Heatwagon VG500 Manual

Installation and Maintenance Manual

Please retain this manual for future reference.

342 N. Co. Rd. 400 East

Valparaiso, IN 46383

219-464-8818 • Fax 219-462-7985

www.heatwagon.com

Revision 4-22

For your safety: Do not use this heater in

a space where gasoline or other liquids

having flammable vapors are stored.

Construction

Heater

VG500

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 emer-

gency 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 stor-

age of LP-gas containers even temporarily inside any recreational vehicle. The standard also pro-

hibits 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 applica-

tions. 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 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 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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Illustrated Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Exhaust Flue Pipe Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Installation and Maintenance Manual

Model VG500

Construction Heater

342 N. Co. Rd. 400 East • Valparaiso, 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.

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 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 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.

SPECIFICATIONS

Model No. VG500

Fuels: Vapor Propane or Natural Gas

Capacity: 500,000 BTU/HR

Blower: 6,475 CFM 2.05” W.C. SP

Electrical Rating: 240 Volts, 15 Amps

Fuel Consumption: NG-500 CFH / Propane-5.5 GPH, 1” FNPT Connection

Remote Thermostat: On/Off

Max. Discharge Temp.: 72ºF @ 0ºF Ambient

Duct Size: 21” Dia., 200 ft. max (straight), temp rating 300ºF min.

Shp. Dimensions: 90”L x 40”W x 60”H

Weight (approximate): 650 lbs.

Gas Supply: Inlet Pressure Manifold Pressure

Max W.C. Min W.C. W.C.

Vapor Propane 14 W.C. 9” W.C. 3.6”

Natural Gas 14 W.C. 9” W.C. 6.1”

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, 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 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 burner manifold

pressure.

Natural Gas 6.1” W.C.

Vapor Propane 3.6” W.C.

• 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.

NATURAL GAS QUICK

REFERENCE HOSE

Hose BTU

Length 500,000

in Feet <1PSI 2PSI 5PSI

10 3/4 3/4 3/4

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

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

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

75 - 3/4 3/4

100 - 3/4 3/4

125 - 3/4 3/4

150 - 3/4 3/4

175 - 3/4 3/4

200 - 3/4 3/4

VAPOR PROPANE QUICK

REFERENCE HOSE

Hose BTU

Length 500,000

in Feet 1/2PSI 10PSI

10 3/4 3/4

25 3/4 3/4

35 1-1/4 3/4

50 1-1/4 3/4

75 1-1/4 3/4

100 1-1/4 3/4

125 1-1/4 3/4

150 1-1/4 3/4

175 1-1/4 3/4

200 1-1/4 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 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 based on the unit capacity and cable length.

• Confirm voltage at heater connection (105V 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 19.

• 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 sure that there are no visible defects on the control and safety devices

and that the unit has been installed correctly.

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

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

higher than the ambient temperature.

3. Open all possible shut-off devices of the fuel supply lines.

START UP (CONTINUED)

4. Turn the control switch on the control box to position “1” (HEATING).

5. When the ambient temperature level is low, 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).

• 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 on the control box to position FAN.

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: 21”.

• Make sure that the duct is safely and properly fastened to the outlet.

• Avoid sharp bends and corners to ensure maximum air flow and avoid back pressure/heat

accumulation in heater.

• FAILURE TO COMPLY WITH THESE RECOMMENDATIONS COULD RESULT IN SHUTDOWN

OF THE HEATER.

SHUT DOWN

• Turn control switch to the right, heat position (*).

• Close fuel supply.

Important!

The air supply fan continues running to cool down the combustion chamber/heat exchanger

and then stops later. The fan can restart for several times before finally switching off!

WARNING!

UNIT MAY BE UNPLUGGED IN EMERGENCY SITUATIONS ONLY. OTHERWISE, DO NOT

STOP THE UNIT BY UNPLUGGING IT. 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.

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/heat exchanger:

For proper cleaning of the unit, manufacturer recommends removal of the complete

combustion chamber with heat exchanger. Clean combustion chamber and exchanger tube with

brush. Vacuum all loose ash and soot. Close all cleaning flanges carefully to avoid damage to

gasket material.

-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. Clean blower

wheel, ignitor electrodes, and photocell. Replace fuel nozzle and fuel filter.

Refer to seperate burner manual for adjustment of burner.

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 I

reset the limit

switch.

• Power supply cord

• Burner lock out on the burner flame

safeguard control box is engaged

• Overheat limit switch is tripped

• 24 volt transformer

• Burner control switch

• Incorrect burner manifold pressure

• Restricted airflow

• Overheat limit switch faulty due to loss of

power

• Test for 240 volts between terminal #4 and #5 on the main terminal block.

• Turn thermostat off for 50 seconds. Turn thermostat on

• Reset switch, located on the main control box under the black screw cap .

• Using a volt meter, check for 24 volts AC between ground and one of the “T”

terminals on the burner control box. If less than 24 replace transformer.

• On the main terminal block, check for 120 volts between terminal 6 and the “C”

terminal on the burner switch and then between terminal 6 and the “1” terminal

on the burner. If there is power on terminal “C” and not on terminal “1” replace

the burner switch.

• Use a low pressure gauge (0-15 inches of water column) with a 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 3.6” W.C. for propane or 6.1” for natural gas.

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

the air outlet, insure the back pressure does not exceed a static pressure of 2”

W.C. Check with low pressure gauge if necessary (0-15 inches of water column).

• 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 (C and 2) at room temperature. Replace if overheat limit switch

fails test.

VG500 TROUBLESHOOTING

Symptom Possible Causes Possible Solutions

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