XTREMEPOWERUS 96958 Forced Air Portable Propane Heater 100K BTU Owner’s Manual

FORCED AIR PORTABLE PROPANE HEATER 100K BTU
ITEM: 96958 (70K BTU) / 96959 (100K BTU)

OWNER’S MANUAL AND SAFETY INSTRUCTIONS
SAVE THIS MANUAL: KEEP THIS MANUAL FOR SAFETY WARNINGS, PRECAUTIONS, ASSEMBLY, OPERATING,  INSPECTION, MAINTENANCE, AND CLEANING PROCEDURES. WRITE THE PRODUCT’S SERIAL NUMBER ON THE  BACK OF THE MANUAL NEAR THE ASSEMBLY DIAGRAM (OR MONTH AND YEAR OF PURCHASE IF PRODUCT HAS  NO NUMBER).
FOR QUESTIONS PLEASE CALL OUR CUSTOMER SUPPORT: (909) 628 0880 MON-FRI 9 AM TO 3 PM PST

IMPORTANT SAFETY INFORMATION

GENERAL SAFETY WARNINGS
Read these instructions for use carefully. Familiarise yourself with the appliance before connecting it to a gas cylinder. Keep these instructions for future reference. This instruction manual contains important information necessary for the proper assembly and safe use of the appliance. Follow all warnings and instructions when using the appliance. If you have questions about assembly, operation,  servicing, or repair of this product, please call Customer Service at 909.628.0880.

CARBON MONOXIDE HAZARD

• This appliance can produce carbon monoxide which has no odor.
• EVER use this appliance in an enclosed space such as a camper, tent, car, or home.
• Keep propane tank(s) below 100°F(37.8°C). Check heater for damage before each use. DO NOT use a damaged heater. Use only the hose and factory preset regulator provided with the heater. Check hose before each use of heater. If highly worn or cut, replace with hose specified by manufacturer before using heater.
• DO NOT alter heater. Keep heater in its original state. Do not use heater if altered.
• 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 THE HAZARDS OF  FIRE, EXPLOSION, BURN, ASPHYXIATION, CARBON MONOXIDE POISONING, AND/OR ELECTRICAL SHOCK.
• Carbon Monoxide (CO) poisoning produces flu-like symptoms, watery eyes, headaches, dizziness, fatigue, and possibly death. You can’t see it and you can’t smell it. It’s an invisible killer. If these symptoms are present during operation of this product get fresh air immediately.
• Keep out of reach of children.

EXPLOSION FIRE HAZARD

• WARNING: Using this heater in a residential garage requires that the heater is positioned so that it is protected against any possible damage by a moving vehicle, etc. It must be positioned so that the base of the heater is no less than 18 inch (450mm)  above the garage floor or 8 ft (2450mm) In repair garages. The heater must be placed on a stable surface. Do not place it on a chair,  ladder, Etc. Raising the heater will reduce BUT NOT eliminate the possibility of lighting the vapor of any Flammable liquids which may be improperly stored or accidentally spilled. If the smell of gasoline is present, DO NOT operate this heater until the area has been properly ventilated.
• NEVER install or remove propane tank while outdoor stove is lighted, near flame, pilot lights, other ignition sources, or while the outdoor stove is hot to touch.
• During operation, this product can be a source of ignition. Never use the heater in spaces that contain or may contain volatile or airborne combustibles, or products such as gasoline, solvents, paint thinner, dust particles, or unknown chemicals. Minimum  clearances from combustible materials: 12 inches from the sides & 48 inches from the top.
• This product is fueled by propane gas. Propane gas is invisible, odorless, and flammable. An odorant is normally added to help detect leaks and can be described as a “rotten egg” smell. The odorant can fade over time so leaking gas is not always detectable by smell alone.
• Propane gas is heavier than air and leaking propane will sink to the lowest level possible. It can ignite by ignition sources including matches, lighters, sparks, or open flames of any kind many feet away from the original leak. Use only propane gas set up for vapor withdrawal.
• Propane gas should be stored or used in compliance with local ordinances and codes or with ANSI/NFP58. Turn off propane hen, not in use.
• CALIFORNIA PROPOSITION 65:WARNING: Fuels used in gas or oil-fired appliances and the products of combustion of such fuels contain Chemicals known to the State of California to cause cancer, birth defects, or other Reproductive Harm. This product contains chemicals, including lead and lead compounds, known to the State of California to cause cancer, birth defects, or other reproductive harm. Wash hands after
• Keep all connections and fittings clean. Inspect propane cylinder and stove propane connections for damage before attaching.
• Locate heater on stable and level surface if heater is hot or operating. Not intended for use on finished floors. Never block air inlet(bottom of shell) or air outlet(around top of shell) of heater. Do not leave heater unattended.

WARNING: Not for home or recreational vehicle use. 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 THAT DO  OR MAY CONTAIN VOLATILE OR AIRBORNE COMBUSTIBLES, OR PRODUCTS SUCH AS GASOLINE, SOLVENTS,  PAINT THINNERS, DUST PARTICLES, OR UNKNOWN CHEMICALS.

• Provide adequate ventilation. Before using heater, provide at least a six-square-foot opening of fresh, outside air. This heater produces carbon monoxide, which is listed by the State of California as a reproductive toxin under proposition 65.
• Install and use heater with care. Follow all local ordinances and codes. In the absence of local ordinances and codes refer to the standard for storage and the natural gas installation code, CSA B149.1. This instructs on the safe storage and handling of propane gas. Use only propane gas set up for vapor withdrawal.
• Provide adequate ventilation. Before using heater, provide at least a six-square-foot opening of fresh, outside air. This heater produces carbon monoxide, which is listed by the State of California as a reproductive toxin under proposition 65. For indoor or outdoor use. Clearance from combustibles MUST be at least 40 inches. The heater must be located at least 6 ft (1.83m) in the US;  or 10ft (3m) in Canada, from any propane gas container.
• The heater is designed for use as a construction heater in accordance with ANSI Z83.7, CSA 2.14. Other standards govern the use of fuel gases and heating products for specific uses. Your local authority can advised you about these. Construction heaters is to provide temporary heating of building under construction, alteration, or repair. Properly used, the heater provides safe economical heating. Products of combustion are vented into the area being heated. We cannot foresee every use which maybe made of our eaters. CHECK WITH YOUR LOCAL FIRE SAFETY AUTHORITY IF YOU HAVE QUESTIONS ABOUT HEATER USE.
• Install and use heater with care. Follow all local ordinances and codes. In the absence of local ordinances and codes refer to the standard for storage and the natural gas installation code, CSA B149.1. This instructs on the safe storage and handling of propane gas. Use only propane gas set up for vapor withdrawal.
• DO NOT use heater in occupied dwellings or in living or sleeping quarters. DO NOT use heater in a basement or below ground level. Propane gas is heavier than air. If a leak occurs, propane gas may sink to the lowest possible level. Keep appliance area clear and free from combustible materials, gasoline, paint thinner, and other flammable vapors and liquids. Dust is combustible. DO NOT   use heater in areas with high dust content.
• The heater is designed and approved for use as a construction heater in accordance with the Standard for Gas-Fired Construction  Heaters ANSI Z83.7 ● CSA 2.14. CHECK WITH YOUR LOCAL FIRE SAFETY AUTHORITY IF YOU HAVE QUESTIONS  ABOUT APPLICATIONS. Other standards govern the use of fuel gases and heat-producing products in specific applications.  Your local authority can advise you about these. the intended use is the temporary heating of a building or structure under construction, alteration, or repair.
• Keep children and animals away from heater. Never move, handle or service a hot or operating heater. Severe burns may result.  Wait 15 minutes after turning heater off. To prevent injury, wear gloves when handling heater. Turn off propane supply to heater when not in use. Use only original replacement parts. This heater must use design-specific parts. Do not substitute or use generic parts. Improper replacement parts could cause serious or fatal injuries. Installation of this appliance at altitudes above 2000 ft (610  m) shall be in accordance with local codes, or in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1/NFPA 54,  or National Standard of Canada, Natural Gas and Propane Installation Code, CSA B149.1..The heater should be inspected before each use, and at least annually by a qualified service person.
• NEVER refill the heater’s fuel tank while heater is operating or still hot. This heater is EXTREMELY HOT while in operation.  Keep all combustible materials away from this heater.
• NEVER use ductwork in front or at the rear of the heater.
• NEVER transport the heater with fuel in its tank.
• Bulk fuel storage should be a minimum of 25 feet away from the heater, torches, portable generators, or other sources of ignition.
• ALWAYS locate the heater on a stable, level surface.
• RISK OF ELECTRICAL SHOCK! Use only the electrical power (voltage and frequency) specified on the model plate of the heater. Use only a local, correct plug and a grounded outlet and extension cord.
• ALWAYS install the heator so that is is not directly exposed to water spray, rain, dripping water, or wind.
• ALWAYS unplug the heater when not in use.

SAVE THESE WARNINGS

PRODUCT INFORMATION

ELECTRICAL WIRING INFORMATION

96958
96959

PRODUCT INFORMATION / ASSEMBLY

96958
96959

96958
96959

HARDWARE COMPONENTS

ASSEMBLY

96958 Tools Required: Medium Phillips Screwdriver
96959 Tools Required: Medium Phillips Screwdriver, 5/16” open-end or adjustable wrench, needle-nose pliers.

HANDLE ASSEMBLY:

1. Align the holes in the upper housing with the 2 holes in the handle as shown. Insert and tighten screws securely with the screwdriver.

CORD WRAP ASSEMBLY:

1. Insert tabs on the cord wrap into slots in the shell support, lining up the holes on the cord wrap with those on the side cover. Insert and tighten screws securely with the screwdriver.

FRAME AND WHEELS ASSEMBLY:

1. Slide the axle through in the wheel support frame.
2. Slide wheels onto each axle, make sure the valve stern (if pneumatic) is to the outside.
3. Slide flat washers (L) onto the axle past the small hole. Insert a cotter pin in the axle hole and bent legs of the pin with needle-nose pliers and secure.
4. Place heater on the assembled frame, make sure that the air inlet end is by the wheels and the mounting holes on the tank flange of the heater align with holes in the frame.
5. Take the rear handle and align the mounting holes with the corresponding holes in the tank flange/wheel flange, Slide a screw through the holes and loosely attach a nut. Repeat for the other 2 holes, then fully tighten all 6 screws and nuts.

OPERATION

For Optimal performance of this heater, it is suggested the 1-K kerosene be used. 1-K kerosene has been refined to virtually eliminate contaminants, such as sulfur. Diesel may also be used if 1-K kerosene is not available. Be advised that these fuels do not burn as clean as  1-K kerosene and care should be taken to provide more fresh air ventilation to accommodate any added contaminants that may be added to the heated space. Use of diesel fuel can cause excess soot production.

NOTE: Store Diesel and/or 1-K kerosene should only be stored in a blue container clearly marked “Diesel” or “Kerosene”. Never put these in a red container. Red is associated with gasoline.
NEVER store diesel, gasoline, or kerosene in a living space.
NEVER use diesel or kerosene that has been stored from one season to the next. It deteriorates over time. Old diesel, kerosene will not burn properly in this heater.

THEORY OPERATION:
FUEL SYSTEM: This heater is equipped with an air pump that operates off of the electric motor. The pump forces air through the airline connected to the fuel tank, drawing fuel to the nozzle in the burner head. Air also passed through the nozzle where it mixes with the fuel and is sprayed into the combustion chamber into a fine mist.

QUICK-FIRE IGNITION: A transformer sends high voltage to a two-prong spark plug. The spark ignition the fuel/air mixture as it is sprayed into the combustion chamber.
AIR SYSTEM: A fan is turned by heavy-duty motor, which forces air around and into the combustion chamber, where it is super-heated and forced out the front of the chamber.
TEMPERATURE LIMIT CONTROL: This heater is equipped with a temperature limit control designed to turn the heater off should the internal temperature rise to an unsafe level if this device activates and turns the heater off, it may require service. Once the temperature falls below the reset temperature, you will be able to start your heater.

ELECTRICAL SYSTEM PROTECTION: The heater’s electrical system is protected by a circuit breaker that protects the system components from damage. If the heater fails, check the fuse first and replace if necessary.

FLAME SENSOR: The heater uses a photocell to see the flame in the combustion chamber. Should the flame extinguish, the sensor will stop the electrical current and the heater will shut off.

NEVER FILL FUEL TANK INDOORS.
ALWAYS FILL FUEL TAHNK OUTDOORS.
BE SURE THAT THE HEATER IS ON LEVEL GROUND WHEN FUELING, AND NEVER OVERFILL FUEL TANK.

NEVER REFUEL THIS HEATER WHILE Mil IT |S HOT OR OPERATING, FIRE OR EXPLOSION COULD RESULT.

It is a good idea to fire the heater outdoors for the first time. This will allow any oils used in the manufacturing process to be burned off in a safe place. This initial burn should last at least 10 minutes.

VENTILATION: ALWAYS provide fresh air opening in the heated soace of at least three square feet for each 29KW/hr of heater output.

STARTING THE HEATER:

1. Fill the tank with fuel up to fuel guage points to “F”. MAke sure the cap is secure.

2. Plug the power cord into a local, correct plug. The extension cord should be at least 6 feet long. Extension cord requirements are as follows:
   6-10ft: 18 AWG wire.
   11-100ft: 16 AWG wire.
   101-200ft: 14 AWG wire.

3. Turn the thermostat control knob to the desired setting. The setting range is from 40 °F to 110 °F. Push the power switch to the  ON position. The power indicator lamp and room temperature display will light up and the heater will start.

If the heater does not fire, the thermostat may be set too low. Turn the control knob to a higher setting until the heater fires. If the eater does not start, push the power switch to OFF, then back to ON. If the heater still does not fire, see the Troubleshooting guide.

NOTE: The electrical components of this heater are protected by a fuse mounted in the PC board. If the heater fails to fire, chek the fuse first and replace if necessary. Also, check the power source to be sure that the proper voltage is being provided to the heater.

STOPPING THE HEATER:
Simply turn the power switch to the OFF position and unplug the power cord.

STOPPING THE HEATER:

1. Wait 10 seconds after shutting off the heater.
2. Turn the power switch to ON position.
3. Be sure to follow all starting procedure precautions.

Shock Hazard

• Never plug in an appliance with more than a 5 amp rating into this outlet.
• Always keep outlet covered when not in use.

STORAGE / MAINTENANCE

DRAIN FUEL TANK

1. For model 96958: Drain fuel through the fuel cap opening using an approved siphon. For model 96959: Drain fuel from through the drain plug at the bottom of the fuel tank.
2. To remove the drain plug, pull the plug grip downward and remove the seal head from the drain hole tank.
3. Using a small amount of diesel, rinse and swirl the diesel inside the fuel tank, then empty the tank completely. Secure the tank by pushing the seal cap fully into the head hole.

Store the heater in a dry, well-ventilated area. Be sure the storage area is free of dust and corrosives vapors.

MAINTENANCE

FUEL/FUELTANK
Flush every 200 hours of operation or as needed. Do not use Water to flush the tank, Wse fresh Diesel (1-K Kerosene} only.

AIR FILTERS:
The air intake Filter should be replaced or washed with soap and Water and dried theroughly every 500 hours of operation, or less, depending on conditions.
The output and lint Filter should be replaced every 500 hours of operation, cr lass, depending on conditions.
NOTE: Use of Diesel (1-K Kerosene} may require additional maintenance.

MAINTENANCE

FAN BLADES:
Blades should be cleaned at least once per heating season, depending on condition.
Remove all accumulated dust and dirt with a damp cloth, taking care not to bend any of the fan blades. Be sure fan blades are dry before re-starting the heater. For Fan removal, see Figure 13.

NOZZLES:
Nozzles should be cleaned or replaced at least once per heating season. Contanimated fuel could make this necessary immediately. To clean dirt from the nozzle, blow compressed air through nozzle front, it may be necessary to soak the nozzle in clean diesel to help loosen any particles.

SPARK PLUG:
Clean and re-gap every 600 hours of operation, or replace as needed. After removing the spark plug, clean the terminals with a wire brush. Re-gap the terminals to 0.35cm

PHOTOCELL:
The Photocell should be cleaned at least once per heating season or more depending on condition.
Use a cotton swap dipped in water or alcohol to clean the lens of the photocell. Note the proper photocell position as noted in Figure 16 and Figure17.
FUEL FILTER:
The fuel filter should be cleaned at least twice per heating season by rinsing, it in clean Diesel (1-K Kerosene). Contaminated fuel could  make this necessary immediately (See Figure 18).

NOTE: To remove the fuel filter for all model, please draw out the rubber plug directly. Use of diesel may require additional  maintenance. Improper maintenance can lead to poor combustion and soot production.

PUMP PRESSURE ADJUSTMENT:
While heater is opérating, turn réliéf valve clockwise to Increase. Counterclockwise to decrease (see Figure 19). Use flat blade screwdriver to turn valve. Correct pump pressure is a5 follows:
For best measurement of pressure, test with full tank of fuel. Optimum pressure occurs when the nose cone os cherry red and there are no extending flames from the heater.

TROUBLESHOOTING

Heater fires, but main PCB shuts heater off after a short period of time lame is flickering, and LED
display show”E1” (1flash}| 1. Intorrect pump pressure.
2. Dirty Input-output or lint filter
3, Dirty fuel filter.
4. Mozzle is dirty.
5. Photocell lens |s dirty.
6. Photocell nat installed properly.
7. Photocell defective.
4.lmproper el#ectrical eannection
between main PCB and photocell,| LAdjust pump Pressure (page 11)
2? Clean/replace air filter (page 9)
3,Clean/replace Fuel Filter (page 10)
4. Cleanfreplace Nozzle (page 9)
©.Clean/replace Photocell (page 10)
6. Adjust Photacell position (page 10)
7. Replace Photecell [page 10)
8.Check to wring connections (See
iring Diagrams, page 12)
Heater will hot operate, or motor
runs for short time, Lamp flickers
and LEO display shows”E1″(1flash)| 1. No Diesel in fuel tank.
2, Incorrect Pump pressure.
3, Cormoded spark plug or incorrect
plug gap.
4. Dirty fuel filter.
5, Dirty nozzle,
6. Moisture in fuel/fuel tank.
7. Improper electrical connection
between transformer and circuit
board.
8. |gnitor wire not connected to
spark plug.
9. Detective ignitor.| 1. Fill tank with fresh Diesel
2, Adjust pump pressure (pagel)
3.Clean/replace spark plug (page 10}
4, Clean/replace fuel filter (page 10}
5. Clean/replace nozzle ipage 9}
6. Rinse out fuel tank with clean fresh Diesel (paged)
7[nspect all electrical connection
{see wiring diagrams pagel?)
Re-attach lanitor wire to spark
plug (paged)
9. Replace ignitor
Fan does not opera when heater is plugged in and power switch is in the “ON” position. The lamp is flickering or on and LED display shows “El” or “F211 flash or 2 flashes)| 1. Thermostat is set too low (Does not apply to ZB-K45)
2. Broken electrical connection
between main Pa and motor| 1. Rotate thermostat to a higher setting
2. Inspect all electrical connection (see wiring diagrams pagel2)
Lamp is flickering and LED display shows “E3” (3flashes)| 1. Thermostat switch has failed| 1. Replace thermostat switch, wiring diagrams (pagel2)
Poor combustion and / or excess soot production| 1. Dirty input-output or lint filter
2. Dirty fuel filter
3. Poor quality of fuel
4. Pump pressure is too high or too low| 1. Clean/replace air filter (page 9)
2.Clean/replace fuel filter (page 10)
3. Be sure fuel is not contaminated or old
4. Use proper pressure (pagell)
Heater does not turn on and the lamp Is not lit| 1. Temperature limit sensor
has overheated
2.No electrical power
3. Fuse blown
4. Improper electrical connection between Temperature Limit Sensor and Circuit Board| 1. Push power switch to “OFF” and allow heater to cool for 10 minutes. Push switch back to “ON” 2. Check power cord and extension cord to insure of proper connection, test power supply
3. Check/replace fuse
4. Inspect all electrical connection (see wiring diagrams pagel2)

DISCLAIMER

PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLYDIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY  REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THATHE OR SHE IS QUALIFIED TO MAKE ANY  EPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN  FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE  BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE  ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF  REPLACEMENT PARTS THERETO.

Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts.

SAVE THESE INSTRUCTIONS

The material in this manual is for informational purposes only. The product(s) it describes are subject to change without prior notice,  due to the manufacturers continuous development program. XtremePowerUS makes no representations or warranties with respect to this manual or with respect to the products described herein. XtremePowerUS shall not be liable for any damages, losses, costs or expenses, direct, indirect, or incidental, consequential or special, arising out of, or related to the use of this material or the products described herein.

Questions, problems, missing parts?
Before returning to your retailer, our exceptional customer service is here to help.
****Call Us: 909.628.0880
Email Us: customer@xtremepowerusa.com
Hours of Operation: 9 am – 4 pm (Monday – Friday)
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