Instruction Manual for heat wagon models including: P1800, P1800 Electric Construction Heaters, Electric Construction Heaters, Construction Heaters, Heaters, P4000, P6000, P600, P900
2024-01-11 — IMPORTANT INSTRUCTIONS. READ ALL INSTRUCTIONS BEFORE USING THIS HEATER. 1. This heater is hot when in use. To avoid burns, do not let bare skin touch hot ...
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DocumentDocument342 N. Co. Rd. 400 East Valparaiso, IN 46383 219-464-8818 · Fax 219-462-7985 www.heatwagon.com Installation and Maintenance Manual Please retain this manual for future reference. Electric Construction Heaters Revision 1-24 For Indoor Use Only Not For Use Outdoors For your safety: Do not use this heater in a space where gasoline or other liquids having flammable vapors are stored. IMPORTANT INSTRUCTIONS READ ALL INSTRUCTIONS BEFORE USING THIS HEATER 1. This heater is hot when in use. To avoid burns, do not let bare skin touch hot surfaces. Use handle when moving this heater. Keep combustible materials at least 6 feet (2 meter) from the front of the heater and keep them away from sides and rear 2. Extreme caution is necessary when the heater is used near children or invalids and whenever the heater is left unattended 3. Always unplug the heater when not in use 4. Do not operate any heater with a damaged cord or plug or after the heater malfunctions, has been dropped or damaged in any manner. Return heater to authorized service facility for examination, electrical or mechanical adjustment or repair 5. Do not use outdoors 6. This heater is not intended for use in bathrooms, laundry areas and similar indoor locations. Never locate the heater where it may fall into a bathtub or other liquid container 7. Do not run cord under carpeting. Do not cover cord with throw rugs, runners, or the like. Arrange cord away from traffic area and where it will not be tripped over 8. TO DISCONNECT HEATER, reduce ambient thermostat to zero. Fan will continue to run (P1800,4000,6000) until unit cools and shuts down automatically, turn switches off, disconnect power. For P600, P900 let fan run one minute then after cooldown, turn switch off, disconnect power. 9. Connect to properly grounded outlets only 10. Do not insert or allow foreign objects to enter any ventilation or exhaust opening as this may cause an electric shock or fire, or damage the heater 11. To prevent a possible fire, do not block air intakes or exhaust in any manner. Do not use on soft surfaces, where openings may become blocked 12. A heater has hot and arcing or sparking parts inside. Do not use in areas where gasoline, paint or flammable liquids are used or stored 13. Do not point to flammable materials 14. Use heater only as described in this manual. Any other use not recommended by the manufacturer may cause fire, electric shock or injury to persons 15. Always plug heaters directly into a wall outlet/receptacle. Never use with an extension cord or relocatable power tap (outlet/power strip) 16. Hyperthermia can result in death. Symptoms of hyperthermia include high body temperature, headache, nausea, vomiting, tiredness, dizziness, fainting, and rapid pulse. If you begin to experience symptoms related to hyperthermia, turn off the heater and seek medical attention. 17. To avoid excessive room temperatures which can cause hyperthermia: DO NOT leave product running unattended in a confined space around infants, or individuals with reduced physical, sensory, or mental capabilities. 18. SAVE THESE INSTRUCTIONS Installation and Maintenance Manual Models P600, P900, P1800-1, P1800-3, P1800D, P4000 and P6000 Construction Heaters Table of Contents: Page Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Principal of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Set Up and Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Maintenance and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Parts Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 -16 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10, 12, 14, 17-19 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 WARRANTY All new Heat Wagon and Sure Flame heaters and fans are guaranteed against defective materials and workmanship for one (1) year from 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. LIMITATIONS Evidence of improper electric power, misapplication or evidence of abuse may be cause for rejection of warranty claims. Travel time, mileage and shipping charges will not be allowed. Minor adjustments of heaters are dealers' responsibility. 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. Heater is not intended for use in pest remediation. 342 N. Co. Rd. 400 East · Valparaiso, IN 46383 219-464-8818 · 888-432-8924 · Fax 800-255-7985 www.heatwagon.com SPECIFICATIONS 3 P600 P900 P1800-1 P1800-3 P1800D Heat Output (Max BTU's) (First Stage) (Second Stage) (Third Stage) 20,500 20,500 N/A N/A 30,700 30,700 N/A N/A 65,000 41,000 65,000 N/A 65,000 41,000 65,000 N/A 65,000 41,000 65,000 N/A Watts (Max) (First Stage) (Second Stage) (Third Stage) 6,000 N/A N/A N/A 9,000 9,000 N/A N/A 18,000 12,000 18,000 N/A 18,000 12,000 18,000 N/A 18,000 12,000 18,000 N/A Electrical Rating 240V 60Hz 1Ø 240V 60Hz 1Ø 240V 60Hz 1Ø 240V 60Hz 3Ø 240V 60Hz 3Ø Min. Voltage at Heater 208 208 208 208 208 Amp Draw (Max) 25 38.0 75 50 50 (First Stage) 25 38.0 50 34 34 (Second Stage) N/A N/A 75 50 50 (Third Stage) N/A N/A N/A N/A N/A Air Flow 250 CFM (425 Cu. m/hr) 350 CFM (600 Cu. m/hr) 590 CFM (1,000 Cu. m/hr) 590 CFM (1,000 Cu. m/hr) 940 CFM (1,590 Cu. m/hr) Ambient Thermostat 32 to 100°F 32 to 100°F 32 to 100°F 32 to 100°F 32 to 100°F Weight 32.9 lbs 48 lbs 62 lbs 62 lbs 62 lbs Ducting (Max) N/A N/A N/A N/A 12" x 50' (straight) Duct PN-WD1225 12"x25' Long Temp Rise (from 0ºF ambient) dB Noise 100ºF 53 dB(A) 1m 100ºF 55 dB(A) 1m 100ºF 58 dB(A) 1m 100ºF 58 dB(A) 1m 100ºF UL LIsted Yes Yes Yes Yes Dimensions 20"L x 12"W x 17"H 23"L x 12"W x 18"H 30"L x 14"W x 20"H 30"L x 14"W x 20"H 30"L x 14"W x 20"H P4000 P6000 136,000 51,200 102,400 136,500 204,700 81,864 163,728 204,606 40,000 16,000 32,000 40,000 60,000 24,000 48,000 60,000 480V 60Hz 3Ø 480V 60Hz 3Ø 440 440 50 75 20 30 40 60 50 75 1,800 CFM (3,000 Cu. m/hr) 1,800 CFM(1,000 Cu. m/hr) (3,000 Cu. m/hr) 32 to 100°F 32 to 100°F 130 lbs 142 lbs 14" x 50' (straight) Duct PN-WD1425 14"x25' Long 14" x 50' (straight) Duct PN-WD1425 14"x25' Long 100ºF 100ºF 82 dB(A) 1m 82 dB(A) 1m Yes 46"L x 20"W x 25"H 46"L x 20"W x 25"H PRINCIPAL OF OPERATION P600, P900, P1800-1, P1800-3 STEEL THERMOSTAT + HANDLE SWITCHES 2 PCS - P600 3 PCS - P900 9 PCS - P1800's PRINCIPAL OF OPERATION P4000, P6000 POWER SELECTOR CONTACTORS RUGGED GALVANIZED STEEL HOUSING OVERHEAT SENSORS COOL AIR IN AMBIENT THERMOSTAT SENSOR TUBE ELECTRIC FAN MOTOR ALUMINUM FAN BLADES SOLID PLASTIC WHEELS WARM AIR OUT FULLY SEALED, NONGLOWING STAINLESS STEEL HEATING ELE- MENT 15 PCS 4 OPERATION REVIEW AND UNDERSTAND ALL WARNINGS IN THIS MANUAL. THEY ARE ESSENTIAL FOR SAFE USE OF THE HEATER. FOLLOW ALL LOCAL CODES. To start heating: 1. Place the heater on a stable, level surface. Make sure that no explosive or combustible fumes or dust are present. See that the heater is not exposed to water spray, rain, or dripping water. Minimum clearances from combustible materials: Outlet: 6 feet, Sides: 1 foot, Top: 2 feet, Rear: 2 feet Floor: combustible 2. Connect heater to proper power source. The P600 requires a 240V, 60Hz single phase 25 Amp power source. The P900 requires a 240V, 60Hz single phase, 40 Amp power source. The P1800-1 requires a 240V, 60 Hz single phase, 75 Amp power source. The P1800-3 requires a 240V, 60 Hz three phase, 50 Amp power source. The P4000 requires a 480V, 60 Hz three phase, 50 Amp power source. The P6000 requires a 480V three phase, 75 Amp power source. Also, ALL POWER SOURCES NEED TO BE EQUIPPED WITH A CIRCUIT BREAKER! Note: When power is first applied to unit, the heater fan may blow air out of heater INLET. If this condition occurs, (after first removing power from cord) reverse the first two hot wires at heater terminal inlet block. (3 Phase Models Only) 3. Set the remote thermostat to a temperature above the ambient room temperature by turning the knob. NOTE: The heater will start only if the thermostat "calls for heat" meaning that it is set to higher than prevailing ambient temperature. 4. Set the selector switch to the desired heating setting. For the P1800 series, the options are #1 for ventilation (fan only), #2 for low heat output of 12Kw (41,000 Btu's), or #3 for high output of 18Kw (65,000 Btu's). For the P4000, the switches are labeled S1 with a heat output of 16Kw (54,600 Btu's), S1 and S2 with a heat output of 32Kw (109,200 Btu's) or S1, S2 and S3 with a heat output of 40Kw (136,000 Btu's). For the P6000, the switches are labeled S1 with a heat output of 24Kw (81,900 Btu's), S1 and S2 with a heat output of 48Kw (163,800 Btu's) or S1, S2 and S3 with a heat output of 60Kw (204,700 Btu's). The heater will now operate automatically, controlled by the thermostat. 5 To Stop Heating: (P1800, P4000, P6000) 1. Turn all switches to "Off". 2. Allow fan to run until unit stops automatically, controlled by unit cooldown thermostat (fan switch). Heater may cycle more than once. 3. Unplug the power supply cable after the fan has stopped cooling down the heater completely. To Stop Heating: (P600, P900) 1. Reduce ambient (room) thermostat to "Heat Off" position. 2. Allow fan to run for at least two minutes. 3. Flip switch to "Off" position. 4. Unplug heater. NOTE: The heater is equipped with an overheat limit switch which may cause the heater to stop. Check and remove the cause for overheating before re-starting. Never disconnect supply plug to stop the heater while in operation!! MAINTENANCE Never service heater while it is plugged in, running or hot. Severe bodily injury or electric shock may occur. Only qualified persons are allowed to open heater for service. 1. Keep heater clean (ex. dry wall dust). Use pressurized air to blow fan blades clean. NOTE: Use moderate pressure to avoid damage to fan blades. 2. Inspect heater before and after each use. 3. The bearings of the fan motor are permanently lubricated and sealed No additional lubrication is needed. 6 GENERAL ELECTRIC HEATER SIZING ISSUES When running Heat Wagon electric heaters from a generator, it is extremely important to make sure that the generator selected for your heater is not undersized. The single largest service issue with Heat Wagon electric heaters is improper set up relating to inadequate voltage due to too small of an electric source and/or too small of a power cord. Generator Selection for Heat Wagon Electric Heaters The chart below will help you when it comes to selecting the correct generator required for your Heat Wagon heater: Model Watts P1500 1,500 P600 6,000 P900 9,000 P1800-1 18,000 P1800-3 18,000 P1800D 18,000 P4000 40,000 P6000 60,000 Phase BTU'S 1 Phase 5,100 1 Phase 20,500 1 Phase 30,700 1 Phase 64,000/41,000 3 Phase 64,000/41,000 3 Phase 64,000/41,000 3 Phase 136,000/109,200/54,600 3 Phase 204,700/163,800/81,900 Volts 120 240 240 240 240 240 480 480 Amps CFM 15 120 25 250 38 350 75 590 50 590 50 950 50 1,800 70 1,800 Recommendations 3KW 10KW 15KW 25KW 25KW 25KW 50KW 75KW So, by reviewing the above chart, a P1800-1 would require a minimum 18,000 Watt (18KW), 240 volt single phase generator that can provide 75 amps of continuous power. Heating Coil Ohm Readings P600 - 20 P900 - 20 P1800's - 26 P4000 - 85 P6000 - 54 7 ELECTRICAL CORD SELECTION FOR HEAT WAGON ELECTRIC HEATERS Once you have established that you have enough power to properly run a Heat Wagon Electric Heater, you still need to deliver the power to the heater adequately. You will need to do a Voltage Drop Formula. The Voltage Drop Formula is amps (source), times resistance (cord's wire size) equals voltage drop. A cords wire size resistance chart is below: Wire Size Resistance Chart #4 0.000308 Resistance per Foot #6 0.000403 Resistance per Foot #8 0.000641 Resistance per Foot #10 0.00102 Resistance per Foot #12 0.00162 Resistance per Foot #14 0.00258 Resistance per Foot #16 0.00409 Resistance per Foot #18 0.00651 Resistance per Foot A sample formula is listed below: Example: P1800-1 phase 75 amp Minimum Voltage Required=208V 150 ft. x 12 gauge wire (0.00162) = .24 75 amps x .24 = 18.0 volt drop 220v (at source) 18v = 202 volts Conclusion: Heater will not run, wire too small or cord too long. Options to Correct the Situation: 1. Increase gauge of wire: If you increased your wire 6 gauge wire, then your formula would be as follows: Example: P1800-1 phase 75 amp Minimum Voltage Required=208V 150 ft. x 6 gauge wire (0.000403) = 0.0605 75 amps x 0.0605 = 4.53 volt drop 220 volts (at source) 4.53 volts= 215.46 volts Now, your heater will run properly. 2. Run a shorter cord. If by chance you could use a 50ft cord instead of a 150ft cord, then your formula would be as follows: Example: P1800-1 phase 75 amp Minimum Voltage Required=208V 50ft. x 12 gauge wire (0.00162) = .08 75 amps x .08= 6 volt drop 220 volts (at source) 6 volts= 214 volts Now, your heater will run properly 8 P600 PARTS BREAKDOWN Key # 1 2 3 4 - 5 6 7 8 9 10 11 12 13 15 Description Part# Bottom Plate HWP 4027013 Rear Panel HWP 4027011 Front Panel HWP 4027012 Inner Mantle HWP 4027014 Air Guide Ring, Inner Mantle HWP 4027020 (not shown) Outer Mantle HWP 4027010 Room Thermostat (Knob Not Included) HWP 20220 (Ambient) Fan Motor HWP 14145 Hub, Fan Motor HWP 17907 Fan Blade HWP 16109 Handle HWP 80100 Heating Element (2) HWP 42800 Wire Bushing (Guard Ring) HWP 36809 Toggle Switch HWP 26900 (400021) Plastic Bracket for Bulb (2) HWP 37910 Key # 16 17 18 19 20 21 22 23 24 25 26 28 29 30 Description Bracket for Inner Mantle Terminal Block Bracket for Terminal Block Strain Reliever Locking Nut, Strain Reliever Power Cord Plug, Handle (2 pcs) Contactor Overheat Limit Switch Limiter, Air Outlet Plug Only Knob, Room Thermostat Bracket for Limiter Ground Lug Part# HWP 4027015 HWP 36704 HWP 4027016 HWP 36922 HWP 36923 ACC 30A10 HWP 80110 HWP 22670 HWP 21201 HWP 21206 HWP 00275-00T HWP 20577 HWP 4027017 Not Included 9 P600 WIRING DIAGRAM Key # C M R1-R2 S1 S2 S3 S4 X1 X2 X3 Description Contactor Fan Motor Heating Element Toggle Switch Room Thermostat Overheat Limit Switch Limiter, Air Outlet Terminal Block Grounding Lug Power Cord & Plug Assembly Note: Grounded plug NEMA 14-30 Part# HWP 22670 HWP 14145 HWP 42800 HWP 26900 (40021) HWP 20220 HWP 21201 HWP 21206 HWP 36704 Not Included ACC 30A10 10 P900 PARTS BREAKDOWN Key # 1 2 3 4 5 6 7 8 9 11 12 13 14 Description Part# Bottom Plate HWP 40081001 Rear Panel HWP 40081002 Front Panel HWP 40081003 Inner Mantle HWP 40081004 Outer Mantle HWP 40081005 Bracket, Inner Mantle HWP 40081006 Bracket, Terminal Block HWP 40081007 Overheat Limit Switch Qty. 1 HWP 21200 (180024) Overheat Limit Switch Qty. 2 for Serial #2132 & beyond HWP 21200 (180024) Plastic Bracket for Thermostat HWP 37910 Ambient Thermostat (Knob Not Included) HWP 20220 Knob for Thermostat HWP 20577 Fan Motor HWP 180014 (14201) Fan Hub, Plastic HWP 17907 Key # 15 16 17 18 19 20 21 22 23 24 25 26 Description Fan Blade Handle Heating Element Plug for Handle (2PK) Plug Strain Reliever Toggle Switch For S/N A0001-A120 For S/N B0121-B0270 For S/N B0270-Greater Contactor Power Cord Assembly Guard Ring / Wire Bushnig Terminal Block Jam Nut Part# HWP 16110 HWP 80100 HWP 42800 (Qty. 3) HWP 80110 HWP 00275-00T HWP 36922 HWP 400021 HWP 26901 HWP 26902 HWP 22670 ACC 50A10 HWP 36809 HWP 36704 HWP 36923 11 P900 WIRING DIAGRAM Key # C M R1-R3 S1 S2 S3 X1 X2 X3 Description Contactor Fan Motor Heating Element Toggle Switch Ambient Thermostat Overheat Limit Switch Qty. 1 Overheat Limit Switch Qty. 2 for Serial #2132 & beyond Terminal Block Grounding Lug Power Cord & Plug Assembly Note: Grounded plug NEMA 14-30 Part# HWP 22670 HWP 14201 (180014) HWP 42800 See Key #21 on page 11 HWP 20220 HWP 21200 (180024) HWP 21200 (180024) HWP 36704 Not Included ACC 50A10 12 P1800-1, P1800-3, P1800D PARTS BREAKDOWN 13A Key # 1 2 3 4 5 6 7 8 9 10 11 12 13 13A 14 15 15 16 17 17 13 Part# Description HWP 180007 Bottom Plate HWP 180006 Front Panel (P1800D - HWP 1800037) HWP 180015 Rear Panel HWP 180002 Hood* (No Hatch) HWP 180032 Hood with Connection Hatch* HWP 180032A Connection Hatch* HWP 180003 Inner Mantle (Including Air Cone) HWP 180009 Bracket HWP 180019 Rear Grill (P1800D - HWP 1800035) HWP 180005 Front Grill HWP 180026 Heating Element (9 per Heater) HWP 180022 Contactor HWP 180021 Main Switch Assembly HWP 180008 Overheat Limit Switch (Outer) HWP 180024 Overheat Limit Switch (Inner) HWP 180025 Unit Cooldown Switch HWP 400018 Thermostat Knob HWP 20577 Thermostat Knob For P1800-1, S/N 1036 & Beyond For P1800-3, S/N 3509 & Beyond For P1800D, S/N 0031 & Beyond HWP 37910 Plastic Bracket HWP 180017 Ambient Thermostat HWP 20220 Ambient Thermostat (Knob Not Included) For P1800-1, S/N 1036 & Beyond For P1800-3, S/N 3509 & Beyond For P1800D, S/N 0031 & Beyond Key # 18 19 20 21 22 23 24 25 26 28 29 30 32 33 Part# HWP 82760 HWP 36809 HWP 401604 HWP 180014 HWP 180033 HWP 180012 HWP 180027 HWP 180001 SFP S1500-105 HWP 180004 HWP 36615 HWP 36630 HWP 36704 (HWP 180023B) HWP 180011 Description Plate Nut Guard Ring Gasket for Connection Hatch* Fan Motor (P1800D - 14350, Includes Blade) Fan Hub (7mm Shaft) P1800-1, P1800-3 only Fan Blade P1800-1, P1800-3 only Circuit Breakers (P1800-1 Only) Handle Bracket for Terminal Block (P1800-1 Only) Gasket Terminal Block (P1800-1 Only) (Qty. 3) Locking Clamp (P1800-1 Only) (Qty. 2) Terminal Block (P1800-3 Only) Fan Hub Cap & Bolt *Similar Equipped Models Only Not Shown ACC WD1225 HWP 1800036 HWP 1800038 HWP 37910 HWP 32116 HWP 180016 HWP 86800 HWP 1800037 Duct for P1800D (12"x25' long) Capacitor for #21, P1800D Capacitor Holder Plastic Bracket for TA Bulb Heating Coil Wire (sold by ft.) Strain Relief Silicone Sleeve (4' section) P1800D Outlet WIRING DIAGRAM HEAT WAGON P1800 SINGLE PHASE HWP 180022 HWP 180027 HWP 180014 HWP 180026 HWP 180021 WIRING DIAGRAM HEAT WAGON P1800 THREE PHASE See Part #17, P. 13 HWP 180025 HWP 180024 HWP 180008 HWP 36615 HWP 180022 HWP 180014 HWP 180026 HWP 180021 See Part #17, P. 13 HWP 180025 HWP 180024 HWP 180008 HWP 180023B 14 P4000 - P6000 PARTS BREAKDOWN 15 P4000 - P6000 PARTS BREAKDOWN Key # 1 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 24 25 26 28 29 30 31 32 33 34 35 36 36A 37 38 39 40 41 41 Part# HWP 400003 HWP 400002 HWP 400027 HWP 400001 HWP 400006 HWP 400008 HWP 400007 HWP 400011 HWP 400005 HWP 4000012 HWP 180024 HWP 180025 HWP 20550 HWP 82770 HWP 400004 HWP 74600 HWP 40019 HWP 400026 HWP 600026 HWP 36809 HWP 400015 HWP 400009 HWP 400010 HWP 40028 HWP 400019 HWP 400020 HWP 400016 HWP 22669 HWP 400022 HWP 180016 HWP 36904 HWP 400021 HWP 38110 HWP PEF1 HWP 36615 HWP 28400 HWP 36616 HWP 37910 HWP 180017 HWP 20220 42 HWP 400018 42 HWP 20577 43 HWP 400043 45 HWP 400014 47 HWP 400012 48 HWP 36802 Description Heat Exchanger Chamber Hood (Including Connection Hatch) Connection Hatch Only Handle Front Panel Duct Adapter Bottom Frame Support Leg Wheel Shaft Plate, Fan Thermostat Overheat Limit Switch (Inner) Cooldown Thermostat Overheat Limit Switch, Air Outlet (PETE) Metal Bracket, or Bulb Wheel Locking Washer Gasket, Rubber Heating Element (15 Per Heater, P4000) Heating Element (15 Per Heater, P6000) Guard Ring, Rubber Rear Panel Partition Panel / Bracket Contactor Mounting Plate Mounting Plate, Fan Motor Fan Guard Grill Bushing, Medium Bushing, large Contactor (3 Per Heater)* Contactor (1 Per Heater) Strain Reliever (Qty 2) Strain Reliever (P6000 only) Toggle Switch Fuse Holder Fuse *For P4000 S/N prior to 2142 use 400022 For P6000 S/N prior to 0561 use 400022 Terminal Block (3 per heater) Transformer Locking Clamp + End Plate Plastic Bracket Ambient Thermostat Ambient Thermostat (Knob Not Included) For P4000, S/N 2022 & Beyond For P6000, S/N 0531 & Beyond Thermostat Knob (for 180017) Thermostat Knob (for 20220) Ground Bolt Fan Motor Fan Blade Bushing, Small Not Shown ACC WD1425 SFP S1500-105 HWP 32116 Duct for P4000, P6000 (14"x25' long) Bracket for Terminal Block Heating coil wire (sold by the foot) 16 P4000 - P6000 CONTROL BOX 11 2 1 2 3 3 4 2 3 6 2A 7 5 9 8 4 10 Item Part No. Description 1 See Part #41, P.16 AMBIENT THERMOSTAT 2 HWP 22669 CONTACTOR, 3-POLE* 2A HWP 400023-24 CONTACTOR, 3-POLE, 2A + AUX 3 HWP 400021 SWITCH 4 HWP 20550 OUTLET AIR THERMOSTAT (PETE) 5 HWP 36615 TERMINAL BLOCK 6 HWP 28400 TRANSFORMER (PETR) *For P4000 S/N prior to 2142 use 400022 For P6000 S/N prior to 0561 use 400022 Item Part No. 7 HWP PEF1 8 HWP 400026 8 HWP 600026 9 HWP 180024 10 HWP 180025 11 HWP 400014 Description FUSE HEATING ELEMENT - P4000 HEATING ELEMENT - P6000 OVERHEAT LIMIT SWITCH (INNER) UNIT COOLDOWN T-STAT FAN MOTOR 17 P4000 - P6000 WIRING 480 Volt 60 Hz 3 PH 15 14 11 12 13 13 2 4 16 16 16 16 5 6 7 8 9 10 16 Key # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 Part# Description HWP 28400 Transformer HWP PEF1 Fuse HWP 400014 Fan Motor HWP 180024 Overheat Limit Switch HWP 180017 Ambient Thermostat HWP 20550 (PETE) Limit Switch - Outer HWP 180025 Unit Cooldown Switch HWP 400021 Control Switch (for output 16KW) HWP 400021 Control Switch (for output + 16KW) HWP 400021 Control Switch (for output + 8KW) HWP 400022 Contactor & Coil (for output 16KW) HWP 22669 Contactor & Coil (for output + 16KW) HWP 22669 Contactor & Coil (for output + 8KW) HWP 22669 Fan Contractor HWP 400022 Pole 4 of Contactor C1 HWP 400026 Heating Elements, 2.7KW each for P4000 HWP 600026 Heating Elements, 4.0KW each for P6000 18 P4000 - P6000 WIRING 19 ELECTRIC HEATER TROUBLESHOOTING Before beginning the Troubleshooting section, please review the Set-up and Installation section of this manual. Most technical issues can be resolved with proper set-up and preventative maintenance. Symptom Cause Turn thermostat up and motor does No power on any phase. not come on: Overheat Limit (TO) Main Switch assembly Motor Motor Relay (P4000 and P6000 Only) Control Transformer (P4000 and P6000 only) Motor Starts but air comes out the Reversed power (hot) wires inlet: Motor starts but no heat: Ambient Thermostat Overheat limit(s) Contactors Circuit Breakers (P1800-1 only) Check Remedy Check for 240V between L1 and L2 Refer to Setup and Operation (for single phase models). Check section. for power between L1 and L2, L2 and L3, and between L1 and L3 (for 3 phase models). Overheat Limit (TO) Check for continuity. The switch Replace should be closed. Check for continuity. Replace Check for proper voltage to motor. Replace Check for 24 volts to contactor. Make sure contactor pulls in. If not, replace. Check for 24 volts out from Control Replace Transformer. Check power at terminal block Switch first two power wires at terminal block Turn thermostat above ambient temperature. Replace Check for continuity. It is a closed Replace switch Make sure they are clean, tight, Replace and that they pull in when voltage is applied Check that none are tripped and Replace power flows thru. Heating Elements Heater operates, fan doesn't cool Fan Cooldown Thermostat the unit after thermostat is satisfied. High limit tripping Low Volume of Air Visual check for burns. Check resistance of each individual element Check for resistance. Check for proper wiring. Duct restrictions. Dust buildup on inlet grill P600 & P900 20 K Ohms, P1800 Series 26 K Ohms, P4000 85 K Ohms, P6000 54 K Ohms Replace Rewire Straighten duct. Clean fan area. 20 21 22 342 N. Co. Rd. 400 East Valparaiso, IN 46383 219-464-8818 · Fax 219-462-7985 www.heatwagon.com