Heatwagon DF400 Manual

DF400/DF600
C US
Construction
Heaters
Installation and Maintenance Manual
Please retain this manual for future reference.
342 N. Co. Rd. 400 East
Va paraiso, IN 46383
219-464-8818 • Fax [phone]
www.heatwagon.com
Revision 5-15
For your safety: Do not use this heater in
a space where gaso ine or other iquids
having f ammab e vapors are stored.
For DF400 Model
SN 27601001 and beyond
For DF600 Model
SN 27701501 and beyond

CON TRUCTION HEATER GENERAL HAZARD WARNING:
Failure to comply with the precautions and instructions provided with this heater,
can result in death, serious bodily injury and property loss or damage from hazards
of fire, explosion, burn, asphyxiation, carbon monoxide poisoning, and/or electrical
shock.
Only persons who can understand and follow the instructions should use or service
this heater.
If you need assistance or heater information such as an instruction manual, labels,
etc., contact your local Heat Wagon dealer or the manufacturer.
Heater is not intended for use in pest remediation.
W A R N I N G
Fire, burn, inhalation, and explosion hazard. Keep solid combustibles, such as build-
ing materials, paper or cardboard, a safe distance away from the heater as recom-
mended by the instructions. Never use the heater in spaces which do or may contain
volatile or airborne combustibles, or products such as gasoline, solvents, paint thin-
ner, dust particles or unknown chemicals.
Not for home or recreational vehicle use!

Table of Contents:
Page
Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Re ommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Maintenan e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Sequen e of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Spe ifi ations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15
Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-19
Installation and Maintenance Manual
Model DF400 - DF600
Construction Heater
342 N. Co. Rd. 400 East • Val araiso, IN 46383
219-464-8818 • 888-432-8924 • Fax [phone]
www.heatwagon.com
WARRANTY
All new Heat Wagon and Sure Flame heaters and fans are guaranteed against defe tive materials and work-
manship for one (1) year from invoi e date.
Warranty repairs may be made only by an authorized, trained and ertified Heat Wagon dealer. Warranty
repairs by other entities will not be onsidered. Warranty laims must in lude model number and serial
number.
LIMITATION
Warrant laims for servi e parts (wear parts) su h as spark plugs, igniters, flame rods will not be allowed.
Diagnosti parts su h as voltage meters and pressure gauges are not warrantable.
Eviden e of improper fuel usage, fuel pressures outside of manufa turer’s spe ifi ation, poor fuel quality,
and improper ele tri power, misappli ation or eviden e of abuse may be ause for reje tion of warranty
laims.
Travel time, mileage and shipping harges will not be allowed. Minor adjustments of heaters are dealers’
responsibility. Defe tive parts must be tagged and held for possible return to the fa tory for 60 days from
date of repair. The fa tory will provide a return goods authorization, (RGA) for defe tive parts to be
returned.
No warranty will be allowed for parts not pur hased from Heat Wagon.

4
Control Board
Note: 1mm = 0.039 inc
#1 Kerosene
#2 Diesel Fuel (Winter Blend)
A-No Thermostat
B-With Thermostat
A
B

5

6
See page 11.

7
ADVANCED TROUBLE HOOTING
Motor runs, no visible ignition and heater reset (red light) comes on
Causes:
1. Fuel filter is dirty.
2. Spray nozzle clogged.
3. Air proving switch defective.
4. Air entering the fuel pump thru the inlet line.
5. Safety thermostat defective or tripped.
6. Fuel pump is defective/or broken pump coupling.
7. Solenoid valve is defective.
8. Control board is defective.
9. Defective transformer.
olutions:
1. Fuel filter dirty. Check the external and internal fuel filters and clean or replace as necessary. ost fuel pumps contain an internal fuel filter
located where the inlet line enters the fuel pump.
2. Spray nozzle clogged. Remove and inspect the spray nozzle. Clean or replace as needed. Do not clean the nozzle orifice with anything
metal as this may enlarge the orifice.
3. Air proving switch is defective. Try to start the heater without ducting. Oil heaters have an air proving switch wired between the control
board and the solenoid valve. (Review Sequence of Operation, page 10). The air proving switch is normally open and requires air from the
turning fan blade to close the switch and send power to the solenoid valve. Set a multi-meter to measure voltage. With the fan blade turning,
check for voltage coming out of the air proving switch to the solenoid valve. If no voltage is read, next check for voltage at the control board
terminals out to the air proving switch. If voltage at the control board is read, the air proving switch is defective. If no voltage is read at the
board, the control board is defective.
4. Air entering the fuel pump thru the fuel inlet line. If air enters the pump it will lose its prime and will not maintain adequate pump pressure.
First make sure all fittings, including the fuel filter on the inlet line are tight. If you still suspect air is entering the pump, start eliminating por-
tions of the inlet line until the air leak is found. Start this process at the fuel tank end of the inlet line. It may be necessary to draw fuel from a
small container rather than the fuel tank.
5. Safety thermostat defective or tripped. Also called overheat switch. Some oil heaters have a safety thermostat wired between the control
board and the solenoid valve. If the heater becomes too hot this normally closed switch will open and interrupt power to the solenoid valve.
Use a multi-meter set to measure ohms. Place the multi-meter probes on the two male terminals of the safety thermostat. If the multi-meter
shows infinity (no continuity) the safety thermostat is defective. If the switch opens up before the heater becomes hot, the safety thermostat is
defective.
6. Fuel pump is defective. The output pressure of the fuel pump can be checked by placing a high pressure fuel gauge into the gauge port of
the fuel pump. Use a gauge with enough capacity to measure the high pressure your particular heater can produce. Use the adjustment on the
pump to set the pump pressure to the manufacturer’s specification. If you do not have a fuel gauge, you may slightly loosen the pump’s output
line connection and place a rag there. Run the heater briefly and see if fuel reaches the rag. If no fuel is pumped, check the connection
between the motor and the fuel pump to make sure the motor can turn the pump. Also check the external and internal fuel filters for blockage,
and clean or replace if necessary. The fuel pumps internal filter is usually located where the fuel inlet line enters the pump. Check to make
sure motor is rotating pump. (BIE 99A 003 Gauge Kit, optional accessory)
7. Solenoid valve is defective. Call tech service for assistance.
8. Control board defective. Use a multi-meter set to measure voltage. Take a voltage reading on the control board terminals that send input
power to the transformer. If proper voltage is not present, the control board is defective. Check fuse on control board.
*NOTE: Top cover shell of heater needs to be
attached during troubleshooting (will affect
operation of airswitch and photocell).

ADVANCED TROUBLE HOOTING CONTINUED
9. Defective transformer.
Call Tech Service.
Heater ignites, runs less than one minute and the flame/safety control trips.
Causes:
1. Photocell dirty or defective.
2. Flame/safety control defective.
olutions:
1. Photocell dirty or defective.
If the photocell “eye” is dirty, it may be cleaned with a soft dry cloth. Should a cleaner be necessary, use an alcohol based cleaner that will dry
completely without leaving an oil residue. If the photocell is clean and this symptom continues, remove the photocell for testing. easure resis-
tance, if zero or infinite-replace photocell.
2. Flame/safety control defective.
The easiest way to test the flame/safety control is to prove the photocell is good or bad using one of the two preceding tests under “1.
Photocell dirty or defective”. If the jumper test will not run the heater or the photocell passes the ohm test, the flame/safety control is defective.
Heater ignites, runs several minutes and shuts down.
Causes:
1. Photocell dirty or defective.
2. Fuel filter dirty.
3. Fuel pump is defective.
olutions:
1. Photocell dirty or defective.
See “1. Photocell dirty or defective” for instructions on cleaning and testing the photocell.
2. Fuel filter dirty.
See “1. Fuel filter dirty”
3. Fuel pump is defective.
See “6. Fuel pump is defective”
8

ADVANCED TROUBLE HOOTING CONTINUED
Heater ignites, but combustion is poor or uneven.
Causes:
1. Fuel pump is defective.
2. Spray nozzle clogged.
3. Fuel filter dirty.
4. Spark plug or electrode(s) not gapped or positioned properly.
5. Weak spark output from transformer.
6. Fuel contaminated by water or impurities.
olutions:
1. Fuel pump is defective.
See “6. Fuel pump is defective”
2. Spray nozzle clogged.
See “2. Spray nozzle clogged”
3. Fuel filter dirty.
See “1. Fuel filter dirty”
4. Spark plug or electrode(s) not gapped or positioned properly.
See page 4.
5. Weak spark from transformer.
See “9. Defective transformer”
6. Fuel contaminated by water or impurities.
Using a flashlight, inspect the fuel in the tank for water or impurities. Bubbles on the bottom of the tank indicate water in the fuel tank. Water
can be removed from the tank by adding an additive to the tank that is designed to dry up moisture in fuel tanks. This type of additive can be
purchased at most automotive supply stores. This is also advisable if the fuel filter contains water or impurities.
Motor and transformer do not operate.
Causes:
1. Incorrect or low voltage supplied to the heater.
2. Fuse in heater is blown. (no green light)
3. Thermostat defective, or not turned up to call for heat.
4. Control board is defective.
5. Reset button has not been reset. (red light on)
6. Wiring disconnected, loose or incorrect.
olutions:
1. Incorrect or low voltage supplied to the heater. ost oil heaters require a minimum of 108 volts to operate properly. A multi-meter set to
measure volts can be used to check the amount of voltage at the end of the extension cord(s). If the measured voltage is too low, the length of
the extension cord (s) must be shortened or a thicker gauge extension cord must be used.
2. Fuse in heater is blown. Locate and remove the in-line fuse of the heater. Set a multi-meter to measure ohms of resistance. Place a multi-
meter probe on each end of the fuse. The multi-meter should read zero ohms (continuity) or the fuse is blown. If a new fuse blows immediate-
ly, check for possible causes. Check for incorrect voltage to the heater. ake sure the total amperage draw of all equipment running on the cir-
cuit is not too great. If the supplied voltage and total amperage draw are correct, check the wiring in the heater for correctness and possible
shorts.
9

ADVANCED TROUBLE HOOTING CONTINUED
3. Thermostat is defective or not turned up to call for heat. Turn the thermostat up to the highest possible setting and try to start the heater.
Next set a multi-meter to measure voltage coming out of the thermostat. If approximately 120 volts is not measured, the thermostat is defec-
tive.
4. Control board is defective. Using a multi-meter set for volts, check the hot and neutral wires which bring voltage into the control board. If
proper voltage is reaching the board then the control board is defective.
5. Reset button has not been reset. Push the reset button and try to start the heater.
6. Wiring disconnected, loose or incorrect. With the heater unplugged, check the wiring from the cord to the terminal blocks, thermostat, and
flame/safety control. Consult the wiring diagram of your heater to make sure all these wires are connected properly.
Heater ignities, but flame is excessive.
Causes:
1. Pump pressure too high.
2. Incorrect fuel.
3. Worn nozzle.
.olutions:
1. Pump pressure too high.
Use a high pressure fuel gauge attached to the pump’s gauge port to check the pump pressure. Use the pump’s pressure adjustment if the
pressure is higher than the manufacturer’s recommended setting.
2. Incorrect fuel.
Only use fuels recommended by the specific manufacturer of the heater. Never use gasoline, thinners, solvents, or any other flammable fluid. If
you suspect incorrect fuel, inspect carefully, then drain and replace if necessary.
3. Worn nozzle.
Over time, impurities in the fuel which are forced thru the nozzle under high pressure will enlarge the orifice and cause the heater to overfire or
run “rich”. Always check first for excessive pump pressure or incorrect fuel. If the pressure and fuel are both correct, a new nozzle is needed.
DF400/DF600 equence of Operation
tep 1 - Plug in power cord. Power flows thru the fuse to five places: the power indicator light, the fuel filter heating element,
the relay terminal #11, the electronic board and thru the control board to the three position on/off switch.
tep 2 - Turn switch to the On position. There are two choices for On with this switch. Selecting the upper On position allows
for continuous operation without attaching an external thermostat control. The upper On position will return power from the
On/Off switch to the control board. This will cause the control board to begin the ignition sequence. Choosing the lower On posi-
tion will cycle the heater on and off with the attachment of an external thermostat control to the thermostat plug on the control
panel. When the external thermostat returns power to the control board the ignition sequence is initiated.
tep 3 - Control Board begins ignition sequence. First the board sends power to the relay terminal #A1. This joins relay con-
tacts #11 and #14 sending power to the motor and transformer.
tep 4 - Control boards sends power to the solenoid valve. After the motor and transformer have received power for approxi-
mately 7 to 10 seconds the control board will send power to the solenoid valve. If the airswitch closes, the power to the solenoid
valve must travel thru an air pressure switch to reach the valve. Air switch is in series with solenoid valve.
tep 5 - Photocell must detect flame. After the control board sends power to the solenoid valve the photocell must detect the
presence of flame in about two seconds. If flame is not detected the reset light will come on and the control board will interrupt
power to the solenoid valve. The cool down phase will run as the control board will continue to power the relay and therefore the
motor for 90 seconds. When flame is detected by the photocell the control board will continue to power the solenoid valve, the
motor, and the transformer.
tep 6 - Turn Control witch to Off position. The control board removes power to the solenoid valve and runs the motor for 90
seconds.
10

FOR 2 RED BLINK CAU E MAY BE:
• No flame at 1st start up (review page 12 and 13)
• Other causes may be defective over heat limit switch (check for continuity)
FOR 4 RED BLINK CAU E MAY BE:
• Photocell senses light before start- up (make sure cover is on and photocell installed properly)
FOR 7 RED BLINK CAU E MAY BE:
• Out of fuel
• Filter or nozzle blocked
• Broken fuel line (intake sucking air)
• Bad photocell
• Overheat limit switch tripped
• Non-volatile lockout (manual reset), in order to reset the system, the reset button must be pressed (less than 5 seconds).
• Volatile lockout, hold reset button for a least one minute, red light should go out, let control board “reboot” for at least
another minute before attempting to start again.
1.
2.
3.
11

165
28
N=7.5
2,00-80ºS
190
Technical Specification
N
12

13
Accessories
FUEL PRE URE GAUGE
#BIE99A 003
THERMO TAT
#THIDF
EXTERNAL FUEL KIT
(allows access to
external fuel source)
#TK400

14
DF400 Wiring Diagram
SN 276000401 and Beyond
CAPACITOR
P/N - E10325

15
DF600 Wiring Diagram
SN 277000401 and Beyond
CAPACITOR P/N - E10325

16
DF400
Breakdown

17
DF400 *
Parts List
E10930
* Note for S/N Starting 27602001
PO P/N DE CRIPTION
08 E10772 otor
09 E10772-1 Capacitor
68 E30443-1 Power cord
85 E10698 otor pump coupling
104 E20965 Cable fastener nut
105 E20964 Cable fastener

DF600
Breakdown
18

DF600 *
Parts List
* Note for S/N Starting 27703001
PO P/N DE CRIPTION
08 E10772 otor
09 E10772-1 Capacitor
68 E30443 Power cord
85 E10698 otor pump coupling
104 E20965 Cable fastener nut
105 E20964 Cable fastener
75 I20115 Iron fitting
19

342 N. Co. Rd. 400 East • Val araiso, IN 46383
219-464-8818 • 888-432-8924 • Fax [phone]
www.heatwagon.com
Accessories
FUEL PRE URE GAUGE
#BIE99A 003
THERMO TAT
#THIDF
EXTERNAL FUEL KIT
(allows access to
external fuel source)
#TK400