D-1000B HEATER Outdoor Use Only OPERATIONS & MAINTENANCE MANUAL ISO 9001: 2000 Registered Quality Management System 33 Kings Highway, Orangeburg, NY 10962 DHS Manual Part Number: 1006395 Revision Date: 01 APRIL 2010 Phone: 845-359-6066 Fax: 845-365-2114 Hotline: 800-977-3647 Web: www.drash.com Email: drash@drash.
Revision History Date Revision Description 03/31/10 1002811 Original Issue. 01 APR 10 1006395 Revised Manual Part Number. Revised Section 1, General, Section 4, Operations, Section 5, Maintenance, and Repair Procedures, and Section 8, Illustrated Parts Breakdown (Rev B). This manual contains privileged and confidential information proprietary to DHS Systems, LLC and is intended solely for use by its customers.
TABLE OF CONTENTS 1. 2. 3. 4. 5. GENERAL................................................................................................................................................... 1-1 1.1 Scope ................................................................................................................................................. 1-1 1.2 Receipt of the D-1000B Heater .......................................................................................................... 1-1 1.
6. 7. 8. 9. 5.4.9 Removal, Installation and Gap Adjustment Procedures for Ignition Electrodes ..................... 5-14 5.4.10 Removal and Installation of the Ignition Control Assembly..................................................... 5-15 5.4.11 Removal and Installation of H.T. Ignition Cables .................................................................... 5-16 5.4.12 Removal and Installation of the Photocell ...............................................................................
D-1000B Heater Operations & Maintenance 1. GENERAL 1.1 Scope This Operator’s Manual describes the safe operation and field maintenance of the DRASH D-1000B heater. 1.2 Receipt of the D-1000B Heater Once the heater has been uncrated, immediately write the model and serial number in the space provided below. Model Number__________________ Serial Number_____________________ Inspect for signs of obvious or concealed freight damage.
D-1000B Heater Operations & Maintenance Maintenance Access Panel Exhaust Stack Heat Outlet Pre-Heated Fuel Filter Accessory Bag Compartment Manufacturer Data Plate and DRASH Serial Number Location Top Cover Air Intake Skid Body Control Panel Power Cord Fuel Cap / Tank Accessory Bag Compartment Figure 1-2 - D-1000B Heater GENERAL 1-2 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.
D-1000B Heater Operations & Maintenance ACCESSORY BAG Figure 1-3 – Heater Duct Connection 1.4 1.4.1 Major Components Shell The D-1000B Heater features a two-piece, molded polymer composite outer body that is rust-resistant and shock proof. The upper cover quickly detaches for service to the combustion chamber, electric motor, or fuel pump assembly by removing four pins as shown in Figure 5-1. 1.4.2 Fuel Tank The fuel tank is made of steel and is corrosion proof.
D-1000B Heater 1.4.7 Operations & Maintenance Performance With a watertight control panel, the D-1000B heater was designed to operate in all different types of environmental conditions. A pre-heated fuel filter allows heater to work continuously in extreme low temperatures. When operating the D-1000B heater, the noise level when measured at a distance of 3 feet (0.92 meters) from the control panel is 76dB.
D-1000B Heater Operations & Maintenance 2. SAFETY 2.1 Scope This chapter contains general information for the safe operation and maintenance of the D-1000B heater. The cautions and warnings point out known conditions that are potentially hazardous. However, no manual can cover every possible situation. If in doubt, contact DHS. DHS Systems Contact Information Before calling DHS for assistance, please identify the heater Phone: 800-977-3647 by its DRASH assigned serial number, (see Section 1.
D-1000B Heater 2.4.1 Operations & Maintenance Heater The following safety precautions should be observed: The D-1000B heater must be used OUTDOORS ONLY. Always follow local ordinances and codes when using this heater. Always remove the fabric covers from each end of the heater before operating. Operate the heater outdoors; upright with the exhaust stack attached and away from flammable or explosive materials (the minimum distance must be 6.5 feet (2 meters).
D-1000B Heater Operations & Maintenance 3. STORAGE & TRANSPORT 3.1 Scope The D-1000B heater is designed for outdoor use only. No special packaging is required for storage or transport. 3.1.1 Transport and Storage IMPORTANT The owner of the Heater is responsible for investigating local ordinances, applicable laws, codes and regulations concerning the transportation of JP8 or Diesel fuel. Before the D-1000B heater is transported or placed in storage, the heater must be totally cooled off.
D-1000B Heater Operations & Maintenance THIS PAGE INTENTIONALLY LEFT BLANK STORAGE & TRANSPORT 3-2 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.
D-1000B Heater Operations & Maintenance 4. OPERATIONS 4.1 General The following chapter contains general information for operating the D-1000B heater. 4.2 CAUTION Outdoor Use Only Control Panel Operation of the D-1000B heater requires the usage of the control panel shown in Figure 4.1 1 2 3 4 5 I II Figure 4-1 - Control Panel Layout Table 4-1 – Control Panel Item 1 2 3 4 5 4.
D-1000B Heater Operations & Maintenance Start up procedures for Normal Operation (Cont) NOTE When the heater is started for the first time or is started after the fuel tank has been completely emptied, the flow of fuel to the burner may be impaired by air in the system. In this case, the control box will cut out the heater and it will be necessary to restart the starting procedures once or twice by depressing the reset button (1). 10.
D-1000B Heater 4.5 Operations & Maintenance Shut Down Procedure 1. Place the power switch (2) to the OFF (0) position or if used set the thermostat to the lowest setting. By placing the power switch in the OFF (0) position or setting the thermostat to the lowest setting, the flame will go out, but the fan continues to spin for approximately 90 seconds cooling the combustion chamber. CAUTION Surfaces and pieces may be hot. 2. 3. 4. 5. 6. 7. 4.6 Remove the exhaust stack and heater duct.
D-1000B Heater Operations & Maintenance THIS PAGE INTENTIONALLY LEFT BLANK OPERATIONS 4-4 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.
D-1000B Heater Operations & Maintenance 5. MAINTENANCE, and REPAIR PROCEDURES 5.1 General This chapter contains general information for operator-level, qualified personnel. A qualified person is one who is familiar with this manual, the operation of the D-1000B heater; the hazard involved in its operation and maintenance, and has been certified by the DHS Training Program. This chapter also describes the procedures for both periodic and daily maintenance.
D-1000B Heater 5.2.4 Operations & Maintenance Annual Maintenance Check all nuts, bolts, fittings, and connections for looseness. Tighten as required. Clean or replace the fuel filter. Drain and flush the fuel tank. Remove burner assembly, clean, and adjust electrode setting. Remove and replace fuel nozzle. 5.
D-1000B Heater Operations & Maintenance NOTE! In the following Repair Procedures, the numbers in parentheses refer to item numbers listed in Chapter 8, Illustrated Parts Breakdown diagram on page 8-1 or otherwise noted. 5.4.2 Removal and Installation Electric Motor Assembly 5.4.2.1 Removal procedures: 1. Disconnect power cord and allow heater to cool. 2. Remove the four quick release pins as shown in Figure 5-1; remove top exterior cover. 3.
D-1000B Heater Operations & Maintenance Electric Motor Removal Procedures (Cont) 11. Slide the plastic cover off the capacitor (11) and disconnect two female terminal couplers. (See Figure 5-3). 12. Using a 13mm socket wrench, loosen and remove the mount nut and lock washer; remove capacitor (11). 13. Using an 8mm nut driver, loosen and remove four screws (78) securing the motor assembly plate (12). 14. Remove the electric motor (10) from the lower heat shield assembly (6). 15.
D-1000B Heater Operations & Maintenance IMPORTANT! Fan blade must be positioned correctly on the electric motor shaft to ensure correct balance of the fan. 11. Using a 4mm Allen wrench, tighten set screw (92) to secure the fan blade (15) in place. 12. Feed the electric motor power harness through lower heat shield into the control panel. 13.
D-1000B Heater Operations & Maintenance 5.4.3 Removal and Installation of the Condenser (Capacitor) 5.4.3.1 Removal procedures: 1. Disconnect power cord from the power source. Allow heater to cool. 2. Using an 8mm nut driver, remove two middle screws from the maintenance access panel (7) and loosen four corner screws (78). 3. Slide maintenance access panel (7) rearward. 4. Slide the plastic cover off the capacitor (11) and disconnect two female terminal couplers as shown in Figure 5-3. 5.
D-1000B Heater Operations & Maintenance 5.4.4 Removal and Installation of Fuel Filter 5.4.4.1 Removal procedures: 1. Disconnect power cord from the power source. Allow heater to cool. 2. Using a 19mm open end wrench, loosen and remove pre-heat probe from bottom of fuel filter assembly 3. Using a 10mm open end wrench, remove bolt, washer and o-ring from top of fuel filter assembly. 4. Using a suitable container, collect the fuel when removing the fuel filter assembly. 5.
D-1000B Heater Operations & Maintenance 5.4.5 Removal and Installation of Fuel Pump Assembly 5.4.5.1 Removal Procedures: 1. Disconnect power cord from power source and allow heater to cool. 2. Remove four quick release pins and remove top cover (see Figure 5-1). 3. Using a 8mm nut driver, remove the upper heat shield (05) by removing six screws (79) and two sheet metal screws (78); remove heat shield and set aside 4. Disconnect the fuel solenoid leads. 5.
D-1000B Heater Operations & Maintenance 71A 71B 71 65 73 72 70 74 19 22A Return to Tank 22B Supply from Fuel Filter 22B Fuel Supply 22A Fuel Return Figure 5-6 – Fuel Pump 5.4.6 Removal, Inspection and Installation of Electric Motor / Fuel Pump Coupling 5.4.6.1 Removal Procedures; 1. Disconnect power cord from power source and allow heater to cool. 2. Remove four quick release pins and remove top cover (see Figure 5-1). 3.
D-1000B Heater 5.4.6.2 Operations & Maintenance Inspection Procedures: 1. Remove the fuel pump plastic coupler (74) (see Figure 5-6). 2. Inspect the plastic coupler (74) for wear, cracks, chips or any other defects to render unserviceable condition. 3. Replace or install (if required) the plastic coupler (74) by aligning flat of shaft with tab inside the coupler. 5.4.6.3 Installation Procedures 1.
D-1000B Heater Operations & Maintenance 5.4.7 Removal and Installation of Fuel Solenoid 5.4.7.1 Removal Procedures: 1. Disconnect power cord and allow heater to cool. 2. Using an 8mm nut driver, remove two middle screws from the maintenance access panel (7) and loosen four corner screws (78). 3. Slide maintenance access panel (7) rearward. 4. Disconnect the fuel solenoid wire leads (red, white, and yellow with green stripe). 5.
D-1000B Heater Operations & Maintenance 5.4.8 Removal and Installation of Fuel Nozzle 5.4.8.1 Removal procedures: 1. Disconnect power cord from power source and allow heater to cool. 2. Remove four quick release pins and remove top cover (see Figure 5-1). 3. Using a 8mm nut driver, remove the upper heat shield (05) by removing six screws (79) and two sheet metal screws (78); remove heat shield and set aside. 4. Disconnect ground wire (103) from terminal lug (94) on combustion head (40). 5.
D-1000B Heater Operations & Maintenance Fuel Nozzle Installation Procedures (Cont) 7. Reconnect ground wire (103) to the terminal lug (94) on combustion head (40). 8. Install heat shield (05). Using an 8mm nut driver install and tighten six screws (79) and two sheet metal screws (78) to secure heat shield. 9. Install the top cover and four quick release pins as shown in Figure 5-1. 10. Test heater in accordance with the operations manual. (See Chapter 6).
D-1000B Heater Operations & Maintenance 5.4.9 Removal, Installation and Gap Adjustment Procedures for Ignition Electrodes 5.4.9.1 Electrode Removal procedures: 1. Disconnect power cord from power source and allow heater to cool. 2. Remove four quick release pins and remove top cover (see Figure 5-1). 3. Using an 8mm nut driver, remove the upper heat shield (05) by removing six screws (79) and two sheet metal screws (78); remove heat shield and set aside. 4. Disconnect both H.T.
D-1000B Heater Operations & Maintenance 5.4.10 Removal and Installation of the Ignition Control Assembly 5.4.10.1 Removal procedures: 1. Disconnect power cord from power source and allow heater to cool. 2. Remove four quick release pins and remove top cover (see Figure 5-1). 3. Using a 8mm nut driver, remove the upper heat shield (05) by removing six screws (79) and two sheet metal screws (78); remove heat shield and set aside. 4.
D-1000B Heater 5.4.10.2 Operations & Maintenance Installation procedures: 1. Install new ignition control assembly (53) onto control panel assembly (29). 2. Using a Phillips head screwdriver, install and tighten two screws (88) securing ignition control assembly (53) to control panel assembly (29). 3. Reconnect two H.T. ignition cables (64) to the ignition control assembly as shown in Figure 5-11. 4. Reconnect four quick disconnect connectors to ignition control assembly. 5.
D-1000B Heater Operations & Maintenance 5.4.12 Removal and Installation of the Photocell 5.4.12.1 Removal procedures: 1. Disconnect power cord from power source and allow heater to cool. 2. Remove four quick release pins and remove top cover (see Figure 5-1). 3. Using a 8mm nut driver, remove the upper heat shield (05) by removing six screws (79) and two sheet metal screws (78); remove heat shield and set aside. 4.
D-1000B Heater Operations & Maintenance Installation of Photocell procedures (Cont) 4. Slide control panel assembly (29) back into base (30). Ensure that electrical wires do not get pinched when sliding control panel assembly into base. 5. Using a Phillip head screwdriver, install and tighten two screws (81) securing control panel assembly (29) to base. 6. Install upper heat shield (05). 7. Using an 8mm nut driver, install and tighten six screws (79) and two sheet metal screws (78). 8.
D-1000B Heater 5.4.13.2 Operations & Maintenance Installation procedures: 1. Install new pressure switch (43). 2. Using a Philips head screwdriver, install and tighten two screws (100) through bracket (99) securing pressure switch (43). 3. Connect two silicone hoses (31) (see Figure 5-13) to the side of the pressure switch (43). 4. Connect the red and white wire connector to the back of the pressure switch (43) (see Figure 5-13). 5. Install pressure switch and bracket assembly into base (30). 6.
D-1000B Heater Operations & Maintenance THIS PAGE INTENTIONALLY LEFT BLANK MAINTENANCE, and REPAIR PROCEDURES 5-20 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.
D-1000B Heater Operations & Maintenance 6. TEST PROCEDURES 6.1 Maintenance Repair Test Procedures 1. Remove all protective fabric covers and accessories bag (if attached) from heater. 2. Install exhaust stack. 3. Add fuel if needed. 4. Connect power cord to power source. 5. Start and run heater outdoors in accordance to start up procedures (see Section 4.3) for ten minutes. 6. Service heater if any problems and or leaks are noted. 6.2 Thermostat / CO Detector Control Device Test 1.
D-1000B Heater Operations & Maintenance Handle Filter Paper Filter Paper Slot Knurled Knob Sampling Tube Figure 6-1 - Smoke Tester Table 6-1 - Smoke Spot SMOKE SPOT COLOR 6.4 CAUSE Light Gray Smoke Good – no adjustment required Yellow or Blue Smoke Contaminated or Bad Fuel White Smoke Excessive Air Flow; No or Low Fuel Pressure, Low Fuel Black Smoke (Excessive) Fuel Pressure too High or Restrictive Air Flow (Lack of Air) Fuel Pressure Test 1. Refer to Section 5.4.
D-1000B Heater Operations & Maintenance NOTE Always start adjustments low and then increase 10. Disconnect pressure gauge hose by pushing down on the black tab at the M10 MNPT elbow and pulling hose out. There may be pressure and or fuel still in the hose; use caution and have a rag or container to collect fuel. CAUTION Pressure gauge and hose may be under pressure. Use caution when depressing black tab and removing hose 11. Loosen and remove the M10 MNPT elbow from fuel pump (70). 12.
D-1000B Heater Operations & Maintenance Remove Plug From “P” Port for Test Elbow Connection Adjustment Screw Plug Clockwise to Increase Counter- Clockwise to Decrease Figure 6-2 - Pressure Gauge Tester TEST PROCEDURES 6-4 No rights are conveyed except as indicated in the legend on the inside front cover of this document.
D-1000B Heater Operations & Maintenance 7. TROUBLESHOOTING 7.1 General This section provides a systematic approach to locating and correcting malfunctions of the D-1000B heater. The section is arranged according to the symptoms of the problem. The steps have been arranged to perform the easiest checks first and to prevent further damage when trouble shooting a disabled unit. WARNING! Tools, equipment, clothing and your body must stay clear of rotating parts and electrical connectors.
D-1000B Heater Operations & Maintenance SYMPTOM / FAULT CORRECTIVE ACTION CAUSE Motor starts, no ignition or cuts out Ignition Control Assembly defective Check connection of H.T.
D-1000B Heater Operations & Maintenance 8. ILLUSTRATED PARTS BREAKDOWN 8.1 D-1000B Heater Exploded Detail To Fuel Pump From Fuel Pump to Burner Head Return From Fuel Pump to Tank Figure 8-1 - D-1000B Heater Detail ILLUSTRATED PARTS BREAKDOWN 8-1 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.
D-1000B Heater 8.2 Operations & Maintenance Burner Head and Nozzle Assembly Exploded View 40 91 94 To Ground Terminal Board 103 63 61 85 64 59 60 62 65 91 93 66 Figure 8-2 – Burner Head and Nozzle Assembly Detail ILLUSTRATED PARTS BREAKDOWN 8-2 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.
D-1000B Heater 8.3 Operations & Maintenance Fuel Pump Assembly Exploded View 71A 71B 71 65 73 72 70 74 19 22A Return to Tank 22B Supply from Fuel Filter 22B Fuel Supply 22A Fuel Return Figure 8-3 – Fuel Pump Assembly Detail ILLUSTRATED PARTS BREAKDOWN 8-3 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.
D-1000B Heater 8.4 Operations & Maintenance Pre-Heated Fuel Filter Exploded View 95 75 96 21 76 21 21 21 Figure 8-4 – Pre-Heated Fuel Filter Assembly Detail ILLUSTRATED PARTS BREAKDOWN 8-4 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.
D-1000B Heater 8.5 Operations & Maintenance Control Panel Assembly Exploded View 87 85 47 77 46 86 45 88 85 53 44 41 54 49 85 55 58 57 97 56 98 Figure 8-5 – Control Panel Assembly Detail ILLUSTRATED PARTS BREAKDOWN 8-5 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.
D-1000B Heater 8.
D-1000B Heater Operations & Maintenance Parts List for Exploded View of D-1000B Heater Continued: Table 8-6 – Parts List (Cont) ITEM DHS PN DHS PART DESCRIPTION 26 1003803 Cap, Fuel w/level indicator 1 27 1008418 Plug, Drain M16 x 1.
D-1000B Heater Operations & Maintenance Parts List for Exploded View of D-1000B Heater Continued: Table 8-6 – Parts List (Cont) ITEM DHS PN 54 1003831 Light, Power Indicating 1 55 1003832 Cord, Power 1 56 1003833 Cap, w/lanyard 1 57 1003834 Plug, Thermostat (remote) 1 58 1003835 Switch, Power, 3-Position 1 59 1008427 Nozzle 0.
D-1000B Heater Operations & Maintenance Parts List for Exploded View of D-1000B Heater Continued: Table 8-6 – Parts List (Cont) ITEM DHS PN DHS PART DESCRIPTION Qty.
D-1000B Heater 8.
D-1000B Heater 8.8 Operations & Maintenance Skid Body Assembly, Heater D-1000B 7 1 6 2 5 4 3 Figure 8-8 – Skid-Body Assembly Detail ITEM DHS PN 1 1002778 Base, Heater D-1000B, Plastic 1 2 1002807 Strip, Wear, Alum, 2 “ Wide x 42.5” Long 2 3 1004781 Screw, Cap Flat Hd, ¼”-20 x ¾”L, 18-8 SS 6 4 1002808 Rod, Carbon Steel, ½”OD x 20-1/2”L 1 5 H100088 Wheel, 0.
D-1000B Heater 8.9 Operations & Maintenance D-1000B Heater Accessories 8 9 10 1 2 3 4 7 6 5 Figure 8-9 – Heater Accessories Details ITEM DHS PN 1 1003581 2 T295157G 3 DHS PART DESCRIPTION Qty. Heater Sub Assembly, Skid Body & Heater 1 Cap, Duct, 12.
D-1000B Heater 8.10 Operations & Maintenance Wiring Schematic Figure 8-10 – Wiring Schematic ILLUSTRATED PARTS BREAKDOWN 8-13 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.
D-1000B Heater Operations & Maintenance Wiring Schematic (Cont) Table 8-10 – Wiring Schematic Key KEY AP TA ST FU LM EV1 RV IT FO CO MV FUA AT PA ILLUSTRATED PARTS BREAKDOWN CODE Control Box Room Thermostat Plug Electric Pilot Lamp Fuse Overheat Thermostat Solenoid Valve Control Transformer H.V. Photocell Condenser Fan Motor Fuse Transformer Air Pressure Switch 8-14 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.
D-1000B Heater Operations & Maintenance 9. WARRANTY DHS SYSTEMS LLC LIMITED WARRANTY DHS Systems LLC provides a limited warranty that all DRASH (Deployable Rapid Assembly Shelter) products shall be free from defects in materials and workmanship for the period of time shown in the Warranty Schedule below.
D-1000B Heater 9.
D-1000B Heater Operations & Maintenance (fold) Return Address: Place Stamp Here DHS Logistics 33 Kings Highway Orangeburg, New York 10962 (fold) WARRANTY 9-3 DHS SYSTEMS LLC No rights are conveyed except as indicated in the legend on the inside front cover of this document.
