Master 100000 BTU/Hr Service manual

Master 100000 BTU/Hr Service manual
SECTION A
SERVICE MANUAL
LOW PRESSURE
PORTABLE FORCED AIR HEATER
HOT SURFACE IGNITION MODELS
Hot Surface Ignition Models Service Manual
SAFETY INFORMATION
WARNINGS
IMPORTANT: Read this owner’s manual carefully and
completely before trying to assemble, operate, or service this heater. Improper use of this heater can cause
serious injury or death from burns, fire, explosion,
electrical shock, and carbon monoxide poisoning.
•
•
•
DANGER: Carbon monoxide poisoning may lead
to death!
Carbon Monoxide Poisoning: Early signs of carbon monoxide
poisoning resemble the flu, with headaches, dizziness, and/
or nausea. If you have these signs, the heater may not be
working properly. Get fresh air at once! Have heater serviced. Some people are more affected by carbon monoxide
than others. These include pregnant women, persons with
heart or lung disease or anemia, those under the influence of
alcohol, and those at high altitudes.
Make certain you read and understand all warnings. Keep this
manual for reference. It is your guide to safe and proper
operation of this heater.
• Use only kerosene or No. 1 fuel oil to avoid risk of fire or
explosion. Never use gasoline, naphtha, paint thinners,
alcohol, or other highly flammable fuels.
• Fueling
a)Personnel involved with fueling shall be qualified and
thoroughly familiar with the manufacturer’s instructions
and applicable federal, state, and local regulations regarding the safe fueling of heating units.
b)Only the type of fuel specified on the heater’s data plate
shall be used.
c)All flame, including the pilot light, if any, shall be extinguished and the heater allowed to cool, prior to fueling.
d)During fueling, all fuel lines and fuel-line connections
shall be inspected for leaks. Any leaks shall be repaired
prior to returning the heater to service.
e)At no time shall more than one day’s supply of heater
fuel be stored inside a building in the vicinity of the
heater. Bulk fuel storage shall be outside the structure.
f) All fuel storage shall be located a minimum of 25 feet
from heaters, torches, welding equipment, and similar
sources of ignition (exception: the fuel reservoir integral
with the heater unit).
g)Whenever possible, fuel storage shall be confined to
areas where floor penetrations do not permit fuel to
drip onto or be ignited by a fire at lower elevation.
For replacement parts contact:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
2
h)Fuel storage shall be in accordance with the federal,
state, or local authority having jurisdiction.
Never use heater where gasoline, paint thinner, or other
highly flammable vapors are present.
Follow all local ordinances and codes when using heater.
Heaters used in the vicinity of tarpaulins, canvas, or similar enclosure materials shall be located a safe distance
from such materials. The recommended minimum safe
distance is 10 feet. It is further recommended that these
enclosure materials be of a fire retardant nature. These
enclosure materials shall be securely fastened to prevent them from igniting or from upsetting the heater due
to wind action.
Use only in well-vented areas. Before using heater, provide at least a three-square-foot opening of fresh, outside
air for each 100,000 Btu/Hr of rating. This heater produces
carbon monoxide, which is listed by the State of California
as a reproductive toxin under Proposition 65.
Use only in places free of flammable vapors or high dust
content.
Use only the electrical voltage and frequency specified
on model plate.
Use only a three-prong, grounded extension cord.
Minimum heater clearances from combustibles:
Outlet: 8 Ft. Sides: 4 Ft. Top: 4 Ft.
Rear: 4 Ft.
Locate heater on a stable and level surface if heater is
hot or running or a fire may occur.
When moving or storing heater, keep heater in a level
position or fuel spillage may occur.
Keep children and animals away from heater.
Unplug heater when not in use.
When used with thermostat, heater may start anytime.
Never use heater in living or sleeping areas.
Never block air inlet (rear) or air outlet (front) of heater.
Never move, handle, refuel, or service a hot, operating,
or plugged-in heater.
Never attach duct work to front or rear of heater.
Approved by the New York City Fire Department under
certificate of approval #4803, #4860, #4908, or #4909.
To be used only at construction sites in accordance with
applicable New York City Codes, Regulations, Rules,
Directives, Permits, etc.
Warning to New York City Residents For Use Only At
Construction Sites in accordance with applicable NYC
codes under NYCFD certificate of approval #4803, #4899,
#4908, #4909, or #4934.
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Hot Surface Ignition Models Service Manual
TABLE OF CONTENTS
GENERAL INFORMATION
General Information
I. ARRANGEMENT OF MANUAL
I.
Arrangement of Manual ..................................... 3
III. Service Preparation ........................................... 3
IV. Tools Required .................................................. 4
V. Parts .................................................................. 4
Specifications
I.
General Specifications
1. Fuel Selection ............................................... 5
2. Electrical ....................................................... 5
3. Ventilation ..................................................... 5
4. Heater Sizing ................................................ 5
II. Heater Performance Specifications ................... 6
This manual contains information and service procedures to
assist the service technician in understanding and correcting
problems on DESA International oil-fired portable forced air
heaters. The first section of the manual contains basic information concerning the operation of the different components
in the heater. This information should be reviewed by service
personnel to provide a basic understanding of how the components function in the working system. The Troubleshooting
section of this manual is intended to provide a quick reference
concerning conditions which result in customer complaints.
These procedures will help the service technician quickly
diagnose a malfunctioning heater. The illustrations in this
manual may not necessarily depict the actual heater model,
and are intended for reference ONLY.
Component Operation
I.
II.
III.
IV.
V.
Air System
1. Air Pump ....................................................... 7
2. Air Filters ...................................................... 7
3. Nozzle .......................................................... 7
Electrical System
1. Motors .......................................................... 7
2. Ignition Control/Photocell ............................. 8
3. Hot Surface Ignitor ....................................... 8
Fuel System ...................................................... 8
Combustion System .......................................... 9
All Systems Working Together .......................... 9
Troubleshooting
I. Safety Requirements ....................................... 10
II. Cautions .......................................................... 10
III. Using The HA1170 Tester
1. Operation .................................................... 10
2. Calibration .................................................. 10
IV. Diagnostic Charts ............................................ 10
III. SERVICE PREPARATION
A clean work area at the start of each job is essential for
efficient service work. Heaters which are extremely dirty
should be cleaned prior to service. Cleaning will occasionally
uncover the problem area. Tools needed for the job should be
obtained before work is started. Delays resulting from locating
tools result in lost time and wages.
Clean fuel should always be used when testing heaters. Many
problems are often traced to the use of the wrong type of fuel
or dirty fuel.
Use caution and common sense when working on a heater.
Always remember that kerosene is flammable, and electrical
parts can result in potential shock. Heater parts are hot during
operation, which could result in burns.
Wiring Diagrams ................................................. 23
For replacement parts contact:
3
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Hot Surface Ignition Models Service Manual
IV. TOOLS REQUIRED
V. PARTS
In addition to common hand tools, the service shop should
have the following tools and instruments for proper repairing
of the heaters. These instruments will be referred to throughout this manual.
In addition to the standard parts we now offer parts kits. Listed
below are the item numbers and the accessory description
INSTRUMENT
RANGE
Control/Photocell Tester
Pressure Gauge
Feeler Gauge
Multimeter
N/A
0-15 P. S. I.
.001 to .1 inch
0-250 VAC
0-200 Ohm
ACCESSORY
HA1180
HA1210
HA1202
HA2210
Air Gauge/All Models
Thermostat/Forced Air & LP Forced Air
Heavy Duty Wheel Kit
Fits: 35, 40, 50, 55, 60, 70 Models
Wheel Kit
Fits: 35, 40, 50, 55, 60, 70 Models
Rear Handle Fits: 110, 115 Models
Rear Handle
Fits: 150, 155, 165, 200 Models
Filler Neck Screen
ITEM NUMBER
REPLACEMENT PART
104068-03
Ignition control
Fits: 35, 40, 50, 55, 60 Models
Ignition control Fits: 70, 110, 115,
150, 155, 165, 200 Models
Rotor Kit 1/2"
Nozzle (35, 40 Models)
Nozzle (50/55 Models)
Nozzle (60 Models)
Nozzle (70 Models)
Nozzle (110, 115 Models)
Nozzle (150, 155 Models)
Nozzle (165 Models)
Nozzle (200 Models)
Hot Surface Ignitor
Air Filter Kit
(35, 40, 50, 55, 60, 70 Models)
Filter Kit
(110, 115, 150, 155, 165, 200 Models)
PART NUMBER
HA1170
HA1180
None*
None**
HA1206
*Available at any auto parts store.
**Available at most electronic stores.
HA2203
HA2204
.025
15
Feeler
Gauge
.00
HA1170
Control
Tester
ITEM NUMBER
104068-02
PP204
PP206
Refer to Owner’s Manual
PP219
PP220
PP221
PP222
PP223
PP235
PP200
PP213
Pressure Gauge
Multimeter
PP214
PP205
M16656-24
PP217
For replacement parts contact:
4
Rotor Kit 5/8"
Photocell
Pump Adjustment Kit
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Hot Surface Ignition Models Service Manual
SPECIFICATIONS
3. Ventilation
I. GENERAL SPECIFICATIONS
The heater should be used only in well-ventilated areas. As a
rule, the following minimum requirements should be followed.
1. Fuel Selection
HEATER SIZE (BTU)
SQUARE FOOT OPENING
One of the most critical specifications for trouble-free operation is the use of a clean, acceptable fuel. Listed below are
guidelines and comments concerning operation of heaters
with different fuels.
35,000/40,000
50,000/55,000/60,000
70,000
110,000/115,000
150,000/155,000
165,000
200,000
1.0 Sq. Ft.
1.6 Sq. Ft.
2.1 Sq. Ft.
3.2 Sq. Ft.
4.5 Sq. Ft.
5.0 Sq. Ft.
6.0 Sq. Ft.
RECOMMENDED
FUELS
COMMENTS
Kerosene
Fuel Oil No.1
Jet "A"
Best overall results. Minimum odor and
minimum maintenance. No additives
necessary for cold weather operation.
ALTERNATE FUELS
COMMENTS
Fuel Oil No. 2
Diesel No. 1
Diesel No. 2
Noticeable increase in odor. Requires
frequent maintenance of fuel filter
and nozzle. Requires a winterizing
additive at temperatures below 20°F
2. Electrical
The heater must be connected to a standard electrical outlet
(120V/60HZ). For safety, all heaters are equipped with a three
prong power cord, which must be grounded. When selecting
an extension cord for heater usage, the following chart should
be used in determining wire size.
LENGTH OF CORD
WIRE SIZE (AWG)
100 Ft.
200 Ft.
300 Ft.
400 Ft.
No. 14
No. 12
No. 10
No. 8
No. 6
For replacement parts contact:
The above is based on ventilation requirements of at least a
3 sq. ft. opening per 100,000 BTU. If possible, it is better to
provide cross-ventilation to achieve better air movement.
4. Heater Sizing
The user should be aware of the proper size heater needed
for a particular application. It is easy to see that a 35,000 BTU
heater would not heat a large warehouse, but the question is
sometimes asked "What size heater should I use?" A simple
formula that can be used to determine heater BTU requirements follows:
Cu. Ft. of Area X .133 X Desired Temp. Rise °F = BTU Size
Needed.
Example:
Area: 50' X 25' X 10' = 12,500 Cu. Ft.
Desired Temp. Rise: 30°F
12,500 (Cu. Ft.)
X .133 (Factor)
1662.5
X 30 (Temp. Rise)
49,875 (Proper Heater Size)
5
ANSWER: A 50,000 BTU
heater should be selected
for this application.
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Hot Surface Ignition Models Service Manual
II. HEATER PERFORMANCE SPECIFICATIONS
Technical Service Heater Performance Data
Heater Model
BTU
Rating
Pump
PSI
± .1
Nozzle
Part No.
Nozzle
GPH
± 5%
Motor
Part No.
Motor
Motor
R.P.M. Horsepower
R35D
REM35C
35,000
3.0
100735-02
(HA3006)
(PP206)
0.30
100088-01
(102001-01)
1725
1/15
R40
REM40
40,000
3.0
100735-02
(PP206)
(HA3006)
0.30
100088-01
(102001-01)
1725
R55A
REM55A
55,000
3.6
100735-17
(HA3024)
(PP219)
0.40
100088-01
(102001-01)
R60
REM60
RM60
60,000
3.4
100735-17
(HA3024)
(PP219)
0.40
R70D
R70DT
70,000
4.7
100735-18
(HA3026)
(PP220)
R110B
R110BT
110,000
5.3
R115
REM115
RM115
115,000
REM150E
Ignitor
Kit
Control
Board
Fuel
Tank
Capacity
(Gal)
Hot Air
Output
(C.F.M.)
AMPS
(Running)
102548-03
104068-03
PP200
3.0
165
2.0
1/15
PP200
102548-03
104068-03
3.0
170
2.0
1725
1/15
PP200
102548-03
104068-03
5.0
175
2.0
100088-01
(102001-01)
1725
1/15
PP200
102548-03
104068-03
5.0
180
2.0
0.50
103609-01
(102001-20)
3450
1/8
102548-03
104068-02
PP200
5.0
250
2.8
100735-19
(HA3027)
(PP221)
0.80
103493-01
(102001-21)
3450
1/5
102548-03
104068-02
PP200
9.0
490
3.6
5.3
100735-19
(PP221)
(HA3027)
0.80
103493-01
(102001-21)
3450
1/5
PP200
102548-03
104068-02
9.0
490
3.6
150,000
5.4
100735-20
(PP222)
(HA3028)
1.10
103493-01
(102001-21)
3450
1/5
PP200
102548-03
104068-02
13.5
550
3.6
R155B
REM155B
RM155
155,000
5.4
100735-20
(HA3028)
(PP222)
1.10
103493-01
(102001-21)
3450
1/5
PP200
102548-03
104068-02
13.5
550
3.6
R165AT
165,000
5.6
100735-21
(HA3029)
(PP223)
1.20
103493-01
(102001-21)
3450
1/5
PP200
102548-03
104068-02
13.5
575
3.6
R200A
200,000
6.2
100735-31
13
(PP235)
1.40
105183-01
(102001-27)
3400
1/4
102548-03
104068-02
PP200
13.5
600
3.6
M16656-24 Photocell will apply to all models for service.
For replacement parts contact:
6
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Hot Surface Ignition Models Service Manual
COMPONENT OPERATION
3. Nozzle
I. AIR SYSTEM
1. Air Pump
The heater's air pump consists of a rotor with four carbon
blades rotating inside a pump body. The rotor is driven directly
by the motor and is attached to the motor shaft by means of
a plastic insert. As the motor rotates, the carbon blades travel
outward rubbing against the inside surface of the steel pump
body. The rotor's position inside the pump body is such that
it is not concentric with the pump body and a .003/.004 of an
inch gap is set at the uppermost quadrant. As the motor
rotates, the air between the blades is compressed and routed
to the nozzle through the air line.
Gap Adjusting
Screw
As mentioned previously, the purpose of the air pump is to
compress air and deliver it to the nozzle. The compressed air,
as it travels through the nozzle, creates a negative pressure
that extends back through the center of the nozzle. This
negative pressure lifts the fuel from the fuel tank. The fuel from
the fuel tank and the compressed air are mixed at the nozzle
which results in a very fine mist of fuel being sprayed into the
combustion chamber. The air pump/nozzle combination eliminates the need for a conventional type fuel pump. It is
important for the service technician to understand the nozzle
operation. In many cases concerning improper operation of a
heater, the problem is the result of a seal leak or a restriction
(dust/dirt) being present within the nozzle. It should also be
pointed out that each model heater requires different nozzles
due to different fuel flow rates.
.003/.004
Clearance
Measured
with Feeler
Gage
Motor Shaft
Insert
Compressed
Air From
Pump
Air Intake Side
Air Output
Side
Rotor
Nozzle Face
Pump Body
Blade
Fuel Lifted From Tank
by Negative Pressure
Direction of Rotation-Clockwise
2. Air Filters
II. ELECTRICAL SYSTEM
The air filtering system consists of an air input filter and an air
output filter. The air input filter is located at the right rear of the
motor and its purpose is to filter all incoming air prior to
entering the air pump. The filter design is such that it can be
cleaned in a mild, soapy solution, thoroughly dried and used
over again. The air output filter is located under the plastic end
cover. This filter's purpose is to prevent any carbon dust (from
rotor or blade wear) from entering the air passages in the
nozzle. This filter is non-cleanable and should be replaced
when considerable buildup of carbon dust is observed. (See
drawings below).
1. Motors
Air Output Filter
Air Output Filter
Air Input
Filter
Air Input
Filter
The motors used on the low pressure heaters are fractional
horsepower motors ranging from 1/15 HP on the smallest
heater to 1/4 HP on the largest heaters. The motors used can
be grouped into two categories. The first category is the
shaded pole motor. The shaded pole motor contains a single
winding and does not require an integral start/run capacitor for
operation. This type of motor is used on 35, 40, 50, 55, and 60
model heaters.
The second category is the permanent start capacitor motor.
This motor contains two separate windings. The first winding
being the auxiliary or start winding and the second being the
main or run winding. This motor utilizes an integral start/run
capacitor which is wired internally and cannot be replaced.
This type of motor is used on the 70, 110, 115, 150, 155, 165,
and 200,000 Btu models.
X
AU
MOTOR
35,000, 50,000, 55,000, and
70,000 BTU
Filter System
AC LINE
110,000, 115,000, 150,000,
155,000, 165,000, and 200,000
BTU Filter System
For replacement parts contact:
Shaded Pole Motor
7
CAPACITOR
MA
IN
AC LINE
Permanent Start Capacitor Motor
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Hot Surface Ignition Models Service Manual
2. Ignition Control/Photo Cell
3. Hot Surface Ignitor
The ignition control circuit consists of a photocell (light sensitive resistor) and an ignition control. The photocell is used to
sense the presence of light inside the combustion chamber.
The resistance of the photocell changes as the light level
inside the combustion chamber changes. When the heater is
operating properly, the flame pattern inside the combustion
chamber is very turbulent which results in the resistance of the
photocell increasing and decreasing very rapidly. This dynamic change in resistance is required by the ignition control
to allow the heater to continue to operate. If the signal from the
photocell becomes “lazy” or steady state indicating a lack of
turbulence, then the heater will be turned off. Some examples
of this condition are a loss of fan and a blocked inlet. Because
the photocell also responds to the color of the flame, the
control will also shut off the heater if the fuel/air mixture is too
lean. With a fuel lean mixture the flame becomes blue in color
and the photocell does not respond to that end of the light
spectrum as well as it responds to orange light which is
present during proper operation. As a service technician, it is
important to understand the operation of the ignition control.
In the past, it has been the single most misdiagnosed part of
the heater. It is suggested that all controls be checked per
instructions listed in the Troubleshooting section, prior to
replacement.
All models will use 102548-03
PP200 Ignitor Kit.
Photocell
The hot surface ignitor is rated for 120 volts. With the rated
voltage applied, the ignitor element heats up to 1400º Celsius
(2550º Fahrenheit) within 5 seconds. When the atomized fuel
is sprayed by the nozzle it is ignited by this extremely hot
surface.
Note: It is important for the service technician to be cautious
when working with the hot surface ignitor due to its extremely
high operating temperature. Care should also be taken not to
bend or strike the ignitor element.
Ignitor
Block
Ignitor Element
III. FUEL SYSTEM (FUEL FILTERS)
There are several types of fuel filters used on different model
heaters. The filters are always located in line with the fuel
pickup tube. The purpose of the filter is to eliminate the
possibility of dirt, dust, etc. from entering the nozzle and
restricting the flow. The filters should be inspected and
cleaned whenever a heater is brought in for service. It is also
important that the bottom of the tank be inspected for sedimentation or dirt buildup. The filter’s design is such that a
possible restriction in the filter screen can be present during
operation and be dislodged back into the tank when the heater
is shut off.
Ignition Control
(mounted on side cover)
35, 40, 50, 55,
60, and 70,000
Btu Models
For replacement parts contact:
8
110, 115, 150,
155, and 165,000
Btu Models
200,000 Btu
Model
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Hot Surface Ignition Models Service Manual
IV. COMBUSTION SYSTEM
V. ALL SYSTEMS WORKING TOGETHER
Air being blown by the fan is directed by the air deflectors into
the combustion chamber through the two louvers and center
opening in the rear head which is riveted to the back of the
combustion chamber. The nozzle and nozzle adapter are
mounted in the burner strap which is fastened to the rear
head. As the atomized fuel exits the nozzle and is ignited it
mixes with the air entering through the rear head. The
combustion process is completed inside the combustion
chamber and the hot air exits the outlet end of the chamber.
There are four basic systems within the heater: the fuel
system, the air system, the electrical system, and the combustion system.
An air pump (A) on one end of the motor shaft forces air
through the air line (G) and out the nozzle (I). The moving air
creates a pressure differential in the nozzle adapter (N)
causing fuel to be drawn from the tank (J). The fuel-air mixture
is sprayed into the combustion chamber (L) in a fine mist.
Additional air is supplied to the combustion chamber by a fan
(O) to enter the combustion chamber where it mixes with the
air and fuel from the nozzle. The remaining air is directed
around and over the combustion chamber. This air mixes with
the heated air from the combustion chamber and is ejected as
a jet of clean, heated air (K).
The ignition system consists of an ignition control assembly
(E) and hot surface ignitor (M). The ignition control assembly
applies 120 volt power to the hot surface ignitor for 10 seconds
which consists of a 5 second preheat period and a 3 to 4
second ignition trial period. The extremely high temperature
of the ignitor element ignites the fuel and air mixture within the
combustion chamber. After the trial period the power is
removed from the ignitor.
Air Deflector
In the safety circuit, the photocell monitors the amount of
flame turbulence inside the combustion chamber.
Fan
L
N
M
A
O
K
J
I
Air For Fuel System
For replacement parts contact:
9
G
Air For Combustion
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E
Fuel
Hot Surface Ignition Models Service Manual
TROUBLESHOOTING
Calibration
I. SAFETY REQUIREMENTS
IMPORTANT: This tester will not function properly without
adequate battery power. Prior to using the tester, the full load
battery voltage must be verified as follows.
This service manual is intended for use by individuals with an
adequate knowledge of electrical and mechanical skills. Attempts to repair this heater by individuals without those skills
can result in personal injury, as well as property damage.
II. CAUTIONS
1. Before servicing, disconnect the heater from the electrical power source by removing the electrical plug from
the wall receptacle.
Note: When certain tests require electrical power to be
applied, connect electrical power only for the time necessary to complete the test.
2. Do not bypass safety devices except when instructed to
do so during troubleshooting procedures.
3. If replacement parts are necessary, do not substitute with
non-factory parts (use only factory authorized replacement parts).
4. Make sure all electrical connections are secure and correct prior to connecting heater to a grounded electrical
power source.
Remove the battery cover to expose the battery and terminals. With the battery connected and the switch in the ON
position (LED on continuous), measure the D.C. voltage
across the battery terminals. If this voltage reads 7.5 volts or
higher, proceed with testing. If the voltage reads lower than
7.5 volts, replace the battery and confirm the full load voltage.
Battery Cover
III. USING THE HA1170 TESTER
The HA1170 control/photocell tester provides a means of
troubleshooting the forced air kerosene heater by verifying
the operation of the ignition control and photocell.
Operation
The tester’s toggle switch has three positions. The middle
position puts the tester in the OFF mode. The switch should
be kept here when the tester is not in use to conserve battery
power. With the switch in the ON position, the red LED is on
continuous. This 2 foot-candle light source can be used to test
the static resistance of the photocell. With the switch in the
PULSE position, the red LED flashes off and on at a rate of 10
times per second (10 hertz). This position is used to verify the
proper operation of the ignition control.
Toggle Switch
Battery
Battery
Terminals
IV. DIAGNOSTIC CHARTS
The following pages contain various diagnostic charts. To use
the charts, find the "Observed Fault" that exists and follow test
procedure.
Observed Fault Index
Motor starts and runs but fuel does not ignite ................. 11
Ignitor element heats up but motor does not start within
five seconds ................................................................... 14
Ignitor does not heat up and motor does not start within five
seconds ........................................................................... 17
Ignitor heats up, motor starts and runs, and fuel ignites, but
heater shuts off after a short period of time .................... 18
Delayed Ignition .............................................................. 22
Test Leads
LED Light
HA1170 Tester
For replacement parts contact:
10
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Hot Surface Ignition Models Service Manual
OBSERVED FAULT
Motor Starts and Runs but Fuel Does Not Ignite
Does Ignitor Element Heat Up?
Yes
No
WARNING: High Voltage!
1
3
Check for Proper Pump Pressure
Check for
Defective Ignitor
Check for Restricted Fuel Flow
Due to:
A. Seal leak
B. Restriction in Nozzle or Nozzle Adapter
C. Defective Solenoid Valve
(200,000 Btu Models Only)
Fuel Filter Restriction
4
2
Defective Ignition
Control Assembly
5
TEST PROCEDURE
1 Check Ignitor
Disconnect ignitor wires from ignition control assembly.
Measure the resistance of the ignitor at the terminals with
an ohmmeter (use 0-200 OHM scale). Ignitor resistance
should measure 30 to 175 OHMS. If resistance measures
outside of this range, then ignitor is defective and should
be replaced.
2 Check Ignition Control Assembly
Remove fuse cover and check fuse (70,000 to 200,000
Btu models only). If fuse is blown replace it with a GMA10 fuse. Disconnect motor red and white wires from control. With Ignitor wires disconnected, attach voltmeter
leads to the ignitor terminals (labeled IGNITOR). Use the
0 to 200 V.A.C. scale. Plug power cord into a grounded
120V/60 Hz outlet. Meter should read 120V(rms) for approximately 10 seconds. If voltage reads 0 or stays at
120 for more than 10 seconds, the control is defective
and should be replaced.
Ignition Control
WARNING: High Voltage!
For replacement parts contact:
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Hot Surface Ignition Models Service Manual
3 Check for Proper Pump Pressure
4 Check for Restricted Fuel Flow
Install HA1180 Pressure Gauge or equivalent to rear of
air filter housing. Start heater and adjust air pressure to
specified pressure. Turn adjustment screw clockwise
to increase pressure and counterclockwise
to decrease pump pressure. The screwdriver must be removed
from the slot after any adjustment before taking a reading on the gauge. (See Heater Performance Specification on page 6 for specified pressures).
Note: Pressure gauge must be scaled in 1/4 pound increments for accurate measurement.
35,000 to 165,000 Btu Models Remove air and fuel lines
from nozzle adapter. Remove nozzle adapter/nozzle from
bracket.
200,000 Btu Model Remove ignitor (do not strike or bend
element) from bracket. Place in a safe location. Remove
air and fuel lines from nozzle adapter. Remove two
bracket screws and remove bracket, nozzle adapter, and
nozzle assembly from combustion chamber.
Using a 5/8" socket wrench, carefully remove the nozzle
from nozzle adapter. (Be extremely careful not to scratch
or score the face of the nozzle).
A. Seal Leak
Inspect nozzle seal or o-ring for damage. Replace if necessary.
Combustion
Chamber
Nozzle/
Adapter
Assembly
Nozzle Face
Nozzle
Seal
Nozzle
Nozzle
Adapter
Air Line
Fitting
Fuel Line
Fitting
35,000 - 165,000 Btu Models
Nozzle Face
Nozzle
Seal
Nozzle
Adapter
Nozzle
Nozzle
Adapter
Bracket
Air Line
Fitting
Fuel Line Fitting
200,000 Btu Models
For replacement parts contact:
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Hot Surface Ignition Models Service Manual
B. Restriction in Nozzle or Nozzle Adapter
Using a compressed air source, blow the compressed
air through the outlet end of nozzle to dislodge any foreign debris.
5 Fuel Filter Restriction
The fuel filter should be inspected and cleaned (see section III, Fuel System (Fuel Filters), page 8. After removing filter, flush with clean kerosene in the reverse direction of the fuel flow.
CAUTION: NEVER DRILL OUT OR TRY TO INCREASE
NOZZLE SIZE.
Fuel Filter,
Bushing,
and Lower
Fuel Line
Also, blow compressed air through the nozzle adapter in
the direction shown to dislodge any foreign debris.
Note: Fuel Filter Location
May Vary According To
Model. Refer to Fuel
System, page 8.
Fuel
Flow
Direction
Flush
In This
Direction
Blowing Compressed Air Through Nozzle
35,000 - 165,000 Btu Models
100,000 - 165,000 Btu Models Shown
200,000 Btu Models
Blowing Compressed Air Through Nozzle Adapter
C. Defective Solenoid Valve (200,000 Btu model only)
Remove upper and lower fuel lines from fittings on solenoid valve. Apply 120V/60 Hz power to valve. Shine a flashlight at one side of valve. Light should be visible from the
other side when the solenoid is energized. If not, the valve
is obstructed or defective. Clean or replace as necessary.
For replacement parts contact:
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Hot Surface Ignition Models Service Manual
OBSERVED FAULT
Ignitor Element Heats Up But Motor
Does Not Start Within Five Seconds
Rotate Fan by Hand to Determine
if Fan Rotates Easily
Fan Rotates Easily by Hand
Fan is Difficult to Rotate
1
Broken Rotor or Blades
5
Open Motor Winding
2
Improper Rotor Clearance
6
Defective Ignition Control Assembly
3
Oversized Rotor
7
Defective Start/Run Capacitor
4
Dry Motor Bearing
8
Improper Voltage to Heater
TEST PROCEDURE
1 Broken Rotor or Blades
Gap
Disassemble the end cover filter and end pump cover
from rear of motor. Visually inspect the rotor and blades
for breakage. Make sure that the rotor and blades are
free of any type of lubricant. Rotor and blades must be
clean and dry for proper operation.
Blade
2 Improper Rotor Clearance
Check rotor with feeler gauge for proper clearance
(.003"-.004") between rotor and pump body. Rotate rotor and make sure all four quadrants of rotor have adequate clearance.
Pump Body
Rotor
3 Oversized Rotor
If the fan is hard to turn when the motor end cover is
installed, but easy to turn when loosened, the rotor should
be removed and lightly sanded. Remove the rotor and
lightly sand by placing rotor in the palm of hand and sanding on a flat surface making figure eight rotations. (Use
the finest grade of sandpaper available).
For replacement parts contact:
Sandpaper
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Hot Surface Ignition Models Service Manual
4 Dry Motor Bearing
If the fan is difficult to turn with air pump parts removed,
then motor bearings are defective. Bearings are permanently lubricated, therefore motor should be replaced.
5 Open Motor Windings
Disconnect motor wires (red and white) from ignition control assembly. Attach the ohmmeter leads to the moter
wire terminals. Using the 0 to 200 OHM scale, measure
the resistance of the motor windings. Refer to the chart
below for resistances for each model. If the resistance is
not within the specified range motor is defective and
should be replaced.
NOTE: Resistances may vary due to motor temperature.
Note: Motor may vary
according to model
MOTOR WINDING RESISTANCE
MODEL
RESISTANCE
RANGE (OHMS)
35,000, 50,000, 55,000, 60,000
5.57-6.81
70,000
6.03-7.37
100,000, 110,000, 150,000
155,000, 165,000
4.14-5.06
200,000
3.96-4.84
Note: In some cases it is possible for the resistance to read
correctly without power applied and the motor still not work
with power applied. If the ignition control assembly is tested
and found to be good, then the motor is defective and should
be replaced.
For replacement parts contact:
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Hot Surface Ignition Models Service Manual
6 Defective Ignition Control Assembly
Disconnect motor wires from control. Attach voltmeter
leads to motor terminals on control. Use 0 to 200 V.A.C.
scale on meter. Plug power cord into a 120V/60 Hz
grounded outlet. Meter should read 0 volts for five seconds, 120 volts for 3 to 4 seconds, then drop to 0 volts. If
the meter remains at 0 volts, the control is defective and
should be replaced.
7 Defective Start/Run Capacitors
Motors used in 70,000 to 200,000 Btu model heaters are
the Permanent Start Capacitor (PSC) type and are
equipped with an integral start/run capacitor. If the resistance of the motor windings read correctly and the ignition control assembly is found to be working properly,
the capacitor may be "open" circuit. The capacitor is wired
internally and cannot be replaced. No service parts are
available and entire motor assembly should be replaced.
8 Improper Voltage Input to Heater
The specified voltage operating range for this product is
108 to 132 volts (rms) 60 hertz. Verify that the voltage
applied to the heater while the motor is running is at least
108 volts and does not exceed 132 volts. Refer to the
Electrical section of this manual (page 5) for proper extension cord sizing.
For replacement parts contact:
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Hot Surface Ignition Models Service Manual
OBSERVED FAULT
Ignitor Does Not Heat Up and Motor
Does Not Start Within 5 Seconds
Possible Causes External to Heater
Possible Causes Internal to Heater
Circuit Breaker is Tripped
1
Check for Broken or Frayed Wires
on Power Cord or Extension Cord
Bad Electrical Connection(s) or
Wired Incorrectly
2
Blown Fuse on Ignition Control
Assembly
3
Defective Ignition Control Assembly
If External Thermostat is Used,
Plug Heater Directly Into AC Source
to Isolate Source of Problem
power to control. Meter should read 0 volts for five seconds, 120 volts for 3 to 4 seconds, then drop to 0 volts. If
measurements differ from those described, control is defective and should be replaced.
TEST PROCEDURE
1 Bad Electrical Connection(s) or Wired Incorrectly
Verify that all connections to the ignition control assembly are secure and wired according to the wiring diagram
on page 23.
Ignitor
Motor
Fuse
Clips
Motor
Ignitor
Fuse
Checking Fuse
2 Blown Fuse on Ignition Control Assembly
Remove fuse cover and
and inspect
inspect fuse.
fuse. Check
Checkfor
forcontinucontinuity
ity with
ohmmeter.
If fuse
is open,
replace
with
a fuse
with
an an
ohmmeter.
If fuse
is open,
replace
with
113752-01
of
the
same
type
and
rating
(GMA-10).
or a fuse of the same type and rating (GMA-10).
3 Defective Ignition Control Assembly
With motor and ignitor wires disconnected, connect voltmeter leads to the ignitor terminals. Use the 0 to 200
V.A.C. scale on the voltmeter. Apply power (120V/60Hz)
to the control. The meter should read 120 volts for ten
seconds and then drop to 0 volts. Remove power to control. Connect meter leads to the motor terminals. Apply
For replacement parts contact:
Meter Leads
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Hot Surface Ignition Models Service Manual
OBSERVED FAULT
Ignitor Heats Up, Motor Starts and Runs, and Fuel Ignites,
But Heater Shuts Off After a Short Period of Time
Safety Control Trips out After
Ten Seconds of Operation
Ignition Control Trips out Within the
First Ten Seconds of Operation
1
Defective Ignition Control
2
Defective or Dirty Photocell
3
Bad Electrical Connection(s) or
Wired Incorrectly
4
Photocell Boot Not Properly Seated
in Bracket
5
Check for proper Pump Pressure
6
Dirty/Clogged Filters in Compressor
7
Check for Restricted Fuel Flow
Due to:
A. Seal Leak
B. Filter Blocked
C. Restriction in Nozzle or
Nozzle Adapter
8
Fuel Cap and Gasket Not Vented
TEST PROCEDURE
Toggle Switch
1 Defective Ignition control
Remove pressure gauge plug from filter end cover. Remove 4 side cover screws that attach the side cover to
the heater. Allow side cover (with ignition control attached)
to rest on fuel tank flange. Disconnect only the photocell
wires from ignition control. Attach the HA1170 leads to
the photocell terminals on the ignition control. Plug the
power cord into a grounded 120V/60 Hz outlet. When
the motor starts turn the HA1170 toggle switch to the
"flashing" red LED position (see page 10 for HA1170
calibration procedures). If the motor shuts off after 3 or 4
seconds, the control is defective and should be replaced.
If the motor continues to run in step 1, the photocell may
be dirty or defective.
For replacement parts contact:
Flashing
Red LED
Test Leads
Photocell
Ends
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Hot Surface Ignition Models Service Manual
2 Defective or Dirty Photocell Assembly
Inspect the lens of the photocell for soot/dirt, etc... If dirty,
wipe off with a clean, damp cloth.
Remove photocell assembly from heater. Turn the toggle
switch on the HA1170 tester to the "solid" red LED position. Place the photocell boot over the red LED on the
tester. Connect the leads of an ohmmeter to the terminals on the photocell assembly. Use the 0 to 20,000 OHM
scale on the meter. The resistance should measure
11,000 OHMS or less. If not the photocell is defective
and should be replaced.
Block off the light source by putting thumb over opening
of photocell. Replace the photocell if a change in resistance is not observed.
The resistance should measure greater than 50,000
OHMS (use the 1 megohm scale on the meter).
3 Bad Electrical Connection(s) or Wired Incorrectly
Verify that all electrical connections are secure and making electrical contact. Verify that wiring is per the wiring
diagram (see diagram, page 23).
4 Photocell Boot Not Properly Seated in Bracket
Make sure photocell boot is seated in bracket securely.
See illustration that follows.
Photocell
Correct Photocell Placement
Photocell
Incorrect Photocell Placement
For replacement parts contact:
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Hot Surface Ignition Models Service Manual
5 Check for Proper Pump Pressure
6 Dirty/Clogged Air Filters in Compressor
Inspect and replace air intake, air output, and lint filter if
necessary. Filters should be replaced after 500 hours of
operation.
Install HA1180 Pressure Gauge or equivalent to rear of
air filter housing. Start heater and adjust air pressure to
specified pressure. Turning adjustment screw clockwise
increases pressure, counterclockwise decreases pressure. The screwdriver must be removed from the slot
after any adjustment before taking a reading on the
gauge. (See Heater Performance Specification, on page
6 for specified pressures). It may be necessary to connect the HA1170 tester in place of the photocell while
adjusting the pressure due to the fast shutdown response
of the control.
Note: Pressure gauge must be scaled in 1/4 pound increments for accurate measurement.
Blade
Pump
Plate
Air
Intake
Filter
Insert
Rotor
HA1180
Pressure
Gauge
Air Output Filter
Fan Guard
Flat Blade
Screwdriver
Adjustment
Screw
For replacement parts contact:
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Filter End
Cover
Hot Surface Ignition Models Service Manual
8 Fuel Cap and Gasket Not Vented
7 Check for Restricted Fuel Flow
Remove fuel cap and inspect the vent hole and gasket
to make sure the passage is open. Verify that only one
gasket has been installed. The fuel tank must be vented
properly for the fuel delivery system to operate correctly.
35,000 to 165,000 Btu Models Remove air and fuel lines
from nozzle adapter. Remove nozzle adapter/nozzle from
bracket.
200,000 Btu Model Remove ignitor (do not strike or bend
element) from bracket. Place in a safe location. Remove
air and fuel lines from nozzle adapter. Remove two
bracket screws and remove bracket, nozzle adapter and
nozzle assembly from combustion chamber.
Using a 5/8" socket wrench, carefully remove the nozzle
from nozzle adapter. (Be extremely careful not to scratch
or score the face of the nozzle).
A. Seal Leak
Inspect nozzle seal or o-ring for damage. Replace if necessary.
Combustion
Chamber
Nozzle/
Adapter
Assembly
Nozzle Face
Nozzle
Seal
Nozzle
Nozzle
Adapter
Air Line
Fitting
Fuel Line
Fitting
35,000 - 165,000 Btu Models
Nozzle Face
Nozzle
Seal
Nozzle
Adapter
Nozzle
Nozzle
Adapter
Bracket
Air Line
Fitting
Fuel Line Fitting
200,000 Btu Models
For replacement parts contact:
21
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Hot Surface Ignition Models Service Manual
OBSERVED FAULT
Delayed Igniton
1
Wrong Fuel
2
Contaminated or Old Fuel
TEST PROCEDURE
1 Wrong Fuel
Refer to Fuel Selection on page 5 of this manual.
2 Contaminated or Old Fuel
Fuel may not be fresh or may be contaminated with water or other foreign liquids. Drain fuel tank and rinse with
clean, fresh kerosene or No. 1 fuel oil. Refer to local city
or county ordinances for proper disposal of fuel oil.
For replacement parts contact:
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Hot Surface Ignition Models Service Manual
WIRING DIAGRAMS
White
102350-01 (104068-01 Kit)
Ignition Control Assembly
AC Neutral (L2)
Photocell
Blue
Photocell
Blue
Photocell
Green
White
Motor Return
Green
Ignitor
Motor
Motor
Red
AC Hot (L1)
Black
ATTENTION: Earth ground must be
connected to ensure operator safety!
Power Plug
120V/60Hz
Ignitor
Gray
Ignitor
Gray
55,000 BTU Model (R55A Model Only)
Blue
Photocell
Blue
Photocell
White
Ignitor
Motor
120V (L1)
Red
Motor
Black
Black
Green
AC Neutral (L2)
Power Plug
120V/60Hz
Green
White
Motor Return
Yellow (-01)
Gray (-02)
Ignition Control Assembly
104040-01/02 (104068-02/03 Kit)
Photocell
If Equipped With
Built-In Thermostat
Thermostat
Ignitor
Ignitor
Yellow (-01)
Gray (-02)
35,000, 40,000, 50,000, 55,000, 60,000, 70,000, 110,000, 115,000, 150,000,
155,000, 165,000 BTU Models
Blue
Photocell
Ignitor
White
Motor Return
Solenoid
Valve
AC Hot (L1)
Thermostat
Red
White
Green
Ignitor
If Equipped With
Built-In Thermostat
Motor
Red
Motor
Black
Black
White
Green
AC Neutral (L2)
Power Plug
120V/60Hz
White
Black
Ignition Control Assembly
104040-01 (104068-02 Kit)
Photocell
Blue
Photocell
Red
Black
Ignitor
200,000 BTU Model
For replacement parts contact:
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