Desa AM50S Construction Heaters Owner's Manual

 sta-warm
N PORTABLE HEATERS
MODEL AMS50S
SPEC. NO. 3158G03
OPERATING, MAINTENANCE and SERVICE
INSTRUCTIONS with PARTS LIST
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AMERICAN a? OIL COMPANY
910 SOUTH MICHIGAN AVENUE CHICAGO, ILLINOIS
Form No. 2871 Litho in U.S. A.
safety rules
Safety Rules for
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
Touse the heater ina confined space, provide one
square foot of ventilating area per each 100,000
BTU rating.
Portable Heaters
5.Use Only Recommended Fuel
Use ONLY kerosene or No. 1 fuel oil.
USE GASOLINE.
DO NOT
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. If an adapter
is used, attach the adapter wiretoa 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 2. Ignition Sy stem. An electric arc that fires
with adequate ventilation and proper electrical power. constantly between a pair of spark plug electrodes
DO NOT use the heater in sleeping quarters. while the heater is in operation ignites the mixture of
2. Purpose of Manual. This manual contains fuel and air.
detailed instructions for operating, maintaining,
trouble shooting, and servicing the heater. A service
parts list is included at the end of the manual. tor shaft supplies additional air to the heater.
ries it into the combustion chamber in a fine spray.
3. Air System. Afanon the other end of the mo-
Part
of this air enters the burner through ports around its
B. PRINCIPLES OF OPERATION outer edge, and helps complete the combustion of the
burning fuel-air mixture.
Operation of the heater involves three basic sys-
tems. (See Figure 1.)
The rest of the air from the fan passes over and
aroynd the combustion chamber. At the front of the
1. Fuel System. An air pump on one end of the hedter it mixes with the hot air coming from inside the
motor shaft forces air through the nozzle. The moving combustion chamber. The air then flows out of the
air lifts fuel from the tank by a siphon action and car- heater as a jet of clean, heated air.
COMBUSTION — _SPARK BURNER FAN _AIR INTAKE AIR
| CHAMBER PLUG [HERD / PUMP FILTER
¡== _ == |
FIN [ <= | <= <=
CLEAN “8 él = <a
HEATED = MOTOR
AIR OUT gg 7 FILTER COOL AIR IN
=> =
- 4
AIR LINE
Nozze) TO BURNER oureur AR
t TRANSFORMER
be
AIR FOR COMBUSTION
ZA AR FOR FUEL SYSTEM <a HEATING <Q FUEL
1059
Figure 1. Schematic Diagram Showing Principles of Heater Operation
A3255-00 .—1-
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
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. 2
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 fo trip. When this occurs, full
line current will flow through the circuit breaker heat-
ing coil causing it to heat up. After about 15 seconds,
A3256-00
the circuit breaker will trip and shut off power to the
heater.
After a trip-out the circuit breaker may be
reset after permitting the heating coil to cool three to
five minutes.
If a flame is established in the heater com-
bustion chamber, the resistance of the Cadmium Sul-
phide cell 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-
perature. At its NO HEAT position, the thermostat
shuts the heater off.
6/72
SECTION ||
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
is grounded. To check the two hole outlet to deter-
mineifit is grounded, use a light buib 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.
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 oil 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.
\
LIGHT GLOWS ONLY 1 q
IF GROUNDED |
СНЕСК ВОТН }
HOLES. >: PLATE
| SCREW
HN
1062 INSULATED TEST PROBES
WALL RECEPTACLE
FACE PLATE
FACE PLATE
SCREW
— ADAPTER
E
HEATER
POWER CORD
7
/0
/
| OUTLET
BOX
14 GA. BARE
COPPER WIRE
TO GROUND
11063
Figure 2. Checking Power Outlet
A3257-00
Figure 3. Grounding A Non-Grounded Outlet
6/72
NOTE: If 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 Figure 5).
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 [II
"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.
COMBUSTION BURNER (%)
CHAMBER | SPARK PLUG (x)
PHOTO CELL
INTAKE
“AIR FILTER (%)
OUTPUT
AIR FILTER
hyo IDE HOUSING)
ha
FUEL FILTER (%)
`
e
AFETY LINT FILTER
1066 SORELY NY A (INSIDE HOUSING)
vn mn |
TRANSFORMER (*
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
~ в
LINT FILTER
OUTPUT
AIR FILTER
CR Er AIR INTAKE
BR FILTER
N
. Ni
N CIRCUIT |
0 > BREAKER 3
UF, BUT TON FILTER \
N HOUSING
, END COVER
416B 417A
Figure 5. Removing Intake Air Filter Figure 6. Access to Air Filter for Maintenance
B, AIR FILTERS C. REMOVING UPPER SHELL
1, Check and clean the intake air filter often.
The filter needs cleaning if you can see a film of dust
onit. 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
outof the housing. Wash it with a mild detergent and “ the spark plug 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 reachtheoutputairfilter, remove the four
screws which attach the filter housing end cover. Lift
the output air filter out. See Figure 6.
NOTE: Cleaning the outputair 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
(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
is not 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
PA
BURNER
HEAD
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of
3 NN
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LA SPARK
AT 7 PLUG
1
FUEL
FILTER
Al]
PHOTO CELL
BRACKET 1067
Figure 9. Burner Head, Spark Plug, and Fuel Filter
1. Disconnect the spark plug wire.
2. Loosen the screw which secures the spark
plug in the burner head and remove the spark plug.
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.
4. Reinstall the spark plug so that the white dot
on the plug (just below the knurled surface is in line
with the retaining screw). (See figure 8.) If the white
dot has been obliteratedor is absent, position the plug
so that the electrode gap will lie across the spray pat-
tern. Tighten the screw to lock the spark plug in this
position.
.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 element dry, 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
NOZZLE FACE
214
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 inthe 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. Tighten the nut securely to assure it will be air
tight.
NOTE: HE 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. I solvent and reverse
airflow 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.
5. 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. I 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
IV
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-
firethe 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 siudge and water. If
you find it, expect to find a dirty nozzle and/or fuel
filter.
2. Spinthefanto be sure it turns freely. I it is
stiff, look for 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. Be sure
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.
paragraph B).
(See Section III,
A3262-00
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. IH anytroubles 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 extension cord 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.
If 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. Sec, III,
Blow dry and replace. Para. G.
с. Nozzle plugged or de- Clean by blowing compressed air Sec. HOI,
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 & L
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
A3265-00
PROBLEM POSSIBLE CAUSE REMEDY DETAILS SEE:
2. (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.
3. 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.
c. Fuel filter loose, Remove and wash fuel filter in Sec. ITI,
leaky or dirty. clean fuel. Para. E.
Check condition of connection
between fuel filter and burner Sec. V,
head. Para. I.
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 Paras. K & L.
motor speed, worn pump if adjustment cannot
pump, pump out of be made.
adjustment.)
-11- 6/72
TROUBLE SHOOTING CHART (Continued)
PROBLEM
POSSIBLE CAUSE
REMEDY
FOR FURTHER
DETAILS SEE:
3. (Continued)
Heater burns,
but puffs of
smoke can be
f. Loose air output line con-
nections between filter
housing and burner.
Be sure connections are tight.
seen; heater g. (Remote possibility) If heater puffs intermittently, Sec. V,
will not burn Rubber sleeve on shank replace the rubber sleeve. Para. J.
steady; heater of nozzle is leaking. (Handle parts carefully to
burns with odor, prevent damage; assemble
heater smokes them carefully to preserve
continuously. 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.
4. Flames come Improper Fuel-Air Mixture (Too much fuel, or not enough air for
out front of
heater. 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.
5. Heater cycles
Electrical System Troubles
intermittently.
a. Thermostat Accessory Set thermostat to a higher tem-
(if used) settoo low. perature for more even operation.
b. Defective thermostat Replace a defective thermostat
accessory (ifused). accessory.
ec. Defective electrical Be sure extension cord and heat-
supply or defective er service cord are in good con-
connections. 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
6A. 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 no-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.
PHOTO
CELL
WIRE eee
NUT
RED BLUE
INTERNAL
GROUND
WIRE CIRCUIT
| FH Ó U
| NOT BREAKER
TRANSFORMER >
WHITE À
| BLUE
|_ BLACK A RED ma
WHITE NUT — 4
GREEN Il
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.
3. 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 foilows:
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. Plugtheheater cord into an outlet of the pro-
per voltage. Observe the spark between the plug's
electrodes. Iftheground 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 that the 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 itautomatically. Be sure to dis-
connect the heater before inspecting the
motor,
1. Mechanical Check. Spin the motor by turning
the fan blades by hand. If the motor turns freely, make
the electrical checkas 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. Takethe relay out of the heater hy 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 ex-
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 that all
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. Ifthe motorfails to start and the relay is
found not to be the cause of failure to start, remove
the motor and install 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. If 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. I 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.
TWO SET SCREWS; ONE MUST
REST ON FLAT IN MOTOR SHAFT.
BOTH SCREWS MUST BE TIGHT
FLAT
MOTOR SHAFT-——
MOUNT FAN —
FLUSH WITH
END OF SHAFT
FAN HUB a
MOTOR
281
Figure 12. Location of Fan on Motor Shaft.
6/72
4, When you 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
pitch as 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 sparkplug 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-
ing compressed air 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 a nozzle 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
-16
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
rotor is 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 withclose tolerances. 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 clean, 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.
с. 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
0 ~~
FFIT ~~ MOTOR END SHIELD
ROTOR INSERT
(FLAT SURFACE ON
THIS SIDE)
PUMP ROTOR Ä
MOTOR SHAFT
005 CLEARANCE GAP ADJUSTING SCREW
‚006 A
MEASURED
WITH
FEELER
GAGE
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.
Toremove 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 13.
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.
а. Install the endcover, using the six screws
which were removed. Reconnect the air line.
A3272-00
391A
-17-
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.
9. 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
and note its index number.
illustration, read across the line of that index number.
SECTION VI
PARTS LIST
This section lists and illustrates all of the replaceable
parts of the heater.
To identify a part, find it on one of the illustrations,
Then, in the parts list for that
You
will find the part number of the part, its name or descrip-
tion and the quantity of the part used at that particular lo-
cation. Attaching hardware is listed immediately after the
part it attaches, and are noted by (AP) following the de-
scription. Standard hardware are indicated by the symbol
Index Part
No. Number Part Name Qty.
1 M25030B Shell, Upper 1
2 M12461-49 Screw, Hex hd, No. 10-24
| x 1/2 (AP) 6
3 M21809 Handle 1
4 NTC-3C Nut, Torque lock, No. 10-24
(AP) 4
5 WP-3C Washer, Plain No. 10 (AP) 4
6 M12345-22 Screw, Oval hd No. 10-24
x 3/8 (AP) 4
7 M25019-1 Combustion Chamber Assy 1
8 M11084-26 Screw, Hex hd, Self-tapping,
No. 10-12 x 3/8 in. (AP) 4
9 Deleted
10 M16656-3 Photo Cell and Bushing
Assembly 1
11 M23443-2 Burner Head Assembly
(For details see Fig. 16) NA
12 M11084-27 Screw, Hex hd, self-tapping
No. 10-12 x 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
- SF4-2-1/2K Setscrew, Socket hd, cup
point, 1/4-28 x 5/16
(Furnished with fan) 2
18 M25023~1 Motor Package Assembly
(For details see Fig. 17) NA
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
24 M11084-27 Screw, Hex hd, self-tapping,
No. 10-12 x 1/2 in. (AP) 4
29 1000576 Grommet 2
26 1000577 Grommet 1
27 ST2-2AC Screw, Rd hd, No. 8-15 x
1/4 in. (Grounding) 1
A3282-00
-20-
(*) and can 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-
ience 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. These canbe foundon the decal affixed to the heater.
NA Indicates "Not Available -- Order individual
parts.
"1
AP indicates "Attaching Parts".
Index Part
No. Number Part Name Qty.
28 M11084-26 Screw, Hex hd, self-tapping,
| No. 10-12 x 3/8 in. 2
29 M16841-15 Wire Assembly 2
29A M16841-16 Wire Assembly 2
30 M13942-2 Connector, Wire 2
31 M13942-4 Connector, Wire 1
32 M24982-1 Control Assembly, Safety 1
33 M25061-1 Relay, Motor start 1
34 RC2-2C Screw , Rd hd No. 8-32 x
1/4 in. (AP) 2
35 M25035 Bracket, Relay 1
36 M16697 Transformer Assembly 1
37 M11084-27 Screw, Hex hd, self-tapping
No. 10-12 x 1/2 in. 2
38 M11143-1 Bushing, Strain relief 1
39 M10813-38 Extension Cord Assembly 1
40 M25032-1C Lower Shell Assembly 1
41 M11084-26 Screw, Hex hd, self-tapping, |
No. 10-12 x 3/8 in (AP) 4
42 M10990-3 Bushing 1
43 Mi1151 Cap, Filler Neck 1
44 M25374-1 Plug Assembly, Drain 1
M25375 . O-Ring 1
M25277 . Plug, Drain 1
45 M25033-1C Fuei Tank Assembly 1
M16749 Decal, Safety Control 1
M22898 Decal, Nameplate 1
M22743 Decal, Warning 1
M24687 Decal, Wiring 1
M17159 Decal, Private Label 1
M20451 Decal, BTU 1
M23132-5 Decal, Model 1
M14994 Decal, Tradename 1
7/72
Index Part
4 No. Number Part Name Qty.
16- M23443-2 Burner Head Assembly Ref
pe 1 M16660 . Bracket, Photo Cell 1
— 2 *M10908-1 . Screw, Hex hd, Self-tapping,
~ 1 | No. 6-32 x 1/4 (AP) 2
7 2 3 *M12461-51 Screw, Hex hd No. 10-24 x 1/2 1
Q y 4 M16895-1 . 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 M10809-1 . 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 Assembly
923A
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 M8643 . Blade, Pump 4
1 M16545 . End Cover, Filter 1 11 M22456-1 . Rotor, Pump 1
2 *M12461-31 . Screw, 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