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Indirect-fired Air Heater Cub 400 Cub 700 OPERATOR’S MANUAL 0170815en 004 0907 0 1 7 0 8 1 5 E N

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Indirect-fired Air Heater

Cub 400Cub 700

OPERATORS MANUAL

0170815en 004

0907

0 1 7 0 8 1 5 E N

Cub 400/700 Table of Contents

1. Foreword 3

2. Safety Information 5

2.1 Operating Safety .................................................................................. 62.2 Operator Safety while using Combustion Burners ............................... 72.3 Service Safety ...................................................................................... 82.4 Safety and Operating Labels .............................................................. 10

3. Operation 11

3.1 System Description ............................................................................ 113.2 Installing the Lift Bar ........................................................................... 123.3 Machine Location ............................................................................... 133.4 System Component Locations ........................................................... 143.5 Control Panel ...................................................................................... 153.6 Preliminary Checks ............................................................................ 163.7 Starting the Machine .......................................................................... 173.8 Shutting Down the Machine ............................................................... 183.9 Using the Remote Thermostat ........................................................... 193.10 Adjusting the Recirculation System .................................................... 203.11 Suggested Venting ............................................................................. 223.12 Connecting the Main Electric Power Supply ...................................... 243.13 Installing the Plenums ........................................................................ 253.14 Checking the Burner Air Setting ......................................................... 26

4. Maintenance 27

4.1 Periodic Maintenance Schedule ......................................................... 274.2 Changing and Adjusting the Supply Blower Belt ................................ 284.3 Replacing the Oil Burner Nozzle ........................................................ 304.4 Checking and Adjusting the Oil Burner Electrodes ............................ 324.5 Checking the Fuel Pressure ............................................................... 344.6 Changing the Fuel Heater Filter ......................................................... 354.7 OIl Burner Adjustments ...................................................................... 364.8 Fuel Blend Guide ................................................................................ 384.9 Oil Burner Set-up Chart ...................................................................... 394.10 Gas Burner Set-up Chart .................................................................... 39

1

Table of Contents Cub 400/700

4.11 Turbulator Setting (Head Setting) ........................................................404.12 Checking and Adjusting the Gas Pressure ..........................................424.13 Checking and Adjusting the Electrode and Ionization Probe ..............444.14 Checking Function of Ionization Probe ................................................454.15 Changing Burner Orifice ......................................................................464.16 Transporting ........................................................................................484.17 Gas Analyzer Access Hole ..................................................................494.18 List of Abbreviations ............................................................................504.19 Troubleshooting ...................................................................................514.20 Wiring Diagram ....................................................................................53

5. Technical Data 55

5.1 Cub 400 Technical Data ......................................................................555.2 Cub 700 Technical Data ......................................................................57

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Foreword

1. Foreword

This manual provides information and procedures to safely operateand maintain this Ground Heaters, Inc. model. For your own safetyand protection from injury, carefully read, understand and observe thesafety instructions described in this manual.

Keep this manual or a copy of it with the machine. If you lose thismanual or need an additional copy, please contact Ground Heaters,Inc. This machine is built with user safety in mind; however, it canpresent hazards if improperly operated and serviced. Follow operatinginstructions carefully! If you have questions about operating orservicing this equipment, please contact Ground Heaters, Inc.

The information contained in this manual was based on machines inproduction at the time of publication. Ground Heaters, Inc. reservesthe right to change any portion of this information without notice.

All rights, especially copying and distribution rights, are reserved.

Copyright 2007 by Ground Heaters, Inc.

No part of this publication may be reproduced in any form or by anymeans, electronic or mechanical, including photocopying, withoutexpress written permission from Ground Heaters, Inc.

Any type of reproduction or distribution not authorized by GroundHeaters, Inc. represents an infringement of valid copyrights and willbe prosecuted. We expressly reserve the right to make technicalmodifications, even without due notice, which aim at improving ourmachines or their safety standards.

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Foreword

wcghi_tx000001gb diesel.fm 4

Cub 400/700 Safety Information

2. Safety Information

This manual contains DANGER, WARNING, CAUTION, NOTICE andNOTE callouts which must be followed to reduce the possibility ofpersonal injury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potentialpersonal injury hazards. Obey all safety messages that follow thissymbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, willresult in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, couldresult in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, couldresult in minor or moderate injury.

NOTICE: Used without the safety alert symbol, NOTICE indicates ahazardous situation which, if not avoided, could result in propertydamage.

Note: Contains additional information important to a procedure.

DANGER

WARNING

CAUTION

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Safety Information Cub 400/700

2.1 Operating Safety

Familiarity and proper training are required for the safe operation ofthis machine. Machines operated improperly or by untrained personnelcan be dangerous. Read the operating instructions contained in boththis manual and the OEM manuals included with this machine.Familiarize yourself with the location and proper use of all controls.Inexperienced operators should receive instruction from someonefamiliar with the machine before being allowed to operate it.NEVER run the machine indoors or in an enclosed area unlessadequate ventilation, through such items as exhaust fans or hoses, isprovided. Exhaust gas from the genset and from the burner containscarbon monoxide, a deadly poison. Exposure to carbon monoxideWILL KILL YOU IN MINUTES.Always use caution when applying power to the machine. Uponapplying power to the machine, the blower may start without warning.

2.1.1 ALWAYS be sure the machine is on a firm, level surface and will nottip, roll, slide, or fall while operating.

2.1.2 NEVER start a unit in need of repair.

2.1.3 Keep unauthorized personnel, children, and pets away from themachine.

2.1.4 ALWAYS operate machine with all safety devices and guards in placeand in working order. DO NOT modify or defeat safety devices. DONOT operate machine if any safety devices or guards are missing orinoperative.

2.1.5 DO NOT smoke while operating the machine.2.1.6 NEVER run the machine in areas that contain flammable objects,

fuels, or products that produce flammable vapors.2.1.7 NEVER connect ductwork between the exhaust outlet port and the

supply air inlet port.

WARNING

WARNING

CAUTION

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Cub 400/700 Safety Information

2.2 Operator Safety while using Combustion Burners

Combustion burners present special hazards during operation andfueling. Read and follow the warning instructions in the burner ownersmanual and the safety guidelines below. Failure to follow the warningsand safety guidelines could result in severe injury or death.NEVER run the machine indoors or in an enclosed area unlessadequate ventilation, through such items as exhaust fans or hoses, isprovided. Exhaust gas from the genset and from the burner containscarbon monoxide, a deadly poison. Exposure to carbon monoxideWILL KILL YOU IN MINUTES.

2.2.1 DO NOT fill or drain the fuel tank near an open flame, while smoking,or while the engine is running.

2.2.2 ALWAYS refill the fuel tank in a well-ventilated area.2.2.3 ALWAYS replace the fuel tank cap after refueling.2.2.4 DO NOT spill fuel when refueling the machine. Clean up spilled fuel

immediately.2.2.5 DO NOT smoke when refueling machine.

DO NOT refuel a hot or running machine.

2.2.6 The machine must be installed by qualified personnel who have readand understand all supplied manuals and instructions.

2.2.7 All connections to natural gas or LP must be performed by qualifiedpersonnel who possess the proper certification or lincensing requiredby the locality, state, or province in which the machine is beinginstalled.

WARNING

WARNING

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Safety Information Cub 400/700

2.3 Service Safety

HIGH VOLTAGE! This unit uses high voltage circuits capable ofcausing serious injury or death. Only a qualified electrician shouldtroubleshoot or repair electrical problems occurring with thisequipment.

2.3.1 All connections to natural gas or LP must be performed by qualifiedpersonnel who possess the proper certification or lincensing requiredby the locality, state, or province in which the machine is beinginstalled.

2.3.2 ALWAYS replace the safety devices and guards after repairs andmaintenance.

2.3.3 ALWAYS keep the machine clean and labels legible. Replace allmissing and hard-to-read labels. Labels provide important operatinginstructions and warn of dangers and hazards.

2.3.4 ALWAYS make sure slings, chains, hooks, ramps, jacks and othertypes of lifting devices are attached securely and have enough weight-bearing capacity to lift or hold the machine safely. Always remain awareof the location of other people in the area when lifting the machine.

2.3.5 ALWAYS replace or repair electrical components with components thatare identical in rating and performance as the original component.

2.3.1 DO NOT use gasoline or other types of fuels or flammable solvents toclean parts, especially in enclosed areas. Fumes from fuels andsolvents can become explosive.

2.3.2 Label Locations

WARNING

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Cub 400/700 Safety Information

4

7

3

12

6

wcghi_gr004415

4

5

8

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Safety Information Cub 400/700

2.4 Safety and Operating Labels

* Not used on NG and LP machines.

Ref. Label Ref Label

1 2

3 4

5* 6

7

HAZARDOUSDo scover in place.Disconnect and lock out

source before openingpanel.

cause severe injury ordeath. M100-256

CAUTION

VORSICHT

PRECAUCION

PRECAUTION

CAUTIONRETURN OR SUPPLY FLEXIBLE DUCTLENGTH NOT TO EXCEED 150 FEET

Arctic Bear Cub Operating Guide NOTE: It is recommended that the shore power extension cords be no longer than 100 ft.

Pre Start Ensure that there is sufficient fuel volume in the fuel tank (fuel gauge), if applicable. Ensure that the control switches is on 0 (main control panel).

Connect Supply and Return Ducts Connect the supply duct to the CUB supply duct collar with the airflow tag pointing toward the structure. Connect the supply duct outlet to the structure. Connect the return duct inlet to the structure with the airflow tag pointing toward the CUB. Connect the return flex duct outlet to the CUB return duct collar.

Start CUB (Main Control Panel) Turn the Operation Mode switch clockwise to the snowflake symbol. The burner will start after a short pre-puge and supply air blower will start after the heater comes up to temperature.

START UP

Shutting Down the CUB NOTE: DO NOT INTERRUPT POWER TO THE CUB UNTIL THE BLOWER HAS

STOPPED. Turn the Operation Mode switch to the 0 position. The Burner will shut down immediately and the blower will shut down after the air temperature display drops sufficiently

Disconnect Supply and Return Ducts Release the duct collar clamps and remove the ducts from the CUB. Separate duct segments (if applicable). Disconnect the ducts from the structure. Neatly stow the ducts in the forward storage bay of the CUB.

SHUT DOWN

Questions Regarding Performance or Operation Should the CUB malfunction in any manner, shut it down immediately and call your distributor to report the malfunction and to receive instructions.

173263

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Cub 400/700 Operation

3. Operation

3.1 System Description

The Cub 400 and Cub 700 heaters are indirect-fired air heaters. TheCub 400 and 700 have stainless steel fireboxes and heat exchangers.They run on three fuel options: diesel, natural gas (NG), or LP. The fuelis consumed in a closed combustion chamber. The exhaust gases arevented outdoors through a vent pipe. The clean, dry hot air is blown orciculated in the space by a centrifugal blower. The blower assembly isprotected by a guard fitted on the air inlet. Cub 400 and Cub 700 heaters are meant to heat air on constructionsites and in other rugged applications. Do not use the Cub 400 or Cub700 for any other purpose.

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Operation Cub 400/700

3.2 Installing the Lift Bar

See graphic: wcghi_gr004433

The Cub 700 diesel with tank machine (item #: 0620213) is shippedwith the lift bar partially assembled. Before use, the lift bar must beremoved from its mounting location and installed on top of themachine. To install the lift bar, carry out the following procedure:

3.2.1 Unpack the machine.

3.2.2 Remove and discard the bolts (a) that secure the lift bar to the side ofthe machine.

3.2.3 Install the lift bar on top of the machine using the supplied 16 bolts (b).Note: The bolts (b) are 3/8 inch 16X1.5 inches and are supplied in asmall plastic bag attached to the lift bar at the time of shipment.

3.2.4 Install the supplied bolts (c) on the support frame.Note: The bolts (c) are 3/8 inch 16X1 inch and are supplied in a smallplastic bag attached to the lift bar at the time of shipment.

3.2.5 The lift bar is now installed.

a

c

b

wcghi_gr004433

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Cub 400/700 Operation

3.3 Machine Location

The machine may be located outdoors or within the area to be heated.When locating the machine within the area to be heated, the exhaustgases must be vented to the outdoors. The machine must be installed: By qualified personnel who have read and understood all

supplied instructions. On a flat, firm surface. With the following minimum clearances:

10 ft. (3.1 m) to front 6 ft. (2 m) to rear 4 ft. (1.1m) to sides 4 ft. (1.1 m) to top

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Operation Cub 400/700

3.4 System Component Locations

Ref. Description Ref. Description

1 Control panel 7 Heated fuel filter

2 Burner assembly 8 Fork lift pockets

3 Recirculation damper 9 Blower temperature capillary tube

4 Heater temperature capillary tube 10 Over temperature capillary tube

5 Supply air port 11 Fuel tank

6 Lifting eye 12 Burner exhaust port

wcghi_gr003885

1

3

5

5

8

8

8

8

5

3

12

12

3

1

2

11

7

6

10 4

9

2

7

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Cub 400/700 Operation

3.5 Control Panel

Ref Component Function

a Operation mode switch

3-position switch which switches power to one of three modes: VENTILATEpower to blower only.

OFFpower to burner is off; power remains to blower until thermo-stat reads 104F (40C) or lower.

HEATpower to burner and blower.

b Reset switch Resets the system after an over-temperature condition. An over-tem-perature condition exists at temperatures above 212F (100C).Remove cap to access reset button.

a

b

wcghi_gr003880

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Operation Cub 400/700

3.6 Preliminary Checks

Before starting the Cub 400 or Cub 700, check the following:

Fuel supply on diesel burning machines. See Fuel Blending Guide.

Position of operation mode switch. It must be in the OFF (0) position.

Power supply.Each machine must be connected to two (2) separate power supplies adhering to specific requirements. Please see the Technical Data tables in this manaul for the specific power requirements.Note: On diesel burning machines, the fuel heater will begin heating the fuel as soon as power is connected to the machine.

Thermostat plug/remote thermostat connection. Either the thermostat plug or the remote thermostat cable must be connected in order for the machine to operate.

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Cub 400/700 Operation

3.7 Starting the Machine

3.7.1 If using the remote thermostat, place it in the area to be heated. Set itto the desired temperature.

3.7.2 Turn the operation mode switch tothe HEAT position.The burner will start. It will go througha prepurge cycle and then light.As soon the air temperature reachesapproximately 104F (40C), theblower will start.The burner will continue to fire until the temperature of the space beingheated reaches the temperature set by the thermostat. At that time, theburner shuts down but the blower will remain on.

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Operation Cub 400/700

3.8 Shutting Down the Machine

3.8.1 Turn the operation mode switch tothe OFF (0) position.The burner will shut down. As soon as the air temperaturedecreases to below approximately104F (40C), the blower will stop.

Electric shock and cutting injury hazard! At temperatures above 104F(40C), electric power is available at the supply blower even with theoperation mode switch in the OFF position. Always remove all powerto the machine before servicing it.

3.8.2 Once the blower has shut off automatically, disconnect the powersupply cord. NOTICE: Do not disconnect the power supply cord until the blower hascooled the heat exchanger and has shut off automatically.

3.8.3 Disconnect the remote thermostat and re-install the thermostat plug.3.8.4 When using NG or LP gas, have a qualified and licensed technician

disconnect the gas supply.

WARNING

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Cub 400/700 Operation

3.9 Using the Remote Thermostat

See Graphic: wcghi_gr003900In order for the machine to function, the remote thermostat (b) or thethermostat plug (a) must be installed into the control panel. To use theremote thermostat:

3.9.1 Plug (c) the remote thermostat into the control panel.3.9.2 Set the sensor end within the space to be heated.3.9.3 Adjust the temperature setting with dial (d).

wcghi_gr003900

c

a

b

d

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Operation Cub 400/700

3.10 Adjusting the Recirculation System

See Graphic: wcghi_gr0038843.10.1 When the machine is positioned within the space (A) to be heated, the

recirculation baffle can be used to reduce fuel costs. The open positionof the recirculation baffle brings air to the heat exchanger from thespace to be heated instead of using cooler, outside air. This practicesaves fuel and provides the ability to achieve higher internal buildingtemperatures because the machine does not have to raise thetemperature of recirculated (preheated) as far as it does the outsidenon-recirculated air.

3.10.2 When the machine is positioned outside of the space (B) to be heated,the recirculation baffle can be used to introduce fresh air into the airsupply.

wcghi_gr003884

A

B

Hot

Warm

Cool

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Cub 400/700 Operation

Notes:

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Operation Cub 400/700

3.11 Suggested Venting

See Graphic: wcghi_gr0033875Suffocation hazard! Exhaust gas from this machine contains carbonmonoxide, which is an odorless, colorless, and deadly gas. Thismachine must be properly vented to reduce the risk of carbonmonoxide poisoning.

When installing vents: Adhere to all local and national codes. Consult all appropriate governing bodies or local contractor for

venting and fresh air requirements. Place the machine in a manner that avoids excessive vent bends

(elbows), and long horizontal runs. Keep air inlets and outlets free from obstruction. Route the venting pipes in a manner that avoids any flammable

material. Route the venting pipes in a manner that avoids contact with

humans.

WARNING

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Cub 400/700 Operation

Exhaust gas from this machine CAN KILL YOU IN MINUTES. Theexhaust contains carbon monoxide, a deadly poison you can not seeor smell. This machine must be properly vented to reduce the risk ofcarbon monoxide poisoning.

The above venting diagram shows suggested venting layouts only. Consult all appropriate governing bodies or local contractor for venting and fresh air requirements.

wcghi_gr003875

WARNING

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Operation Cub 400/700

3.12 Connecting the Main Electric Power Supply

Electric shock hazard. High voltage can cause severe injury or death.Shut down and lock out the main source of electric power beforeconnecting it to the machine.

The main electrical power source and mating electrical adapters areprovided by the end user. The power source must adhere to thefollowing guidelines:Cub 400

The power supplies must be 115V, 15A (NEMA 5-15) and 230V, 20A (NEMA L6-20).

Cub 700

The power supplies must be 115V, 15A (NEMA 5-15) and 230V, 30A (NEMA L6-30).

All machines

The cord must be no longer than 30 m (100 ft.). The main power source must be connected to the machine at the

main control panel.

WARNING

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Cub 400/700 Operation

3.13 Installing the Plenums

See Graphic: wcghi_gr003891Various plenums are available as accessories. Plenum configurationsfor the Cub 400 include: 3x12 in., 2x16 in., and 1x20 in. Plenumconfigurations for the Cub 700 include: 3x16 in., and 2x20 in. Theplenums (a) are mounted to the front of the machine using four bolts.

wcghi_gr003891

a

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Operation Cub 400/700

3.14 Checking the Burner Air Setting

See Graphic: wcghi_gr003868To check burner air setting, carry out the following procedure.

3.14.1 Shut down the machine and allow it to cool.3.14.2 Loosen the two screws (a) that secure the air adjustment plate (b).3.14.3 Rotate the air adjustment plate so that the proper number on the air

adjustment plate lines up with the setting indicator (c). See the burnerset-up chart.

3.14.4 Once the air adjustment plate is set, tighten the two screws (a).

Note: This procedure must be performed at each new job site. The proper settingdepends on environmental conditions at the work site.

4.9

b

c a

wcghi_gr003868

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Cub 400/700 Maintenance

4. Maintenance

4.1 Periodic Maintenance Schedule

Every 600 hours

or 6 months

Every 1200 hours

or yearly

Check/adjust supply blower belt.

Replace oil burner nozzle.

Check/adjust oil burner electrodes.

Check /adjust oil burner fuel pressure.

Replace fuel heater filter.

Check gas burner distributor head & mixing plate.

Check gas burner ignition electrode.

Check gas burner ionization probe.

Check gas pressure.

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Maintenance Cub 400/700

4.2 Changing and Adjusting the Supply Blower Belt

See Graphic: wcghi_gr003887To change and adjust the supply blower belt, carry out the followingprocedure. Replace glazed, worn, or cracked belts.Removal:Electric shock and cutting injury hazard! Disconnect the main powersupply to the machine before servicing the supply blower.

4.2.1 Remove the screws that secure the access panel and remove theaccess panel.

4.2.2 Loosen the nuts on the four screws (a) that secure the motor plate tothe mounting flange.

4.2.3 Rotate the motor plate to release tension on the belt.4.2.4 Roll the belt off of the pulleys.

Installation:4.2.5 Roll a new belt onto the pulleys.4.2.6 Rotate the motor plate to apply tension to the belt. A properly adjusted

belt will have approximately 3/81/2 inches (1013 mm) of deflectionat the center of the belt when pressed with moderate pressure.

4.2.7 Tighten the nuts on the four screws (a) that secure the motor plate tothe mounting flange. When tightening the nuts, be sure to keep themotor plate parallel with the blower housing, and the motor pulleyparallel to the blower pulley.

4.2.8 Secure the access panel to the machine.

WARNING

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Cub 400/700 Maintenance

wcghi_gr003887

3/81/2 in.(1013mm)

a

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Maintenance Cub 400/700

4.3 Replacing the Oil Burner Nozzle

See Graphic: wcghi_gr003865To replace the burner nozzle, carry out the following procedure.Removal:

4.3.1 Shut down the machine and allow it to cool.4.3.2 Remove the burner assembly cover.4.3.3 Loosen screw (3).4.3.4 Carefully pull the control box (1) back, then up and away from the

burner assembly.4.3.5 Remove the two screws (4) that secure the air tube cover plate (5) and

remove the air tube cover plate.4.3.6 Loosen screw (2), then slide the complete drawer assembly out of the

combustion head.4.3.7 Loosen screw (6), then remove the nozzle adapter (7) from the drawer

assembly.4.3.8 Remove the nozzle (8) from the nozzle adapter.

Installation:4.3.9 Install the nozzle (8) into the nozzle adapter (7).4.3.10 Install the nozzle adapter into the drawer and secure it with screw (6).4.3.11 Install the drawer assembly into the combustion head and secure it

with screw (2).4.3.12 Install the air tube cover plate (5) with two screws (4).4.3.13 Install the control box (1).4.3.14 Tighten screw (3).4.3.15 Install the burner assembly cover.

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Cub 400/700 Maintenance

7

6 wcghi_gr003865

8

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Maintenance Cub 400/700

4.4 Checking and Adjusting the Oil Burner Electrodes

See Graphic: wcghi_gr003866To check and adjust the burner electrodes, carry out the followingprocedure.

4.4.1 Shut down the machine and allow it to cool.4.4.2 Remove the cover from the burner assembly.4.4.3 Loosen screw (3).4.4.4 Carefully pull the control box (1) back, then up and away from the

burner assembly.4.4.5 Remove the two screws (4) that secure the air tube cover plate (5) and

remove the air tube cover plate.4.4.6 Loosen screw (2), then slide the complete drawer assembly out of the

combustion head.4.4.7 Loosen the electrodes and adjust them as shown.4.4.8 Install the drawer assembly into the combustion head and secure it

with screw (2).4.4.9 Install the air tube cover plate (5) with two screws (4).4.4.10 Install the control box (1).4.4.11 Tighten screw (3).4.4.12 Re-install the cover to the burner assembly.

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Cub 400/700 Maintenance

5/32 in. (4 mm)

5/323/64 in. (45 mm)

13/64 in. (5 mm)

wcghi_gr003866

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Maintenance Cub 400/700

4.5 Checking the Fuel Pressure

See Graphic: wcghi_gr003867To check fuel pressure, carry out the following procedure.

4.5.1 Shut down the machine and allow it to cool.4.5.2 Remove the bleeder valve (a) from the fuel pump.4.5.3 All pump ports are British Parallel thread design. A gauge with like

threads must be used, or an appropriate adapter. Insert the gauge oradapter in place of the bleeder valve.

4.5.4 Start the machine.4.5.5 With the burner firing, check the pump pressure. The fuel pumps

range is 145200 psi (1013.8 bar). See burner set-up chart.

wcghi_gr003867

RIELLOP

V

a

a

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Cub 400/700 Maintenance

4.6 Changing the Fuel Heater Filter

See Graphic: wcghi_gr003870The fuel heater assembly (a) is located near the burner. To replace thefuel heater filter, carry out the following procedure.Removal:

4.6.1 Shut down the machine and allow it to cool.4.6.2 Remove the screw that secures the cover to the housing.4.6.3 Remove the filter (b).

Installation:4.6.4 Install the new filter (b).4.6.5 Install the cover.

wcghi_gr003870

ab

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Maintenance Cub 400/700

4.7 OIl Burner Adjustments

The machine should be operated with standard diesel/fuel oil (OIL)DIESEL. Note: All burners are test fired at Ground Heaters, Inc.'s factorylocated 600 ft.(180 m) above sea level (asl) using 70/30% blend of #2diesel with additives (70%) and #1 (K1) diesel (30%) with additives. The use of a high quality combustion analyzer and fuel pressure testgauge is mandatory. All adjustments must be accomplished by alicensed professional and must conform to the requirements of local,state and federal codes and authorities. A qualified technician mustrecalibrate the burner air and fuel settings to obtain proper combustionat your work site.To ensure proper burner performance and to avoid machine downtimedue to heater sooting, burner combustion verification and adjustmentmust be performed: Before operating at elevations 1,000 ft (305 m) above or below

the last adjustment. Before starting at a new job site. After any burner maintenance has been performed. If burner performance is in question for any reason.

Fuel Pressure Adjustment:4.7.1 Remove the bleeder valve. Install an adapter with British Parallel

threads to accept a 0300 psi fuel pressure gauge. Do not use jointcompound (pipe dope) on the adapter.

4.7.2 Turn the operation mode switch to HEAT. The burner will begin a 15-second pre-purge. Monitor the fuel pressure during the pre-purge andmake adjustments using the fuel pressure adjusting screw.

4.7.3 Turn the adjusting screw (located on the side of the fuel pump)clockwise to increase fuel pressure or counterclockwise to decreasefuel pressure until it is stable.Once the fuel pressure is set, proceed with air setting and adjustment.

O2 Content:A Combustion Analyzer, Smoke True Spot Tester and common handtools will be required for O2 content sampling.

4.7.4 Follow the combustion analyzer manufacturers instructions for pre-purge and exhaust sampling.

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Cub 400/700 Maintenance

4.7.5 Sample the exhaust gas. Exhaust O2 content must be 3 to 4% for

optimum performance and minimum soot production. Several samplesshould be taken as the heater warms. The final sample should betaken just before the heater reaches 160F.

Smoke Spot Sampling:4.7.6 Follow the smoke spot tester manufacturers instructions for accurate

exhaust sampling.4.7.7 Sample the burner exhaust for smoke. Smoke spot production must be

1 or less. Several samples should be taken as the heater warms. Thefinal sample should be taken just before the heater reaches 160F.Note: Higher O2 percentage (excess air settings) lowers sootproduction but raises stack temperature and reduces efficiency. LowerO2 percentage (inadequate air settings) increases efficiency andlowers stack temperature but may cause soot build-up. A burneroptimized for clean and efficient operation will have O2 levels of 3 to4% and a smoke spot value of 1 or less.

4.7.8 Loosen the air damper locking screws enough to provide movementfor adjustment.

4.7.9 Turn the operation mode switch to HEAT. The burner will begin a 15-second pre-purge followed by the ignition sequence.

4.7.10 Once the burner lights, sample the exhaust as outlined above. Adjustthe air damper until combustion parameters fall within the aboveoutlined values.

4.7.11 Lock the air damper in place by tightening the locking screws.

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Maintenance Cub 400/700

4.8 Fuel Blend Guide

Fuel Blend Guide

Temperature Range Fuel Blend

15 to 30F 80% #2 : 20% #1

0 to 15F 70% #2 : 30% #1

15 to 0F 50% #2 : 50% #1

below 15F 30% #2 : 70% #1

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Cub 400/700 Maintenance

4.9 Oil Burner Set-up Chart

4.10 Gas Burner Set-up Chart

CUB 400

1 2 3 4 5

Actual firing rate 5% Nozzle size

Pump pressure

Turbulator setting

(head setting)

Air damper setting

gph l/h gph psi bar

2.71 10.26 2.0 x 60 184 12.7 4.0 4.9

CUB 700

1 2 3 4 5

Actual firing rate 5% Nozzle size

Pump pressure

Turbulator setting

(head setting)

Air damper setting

gph l/h gph psi bar

5.14 19.4 4.0 x 60 165 11.4 4.0 4.0

Cub 400 Cub 700

NG LP NG LP

Air damper setting 3.8 3.8 3.6 3.6

Combustion head setting 4.5 4.5 4.0 4.0

Gas manifold pressure (in. wc) 2.15 2.9 2.6 4.0

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Maintenance Cub 400/700

4.11 Turbulator Setting (Head Setting)

To set the turbulator (head), carry out the following procedure.4.11.1 Shut down the machine and allow it to cool.4.11.2 Remove the burner assembly

cover.4.11.3 Loosen the nut (a).4.11.4 Turn screw (b) until the index

marker (c) is aligned with thecorrect number on the burnerset up chart.

4.11.5 Retighten the nut (a).4.11.6 Re-install the burner

assembly cover.

b

c

a

wcghi_gr003904

05

5 0

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Cub 400/700 Maintenance

Notes:

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Maintenance Cub 400/700

4.12 Checking and Adjusting the Gas Pressure

See Graphic: wcghi_gr003895To check the gas pressure, a manometer will be needed. To check thethe gas pressure, carry out the following procedure:

4.12.1 Shut down the machine and allow it to cool.4.12.2 Remove the large shroud covering the burner assembly.4.12.3 Locate the pressure test port (a).4.12.4 Insert a small screwdriver into the pressure test port and back off the

needle valve (b) two turns.4.12.5 Connect the hose of the manometer (c) to the pressure test port.4.12.6 Start the machine.4.12.7 With the burner firing, check the pressure reading on the manometer.

Adjust the gas pressure at the regulator (d):4.12.8 Remove the cap (e) from the regulator.4.12.9 Turn the screw (f) to adjust the pressure.4.12.10 Reinstall the cap.

Once the gas pressure is set:4.12.11 Shut down the machine.4.12.12 Remove the manometer tube from the pressure test port.4.12.13 Tighten the needle valve.

NOTICE: Do not overtighten the needle valve. Damage to the needlevalve will occur.

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Cub 400/700 Maintenance

a b

c

e

f

wcghi_gr003895

d

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Maintenance Cub 400/700

4.13 Checking and Adjusting the Electrode and Ionization Probe

See Graphic: wcghi_gr003894To adjust the electrode and the ionization probe, carry out the followingprocedure:

4.13.1 Remove the combustion head. See section Removing the CombustionHead.

4.13.2 Clean the head as necessary.4.13.3 Adjust the ionization probe (a) so that it is positioned from the mixing

plate as shown.4.13.4 Adjust the electrode (b) so that it is positioned from the mixing plate as

shown.NOTICE: On Cub 400 machines, when adjusting the electrode, keepas much distance between the electrode and the ionization probe aspossible. If the electrode is positioned too close to the ionization probe,the amplifier of the control box may be damaged.

45 mm

3740 mm

Cub 400

Cub 700

a

a

a

b

wcghi_gr003894

0- 0.58

6

0-0.5

40

3.7

23

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Cub 400/700 Maintenance

4.14 Checking Function of Ionization Probe

See Graphic: wcghi_gr003899The minimum amount of current necessary for the control module tooperate properly is 5 micro Amps (uA). This current is provided by theionization probe. To check the ionization current, carry out thefollowing procedure:

4.14.1 Shut down the machine and allow it to cool.4.14.2 Remove the cover from the burner assembly.4.14.3 Disconnect the red connector (a) in the wire between terminal 9 and

the ionization probe (c) .4.14.4 Connect an microammeter (b) in series as shown.4.14.5 Start the machine.4.14.6 With the burner firing check the meter reading. It must be above 5 mA.

a

a a

b

c

9

wcghi_gr003899

+

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Maintenance Cub 400/700

4.15 Changing Burner Orifice

See Graphic: wcghi_gr003896The burner is set up at the factory to burn natural gas. By changing theburner orifice, the burner can be set up to burn LP gas. Each orifice isstamped with the orifice size. To change the orifice:

4.15.1 Shut down the machine and allow it to cool.4.15.2 Remove the combustion head (a). See section

Removing the Combustion Head.4.15.3 Remove the natural gas orifice (b) (2.2 or 3.7).4.15.4 Install the LP gas orifice (c) (1.5 or 2.0).4.15.5 Affix the LP gas label (d) to the burner.4.15.6 Re-install the combustion head.

MachineOrifice marking

natural gas LP

Cub 400 2.2 1.5

Cub 700 3.7 2.0

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Cub 400/700 Maintenance

wcghi gr003896

c

ab

d

wcghi_tx000684gb.fm 47

Maintenance Cub 400/700

4.16 Transporting

See Graphic: wcghi_gr003905Cub 400/700 machines must be transported one of two ways. Themachines can be lifted and transported using the fork pockets or bymeans of an aerial lifting rig. NOTICE: DO NOT route straps or chains over the top of the machine.Failure to comply will damage the machine.

4.16.1 These machines are NOT designed to be towed with any vehicle. 4.16.2 Openings on the entire unit should be covered during transport to

avoid road debris and clutter. 4.16.3 All venting external to the machine must be removed prior to

transporting.4.16.4 Fork pockets on any side of the machine may be used.4.16.5 ALWAYS use the lifting point on the top of the machine when using an

aerial lifting rig.4.16.6 Only qualified riggers should attempt aerial lifting.

wcghi_tx000684gb.fm 48

Cub 400/700 Maintenance

4.17 Gas Analyzer Access Hole

See Graphic: wcghi_gr00393For analyzing the exhaust gas, drill an access hole as shown.

Return air

blower

Return air

blower

wcghi_gr003933

CUB 400

CUB 700

.375 DIA

1-1/2 in.

4 in.

11/16 in.

1-1/2 in.

.375 DIA

5 in.

3 in.

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Maintenance Cub 400/700

4.18 List of Abbreviations

Amp ampere (unit of electrical current)

asl above sea level

BTU British Thermal Unit

C Celsius (metric unit of temperature)

F Fahrenheit (unit of temperature)

ft2 square foot/square feet (measurement of area)

ft.lbs. foot pounds (unit of torque)

gph gallons per hour (unit of liquid flow)

GFI Ground Fault Interrupt(er) (protection device)

Hz Hertz (unit of frequency)

ID inner diameter

in. inch

kg kilogram

kilo-cal kilo-calorie (1000 calories) (metric unit of heat energy)

kPal kilo-Pascals (metric unit of pressure)

kW kilo-Watt (unit of electrical power)

lb. pound

m meter

mm millimeter (1/1000 of a meter)

psig pounds per square inch gauge (unit of pressure)

VAC Volts, Alternating Current

VDC Volts, Direct Current

VFD Varible Frequency Drive

HTF Heat Transfer Fluid

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Cub 400/700 Maintenance

4.19 Troubleshooting

Issue Possible Cause Description

The burner does not start The remote thermostat or thermostat plug is not inserted correctly.

Faulty cable or power supply

The over temperature limit has tripped

Insert the remote thermostat or thermostat plug. Check cable and power supply

Call Ground Heaters for service assistance

The burner starts, the flame does not ignite, the unit locks out

No fuel Worn burner nozzle Faulty electrodes Ionization probe faulty

Cad cell defective Burner control defective

Fill fuel tank Replace burner nozzle Replace electrodes Clean, adjust, or replace

ionization probe

Call Ground Heaters for service assistance

The burner starts, flame ignites, but the unit locks out

Incorrect fuel pressure Worn burner nozzle Incorrect air adjustment Ionization probe faulty

Cad cell defective Burner control defective

Increase fuel pressure Replace burner nozzle Readjust air supply Clean, adjust, or replace

ionization probe

Call Ground Heaters for service assistance

Combustion is poor or noisy Lack of fresh air to burner

Ensure there is an adequate air supply

Call Ground Heaters for service assistance

Excessive blower noise Defective motor bearings Mounting base not

secure Misaligned pulleys Damaged wheel

Replace motor bearings Tighten mounting

hardware Correct alignment Replace wheel

Fan inoperative Open circuit breaker Loose or disconnected

wiring Defective motor Broken belt(s)

Reset circuit breaker Check wiring and repair

as needed Replace motor Replace belt(s)

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Maintenance Cub 400/700

Motor overheating Belt slippage Over or under voltage

Adjust belt tension Check power supply

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Cub 400/700 Maintenance

4.20 Wiring Diagram

115 V60 Hz

230 V60 Hz

SM Thermal protectorTH Thermostat

BR BurnerIR SwitchM Fan motorMR Terminal boardPT Thermostat socket

A1

TR

SM 95

96

IR

L

STB

TH

MR

PT

M

LIM FAN

2 2 1 2 1

C C

642

531

23

FR Heated filter

L2 FR

PB Burner socket ( 115V )

N L1

PB

23

ie

5431 2 10 11 12876 9

U1/T4UT1

WH

T

U1 V1 W1

LINESINGLE-PHASE-MOTOR

W2 U2 V2

WHT

WHT

RED

RED

CAPACITOR

W2 U2 V2

V1U1 W1

REVERSAL OF ROTATION

LINESINGLE-PHASE-MOTOR

WHT RED

RED WHT

CAPACITOR

WH

T

WH

T

BLK

BLK

WH

T

BLK

WH

TW

HT

BLK

BLK

BR

N

BR

N

BLU

wcghi_gr004497

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Maintenance Cub 400/700

wcghi_tx000684gb.fm 54

Cub 400/700 Technical Data

5. Technical Data

5.1 Cub 400 Technical Data

Item Number: 0620206 0620211 0620212

Cub 400

Dimensions LxWxH in (cm) 94 x 34 x 52(241x86x132)

95 x 34 x 75(241x86x191)

95 x 34 x 52(241x86x132)

Weightwith fuelwithout fuel

lbs. (kg)---

585 (265)1373 (623)898 (407)

---585 (265)

Gross input BTU/hr 380,000 380,000 380,000

Net output BTU/hr 304,000 304,000 304,000

Efficiency % 80 80 80

Air output volume cfm 5200 5200 5200

Static pressure in. wc 1.77 1.77 1.77

Power requirements VAC,Amps, Hz;

Plug

115, 15, 60; NEMA 5-15

and230, 20, 60;NEMA L6-20

115, 15, 60; NEMA 5-15

and230, 20, 60;NEMA L6-20

115, 15, 60; NEMA 5-15

and230, 20, 60;NEMA L6-20

Blower motor VAC,Amp 230, 10 230, 10 230, 10

Vent pipe diameter (nominal) in. (cm) 8 (20) 8 (20) 8 (20)

Burner nozzle (solid spray) gph --- 2.0, 60 2.0, 60

Fuel pressure psig (bar) --- 184 (12.7) 184 (12.7)

Fuel consumption gph (l/h) --- 2.71 (10.26) 2.71 (10.26)

Air shutter (factory setting) 3.8 4.9 4.9

Fuel capacity gal. (l) --- 67 (254) ---

Hours of operation per tank --- 24.72* ---

wcghi_td000198gb.fm 55

Technical Data Cub 400/700

* Longer run time are achieved when using the machine indoors

NG LPOrifice 2.2 1.5

Supply fuel pressure (max.) in. wc 10.0

Manifold pressure (operating) in. wc 2.15 2.9

Fuel consumption ft3/hr(m3/hr)

380(10.76) ---

gph(l/hr) ---

4.15 (15.7)

wcghi_td000198gb.fm 56

Cub 400/700 Technical Data

5.2 Cub 700 Technical Data

* Longer run time are achieved when using the machine indoors

Item Number: 0620208 0620213 0620207

Cub 700

Dimensions LxWxH in (cm) 117x45x67(297x114x170)

119x45x88(302x114x224)

119x45x67(302x114x170)

Weight: with fuel without fuel

lbs. (kg) ---963 (436.8)

2508.5 (1138)1494 (677)

---963 (437)

Gross input BTU/hr 720,000 720,000 720,000

Net output BTU/hr 576,000 576,000 576,000

Efficiency % 80 80 80

Air output volume cfm 7700 7700 7700

Static pressure in. wc 2.09 2.09 2.09

Power requirements VAC,Amps, Hz;

Plug

115, 15, 60; NEMA 5-15

and230, 30, 60;NEMA L6-30

115, 15, 60; NEMA 5-15

and230, 30, 60;NEMA L6-30

115, 15, 60; NEMA 5-15

and230, 30, 60;NEMA L6-30

Blower motor VAC, Amp 230, 13 230, 13 230, 13

Vent pipe diameter (nominal) in. (cm) 10 (25.4) 10 (25.4) 10 (25.4)

Burner nozzle (soilid spray) gph --- 4.0 60 4.0 60

Fuel pressure psig(bar) ---

165(11.4)

165(11.4)

Fuel consumption gph(lph) ---

5.13(19.4)

5.13(19.4)

Air shutter (factory setting) 4.3 4.4 4.4

Fuel capacity gal. (l) --- 145 (549) ---

Hours of operation per tank 28.26* ---

NG LPOrifice 3.7 2.0

Supply fuel pressure (max) in. wc 10

Manifold pressure (operating) in. wc 2.7 4.0

Fuel consumption ft3/hr(m3/hr)

720 ---

gph (l/hr) --- 7.87

wcghi_td000198gb.fm 57

Technical Data Cub 400/700

wcghi_td000198gb.fm 58

1. Foreword 32. Safety Information 52.1 Operating Safety 62.2 Operator Safety while using Combustion Burners 72.3 Service Safety 82.4 Safety and Operating Labels 10

3. Operation 113.1 System Description 113.2 Installing the Lift Bar 123.3 Machine Location 133.4 System Component Locations 143.5 Control Panel 153.6 Preliminary Checks 163.7 Starting the Machine 173.8 Shutting Down the Machine 183.9 Using the Remote Thermostat 193.10 Adjusting the Recirculation System 203.11 Suggested Venting 223.12 Connecting the Main Electric Power Supply 243.13 Installing the Plenums 253.14 Checking the Burner Air Setting 26

4. Maintenance 274.1 Periodic Maintenance Schedule 274.2 Changing and Adjusting the Supply Blower Belt 284.3 Replacing the Oil Burner Nozzle 304.4 Checking and Adjusting the Oil Burner Electrodes 324.5 Checking the Fuel Pressure 344.6 Changing the Fuel Heater Filter 354.7 OIl Burner Adjustments 364.8 Fuel Blend Guide 384.9 Oil Burner Set-up Chart 394.10 Gas Burner Set-up Chart 394.11 Turbulator Setting (Head Setting) 404.12 Checking and Adjusting the Gas Pressure 424.13 Checking and Adjusting the Electrode and Ionization Probe 444.14 Checking Function of Ionization Probe 454.15 Changing Burner Orifice 464.16 Transporting 484.17 Gas Analyzer Access Hole 494.18 List of Abbreviations 504.19 Troubleshooting 514.20 Wiring Diagram 53

5. Technical Data 555.1 Cub 400 Technical Data 555.2 Cub 700 Technical Data 57

1. Foreword2. Safety Information2.1 Operating Safety2.2 Operator Safety while using Combustion Burners2.3 Service Safety2.4 Safety and Operating Labels3. Operation3.1 System Description3.2 Installing the Lift Bar3.3 Machine Location3.4 System Component Locations3.5 Control Panel3.6 Preliminary Checks3.7 Starting the Machine3.8 Shutting Down the Machine3.9 Using the Remote Thermostat3.10 Adjusting the Recirculation System3.11 Suggested Venting3.12 Connecting the Main Electric Power Supply3.13 Installing the Plenums3.14 Checking the Burner Air Setting4. Maintenance4.1 Periodic Maintenance Schedule4.2 Changing and Adjusting the Supply Blower Belt4.3 Replacing the Oil Burner Nozzle4.4 Checking and Adjusting the Oil Burner Electrodes4.5 Checking the Fuel Pressure4.6 Changing the Fuel Heater Filter4.7 OIl Burner Adjustments4.8 Fuel Blend Guide4.9 Oil Burner Set-up Chart4.10 Gas Burner Set-up Chart4.11 Turbulator Setting (Head Setting)4.12 Checking and Adjusting the Gas Pressure4.13 Checking and Adjusting the Electrode and Ionization Probe4.14 Checking Function of Ionization Probe4.15 Changing Burner Orifice4.16 Transporting4.17 Gas Analyzer Access Hole4.18 List of Abbreviations4.19 Troubleshooting4.20 Wiring Diagram5. Technical Data5.1 Cub 400 Technical Data5.2 Cub 700 Technical Data