CH 5000 - Wacker Neuson

OPERATOR’S MANUAL 

0 1 7 1 7 3 2 E N 

Cross-Heater 

CH 5000 

0171732en 001 

1107

CH 5000 Table of Contents 

1. Foreword 5 

2. Safety Information 7 

2.1 Operating Safety .................................................................................. 8 

2.2 Operator Safety while using Generators .............................................. 9 

2.3 Operator Safety while using Combustion Burners ............................. 10 

2.4 Maintenance Safety ............................................................................ 10 

2.5 Label Locations .................................................................................. 12 

2.6 Safety and Operating Labels .............................................................. 13 

3. Operation 21 

3.1 System Description ............................................................................ 21 

3.2 System Component Locations ........................................................... 22 

3.3 Control Panel ...................................................................................... 23 

3.4 Pre-Season Start-up Preparation ....................................................... 24 

3.5 Positioning the Machine ..................................................................... 25 

3.6 Preliminary Checks ............................................................................ 26 

3.7 Starting the Generator ........................................................................ 27 

3.8 Starting the Machine .......................................................................... 28 

3.9 Warming the Hoses ............................................................................ 29 

3.10 Unwinding and Positioning the Hoses ................................................ 30 

3.11 Using the Remote Manifolds .............................................................. 31 

3.12 Changing Fuel Sources ...................................................................... 32 

3.13 Monitoring the Operating Parameters ................................................ 34 

3.14 Clearing a Low Level Fault ................................................................. 35 

3.15 Filling the HTF Reservoir .................................................................... 36 

3.16 Shutting Down the Machine at End of Day ......................................... 37 

3.17 Shutting Down and Restarting the Machine During Operation ........... 38 

3.18 Rewinding the Hoses ......................................................................... 39 

3.19 Shutting Down the Generator ............................................................. 40 

3.20 Activating the RMS Service ................................................................ 41 

3.21 Testing the RMS Communications ..................................................... 41 

3.22 Operating the RMS 6000 .................................................................... 42 

4. Maintenance 43 

3

Table of Contents CH 5000 

4.1 Periodic Maintenance Schedule ..........................................................43 

4.2 Installing the NG/LP Burner .................................................................44 

4.3 Installing the Diesel Burner .................................................................46 

4.4 Setting Up the NG/LP Burner ..............................................................47 

4.5 Adjusting the Fuel Pressure ................................................................48 

4.6 Adjusting the Burner Air Settings ........................................................50 

4.7 Verifying the Burner Combustion ........................................................51 

4.8 Changing the Genset Oil and Filter .....................................................53 

4.9 Replacing the Genset Fuel Filter .........................................................54 

4.10 Cleaning the HTF Strainer Basket .......................................................56 

4.11 Storing the Machine ............................................................................58 

4.12 List of Abbreviations ............................................................................59 

4.13 Troubleshooting ...................................................................................60 

4.14 Electrical Schematics ..........................................................................62 

5. Technical Data 66 

5.1 CH5000 Technical Data ......................................................................66 

wcghi_bo0171732en_001TOC.fm 4

1. Foreword 

wcghi_tx000001gb diesel.fm 5 

Foreword 

This manual provides information and procedures to safely operate 

and maintain this Ground Heaters ® , Inc. model. For your own safety 

and protection from injury, carefully read, understand and observe the 

safety instructions described in this manual. 

Keep this manual or a copy of it with the machine. If you lose this 

manual or need an additional copy, please contact Ground Heaters ® , 

Inc. This machine is built with user safety in mind; however, it can 

present hazards if improperly operated and serviced. Follow operating 

instructions carefully! If you have questions about operating or 

servicing this equipment, please contact Ground Heaters ® , Inc. 

The information contained in this manual was based on machines in 

production at the time of publication. Ground Heaters ® , Inc. reserves 

the 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 any 

means, electronic or mechanical, including photocopying, without 

express written permission from Ground Heaters ® , Inc. 

Any type of reproduction or distribution not authorized by Ground 

Heaters ® , Inc. represents an infringement of valid copyrights and will 

be prosecuted. We expressly reserve the right to make technical 

modifications, even without due notice, which aim at improving our 

machines or their safety standards.

wcghi_tx000001gb diesel.fm 6 

Foreword

CH 5000 Safety Information 

2. Safety Information 

DANGER 

WARNING 

CAUTION 

This manual contains DANGER, WARNING, CAUTION, NOTICE and 

NOTE callouts which must be followed to reduce the possibility of 

personal injury, damage to the equipment, or improper service. 

This is the safety alert symbol. It is used to alert you to potential 

personal injury hazards. Obey all safety messages that follow this 

symbol to avoid possible injury or death. 

DANGER indicates a hazardous situation which, if not avoided, will 

result in death or serious injury. 

WARNING indicates a hazardous situation which, if not avoided, could 

result in death or serious injury. 

CAUTION indicates a hazardous situation which, if not avoided, could 

result in minor or moderate injury. 

NOTICE: Used without the safety alert symbol, NOTICE indicates a 

hazardous situation which, if not avoided, could result in property 

damage. 

Note: Contains additional information important to a procedure. 

wcghi_si000216gb.fm 7

Safety Information CH 5000 

2.1 Operating Safety 

WARNING 

Familiarity and proper training are required for the safe operation of 

this machine. Machines operated improperly or by untrained personnel 

can be dangerous. Read the operating instructions contained in both 

this 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 someone 

familiar with the machine before being allowed to operate it. 

NEVER run the machine indoors or in an enclosed area unless 

adequate ventilation, through such items as exhaust fans or hoses, is 

provided. Exhaust gas from the genset and from the burner contains 

carbon monoxide, a deadly poison. Exposure to carbon monoxide 

WILL KILL YOU IN MINUTES. 

Danger of Electrocution! 

Danger of electrocution or severe electrical shock is present 

throughout the generator when the engine is running! Read all safety 

DANGER 

notes contained in this manual before operating or servicing this 

equipment. 

Only a trained electrician, familiar with this equipment, should attempt 

repairs to the generator! Test procedures which require that the 

generator be running must be performed using extreme caution. 

This machine is built with user safety in mind; however, like any 

electrical device it can present serious hazards if improperly operated 

and serviced. Follow instructions carefully! Should questions arise 

during operation or service of this equipment, contact your local 

Ground Heaters dealer. 

2.1.1 NEVER start a unit in need of repair. 

2.1.2 NEVER transport people in or on the machine. 

2.1.3 NEVER run the machine in areas that contain flammable objects, 

fuels, or products that produce flammable vapors. 

2.1.4 Keep unauthorized personnel, children, and pets away from the 

machine. 

2.1.5 ALWAYS be sure the machine is on a firm, level surface and will not 

tip, roll, slide, or fall while operating. 

2.1.6 ALWAYS operate machine with all safety devices and guards in place 

and in working order. DO NOT modify or defeat safety devices. DO 

NOT operate machine if any safety devices or guards are missing or 

inoperative. 

2.1.7 ALWAYS refer to the applicable Department of Transportation 

regulations before towing. 

2.1.8 ALWAYS wear gloves when handling hoses and hot components. 

2.1.9 DO NOT smoke while operating the machine. 

WARNING 



2.2 Operator Safety while using Generators 

WARNING 

WARNING 

WARNING 

HIGH VOLTAGE! This unit uses high voltage circuits capable of 

causing serious injury or death. Only a qualified electrician should 

troubleshoot or repair electrical problems occurring with this 

equipment. 

Generators present special hazards during operation and servicing. 

Read and follow the warning instructions in the genset owner’s 

manuals and the safety guidelines below. Failure to follow the 

warnings and safety guidelines could result in severe injury or death. 






2.2.1 NEVER operate the generator when open containers of fuel, paint, or 

other flammable liquids are near. 

2.2.2 Engine antifreeze is toxic to humans and animals. Clean up spills and 

dispose of used engine antifreeze in accordance with local 

environmental regulations. 

2.2.3 NEVER overload the generator. The total amperage of the tools and 

equipment attached to the generator must not exceed the load rating 

of the generator. 

2.2.4 NEVER operate the generator, or tools attached to the generator, with 

wet hands. 

2.2.5 NEVER allow untrained personnel to operate or service the generator. 

The generator set should be set up by a certified electrician. 

2.2.6 NEVER touch the hot engine, exhaust, or generator components. 

Burns will result. 

2.2.1 ALWAYS follow starting and stopping instructions described in this 

manual. Know how to operate and stop generator before starting it. 

2.2.2 ALWAYS remove jewelry, make sure clothing and shoes are dry, stand 

on a dry wooden platform or rubber insulating mat, and use tools with 

insulated handles when servicing the machine. 

2.2.3 DO NOT start the engine if fuel has spilled or a fuel odor is present. 

Move the generator away from the spill and wipe the generator dry 

before starting. 

2.2.4 DO NOT remove the radiator cap when the engine is running or hot. 

The radiator fluid is hot and under pressure and may cause severe 

burns! 



2.2.5 DO NOT pressure wash the control panel, generator end, or any other 

electrical components when cleaning the unit. Never allow water to 

accumulate around the base of the generator set. If water is present, 

DO NOT service! 

2.3 Operator Safety while using Combustion Burners 

WARNING 

WARNING 

Combustion burners present special hazards during operation and 

fueling. Read and follow the warning instructions in the burner owner’s 

manual and the safety guidelines below. Failure to follow the warnings 

and safety guidelines could result in severe injury or death. 






2.3.1 ALWAYS refill the fuel tank in a well-ventilated area. 

2.3.2 ALWAYS replace the fuel tank cap after refueling. 

2.3.3 DO NOT fill or drain the fuel tank near an open flame, while smoking, 

or while the engine is running. 

2.3.4 DO NOT spill fuel when refueling the machine. Clean up spilled fuel 

immediately. 

2.3.5 DO NOT touch or lean against hot exhaust pipes. 

2.3.6 DO NOT refuel a hot or running machine. 

2.4 Maintenance Safety 

WARNING 

HIGH VOLTAGE! This unit uses high voltage circuits capable of 

causing serious injury or death. Only a qualified electrician should 

troubleshoot or repair electrical problems occurring with this 

equipment. 

2.4.1 DO NOT use gasoline or other types of fuels or flammable solvents to 

clean parts, especially in enclosed areas. Fumes from fuels and 

solvents can become explosive. 

2.4.2 ALWAYS disconnect the negative (-) battery cable before servicing the 

machine. 

2.4.3 ALWAYS replace the safety devices and guards after repairs and 

maintenance. 

2.4.4 ALWAYS keep the machine clean and labels legible. Replace all 

missing and hard-to-read labels. Labels provide important operating 

instructions and warn of dangers and hazards. 



2.4.5 ALWAYS make sure slings, chains, hooks, ramps, jacks and other 

types of lifting devices are attached securely and have enough weightbearing 

capacity to lift or hold the machine safely. Always remain 

aware of the location of other people in the area when lifting the 

machine. 

2.4.6 ALWAYS replace or repair electrical components with components 

that are identical in rating and performance as the original component. 

2.4.7 ALWAYS check the tires on the trailer for tread wear, inflation, and 

condition. Replace worn tires. 

2.4.8 ALWAYS connect the safety chains. 

2.4.9 ALWAYS make sure directional and trailer lights are connected and 

working properly. 

2.4.10 ALWAYS check that the lug nuts holding the wheels are tight and that 

none are missing. 

2.4.11 DO NOT attempt tire repairs. Always have a qualified tire dealer or 

repair service perform tire repairs. 



2.5 Label Locations 

1 

3 

14 

6 

9 

13 

13 

10 21 

15 

21 

wcghi_si000216gb.fm 12 

4 

18 

5 

19 

6 

28 

3 

23 

16 

13 

2 

20 

12 

7 

ghi_gr004615 

13 

17 

11 

8


2.6 Safety and Operating Labels 

Ref. Label Meaning 

1 Warning: Electrical shock hazard! 

Refer to the Operator’s Manual. 

2 Warning: Hot surface hazard! 

WARNING 

Strainer is hot. 

Refer to the Operator’s Manual. 

WARNUNG 

ADVERTENCIA 

AVERTISSEMENT 

3 Warning: Hot surface hazard. 

WARNING 

Wear safety gloves. 

WARNUNG 

Wear eye protection. 

ADVERTENCIA 

AVERTISSEMENT 

173199 

4 Warning: 

WARNING 

Read and understand the supplied 

Operator’s Manual before operating this 

machine. Failure to do so increases the risk 

READ AND UNDERST AND THE SUPPLIED OPERA TOR’S MANUAL BEFORE 

OPERATING THIS MACHINE . FAILURE TO DO SO INCREASES THE 

of injury to yourself and others. 

RISK OF INJURY TO OURSELF Y OR OTHERS. 

WARNUNG 

VOR INBETRIEBNAHME DIESES GREÄTES BEIGEFÜG TE BETRIEB SVOR- 

SCHRIFT LESEN UND VERSTEHEN. NICHTBEFOLGUNG ERHÖHT AS D 

RISIKO ZU EIGENER VERLETZUNG ODER ANDERER. 

ADVERTENCIA 

LEA Y ENTIENDA EL MANUAL DE OPERACION PRO VISTO CON EL 

EQUIPO ANTES DE QUE OPERE ESTE . EQUIPO DE NO HACERSE 

ASI. PODRIA AUMENTAR EL RIESGO DE AÑOS D PERSONALES Y 

A OTRAS PERSONAS. 

AVERTISSEMENT 

LIRE ET COMPRENDRE LA NOTICE OI D’EMPL FOURNIE VEC A LA 

MACHINE AVANT DE LA MET TRE EN SERVICE . A DEFAUT. VOUS 

AUGMENTERIEZ LE RISQUE DE VOUS EXPOSER UTRES ET LES A 

A DES BLES SURES. 


172634 

173221



5 Danger: Exhaust gas is deadly! 

DANGER 

Do not operate machine indoors. Refer to 

GEFAHR 

the Operator’s Manual. 

PELIGRO 

DANGER 

EXHAUST GAS IS DEADLY. 

DO NOT OPERATE MACHINE INDOORS. 

REFER TO OPERATORíS MANUAL. 

ABGAS IST T÷DLICH . 

MASCHINE NUR IM FREIEN BETREIBEN. 

SIEHE BETRIEBSANLEITUNG. 

EL GAS DE ESCAPE ES MORTAL . 

NO OPERE LA M¡QUINA EN I NTERIORES. 

CONSULTE EL MANUAL DE OPERACI”N. 

LES GAZ D'…CHAPPEMENT SONT MORTELS. 

NE PAS UTILISER LA MACHINE ¿ L'INT…RIEUR . 

SE REPORTER ¿ LA NOTICE D'EMPLOI. 

6 Warning: Hand entanglement hazard! 

WARNING 

Moving parts can crush and cut. Do not 

operate with guard removed. 

WARNUNG 

ADVERTENCIA 

AVERTISSEMENT 

7 Warning: Fire and explosion hazard! 

WARNING 

WARNUNG 

G20 

ADVERTENCIA 

AVERTISSEMENT 

WARNING 

WARNUNG 

G31 

ADVERTENCIA 

AVERTISSEMENT 


173224 

173222 

172626 

When using G20 (Natural Gas), position 

the fuel selection valve in the open 

position. 

Warning: Fire and explosion hazard! 

When using G31 (Propane), position the 

fuel selection valve in the closed position.



8 

WARNING 

WARNUNG 

ADVERTENCIA 

AVERTISSEMENT 

LICENSED GAS TECHNICIAN REQUIRED. 

NATURAL GAS/LIQUID PROPANE BURNER SETUP AND INSTALLATION, F UEL SUPPLY 

CONNECTION, TEST FIRING AND BURNER ADJUSTMENT MUST BE PERFORMED B Y A 

LICENSED PROFESSIONAL GAS TECHNICIAN AND MUST CONFORM TO THE REQUIREMENTS 

OF ALL RELEVANT LOCAL, STATE, PROVINCIAL AND FEDERAL AUTHORITIES. 

FAILURE TO HEED THIS WARNING MAY RESULT IN AN EXPLOSION AND/OR FIRE CAUSING 

PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 

ZUGELASSENER GASTECHNIKER ERFORDERLICH. 

DIE EINRICHUNG UND INSTALLATION DES ERDGAS/FL‹S SIGPROPANGAS-BRENNERS, DES 

KRAFTSTOFFVERSORGUNGSANSCHLUSSES, DER TESTZ‹NDUNG UND 

BRENNEREINSTELLUNG MUSS VON EINEM AUSGEBILDETEN UND ZUGELASSENEN 

GASTECHNIKER VORGENOMMEN WERDEN UND MUSS DEN ANFORDERUNGEN ALLER 

GELTENDEN VORSCHRIFTEN AUF LOKALER, LANDES- UND BUNDESEBENE ENTSPRECHEN. 

DIE NICHTBEACHTUNG DIESER WARNUNG KANN ZU EXPLOSION UND/ODER BRAND F‹HREN 

UND SACHSCHADEN, VERLETZUNGEN ODER TOD VERURSACHEN. 

SE REQUIERE UN T…CNICO GASISTA AUTORIZADO. 

EL MONTAJE Y LA INSTALACI”N DEL QUEMADOR DE PROP ANO LÕQUIDO/GAS NATURAL, LA 

CONEXI”N DEL SUMINISTRO DE COMBUSTIBLE , EL DISPARO EXPERIMENTAL Y EL AJUSTE 

DEL QUEMADOR DEBEN SER REALIZADOS POR UN T…CNICO GASISTA PROFESIONAL 

AUTORIZADO Y DEBEN CUMPLIR CON LOS REQUISITOS DE TODAS LAS AUTORIDADES 

RELEVANTES LOCALES, ESTATALES, PROVINCIALES Y FEDERALES. 

EN CASO DE NO CUMPLIR ESTA ADVERTENCIA PODRÕA PROVOCARSE UNA EXPLOSI”N O UN 

INCENDIO QUE CAUSAR¡ D A—OS MATERIALES, LESIONES PERSONALES O LA MUERTE. 

TECHNICIEN QUALIFI…, SP…CIALISTE DU GAZ INDISPENSABLE. 

L'INSTALLATION DE BR¤LEURS DE GAZ NATUREL/PROPANE LIQUIDE, LE RACCORDEMENT 

DE L'ARRIV…E DE CARBURANT, L'ALLUMAGE D'ESSAI ET L'AJUSTEMENT DES BR¤LEURS 

DOIVENT TRE CONFI…S ¿ UN TECHNICIEN PROFESSIONNEL QUALIFI…, SP…CIALISTE DU 

GAZ ET EFFECTU…S CONFORM…MENT AUX EXIGENCES DE TOUTES LES INSTANCES 

LOCALES, R…GIONALES, PROVINCIALES ET NATIONALES. 

RESPECTER CET AVERTISSEMENT SOUS PEINE D'EXPLOSION ET/OU D'INCENDIE CAUSANT 

DES D…G¬TS MAT…RIELS ET DES BLESSURES, …VENTUELLEMENT MORTELLES. 

173216 

Warning: Fire hazard! 

Natural gas/liquid propane burner setup and installation, fuel supply connection, 

test firing, and burner adjustment must be performed by a licensed, professional 

gas technician and must conform to the requirements of all relevant local, state, 

provincial, and federal authorities. 

Failure to heed this warning may result in an explosion and/or fire causing 

property damage, personal injury, or death. 

9 Warning: 

WARNING 

Do not engage trailer jack while 

WARNUNG 

transporting the machine. 

ADVERTENCIA 

Refer to the Operator’s Manual for further 

AVERTISSEMENT 

instructions on transporting the machine. 

173200 




10 Caution: Lift point. 

CAUTION 

Attach lifting device in this location. 

VORSICHT 

PRECAUCION 

PRECAUTION 

11 Caution: Only diesel fuel may be used in 

this machine. 

! CAUTION 

! VORSICHT 

D ! PRECAUCION 

DIESEL ! PRECAUCION 

12 Low level cutoff device label: 

Refer to Operator’s Manual. See section 

Clearing a Low Level Fault. 

13 Tie down location label: 

This label indicates areas on the machine 

that may be used for securing the machine 

during transport or storage. 

173202 


173201



14 Hose reel brake label: 

This label indicates information regarding 

the operation of the hose reel brake 

assembly. 

15 Lifting point range label: 

This label indicates the range of lifting 

points (between the center of gravity 

labels). 

173204 

16 Weight/mass label: 

This label indicates the total weight of the 

LBS 

KG 

11750 

5350 173217 


machine, including the trailer and a full fuel 

tank. 

17 Diesel fuel blend guide: 

This label gives diesel fuel blending 

requirements. Refer to the Operator’s 

Manual for more information. 

5 < < 25 ( / 15 ) ( / -4 ) 

25 



18 

19 

NATURAL GAS (NG) BURNER 

FIRING RATE/TAUX CHAUFFE 

550 CFH 

CAPACITY/CAPACIT… BTUH / KW 

550,000 / 161.2 

BURNER MODEL/BRULEUER MODELE 

BECKETT CG 10.3 S 

ELECTRICAL RATING/LA TAUX ELECTRIQUE 120/240 VAC / 60 Hz / SINGLE PHASE / LES S THAN 50 AMP 

MIN CIRCUIT AMP ACITY/AMPERES DU CIRCUIT DU MIN 

1 x 15A / 1 x 50A 

GAS SUPPLY PRESSURE/PRESSION D’ORIFICE DE GAZ 

3.5" TO 9" W.C. 

MANIFOLD GAS PRES SURE/PRESSION DE GAZ DIVERSE 

2.1" W.C. 

GAS MANIFOLD ORIFICE 

1.265" 

LIQUID PROPANE VAPOR (LP) BURNER 


220 CFH 


550,000 / 161.2 


BECKETT CG 10.3 S 



1 x 15A / 1 x 50A 

GAS SUPPLY PRESSURE/PRESSION D’ORIFICE DE GAZ 

3.5" TO 9" W.C. 

MANIFOLD GAS PRES SURE/PRESSION DE GAZ DIVERSE 

2.1" W.C. 

GAS MANIFOLD ORIFICE 

.437" 

DIESEL / OIL BURNER 


4.0 US GPH 

NOZZLE SIZE/TYPE CICLEUR 

4.0 GPH 80 B 


550,000 / 161.2 


BECKETT GH203 



1 x 15A / 1 x 50A 

FUEL NOT HEAVIER THAN NO. 2 FUEL OIL/COMBUSTIBLE PAS PLUS LOURD QUE DE L’HUILE A FOURNAISE NO. 2 

Ground Heaters, Inc. 

1271 Judson Road 

Spring Lake, Michigan 49456 

CH5000 

HEATER RATING PLATE 

Æ 

C US 

Heater rating label: 

This label displays important technical information relating to the setup and 

operation of the machine. 

172632 


CSA B140.7 UL 726 

CSA B140.0 UL 795 

ANSI Z21.13∑CSA 4.9 LOW PRESS. BOILER 

173225 

Start pump: 

The label indicates that to start the pump 

on the machine, the pressure valve must 

be in the open position. 

Run machine: 

To run the machine, the pressure valve 

must be in the closed position.



20 HTF fill instructions: 


In normal operation mode, the fill valve 

must be in the closed position 

and the coolant control valve 

must be in the open position. 

In HTF fill mode, the fill valve must be 

in the open position 

and the coolant control valve 

must be in the closed position. 

21 Center of gravity. 

22 Hand entanglement hazard! 

Moving parts can crush and cut. Do not 

operate with guard removed. 

23 Hot surface hazard! 

24 Electric shock hazard! 

172624



25 Wear safety gloves! 

26 Wear eye protection! 

27 Consult Operator’s Manual! 

28 Temperature indication label: 

THERMAX This label indicates the temperature of the 

flue box. The black circles represent the 

temperature of the flue box at that location. 

The maximum recommended temperature 

of the flue box is 149°C (300°F). 

fi 

132”C 138”C 

4 LEVEL STRIP 

143”C 149”C 

270”F 

280”F 290”F 

CENTERS TURN BLACK AT RATING SHOWN 

300”F 


CH 5000 Operation 

3. Operation 

3.1 System Description 

The Cross Heater 5000 is a versatile hydronic heating system that 

uses advanced technology to thaw frozen ground, cure concrete, 

prevent frost, and heat or dry multiple types of work spaces. The Cross 

Heater hydronic heating system consists of: 

• Trailer-mounted heater/burner assembly 

• Self-contained pump system 

• Removable remote manifold that allows for maximum Heat 

Transfer Fluid flow at long distances 

• Optional robust 12kW genset that powers external Hose 

Handling Systems or Heat Xchangers 

The Cross Heater 5000 system heats the heat transfer fluid (HTF), 

which is continuously circulated through a vented, closed loop system. 

The vented, closed loop system includes a hose system which carries 

the heated HTF through the machine, thereby radiating and 

transferring the heat to the required application area. 

wcghi_tx000732gb.fm 21

Operation CH 5000 

3.2 System Component Locations 

Ref. Description Ref. Description 

1 Hose reel 6 Trailer jack 

2 Hose connection manifold 7 HTF pump and motor 

3 HTF fill access panels 8 Fuel tank fill access panel 

4 Burner exhaust 9 Lifting point 

5 Generator 10 Strobe light 

wcghi_tx000732gb.fm 22 

1 

5 

2 

10 

6 

7 

9 

3 

wcghi_gr004101 

4 

8


3.3 Control Panel 

b 

c 

d 

e 

f 

Ref. Instrument/switch Function 

a Start button Connects power to the machine 

controls. 

b Ground fault interrupter (GFI) Electrical safety mechanism that 

protects the operator from injury. 

c Low level fault indicator light Signifies low level fault when lit. 

d Burner fault indicator light Signifies burner fault when lit. 

e HTF fill switch Overrides the low level cutoff device to 

operate pump during HTF filling. 

f Pump ON-OFF switch Switches power to the pump. 

g Light ON-OFF switch Switches power to the light. 

h Burner ON-OFF switch Switches power to the burner. 

i Main temperature controller Sets desired temperature of HTF. 

j Hour meter Meters usage of CH 5000. 

k Stop button Disconnects power to the machine 

controls. 


TM 

j 

a 

k 

i 

h 

g 

wcghi_gr004107


3.4 Pre-Season Start-up Preparation 

Before each seasonal use, the machine must be prepared for 

operation. Perform the following tasks after taking the machine out of 

storage: 

• Remove all plastic wrap or other waterproof material from the 

chimney and burner. 

• Remove all carbon buildup from the heater and burner 

assemblies. 

• Replace the burner nozzle. 

• Replace the fuel filter element. 

• Verify electrode position. 

• Verify fuel pump pressure. 

• Verify burner combustion quality. See section Burner 

Adjustments. 

• Verify correct operation of the low level shutdown device. 

• Verify correct operation of the temperature control device. 

• Clean the HTF strainer basket. See section Cleaning the HTF 

Strainer Basket. 



3.5 Positioning the Machine 

1 

2 

3 

4 

Normal positioning and setup is as follows: 

3.5.1 Position the CH 5000 trailer close to the application area. 

3.5.2 Chock the wheels to prevent accidental rolling. 

3.5.3 Level the trailer using the trailer jack. 

3.5.4 Place the machine on solid, stable ground to prevent rollovers. 

Note: The CH 5000 machine may be air lifted to the top of a structure 

for operation if necessary. Use the lifting point to do so. 


wcghi_gr004096


3.6 Preliminary Checks 

Before starting the machine, check the following: 

• Location—see section Positioning the Machine. 

• Fuel supply—verify the tank is filled with the correct type of fuel. 

• Generator—check the following: 

- Oil level 

- Coolant level 

- Exhaust system integrity 

- Fuel system integrity 

- Electrical system integrity 

- Mechanical system integrity 

• Heat transfer fluid level—verify the reservoir is full. 

• Circuit breaker and control switches—all must be in the OFF 

position. 

• Hose connections—verify all fuel and heat transfer hose 

connections are secured. 



3.7 Starting the Generator 

3.7.1 Perform the preliminary checks on the machine. See section 

Preliminary Checks. 

3.7.2 Move the circuit breakers on the genset control panel to the OFF 

position. 

3.7.3 Prime the fuel system if: 

• Fuel has been replenished 

• Fuel filter has been changed 

Note: If these conditions have not 

been met, the fuel system does NOT 

need to be primed. 

3.7.4 

To prime the fuel system, hold the 

control switch to the STOP/PRIME 

position for at least one minute. 

Note: The priming sequence will 

begin after two seconds. 

Push and hold the control switch to 

the START position until the genset 

starts. The status indicator light on 

the control switch will flash during the 

preheat and crank sequences. The 

indicator light will illuminate solid 

when the starter disconnects, 

indicating a successful start. 

Note: In colder temperatures, the 

preheat sequence can last up to 15 

seconds. 

NOTICE: DO NOT crank the starter 

for more than 30 seconds at a time 

and wait at least two minutes before 

trying again. Excessive cranking can 

overheat and damage the starter. 

3.7.5 In cold weather, allow the genset to warm up for at least two minutes 

before operating the machine. 

3.7.6 Move the circuit breakers on the genset control panel to the ON 

position. 


START 

STOP 

START 

STOP


3.8 Starting the Machine 

3.8.1 Perform the necessary preliminary checks. See section Preliminary 

Checks. 

3.8.2 Start the generator. See section Starting the Generator. 

3.8.3 Press the Start Button. 

3.8.4 Warm the hoses. See section Warming the Hoses. 

3.8.5 Initiate the HTF flow: 

• Verify the pressure valve is in the OPEN position. 

• Turn the pump switch to the ON position. 

• Verify the pressure is rising by monitoring the pump pressure 

gauge. 

3.8.6 Unwind and position the hoses in the application area. See section 

Unwinding and Positioning the Hoses. 

3.8.7 Specify the set value (SV) on the 

temperature controller to the desired 

application temperature. 

3.8.8 Move the pressure valve to the CLOSED 

3.8.9 

position. 

Continue with normal operating 

## C 

PV 

procedures. 

## C SV 


omron E5CN 

wcghi_gr004070


3.9 Warming the Hoses 

3.9.1 

NOTICE: The machine is equipped with a variable frequency drive 

(VFD) which requires a minimum temperature of -9°C (15°F) to 

operate properly. The VFD is equipped with an automatic heater that 

initiates when the start button is pressed. The pump motor will not 

engage until the VFD has reached -9°C (15°F). This process can take 

up to 30 minutes at -40°C (-40°F). 

After starting the generator and pressing the start button, carry out the 

following procedure to warm the hoses. 

Use the up and down arrows on the 

temperature controller to make the set value 

(SV) 21°C (70°F). 

Note: The actual temperature of the HTF 

(PV) is displayed in red. 

## C 

PV 

3.9.2 Move the burner switch to the ON (|) position. 

Verify the following sequence occurs: 

• After a 5-second delay, the burner motor 

starts. 

• After another 15-second delay, the 

burner fires. 

• The burner is operating with no visible 

exhaust smoke. 

Note: If the burner is not operating properly, 

contact your local Ground Heaters, Inc. distributor. 


## C 

SV 

omron E5CN 


wcghi_gr004071


3.10 Unwinding and Positioning the Hoses 

See Graphic ghi_gr004631 

To unwind and position the hoses, carry out the following procedure. 

3.10.1 Turn the hose reel brake T-handle counter-clockwise to release the 

brake. 

3.10.2 Connect loop 1 to the male hose connection manifold (a). 

3.10.3 Move the pump switch to the OFF position. Allow the pressure to drop 

to 0 kg/cm 2 (0 psi). 

3.10.4 Pull the hose loop off the hose reel and position the hose within the 

application area. 

3.10.5 Stop pulling the hose when the connection between loop 1and loop 2 

is exposed. 

NOTICE: Do NOT over-spin the hose reel near the end of hose loop 2. 

Failure to comply will damage the machine. 

3.10.6 Disconnect loop 1 from loop 2 at the quick connect coupling. 

3.10.7 Connect loop 1 male coupling to the return female hose connection 

manifold. 

3.10.8 Connect loop 2 male coupling to the female hose connection manifold. 

3.10.9 Connect loop 2 female coupling to male hose connection manifold. 

3.10.10 Position hose loop 2 within the application area. 

3.10.11 Turn the hose reel brake T-handle clockwise to lock the hose reel. 

3.10.12 Repeat the preceding steps for the remaining hose reel. 

3.10.13 Move pump switch to the ON position. 

3.10.14 Continue with normal operating procedures. 


a 

ghi_gr004631


3.11 Using the Remote Manifolds 

See Graphic ghi_gr004630 

In order to use the remote manifolds, you need two additional leader 

hoses from Ground Heaters, Inc. 

3.11.1 Turn the hose reel brake T-handle counter-clockwise to release the 

brake. 

3.11.2 Move the pump switch to the OFF position. Allow the pressure to drop 

to 0 kg/cm 2 (0 psi). 

3.11.3 Remove the remote manifolds (a) from the machine and place them in 

the application area. 

• Place the manifolds no more than 50 feet from the machine to 

allow the leader hoses to be connected. 

3.11.4 Pull both loops off the hose reel and disconnect at the middle coupling. 

3.11.5 Connect one leader hose (b) to the male connection manifold. 

3.11.6 Connect the remaining leader hose to the female connection manifold. 

3.11.7 Connect the remaining leader hose ends to the supply and return 

fittings on the ends of the remote manifolds. 

3.11.8 Connect each end of the hose loops to the remote manifolds. 

3.11.9 Repeat the preceding steps for the remaining hose reel. 

3.11.10 Position the hose loops in the application area. 



b 

a 

ghi_gr004630 

a 

b


3.12 Changing Fuel Sources 

WARNING 

Extreme fire and explosion hazard! Only a licensed, professional gas 

technician should attempt installation, fuel supply connection, setup, 

adjustment, and testing of the burner. All connections and settings 

must conform to relevant local, state, provincial, and federal 

requirements. 

The machine runs on three types of fuel; natural gas (NG), liquid 

propane (LP), and diesel fuel. Before operation, verify the correct type 

of burner is installed and that the burner has been properly setup and 

tested. 

• For NG and LP, the NG/LP burner must be installed. See section 

Installing the NG/LP Burner. 

• For diesel fuel, the diesel burner must be installed. See section 

Installing the Diesel Burner. 

To change from NG or LP to diesel fuel, carry out the following 

procedure: 

3.12.1 Remove the NG/LP burner. 

3.12.2 Install the diesel burner. See section Installing the Diesel Burner. 

3.12.3 Adjust the fuel pressure if necessary. See section Adjusting the Fuel 

Pressure. 

3.12.4 Adjust the burner air settings. See section Adjusting the Burner Air 

Settings. 

3.12.5 Verify the burner combustion values. See section Verifying the Burner 

Combustion. 

To change from diesel fuel to NG/LP, carry out the following 

procedure: 

3.12.6 Remove the diesel burner. 

3.12.7 Install the NG/LP burner. See section Installing the NG/LP Burner. 


Pressure. 

3.12.9 Adjust the burner air setttings. See section Adjusting the Burner Air 

Settings. 


Combustion. 



To change from NG to LP or vice-versa, carry out the following 

procedure: 

3.12.11 Verify that the machine is shut down and all power is disabled. 

3.12.12 Move the fuel selection valve (a) to the appropriate position: 

• NG - Move the fuel selection valve to the OPEN position 

• LP - Move the fuel selection valve to the CLOSED position. 


Pressure. 

3.12.14 Adjust the burner air settings if necessary. See section Adjusting the 

Burner Air Settings. 


Combustion. 


a 

LP NG 

ghi_gr004628


3.13 Monitoring the Operating Parameters 

The following parameters should be monitored every 8–24 hours: 

• Fuel level 

Keep track of fuel consumption to plan a needed filling schedule. 

• Flue box temperature 

Check the temperature indication labels often; if the temperature 

rises above 149°C (300°F), shut down the machine and inspect 

the flue box. 

• HTF level 

• HTF supply pressure 

• Leaks 

Keep a watchful eye on all hoses, fittings, and connections. 

• Strobe light—The strobe (performance monitoring light) flashes 

when all systems are functioning properly. The strobe will go out 

when there is a power failure or a burner fault. 

• HTF return temperature— Consult your site engineer for the 

proper HTF return temperatures OR contact Ground Heaters, 

Inc. for application support. 

Note: The proper temperatures for all applications are based on tests 

conducted at Ground Heaters, Inc. ® Your application temperatures 

may vary depending on environmental conditions at the work site. 



3.14 Clearing a Low Level Fault 

To clear a low level fault condition, carry out the following procedure: 

3.14.1 Move the burner switch to the OFF position. 

3.14.2 Move the pump switch(es) to the OFF position. 

3.14.3 Locate and repair the source of the low level fault. 

3.14.4 Fill the HTF to the minimum indicator mark. See section Filling the HTF 

Reservoir. 

3.14.5 Press the manual reset button (a). 

3.14.6 After the burner ignites, move the pump switch(es) to the ON position 

(one at a time). 

3.14.7 Continue with normal operational procedures. 


a 

ghi_gr004666


3.15 Filling the HTF Reservoir 

See graphic: ghi_gr004667 

To fill the HTF reservoir, carry out the following procedure. 

Setting up: 

3.15.1 Verify that the machine is operational. 

3.15.2 Move the burner switch to the OFF position. 


3.15.4 Allow the machine to cool 10 minutes or more. 

3.15.5 Remove and clean the HTF fill hose. 

3.15.6 Place the hanging end of the fill hose into a container of HTF. 

3.15.7 Move the coolant control valve (c) to the CLOSED position. 

3.15.8 Move the fill valve (b) to the OPEN position. 

Filling: 

3.15.9 Move the HTF fill switch to the ON position. 

Note: The pump will operate at 1/3 speed. 

3.15.10 Observe the sight gauge on the HTF reservoir. 

3.15.11 Move the HTF fill switch to the OFF position when the reservoir is filled 

to the minimum indicator mark. 

Preparing for operation: 

3.15.12 Move the coolant control valve (c) to the OPEN position. 

3.15.13 Move the fill valve (b) to the CLOSED position. 

3.15.14 Remove the HTF fill hose from the container, clean it, and return it to 

the storage location. 

3.15.15 Warm the hoses. See section Warming the Hoses. 



b 

c 

ghi_gr004667


3.16 Shutting Down the Machine at End of Day 

3.16.1 Move the burner switch to the OFF 

position. 

3.16.2 Move the pump switch to the OFF 

position. 

3.16.3 Rewind the hose. See section Rewinding the Hose. 

3.16.4 Disconnect and store all accessory components. 

3.16.5 Open the pressure valve. 

3.16.6 Disconnect and remove any power cords. 

3.16.7 Close and lock all doors. 

3.16.8 Shut down the generator. See section Shutting Down the Generator. 



ghi_gr004669


3.17 Shutting Down and Restarting the Machine During Operation 

This procedure is ONLY to be used to temporarily shut down the 

machine in order to: 

• change the genset oil 

• refuel 

• reposition hoses 

• perform tasks other than normal operation or maintenance 

To temporarily shut down and restart the machine, carry out the 

following procedures: 

3.17.1 

Shut down: 

Move the burner switch to the OFF position. 

3.17.2 Wait five minutes to allow adequate cooling. 


3.17.4 Move the pressure valve to the OPEN position. 

3.17.5 Shut down any accessories. 

3.17.6 Move the breaker switch(es) to the OFF position, if applicable. 

3.17.7 Shut down the generator. See section Shutting Down the Generator. 

3.17.8 Perform the necessary task(s). Refer to the OEM manuals for 

changing oil or other such tasks. 

Restart: 

3.17.9 Start the generator. See section Starting the Generator. 

3.17.10 Move the breaker switch(es) to the ON position, if applicable. 

3.17.11 Press the start button. 

3.17.12 Move the burner switch to the ON position. 

3.17.13 Wait five seconds. 

3.17.14 Move the pump switch to the ON position. 

3.17.15 Move the pressure valve to the CLOSED position. 

3.17.16 Restart any accessories. 




3.18 Rewinding the Hoses 

CAUTION 


Always wear gloves to protect hands while handling hoses. 

NOTICE: Verify that the pump AND the burner are OFF before 

rewinding the hoses. 

3.18.1 Turn the hose reel brake T-handle in the counter-clockwise direction to 

unlock the brake. 

3.18.2 Remove the foot pedal and place it on a firm, flat surface. 

3.18.3 Connect the hose loops in series. 

3.18.4 Turn the rewind switch to the desired position. Power will be directed 

to the foot pedal. 

3.18.5 Engage the clutch using the foot pedal. Guide the hose evenly onto the 

reel. 

3.18.6 Disengage the clutch using the foot pedal before reaching the end of 

the hose. 

3.18.7 Wind the remainder of the hose onto the hose reel by hand. 

3.18.8 Repeat this procedure for any remaining hoses. 

3.18.9 Turn the hose reel brake T-handle in the clockwise direction to lock the 

brake. 

3.18.10 Return the foot pedal to its storage location.


3.19 Shutting Down the Generator 

3.19.1 Shut down the machine. See section Shutting Down and Restarting 

the Machine During Operation. 

3.19.2 Allow the generator to run for a minimum of two minutes to allow 

adequate cooling. 

3.19.3 Move the breaker switch on the generator to the OFF position. 

3.19.4 Push the generator power switch to 

STOP. 


START 

STOP


3.20 Activating the RMS Service 

RMS 6000 is an optional satellite-based transponder that is configured 

to send a general fault code to ground-based monitoring facilities 

should there be a burner fault or unexpected shut-down. The RMS 

6000 uses GPS technology and can pinpoint its location any time it is 

switched on. The built-in battery will continue sending location and 

fault codes for up to four hours after power to the smart plug is lost. The 

RMS 6000 is portable but does require installing a roof-mounted 

antenna prior to use. 

Note: Before the RMS 6000 can be used, the RMS service must be 

activated through Micrologic Inc. See the instructions in this manual to 

activate the service. 

3.20.1 

To activate the RMS service: 

Use the RMS Activation Form included with this manual. 

3.20.2 Completely fill out the form and return to Micrologic, Inc. 

3.20.3 Test the RMS communications before operation. 

3.21 Testing the RMS Communications 

To test the RMS communications: 

3.21.1 Verify the RMS service has been activated through MicroLogic, Inc. 

3.21.2 Start up your Ground Heaters, Inc. machine using the instructions in 

this manual. 

3.21.3 Move the power switch on the RMS 6000 unit to the “Activate” position. 

Note: This action does NOT activate your RMS service. See section 

“Activating the RMS Service”. 

3.21.4 Unplug the RMS unit from the smart receptacle on the Ground 

Heaters, Inc. machine. 

• This action simulates an equipment failure. 

• An “EQUIPMENT DOWN” message will be initiated. 

• This message may take several minutes or hours to reach the contact 

information depending on the geographic location of your RMS unit. 

3.21.5 After successful completion of this test, wait 15 minutes and reconnect 

the RMS 6000 unit to the smart receptacle on the Ground Heaters, Inc. 

machine. 

3.21.6 Your RMS 6000 unit is now ready for normal operation. Continue 

normal operating procedures. 



3.22 Operating the RMS 6000 

Startup: 

3.22.1 Verify that the RMS unit is properly installed and the RMS service has 

been activated and tested using the instructions in this manual. 

3.22.2 Start up your Ground Heaters, Inc. machine using the instructions in 

this manual. 

3.22.3 Move the power switch on the RMS 6000 unit to the “Activate” position. 

The green indicator light will illuminate. 

Note: This action does NOT activate your RMS service. See section 

“Activating the RMS Service”. 

3.22.4 Continue normal operating procedures for your Ground Heaters, Inc. 

machine. 

Shutdown: 

3.22.1 Move the power switch to the “Deactivate” position. 

Note: An “UNINTENDED SHUTDOWN” message will be transmitted if 

you do not move the power switch to “Deactivate” before shutting down 

the Ground Heaters, Inc. machine. 

3.22.2 Shut down the Ground Heaters, Inc. machine using the instructions in 

this manual. 


CH 5000 Maintenance 

4. Maintenance 

4.1 Periodic Maintenance Schedule 

Clean/change genset engine air filter. 

After 

first 50 

hours 

or two 

weeks 


Every 

250 

hours 

Every 

500 

hours 

Every 

1000 

hours 

Change genset engine fuel filter. 

Change genset engine oil. 

Change genset engine oil filter. 

Change genset engine air filter. 

Note: Change the filter more often 

when operating in dusty conditions. 

Check /adjust burner fuel pressure. 

Check/adjust the burner air setting. 

Clean the HTF strainer basket. 

Verify the burner combustion. As needed 

 

Every 

1200 

hours 

or 

yearly

Maintenance CH 5000 

4.2 Installing the NG/LP Burner 

WARNING 

WARNING 

Extreme fire and explosion hazard! 

Only a licensed, professional gas technician should attempt 

installation, fuel supply connection, setup, adjustment, and testing of 

the burner. All connections and settings must conform to relevant local, 

state, provincial, and federal requirements. 

The fuel supply MUST include a regulator to adjust the fuel supply 

pressure to the recommended values (located on the heater rating 

label). 

4.2.1 

To install the NG/LP burner, carry out the following procedure: 

Verify that the machine is shut down and all power is disabled. 

4.2.2 Remove the burner assembly (a) from the box. 

4.2.3 Position the burner in the machine. 

4.2.4 Install the 3 bolts (b) that secure the burner to the machine. 

4.2.5 Connect the power cables to the supplied power receptacles. 

4.2.6 Connect the fuel supply. 

4.2.7 Position the fuel selection valve (c) in the appropriate position for the 

fuel supply to be used: 

• NG - Move the fuel selection valve to the OPEN position 

• LP - Move the fuel selection valve to the CLOSED position. 

4.2.8 Set up the burner. See section Setting up the NG/LP Burner. 



b 


c 

a 

LP NG 

wcghi_gr004627


4.3 Installing the Diesel Burner 

WARNING 






To install the diesel burner, carry out the following procedure: 

4.3.1 Verify that the machine is shut down and all power is disabled. 

4.3.2 Remove the burner assembly (a) from the box. 

4.3.3 Position the burner in the machine. 

4.3.4 Install the 4 bolts (b) that secure the burner to the machine. 

4.3.5 Connect the power cable to the supplied power receptacle. 

4.3.6 Connect the fuel supply lines. 


Combustion. 


b 

a 

ghi_gr004641


4.4 Setting Up the NG/LP Burner 

WARNING 






4.4.1 

To set up the NG/LP burner, carry out the following procedure: 

Verify that the machine is shut down and all power is disabled. 

4.4.2 Install the NG/LP burner (a). See section Installing the NG/LP Burner. 

4.4.3 Install a manometer at the supply pressure test port (b). 

4.4.4 Verify that the pressure is at the recommended value (located on the 

heater rating plate). 

4.4.5 Start the machine. See section Starting the Machine. 

4.4.6 Reset the burner pressure switches (c and d). 

• Press the black button on the front of the switch. 

4.4.7 Install a manometer at the manifold test port (e). 

4.4.8 Verify that the pressure is set at the recommended value (located on 

the heater rating plate). 


Pressure. 

4.4.10 Adjust the burner air settings if necessary. See section Adjusting the 

Burner Air Settings. 

4.4.11 Verify the combustion values. See section Verifying the Burner 

Combustion. 

c 


b 

a 

e 

d 

wcghi_gr004625


4.5 Adjusting the Fuel Pressure 

WARNING 






To adjust the fuel pressure, carry out the following procedure: 

4.5.1 Verify that the machine is started. See section Starting the Machine. 

4.5.2 Verify that the supply pressure is at the recommended value (located 

on the heater rating label). 

NG/LP Burner (1): 

4.5.3 Install a pressure gauge at the fuel pressure test port (e). 

4.5.4 Remove the cap from the HI adjustment port on the right (f) to access 

the adjustment screw. 

4.5.5 Adjust the pressure: 

• To increase the pressure, turn the adjustment screw clockwise. 

• To decrease the pressure, turn the adjustment screw counterclockwise. 

4.5.6 Replace the cap. 

4.5.7 Remove the pressure gauge. 

Diesel burner (2): 

4.5.8 Install a pressure gauge at the fuel pressure test port (g). 

4.5.9 Adjust the pressure: 

• To increase the pressure, turn the adjustment screw (h) 

clockwise. 

• To decrease the pressure, turn the adjustment screw (h) counterclockwise. 

4.5.10 Remove the pressure gauge. 



1 

2 


e 

f 

h 

g 

ghi_gr004626


4.6 Adjusting the Burner Air Settings 

See Graphic: wcghi_gr003868 

WARNING 






To adjust the burner air settings, carry out the following procedure: 

4.6.1 Verify that the machine is machine is shut down and all power is 

disabled. 

4.6.2 Loosen the locking screws (a and f) on both the air band (c) and air 

shutter (b). 

4.6.3 Adjust the settings: 

• For large adjustments, move the air band. 

• For small adjustments, move the air shutter. 

• To increase the oxygen content, move the air band or shutter so 

the pointers (d and e) are at a higher number. 

• To decrease the oxygen content, move the air band or shutter so 

the pointers (d and e) are at a lower number. 

4.6.4 Sample the exhaust smoke. See section Verifying the Burner 

Combustion. 

4.6.5 Re-adjust if necessary. 

4.6.6 Tighten both of the locking screws (a and f). 

a b c d e f 


ghi_gr004641


4.7 Verifying the Burner Combustion 

WARNING 

WARNING 






The fuel supply MUST include a regulator to adjust the supply pressure 

to the recommended values (located on the heater rating label). 

Note: All burners are test fired at Ground Heaters, Inc.'s factory 

located 600 ft.(180 m) above sea level (asl). 

To ensure proper burner performance and to avoid machine downtime 

due to heater sooting, burner combustion verification and adjustment 

must 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. 

Adjust the fuel pressure: 

4.7.1 Adjust the fuel pressure to the recommended values (located on the 

heater rating label). See section Adjusting the Fuel Pressure. 

Sample the oxygen content: 

A combustion analyzer, smoke true spot tester and common hand 

tools will be required for oxygen content sampling. 

4.7.2 Follow the combustion analyzer manufacturer’s instructions for prepurge 

and exhaust sampling. 

4.7.3 Sample the exhaust gas. 

Note: Exhaust O2 content must be 3 to 4% for optimum performance 

and minimum soot production. Several samples should be taken as the 

heater warms. The final sample should be taken just before the heater 

reaches 160°F. 



Smoke spot sampling: 

4.7.4 Follow the smoke spot tester manufacturer’s instructions for accurate 

exhaust sampling. 

4.7.5 Sample the burner exhaust for smoke. 

• Smoke spot production must be 1 or less. 

• Several samples should be taken as the heater warms. 

• The final sample should be taken just before the heater reaches 

160°F. 

Note: Higher O2 percentage (excess air settings) lowers soot 

production but raises stack temperature and reduces efficiency. Lower 

O2 percentage (inadequate air settings) increases efficiency and 

lowers stack temperature but may cause soot build-up. A burner 

optimized for clean and efficient operation will have O2 levels of 3 to 

4% and a smoke spot value of 1 or less. 

Adjust the burner air settings: 

4.7.6 Adjust the burner air settings to obtain the proper oxygen content. See 

section Adjusting the Burner Air Settings. 



4.8 Changing the Genset Oil and Filter 

To change the genset oil and filter, carry out the following procedure: 

4.8.1 Run the genset until warm and shut it off. 

4.8.2 Pull the oil dipstick out a small distance to allow faster draining. 

4.8.3 Remove the front and bottom access covers and place the end of the 

drain hose (c) into a container. 

4.8.4 Open the drain valve (b). The oil will drain into the container. 

4.8.5 Close drain valve (b) when all the oil is drained. 

4.8.6 Remove the oil filter (a) and clean the mounting surface. Be sure to 

remove the old gasket if it remains on the engine block. 

4.8.7 Apply a thin film of clean oil to the gasket on the new filter. 

4.8.8 Hand tighten the new filter. Turn it an additional 1/2 to 3/4 turn. 

NOTICE: Do NOT overtighten. 

4.8.9 Refill the oil reservoir with two quarts of oil and check the level. 

4.8.10 Push the oil dipstick in. 

4.8.11 Store the drain hose and re-install the front and bottom access covers. 

a 


b 

a 

c 

wcghi_gr004313


4.9 Replacing the Genset Fuel Filter 

See graphic: wcghi_gr004312 

To replace the genset fuel filter, carry out the following procedure. 

Removal: 

4.9.1 Close the fuel supply valve. 

4.9.2 Disconnect the negative (-) battery cable. 

4.9.3 Disconnect the two flarenuts (c) that secure the access cover to the 

genset and remove the access cover. 

4.9.4 Disconnect the fuel lines (a and b). Be careful not to spill fuel. 

4.9.5 Remove the filter mounting nut (d) and two filter bracket mounting 

screws (e). 

4.9.6 Remove the filter bracket (f) and filter (g). Dispose of the filter 

according to state and local regulations. 

Installation: 

4.9.7 Secure the filter bracket (f) loosely to the new filter (g). Place the filter 

bracket and new filter in the generator. 

4.9.8 Loosely secure the filter and filter bracket (f) to the generator with the 

two filter bracket mounting screws (e) and re-connect the fuel lines (a 

and b). 

Note: Take care not to cross-thread the fuel fittings. Thread them in by 

hand and tighten one flat past seating. 

4.9.9 Tighten the filter mounting nut (d) and filter bracket mounting screws 

(e). 

4.9.10 Re-install the access cover using the two flarenuts (c). 

4.9.11 Connect the negative (-) battery cable. 

4.9.12 Open the fuel supply valve. 

4.9.13 Prime the fuel system. 

• Hold the control switch to the STOP/PRIME position for at least 

one minute. 

Note: The priming sequence will begin after two seconds. 

4.9.14 Replace any covers, guards, or access panels. 



: 

g 

f 


a d b 

c c 

e 

wcghi_gr004312


4.10 Cleaning the HTF Strainer Basket 

See Graphic: ghi_gr004645 

CAUTION 

The strainer basket is very hot during normal operation. Shut down the 

machine before attempting to clean the strainer basket. See section 

Shutting Down and Restarting the Machine During Operation. 

To clean the HTF strainer basket, carry out the following procedure. 

Disassembly: 

4.10.1 Verify the machine is machine is shut down and all power is disabled. 

4.10.2 Move the HTF shutoff valves (a and b) to the CLOSED position. 

4.10.3 Move the coolant control valve (c) to the CLOSED position. 

4.10.4 Remove the locking screw (d) from HTF strainer housing cap (e). 

4.10.5 Twist counter-clockwise and remove the HTF strainer housing cap. 

4.10.6 Lift the HTF strainer basket (f) out of the housing. 

4.10.7 Clean the HTF strainer basket using warm water. 

Assembly: 

4.10.8 Place the HTF strainer basket (f) into the housing. 

4.10.9 Replace and twist clockwise to install the HTF strainer housing cap (e). 

4.10.10 Install the locking screw (d) on the top of the HTF strainer housing cap 

(e). 

4.10.11 Move the coolant control valve (c) to the OPEN position. 

4.10.12 Move the HTF shutoff valves (a and b) to the OPEN position. 

4.10.13 Your HTF strainer basket is now clean. Continue with normal operating 

procedures. 



a 

e 


d 

f 

b 

c 

f 

e 

ghi_gr004645


4.11 Storing the Machine 

4.11.1 Fill fuel tank with stabilized fuel. Operate the burner for at least fifteen 

minutes to ensure circulation through entire fuel system. Any brand of 

fuel stabilizer is acceptable. 

4.11.2 Allow heater to cool sufficiently. Cover the chimney and the burner with 

plastic wrap or other waterproof material. This will prevent corrosive 

moisture build-up and blockages caused by animal nests. 

4.11.3 Remove the emergency break-away battery and store the battery in a 

cool, dry place. Connect battery to a trickle charger once every 30 days 

to maintain full charge. 

4.11.4 Shut and lock all doors. 

4.11.5 Protect the tires from direct sun light. 



4.12 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) 

ft 2 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 



4.13 Troubleshooting 

Note: The following symptoms and remedies are some of the more 

common issues that have arisen during the history of this machine. 

These do not represent all the possibilities. If you need advanced 

troubleshooting assistance, please contact your local distributor. 

Issue Possible Causes Remedy 

The burner does not start • Improper switch position 

or protective function 

action 

• The over-temperature 

limit has tripped 

• Faulty cable or power 

supply 

• Burner control is in 

lockout mode 

The burner starts, the flame 

does not ignite 

The burner does not start; 

the flame ignites, but the 

unit locks out 

• No fuel 

• Worn burner nozzle 

• Faulty electrodes 

• Cad cell defective 

• Burner control defective 

• Incorrect fuel pressure 

• Worn burner nozzle 

• Incorrect air adjustment 

• Cad cell defective 

• Burner control defective 

Combustion is poor or noisy • Lack of fresh air to 

burner 

Thaw progress is below 

capacity 

• Insufficient insulation 

• Insufficient moisture 

• No vapor barrier 

• HTF is not flowing 

• Temperature control is 

not set properly 

• Soil conditions are not as 

expected 


• Verify that the HTF level 

is within range and low 

level shutdown device is 

reset (low level indicator 

light must be OFF) 

• Allow burner to cool 

• Replace faulty cable or 

power supply 

• Reset burner control 

• Fill fuel tank 

• Replace burner nozzle 

• Replace electrodes 

• Increase fuel pressure 

• Replace burner nozzle 

• Readjust air supply 

• Ensure that there is an 

adequate air supply 

• Add additional blankets. 

• Verify standing water on 

work site 

• Lay down vapor barrier 

• Verify that the pump 

pressure is nominal and 

hoses are not restricted 

• Set temperature control 

to optimum setting. This 

setting depends on 

environmental conditions 

at the work site.


Pump will not start • No supply power 

• HTF temperature is 

below -26°C (-15°F) 

• VFD temperature is 

below -9°C (15°F) 

Hose rewind does not work • Hose reel brake is not 

fully released 

• Motor temperature is 

below nominal value 

(


4.14 Electrical Schematics 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

16 

17 

1/UNIT 

4.14.1 Machine with gas burner (page 1) 

1 

2 

BLK 

1 

BLK 

33 

L1 

1 

TO LINE 18 

M 

13 A 

GFCI 

FU1 

FNM-5 

29 

JJN-50 

240VAC, 50A 

28 

E-STOP 

FOOT 

SWITCH 


18 

TO LINE 26 

BLU 

RED 

FU4 

14 

30 

JJN-50 

31 

8 

CLR 

RED 

BLK 

35 

FU2 

17 

23 

5 A 

RED RED 

3AG 5.0 SB 

7 8 11 

JUMPER 

12 

16 COIL 

RED 

K2 

COIL 

RED 

RED 

32 

LOW LEVEL OVERRIDE 

Off 

On 

K1 

6 

FU5 

MOMENTARY 

11 BLU 

12 

19 

15 

STOP 

R 

REWIND 

OFF 

Variable Frequency Drive 

L3 

L2 

L1 

2 

12A 

13A 

13B 

+ - 

L 

Off 

6 

36 

2 

RECT1 

VFD Heater 

PUMP 

START 

M 

13 14 

27 

BLK 

21 

GRN 

120VAC, 15A 

T1 

T2 

T3 

On 

5 1 

BLK 

WHT 

RED 

RED 

6 

SOL1 

SOL2 

37 

M 

95 96 

WHT 

WHT 

ORG 

PUMP 

230V 3Ø 

7.5HP 

38 

R. CLUTCH 

4A, 12VDC 

L. CLUTCH 

4A, 12VDC 

22 

MTR3 

2 

REWIND 

2.3 FLA 

1/6 HP 

1.0 SF 

M 

8 

TO LINE 27 

M 

13 A 

3 

4 

34 

WHT 

TO LINE 18 

N1 

2 

GFCI 

ghi_gr004646 

5 

6


FROM LINE 17 

120VAC 

18 

19 

20 

21 

22 

23 

24 

25 

26 

27 

28 

29 

30 

31 

BLK 

Machine with gas burner (page 2) 

1 

FU3 

LOW LEVEL 

H N 

2 

1 

2 

3AG 2.0 

A 

4 ORG 

C 

B 

RED 5 

0 

K1 

1 

2 

PUMPS, ENABLE 

1 

1 

1 

1 

K1 

4 3 

K1 

4 2 

25 

20 

TO LINE 11 

TO LINE 11 

BURNER 

Off 


17 

8 

T/C 

TYPE T 

On 

TS1 

BLU 

RED 

K3 

CAB LIGHT 

Off On 

3 

F.R. 

26 

17 (+) 

18 (-) 

5 

7 

5 

6 

10 

7 

8 

9 

F 

G 

4 

L2 

3 

6 4 

6 

14 

K2 

K2 

2 

TEMP. 

CONTROLLER 

9 10 

15 

6 

24 

GV1 

PL1 

R 

13 2 

H.G.P.S. L.G.P.S. 

MTR4 

GV2 

K3 

IGN 

GV2 

FROM LINE 17 

PL2 

R 

HR1 

N 

2 

2 

2 

2 

2 

2 

LOW LEVEL FAULT 

BURNER FAULT 

DUPLEX 

HOUR METER 

CAB LIGHT 

ghi_gr004647


1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

16 

17 

1/UNIT 

4.14.2 Machine with diesel burner (page 1) 

1 

2 

BLK 

1 

BLK 

33 

L1 

1 

TO LINE 18 

M 

13 A 

GFCI 

FU1 

FNM-5 

29 

JJN-50 

240VAC, 50A 

28 

E-STOP 

FOOT 

SWITCH 


18 

TO LINE 26 

BLU 

RED 

FU4 

14 

30 

JJN-50 

31 

8 

CLR 

RED 

BLK 

35 

FU2 

17 

23 

5 A 

RED RED 

3AG 5.0 SB 

7 8 11 

JUMPER 

12 

16 COIL 

RED 

K2 

COIL 

RED 

RED 

32 

LOW LEVEL OVERRIDE 

Off 

On 

K1 

6 

FU5 

MOMENTARY 

11 BLU 

12 

19 

15 

STOP 

R 

REWIND 

OFF 

Variable Frequency Drive 

L3 

L2 

L1 

2 

12A 

13A 

13B 

+ - 

L 

Off 

6 

36 

2 

RECT1 

VFD Heater 

PUMP 

START 

M 

13 14 

27 

BLK 

21 

GRN 

120VAC, 15A 

T1 

T2 

T3 

On 

5 1 

BLK 

WHT 

RED 

RED 

6 

SOL1 

SOL2 

37 

M 

95 96 

WHT 

WHT 

ORG 

PUMP 

230V 3Ø 

7.5HP 

38 

R. CLUTCH 

4A, 12VDC 

L. CLUTCH 

4A, 12VDC 

22 

MTR3 

2 

REWIND 

2.3 FLA 

1/6 HP 

1.0 SF 

M 

8 

TO LINE 27 

M 

13 A 

3 

4 

34 

WHT 

TO LINE 18 

N1 

2 

GFCI 

ghi_gr004646 

5 

6


FROM LINE 17 

120VAC 

18 

19 

20 

21 

22 

23 

24 

25 

26 

27 

28 

29 

30 

31 

BLK 

Machine with diesel burner (page 2) 

1 

FU3 

LOW LEVEL 

H N 

2 

1 

2 

3AG 2.0 

A 

4 ORG 

C 

B 

RED 5 

0 

K1 

1 

2 

PUMPS, ENABLE 

1 

1 

1 

1 

K1 

4 3 

K1 

4 2 

25 

20 

TO LINE 11 

TO LINE 11 

BURNER 

Off 


17 

8 

T/C 

TYPE T 

On 

TS1 

BLU 

RED 

K3 

CAB LIGHT 

Off On 

3 

F.R. 

26 

17 (+) 

18 (-) 

5 

7 

5 

6 

10 

7 

8 

9 

F 

G 

4 

L2 

3 

6 4 

6 

14 

K2 

K2 

2 

TEMP. 

CONTROLLER 

9 10 

15 

6 

24 

GV1 

PL1 

R 

13 2 

H.G.P.S. L.G.P.S. 

MTR4 

GV2 

K3 

IGN 

GV2 

FROM LINE 17 

PL2 

R 

HR1 

N 

2 

2 

2 

2 

2 

2 

LOW LEVEL FAULT 

BURNER FAULT 

DUPLEX 

HOUR METER 

CAB LIGHT 

ghi_gr004647

Technical Data CH 5000 

5. Technical Data 

5.1 CH5000 Technical Data 

Item No. 

Machine 

Length cm (inches) 480 (189) 

Width cm (inches) 249 (98) 

Height cm (inches) 242 (95) 

Weight (with fuel) kg (lbs.) 5330 (11,750) 

Fuel capacity L (gal.) 946 (250) 

Heat transfer hose length m (ft.) 1524 (5000) 

Hose reels units 2 

Circulation loops qty. 4 

Heat output BTU/hr. 550,000 

Fuel consumption (burner on) L/hr (gal./hr.) 17.15 (4.53) 

Run time hr. 100 

wcghi_td000218gb.fm 66 

CH5000 

0620242 

Power requirements Amps x VAC 50 X 230 and 15 X 115 

Normal hose pressure bar (psi) 8.62 (125) 

Thawing capacity m 2 (ft 2 ) 

Curing heating capacity m 2 (ft 2 )

This Information is REQUIRED To Activate Transponder 

Please Fax completed form to 508-621-1100 or e-mail information to 

cservice@micrologic.com when installation is completed. 

Questions: call MicroLogic, Inc. Customer Service-(508)621-1029 

1- Account Info: 

Account Number: Equipment Location : 

2- Equipment Info: 

Equipment ID 

Number: 

Manufacturer: GroundHeaters, Inc 

3- Transponder Info: 

Type: Ground Heater 

Model: 

Serial Number: ST250504 

I/O Box Serial 

Number: 

4-Ground Heater Stop Notification Information: 

Name (1): Email/Cellular Number (If Cellular device include service carrier): 





Installation 

Company: | Date: / / 

Installer Name & 

Telephone:

Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90 

Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957 

Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21

CH 5000 - Wacker Neuson

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