Heatwagon S405 Manual

Installation and Maintenance Manual
Please retain this manual for future reference.
342 N. Co. Rd. 400 East
Valparaiso, IN 46383
219-464-8818 • Fax [phone]
www.heatwagon.com
Revision 7-29-02
S405
For your safety: Do not use this heater in
a space where gasoline or other liquids
having flammable vapors are stored.
Construction
Heater

IMPORTANT INFORMATION! READ FIRST
The heater is designed for use as a construction heater under ANSI Z83.7a-1993. The primary
purpose of construction heaters is to provide temporary heating of buildings under construction,
alteration, or repair and to provide emergency heat. Properly used, the heater provides safe,
economical heating. Products of combustion are vented into the area being heated.
The heater IS NOT designed as an Unvented Gas Fired Room Heater under ANSI-Z21.11.2 and
SHOULD NOT be used in the home.
ANSI A119.2(NFPA 501C)-1987 Recreational Vehicle Standard prohibits the installation or
storage of LP-gas containers even temporarily inside any recreational vehicle. The standard also
prohibits the use of Unvented Heaters in such vehicles.
NFPA-58 1989 STANDARD FOR THE STORAGE AND
HANDLING OF LIQUEFIED PETROLEUM GASES
Use of the heater must be in accordance with this Standard and in compliance with all governing
state and local codes. Storage and handling of propane gas and propane cylinders must be in
accordance with NFPA 58 and all local governing codes.
We cannot anticipate every use which may be made for our heaters. CHECK WITH YOUR
LOCAL FIRE SAFETY AUTHORITY IF YOU HAVE QUESTIONS ABOUT LOCAL REGULATIONS.
Other standards govern the use of fuel gases and heat producing products in specific
applications. Your local authority can advise you about these.
FOR YOUR SAFETY
DO NOT USE THIS HEATER IN A SPACE WHERE GASOLINE OR OTHER
LIQUIDS HAVING FLAMMABLE VAPORS ARE STORED OR USED.
CONSTRUCTION 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.
WARNING
Fire, burn, inhalation, and explosion hazard. Keep solid combustibles, such as
building materials, paper or cardboard, a safe distance away from the heater as
recommended 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 thinner, dust particles or unknown chemicals.
Not for home or recreational vehicle use!

Table of Contents: Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Proper Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
On-site Safety Problems & Operating Instructions . . . . . . . . . . . . . . . .7
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12
Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-14
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-16
Installation and Maintenance Manual
Model S405
Construction Heater
342 N. Co. Rd. 400 East • Valparaiso, 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 defective materials and
workmanship for one (1) year from invoice date.
Warranty repairs may be made only by an authorized, trained and certified Heat Wagon dealer. Warranty
repairs by other entities will not be considered. Warranty claims must include model number and serial
number.
LIMITATIONS
Warrant claims for service parts (wear parts) such as spark plugs, igniters, flame rods will not be allowed.
Diagnostic parts such as voltage meters and pressure gauges are not warrantable.
Evidence of improper fuel usage, fuel pressures outside of manufacturer’s specification, poor fuel quality,
and improper electric power, misapplication or evidence of abuse may be cause for rejection of warranty
claims.
Travel time, mileage and shipping charges will not be allowed. Minor adjustments of heaters are dealers’
responsibility. Defective parts must be tagged and held for possible return to the factory for 60 days from
date of repair. The factory will provide a return goods authorization, (RGA) for defective parts to be
returned.
No warranty will be allowed for parts not purchased from Heat Wagon.

DESIGN RELATED SAFETY FEATURES
1. Locking position for LPG on gas selector lever: Units used with LPG while the gas selector
valve is positioned for Natural Gas will throw significantly more heat than the rated Btu/h.
This is definitely a safety hazard.
2. Low Skin Temperature: Sure Flame Heaters are designed to have a low skin temperature. This
provides added safety in the workplace.
3. Durable Construction: The Model S405 uses a stainless steel burner for long life and
consistent performance.
In order to maintain the highly efficient combustion of the Sure Flame Heater, the combustion
chamber must remain as manufactured. Any change or distortion could alter the fuel/air mixture
and create unwanted gases. SAFETY FEATURES
Servicing of Sure Flame Construction Heaters normally involves one of several built-in safety
features. The Model S405 incorporates devises to detect the following:
1. LOSS OF FLAME Gas supply is shut off if flame is lost to prevent raw gas from leaving heater
2. OVERHEATING a) Thermal overload protection in the motor
b) High temperature limit switch in the combustion chamber
3. LOSS OF POWER Total shutdown with manual reset required. Any one of the safety devices will
create a loss of power situation
4. BLOCKED AIR SUPPLY A switch detects the differential pressure in the combustion chamber
and shuts down when insufficient
4
SPECIFICATIONS
Model No. S405
Designed to ANSI Z83.7a-1993 Construction Heater
Gases: Natural or Propane
Capacity: 400,000 Btu/h maximum
Orifice Size: 42 DMS (x18)
Blower: 2,000 CFM
Electrical Rating: 115V 60Hz 12 amps, single phase
Minimum Temperature Rating: Minus 40 degrees F
Gas Supply: Inlet Pressure Manifold Pressure
Max W.C. Min W.C. W.C.
Propane 14”7”W.C. 1.3”
Natural Gas 14”7”W.C. 4.0”
(Minimum inlet pressure is for purpose of input adjustment)
Inlet Connection: Weight (approximate): 100 lbs.
Model S405 1”NPT

5
INSTALLATION
The Sure Flame S405 is a direct fired gas heater intended to be used primarily for the temporary
heating of buildings under construction, alteration, or repair. Since all the products of combustion
are released into the area being heated, it is imperative that adequate ventilation is provided. The
flow of supply air and combustion gases must not be obstructed in any way. Do not use the heater
with ductwork as this will restrict the flow supply air.
1. Install the heater in a horizontal position and allow the following clearances from any
combustible material or fuel containers:
Front Outlet: 12 feet Sides: 2 feet
Intake: 2 feet Top: 5 feet
Front outlet must not be directed at any LP-Gas container within 20 feet.
Also make sure that no flammable vapors are present in the space where the heaters is being
used.
2. When connecting the heater to a natural gas or propane supply line ensure that the pressure at
the heater inlet is within the specified range. Please refer to Propane and Natural Gas installation
sections on pages 6-7. Excessive pressure (over 1/2”psig) will damage the controls and void the
warranty.
3. Visually inspect the hose assembly and ensure that it is protected from traffic, building materials,
and contact with hot surfaces. If it is evident that there is excessive abrasion or wear, or the hose
is cut, it must be replaced.
4. After installation, check the hose assembly for gas leaks by applying a water and soap solution to
each connection.
5. Connect the heater to an adequate 115 volt electrical supply and in compliance with the
National Electrical Code ANSI/NFPA 7.0. For protection against shock hazard the supply cord
should be plugged directly into a properly grounded three-prong receptacle.
6. In all applications install the heater in such manner that it is not directly exposed to water spray,
rain and/or dripping water.

6
INSTALLATION USING A PROPANE SUPPLY TANK(S)
1) When installing the heater for use with propane gas, set the gas selector to “Propane”
and lock in position.
2) The supply container must be equipped with an LP Gas Regulator that complies with ANSI/UL
144 Standard for Pressure Regulating Valves for LP Gas. Another regulator must be installed on
the heater to reduce the pressure from this regulator down to a maximum inlet pressure of
1/2 psig.
3) Arrange the cylinder supply system to provide for vapor withdrawal from the operating
cylinder. Supplying liquid propane to the heater is dangerous and will damage the components.
4) Ensure that for the surrounding temperature the size and capacity of the propane supply
cylinder is adequate to provide the rated BTU/H input to the heater.
5) Turn off the propane supply valve at the cylinder when the heater is not in use.
6) The installation must conform with local codes, or in the absence of local codes, with the
Standard for Storage and Handling of Liquefied Petroleum Gases ANSI/NFPA 58-1989
7) When the heater is to be stored indoors the propane cylinder must be disconnected from the
heater and the cylinder moved away and stored in accordance with Chapter 5 of the above
National Standard.
INSTALLATION USING NATURAL GAS APPLICATIONS
1) When installing the heater for use with natural gas, set the gas selector valve to the
“Natural”position.
2) A regulator must be installed on the heater only if the line pressure to the heater is greater than
1/2 psi.
3) The installation of this heater to a natural gas supply must conform with all applicable local
codes or, in the absence of local codes, with the National Fuel gas Code, ANSI Z223.1/NFPA 54.
COMMON INSTALLATION AND OPERATIONAL PROBLEMS
1) LOW VOLTAGE AT THE HEATER
This is one of the most common problems and is usually the result of the supply cord having
too small a wire gauge for its length, or low voltage at the power source. Low voltage results in
the motor overheating, burnt relay contacts, or a relay that will not make contact. Check
voltmeter on heater before start-up.
2) GAS SUPPLY LINE UNDERSIZED
3) INSUFFICIENT VAPORIZATION AT SUPPLY
Normally caused by undersized supply tank.

7
OPERATING INSTRUCTIONS
1) Set the gas selector valve for fuel being used. The conversion shall be done by the owner or
lessor of the equipment.
NOTE: When using Propane Gas the Selector Valve MUST be locked in the “ON”position.
2) Ensure the manual shut-off valve (valve nearest the burner) is in the “ON”position.
3) Connect power supply (115 volt). Check voltmeter to confirm full voltage.
4) Slowly open shut-off valve at gas meter or propane tank. Check for leaks.
5) Push START button
6) Set thermostat for desired room temperature.
7) To stop turn gas off.
The appliance area should be kept clear and free from combustible materials, gasoline, and other
flammable vapors and liquids.
Ensure that the flow of supply air and combustion gases is not obstructed.
The installation and operation of the heater shall comply with the code requirements specified by
the authorities having jurisdiction.
General criteria for the use of construction heaters may be found in the applicable sections of
American National Standard A-10.10-1987, Safety Requirements for Temporary and Portable Space
Heating Devises and Equipment Used in the construction industry.
THE INSTALLATION AND MAINTENANCE OF THE HEATER MUST BE ACCOMPLISHED BY A
QUALIFIED SERVICE PERSON.
3) INSUFFICIENT VAPORIZATION AT SUPPLY
Normally caused by undersized supply tank.
4) IMPROPER GAS SUPPLY PRESSURE
Usually a result of propane supply pressure being too high because of improper or lack of
regulation or too low of natural gas pressure at meter.
5) DIRTY GAS SUPPLY
Dirty gas can cause strainers to plug or form a build-up in the burner orifice.
6) LACK OF PREVENTIVE MAINTENANCE
Heaters must be cleaned as required, especially when used in a dirty environment.
7) IMPROPER SUPPLY OF FRESH AIR
It is normally recommended that the intake air of the heater be taken from outside the enclosed
area. This provides a slight pressurization and prevents any problems associated with re-
circulation.

8
PREVENTIVE MAINTENANCE
Sure Flame construction heaters are built to withstand the rigors of operating on construction sites,
for mining applications, and a multitude of other locations where heaters are used. To maintain the
reliable performance required it is necessary to do a certain amount of regular maintenance.
A)VISUAL CHECKS
The following items should be checked for excessive wear or damage:
1) Wheels (if installed)
2) Cords and Connectors
3) Wiring and Conduit
4) Heater shell (including heat shield) and control box
It is recommended that units purchased as spares be rotated periodically, so that each unit will be
placed in operation at least once every 90 days.
B)BURNER
Flame rod and insulator -Clean with soap and water or solvent on a routine basis. Any build
up on burner should also be removed at this time.
Spark Plug - Clean with solvent and check spark gap, approximately .070 to .085
C)CONTROL BOX
The inside of the control box should be cleaned using a dry cloth or by blowing compressed air.
Do not use any liquid or aerosol spray cleaners. Also check that all electrical connections are snug
and tight.
D)MOTOR
The electric motor on the S405 heater is fitted with sealed bearings and no oiling required. Keep
the motor clean by blowing or wiping off dust or dirt in order to prevent the motor from over
heating.
F)FAN
Check for dust or dirt build up on fan blades. Check the tightness of the set screws and run the
heater to check for fan vibration.
ON-SITE SAFETY PROBLEMS
1) SHORTING OUT OF DEFECTIVE COMPONENTS
This is a very common problem which saves short term expense at the risk of a large future cost.
Any heaters found in this condition should be removed immediately.
2) IMPROPER ENCLOSURES
When heaters are installed partially to the outside for fresh air intake, strict adherence must be
made to the minimum clearance to combustibles given on the instruction plate. Wood framing
around a heater can cause a safety hazard.
3) SUPPLYING LIQUID PROPANE TO HEATER
This problem has occurred from time to time. To minimize the damage, shut off the gas
supply and let the heater run until all of the liquid in the lines had been consumed.

9
TROUBLE SHOOTING
SEQUENCE
1.Press START - Power
relay closes indicated by a
“click”sound (adjust
thermostat clockwise for
S405 and S400T Off/On
model only)
Fan motors starts
2.Ignition control
produces spark
Short delay until fan
reaches full RPM
Air switch closes
Safety shut-off gas valve
open indicated by “click”
sound
3. Gas ignites, flame is
proven
4. Light ON
PROBLEM
Relay does not close
Motor does not start
No spark
Valve does not open, no
gas
No flame
CHECK
-If no power between L1, L2
-If no power at limit switch
-If no power at transformer
-If no power at relay coil
-If power at relay coil
If no power between T1,T2
If power between T1, T2
-If power between Power
and GND on ignition
control
-If NO power between
Power and GND on ignition
control
-If NO power at air switch
-If power at air switch
-Recheck sequence #2
-Press STOP button to
reset return to Sequence #1
above
CAUSE
-No power at plug
-Faulty stop/start switch
-Faulty limit switch
-Faulty ignition control
-Faulty Relay
-Faulty relay contacts
-Faulty Motor
-Faulty ignition control or
spark plug
-Faulty transformer
-Insufficient air pressure
differential to close air
switch or faulty air switch
-Faulty solenoid
-Insufficient gas pressure
-Check gas supply

S405 Heater Parts
Ref. Part No. Description
1 SFP 40SV01 Strainer (S400-80)
2 SFP 2524 Low Pressure Regulator
3 SFP 4514 Solenoid Shut Off Valve 24V
4 SFP 40SV04 Gas Selector Valve (S400-73)
5 SFP 2538 Manual Shut Off Valve 3/4”valve
6 SFP 2430 Motor 1/4 H.P.
7 SFP 2420 Fan Blade
8 SFP 40SB26 Burner
9 SFP 2142 Spark Plug
10 40SB28 Flame Rod
11 SFP 7465 24VAC 5-Second Delay-ON-Break Timer
12 SFP 4519 Control Relay 24V
13 SFP 4510 Transformer 24V
14 SFP 5943 Direct Spark Ignition Control
15 SFP 5124 Air Switch
16 SFP 4519 Motor Relay 24V
17 SFP 2446 Hi Limit Thermoswitch
18 SFP 4518 Indicator Light 24V
19 SFP 2453 Thermostat
20 SFP 3337R OFF Switch (Red)
Ref. Part No. Description
20A SFP 3337G On Switch (Green)
21 SFP 5768 Terminal Block
22 SFP S400-2 Heat Shield
23 SFP S400-57 Front Leg Assembly
24 SFP S400-47 Rear Leg Assembly
(less motor mount & screen)
25 SFP 4517 Control Box Lid
26 SFP SC400-38 Valve Train Cover
27 SFP S400-53 Heater Body Includes 22, 23 & 29
28 SFP SFP3859 Motor Mount (with screen & rear legs)
29 SFP S400-3 Nose Cone
30 ACC-SWK1 Wheel Kit (Optional)
31 ACC-40SV06 Regulator (Optional)
10

11
S405 CONSTRUCTION HEATER
WIRING DIAGRAM
NOTE: This wiring diagram
applies to heaters with
serial #5437 and greater

12