heat during construction Ground Heaters Inc s revolutionary technology enables construction activities to continue throughout the cold weather months The SAH 1250 provides temporary heat to the workspace easily and economically The Sahara Air Heater Model 1250 Heats workspace easily amp economically e Inputs of 745 000 to 1 100 000 BTU H Fuel flexible choice of natural gas propane or diesel e Takes only minutes to change over from one fuel to another Provides dry hot air no moisture added to workspace prevents mold and mildew Hemoves excess moisture from workspace and building materials Provides clean air no combustion by products in workspace Is self contained all system components are on one trailer Is rental friendly easy setup and uses only 2 x 20 amp 120 volts AC circuits Is multi functional with accessories this system can be used as a surface heater 1 1 EXTERNAL FEATURES Photo 1 1 1 du 3 in 76 mm Pintle Style Hitch or Adjustable 2 45 59 mm Ball Lifting Bail Door Tiebacks Lockable Cab Door Loading Ramp Storage Electric Brakes with Breakaway V 1 Rev 2 17 04 2004 Ground Heaters Inc 1 1 n AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 1 6 Ground iii 1 2 INTERNAL CO
31. LED Valve 6 SHUT SHUT Valve 4 FILL HOSE SHUT HYDRONIC HEATER V 1 Rev 2 17 04 SAH 1250 VALVE POSITIONING FOR ADDING HTF SAH 200 HEAT EXCHANGER HTF BOOSTER PUMP CONNECTIONS WITH PROTECTIVE CAPS INSTALLED RETURN MANIFOLD SUPPLY MANIFOLD CHECK VALVE 6 p Valve 5 SHUT 7 SHUT ANA FILL HOSE 5 i OPEN MAIN CIRCULATION PUMP P N M100 647 Valve 3 SHUT HYDRONIC HEATER PRESSURE GAUGE FLOW INDICATOR 2 V 1 Rev 2 17 04 2004 Ground Heaters Inc SAH 1250 QUICK CONNECT AND CAM LOCK CARE AND MAINTENANCE 4 0014 LAMSVD NOLIA 002 00 HN N d MOOTAVS 3 IVIN 824 00 N d 3490 FNVO JINA lt 692 00 LN N d LOANNOO MOIND 3 1VIN3J
32. LEVEL and LOW WATER LIGHTS ARE LIT Refer to Appendix A 21 SAH 1250 SAFETY CONTROLS LOW WATER CUT OFF P N P100 198 Perform the following when LOW HTF LEVEL refer to control panel and LOW WATER LOW LEVEL SHUTDOWN lights are lit 1 Turn BURNER PUMP and REWIND MOTOR switches OFF 2 Locate and correct cause of low HTF condition i e fix the leak 3 Hestore HTF level to normal operating level per Section 4 1 ADDING HEAT TRANSFER FLUID 4 Depress MANUAL RESET button to clear low level condition Reset will complete in 15 seconds Call your Ground Heaters Distributor if HTF level is between MIN and MAX and Low Level Shutdown device will not reset e LOW HTF LEVEL light refer to control panel remains on after depressing the Low level Shutdown device RESET button or Burner control locks out the burner and will not remain reset Low Level Shutdown Device The LOW HTF LEVEL light refer to control panel is activated for 15 seconds after initial power up and then goes out Reset is accomplished by pressing the RESET button for 1 to 2 seconds by momentarily shutting OFF BREAKER 1 Refer to control panel BURNER CONTROL LOCKOUT Refer to Appendix A 19 and A 20 Refer to Appendix A 19 GAS or A 20 DIESEL for safety controls component identification Gas Burner Control The POWER light will illuminate only during the heating cycle After flame is established the POWER PILOT MAIN and FLAME lights should all be i
33. MPONENTS 1 2 1 for Heater with Burner Options The following components are accessed via the side door Photo 1 2 1 Control Panel 4 Low Heat Transfer Fluid Level Shutdown with Manual Reset 2 Hydronic Heater 5 Gas Train 3 Gas Burner 6 Optional Diesel Burner 1 2 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 1 GR Ground a 1 2 2 Inside Rear Doors The following components are located inside the rear door Photo 1 3 1 HX 200 Heat Exchangers 2 Cab Interior Light 3 Ramp Alignment Pins AAA al Wa 444 OM S Ke Ga I 1 WI LJ 25 55 25 eg d DU AN HA n Bif Se MW WM M MM mmm el rmm a Se pm um Te 1 3 IDENTIFICATION The Sahara Air Heater Model 1250 serial number is located on the control panel Always reference the SAH 1250 serial number when ordering parts or requesting technical assistance V 1 Rev 2 17 04 2004 Ground Heaters Inc 1 3 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 1 6 Ground inc NS Heaters 1 4 SAFETY FEATURES Sahara Air Heaters are safe quality equipment are NHTSA compliant meet all state requirements and meet all Transport Canada requirements Spe
34. Reset burner safety on burner control Appendix A 19 or A 20 e Verify fuel supply is adequate No fuel e Verify both fuel line quick connects are Section connected oil burner 421 e Have an electrician verify voltage at Burner safety control panel is 110 volts min while trips no flame attempting to start burner s Ensure powercordsareatleast 10 Insufficient voltage for ignition gauge wire and lt 50 ft 15 3 m in length e Verify power cords are supplied by separate 20 amp 120 volts AC 60 Hz electrical power circuits Burner safety trips Control not sensing flame e Call your Ground Heaters Distributor flame occurs Heat exchanger No electrical power e Verify 120 volts AC to heat exchanger blower will not Thermostat or speed selector e Set thermostat above room temperature start setting incorrect e Set speed selector to desired fan speed Brake not fully released e Fully release hose reel brake Fr Rewind motor is too cold rewind motor may not start if e Warm rewind motor rewind below 18 Hoses will not Faulty foot pedal e Call your Ground Heaters Distributor If problem is not resolved by performing the above steps call your Ground Heaters Distributor for assistance 6 2 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 6 6 2 NOTE 6 2 1 6 3 6 3 1 6 3 2 IF LOW HTF
35. T and LOCKED in the SHUT position to prevent accidentally opening them Verify that the male and female cam lock fittings on valves 6 and 7 are plugged and capped respectively to prevent accidental injury Refer to Appendix A 12 SAH 1250 VALVE POSITIONING FOR NORMAL OPERATION After rinsing the QC s in a bucket of water to remove sand dirt quick connect the ends of the supply and return circulation hoses to the supply and return manifolds The supply manifold has male QC s and the return has female QC s Quick connect the opposite ends of the supply and return hoses to each of the heat exchangers Support the QC fittings on the heat exchanger with one hand when making these connections to avoid damaging the radiator Ensure hoses lay on top of heat exchanger once connection is made to avoid HTF restrictions V 1 Rev 2 17 04 2004 Ground Heaters Inc 2 3 IR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 2 GR 2 3 5 Optional Booster Pump 2 3 5 1 Connecting Refer to Appendix A 11 SAH 1250 VALVE POSITIONING FOR BOOSTER PUMP USE Place the optional booster pump within 10 ft 3 m of the Sahara booster pump connection points Remove the hoses and the power cord stowed in the interior of the booster pump enclosure Ensure that valves 6 amp 7 are SHUT and LOCKED Ensure the BOOSTER PUMP BREAKER switch is OFF Refer to booster pump control panel Ensure the MAIN PUMP switch is OFF Refer to main control panel
36. Technical Assistance 231 799 9600 877 799 9600 This Sahara Air Heater Manual Contains The Following Sahara Air Heater 1250 Operator s Manual Customer Delivery Checklist and Warranty Pump Manufacturer s Manual Burner Manufacturer s Manual NOTE To activate the warranty on your new Sahara Air Heater the Distributor must complete and mail to Ground Heaters Inc the Customer Delivery Checklist located directly behind this cover page 2004 Ground Heaters Inc 1 Rev 2 17 04 Ground inc SAHARA AIR HEATER 1250 SN Heaters CUSTOMER elivery Date DELIVERY CHECKLIST VEU Distributor Customer Buyer Company Company Address Address City State City State Zip Phone Fax Phone Fax Email Email You must complete this form with your customer during delivery process to activate warranty GIVE one copy to your Customer KEEP one copy for your Distributor file MAIL one copy to Ground Heaters Inc O Visually inspect the exterior of the machine paying special attention to those areas that may have been damaged during shipping Ensure all discrepancies caused by shipping are filed with the freight carrying company Heat Exchangers HX 200 Qty HX 100 Qty 1 HX 50 Qty O Verify proper door s operation locate Manual and perform all steps to verify the following section OVERVIEW 1 1 1 Locate and explain purpose of exter
37. an 100 ft 30 m above the SAH trailer provided they are connected with any combination of the standard supplied hose lengths i e 50 100 and 200 ft 15 30 and 61 m OR if connected to 400 ft 122 m hose lengths up to 5 heat exchangers may be placed up to 400 ft 122 m away from the SAH trailer provided they are located no higher than 20 ft 6 m above the trailer Booster Pump Option and Performance All Sahara Air Heaters SAH are electrically equipped and plumbed to accept the addition of optional Booster Pump Refer to Section 2 3 5 Optional Booster Pump for setup instructions Hose Configuration Limitations Do not create long hose lengths by quick connecting multiple short lengths together Multiple quick connects QC s cause a loss of working pressure and restrict flow Regardless of length no more than two hoses should be quick connected one way e Regardless of length no more than four hoses should be quick connected two ways No more than 400 ft 122 m one way No more than 800 ft 244 m two ways Crane Lifting The trailer can be crane lifted to the top of the vertical structure for heating workspaces All Sahara Air trailers and heat exchangers are equipped with crane lifting points Insulate the Hoses Circulation hoses located outside of the building or space to be heated should be insulated extremely well Ground Heaters Inc recommends wrapping a cut to size Red Wave bl
38. anket over exposed hoses Secure the wrapped blankets to minimize air infiltration and heat loss Contact your local Ground Heaters Distributor for additional system configuration advice V 1 Rev 2 17 04 2004 Ground Heaters Inc 2 1 2 2 2 2 1 2 2 2 2 2 3 2 3 2 3 1 2 3 2 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 2 GR CARE AND HANDLING OF HOSE QUICK CONNECTS AND CAM LOCKS Hose Do not drive any vehicles or equipment over the hoses hoses must be deployed in traffic areas construct ramps or guards to protect the hoses from damage Propylene glycol leaks may discolor floor surface Provide extra protection and care to hoses when floor cosmetics is critical Place hoses away from high traffic areas Quick Connects and Cam Locks Refer to Appendix A 14 SAH 1250 QUICK CONNECT AND CAM LOCK CARE AND MAINTENANCE 1 Clean In order to seal properly quick connects must be clean and free of sand and dirt particles before they are connected horoughly rinse each male and female quick connect in a bucket of clean water before connecting 2 Care Bent scored or otherwise damaged quick connects may not operate or seal properly avoid damage handle the quick connects carefully Do not drop quick connects on concrete floors or other hard surfaces drive any vehicles or equipment over quick connects Warranty Exclusion Quick connects on Sahara
39. ate exhaust sampling Sample the burner exhaust for smoke by inserting the smoke spot sampling probe into the chimney access hole provided through the exhaust guard The probe must be greater then 5 in 127 mm in length for an accurate sampling Smoke spot production must be 1 or less Several samples should be taken as the heater warms The final sample should be taken just before the heater reaches 180 F 82 2 Higher percentage excess air settings lowers soot production but raises stack temperature and reduces efficiency Lower percentage inadequate air settings increases efficiency and lowers stack temperature but may cause soot build up A burner optimized for clean and efficient operation will have levels of 4 to 6 and a smoke spot value of 1 or less 4 Loosen the air dampers locking screws enough to provide movement for adjustment Open the top damper 10096 and fully shut the bottom damper Refer to Appendix A 16 SAH 1250 GAS BURNER P N P100 673 COMPONENT IDENTIFICATION 5 Adjust the air dampers until combustion parameters fall within the above outlined values 6 Lock the air dampers in place by tightening the locking screws Burner Shutdown 1 2 3 Shut down the burner by turning the BURNER switch OFF Turn both MAIN BREAKERS OFF Shut OFF the main gas supply Remove the manometers petcocks and adapters and reinstall pipe plugs use pipe dope Should the burner fail to respond durin
40. ately lift and hold the LOW LEVEL OVERRIDE switch to begin filling 15 Continue filling using the LOW LEVEL OVERRIDE switch until fluid is observed in the bottom of the sight gauge 16 The LOW LEVEL RESET button may now be pressed to clear the low level shutdown condition lt is not necessary to stop the filling process during this step 17 After the Low Level Shutdown device has cycled through a 15 second self test the low level condition will clear V 1 Rev 2 17 04 O 2004 Ground Heaters Inc 4 1 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 4 NOTE 4 2 4 2 1 4 2 1 1 NOTE 18 19 20 21 22 The PUMP switch may now be turned ON and the LOW LEVEL OVERRIDE switch released to finish filling Continue filling until the HTF level is between the MIN and MAX as observed in the HTF sight gauge Do not over fill Once adequate HTF levels are verified in the sight gauge remove the fill hose from the HTF container but continue running the HTF pump Elevate and outstretch the fill hose to clear excess fluid from the hose Close fill valve 4 and insert the locking pin Open pump suction valve 3 Clean the fill hose exterior and replace the dust cap Stow the hose neatly in between the HTF pump and the manifold rack HTF Low Level Shutdown device green and red lights will blink for 15 seconds while device performs self diagnostic tests After 15 seconds the red light will go out and the green
41. cific safety features include 1 Trailer Brakes electric with breakaway switch 12 VDO 2 Hydronic Heater operates at zero atmospheric pressure 3 Low HTF Level Shutdown turns off the burner and pumps if Heat Transfer Fluid HTF level in the system drops below minimum operating level Manual reset requirement prevents unsupervised pump burner start up 4 Ground Fault Interrupters GFI built into control panel to protect all circuits Circuit Overload Protection built into control panel to protect all components 6 Burner Flameout Protection Primary Controller uses optic flame sensor to turn off burner if burner fails to ignite or upon loss of flame Manual reset requirement prevents unsupervised restart 7 Pump Motor Overload Protection internal thermal overload trip with automatic reset Burner Motor Overload Protection internal thermal overload trip with manual reset Reflective Markers enhance night identification 10 Foot Pedal for rewind system wired with low voltage 12 VDC signal to protect personnel from shock hazard should the foot pedal become accidentally immersed in water 11 Digital Temperature Control fails safe Burner Off upon loss of power or temperature sensor malfunction 1 5 SAFETY PRECAUTIONS Ground Heaters Inc develops and manufactures equipment that is safe to operate However an accident could occur if the Sahara Air Heater is used improperly Safe operation requires that all instructi
42. d Ss ONINNAY 3399 NYS GQNNOYD AAILVDAN ALIHM LHM L331 439 cl 10 0351 LON 13A AYSLLVE H3ouvHO S 12 331 oras C 3orias Ling OQ 21 NHO 039 ATOIHSA MOL 1 CABLE TO BATTERY 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAH 1250 CIRCULATION BOOSTER PUMP MOTOR WIRING WIRE COLORS BLK BLACK _ m RED RED pen WHT WHITE 3 GRN GREEN se BLU BLUE YEL YELLOW ORG ORANGE mem WHITE WITH YELLOW TRACE X2 POWER CABLE LP PPP A BEA BALDOR ELEC MOTOR CIRCULATION BOOSTER PUMP ASSY 1 5 HP 15 8 FLA 18 8 SFA P N M100 647 YEL YEL YEL YEL YEL EMERSON ELEC MOTOR CIRCULATION BOOSTER PUMP ASSY 1 5 HP 15 8 FLA 18 8 SFA fi N P N M100 647 A 8 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAH 1250 REWIND MOTOR WIRING 034 NHO 1 0019 ZH 09 OZ dH 9 4 HOLON NYS LHM cn lt a m jONVHO 7 MOTISA TSA Pen
43. d by this Limited Warranty include all machines manufactured by Ground Heaters Inc and sold in the ordinary course of business and all accessories therefor which are registered with Ground Heaters Inc except for the following components Heat Transfer Hoses Tires Generator Powerheads and Engines These are considered to be wear items and or are covered by warranties of the component manufacturer NOTE Failure to maintain proper inflation or operating tires at speeds or under loads in excess of those recommended in the 5 manual may void the tire manufacturer s warranty Failure to fully pay for Product will void this Limited Warranty No agent or employee of Ground Heaters Inc is authorized to modify extend or otherwise change this limited warranty Rev 8 8 03 kk Ground inc SAHARA AIR HEATER 1250 SN _ Heaters DISTRIBUTOR elivery Date DELIVERY CHECKLIST _ CE Distributor Company Inspector Address City State Province Postal Code Phone Fax Email You must complete this form within 30 days of delivery date to activate warranty KEEP one copy for your Distributor file MAIL one copy to Ground Heaters Inc If Distributor is placing this unit into rental service the Customer Delivery Checklist must also be filed with Ground Heaters Inc to activate warranty Visually inspect the exterior of the machine paying special attention to those areas that may have been damaged d
44. d pressure as this will over fire the heater and cause damage V 1 Rev 2 17 04 2004 Ground Heaters Inc 4 3 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 4 4 2 2 1 Installation Refer to Appendix A 16 SAH 1250 GAS BURNER P N P100 673 COMPONENT IDENTIFICATION 1 10 11 Remove the trailer enclosure lower panel located below the trailer s left side door adjacent to the Remove this panel before fender to provide unrestricted access to the burner removing burner mounting plate on the Sahara Air hydronic heater E Photo 4 2 Verify that the gasket is properly positioned on the mounting flange and burner blast tube Insert the blast tube into the hydronic heater burner mounting plate and attach with the four bolts which have been supplied The burner should be oriented with the Power Flame Model JR30A 12 label oriented right side up Using the supplied 1 in x Die in bolts washers and nuts install the burner support bracket on the trailer floor below the burner Extend the adjusting rod such that the square pad firmly contacts the burner support flange Tighten the jam nut to keep the support rod from backing off Reinstall the enclosure panel next to the fender Attach the 3 pin quick connect burner power cord leading from the main control panel to the connection socket located just behind the blue Honeywell burner control Attach the gas train at the pipe union with
45. efer to Appendix A 16 SAH 1250 GAS BURNER P N P100 673 COMPONENT IDENTIFICATION Turn on the main gas supply Crack open the installed petcock slowly while continuously monitoring gas pressure Immediately shut the petcock if the gas pressure climbs past 14 in WC Contact your fuel supplier for gas pressure adjustment of no more than 12 to 14 in WC before proceeding with further adjustment Once a gas supply pressure of 12 to 14 in WC has been verified open the gas train inlet ball valve Remove the protective cap from the manifold pressure regulator to access the regulator adjusting stem Refer to Appendix A 16 SAH 1250 GAS BURNER P N P100 673 COMPONENT IDENTIFICATION Using a screwdriver adjust the manifold pressure regulator stem until it is no more than 4 in below the threaded opening if using LP or no more than in below the threaded opening if using NG This will avoid over firing upon initial start up Open the gas manifold valve Turn ON both MAIN BREAKERS Allow a 15 second time delay for the low heat transfer fluid HTF system to recycle and clear Ensure that the digital temperature control s green numbers temperature set point are at least 10 to 20 F 5 to 11 C degrees higher than the red numbers actual HTF temperature Turn the BURNER switch ON After a 15 second pre purge the burner will begin the ignition sequence the pilot gas valve will open followed 15 seconds later by the main gas valves MGV s
46. erature 2 5 4 Visually inspect all internal plumbing and hose connections for signs of leakage A 23 SAH 1250 LWCO shuts down the pump and burner when the TEST button is pressed the LOW HTF LEVEL light will illuminate 2 6 SHUT DOWN 2 6 1 SAH 1250 and Heat Exchangers shut down normally Disconnect power cords 2 6 4 Store Heat Exchangers in the trailer and stow the ramp Shut and lock all doors Record any discrepancies Ensure Operator s Manual is returned to its holder inside the Sahara Air Heater Distributor hereby acknowledges receipt of the above specified Sahara Air Heater Distributor also confirms with her her signature below that said Sahara Air Heater has been fully inspected and is in proper physical and operating condition Inspector s Signature Date Distributor Branch Manager s Signature Date Ground Heaters Inc 1271 Judson Rd Spring Lake Michigan 49456 p 231 799 9600 f 231 799 9500 www groundheaters com 2004 Ground Heaters Inc mp SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL 65 round lt Ino LIST OF ABBREVIATIONS n LIST OF ABBREVIATIONS The following is a list of abbreviations used throughout the Operator s Manual Abbreviation Symbol Term Meaning amp asl BTU C cm SE ft ft ft lbs gph GFI GHI GVWR HHS HTF kg Kilo Cal kPa kW V 1 Rev 2 17 04 ampere measurement of electrical current above sea level British Thermal Unit measurement of heat ene
47. g any of the air adjustments or if the fuel pressure cannot be adjusted or drifts discontinue burner setup and contact your Sahara Air 1250 Distributor V 1 Rev 2 17 04 2004 Ground Heaters Inc 3 3 3 2 3 2 1 NOTE 3 2 1 1 3 2 1 2 3 2 1 3 AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 3 GR DIESEL FUEL OIL Burner Adjustment Before beginning these steps it is assumed that the optional diesel burner has been installed per Section 4 2 BURNER INSTALLATION CHANGEOVER The use of a high quality combustion analyzer and fuel pressure test gauge is mandatory Use air band and shutter settings and fuel pressure adjustments to obtain an Exhaust value of 4 to 6 and a smoke spot value of 1 or less Maintaining in 4 to 696 range assures that there are unburned hydrocarbons remaining in the exhaust Unburned hydrocarbons cause soot production If the above values cannot be obtained by adjusting the burner air band and shutters alone it may be necessary to reduce the firing rate lower fuel pressure and or install a smaller nozzle This is especially true at elevations above 3 000 ft 914 m Fuel Pressure Adjustment Ensure that the fuel quick connects are not connected Remove the pressure tap plug located on the top of the burner fuel pump Install an adapter to facilitate using a O to 300 psi pressure test gauge Do not use pipe dope Connect the fuel quick connect
48. h the four bolts which have been supplied 4 Using the supplied 114 in x Die in bolts washer and nuts install the burner support bracket on the trailer floor below the burner Extend the adjusting rod such that the round pad firmly contacts 2004 Ground Heaters Inc V 1 Rev 2 17 04 4 2 1 2 RA AIR HEATER MODEL 1250 5 MANUAL SECTION 4 GR the underside of the blower housing on the burner Tighten the jam nut to keep the support rod from backing off 5 Attach the 3 pin quick connect burner power cord leading from the main control panel to the mating part located just below the Honeywell controller on the burner 6 Plug the male Oil Pre Heater pigtail attached to the burner into the female Oil Pre Heater pigtail attached to the main control panel 7 Route both the supply and return fuel lines from the fuel tank through the 5 127 mm square access hole in the trailer floor below the burner 8 Using the quick connect and hose barb supplied with the oil burner attach the supply fuel line to the fuel filter on the burner 9 Attach the return fuel line to the return hose quick connect and hose barb on the burner Setup 1 Set air band at 6 and the air shutter at 6 These initial air settings will be fine tuned later 2 With fuel in the remote tank power up the SAH control panel as directed in Section 2 4 START UP 3 After the low level device runs through its self diagn
49. is capable of providing a minimum of 1325 CFH NG or 470 CFH LP vapor at 12 to 14 in water column pressure 4 3 NOTE 4 4 1 HIGH ELEVATION OPERATIONS The following procedures are recommended when operating the SAH 1250 at elevations higher than 5 000 ft 1 524 m asl These procedures keep the SAH 1250 running smoothly and prevent the possibility of premature soot build up inside the hydronic heater fire tubes ALL PROCEDURES LISTED BELOW SHOULD BE PERFORMED BY CERTIFIED PERSONNEL AT YOUR GROUND HEATERS DISTRIBUTOR When operating the SAH 1250 at high elevations the hydronic heater should be spot checked every 500 hours for sooting or other combustion abnormalities Combustion Analyzer and Smoke Spot Tester must be used for this test In addition to air adjustments fuel pressure may be reduced to a lower pressure To decrease fuel burning rate refer to Section 3 BURNER ADJUSTMENT AND SHUTDOWN for fuel pressure adjustment instructions Always verify burner exhaust O and smoke levels after completing any adjustments to fuel pressure as directed in either Section 3 1 1 Gas Burner Adjustment or 3 2 1 Diesel Burner Adjustment 1 RECOMMENDED FUELS Sahara Air Heaters are typically used outdoors in cold weather Care must be taken in selecting a fuel blend which will work properly in your jobsite conditions 2 Diesel fuel will thicken jell at low temperatures Jelling also known as waxing may cause the burne
50. light will stay on signaling the unit is ready to operate The red LOW HTF LEVEL light on the control panel Will go out BURNER INSTALLATION CHANGEOVER From NG LP to Diesel Fuel Oil 1 CF800 oil burners are shipped by Ground Heaters Burner setup and installation fuel supply connection test firing and burner adjustment should be authorities Main heater unit trailer must not be installed within 12 ft 3 6 m of combustible materials combustion verification and adjustment must be performed e before operating at elevations 1 000 ft 305 m above or below the last adjustment e before starting at a new job site e after any burner maintenance has been performed e after changing fuel type NG LP to 2 fuel oil etc e if burner performance is in question for any reason NM A Combustion Analyzer Smoke True Spot Tester and TE common hand tools will be required Installation Photo 4 1 Inc with the proper nozzle 4 5 GPH 45 solid installed Burner Mounting Flange and the proper pump pressure set 140 psi BurnerAir Tube Burner F uel Pump 1 Slide the flange gasket over the burner air tube and align the gasket with the mounting flange holes 2 Install the 12 in insulation and the mounting plate for the oil burner supplied by GHI when you purchase an oil burner on the hydronic heater burner mounting plate 3 Insert the burner air tube into the hydronic heater and attach wit
51. lluminated If flame failure of any nature is sensed during the start up or heating cycle the control will stop all burner function and begin Lockout mode Lockout Mode e ALARM light will illuminate e PILOT FLAME and MAIN lights will go out Momentarily press the RESET button to clear the lockout condition Oil Burner Control The DIAGNOSTIC light green LED will illuminate during the heating cycle after the 15 second pre purge time has elapsed and flame has been established If flame failure is sensed during the start up or heating cycle the control will stop all burner function and begin one of three protective modes 1 Recycle Mode The DIAGNOSTIC light will flash in two second intervals while attempting three automatic restarts the flame fails after three successive attempts the control will go into Lockout mode 2 Lockout Mode The DIAGNOSTIC light will flash in one half second intervals The RESET button must be momentarily pressed to clear the lockout and attempt a burner restart After three attempts to manually clear the lockout mode the control will begin Restricted Lockout mode V 1 Rev 2 17 04 2004 Ground Heaters Inc 6 3 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 6 Ground ine Heaters 3 Restricted Lockout Mode The DIAGNOSTIC light will flash in one half second intervals The RESET button must be pressed and held for 30 seconds or until the DIAGNOSTIC light co
52. mes on for two seconds and then goes out The control will return to Restricted Lockout mode with each flame failure until one successful heating cycle has occurred 6 4 2004 Ground Heaters Inc V 1 Rev 2 17 04 THERMOCOUPLE FOOTSWTCH REWIND CLUTCH CH AUX PUMP H BURNER CH OVER TEMP H REWIND MOTOR CH eee zoue H PART Pump Sw Burner Sw Hose Rewind Sw Cab Light Sw LL Override Sw Low HTF Lamp Temp Control Breaker 1 amp 2 HR 1 Hour Meter Breaker 2 GFI 1 amp 2 20A V 1 Rev 2 17 04 PUMP P N E100 101 E100 101 E100 101 E100 101 E100 230 E100 121 E100 084 E100 123 E100 096 E100 123 E100 093 SAH 1250 CONTROL PANEL EXTERIOR LAYOUT _ zziii LOW LEVEL PANEL EXTERIOR DANGER HAZARDOUS VOLTAGE 1 2 e GFI 1 PRs TEST RESET TEST RESET omron E5CN EMERGENCY SHUTDOWN PROCEDURE LOW HTF LEVEL 6 CONTROL TEMPERATURE T LEVEL OVERRIDE ON ON ON OFF OFF OFF OFF HOSE CAB REWIND LIGHT TM PUMP BURNER
53. n the 4 to 696 range assures that there are no unburned hydrocarbons remaining in the exhaust Unburned hydrocarbons cause soot production If the above values cannot be obtained by adjusting the burner air dampers alone it may be necessary to reduce the firing rate lower fuel pressure This is especially true at elevations above 3 000 ft 914 m V 1 Rev 2 17 04 2004 Ground Heaters Inc 3 1 AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 3 GR 133 inc 3 1 1 1 Fuel Pressure Adjustment NOTE 3 1 1 2 1 10 11 12 13 14 T9 16 17 18 Ensure that the fuel supply source is OFF Ensure that the gas train inlet ball valve is SHUT Remove the 14 in pressure tap plug located in the gas train inlet ball valve body opposite of the pilot gas valve Install a 1 4 in petcock and pipe adapter in the location of the pipe plug to facilitate connecting the 0 to 30 in WC manometer Ensure the petcock is SHUT Do not use pipe dope on this joint Remove the in pressure tap plug located at the end of the T fitting just below the gas train union Install a 1 4 in petcock and pipe adapter in the location of the pipe plug to facilitate connecting the 0 to 15 in WC manometer Ensure the petcock is SHUT Do not use pipe dope on this joint Loosen the air dampers locking screws enough to provide movement for adjustment Open the top damper 100 and fully shut the bottom damper R
54. nal features 1 1 2 Locate and explain purpose of internal features 1 1 4 Explain purpose and function of gauges indicators and safety features 2 3 SETUP Explain the following 14 and use of quick connects and cam locks 1 2 3 1 Proper positioning of the Sahara Air Heater 1250 for operation 2 3 2 Loading ramp storage and use O 2 3 2 Heat Exchangers positioning and connecting 1 2 3 3 Proper Heat Transfer Fluid level 2 3 4 Circulation hose unwinding 2 3 4 Control panel switch functions and power connecting 2 4 START UP Explain the following 2 4 Digital temperature control setting when power is applied and main breakers are switched ON 2 4 4 Circulation pump start up and operating parameters 2 4 5 Burner start up 2 4 6 Heat Exchangers power connecting blower speed and temperature setting 2 6 SHUT DOWN Demonstrate the following 2 6 1 SAH 1250 and Heat Exchangers shut down 2 6 3 Circulation hose rewinding 2 6 4 Heat Exchangers and ramp storage 2 6 4 Power disconnecting the door locking Record any discrepancies Give Operator s Manual to your customer and explain warranty policy on reverse side of this form Buyer hereby acknowledges receipt of the Operator s Manual from Distributor explanation of the GHI warranty by Distributor and the above Sahara Air Heater 1250 is in proper operating condition Distributor Representative s Signature Date Customer s Bu
55. ons and precautions be followed Key safety precautions are posted with decals throughout the machine Read and understand all material in this Operators Manual and on the decals posted on the SAH before attempting to operate it 1 5 1 Operators There are no published standards or certification requirements for operating portable hydronic heating machines The following criteria reflect the experience of Ground Heaters Inc and should be considered a guide not a comprehensive requirement The following operator characteristics will prevent accidents facilitate satisfactory results and ensure reliable service from the Sahara Air Heater 1 Patience Insures the system runs at optimum levels leaks are found and fixed valves are properly set and switches are activated properly 2 Qood Hearing Vision and Smell Enable operator to assess equipment and detect potential malfunctions 3 Self Respect Dresses for the weather wears eye protection and gloves and does not take chances substances 4 Careful and Responsible Insures the machine is operating properly before leaving it unattended keeps track of fluid levels locks compartments conducts operational checks at regular intervals and ensures proper officials are notified of the machine s use 5 Above all a Sahara Air Heater M operator reads and understands this Operators Manual and the decals posted on the machine Failure to adhere to all safety precautions and recommenda
56. orque the wheel lug nuts sequentially as shown Torque to the values listed onthe decal located on the whed 4 Lug nuts torque value is as directed on wheel decal Photo 5 2 V 1 Rev 2 17 04 2004 Ground Heaters Inc 5 1 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 6 1 Ground 555 inc NS TROUBLESHOOTING 6 1 TROUBLESHOOTING CHART Contact your local Ground Heaters Distributor for situations not covered in this section NOTE Discontinue troubleshooting activities and shut down the Sahara Air Heater SAH 1250 if one of the following occurs 1 One of the GFIs trips and will not remain reset 2 Anelectric motor hums but does not turn 3 The Burner Safety will not reset when the MANUAL RESET button is pushed 4 Dark smoke emits from the hydronic heater exhaust Once the SAH 1250 is shut down call your local Ground Heaters Distributor for assistance Symptom Possible Cause Corrective Action e Verify both MAIN BREAKERS are ON No power due to incorrect switch Verify both GFIs are reset position or protective function Appendix A 1 e Verify HTF level is between MIN and MAX Heat transfer level and LOW HTF LEVEL light is not lit fluid pump will not start HER Motor internal overload is e Allow motor to cool it will reset tripped automatically Appendix Pump motor fuse is blown e Replace fuse A 2 e Have an electrician verify voltage at control panel is 1
57. ostic cycle the burner should pre purge and then light The oil primary control may have to be re set several times for the initial start up to purge air out of the fuel supply line 4 2 2 From Diesel Fuel Oil to NG LP 1 Burner setup and installation fuel supply connection test firing and burner adjustment should be All gas and propane connections must be leak tested prior to placing into service Main heater unit trailer must not be installed within 12 ft 3 6 m of combustible materials All gas burners are test fired at Ground Heaters Inc s factory prior to shipment Ground Heaters technicians have installed an Bm in orifice This orifice is suitable for burning both NG and LP fuels and does not need to be changed in the field combustion verification and adjustment must be performed e before operating at elevations 1 000 ft 305 m above or below the last adjustment e before starting at a new job site e after any burner maintenance has been performed e after changing fuel type NG LP to 2 fuel oil etc e if burner performance is in question for any reason 6 A Combustion Analyzer Smoke True Spot Tester and common hand tools will be required Do not exceed 14 in water column supply pressure Excessive pressure will damage the gas train components NG Do not exceed 4 0 in water column manifold pressure as this will over fire the heater and cause damage LP Do not exceed 2 0 in water column manifol
58. ound se crus Heaters 3 2 1 4 Smoke Spot Sampling 1 Follow the smoke spot tester manufacturer s instructions for accurate exhaust sampling 2 Sample the burner exhaust for smoke by inserting the smoke spot sampling probe into the chimney access hole provided through the exhaust guard The probe must be greater than 5 in 127 mm in length for an accurate sampling Smoke spot production must be 1 or less 3 Several samples should be taken as the heater warms The final sample should be taken just before the heater reaches 180 F 82 2 NOTE Higher percentage excess air settings lowers soot production but raises stack temperature and reduces efficiency Lower percentage inadequate air settings increases efficiency and lowers stack temperature but may cause soot build up A burner optimized for clean and efficient operation will have levels of 4 to 6 and a smoke spot value of 1 or less 4 Loosen the air band and shutter locking screws enough to provide movement for adjustment Refer to Appendix A 18 SAH 1250 DIESEL BURNER P N P100 690 COMPONENT IDENTIFICATION 5 Start the burner by turning the BURNER switch ON The burner will start and begin a 15 second pre purge followed by the ignition sequence 6 Once the burner lights sample the exhaust as outlined in Section 3 2 1 1 Adjust the air band and shutter until combustion parameters fall within the above outlined values 7 Lockthe air band and shutter in
59. ound Heaters Inc confirms that such products are defective Use of repair or replacement parts not manufactured by Ground Heaters Inc may void this warranty Ground Heaters Inc s liability hereunder shall be limited to the contract price of that portion of the Product on which such liability is based The existence of a defect shall be determined by Ground Heaters Inc in its sole discretion GROUND HEATERS INC SHALL NOT BE RESPONSIBLE FOR ANY LABOR CHARGES OR LOST HEAT TRANSFER FLUID IN CONNECTION WITH WARRANTY SERVICE USE OF ANY ANTI FREEZE OR HEAT TRANSFER FLUID OTHER THAN GROUND HEATERS BRAND HEAT TRANSFER FLUID VOIDS THIS WARRANTY IN ITS ENTIRETY THIS WARRANTY IS EXCLUSIVE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND WARRANTIES ARISING FROM A COURSE OF DEALING OR USAGE OF TRADE ARE SPECIFICALLY EXCLUDED AND THERE ARE NO WARRANTIES EXPRESSED OR IMPLIED OTHER THAN THE LIMITED WARRANTY EXPRESSLY SET FORTH HEREIN GROUND HEATERS INC SHALL NOT BE LIABLE FOR INCIDENTAL CONSEQUENTIAL SPECIAL OR OTHER DAMAGES INCLUDING BUT NOT LIMITED TO DAMAGES FOR LOSS OF PROFITS OR PRODUCTION OR INJURY TO PERSON OR PROPERTY WITHOUT LIMITING THE GENERALITY OF THE FOREGOING GROUND HEATERS INC SHALL NOT BE LIABLE FOR ANY CLAIMS BASED ON THE CONDITION USE OR OPERATION OF THE PRODUCTS WHETHER BASED ON CONTRACT TORT OR OTHER THEORIES OF LAW INCLUDING WITHOUT LIMITATIONS THEORIES OF NEGLIGENCE The Products covere
60. place by tightening the locking screws Do not exceed 150 psi fuel pressure Do not set below 100 psi fuel pressure 3 2 2 Burner Shutdown 1 Shut down the burner by turning the BURNER switch OFF 2 Turn both MAIN BREAKERS OFF 3 Separate fuel quick connects and remove the fuel pressure gauge Reinstall the pressure tap plug 4 Reconnect both fuel quick connects NOTE You may need to install a smaller nozzle at high elevations or if ambient temperature is below 10 F 12 C The table below shows the approximate firing rate at various fuel pressures with the 4 5 GPH nozzle Fuel Firing Pressure Rate psi GPH 100 4 50 110 4 72 120 4 94 125 5 04 130 5 13 140 5 32 V 1 Rev 2 17 04 2004 Ground Heaters Inc 3 5 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 4 GR Ground inc MAINTENANCE 4 1 NOTE 4 1 1 NOTE Fluid HTF The standard SAH 1250 includes 140 US gallons 530 liters of HTF for normal operation Ground Heaters Inc recommends that the HTF be replaced every three years to ensure that the corrosion inhibitors are sufficiently active to protect the system components ADDING HEAT TRANSFER FLUID Refer to Appendix A 13 SAH 1250 VALVE POSITIONING FOR ADDING HTF Shut down all pumps including optional booster pump HTF levels will rise approximately 1 in 25 mm per five gallons of HTF added If using optional booster pump refer to Section 2 3 5
61. r not to light and or fuel pump damage Contact your local fuel supplier to obtain potential jelling temperatures for your fuel as specifications for diesel fuel vary from terminal to terminal Some fuel suppliers may add products such as Valvetech to prevent jelling or Diesel 911 after jelling has occurred Your fuel supplier should supply this information and make recommendations for the selection and use of such products If ambient temperatures are such that your fuel supplies cannot insure the fuel will not jell K1 Kerosene or 1 diesel fuel dyed K1 for off road use must be added by ratio until does not occur V 1 Rev 2 17 04 2004 Ground Heaters Inc 4 5 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 4 4 5 NOTE 4 6 5 Refer to the Fuel Blend Guide below consult your fuel supplier for assistance in calibrating these values to your fuel Fuel Blend Guide Temperature Range Fuel Blend 15 to 30 F 80 2 to 20 1 0 to 15 F 70 2 to 30 1 0 to 15 F 50 2 to 50 1 15 F and below 30 2 to 70 1 SUMMER STORAGE INSTRUCTIONS 1 Allow the 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 Burners not installed should be stored in a cool dry place Remove emergency break away battery and store the battery in a cool dry place Connect
62. rgy degrees Celsius metric measurement of temperature centimeter 1 100 of a meter degrees Fahrenheit measurement of temperature foot feet measurement of length distance square foot square feet measurement of area foot pounds measurement of torque gallons per hour measurement of liquid flow Ground Fault Interrupt interrupter protection device Ground Heaters Incorporated Gross Vehicle Weight Rating Ground Heaters Hose Handling System Ground Heaters Heat Transfer Fluid hour measurement of time Hertz measurement of frequency measurement of Inner Diameter inch inches measurement of length distance kilogram metric measurement of weight Kilo Calorie 1000 Calories metric measurement of heat energy kilo Pascals metric measurement of pressure kilo Watt measurement of electrical power pound measurement of weight meter metric measurement of length distance millimeter 1 1000 of a meter pounds per square inch gauge measurement of pressure Revision Sahara Air Heater Temperature Controller National Highway Transportation Safety Administration Version Volts Alternating Current Volts Direct Current iii 2004 Ground Heaters Inc SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL GR Ground inc Hs Heaters TABLE OF CONTENTS Page LIST OF ABBREVIATIONS iii INTRODUCTION 1 1 EXTERNAL FEATURES eet geegent 1 1 1 2 INTERNAL COMPONENTSG 1 2 1 2 1 for Heater with Burner
63. rn the foot pedal to storage location Completing Unit Shutdown 1 Retrieve and reload the heat exchangers into the trailer Stow ramp and latch and lock rear doors to secure heat exchangers If a Booster Pump was connected refer to Section 2 3 5 4 Disconnecting Disconnect fuel supply line s NG or LP disconnection may require a qualified technician Check local codes and regulations Turn OFF cab light and both MAIN BREAKERS Disconnect and remove the power cords latch and lock all remaining doors 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION BURNER ADJUSTMENT AND SHUTDOWN NOTE 3 1 3 1 1 NOTE The Sahara Air Heater SAH can be operated on natural gas NG liquid propane vapor LP or diesel fuel oil OIL Refer to Appendix A 16 GAS or A 18 DIESEL for burner component identification burners are test fired at Ground Heaters Inc s factory located 600 ft 180 m above sea level asl using NG LP and winter blend diesel For NG and LP Burners The air and or gas settings are returned to zero after factory test firing A CERTIFIED AND LICENSED GAS TECHNICIAN MUST RECALIBRATE THE BURNER AIR AND FUEL SETINGS TO OBTAIN PROPER COMBUSTION AT YOUR WORK SITE 1 Burner setup and installation fuel supply connection test firing and burner adjustment MUST PERFORMED BY A LICENSED PROFESSIONAL AND MUST CONFORM TO THE REQUIR
64. running or when the HTF temperature is above 120 F 49 C Do not attempt tire repairs Have a qualified tire dealer or repair service perform required tire maintenance Torque for wheel lug nuts should be set at 110 ft lbs Failure to observe these warnings may result in injury or death REPAIR PARTS AND ACCESSORIES Your Ground Heaters Distributor carries a complete line of parts and accessories needed for all repair or replacement requirements MAINTENANCE All maintenance with exception of routine lubrication and cleaning should be performed by a qualified service technician using the Ground Heaters Service Manual The following preventative maintenance should be performed once per year or every 1 500 hours whichever comes first e Heater and burner cleaning and inspection refer to the Service Manual e Low level shutdown operation verification refer to Section 2 of the Service Manual e Temperature control accuracy and operation verification refer to Section 2 of the Service Manual e Routine trailer axle maintenance common mechanical experience V 1 Rev 2 17 04 2004 Ground Heaters Inc 1 5 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 1 6 Ground 51 me 1 8 1 6 OBTAINING WARRANTY SERVICE Your satisfaction is important to your Ground Heaters Distributor as well as to Ground Heaters Inc Warranty details are explained in the Ground Heaters Inc Statement of Warranty found on
65. s Turn the BURNER switch ON The burner will begin a 15 second pre purge Monitor the fuel pressure during the pre purge and make adjustments using the fuel pressure adjusting screw Refer to Appendix A 18 SAH 1250 DIESEL BURNER P N P100 690 COMPONENT IDENTIFICATION 7 Turn the adjusting screw clockwise to increase fuel pressure or counter clockwise to decrease fuel pressure until it is stable at 140 psig quo c 8 Once the fuel pressure is set proceed with air setting and adjustment Air Setting and Adjustment Air Band and Shutter may be opened or closed in amounts sufficient to adjust exhaust 05 levels as sampled using a combustion analyzer Refer to Appendix A 18 SAH 1250 DIESEL BURNER P N P100 690 COMPONENT IDENTIFICATION Content Sampling 1 Follow the combustion analyzer manufacturer s instructions for pre purge and exhaust sampling 2 Sample the exhaust gas by inserting the combustion analyzer sampling probe into the chimney access hole provided through the exhaust guard The probe must be greater than 5 in 127 mm in length for an accurate sampling Exhaust content must be 4 to 6 for optimum performance and minimum soot production 3 Several samples should be taken as the heater warms The final sample should be taken just before the heater reaches 180 F 82 2 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAHARA AIR MODEL 1250 OPERATOR S MANUAL SECTION 3 GR Gr
66. s been established If flame failure is sensed during the start up or heating cycle the control will stop all burner function and begin one of three protective modes 1 Io ES Hecycle Mode The STATUS light will flash in two second intervals while attempting three automatic restarts If the flame fails after three successive attempts the control will go into Lockout mode Lockout Mode The STATUS light will flash in 1 second intervals The RESET button must be momentarily pressed to clear the lockout and attempt a burner restart After three attempts to manually clear the lockout mode the control will begin Restricted Lockout mode Restricted Lockout Mode The STATUS light will flash in 1 second intervals The RESET button must be pressed and held for 30 seconds or until the STATUS light comes on for two seconds and then goes out The control will return to Restricted Lockout mode with each flame failure until one successful heating cycle has occurred DIAGNOSTIC LIGHT ING SEC ON RECYCLE 1 2 SEC ON LOCKOUT PUSH RED BUTTON TO RESET FROM LOCKOLUT VALVE ON DELAY TIME 15 SEC FIXED RESET BUTTON POAT BLK HED WHT GRN BLU YEL ORG VIO AAN BURNER WIRING AN IN IN WIRE COLORS
67. s easily towed by a vehicle rated to tow 7 000 16 3 175 kg and fitted with a Class III or above hitch Photo 5 1 The SAH 1250 has a tongue weight of 1 120 Ibs 508 kg Towing vehicle must be equipped with an electric brake system controller NOTE A trailer plug wiring decal is located on the inside frame wall across from the trailer junction box Refer to Appendix A 6 SAH 1250 TRAILER WIRING and Appendix A 7 SAH 1250 TRAILER JUNCTION BOX AND BATTERY WIRING 5 2 CRANE and AIR LIFTING The SAH 1250 is equipped with a lifting bale The lifting bar s multiple holes accommodate various weight loads A qualified rigger should set up and perform all rigging 5 3 TRANPORTING on a FLATBED The SAH 1250 may be loaded onto a 98 in 250 cm or wider flatbed using common sized loading ramps and docks The SAH 1250 should be chained down to the flatbed trailer Refer to Appendix A 15 SUGGESTED METHOD FOR SECURING THE SAH 1250 ONTO A TRUCK BED 5 4 COMMON MECHANICAL INSPECTIONS PRIOR TO TRANSPORTING 1 Trailer lights brakes wiring and wheel bearing inspection FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN WHEEL LOSS WHICH CAN 2 Tires inflated to proper pressure and NEA CAUSE i ee OR CEM free of defects 3 TORQUE WHEEL NUTS TO 90 120 LB FT BEFORE FIRST ROAD USE j i 90 120 LB FT AFTER 10 25 AND 50 MILES 3 Plumbing internal and field hose 2 api integrity check T
68. the battery to a trickle charger once every 30 days to maintain full charge Perform a thorough inspection for leaks and correct Double check that all valves are shut Shut and lock all doors Protect the tires from direct sunlight if stored outdoors Do not drain the HTF The heater and plumbing must remain flooded with HTF to prevent corrosion rusting PRE SEASON MAINTENANCE Refer to Section 3 of the Service Manual for detailed instructions 1 er Remove waterproof wrapping or covering from chimney and burner Test and reinstall emergency break away battery Hemove flue door Inspect fire tubes Clean out any soot or flaked material Remount flue door For Oil Burners Remove the burner electrode assembly Replace the nozzle with an exact replacement Adjust or replace the electrodes as necessary Remove the burner to inspect and clean the flame head Replace fuel filter element Reinstall the electrode assembly and verify the Z distance is correctly set burner using a new burner mounting gasket Adjust burner settings as directed in Section 3 BURNER ADJUSTMENT AND SHUTDOWN Verify HTF level 2004 Ground Heaters Inc V 1 Rev 2 17 04 VIP AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 5 GR Heaters TRANSPORTING THE SAH 1250 This section describes the three basic methods of SAH 1250 transport and associated precautions 5 1 TOWING The SAH 1250 i
69. the horizontal portion of the gas train extending toward the tongue of the trailer Do not use pipe dope on this joint Attach the 2 pin quick connect power cord leading from the burner control to the electrical junction box mounted on the gas train Connect the 90 end of the braided pilot gas line to the fitting provided on the left side of the gas train do not use pipe dope on this joint Verify that the two ball valves and the pilot valve on the gas train are turned OFF Attach the 36 in x in poly vent hose to the main gas pressure regulator vent and route it outside through the 5 in 127 mm square access panel in the floor Attach the 17 in x in poly vent hose to the pilot pressure regulator and route it outside through a slot in the trailer floor along the left side of the trailer Attach the NG or LP gas supply line to the main gas inlet fitting at the left side of the gas train This gas line should enter the trailer through the 5 in 127 mm square access panel in the floor of the trailer 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAHARA AIR HEATER MODEL 1250 5 MANUAL SECTION 4 GR Ground inc 4 2 2 2 Setup Open the top burner air inlet damper 100 percent The bottom air inlet damper should be completely closed This initial setting will be fine tuned later Do not turn on the gas at this time NOTE The gas supply line must be sized such that it
70. tions may result in damage to the Sahara Air Heater damage to other property personal injury or possibly death 1 4 2004 Ground Heaters Inc V 1 Rev 2 17 04 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 1 GR Ground 1 5 2 1 6 1 7 oafe Operation and Maintenance Read and understand all material in this Operators Manual and on the decals posted on the Sahara Air Heater M before attempting to operate it Keep unauthorized people especially children away from the SAH Keep guards in place Do not disable safety features Keep safety and instruction decals clean and legible Replace damaged decals Do not operate the burner while the Sahara Air Heater is an enclosed non ventilated area The burner exhaust contains carbon monoxide an odorless and deadly poisonous gas Locate the SAH on firm level ground and chock wheels before operating The Sahara Air Heater is not designed to be operated during transit Do not operate the SAH while it is being towed or carried by truck Do not smoke while refueling Do not refuel near open flame or sparks Clean up fuel spills immediately Do not transport people in or on the Sahara Air Heater M If the SAH starts to function improperly turn off immediately and repair before restarting Always wear gloves when handling hot or cold components especially the Circulation Hose Never loosen or remove Circulation Hose while a pump or the heater is
71. tripping the electrical circuit breakers Periodically verify proper system operation using the dashboard gauges Adjust valve 2 so that the pressure gauge reads 30 psi The flow indicator should spin at medium speed The HTF return temperature should read approximately 40 to 50 F 22 to 28 C less than the supply temperature red numbers on the control panel Check each heat exchanger and verify that the thermostats are set at the proper target temperature and that the blowers are running Output air will increase in temperature as the system warms up Blowers will not run if the heat exchanger thermostats are set too low 8 Check hoses and connections to verify that no leaks exist MONITORING OPERATING PARAMETERS The following parameters should be monitored every six to eight hours 1 2 3 4 Fuel Tank Level Keep track of fuel consumption to plan needed filling schedule HTF Level Level should remain between MIN and MAX lines on the HTF sight gauge Photo 2 4 Hydronic Heater Temperature HTF outlet temperature as displayed on the Temperature Control Hydronic heater temperature will operate 40 to 50 F 22 to 28 C greater than return temperature until reaching control set temperature Plumbing and Fitting Leaks Always check for leaks during each monitoring period V 1 Rev 2 17 04 2004 Ground Heaters Inc 2 5 2 6 2 6 1 2 6 2 2 6 3 2 6 4 IR HEATER MODEL 1250 OPERATOR S MANUAL
72. uring TU D D D D D 0 O shipping Ensure all discrepancies caused by shipping are filed with the freight carrying company Heat Exchangers HX 200 Qty HX 100 Qty 1 HX 50 Qty Verify proper door s operation locate Operator s Manual and perform all steps to verify the following section 2 3 SETUP 2 3 1 Sahara Air Heater is positioned correctly for operation 2 3 2 Loading ramp slides smoothly out of its storage rack 2 3 2 gt Heat Exchangers roll freely and are free of any shipping damage to exterior or blower components 2 3 3 Verify Heat Transfer Fluid HTF level is adequate for operation 2 3 4 Control panel switches are ready for power to be connected 2 3 4 Circulation hose unwinds smoothly 2 2 2 Circulation hose quick connect fittings separate easily 2 4 Digital temperature control and low water cut off LWCO activate when power is applied and main breakers are switched ON 2 4 8 All circulation hose connections are free of leaks 2 4 START UP 2 4 4 Circulation pump starts and runs with no abnormal noises 2 4 5 Burner starts and runs with no visible smoke in the exhaust 2 4 Heat Exchangers are connected to power and stepped through all blower speeds without abnormal noise vibration TESTING AND INSPECTION 2 4 7 Gauges and indicators function satisfactorily 2 5 3 SAH 1250 temperature control shuts down the burner when the set point is lowered 10 F 5 5 C below fluid temp
73. valve 5 2 3 5 3 Shutdown Turn the BURNER switch OFF Continue to operate both pumps until the HTF has cooled 120 F 49 C Turn the MAIN PUMP switch OFF Refer to main control panel Turn the BOOSTER PUMP BREAKER switch OFF Refer to booster pump control panel SHUT and LOCK valves 6 and 7 OPEN valve 5 aS e Ie I 2 3 5 4 Disconnecting 1 Disconnect the Booster Pump Hoses one at a time by simultaneously swinging the cam lock handles to the UNLOCKED position Refer to Appendix A 14 SAH 1250 QUICK CONNECT AND CAM LOCK CARE AND MAINTENANCE Take care not to spill the HTF contained in the pump and hose 2 Engage the protective cap onto the booster pump hose and LOCK into place 2 4 2004 Ground Heaters Inc V 1 Rev 2 17 04 2 4 NOTE 2 5 SAHARA AIR HEATER MODEL 1250 OPERATOR S MANUAL SECTION 2 GR Ground 111 me Heaters 3 4 5 Repeat Steps 1 through 2 for the remaining hose Disconnect the power cord and extension cord Stow the booster pump power cord and hoses neatly in the booster pump enclosure Replace the protective caps on the booster pump connection points on the SAH 1250 and LOCK into place START UP Using two separate 20 amp 120 volts AC 60 Hz electrical power circuits connect one each to the SAH power pigtails marked MAIN 1 and MAIN POWER 2 Route both extension cords into the trailer enclosure through one of the 5 in square access holes in the floor
74. wer the blower Use 10 gauge extension cords of no more than 100 ft 30 m in length 4 Heat Transfer Fluid HTF Open the two left side doors on the trailer and latch them to stay open Verify the following If fluid level is not above MIN level refer to Section 4 1 ADDING HEAT TRANSFER FLUID to correct before attempting to start the burner or HTF pump Deployment of Circulation Hoses 1 Test the blowers to be sure they run Slowly step through speeds 1 2 and 3 to avoid possibly tripping the electrical circuit breakers Turn the blowers OFF HTF is between MIN and MAX in the sight gauge Photo 2 4 e control panel switches and both MAIN BREAKER switches OFF Refer to Appendix A 1 SAH 1250 CONTROL PANEL LAYOUT Once the burner has been test fired and properly adjusted deploy the circulation hoses The hose reel contains ten pieces of hose i e four pieces x 50 ft 15 four pieces x 100 ft 30 m and two pieces x 200 ft 61 m Partially release the hose reel brake by turning the brake knob counterclockwise and pull the first length of hose off the reel Disconnect each hose quick connect as it comes off the reel Based on how far away from the SAH trailer each of the heat exchangers has been placed select the shortest appropriate lengths of hose to run a supply and return line to each heat exchanger Verify that valves 1 2 and 3 are SHUT Valves 4 6 and 7 must be SHU
75. yer s Signature Date Ground Heaters Inc 1271 Judson Rd Spring Lake Michigan 49456 p 231 799 9600 f 231 799 9500 www groundheaters com 2004 Ground Heaters Inc Tmp Ground inc Heaters One Year Limited Warranty see your distributor to file warranty claim Ground Heaters Inc warrants that the Products described in this Limited Warranty shall be free of defects in material and workmanship under normal use and service for a period of one year from the date first placed in service This Limited Warranty is expressly limited to crediting the purchase price of the defective Product or to repairing or replacing the defective Product at the sole option of Ground Heaters Inc This warranty shall not extend to any repair work performed by anyone other than Ground Heaters Inc or an authorized representative of Ground Heaters Inc Such credit repair or replacement shall be Ground Heaters 5 sole obligation and buyer s exclusive remedy hereunder and shall be conditioned upon Ground Heaters Inc s timely receipt of written notice of the alleged defect and at Ground Heaters Inc s option return of such product to Ground Heaters Inc FOB its Spring Lake Michigan facility This exclusive remedy shall not be deemed to have failed of its essential purpose provided Ground Heaters Inc is willing and able to repair or replace the defective Product or to credit the purchase price within 90 days of the date on which Gr

2004 SAH 1250 Operators Manual

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