Desa A50S Construction Heaters Owner's Manual 24 Pages
Desa A50S is a portable heater designed to provide temporary heat wherever you need it. It features a simplified solid state control that shuts down the heater in case it does not ignite or if the flame goes out during operation. The heater has a 50,000 BTU per hour output rating and a cold air flow of approximately 105 cubic feet per minute. It uses a three-prong plug for grounded power and a three-wire extension cord is recommended for adequate voltage. The heater comes with an intake air filter that should be checked and cleaned often, and an output air filter that should be replaced once each heating season.
Desa A50S Construction Heaters Owner's Manual
Desa A50S is a portable heater designed to provide temporary heat wherever you need it. It features a simplified solid state control that shuts down the heater in case it does not ignite or if the flame goes out during operation. The heater has a 50,000 BTU per hour output rating and a cold air flow of approximately 105 cubic feet per minute. It uses a three-prong plug for grounded power and a three-wire extension cord is recommended for adequate voltage. The heater comes with an intake air filter that should be checked and cleaned often, and an output air filter that should be replaced once each heating season.
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a tonmáeter SYSTEM PORTABLE HEATERS | MODEL A50S Spec. No.3158G02 Operation and Maintenance Instructions with Parts List EN CA KOEHRING Form No. 2838 (6/72) ORIGINAL ISSUE Koehring Master Division Litho in U.S. A. wor safety rules Safety Rules for Portable Heaters Fa 1.Know Your Portable Heater Read and understand the complete owners manual before starting the heater. 2. Heater Location Do not use the heater in the presence of flam- mable vapors, or within five feet of combustible - materials. Gasoline vapors are heavier than air and will accumulate in low areas. The heater must not be used in garages unless the door is kept open and it leads to an adjacent ground or driveway level that is at or below the level of the garage floor. | 3. Sleeping Quarters Do not use the heater in sleeping quarters. 4. Provide Ventilation To use the heater ina confined space, provide one square foot of ventilating area per each 100,000 BTU rating. 5. Use Only Recommended Fuel Use ONLY kerosene or No. 1 fuel ой. DO NOT USE GASOLINE. 6. Refueling Do not add fuel while the heater is operating. 7. Disconnect Heater Before servicing, cleaning, moving, etc. 8. Keep Unit Grounded Use the three prong plug provided. I an adapter is used, attach the adapter wire to a known ground. Never remove the third prong. Use only three- conductor extension cords. 9. Keep a Fire Extinguisher Accessible... It is recommended that a Dry Chemical type fire extinguisher be available when the heater is used. A3229-00 6/72 SECTION | INTRODUCTION A. GENERAL 1. Purpose of Heater. Use this portable heater wherever you need temporary heat. It must be used with adequate ventilation and proper electrical power. DO NOT use the heater in sleeping quarters. 2. Purpose of Manual. This manual contains detailed instructions for operating, maintaining, trouble shooting, and servicing the heater. A service parts list is included at the end of the manual. B. PRINCIPLES OF OPERATION Operation of the heater involves three basic sys- tems. (See Figure 1.) 1. Fuel System. An air pump on one end of the motor shaft forces air through thenozzle. The moving air lifts fuel from the tank by a siphon action and car- ries it into the cembustion chamber in a fine spray. 2. Ignition System. An electric arc that fires constantly between a pair of spark plug electrodes while the heater is in operation ignites the mixture of fuel and air. 3. Air System. Afanon the other end of the mo- tor shaft supplies additional air to the heater. Part of this air enters the burner through ports around its outer edge, and helps complete the combustion of the burning fuel-air mixture. The rest of the air from the fan passes over and aroynd the combustion chamber. At the front of the hedter it mixes withthe hot air coming from inside the combustion chamber. The air then flows out of the heater as a jet of clean, heated air. COMBUSTION _SPARK BURNER FAN AIR INTAKE AIR | CHAMBER PLUG [HERD / [PUMP FILTER == <=! | RH - [ <= || <= <= CLEAN € и = |< HEATED >» FUEL | COOL A AIR OUT оба 4 DR EL TER ib OOL AIR IN MM >| > A + <= : / à \ _ | À AIR LINE OUTP NOZZLE- | TO BURNER \oureur AR ; TRANSFORMER SU a AIR FOR COMBUSTION ZZ AR FOR FUEL SYSTEM BAND HEATING FUEL 1059 Figure 1. Schematic Diagram Showing Principles of Heater Operation A3255-00 —]- 6/72 C. SPECIFICATIONS CHARACTERISTIC Output rating (BTU per hour) ......., 50,000 Cold Air Flow, Approx. (Cubic feet per minute) _,........... 105 Amperage (During normal run) ,........ 4 Weight, Approx. (Lbs.) Shipping ........ 47 Net Dry ........ 41 + ет а те a CHARACTERISTIC Fuel Tank Capacity ............. 4.5 gallon (U.S. Gallons) Fuel Consumption (Gallons per Hour) ............... 0.33 Voltage and Cycles ............... 115/60 Motor RPM ,.................. 3,450 Duct ............. No duct recommended D. CONTROL SYSTEM 1. Description. The simplified solid state control installed on this heater is designed to shut down the heater in case ‘it does not ignite at start-up or if the flame should go out during operation. The control consists of a light sensitive cell, which has a low electrical resistance under the in- fluence of light rays and a high resistance when light is absent; a silicon controlled rectifier (SCR), whose excitation voltage is controlled by the light sensitive cell; and a circuit breaker whose internal heating coil is controlled by the SCR. : 2. Operation. When the heater is plugged into a power source and it fails to ignite, the high resistance of the Cad- . mium Sulphide cell (due to the lack of flame) will per- mit the gate of the SCR to trip. When this occurs, full _ line current will flow through the circuit breaker heat- _ ingcoil causing it to heat up. After about 15 seconds, A3256-00 Perature, the circuit breaker will trip and shut off power to the heater. After a trip-out the circuit breaker may be resetafter permitting the heating coil to cool three to five minutes. H a flame is established in the heater com- bustion chamber, the resistance of the Cadmium Sul- phidecell will drop. This in turn reduces the voltage atthe gate of the SCR below its excitation level. Cur- rent cannot flow through the circuit breaker coil, therefore it does notheatup. The circuit breaker will remain closed and keep the heater operating. E. ACCESSORIES A thermostat control kit, Part No. HA1200 is available as an accessory for use with these heaters. The thermostat can be set for any temperature be- tween 30 and 90 F, and will cycle the heater on and off to maintain the surrounding air at the desired tem- At its NO HEAT position, the thermostat shuts the heater off. 6/72 SECTION II OPERATION A. CHECKING POWER OUTLET The heater power cord is equipped with a three- prong plug and must be plugged into a grounded three- hole outlet. If your outlet has only two holes you can use a grounding adaptor providing that the outlet box 1s grounded. To check the two hole outlet to deter- mine if it is grounded, use a light bulb test lamp, 100 watts or more. Follow these steps to check. 1. Insert one test probe into one hole of the two hole outlet, then place the second probe on the face plate screw. If the receptacle is grounded the light will glow. Be sure to check both holes. (See Figure 2.) 2. A three hole outlet is checked the same as a two hole outlet except place one wire of the test lamp - in the round hole of the outlet. 3. To ground a non-grounded outlet, install a bare 14-gauge copper wire from the outlet box (figure 8) to a metal rod which has been driven at least 18 inches into the ground. Use a metal grounding clamp when attaching the wire to the metal rod. LIGHT GLOWS ONLY IF GROUNDED CHECK BOTH | FACE HOLES. PLATE SCREW 1062 INSULATED TEST PROBES B. EXTENSION CORD WIRE SIZES Be sure to use a three-wire extension cord of the proper size to assure adequate voltage at the heater. Length of cord (feet) 100 200 300 400 500 Wire Size (AWG) 14 12 10 8 6 C. FUEL 1. Be sure the tank is clean. Fill it with clean kerosene or No. 1fuel 0il ONLY. Do not use any other fuel. 2. Whenthe heater is operated at very low tem- peratures (beyond 10. F below zero), the fuel may con- geal. To prevent this, a non-toxic anti-icer can be added to the fuel. D. STARTING a. Check for adequate fuel supply. b. Plug the heater power cord into the grounded power supply outlet. The heater will start and run. WALL RECEPTACLE FACE PLATE FACE PLATE NN SCREW | O ADAPTER A 7 OUTLET \ BOX 14 GA. BARE COPPER WIRE POWER CORD 11063 Figure 2. Checking Power Outlet © A3257-00 Figure 3. Grounding A Non-Grounded Outlet 6/72 NOTE: I the heater should fail to ignite or the five minutes then press in on the reset button fire should go out during operation, the safety con- (See Figures). trol will shut off all power to the heater and ren- der the heater inoperable. The heater may be re- E. STOPPING | started after the cause of the shut down has been ° To stop heater, unplug heater cord from outlet. corrected. To restart the heater, wait three to (If the heater has a thermostat accessory, set the dial to NO HEAT. SECTION Ill MAINTENANCE Maintenance consists of the simple operations the ‘ A. FUEL TANK MAINTENANCE owner or user of the heater can perform to keep the heater running and in good condition. If ordinary main- tenance fails to return the heater to good operating Drainthe fuel tank after every 150 hours of oper- condition, refer to Section IV in this manual for check- ation, and flush it out with clean fuel. Refill with new ing and trouble shooting. See Figure 4 for maintenance clean fuel. points. | I * COMBUSTION BURNER (X) CHAMBER | SPARK PLUG (x) PHOTO CELL FUEL FILTER (3¢) TNC SAFETY ~ 1066 CONTROL Ne 7 —_ TRANSFORMER INTAKE AIR FILTER (e) OUTPUT AIR FILTER (INSIDE HOUSING) (>) LINT FILTER (INSIDE HOUSING) (%) Figure 4. Heater Maintenance Points Symbol (*) indicates parts. recommended as replaceable by owner or user of heater. (For clarity, heater is shown without tank, wheels and handles, and with upper shell removed.) A3258-00 _4- 6/72 LINT FILTER OUT PUT AIR FILTER CIRCUIT AIR INTAKE BREAKER FILTER = y \ N E . A > @ N [> )/ CIRCUIT | 5 BREAKER | - Я UZ7 BUTTON FILTER \ A HOUSING END COVER 4168 417A Figure 5. Removing Intake Air Filter Figure 6. Access to Air Filter for Maintenance B. AIR FILTERS с. REMOVING UPPER SHELL 1. Check and clean the intake air filter often. The filter needs cleaning if you can see a film of dust ‚оп И. It will need cleaning more often if the heater is operated in dusty air. See Figure 5. WARNING With the upper shell removed, the service cord must be unplugged as the heater can be 2. To clean the intake air filter, simply pull it dangerous. Be careful to keep away from out of the housing. Wash it with a mild detergent and — thesparkplug lead andthe fan when the upper hot or cold water, Dry it thoroughly, and replace it shell is off. in the housing. CAUTION: Do not oil the filter element. OIL FAN-END MOTOR BEARING HERE 3. Replacethe outputair filter once each heating season. 4. To reach the outputairfilter, remove the four screws which attach the filter housing end cover. Lift the output air filter out. See Figure 6. NOTE: Cleaning the output air filter may cause a change in the air pump output pressure. If the heater burns improperly after cleaning, have the air pump pressure checked. See Section V, par- agraph L. | 5. When changing the output air filter, clean the lint filter. Pick it out of the housing, wash with mild detergent and hot or cold water. Dry thoroughly. Do not oil. | 419A 6. Replace the lint filter, the output air filter, thefilter housing end cover, and the screws and wash- * ers. Figure 7. Lubrication of Motor Bearing chango 7 es OST Wo 050 GAP (THICKNESS OF A DIME) INSERT SPARK PLUG TO SHOULDER, TURN PLUG TILL WHITE DOT IS, IN LINE WITH LOCKING SCREW. TIGHTEN LOCKING SCREW. Figure 8. Spark Plug Gap Setting It will be necessary to remove the upper shell to perform the following maintenance operations. The heater will not operate properly when the upper shell isnot in place. Remove the upper shell by taking out the six screws (3 on each side) that hold the upper shell to the lower shell. Lift the upper shell off. — To replace the upper shell, align the six holes located along its lower edge over the six speed nuts on the lower shell, and install the screws. D. CLEANING THE FAN Clean the fan blades after every 500 hours of op- eration, or whenever you see that they are getting dirty. A build-up of dirt will reduce the air supply and cause faulty operation. | To clean, wipe the blades with a cloth moistened .-. with kerosene or solvent. Be careful not to bend the blades. Dry the fan thoroughly. E. MOTOR LUBRICATION The ball bearing on the pump-end of the motor is lubricated for the life of the motor. Do not lubri- cate it. Oil the sleeve bearing on the fan-end of the motor (See Figure:7) once each year with 10 to 20 drops of Mobile DTE-13 oil. Do not over-oil. F. SPARK PLUG WARNING Be sure the heater is not plugged into the outlet. The spark plug wire carries high “voltage during heater operation. A3260-00 COMBUSTION CHAMBER- BURNER HEAD “SPARK FUEL PLUG FILTER PHOTO CELL BRACKET 1067 Figure 9. Burner Head, Spark Plug, and Fuel Filter 1. Disconnect the spark plug wire. Check “the gap | between the electrodes. The gap must be within the limits shown in figure 8. 3. Adjust the gap by bending the outside elec- trode. Lm 4, Reinstall the spark plug otha hclctrodo go il i-voroas-ho-spray par ¡G. CLEANING THE FUEL FILTER The fuel filter is in the tube which leads up from the fuel tank to the burner. Clean it twice each sea- son, or if the Trouble Shooting Chart indicates. "To remove the fuel filter, loosen the hex nut at~ taching the filter tube and push the filter tube down into the tank so that the tube will clear the male connector on the bottom of the burner head. Move the tube to one side and withdraw the filter element. (See Fig. 9). The filter consists of a tube and a removable fine plastic-mesh filter element. Clean the filter as fol- lows: a. Slipthefilter element out of its tube, and rinse it several times in clean fuel. b. Blow the elementdry, gently, through the large end. Use caution to prevent damaging the filter element with air pressure. 6/72 RUBBER SLEEVE SEAL WASHER SPRING - SEAL WASHER LU É, NOZZLE PASSAGE с NOZZLE FACE 2) ÿ N \ Figure 10. Blowing out Nozzle with Compressed Air c. If the filter element is damaged or lost, it must be replaced with a new element. CAUTION: The heater should not be operated without the filter element in place. Failure to use the filter element will result in clogging and permanently damaging the nozzle. When reinstalling the filter, moisten the tube so it will slip into the grommet in the fuel tank top Check that the filter element is seated properly in the filter tube, then connect the tube to the fitting in the burner head. Tightenthenut securely to assure it will be air tight. NOTE: If the burner head is to be removed for maintenance, do not reinstall the fuel filter until ready to reinstall the burner. H. BURNER REMOVAL, CLEANING AND REPLACEMENT 1. Be sure the heater cord is unplugged, then remove the lead wire from the spark plug. Remove fuel filter from burner head. Disconnect the air line from the fitting in the right side of the nozzle adaptor. 2. Remove the photocell assembly from its bra- cket, then remove the screws that fasten the burner head to the rear of the combustion chamber and re- | move the burner head. A3261-00 3. Remove the nozzle carefully, using a socket wrench. Hold the nozzle adapter with another wrench while removing the nozzle. CAUTION Do not attempt to open the nozzle passage with a steel drill, a wire or any other tool. Any change in the nozzle opening will alter the flow characteristics which will affect heater performance. If solvent and reverse air flow through the nozzle cannot remove the contamination, replace the nozzle. Always protect the nozzle face when ever the burner head is removed from the heater. 4. Soak the remaining parts of the burner head assembly for one hour in non-flammable liquid clean- ing agent. (DO NOT use kerosene or fuel oil). Blow dry through fittings in rear of burner. Blow the nozzle dry through the face (OUTLET) end ONLY. See Fig- ure 10, o. Re-check the spark plug electrode setting after cleaning the burner. See Paragraph F of this Section. 6. When reinstalling the burner, place it on the back of the combustion chamber so the fitting for the fuel filter is down, and the spark plug is just above center, on the right. Install the attaching screws and tighten. 7. Connect the fuel filter and the air line from the filter housing, to their respective fittings on the nozzle adapter. 8. Install the photocell into its bracket, then in- stall the spark plug, and snap the spark plug lead onto the terminal. It must snap, or it may not be tight enough to prevent loosening as the heater is moved. CAUTION Do not attempt to repair the nozzle. If the nozzle is defective, replace it. I. REASSEMBLY AFTER MAINTENANCE Put the heater back together in the reverse order of disassembly. Be sure all parts are in place and all screws and electrical connections are tight, before attempting to use the heater. 6/72 SECTION Гу TROUBLE SHOOTING A. GENERAL If normal maintenance fails to keep a heater in good operating condition, it probably requires repair or replacement of some parts. Examine, then test- fire the heater to gain first-hand knowledge of why the service might be needed. This section tells how to examine and test-fire the heater. It also contains a Trouble Shooting Chart for help in diagnosing heater troubles and finding the rem- edies. B. EXAMINATION 1. Check the fuel tank for sludge and water. If you find it, expect to find a dirty nozzle and/or fuel filter. 2. Spinthefanto be sure it turns freely. If it is stiff, lookfor a worn or dry bearing on the fan-end of the motor, or for a binding pump rotor. 3. Check the heater for dirt and foreign mater- ials around the pump, fan, and air filters. the heater is reasonably clean before test-firing it. 4. Check the heater cord for obvious breaks or other unsafe conditions. If the cord is doubtful, repair it or install a new one before test-firing. C. TEST-FIRING 1. Clean the fuel tank and fill it with at least 2 gallons of fuel. A minimum of 3/4 gallon of fuel must be in the tank for proper test-firing. 2. Clean the air intake filter. (See Section III, paragraph B). ' A3262-00 Be sure 3. Check and adjust the air pressure, as de- scribed in Section V, paragraph L, except that fuel must be used for test-firing. NOTE: It is not possible to test-fire a heater properly if this adjustment cannot be made. | 4, Allow the heater to run for 15 minutes. Ob- serve its operation during the test-run. 5. After making the pressure check, adjustment, and test-firing, remove the gage and reinstall the plug. Tighten plug until sealed. Use soapy water to check for sealing. Do not overtighten. 6. Ifanytroubles show up during the test-firing, refer to the Trouble Shooting Chart to find out how to correct them. D. TROUBLE SHOOTING The following chart lists the problems you might findina heater. For each problem, there is a list of "Possible Causes." The "Remedy" column tells you how to correct the problem, or tells you by means of a section and paragraph number where to find detailed instructions for correcting it. In Trouble Shooting, remember that the air pump is part of the fuel system, because the air it supplies lifts the fuel from the tank and pushes it through the nozzle. NOTE: Be sure to follow all cautions and warn- ings. They will help you prevent damage to the heater or injury to yourself. 6/72 TROUBLE SHOOTING CHART § FOR FURTHER PROBLEM POSSIBLE CAUSE REMEDY DETAILS SEE: 1. Motor does Electrical Troubles not start. a. No power or low Be sure power is reaching heater; check voltage at heater. condition of heater cord. Repair or re- place as needed. Use extensioncord with wires heavy Sec. II, enough to carry the electrical load of Para. B. the heater. | Be sure voltage at outlet is same as shown on heater instruction plate. b. Damaged motor, Check motor, Sec. V, motor starting re- Para. F. lay, binding fan- end bearing; binding Replace a defective motor (or motor Sec. V, pump. starting relay). . Para. F. Lubricate motor (Fan-end only). — Sec, III, Para. E, Rebuild motor. Motor Mfr's| Instructions Rebuild or replace a binding pump. Sec. V, Para. K. Mechanical Troubles c. Dry bearing on Lubricate motor. Sec. III, fan-end of motor. Para. E. TI lubrication does not solve Sec. V, problem, check pump. . Para. K. d. Pump rotor binding Rebuild pump. Sec. V, or carbon blades | Para. K. worn out, e. Fan obstructed by Check for bent outer shell. Sec. V, mechanical damage Para. H. or dirt. Check for damaged fan; replace if defective. Check for damaged motor mount. A3263-00 -9- 6/72 TROUBLE SHOOTING CHART (Continued) FOR FURTHER PROBLEM POSSIBLE CAUSE REMEDY DETAILS SEE: 2. Heater will Fuel System Troubles not ignite. | ; | | a. Fuel tank empty, Check for water in tank; clean tank water in fuel, wrong and fuel filter if water is found. (Water fuel. in the tank will form globules in the bottom, which you can see). Fill tank with new, clean kerosene or No. 1 fuel oil. b. Fuel filter clogged. Remove and wash in clean fuel. бес. Ш, Blow dry and replace. Para. G. c. Nozzle plugged or de- Clean by blowing compressed air бес. Ш, fective. through nozzle from outlet end of Para. H. nozzle. Replace nozzle if cleaning does not Sec. V, solve the problem. Para. J. d. Low air pump Check pressure; adjust, rebuild, Sec. V, pressure. or replace air pump as needed. Paras. K € Ц Check rubber sleeve around shank Sec. V, of nozzle; replace if leaking. Para. J. Check to be sure all air line con- nections from pump to burner are secure. Check to be sure air filter end cover is securely fastened, without air leaks. Be sure air filters are clean. Sec. III, Para. B. e. Air leak at Check fuel filter for air leaks and fuel filter. for tightness of fitting where filter is connected to burner head. Ignition Troubles f. Defective spark Measure gap between electrodes, Sec. III, plug. (Wrong gap, using thickness of a dime as a Para. F. plug wet with fuel gage. Adjust electrode gap. or electrodes car- boned, or plug Inspect plug for broken porcelain — damaged. ) or electrodes. Discard a damaged spark plug. g. Spark plug wire dis- Disconnect heater cord! | connected from plug or from terminal of Check at plug and transformer to transformer. be sure wire is tight at both ends. A3264-00 -10- 6/72 TROUBLE SHOOTING CHART (Continued) FOR FURTHER PROBLEM POSSIBLE CAUSE REMEDY DETAILS SEE: (Continued) h. Defective Disconnect spark plug wire from trans- Sec. V, Heater will transformer, former, and check transformer for Para. E. not ignite. spark; replace if no spark can be obtained. i. Safety control Reset Safety Control. tripped. Heater burns, Improper Fuel-Air Mixture (Not enough fuel) but puffs of - smoke can be a. Heater running out of Shut heater off; check fuel tank. seen; heater fuel; water condensa- If you can see globules of water will not burn tion in fuel tank; wrong | in the bottom, drain and flush steady; heater fuel. the tank and filter with clean fuel. burns with odor, heater smokes Refill with new, clean kerosene continuously. or No. 1 fuel oil. b. Dirty air filters caus- | Remove and clean the air filters. Sec. III, ing reduced air flow Para. B. through nozzle, re- Be sure air intake is not blocked. sulting in low fuel flow. с. Fuel filter loose, Remove and wash fuel filter in Sec. III, leaky or dirty. clean fuel. Para. E. Check condition of connection between fuel filter and burner Sec. V, head. Para. 1. Replace with new filter and fitting if connection can't be — tightened without leaks. d. Dirty nozzle. Remove and clean the burner Sec. III, head. Para. H. Blow compressed air through nozzle from outlet end. Never use a drill, wire, or other tool to open a nozzle passage. Replace a defective nozzle. Sec. V, Para. J. e. Low pump output Check and adjust pump output Sec. V, pressure. (Low pressure; repair or replace Рагав. К & Г. motor speed, worn pump if adjustment cannot pump, pump out of be made. adjustment.) A3265-00 —11- 6/72 TROUBLE SHOOTING CHART (Continued) PROBLEM T Lr tn ma FOR FURTHER 3. (Continued) Heater burns, but puffs of smoke can be seen; heater will not burn steady; heater burns with odor, heater smokes continuously. 4. Flames come out front of heater. POSSIBLE CAUSE REMEDY DETAILS SEE: f. Loose air output line con- | Be sure connections are tight. nections between filter housing and burner. g. (Remote possibility) If heater puffs intermittently, Sec. V, Rubber sleeve on shank replace the rubber sleeve. Para. J. of nozzle is leaking. (Handle parts carefully to | prevent damage; assemble them carefully to preserve airtightness. ) h. (Remote possibility) Tighten screws. If parts are Combustion chamber not warped from heat, replace warped tight against burner head, | parts. There must be no air gap allowing too much air to | between face of burner head and . enter combustion back of combustion chamber. chamber. Improper Fuel-Air Mixture (Too much fuel, or not enough air for amount of fuel being supplied. a. Dirty fan, or air passage- | Clean the fan. Be sure the air way through heater block- | passageway through the heater is ed by dirt or trash. clean. Keep the heater clean. b. Pump output pressure Check and adjust pump output Sec. V, is too high, causing too pressure. Para. L. much fuel to be supplied. c. Fan loose or improperly Check fan; correct if not right. Sec. V, located on shaft. Para. H. d. Bent or damaged fan. Replace. Do not attempt repair of fan, 15. Heater cycles intermittently. Electrical System Troubles a. Thermostat Accessory (if used) settoolow. Set thermostat to a higher tem- perature for more even operation. b. Defective thermostat accessory (if used). ‘Replace a defective thermostat ‘accessory. ¢. Defective electrical supply or defective connections. - Be sure extension cord and heat- er service cord are in good con- dition, without intermittent open circuits. Check mechanical and electrical soundness of all wiring connec- tions in the heater and service cord. A3266-00 -12- 6/72 TROUBLE SHOOTING CHART (Continued) | FOR FURTHER PROBLEM POSSIBLE CAUSE REMEDY DETAILS SEE: 6. Control System Troubles GA. Heater ignites, | a. Defective photo cell. Check to see if glass face of cell is but red button so dirty it can't "'see" the flame; of circuit clean glass if dirty. breaker pops out anyway. Replace with a cell that is known to be good. b. Defective electrical Be sure all solder joints and wiring connections in circuit connections are secure. Check through cell and coil wiring diagram. of control relay. 6B. Circuit breaker | a. Defective circuit Replace with a circuit breaker fails to trip breaker. that is known to be good. when a ho-flame condition exists. | b. Open connection Check connections. in circuit through circuit breaker. 6C. Button on circuit | a. Resetting is tried Wait 5 minutes and try again. breaker won't too soon after the stay in when breaker trips. ~ pressed. b. Defective circuit Replace with a circuit breaker breaker. that is known to be good. к PHOTO CELL WIRE pa NUT WHITE RED BLUE INTERNAL GROUND | | RE >| [BLACK Not <K CIRCUIT IH NUT BREAKER ACK TRANSFORMER BL > | WHITE À BLUE H | BLACK | AA RED A. WIRE WHITE NUT — 4 WHITE A GREEN IE À BLACK 1057 Figure 11. Wiring Diagram A3267-00 -13- 6/72 SECTION V SERVICE AND REPAIR A. GENERAL This sectioncovers replacement of parts, repair and rebuilding of heater components, and the making .of adjustments. Check to be sure the maintenance of the heater has been done, before going into the more extensive service operations. Whenever a part needs to be replaced, you can identify it on the exploded view in the Parts List por- tion of this book, Section VI. Order any needed part by name and part number. B. SPECIAL TOOLS, EQUIPMENT, AND SUPPLIES The following tools, equipment and supplies should be available for complete servicing of the heater. 1. Air Gage, Part No. M9148, or any gage with a 15 pound pressure range and 1/4 pound divisions, able to indicate 4-1/4 pounds accurately, plus fittings for installation into a 1/8-inch standard pipe-threaded hole. : 2. Oil Burner Nozzle Wrench, or any deep 5/8- inch socket wrench. 8. Cleanfuel, either kerosene or No. 1 fuel oil. 4. Non-flammable, non-toxic liquid cleaning sol- vent. CAUTION Fumes given off by solvents may be toxic, therefore use solvents in a well ventilated area. 5. Compressed air is advisable, but not ab- solutely necessary. C. THERMOSTAT ACCESSORY 1. Turn the knob slowly, through the full range of the thermostat, two or three times. If the heater does not start, proceed as follows: 2. Takethe thermostat accessory out of the cir- cuit by unplugging the heater from the thermostat ac- cessory. A3269-00 —14- 3. Plug the heater service cord into an outlet. If the heater operates properly, the thermostat ac- cessory is defective and must be replaced. D. REMOVAL OF UPPER SHELL It will be necessary to remove the upper shell in order to perform the following service operations on the heater. See Section III, paragraph C. E. TRANSFORMER WARNING To begin the transformer test, first be sure the heater is not plugged in. Then, when power is required, be EXTREMELY careful when checking the transformer. A transformer in- good condition produces VERY high voltage at the output terminals. Check the transformer as follows: 1. Connect the transformer lead to a properly gapped spark plug. . The gap should be 0.050 inch, plus or minus 0.005 inch. See Figure 8. 2. Establish a good ground between the spark plug and the heater. Be careful not to let any part of your person become a portion of the ground circuit. 3. Plug the heater cord into an outlet of the pro- per voltage. Observe the spark between the plug's electrodes. H the ground is good and a spark does not jump between the electrodes, the transformer is de- fective. Replace it. 4. To replace the transformer, take out the two screws which attach it to the motor mounting bracket. Make sure thatthe new transformer mounting tabs are free of paint, to assure a satisfactory ground. 5. Reinstall the attaching screws, and make wiring connections in accordance with Figure 11. 6. Snap the spark plug lead tightly onto the plug terminal, to prevent its coming loose when the heater is moved. F. CHECKING THE MOTOR STARTING CIRCUITS In case the motor fails to start when the cord is plugged in, or the thermostat is set to call for heat, 6/72 check the motor and its starting circuit components as described in the following paragraphs. WARNING The motor contains an automatic thermal overload protector. This may stop the motor, due to overload or low voltage, then RESTART it automatically. Be sure to dis- connect the heater before inspecting the motor, 1. Mechanical Check. Spin the motor by turning thefan blades by hand. Tf the motor turns freely, make the electrical check as described in paragraph 2. Any stiffness of the motor indicates mechanical troubles. See "Motor Service, " paragraph G of this Section. 2. Electrical Check, The heaters have 1/8 horsepower motors and separate starting relays. (See the Wiring Diagrams, Figure 11). NOTE The starting relay is "position-sensitive" and must be tested in the same position as when installed in the heater (with the con- tacts on the bottom). | a. Taketherelay out of the heater by taking out the screw which holds its bracket to the left side of the lower shell, near the motor. CAUTION Avoid touching the bar wires or the ех- posed wire terminals. b. Take the black motor wire off its termi- nal of the starting relay. Touch this wire to the ter- minal of the red motor wire, at the relay. The motor = should start. As soon as the motor reaches operat- ing speed, remove the black wire from contact. The motor should continue to run. c., If the motor starts, install a new relay, and reconnect the wiring according to the Wiring Diagram, Figure 9. ~d. Failure of the motor to start could re- sult from either of the following, assuming thatall other circuits in the heater are operating correctly. (1) Internal fault in the motor, such as ~ burned-out stator, or failure of thermal overload protector. A3270-00 (2) Failure of the starting relay. e. If themotoríails to start and the relay is found not to be the cause of failure to start, remove the motor andinstall a new or rebuilt motor, Send the defective motor to the nearest authorized service sta- tion for repair, or order a replacement motor from the Master Service Parts Department. NOTE When sending the motor away for repairs, remove the fan, the air filter housing, and the pump end cover. Take out the pump rotor and the carbon blades but do not dis- turb the pump body, which is the ring at- tached to the end of the motor. (See para- graph K for pump service instructions). G. MOTOR SERVICE 1. Applyafew drops of oil to the fan-end bearing of a stiff motor. I this fails to correct the starting difficulty, rebuild the pump, as described in paragraph K of this section. 2. During rebuilding of the pump, check the motor againfor stiffness. If stiffness still exists, rebuild the motor according to the manufacturer's instructions. 3. Whenever a motor has been rebuilt, be sure to check the pump rotor clearance as described in para- graph K-4 of this Section, before reassembling the motor into the heater. N f WU | куб /TWO SET SCREWS: ONE MUST REST ON FLAT IN MOTOR SHAFT. 0 | BOTH SCREWS MUST BE TIGHT MOTOR “— MOUNT FAN — FLUSH WITH END OF SHAFT FAN HUB a MOTOR 281 Figure 12. Location of Fan on Motor Shaft. 6/72 4. Whenyou install the motor, insert the spacers between the ends of the motor mounting clamps. H, FAN SERVICE Replace a damaged or bent fan. Do not attempt repair except as a temporary emergency measure. Loosen two setscrews to remove the fan from the mo- tor shaft. Be sure the replacement fan has the same blade pitchas the fan that was removed. This is important in order to retain the air flow and combustion charac- teristics of the heater. Check for proper fan location of the motor shaft. | Make sure the fan is in the same position and location as before it was removed. See figure 12. I. FUEL FILTER SERVICE 1. Remove the fuel filter from the heater and clean it, as described in Section III, paragraph G. 2. Before reinstalling the fuel filter, check the rubber bushing where it enters the fuel tank. Be sure the bushing is in good condition -- not cut or cracked. Replace a damaged bushing. | 3. Reinstall the fuel filter according to Section III, paragraph G. Replace with a new filter if the con- necting parts are damaged to prevent a tight con- nection. J. BURNER HEAD SERVICE 1. Take outthe spark plug and remove the burner head. Clean the entire burner head, as described in Section III, paragraph H. 2. If there is any sign of damage to the nozzle, or if it is impossible to clean out the nozzle by blow- ingcompressedair into it through the outlet-end, re- place with a new nozzle. Always blow a nozzle out thoroughly with air, from the outlet-end, before in- stalling it into the burner. CAUTION NEVER try to open a nozzle passage with a drill. Any change in the size or shape of the passage will alter the flow characteristics. Protect the passage from damage whenever you work on the burner or nozzle. 3. Always install a new rubber sleeve whenever you install anozzle into the burner. The sleeve is the part that helps maintain the needed pressure difference between the air and fuel chambers of the burner head. If bubbles have appeared in the fuel tank during opera- A3271-00 tion, the rubber sleeve is probably leaking and should be replaced. 4. Be sure the seal washer, spring, and second seal washer are in place on the nozzle before you in- stall the rubber sleeve. 5. When seating the nozzle firmly against the burner head, do not apply too much pressure with the wrench, or the nozzle could be distorted. 6. Adjustthe sparkplug gap as expalined in Sec- tion III, paragraph F. K. AIR PUMP REPAIR NOTE: Because of the close tolerances and cri- tical positioning of the parts, we recommend that only skilled mechanics attempt any repair of the air pump. The heater's air pump consists of a rotor with four carbonblades, rotating inside a pump body. The rotoris driven directly by the motor, and is supported by the ball-bearing end of the motor. One of the pump end plates is the motor's back end plate. The other pump end plate is part of the housing for the air intake and outlet filters. Handle all pump parts with care and keep them clean. The parts are made withclosetolerances. Dirt and oil on pump parts will hinder the performance of the pump. If pump repair is required, you may order a com- plete pump package, or individual parts, as shown in the Parts List, Section VI. 1. Disassembly. CAUTION Do not take the pump apart any further than you need to in order to reach the parts which must be replaced. a. Remove the end cover and take out the in- take and outlet air filters and the lint filter. Dis- connect the air line from the elbow. b. Hold a ciean, dry cloth under the pump and remove the six screws that hold the end cover to the pump body. Catch the carbon blades in the cloth, if they fall out as the pump body is removed. c. Take all four carbon blades out of the rotor. Pull the rotor and the insert off the motor shaft. 2. Replacing Carbon Blades. a. Worn or sticking carbon blades cause 6/72 CHECK FOR SQUARENESS OF FIT ~~ MOTOR END SHIELD 7 ROTOR INSERT и (FLAT SURFACE ON PUMP ROTOR (LA THIS SIDE) 7 MOTOR SHAFT .005 006 CLEARANCE MEASURED WITH FEELER GAGE GAP ADJUSTING SCREW END SHIELD BLADE MOTOR SHAFT 877 Figure 13. Checking Clearance of Air Pump Rotor loss of air pressure. If the blades are worn, or are sticking in the rotor slots, replace them. (It is not necessary to remove the rotor or the pump body to replace the carbon blades). b. Install the carbon blades into the slots. 3. Replacing the Rotor. Use a new rotor only if deep grooves or un- even wear appear on the surfaces. Check the insert for wear, and replace it if worn or loose. To remove the rotor, first remove the pump body. 4. Reassembly of Air Pump. a. Install the insert in the pump rotor as shown in Figure 13, then assemble rotor on the motor shaft. When installing the rotor, take care to keep it perpendicular to the motor shaft. Attach the pump body to the motor with the two recessed screws which were removed to take it off. —b. Adjustthe pump body to provide 0.005 to 0.006 inch clearance at the point shown in Figure 18. Measure the clearance with a feeler gage. Spin the motor by hand to be sure the rotor does not rub on the pump body. The proper clearance must be maintained. Be sure the recessed screws are tight after adjusting. с. Insertcarbon blades as described above. d. Install theendcover, using the six screws which were removed. Reconnect the air line. A3272-00 -1 7- Figure 14. Checking and Adjustment of Air Pump Pressure L. ADJUSTMENT OF PUMP PRESSURE 1. Remove the plug from the air filter hous- ing, and install the pressure gage (listed in paragraph B of this Section) into the hole. See figure 14. 2. Starttheheater. (You do not need to have fuel in the tank for this pressure check and adjustment). 3. Pump pressure must be 4 psi plus or minus 1/16 pound. If the pressure is not within this range, adjust the pressure relief valve. 4, To adjust pump pressure, screw the valve stem in to raise the pressure; out to lower it. 5. Remove the gage and replace the plug. M. REASSEMBLY OF HEATER 1. Put the heater back together in the reverse order of disassembly. 2. Checkall wiring to be sure it agrees with the wiring diagram. Be sure all electrical connections are tight. 3. Tighten the connections at both ends of the air line, and tighten the connection where the fuel filter is assembled to the burner head. 4, Make sure the electrode lead is snapped onto the spark plug and the transformer output terminal. 6/72 5. Besure all parts are in place and the screws are tight before attempting to use the heater. N. CONTROL SYSTEM SERVICE Since no adjustment is possible on the parts of the control system, service is limited to cleaning the glass face of the light-sensitive cell, cleaning the dirt from the exposed contacts of the relay (if the contacts A3273-00 -18- are exposed), and replacing defective parts of the sys- tem with parts that are known to be good. O. FINAL CHECK | Put atleast two gallons of fuel in the fuel tank:and test-fire the heater for a few minutes, after all service has been completed, to be sure it will operate satis— factorily. 6/72 1068 Figure 15. Heater Exploded View SECTION VI PARTS | This section lists and illustrates all of the replaceable - parts of the heater. | To identify a part, finditon one of the illustrations, and note its indexnumber. Then, in the parts list for that illus- tration, readacross the line of that index number. You will find the part number of the part, its name or description, and the quantity of the part used at that particular location. Attaching hardware is listed immediately after the part it ‚| attaches, and are noted by (AP) following the description. — Standard hardware are indicated by the symbol (*) and can Index Part | No. Number Part Name Qty. 1 M25030-2A Shell, Upper . 1 2 *M12461-51 Screw, Hex hd No. 10-24 x 1/2 (AP) 6 3 M25278 Handle 1 4 Ml12439L Support, Handie 2 5 WP-4C Washer, Plain, | No, 1/4 (AP) 4 6 M15823-11 *Screw, Self-tapping, Hex hd. , No. 12-11 x 1-3/4 in. 4 7 M25019-1 Combustion Chamber Assembly 1 8 *M11084-26 Screw, Hex hd, self-tapping, No. 10-12 x 3/8 in. | (AP) 4 9 ee Not-Used À perdure + | 10 M16656-3 Photo Cell and Bushing Assy 1 11 M23443-2 Burner Head Assembly (See details in Fig, 16) NA 12 *M11084-27 Screw, Hex hd, self- tapping No. 10-12 x a 1/2 in. (AP) 3 -13 M19630 Filter, Fuel 1 14 M16790-14 Tube, Fuel Filter 1 15 M13849 Nut, Flared 1 16 M25021 Air Line 1 17 M25037 Fan, 25/32 pitch, 1/4-28 x 5/16 1 *SF4-2-1/2K Setscrew, Socket hd, cup point, (Furnished with fan) 2 M25023-1 Motor Package Assy (For details see Fig. 17) 19 *NPC-4C Nut, Plain, Hex 1/4-20 (AP) 2 20 *WLM-4 Lockwasher, 1/4 in. (AP) 2 21 *HC4-10C Screw, Hex hd 1/4-20 x | 1-1/4 in. (AP) 2 22 M16661 Clamp, Motor 4 23 M25059 Bracket, Motor Support 1 *Standard Hardware. AP indicates attaching parts. A3276-00 -20~ LIST be procured locally. Order parts by name and part number only. Do not use the index numbers from the illustrations when ordering parts, as these index numbers are intended for your conven- lence in identifying parts in the list, and they may change from time to time as later editions of this book are issued. When ordering parts for this heater, be sure to include the serial number and model number of the heater with your order. Thesecanbefoundon the decal affixed to the heater. Index Part No. Number Part Name Qty. 24 *M11084-27 Screw, Hex hd, self- tapping No. 10-12 x 1/2 in. (AP) 4 25 1000576 Grommet 2 26 1000577 Grommet | | 1 27 *ST2-2AC Screw, Rd hd No. 8-15 x 1/4 in. (Grounding) 1 28 *M11084-26 Screw, Hex hd, self-tapping No. 10-12 x 3/8in. 2 29 M16841-15 Wire Assembly 1 30 M13942-2 Connector, Wire 2 31 M13942-4 Connector, Wire 1 32 M24983-1 Control Assembly, Safety 1 33 M25061-1 Relay, Motor start 1 34 *RC2-2C Screw, Rd hd No. 8-32 - x 1/4 (AP) 2 35 M25035 Bracket, Relay 1 36 M16697 Transformer Assembly 1 37 *M11084-26 Screw, Hex hd, self-tapping, No. 10-12 x 3/8 in. 2 38 M11143-1 Bushing, Strain relief 1 39 M10813-38 Extension Cord Assembly 1 40 M25032-1B Lower Shell Assembly 1 41 *M11084-27 Screw, Hex hd. , Self-tapping, | No. 10-12 x 1/2 in. (AP) 8 42 M10990-3 Bushing 1 43 M11151 Cap, Filler Neck 1 44 M25374~1 Plug, Drain 1 M25375 . O-Ring 1 M25277 . Plug, Drain 1 45 M25033-1B Fuel Tank Assembly 1 M16749 Decal, Safety Control 1 M228 98 Decal, Nameplate 1 M22743 Decal, Warning 1 M24687 Decal, Wiring 1 M17157 Decal, Private Label 1 M20451 Decal, BTU 1 M23132-4 Decal, Model 1 M25025 Decal, Tradename 1 M16841-16 Wire Assembly (Safety Control) 1 6/72 / Del Ae Index / Part 4 No. | Number Part Name Qty. 16- M23443-2 Burner Head Assembly Ref pe 1 M16660 . Bracket, Photo Cell 1 — 2 1*MI10908-1 . Screw, Hex hd, Self-tapping, ~ 1 | No. 6-32 x 1/4 (AP) 2 7 2 3 —Serew-Hexhd-No=0-24-x-+/2--—4= Q y 4 . Spark Plug 1 10 5 M16741-18 . Ring, Retaining 1 M23151-2 . Nozzle Adapter Assembly 1 6 § M5976 . . Connector, Male 1 / 7 | M8882 . . Sleeve, Nozzle Seal 1 8 M10659-1 . . Washer, Nozzle Seal 2 9 Mi0809-1 . . Spring, Nozzle Seal 1 10 M13960 . . Nozzle, Aspirating 1 6 11 M16791 . . Connector, Male 1 12 | 12 M16535 . . Adapter, Nozzle 1 1053 11 13 M25020 . Body, Burner Head 1 Figure 16. Burner Head Assembl ; Ш a ; MI0964 -Z % 923A 16 Figure 17. Motor Package Assembly Index Part Index Part No. Number Part Name Qty. No. Number Part Name Qty. 17- M25023-1 Motor Package Assembly 1 10 M8 643 . Blade, Pump 4 I M16545 . End Cover, Filter 1 11 M22456-1 . Rotor, Pump 1 2 *M12461-31 . Serew, Hex hd No. 10-32 12 M22009 . Insert, Rotor 1 x1 (AP) 4 13 ‘M8645 . Pump Body 1 3 *WLI-3 . Lockwasher, Internal No. | 14 *FHPF3-4C . Screw (Pump Body to Motor) 2 10 (AP) 4 15 69248 . Elbow, 90° 1 4 M12179 . Intake Air Filter 1. 16 M22997 . Plug 1 5 M12244-1 . Output Filter Assy 1 17 M23105 . Screw, Pressure Adjustment 1 6 M11637 . Filter, Lint „1 18 M10993-1 . Spring, Compression 7 M12233 . Front Cover, Pump (Port Plate) 1 (Pressure Relief) 1 8 *M12461-32 . Screw, Hex hd, No. 10-32 x 19 M8940 . Ball 1/4 in. dia. 1 1-1/8 (AP) 6 20 M25022-1 . Motor 1 9 WLI-3 . Lockwasher, Internal AP indicates attaching parts. No. 10 (AP) 6 * Standard hardware. Purchase locally. A3275-00 -21- | | 6/72 WARRANTY We warrant Products sold by us to be in accordance with our published specifications or those specifications agreed to by us in writing at time of sale, Our obligation and liability under this ‘warranty is expressly. limited to repairing or replacing, at our option, within one year or as otherwise set forth in our published specifications, any product not meeting the specifications, WE MAKE NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND MAKE NO WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR ANY PARTICULAR PURPOSE, Our obligation under ~ this Warranty shall not include any transportation chargesor costs of installation or any liability ~ for direct, indirect or consequential damage or delay, If requested by us, Products or parts for which a warranty claim is made are to be returned transportation prepaid to our factory, Any _ improper use, operation beyond rated capacity, substitution of parts not approved by us, or any alteration or repair by others in such manner as in our judgment affects the Product materially and adversely shall void this Warranty, NO EMPLOYEE OR REPRESENTATIVE IS AUTHOR- IZED TO CHANGE THIS WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY, WE RESERVE THE RIGHT TO AMEND THESE SPECIFICATIONS AT ANY TIME WITHOUT NOTICE. THE ONLY WARRANTY APPLICABLE IS OUR STANDARD WRITTEN WARRANTY. WE MAKE NO OTHER WARRANTY, EXPRESSED OR IMPLIED. KOEHRING Koehring Master Division Dayton, Ohio 45401 А1632 -03
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Key Features
- 50,000 BTU per hour output rating
- Simplified solid state control for safety
- Three-prong plug for grounded power
- Three-wire extension cord recommended for adequate voltage
- Intake air filter for easy maintenance
- Output air filter for clean heated air