heat wagon VG1000 Construction Heater Instruction Manual

Installation and Maintenance Manual
Please retain this manual for future reference.
VG1000
Construction
Heater

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Revision 7-23

VG1000 Construction Heater

For your safety: Do not use this heater in a space where gasoline or other liquids having flammable vapors are stored.

IMPORTANT INFORMATION! READ FIRST
The heater is designed for use as a construction heater under ANSI Z83.7a-2000. Heater is not intended 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 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!
If you have read this entire manual and you still have questions, please call us at 219-464-8818

Installation and Maintenance Manual
Model VG1000
Construction Heater

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.

LIMITATIONS
Warranty claims for service parts (wear parts) such as spark plugs, igniters, and 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, 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 responsibility 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.

342 N. Co. Rd. 400 East • Valparaiso, IN 46383
219-464-8818 • 888-432-8924 • Fax 800-255-7985
www.heatwagon.com

WARNING – AIR QUALITY HAZARD

• Do not use this heater for heating human living quarters.

• Use of direct-fired heaters in the construction environment can result in exposure to levels of CO, CO2 and NO2 considered to be hazardous to health and potentially life threatening.

• Do not use in unventilated areas

• Know the signs of CO and CO2 poisoning
  – Headaches, stinging eyes
  – Dizziness, disorientation
  – Difficulty breathing, feels of being suffocated

• Proper ventilation air exchange (OSHA 29 CFR 1926.57) to support combustion and maintain acceptable air quality shall be provided in accordance with OSHA 29 CFR Part 1926.154, ANSI A10.10 Safety Requirements for Temporary and Portable Space Heating Devices and Equipment used in the Construction Industry or the Natural Gas and Propane Installation Codes CSA B149.1
  – Periodically monitor levels of CO, CO2 and NO2 existing at the construction site – at the minimum at the start of the shift and after 4 hours.
  – Provide ventialtion air echange, either natural or mechanical, as required to maintain acceptable indoor air quality

USA 8-Hr Time weighted average
(OSHA 29 CFR 1926.55 App A)| Canada 8-hr time weighted average
Worksafe BC OHS Guidelines Part 5.1
and Ontario Workplaces Reg 833
---|---
CO 50 ppm
CO2 5000 ppm
NO2| 25 ppm
5000 ppm
3 ppm (Reg 833)
USA – Ceiling Limit
(Short Term Exposure Limit = 15 minuntes)| Canada STEL (15 minutes Reg 833/1 hour
WSBC) WorkSafe BC OHS Guidelines Part 5.1
and Ontario Workplaces Reg 833
CO
CO2
NO2 5 ppm| 100 ppm
15000 ppm (WSBC)
30000 ppm (Reg 833)
1.0 ppm (WorkSafeBC)
5.0 ppm (reg 833)

• Ensure that the flow of combustion and ventilation air exchange cannot become obstructed.
• As the building “tightens up” during the construction phases ventilation may need to be increased.

SPECIFICATIONS

Model No. VG1000

Fuels:
Gas Inlet
Capacity:
Note: Derate input for altitude over 2000 Ft.
Blower:
Electrical Rating:
Fuel Consumption:
Remote Thermostat:
Max. Discharge Temp.:
Duct Size:
Shp. Dimensions:
Weight (approximate):| Vapor Propane or Natural Gas
1-1/4” FNPT (Both Wayne & Midco Burner)
1,000,000 BTU/HR
(609.6 M) by 4% each 1000 Ft. (304.8 M) above sea level.
4,075 CFM, 5.0HP, 2.0”SP
240 Volts, 1Ø 30 Amps
NG-1000 CFH / Propane-11 GPH
On/Off
200ºF @ 0ºF Ambient
20” Dia., 200 ft. max (straight)
120”L x 31.5”W x 54”H
1,300 lbs.
---|---
Gas Supply:| Inlet Pressure| Manifold Pressure| Pilot Orifice
---|---|---|---
Midco Burner| Max W.C.| Min W.C.| W.C.|
Vapor Propane| 14” W.C.| 9” W.C.| 2.6”| 0.046
Natural Gas| 14” W.C.| 9” W.C.| 4.1”| 0.052
Wayne Burner| Max W.C.| Min 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

SAFETY & CAUTION

• Instructions given in this manual and the applicable regulations 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 regulations 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, MANUFACTURER WILL NOT BE HELD RESPONSIBLE AND WARRANTY WILL BECOME VOID.

OPERATING INSTRUCTIONS

INSTALLATION

• When transporting, use both lifting eyes located on sides of heater.

• 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 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 regulations 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.

VAPOR PROPANE QUICK REFERENCE HOSE CHART

NATURAL GAS QUICKREFERENCE HOSE CHART

Hose
Length in Feet| BTU 1 Million
---|---
< 1PSI| 1PSI| 2PSI| 5PSI
10| 01-01-02| 01-01-04|      3/4|       3/4
25| 2| 01-01-04|      3/4|       3/4
35| 2| 01-01-04|      3/4|       3/4
50| 2| 01-01-04| 1|         3/4
75| 2| 01-01-04|    1-1/4|      3/4
100| 2| 01-01-04|    1-1/4|      3/4
125| 02-01-02| 01-01-02|    1-1/4| 1
150| 02-01-02| 01-01-02|    1-1/4| 1
175| 02-01-02| 01-01-02|    1-1/4| 1
200| 02-01-02| 01-01-02|    1-1/4|    1-1/4
225| 02-01-02| 01-01-02|    1-1/4|    1-1/4

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.

• 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 Gas Code ANSI Z223.1/NFPA 54.
  For vapor propane, refer to standard for Storage and Handling of Liquified Petroleum Gases 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).
  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 MAY BE DISCONNECTED IN EMERGENCY SITUATIONS ONLY. OTHERWISE, DO NOT STOP THE UNIT BY DISCONNECTING POWER. UNIT NEEDS TO COOL DOWN USING ITS OWN FAN. FAILURE TO COMPLY WITH PROPER SHUT-DOWN PROCEDURES CAN CAUSE DAMAGE TO THE COMBUSTION CHAMBER, HEAT EXCHANGER, SAFETY FEATURES AND VOID WARRANTY.

VG1000 TROUBLESHOOTING- Use after proper setup requirements have been achieved.

1. Turn the heater to
position #1 and nothing
happens.| • Power supply cord
• Burner reset button on the burner flame
safeguard control box is engaged
• Overheat limit switch is tripped| • 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| • 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.
• Burner sensor| • On 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 26.
Replace sensor if reading is out of range.
• Heater control unit (HCU)| • On 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.
2. Burner motor comes on, but the heater won’t ignite.| • Pilot (Midco Burner Only)
• Fuel pressure or volume| • See instructions on page 31
• 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. Ensure proper purge procedure (see Fuel Supply Installation).
• Air inlet damper adjustment| • 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.
• Ignition electrode| • Clean with fine sandpaper.  Make sure it is free from buildup or cracks.
• Electronic igniter| • 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.
• Burner airflow switch| • 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.  ONLY AS A TEST, wire around the air switch.  If this test solves the problem, adjust or replace the switch (Midco Burner Only).
• Gas valve| • 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.
• Pressure switches
(Wayne burner only)| • Make sure both reset buttons are depressed. (Items 14 and 15 on page 22) These switches typically activate when unit runs out of fuel.
3. The burner lights for only 5 seconds and then shuts down| • Flame sensor| • Clean with fine sandpaper and check metal for fatigue and ceramic of any hairline cracks.
• Flame safeguard| • Set multimeter to D.C. volts, insert test leads (red positive, black negative) into corresponding holes located on the front face of the Honeywell control.
• Fuel pressure or volume| • 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.
Ensure proper purge procedure (see Fuel Supply Installation).
• Air inlet damper adjustment| • 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.
4. The heater runs for a little while, but shuts down.  It won’t come on again until the limit switch is reset.| • Incorrect burner manifold pressure| • (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.
• Restricted airflow| • 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.
• Overheat limit switch| • 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.
5. The heater has a loud
rumbling sound.| •  Air damper setting • Dirt on burner blower wheel| • 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.
• Flue pipe setup or flue pipe
restrictions| • Clean the burner blower wheel with a small brush
• Refer to the flue pipe chart in this manual.  Check flue for restriction
• Gas manifold pressure| • 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.
• Heat exchanger|  • Refer to the cleaning instructions in this manual.
6. The heater
blows black
smoke out of
the vent stack.| • Air damper setting| • 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.
• Dirt on burner blower wheel| • Clean the burner blower wheel with a small brush
• Flue pipe setup or flue pipe
restrictions| • Refer to the flue pipe chart in this manual.  Check flue for restriction
• Gas manifold pressure| • 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.
• Heat exchanger| • Refer to the cleaning instructions in this manual.
7. The burner
seems to
cycle on and
off more
frequently
than what it
should.| • Gas manifold pressure| • 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.
• Dirt on main air blower or setup
of outlet air duct| • 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 .5” W.C.
• Burner sensor| • On 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 out of range.
• Heater Control Unit (HCU)| • If all of the above check good, replace the HCU.
8. The burner
starts, but the
main fan
never comes
on.| • Fan sensor| • On the heater control unit (HCU) disconnect the wires from terminals X12 and X13.  Using an ohm meter, check the resistance between the two wires for a reading. Compare to Sensor Resistance Chart page 25.
• Heater Control Unit (HCU)| • Turn the 3-position main switch to the fan position.  If the blower runs, check the fan sensor.  If it is good, replace the HCU.
• Blower motor relay| • Turn the 3-position main switch to the fan position. If the relay pulls in, check for voltage between the L1 and L2 terminals. Then check the voltage between terminals T1 and T2.  The voltage should be the same.  If it is less than 105 volts, replace the relay.
• Current overload on blower motor| • Push the reset button on the overload between terminals A1 and A2 on the motor relay.  If there is no voltage, replace the overload.
• Blower motor| • Turn the 3-position main switch to the fan position.  Check for voltage between
terminals T1 and T2 on the motor relay.  If the voltage checks at 120 volts, replace the motor.
9. The burner    continues to run, but the
fan cycles on and off.| • Gas manifold pressure| • 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.
• Fuel supply pressure and volume| • 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.
• Fan sensor| • On the heater control unit (HCU) disconnect the wires from terminals X12 and X13.  Using an ohm meter, check the resistance between the two wires for a reading.  Compare to Sensor Resistance Chart page 26.  If the test falls out of this range, replace fan sensor.
• Turn the 3-position main switch to the fan position.  If the blower runs, check the fan sensor.  If it is good, replace the HCU.

MAINTENANCE

Prior to starting any maintenance work be sure to disconnect unit from power supply until unit cools down fully and fan shuts off! (Shut Down Procedures page 7)
To ensure the proper function of the unit, it must be serviced on regular basis. Maintenance can be performed, excluding the control devices and safety limit controls, by an authorized trained & certified Heat Wagon dealer. The control devices and safety limit controls do not need routine maintenance. If these items fail they must be replaced.

• Do not use any aggressive cleaning agents, which are harmful or environmentally unfriendly, when cleaning the unit.
• Do not use water jet when cleaning the unit.
• Pressurized air may be used for maintenance. Be careful not to damage the fan blower wheel with too much pressure.
• Check whether the unit is free from mechanical damage, replace faulty parts as necessary.
• Check fan blower wheel of the fan at regular intervals and clean it when needed.
• Check functionality of control and safety devices regularly.
• Have the flue gas values of the burner checked regularly by authorized agents.
• Be sure to store the unit in a dust free and dry place when it is not used for a long period of time. Cover the exhaust flue to prevent entry of foreign objects.

SERVICE

• The complete unit, including heat exchanger, combustion chamber and burner should be cleaned from dust and dirt after every heating period, at a minimum of once per year.

Removal of combustion chamber: For proper cleaning of the unit, manufacturer recommends removal of the complete combustion chamber with heat exchanger.

Disassembling of burner:

1. Disassemble four tightening bolts on the combustion chamber flange and remove burner’s mounting flange. Take care not to damage the flange seal.
2. Pull out the burner. Take care not to damage the burner head and power cable.

Next step:

1. Pull off collar (1) from flue gas adapter after having removed the fixing screws.
2. Disassemble flue gas adapter (2) from combustion chamber and pull it off.
3. Disassemble center side panel (3) and insulation (4). Manufacturer recommends removing the left center side panel (seen from the control box end).
4. Disassemble tightening bolts at supports of combustion chamber (5) and pull out combustion chamber sideways.

Important! Take care not to bend or damage supports of combustion chamber!

Heat exchanger
When cleaning the heat exchanger:

1. Disassemble revision cover of heat exchanger (1).
2. Be careful not to tear or damage gasket.
3. Pull all flue gas suppressors (5) (all 15 pcs) out from flue gas passages. Do not bend them.
4. Clean all flue gas passages (6) with a brush or vacuum cleaner.
5. Clean flue gas suppressors or replace them, as necessary.
6. Check gasket of revision cover and replace, as necessary.

Combustion chamber
When cleaning the combustion chamber:

1. Clean combustion chamber (7) through its opening (8) with a vacuum cleaner.

Burner
When servicing the burner:

1. Read the operating and maintenance instructions of the gas burner.
2. Make sure that the burner is exclusively maintained by authorized agents.

Re-assembly of the unit.
Heat exchanger:

1. Replace all removed parts in reverse order.
2. Make sure that the gaskets and the revision cover (1) are correctly seated.

Combustion chamber and burner:

1. Carefully assemble combustion chamber into unit and adjust it. Hand tighten bolts (final tightening after installing the burner’s mounting flange).
2. Install burner’s mounting flange.
3. Check flange gasket and replace, if necessary.
4. Tighten the screws of combustion chamber supports.
5. Remount all trim panels.
6. Remount flue gas adapter, check gaskets and replace, if necessary.
7. Install burner to the mounting flange. Take care not to damage the burner head and power cable.
8. Re-install all connections and joints and check them thoroughly.
9. Put unit into service and check proper function of all operating modes.
10. Adjust the burner, if necessary.

Important!
An operation or use other than that indicated in these instructions is prohibited!

VG1000 PARTS BREAKDOWN

Gas Burner
11| HWP 214411| Burner Compartment Door
12| HWP 214412| Base
13| HWP 214413| Oil Collector
14| HWP 214414| Insulation, Center (left/right)
15| HWP 214415| Insulation, Burner End (left/right)
16| HWP 214416| Side Panel, Burner End (2, with louvres)
17| HWP 214417| Side Panel, Center (left/right)
18| HWP 214418| Air Inlet Adapter (1, left/right/right options)
19| HWP 214419| Louvre Panel, Fan End (2, left/right/right options)
20| HWP 214420| Upper Side Panel, Fan End (2)
21| HWP 214421| Radial Fan
22| HWP 214422| Door Belt
23| HWP 214423| Control Compartment Door
24| HWP 214424| Main Control Box
25| HWP SM6162| Fan Motor
27| HWP 214427| Guide Rail (2 Required)
28| HWP 214428| Combustion Chamber & Heat Exchanger
29| HWP 214429| Air Outlet Cone

Not Shown

Obsolete

MIDCO BURNER PARTS BREAKDOWN

Not Shown

WAYNE BURNER PARTS BREAKDOWN

WAYNE BURNER PARTS BREAKDOWN

Not Shown

WAYNE BURNER SERVICING

Caution: Make sure that the main manual gas valves and main electrical power disconnect are turned off before opening burner or removing any parts for service. All cover plates,
enclosures, and guards must be in place at all times, except during maintenance and servicing.

A. BURNER HEAD AND ELECTRODE/SENSOR ASSEMBLY

The burner head, electrodes, and manifold pipe are part of the gas pipetrain assembly. (See Figure 21) To remove the burner head assembly, follow the procedure outlined below:

• Disconnect the union fitting closest to the burner in the gas pipetrain.
• Remove the four allen head screws that hold the manifold pipe to the burner housing.
• Remove the retaining nut that holds the hinged flange together and swing the fan housing slightly to the side. It may be necessary to disconnect the electrical supply to the control panel _ (if mounted on the burner). Before doing so, make sure the electrical supply is off.
• Disconnect the ignition wire from the electrode and the sensing wire from the flame rod. Swing the fan housing to the side.
• Remove the allen screw that holds the head adjustment knob in place. Remove the knob.
• Remove the scew on the left side of the burner head assembly and pull the head assembly out of the burner.

When servicing, clean burner head ports, electrodes and sensor probe. Inspect the sensor probe and electrode wires and porcelain insulators carefully for hairline cracks, which might provide an electrical leak path that could short out the ignition spark, or flame signal.
Examine the electrode and sensor probe for any serious corrosion or deterioration of metal! at the tips. Check for proper dimensional settings of the sensor probe and electrode . Adjust and/or replace these assemblies as necessary. Make sure that the ignition and sensor probe wires go to the correct electrodes and the ignition wire boot is in place over the electrode porcelain.
Make sure that the burner tube end is properly positioned in the combustion chamber entry. It must be set 1/2” (12.7mm) short of the inside face of the combustion chamber.

ELECTRODE SETTING

WAYNE BURNER SERVICING

WAYNE BURNER COMBUSTION SYSTEM

MIDCO BURNER VG1000

WAYNE BURNER – Serial No. M5895 & Beyond

WAYNE BURNER – Serial No. M5659 & Lower

MIDCO BURNER VG1000

SENSOR RESISTANCE CHART

• Correct Ohm: reading when sensors are at the above listed temperatures

CONTROL BOX MAIN CIRCUIT DIAGRAM

CONTROL BOX WIRING DIAGRAM

CONTROL BOX WIRING

CONTROL BOX PARTS

EXHAUST FLUE PIPE GUIDELINES

CAPACITY OF TYPE B DOUBLEWALL VENTS SERVING A SINGLE DRAFT HOOD-HEATER x 1000 BTU’S
FOR INDOOR APPLICATIONS

SETTING THE PILOT FOR THE VG1000 WITH THE MIDCO BURNER
Setting the pilot light on the Midco burner should be your first priority after your correct, initial, basic set-up.
Remember, these instructions are for the Midco burner only!
To set the pilot on the VG1000’s with the Midco burner, you will need a few tools of the trade, and they are as follows:

1. A multi-meter (voltmeter) that is capable of reading D.C. voltages
2. An adjustable wrench
3. A small slotted screwdriver
4. A low pressure gas gauge capable of measuring inches of water column

When the VG1000 has been placed at your desired location and your basic set up has been accomplished (Correct flue piping, correct electrical set-up, and correct gas supply set-up), we will need to make sure we have the correct pilot orifice.
The correct propane pilot orifice is part# 6772-09 and will be stamped “.046”, and the natural gas orifice (part# 6772-08) will be stamped “.052”.

SETTING THE PILOT

1. Install the correct pilot orifice for the fuel source. The pilot orifice is located at the back of the drawer assembly, at the end of the pilot gas line.
2. Remove the 1/8” pipe plug on top of the pilot orifice and install the low pressure gauge.
3. Make sure your air damper (located on the right hand side of the burner) is open at least half way using your ad justable wrench to loosen and then tighten the nut for the air damper.
4. Set your multi-meter for D.C. volts and insert the meter probes into the test ports located on the blue Honeywell flame safeguard control. Make sure that the red (positive) lead is inserted into the “+” port and the black (negative) lead is inserted into the “-“ port. You need to adjust your leads as needed to make sure they make a good electrical connection!
5. Close the main 1-1/4”ball valve and bleed all of the air from the supply line thru the 1/8” pipe plug next to the 1/4” ball valve.
6. Start the heater.
7. Make sure you have the correct pilot pressure for your gas set up. For both propane and natural gas, the correct pilot pressure is 4” W.C.. If your pilot pressure is not correct, you will need to remove the cap on your pilot regulator using your slotted screwdriver and adjust your pressure accordingly.
8. Once you have your correct pilot pressure set, check your voltmeter for a D.C. volt reading. A minimum of 2 volts D.C. is required to prove flame but ideally, we would like to see   higher reading.
9. Now, you need to loosen the nut on your air damper and slowly open or close your damper while watching your multi-meter. As you open (or close) your damper, your voltage reading on your meter should rise. Keep adjusting your damper SLOWLY until your meter starts to drop and then slowly move your damper back until your meter has its highest D.C. volt reading. Then, tighten the air damper nut when you have reached the highest voltage reading.
10. Now, you can open your 1-1/4” ball valve back open and your heater should have gas to the main burner.
11. Now, you can adjust the main burner pressure by removing the cap to your regulator and setting your correct mani fold pressure. For propane, the correct manifold pressure is 2.6” W.C. and for natural gas, the pressure should be set at 4.1” W.C.

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Valparaiso, IN 46383
219-464-8818 • Fax 219-462-7985
www.heatwagon.com

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