Vulcan-Hart Core One User manual

Vulcan Core One
SERVICE MANUAL
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Rev. 09/2020

Vulcan Core One 0 Content
1
Content
Content ............................................................................................................................................. 1
1 Introduction ................................................................................................................................ 2
2 Maintenance Kit ......................................................................................................................... 3
3 Step-by-Step Guide ...................................................................................................................
3.1 Get Access ......................................................................................................................... 5
3.2 Remove Fuel Lines ............................................................................................................. 6
3.3 Disconnect Internal Electric Connectors ............................................................................. 7
3. Remove Burner Head ......................................................................................................... 8
3.5 Exchange Nozzle ................................................................................................................ 9
3.6 Assemble Burner Head ..................................................................................................... 10
3.7 Reattach Burner Head ...................................................................................................... 10
3.8 Connect Internal Electric Connectors ................................................................................ 10
3.9 Attach Fuel Lines .............................................................................................................. 10
3.10 Side Panel on ................................................................................................................... 11
3.11 Disassemble Fuel Filter .................................................................................................... 12
3.12 Exchange Filter ................................................................................................................. 13
3.13 Close Vulcan and Reconnect ............................................................................................ 1
Notes ....................................................................................................................................... 15

Vulcan Core One 1 Introduction
2
1 Introduction
Content and purpose
This handbook is for maintenance of water heater
Vulcan Core One (further referred to as Vulcan).
ATTENTION:
Work on the Vulcan may only be performed by
briefed and/or trained by EKU personnel.
Effectivity of the maintenance manual
The maintenance manual applies to the Vulcan Core
One heater supplied by EKU Power Drives. It may be
subjected to modifications and amendments.
The respectively currently effective version is binding.
This version can be found on the EKU Power Drives
website under Products/Vulcan Heater/Downloads.
Meaning of highlighted content
Throughout this manual the emphasized words, Cau-
tion!, ATTENTION: and NOTE: used as follows:
Ha ardous to health!
This caption is used to indicate possible minor
injuries if instructions or procedures are carried
out incorrectly or entirely disregarded.
ATTENTION:
This caption points to actions which may cause
material damage.
NOTE:
This caption is used to draw attention to an important
feature.
Symbols
Symbol tightening torque value:
Identifies in graphics parts (e.g. nuts, bolts)
that are to be mounted with a specific tight-
ening torque. The torque values are shown
at the symbol and are binding.
Further documentation to be used
The use of additional service literature may be re-
quired. Use the following documents during operation
and maintenance of the Vulcan:
• Installation Instructions
• Operating Instructions
• Spare Parts List
• Workshop Manual by Valeo
Safety information and regulations
Basically, general accident prevention provisions and
the valid industrial safety directions must be adhered
to. "General Safety Regulations" which exceed the
framework of these provisions are listed below. The
specific safety regulations which affect the present
manual are issued highlighted in the individual sec-
tions or procedures.
General safety regulations
Read the Vulcan Operating Instructions before oper-
ating the heater for first time. Familiarize yourself with
the Vulcan Installation Instructions before you make
any modifications to the existing heater installation.
NOTE:
The Vulcan Operating and Service Instructions con-
tain safety instructions and regulations to be followed
for safe operation of the heater.
The Vulcan Installation Instructions contain the statu-
tory regulations and other hints and regulations for
the proper installation of the heater.

Vulcan Core One 2 Maintenance Kit
3
2 Maintenance Kit
Please check if the maintenance kit DN-3779 provided by EKU Power Drives is complete. It should
contain the following:
Qty. Description EKU Design Number
1 M12 Sealing Washer Aluminum DN-3687
2 M10 Single Hollow Screw A2K DN-191
4 M10 Sealing Washer Aluminum DN-3 63
4 M6 Washer A2K DN-66
4 M6 Hex Lock Nut Brass DN-3689
1 Fuel Filter Insert DN-3778
1 High Pressure Atomizer Nozzle DN-3776
1 Vulcan Service Handbook
Tools required for the task:
• 10mm wrench or socket
• 13mm wrench or socket
• 16mm wrench
• 17mm wrench
• 19mm open-end wrench
• Flex ratchet handle with 16mm socket
• Torque wrench
• Slotted screwdriver

Vulcan Core One 3 Step- y-Step Guide
3 Step-by-Step Guide
Please make sure the electric connections and fuel lines are plugged off the Vulcan before you start
working on it. If you cannot access all sides of the Vulcan, please demount it and place it on a clean
and even surface. Inside the Vulcan are feet (1, Fig.1) you can use to lift the Vulcan.
Risk of scalds!
The Vulcan may still be hot after operation.
Make sure to give it a proper cool down time.
ATTENTION:
Do not place the exhaust on the surface!
ATTENTION:
Prior to disassembling components the heater must be disconnected from the vehicle elec-
trical system.
ATTENTION:
Sealing elements between disassembled components must be principally discarded and re-
placed.
This does not apply to the temperature sensor gasket ring, as it is permanently attached.
Screws with coated threads must be discarded and replaced.
It is permitted to remove components from the heater, while the heater is installed in the vehicle,
assuming that sufficient space is available and no components will be damaged.
NOTE:
If components are disassembled to a degree not covered in this maintenance manual, any warranty
claim shall be voided.
Only genuine EKU Power Drives spare parts should be used.

Vulcan Core One 3 Step- y-Step Guide
5
3.1 Get Access
Fig.1 Open all panels of Vulcan enclosure
1 - Service Feet
2 - Side Panel
3 - Flat Washer, DN-66
- M6 Hex Lock Nut, DN-3689
Open the front and back door.
Open the side panel (2, Fig.1) by unscrewing all four nuts ( , Fig.1).
NOTE:
The nuts are lock nuts and should only be used once. Please dispose them.

Vulcan Core One 3 Step- y-Step Guide
6
3.2 Remove Fuel Lines
Fig.2 Fuel lines connected to burner head
1 - M10 Hollow Screw, DN-191
2 - M10 Aluminum Seal Washer, DN-3 63
3 - Fuel line
- Fuel inlet
Untighten the bolt on the return side first. Put the bolt (1, Fig.2) and the sealing ring (2, Fig.2) in the
trash.
Same goes for the supply side ( , Fig.2).
ATTENTION:
Diesel fuel is leaking. Make sure any fuel leaking is immediately contained and professional-
ly disposed.

Vulcan Core One 3 Step- y-Step Guide
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3.3 Disconnect Internal Electric Connectors
Fig.3 Connectors on burner head
1 - Temperature Sensor
2 - Service Connector
3 - Main Connector
Disconnect all internal electric connectors.
Third from the top is just a cap. It does not need to come off.

Vulcan Core One 3 Step- y-Step Guide
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3.4 Remove Burner Head
Fig. Burner head disassembled from heater body
1 - Burner Head
2 - Nuts
Two nuts (2, Fig. ) need to be unscrewed in order to remove the burner head (1, Fig. ).
Please place the burner head on an even and clean surface to continue working on it.

Vulcan Core One 3 Step- y-Step Guide
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3.5 Exchange No le
Fig.5 Burner head disassembly
1 - Burner Head
2 - Sensor Tube
3 - Disc
- Ignition Electrode
5 - Fuel Nozzle, DN-3776
Carefully unplug the ignition electrodes ( , Fig.5). The slotted screwdriver may help.
Remove any diesel and dirt remnants from the disc (3, Fig.5) with a clean, dry rag. Lift the disk and
put it aside so you can access the sensor tube (2, Fig.5).
Remove the sensor tube.
Unscrew the top nozzle (5, Fig.5) with the 16mm socket and put it in the trash.
ATTENTION:
Do not bend the electrodes! The distance is fixed and mandatory for operation.

Vulcan Core One 3 Step- y-Step Guide
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3.6 Assemble Burner Head
See figure 5.
Install new nozzle DN-3776 included in maintenance kit. Tighten with 20±2 Nm.
Put the sensor tube (2, Fig.5) then the disk back in place. Make sure the tube is clean!
Fit the disc (3, Fig.5) onto the nozzle and align it so that the ignition electrode may be inserted into
the unit.
Plug in the ignition electrodes ( , Fig.5). Be careful not to bend the electrodes.
ATTENTION:
Careful with the sensor! Contamination can lead to malfunction!
NOTE:
Do not touch the new nozzle’s orifice! Small particles could cause congestion.
3.7 Reattach Burner Head
See figure .
Tighten the two nuts (2, Fig. ) with 8±0.5 Nm.
3.8 Connect Internal Electric Connectors
See figure 3.
There is only one way they will fit.
3.9 Attach Fuel Lines
See figure 2.
Use new bolts DN-191 and sealing rings DN-3 63 included in maintenance kit.
Tighten with 16±1 Nm.

Vulcan Core One 3 Step- y-Step Guide
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3.10 Side Panel on
Check if sealant ring (1, Fig.10) is in place.
Use new safety nuts DN-3689 and washers DN-66 included in maintenance kit.
Tighten all four nuts ( , Fig.10) with 7±1 Nm.
Fig.10 Reattachment of side panel
1 - Sealant Ring
2 - Side Panel
3 - Flat Washer, DN-66
- M6 Hex Lock Nut, DN-3689

Vulcan Core One 3 Step- y-Step Guide
12
3.11 Disassemble Fuel Filter
Fig.11 Disassemble fuel filter
1 - Top Bolt
2 - Sealing Washer
3 - Filter Head
- Filter Body
Untighten the top bolt (1, Fig.11) on the filter’s head (3, Fig.11). Hold the filter bottom ( , Fig.11)
while unscrewing the top bolt.
ATTENTION:
The filter still contains diesel fuel. Dispose of remaining fuel correctly.

Vulcan Core One 3 Step- y-Step Guide
13
3.12 Exchange Filter
Fig.12 Full disassembly of fuel filter
1 - Top Bolt
2 - Sealing Washer, DN-3687
3 - Filter Head
- Filter Body
5 - Diesel Filter, DN-3778
6-1 - ignore
Pull out the old filter (5, Fig.12) and replace with new one DN-3778 included in the maintenance kit.
ATTENTION:
Fuel filter must be filled with diesel!
Otherwise fuel lines and filter must be vented before starting the heater.
Assemble the filter body inside the Vulcan.
Use new aluminum sealing washer DN-3687 included in maintenance kit.
Tighten the top bolt (1, Fig.12) with 11±1 Nm
Throw away old sealing ring.

Vulcan Core One 3 Step- y-Step Guide
1
3.13 Close Vulcan and Reconnect
Fig.13 Close Vulcan doors
1 - Service Feet
Unscrew the four feed on the bottom and place them back inside the box (1, Fig.13).
Close both doors.
Mount the Vulcan back to its original location and reconnect the wires as well as the coolant lines.
Maintenance is done!
NOTE:
There are notes on the last page.

Vulcan Core One 4 Notes
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4 Notes