Heatwagon Vg1000 Manual

Construction

Heater

VG1000

C US

Dept. of Buildings

29-05-E

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 219-462-7985

www.heatwagon.com

Revision 12-14

For your safety: Do not use this heater in

a space where gaso ine or other iquids

having f ammab e vapors are stored.

I PORTANT INFOR ATION! READ FIRST

The heater is designed for use as a construction heater under ANSI Z83.7a-2000. Heater is not in-

tended for use in pest remediation. 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 outside 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 PETROLEU 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 ac-

cordance 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 LIQ-

UIDS HAVING FLA ABLE 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 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!

If you have read this entire manual and you still have ques-

tions, please call us at 219-464-8818

Table of Contents:

Page

Safety & Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Illustrated Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Senso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Exhaust Flue Pipe Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Installation and Maintenance Manual

Model VG1000

Construction Heater

342 N. Co. Rd. 400 East • Val araiso, IN 46383

219-464-8818 • 888-432-8924 • Fax 800-255-7985

www.heatwagon.com

WARRANTY

This heater is guaranteed against defective materials and workmanship for one (1) year from Heat Wagon 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. Components

are guaranteed to the extent of the component manufacturer’s warranty.

LI ITATIONS

Warranty claims for service parts (wear parts) such as spark plugs, igniters, and flame rods will not be allowed. Di-

agnostic 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, improper electric power, misapplication

and/or evidence of abuse may be cause for rejection of warranty claims.

Labor, travel time, mileage and shipping charges will not be allowed. Minor adjustments to heaters are the respon-

sibility of the dealer. 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.

SAFETY & CAUTION

• Instructions given in this manual and the applicable regulation of the local authorities

must be followed.

• The unit may be operated only by those persons who have been instructed in its proper use.

• The unit is to be installed and operated in such a way as to ensure the safety of employees and

surroundings.

• Never cover the unit’s air openings.

• Always ensure adequate fresh air supply to the unit.

• Never stand in front of the discharge end of the heater.

• Keep a minimum clearance of 10 feet from the fuel source. Storing and use of liquid fuel must

comply with the regulation and instructions given by the local authorities.

• Unit’s emitted noise level at the range of 3 feet: 74 dBA.

• Do not introduce foreign objects into the unit.

• Do not expose the unit to direct water jets.

• All electric cables outside the unit are to be protected against damage.

• Always disconnect the unit from power supply and turn off the gas supply when maintenance

or service is being performed.

• IF NOT OPERATED WITHIN GUIDELINES OF THESE OPERATING INSTRUCTIONS,

ANUFACTURER WILL NOT BE HELD RESPONSIBLE AND WARRANTY

WILL BECO E VOID.

4

SPECIFICATIONS

odel No. VG1000

Fuels: Vapor Propane or Natural Gas

Gas Inlet 1-1/4” FNPT (Both Wayne & Midco Burner)

Capacity: 1,000,000 BTU/HR

Blower: 4,075 CFM 5.0HP 2.0”SP

Electrical Rating: 240 Volts, 1Ø 30 Amps

Fuel Consumption: NG-1000 CFH / Propane-11 GPH

Remote Thermostat: On/Off

Max. Discharge Temp.: 200ºF @ 0ºF Ambient

Duct Size: 20” Dia., 200 ft. max (straight)

Shp. Dimensions: 120”L x 31.5”W x 54”H

Weight (approximate): 1,300 lbs.

Gas Supply: Inlet Pressure anifold Pressure Pilot Orifice

idco Burner ax W.C. in W.C. W.C.

Vapor Propane 14” W.C. 9” W.C. 2.6” .046

Natural Gas 14” W.C. 9” W.C. 4.1” .052

Wayne Burner ax W.C. in W.C. W.C.

Vapor Propane 14” W.C. 9” W.C. 3.0” N/A

Natural Gas 14” W.C. 9” W.C. 4.6” N/A

OPERATING INSTRUCTIONS

INSTALLATION

• When transporting, use all four lifting eyes in upper corners or forklift openings in the base of

the units.

• Place the unit on a level and non-combustible surface.

• Minimum clearances from combustibles:

- outlet, minimum 10 feet

- sides, minimum 3 feet

- top, minimum 3 feet

- flue pipe exhaust, gas discharge minimum 2 feet

• Manufacturer recommends a free zone of 5 feet around the unit and a minimum distance of 10

feet at the unit’s flue gas openings are to be maintained.

• If the unit is placed indoors, secure an adequate fresh air opening for the burner combustion air.

• The unit may not be installed and operated in premises where explosive or combustible fumes

or dust are present. Always check the regulation of local authorities.

• Be certain that neither the air inlet nor the air outlet is obstructed.

FUEL SUPPLY

• This heater is shipped as either natural gas or vapor propane. Check for proper pilot orifice in

burner (Midco burner only).

Natural Gas .052

Vapor Propane .046

• Be certain to use adequate hose or pipe size to ensure proper volume and pressure.

See Chart Below.

For supply pressures greater than 1/2psi

• A regulator must be installed on the heater to ensure that the pressure to the heater does not

exceed 1/2 psi inlet pressure. Excessive pressures over 1/2 psi (14” W.C.) will damage controls

and void warranty.

5

NATURAL GAS QUICK

REFERENCE HOSE

Hose BTU

Le gth 1 Millio

i Feet <1PSI 1PSI 2PSI 5PSI

10 1-1/2 1-1/4 3/4 3/4

25 2 1-1/4 3/4 3/4

35 2 1-1/4 3/4 3/4

50 2 1-1/4 1-1/4 3/4

75 2 1-1/4 1-1/4 3/4

100 2 1-1/4 1-1/4 3/4

125 2-1/2 1-1/2 1-1/4 3/4

150 2-1/2 1-1/2 1-1/4 3/4

175 2-1/2 1-1/2 1-1/4 3/4

200 2-1/2 1-1/2 1-1/4 3/4

VAPOR PROPANE QUICK

REFERENCE HOSE

Hose BTU

Le gth 1 Millio

i Feet 1/2PSI 10PSI

10 1-1/4 3/4

25 1-1/4 3/4

35 1-1/4 3/4

50 - 3/4

75 - 3/4

100 - 3/4

125 - 3/4

150 - 3/4

175 - 3/4

200 - 3/4

FUEL SUPPLY (CONTINUED)

• Ensure that for the surrounding temperature, size and capacity of the propane supply cylinder

is adequate to provide the rated Btu/hr input to the heater.

• 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, replace it immediately.

• Purge air from line and wait 10 minutes for gas to dissipate.

• After installation, check the hose assembly for gas leaks by applying a water and soap solution

to each connection.

• Fuel hose must be UL approved.

• The installation of this heater to a natural gas supply must confirm with all applicable local

codes or, in the absence of local codes, with the National Fuel Ga Code ANSI Z223.1/NFPA 54.

For vapor propane, refer to standard for Storage and Handling of Liquified Petroleum Ga e

ANSI/NFPA 58.

ELECTRICAL

• Electric cable extensions must be connected by qualified authorized electricians based on the

unit capacity and cable length.

• Connect unit to a power supply with a suitable appliance receptacle (30 Amp). Green

indicator lamp will light up.

• Confirm voltage at heater connection (208V min.) to ensure proper operation.

EXHAUST FLUE PIPE

• The unit is to be connected to a flue pipe with adequate draft, to ensure the proper start and

operation of the unit. Refer to page 27.

• The flue pipe is to be made of non-combustible material and clearances from combustible

materials must be a minimum 8 inches (temperature of flue gases is approximately 410º F).

• The flue pipe and its installation must comply with the regulations and instructions given by

the local authorities.

START UP

• Only people trained in the operation and supervision of this heater should operate

and maintain the unit.

• Check the unit to make certain that there are no visible defects on the control and safety

devices and that the unit has been installed correctly.

1. Open door at back of unit (control box compartment).

2. Check that the control switch in the control box is in position “0” (STOP).

3. Pre-select desired room temperature on the room thermostat. The temperature must be set

higher than the ambient temperature.

4. Open all possible shut-off devices of the fuel supply lines and push the reset on the low

pressure gas switch (Wayne Burner Only).

6

START UP (CONTINUED)

5. Turn the control switch in control box to position “1” (HEATING).

6. When the ambient temperature level is lower than thermostat setting, the burner switches

on automatically. The fan does not switch on until the set temperature (104ºF) of the heat-

exchanger has been reached (will take approximately 1-5 minutes).

7. The green indicator lamps for “heating on” and “fan on” will light up now.

8. Close the door in order to protect the unit against unauthorized adjustments.

• After startup, the heater is operated automatically by the room thermostat and governed by all

control devices, including the safety limit controls.

• The room thermostat (TSTAT) and burner sensor control the running sequences of the

burner and the fan sensor controls the fan function.

• Overheat limit reset (STB) controls and shuts off the heater (burner) in the case of overheating.

• The unit can also be used for ventilation purposes only, if needed.

1. Turn the control switch in control box to position “2” (VENTILATION).

2. The unit is now in the continuous ventilating mode.

3. Heating is not possible in this mode.

DUCTING (Warm Air)

• Minimum clearance from combustible materials is 4 inches.

• Use steel ducting or fabric ducting capable of withstanding maximum temperature of 300ºF.

• Maximum length of duct: 200’ (straight).

• Duct diameter: 20”.

• Make certain that the duct is safely and properly fastened to the warm air outlet.

• Avoid sharp bends and corners to ensure maximum air flow and avoid back pressure that can

cause heat accumulation in heater.

• FAILURE TO COMPLY WITH THESE RECOMMENDATIONS COULD RESULT IN SHUTDOWN

OF THE HEATER.

SHUT DOWN

• Turn control switch to position “0” (STOP).

• Close fuel supply.

Important!

The air supply fan continues running for several minutes to cool down the combustion

chamber/heat exchanger. The fan can restart several times before finally switching off!

WARNING!

ELECTRICAL POWER TO THE UNIT AY BE DISCONNECTED IN E ERGENCY SITUATIONS

ONLY. OTHERWISE, DO NOT STOP THE UNIT BY DISCONNECTING POWER. UNIT NEEDS

TO COOL DOWN USING ITS OWN FAN. FAILURE TO CO PLY WITH PROPER SHUT-DOWN

PROCEDURES CAN CAUSE DA AGE TO THE CO BUSTION CHA BER, HEAT

EXCHANGER, SAFETY FEATURES AND VOID WARRANTY.

7

8

1. Turn the

heater to

position #1

and nothing

happens.

2. The heater

runs for a little

while, but

shuts down. It

won’t come on

again until the

limit switch is

reset.

• Power supply cord

• Burner reset button on the burner flame

safeguard control box is engaged

• verheat limit switch is tripped

• Burner motor relay

• Burner sensor

• Heater control unit (HCU)

• Incorrect burner manifold pressure

• Restricted airflow

• verheat limit switch

• Test for 240 volts (min 208) between L1 and L2 on the main terminal block.

• Reset the blue button on the flame safeguard control.

• Reset the switch, which is located in the burner compartment on the gray box

on the left hand side of the burner.

• Burner motor relay is located in the main control box (K2). Check between

ground and L1, then ground and T1 for 120 volts. If less than 105 volts replace

relay.

• n the heater control unit (HCU) disconnect the wires from terminals X10 and

X11. Using an ohm meter, check the resistance between the two wires for a

reading. Compare to Sensor Resistance Chart page 25.

Replace sensor if reading is out of range.

• n the main terminal block, check for 120 volts between terminals 8 and N

when the 3-position switch is in the HEAT position. If less than 105 volts,

replace HCU.

• (Midco Burner) Use a low pressure gauge (0-15 inches of water column) with a

1/4” NPT inlet. Install gauge in the pressure tap port located on the output side

of the last gas solenoid valve in line. Run unit and adjust the manifold

pressure by turning the pressure adjusting screw (located in the center of the

Maxitrol RV81 regulator) in or out until the gauge reads 2.6 inches of W.C. for

propane or 4.1 inches of W.C. for natural gas. (Wayne Burner) 3 inches of W.C.

for propane or 3.5 inches of W.C. for natural gas.

• Check for dirt or ice buildup on the air inlet or blower wheel. If using duct on

the air outlet, ensure the back pressure does not exceed a static pressure of

.2” W.C. Check with magnehelic gauge if necessary.

• Adhere to the proper shut down procedures.

Power must remain at the unit until it cools down fully. Blower will shut down on

its own when cool. Test overheat limit switch for continuity between

the two male terminals at room temperature. Replace if overheat limit switch

fails test. The limit switch is located in the upper left hand corner of burner

compartment.

VG1000 TROUBLESHOOTING

Symptom Possible Causes Possible Solutions

9

3. Burner motor

comes on,

but the heater

won’t ignite.

• Fuel pressure or volume

• Air inlet damper adjustment

• Ignition electrode

• Electronic igniter

• Burner airflow switch

• Gas valve

• Use a low pressure gauge (0-15 inches of water column) with 1/8” NPT inlet.

Install gauge in the pressure tap port located on the output side of the gas

valve. Run the heater. Adjust the pressure by turning the pressure adjusting

screw (located on the input side top of the gas valve) counter clockwise until

the gauge reads the proper manifold pressure. Refer to pipe sizing charts in

the Heat WagonEngineering Guide. Heater requires 9-14” W.C. inlet pressure.

Ensure proper purge procedure (see Fuel Supply Installation).

• Rough setting at 1/2 open. Minor adjustments from the rough settings can be

made to achieve a smooth sounding burner with no soot from the flue pipe.

Insert volt meter probes into provided + and – terminals on the Honeywell

Flame Safeguard Control. Set the volt meter on DC volts and run the heater.

Adjust the air damper until the volt meter reads the highest voltage between 2

and 5 volts.

• Clean with fine sandpaper. Make sure it is free from buildup or cracks.

• Turn off the gas valve, turn on the burner. Use insulated pliers to hold the

ignition wire and short it to ground. Pull the wire away from ground slowly. A

rainbow colored arc should travel between the wire and the ground at a

distance of 3/8 of an inch for a duration of 4-5 seconds.

• The burner airflow switch (located above blue Honeywell safeguard control) will

not allow power to the flame safeguard control when it is open. Check the

tubes supplying air to the switch for any restrictions. NLY AS A TEST, wire

around the air switch. If this test solves the problem, adjust or replace the

switch (Midco Burner nly).

• If there is power at the flame safeguard control and no power out to the

solenoid valves, replace the flame safeguard control. Check for continuity

between the terminals on the solenoid valve coil. If no continuity, replace gas

valve.

VG1000 TROUBLESHOOTING

Symptom Possible Causes Possible Solutions

4. The heater

has a loud

rumbling

sound.

5. The heater

blows black

smoke out of

the vent stack.

• Air damper setting

• Dirt on burner blower wheel

• Flue pipe setup or flue pipe

restrictions

• Gas manifold pressure

• Heat exchanger

• Air damper setting

• Dirt on burner blower wheel

• Flue pipe setup or flue pipe

restrictions

• Gas manifold pressure

• Heat exchanger

• Rough setting at 1/2 open. Minor adjustments from the rough settings can be

made to achieve a smooth sounding burner with no soot from the flue pipe.

Insert volt meter probes into provided + and – terminals on the Honeywell

Flame Safeguard Control. Set the volt meter on DC volts and run the heater.

Adjust the air damper until the volt meter reads the highest voltage between 2

and 5 volts.

• Clean the burner blower wheel with a small brush

• Refer to the flue pipe chart in this manual. Check flue for restriction

• Use a low pressure gauge (0-15 inches of water column) with 1/8” NPT inlet.

Install gauge in the pressure tap port located on the output side of the gas

valve. Run the heater. Adjust the pressure by turning the pressure adjusting

screw (located on the input side top of the gas valve) counter clockwise until

the gauge reads the proper manifold pressure. Refer to pipe sizing charts in

the Heat Wagon Engineering Guide. Heater requires 9-14” W.C. inlet pressure.

• Refer to the cleaning instructions in this manual.

• Rough setting at 1/2 open. Minor adjustments from the rough settings can be

made to achieve a smooth sounding burner with no soot from the flue pipe.

Insert volt meter probes into provided + and – terminals on the Honeywell

Flame Safeguard Control. Set the volt meter on DC volts and run the heater.

Adjust the air damper until the volt meter reads the highest voltage between 2

and 5 volts.

• Clean the burner blower wheel with a small brush

• Refer to the flue pipe chart in this manual. Check flue for restriction

• Use a low pressure gauge (0-15 inches of water column) with 1/8” NPT inlet.

Install gauge in the pressure tap port located on the output side of the gas

valve. Run the heater. Adjust the pressure by turning the pressure adjusting

screw (located on the input side top of the gas valve) counter clockwise until

the gauge reads the proper manifold pressure. Refer to pipe sizing charts in

the Heat Wagon Engineering Guide. Heater requires 9-14” W.C. inlet pressure.

• Refer to the cleaning instructions in this manual.

VG1000 TROUBLESHOOTING

Symptom Possible Causes Possible Solutions

10

6. The burner

seems to

cycle on and

off more

frequently

than what it

should.

7. The burner

starts, but the

main fan

never comes

on.

• Gas manifold pressure

• Dirt on main air blower or setup

of outlet air duct

• Burner sensor

• Heater Control Unit (HCU)

• Fan sensor

• Heater Control Unit (HCU)

• Blower motor relay

• Current overload on blower motor

• Blower motor