Desa F66D Construction Heaters Owner's Manual

 Knipco
| PORTABLE HEATERS
MODEL F66D
Spec. No. 3182G02
OPERATING, MAINTENANCE and SERVICE
INSTRUCTIONS with PARTS LIST
| Koehring
¿| Master Division
SAFETY RULES
SAFETY RULES FOR PORTABLE HEATERS
2. Heater
1. Know Your Portable Heater
Read andunderstand the complete owners manual
before starting the 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
5.
Use Only Recommended Fuel
Use ONLY kerosene or No. 1 fuel oil. DO NOT
USE GASOLINE.
Refueling
Do not add fuel while the heater is operating.
Disconnect Heater
‘Before servicing, cleaning, moving, etc.
_ 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.
8. Keep Unit Grounded
Use the three prong plug provided. If an adapter
is used, attach the adapter wire to a known ground.
Never remove the third prong. Use only three-
conductor extension cords.
Keep a Fire Extinguisher
Accessible...
It is recommended that a Dry Chemical type fire
extinguisher be available when the heater is used.
TUNE UP
To keep your heater in top operating condition, perform the following : services at the start of each heater season
then at the interval ‚specified belöw:
Clean and flush fuel ФарК.. .. ..........
Clean and/or replace fuel filter
. 4 = 4 u = = = * +
Clean or replace air filters
в т |. + # 8 + # 4 # # 5 + + *
Clean burner nozzle.
- + wn =: Ww + = #* =
Clean and adjust spark plug
Clean photo cell. . .............. , ..
A3229-01
filter, remove and clean it.
heater operation.
а я ев т ое о обоя йа т окон Bc sss we Now
After every 150 hours operation.
Clean atleast twice a season. More often if heater performance
© indicates the need. Replace if necessary.
Check air filter frequently. If a film of dust is apparent on the
~ Replace after each 200 hours of
Clean fan after every 500 hours of operation. Clean more fre-
quently if heateris operating in dusty areas or if there is a build-
| up € of dirt on the blades.
Clean the nozzle at least once during the heater season or more
often if heater performance indicates the need.
— After every 300 hours of operation, clean and adjust spark plug
electrodes. Adjust gap or replace the plug if electrodes have
been burned or erroded. Co
Clean the photo cell face with a soft cloth at least once during
the heater season. If cell face tends to soot up, check with your
nearest service station to determine the cause. |
-i- 8/73
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 shaftforces air through the nozzle. The moving
air lifts fuel from the tank by a siphon action and car-
ries it into the combustion 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. Afanonthe 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 fron: the fan passes over and
around the combustion chamber. At the front of the
heater it mixes with the hot air coming from inside the
combustion chamber. The air then flows out of the
heater as a jet of clean, heated air.
COMBUSTION
AIR
ZAR FOR FUEL SYSTEM
a
| SPARK BURNER FAN — INTAKE
| CHAMBER PLUG [HEAD / PUMP /FILTER
\
Г Хх L <= | <= <=
CLEAN <a v. La
HEATED - = 5 MOTOR
ER FUEL | ‹
AIR OUT gg $ FILTER COOL AIR IN
jl |
Ra == <= | E \ <=
| 7 I \ \ y
AIR LINE OUTPUT
NOZZLE 4 TO BURNER FILTER
TRANSFORMER
\
Au IR FOR COMBUSTION
“AND HEATING
a»
<Q FUEL
Figure 1. Schematic Diagram Showing Principles of Heater Operation
A3577-00
—1-
4/73
The safety control circuit essentially consists of
three parts: a light-sensitive cell (flame sensor), a
silicon-controlled rectifier (SRC), and the circuit
breaker. The circuit breaker automatically trips if
the flame fails, thereby causing the heater to shut
down. (See figure 2.)
The flame sensor is used to sense the presence
of light due to the flame inside the combustion cham-
ber. It varies its electrical resistance in relation to
light rays. When under the influence of light, the cell
has verylow resistance. The resistance is high when
little or no light strikes the light-sensitive surface.
The flame sensor's function is to control the trigger
voltage of a silicon-controlled rectifier.
The SCR acts às a voltage-operated switch. When
the trigger voltage reaches a certain level, the SCR
will conduct and allow a current to flow through the
heating coil of the circuit breaker. When the voltage
drops, suchas whenthe flame sensor senses light and
decreases its resistance, the SCR will turn off and
block the flow of current. |
The circuit breaker is a thermally operated switch.
Current flowing through the heating coil will cause it
to heat. When a specific temperature of a bi-metal
element is reached, the contacts of the breaker will
open to interrupt the current flow to the motor and
transformer. This action takes approximately 15
seconds at 70 degrees F. The breaker must be man-
ually reset by pressing the red circuit breaker reset
button. The flow of current through the heating coil
is controlled by the action of the SCR. If ignition takes
place before the breaker trips, the flow of current
through the coil is virtually stopped, the heating action
stops and the contacts remain closed, thus allowing
current to continue to flow to the motor and trans-
former. ©
The SCR and its circuit are mounted on top of the
circuit breaker and is replaceable only as a com-
plete unit.
Athermostataccessory (Model No. HA1200) may
be incorporated into the electrical circuit.
cessory canbe setto any desired temperature between
35 degrees F. and 95 degrees F. When the temperature
of the surrounding air reaches the preset tempera-
A3571-06
The ac-
ture, the thermostat contacts open to shut down the
heater. Whentheaircools, the contacts close and the
heater recycles. To shut down the heater when using
the thermostat accessory, place the dial in the "NO
HEAT" position.
C. POWER REQUIREMENTS
| The heaters are manufactured for use on 115 volt,
60 cycle power.
D. SPECIFICATIONS
Output Rating (BTU per hour). .......e. 63,000
Amperage (During normal run) ........ 4.0
Air Pump Pressure (PSI) ..... .e.oso. 4+1/4
Weight (Approx.) (Lbs.)
Shipping 6 8 8 8 08 48 8 8 5 BAS BP EON RPE EES 60
Dry (NEL) 00000000000000000000000088 47
Fuel Tank Capacity, U.S. Gallons .... 4.5
Fuel Consumption, Approx.
U.S. Gallons per hour .....sesosooco 0.45
Electrical Requirements
Voltage 2000008000510 05. 0080 то ее 115
Cycles (HZ) ..0.00000000000 0 000000 60
Motor RPM 9% & 48 5 8 8 6 веет $8 Pa 3350
Fuel .......... Kerosene or No. 1 Fuel Oil only
Duct No Duct Recommended
2 8 0 xm==ooran ao rro
Е. 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 35° and 55°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. a
5/73
SECTION ||
OPERATION
A. OPERATING CAUTIONS
1. Usethe heater in a well-ventilated area only.
A partly-opened door or window near the heater will
give enough ventilation. We do not recommend the
use of this heater as a source of heat in sleeping
quarters.
2. Use ONLY kerosene or No. 1 fuel oil. DO
NOT USE GASOLINE, AS IT IS VOLATILE AND
DANGEROUS. Do not use No. 2 or No. 3 fuel oil, as
they contain tars which will contaminate the heater.
3. Usetheheater only on the specified electrical
power. This is given on the heater instruction plate.
4. Plug theheater into a grounded receptacle, or
use a grounding adapter. Be surethe heater is ground-
ed whenever it is in operation and whenever you are |
working on it.
5. Keeptheheater af least 5 feet from any com-
bustible material.
6. Donotuse the heater in the presence of flam-
mable vapors like those from paint or gasoline.
7. Do not add fuel while the heater is operating.
8. Check spark plug gap after each 300 hours of
operation. Make checking the spark plug gap a part
of your periodic heater maintenance program.
B. EXTENSION CORD WIRE SIZES
Be sure to use an 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
Be sure the tank is clean. Fill it with clean ker-
osene or No. 1 fuel oil ONLY. Do not use any other
fuel.
When the heater is operated at very low temper-
atures (beyond 10 F below zero), the fuel may con-
geal.
To prevent this, add a non-toxic anti-icer to the
fuel. Follow the mixing instructions contained on the
anti-icer container. |
D. STARTING
1. Power Supply. Be sure that the power avail-
able to the heater matches that shown on the instruc-
tion plate, in both voltage and frequency (cycles).
2. Heaters Without Thermostat Accessory. The
heater will normally ignite as soon as it is plugged
into the outlet,
A3515-00
3. Heaters With Thermostat Accessory. Set the
temperature dial of the thermostat accessory to the
desired temperature.
a. If the dial is set to a temperature set-
ting, the heater should ignite immediately, providing
the surrounding air is cooler than the setting of the
dial. The heater will operate until the temperature
of the air reaches the dial setting, then will shut off.
When the surrounding air temperature falls below the
dial setting, the heater will start.
b. If the heater does not ignite, press the
red reset button onthe rear of the heater. The heater
should start immediately.
с. If the heater fails to start, the red but-
ton will pop out within 15 to 45 seconds, depending on
surrounding temperature. If it pops out, wait from
three to five minutes for the control circuit breaker
tocool, then press the red button again, after check-
ing for the reason the heater did not start.
d. The heaters will generally restart after
they are shut off, without pressing the red reset button,
E. STOPPING
To stop the heater, unplug the heater cord from
the outlet. (If the heater has a thermostat accessory,
set the dial to "NO HEAT" position.
5/73
SECTION Ili
MAINTENANCE
~ Maintenance consists of the simple operations the
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
condition, refer to Section IV in this manual for check-
ing andtrouble shooting. See Figure 2 for component
identification. - E.
A. FUEL TANK MAINTENANCE
— Drainthefuel tank after every 150 hours of oper-
ation, and flush itout with cleanfuel. Refill with fresh
clean fuel.
B. AIR FILTERS
1. Check and clean the intake air filter often.
The filter needs cleaning if you can see a film of dust
on it. It will need cleaning more often if the heater is
operated in dusty air. See Figure 3.
2. To clean the intake air filter, simply pull it
out of the housing. Wash it with a mild detergent and
hot or cold water. Dry it thoroughly, and replace it
in the housing. |
CAUTION: DO NOT OIL the filter element.
3. Replace the outputair filter once each heating
season.
4. Toreachthe outputair filter, remove the four
screws which attach the filter housing end cover. Re-
move the output air filter. See Figure 4.
NOTE: Cleaning the output air filter may cause
a change inthe air pump output pressure.
If the heater burns improperly after
cleaning, have the air pump pressure
checked. See Section V, paragraph L.
~ CHAMBER
~
| OS -
FUEL FILTER (6) > >
oo ``
ss
SAFETY
CONTROL
COMBUSTION BURNER (x)
SPARK PLUG (%)
PHOTO CELL
FAN
SAFETY CONTROL
"RESET BUTTON
INTAKE
~AIR FILTER (%)
OUTPUT
AIR FILTER
(INSIDE HOUSING)
00
LINT FILTER
(INSIDE HOUSING)
a ee
TRANSFORMER ‘*
Figure 2. Heater Component Identification
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)
A3578-00
- 5/73
416
Figure 3. Removing Intake Air Filter
5. Whenchanging the output air filter, clean the
lintfilter. Pick it out of the housing, wash with mild
detergent andhot or cold water. Dry thoroughly. Do
not oil. ;
6. Replace the lint filter, the output air filter,
the filter housing end cover, and the screws and
washers.
‘С. REMOVING UPPER SHELL
WARNING
With the upper shell removed and the service
cord plugged in, the heater canbe dangerous.
Always unplug the heater when performing
the following maintenance operations.
. Remove the upper shell by removing the eight
screws (4 on each side) that hold the upper shell to the
lower shell. Lift the upper shell off. |
To replace the upper shell, align the eight holes
located along its lower edge over the eight 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. Abuild-upof dirtwill 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 lubricate
it.
A2303-03
LINT FILTER
OUTPUT
(AIR FILTER
AIR INTAKE
FILTER
HOUSING
END COVER 417
Figure 4. Access to Air Filter for Maintenance
Oil the sleeve bearing on the fan-end of the motor
(See figure 5) once each year with 10 to 20 drops of
Mobil DTE-LC or DTE-23 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.
1. Disconnect the spark plug wire.
2. Remove the spark plug from the burner head,
and check the gap between the electrodes. The gap
must be within the limits shown in Figure 6.
OIL FAN-END MOTOR
BEARING HERE
419
Figure 5. lubrication of Motor Bearing
10/71
BEND HERE TO
ADJUST GAP /
>
050 ao
\ Figure 6. Spark Plug Gap Setting
3. Adjustthe gap by bending the outside electrode
where shown infigure 6. If you do not install the plug
immediately, protect it from damage until it is re-
installed. | ОЙ
4. Install the plug into the burner head, if no
further burner head maintenance is required. Make
sure the sparkplug is seated firmly in the burner head.
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.
1. To remove the fuel filter, loosen the hex nut
attaching the filter tube to the burner head.
2. Slide the tube down into the tank so that the
tube will clear the male connector in the nozzle adapt-
er. Push the tube to one side. Withdraw the filter
element and tube from the fuel tank. Withdraw the
filter element out of the tube. Rinse it several times
in clean fuel.
3. Blow the element dry, with a gentle stream
of compressed air, through the large end. Use care
to prevent damaging the filter element with air pres-
sure.
4. If the filter element is damaged or lost, it
must be replaced with a new element. NEVER oper-
ate the heater without the element in place. Failure to
use thefilter clement may result in clogging and per-
manent damage to the nozzle.
5. Insertthefuel filter element into the tube mak-
ing sure that it seats properly in the tube. Install the
A2818-03
COMBUSTION
CHAMBER
BURNER
HEAD
FUEL
FILTER
Figure 7. Burner Head, Spark Plug, and Fuel Filter
flared nut onto the tube. Insert the filter element and
tube into the fuel tank. Position the filter tube carefully
to seat on the male connector and thread the flare nut
to secure the filter and tube. В
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. Besuretheheater cord is unplugged, and re-
move 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 adapter.
2. Removethe screws thatfasten the burner head
to the rear of the combustion chamber and remove the
burner head.
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,
as you will damage it beyond repair. Protect
the nozzle face from damage while the burner
is out of the heater. This is important!
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 the face (OUTLET) end ONLY. See Fig-
ure 8.
5/73
5. Re-check the spark plug electrode setting
after cleaning the burner. Sez 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 hole is just
above center, onthe right. Install the attaching screws
and tighten.
7. Connect the fuel filter and the air line to their
respective fittings on the nozzle adapter.
8. Install the spark plug (refer to paragraph F,
step 4), and snap the spark plug lead onto the termi-
nal. It must snap, or it may not be tight enough to
prevent loosening as the heater is moved.
I. SAFETY CONTROL SYSTEM
For servicing the safety control system, refer to
Section V.
J. 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.
A3517-00
RUBBER SLEEVE
/ — SEAL WASHER
/ SPRING
SEAL WASHER
NOZZLE FACE
— NOZZLE PASSAGE
ag
27
Figure 8. Blowing Out Nozzle With Compressed Air
5/73
SECTION
IV
TROUBLE SHOOTING
A. GENERAL
WARNING
Always unplug the heater whenever you are .:
servicing it. Use extreme care when per-
forming those service operations which re-
quire the heater to be plugged 1 into a power
source.
If normal maintenance fails to keep a heater in
it probably requires repair
good operating condition,
or replacement of some parts. Examine it and test-
fireitto 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 re-
medies. |
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, look for 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, re-
pair it or install a new one before test-firing.
C. TEST-FIRING
1. Clean the fuel tank and fill it with at least 3
A0387-05
Be sure
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).
3. Checkandadjustthe air pressure, as describ-
ed in Section V, paragraph L.
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.
CAUTION
Tighten plug until sealed. Use soapy water
to check for sealing. Do not overtighten.
6. Iftroubles showup during the test-firing, re-
fer to the Trouble Shooting Chart for remedy.
D. TROUBLE SHOOTING
The following chart lists problems, "Possible
Causes" and "Remedy", to correct the problem or
tells you 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: Besure to follow all cautions and warn-
ings. They will help you prevent damage
to the heater or injury to yourself.
5/13 —
TROUBLE SHOOTING CHART
PROBLEM
FOR FURTHER
1. Motor does not
start; thermostat
(if used) is set
to call for heat. a
Rebuild or replace a binding pump.
POSSIBLE CAUSE REMEDY DETAILS SEE:
Electrical Troubles |
a. No power or low Be sure power is reaching heater;
voltage at heater. check condition of heater cord.
Repair or replace as needed.
Use extension cord with wires Sec. II,
heavy enough to carry the elec- Para. B.
trical load of the heater.
Be sure voltage at outlet is same
as shown on heater instruction plate.
b. Damaged motor, Check motor, Sec. V,
motor starting Para. F.
relay, binding fan- Replace a defective motor (or motor
end bearing; bind- starting relay).
ing pump. |
| | Lubricate motor (Fan—end only). Sec. III,
| | Para. E.
Rebuild motor. Motor Mfr's.
Instructions.
Sec. V, Para. K.
c. Thermostat (if
used) damaged.
Replace
Mechanical Troubles
d. Dry bearing on
fan-end of motor.
Lubricate motor.
If lubrication does not solve
problem, check pump.
Sec. IU, Para. E.
Sec. V, Para. K.
e. Pump rotor binding
or carbon blades
worn out.
Rebuild pump.
Sec. V, Para. K.
f. Fan obstructed by
mechanical damage
or dirt.
Check for bent outer shell.
Check for damaged fan; replace
if defective.
Check for damaged motor mount.
Sec. V,
Para. H.
2. Heater will not
ignite, but motor
runs for a short
time,
Fuel System Troubles
a. Fuel tank empty,
water in fuel,
wrong fuel.
Check for water in tank; clean
tank and fuel filter if water is
found. (Water in the tank will
form globules in the bottom,
which you can see.)
Fill tank with fresh, clean
kerosene or No. 1 fuel oil.
A3518-00
5/73
TROUBLE SHOOTING CHART (Continued)
PROBLEM
POSSIBLE CAUSE REMEDY FOR FURTHER
DETAILS SEE: -
2. (Continued) b. Fuel filter clogged. | Remove and wash in clean fuel. Sec. III,
Heater will not Blow dry and replace. Para. G.
ignite, but motor | - — - —
runs for a short с. Nozzle plugged or Clean by blowing compressed air Sec. III,
time. defective. through nozzle from outlet end Para. H.
of nozzle.
Replace nozzle if cleaning does Sec. V,
not solve the problem. Para. J.
d. Low air pump Check pressure; adjust, rebuild, Sec. V,
pressure, or replace air pump as needed. Para. K & L.
Check rubber sleeve around shank
of nozzle; replace if leaking.
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. HI, Para. B.
e. Air leak at fuel Check fuel filter for air leaks and
filter. for tightness of fitting where filter
is connected to burner head.
Ignition Troubles
e. Defective spark Measure gap between electrodes, Sec. III, Para. F.
plug. (Wrong gap, using thickness of a dime as a
plug wet with fuel gage. Adjust electrode gap.
or electrodes car-
boned, or plug Inspect plug for worn or erroded
damaged. ) electrodes. Replace a damaged
spark plug.
f. Spark plug wire | Discomect heater cord!
disconnected from | |
plug or from termi-| Check at plug and transformer to
nal of transformer. | be sure wire is tight at both ends.
g. Defective | Disconnect spark plug wire from Sec. V, Para. E.
transformer. transformer, and check trans-
former for spark; replace if no
- spark can be obtained.
A3519-00 -10-
5/73
TROUBLE SHOOTING CHART (Continued)
PROBLEM
POSSIBLE CAUSE
3. Heater burns,
but puffs of
REMEDY
FOR FURTHER
DETAILS SEE:
Improper Fuel-Air Mixture (Not enough fuel)
smoke can-be a. ‘Heater running out Shut heater off; check fuel tank. If
seen; heater - of fuel; water con- you can see globules of water in the
will not burn densation in fuel bottom, drain and flush the tank
steady; heater - tank; wrong fuel. and filter with clean fuel.
burns with | ©
odor; heater Refill with fresh, clean kerosene
smokes or No. 1 fuel oil.
continuously.
b. Dirty air filters — Remove and clean the air filters. Sec. II, Para. B.
causing reduced
air flow through Be sure air intake is not blocked.
nozzle, resulting |
in low fuel flow.
c. Fuel filter loose, Remove and wash fuel filter in Sec. IIT Para. G.
— dirty or con- clean fuel.
nection loose.
a | Check condition of connection Sec. V, Para. I.
between fuel filter and burner
head.
Replace with new filter tube,
nut, or fitting if connect: a
can't be tightened withou.
leaks.
d. Dirty nozzle. Remove and clean the burner Sec. III, Para. H.
A В head. |
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, - | pump if adjustment cannot be
worn pump, pump made.
out of adjustment.) |
o Check to be sure that no dirt
or trash (or dirty fan blades)
| could be causing motor
slowdown.
Lubricate fan-end bearing
of motor, Sec. III, Para. Е.
Е. Loose air output line! Be sure connections are tight.
connections between
filter housing and
burner.
A2821-01 -11-
5/73
TROUBLE SHOOTING CHART (Continued)
PROBLEM POSSIBLE CAUSE REMEDY FOR FURTHER
| DETAILS SEE:
3. (Continued) g. (Remote possibility) If heater puffs intermittently, Sec. V, Para. J.
Heater burns, Rubber sleeve on shank replace the rubber sleeve. |
but puffs of of nozzle is leaking. — (Handle parts carefully to
smoke can be В | prevent damage, assemble
seen; heater ВЕ them carefully to preserve
will not burn ; | | airtightness.)
steady; heater . .
burns with h. (Remote possibility) | Tighten screws. If parts are
odor; heater Combustion chamber warped from heat, replace
smokes — not tight against | warped parts. There must be
continuously. burner head, allowing no air gap between face of
too much air to enter burner head and back of
‘combustion chamber. - combustion chamber.
4, Flames come out Improper Fuel-Air Mixture (Too much fuel, or not enough air for
front of heater. amount of fuel being supplied.)
a. Dirty fan, or air pas- Clean the fan. Be sure the air
sageway through heater | passageway through the heater is
blocked by dirt or | clean. Keep the heater clean.
trash. a | |
b. Pump output pressure Check and adjust pump output Sec. V, Para. L.
is too high, causing too pressure.
much fuel to be supplied.
c. Fan loose or improperly| Check fan; correct if not right. Sec. V, Para. H.
located on shaft.
d. Bent or damaged fan. Replace. Do not attempt
| repair of fan.
5. Heater cycles Electrical System Troubles
intermittently. = | | |
a. Thermostat (if used) Set thermostat to a higher
set too low. | temperature for more even
operation.
b. Defective thermostat | |
(if used). Replace a defective thermo- Sec. V, Para. C.
| stat. |
с. Low voltage causing Check power line voltage.
tripout of motor |
overload protector. Use extension cord with
| proper size wire. | | Sec. II, Para. B.
d. Defective electrical Be sure extension cord and
supply or defective heater service cord are in
connections. good condition, without
intermittent open circuits.
Check mechanical and
electrical soundness of
all wiring connections in the
heater and service cord.
A3579-00 -12- 5/73
TROUBLE SHOOTING CHART (Continued)
PROBLEM
POSSIBLE CAUSE
REMEDY 1 FOR FURTHER
DETAILS SEE:
Control System
Troubles
Heater ignites,
but red button
of safety control
circuit breaker
pops out anyway.
a. Defective photo cell.
Sec. V, Para. N.
Check to see if glass face of cell is
so dirty it can't "see" the flame;
clean glass if dirty.
Replace with a cell that is known
to be good. . |
b. Defective safety
control.
Replace with a control that is
known to be good.
ec. Defective electrical
connections in circuit
relay.
through cell and control
Be sure all solder joints and wiring
connections are secure. Check
wiring diagram.
Safety Control cir-
cuit breaker fails
to trip when a
no-flame condition
exists.
a. Defective circuit
Replace with a circuit breaker that
‘breaker. | is known to be good.
b. Contacts dirty or Replace defective contacts with one
defective. that is known to be good.
с. . Photocell electrical
| leads shorted.
Check photocell leads for shorted
Button on safety
control circuit
breaker won't stay
in when pressed.
a. Resetting is tried too
soon after the breaker
trips. |
leads. Replace photocell if damaged.
Wait 5 minutes and try again.
b. Defective circuit
breaker.
Replace with a circuit breaker that is known
to be good.
c. Photocell circuit open.
Check photocell for open condition. Replace
if damaged.
INTERNAL
GROUND
CIRCUIT
BREAKER
1360
A3521-01
Figure 9. Wiring Diagram
-13-
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 installationintoa 1/8-inch standard pipe-threaded
hole.
2. Oil Burner Nozzle Wrench, or any 5/8-inch
socket wrench.
3. Cleanfuel, either kerosene or No. 1 fuel oil.
; 4. Non-flammable, non-toxic liquid cleaning sol-
vent. о,
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.
A3580-00
-14-
3. Plug the heater service cord into an outlet.
If the heater operates properly, the thermostat 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.
Е. 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 6.
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. Ifthe 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 surethatthe 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 9.
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, and the thermostat is set to call for heat,
4/73
check the motor and its starting circuit components
as described in the following paragraphs.
1. Mechanical Check. Spin the motor by turning
thefan blades by hand. If 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 9).
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 by taking
out the screw which holds its bracket to the left side
of the lower shell, near the motor.
CAUTION
o Avoid touching the bare wires on 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 thered 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.
Cc. 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. :
— A3575-00
-15—
(2) Failure of the starting relay.
e. Ifthe motor fails 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. Applya few 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. If stiffness still exists, rebuild the
motor according to the manufacturer's instructions.
3. Whenever a motor has beenrebuilt, 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.
SETSCREWS MUST REST
IN INNER GROOVE IN
MOTOR SHAFT
MOTOR SHAFT
OUTER GROOVE
INNER
FAN HUB
| GROOVE
MOTOR
223
Figure 10. Location of Fan on Motor Shaft
5/73
4, When you install the motor, be sure it is not
misaligned after tightening the 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 10.
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 will not provide an air tight connection.
J. . BURNER HEAD SERVICE
1. Takeout the 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-
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 {гу 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
partthathelps 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-
A3559-00
-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 spark plug gap as described 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 with close 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
needed to reach the parts which must be re-
placed. a.
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.
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
4/73
CHECK FOR SQUARENESS
OF FIT — MOTOR END SHIELD
7 ROTOR INSERT
VA (FLAT SURFACE ON
PUMP ROTOR
THIS SIDE)
MOTOR SHAFT
.005
006 CLEARANCE
MEASUREO
WITH
FEELER
GAGE
GAP ADJUSTING SCREW
END SHIELD
877
Figure 11. 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 11, 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 11.
Measure the clearance with a feeler gage. Spin the
motor by handto 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.
c. Insertcarbon blades as described above.
d. Instali the endcover, using the six screws
which were removed. Reconnect the air line.
A3581-01
-17-
Figure 12. 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 12.
2. Remove the upper shell and wire nuts at the
photocell connections. Install a jumper lead across
the photocell to bypass it. Tape these connections to
prevent accidentally grounding against the shell. Re-
install the shell, then start up the heater.
3. Pumppressuremustbe 4psi. I 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 shell and disconnect jumper wire
from photocell connections. Reinstall wire nuts to
electrical leads (see figure 9).), Install upper shell,
then 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.
5. Besure all parts are in place and the screws
are tight before attempting to use the heater.
N. SAFETY CONTROL CIRCUIT
; 1. Testing.
| NOTE: The following testing procedures should .
be performed only if troubles indicate
the safety control circuit may be at fault.
Unplug the heater power cord. Disconnect and
tape all motor leads from the relay. This will help
prevent accidental injury and will prevent fuel from
being ejected from the nozzle. Disconnect the red
lead from terminal No. 4 of the circuit breaker (Fig-
ure 9) and tape the end of the red lead.
~ Make certainthe reset button of the flame sensor
control and circuit breaker is pressed in (figure 2).
Set the thermostat (if used) to a temperature above
the temperature of the surrounding air.
Position the flame sensor, circuit breaker and
relay assembly as instructed in the test procedure for
the motor and relay, page 15.
~ Remove the wire nut from the connection point of
the white lead of the transformer, the white lead of
the motor, the red lead of the flame sensor, the white
lead of the power cord, and the white lead of the con-
trol and circuit breaker.
9.)
~ Connect a meter or test light between the No. 4
terminal of the circuit breaker and the white wire to
the motor and transformer. (See wiring diagram
Figure 9.) There should be a voltage reading or the
test light should come on between the terminal and
the connection point when the power cord is plugged
in. If a voltage reading is present or if the test light
illuminates, the safety control circuit is functioning
properly. If not, continue on with the testing.
CAUTION
Unplug the power cord before continuing the
test.
Check the photo cell (flame sensor) by removing
it from the mounting bracket. Take care not to bend
the bracket. Hold the rubber hood end of the photo
cell against a metal surface such as the side of the
shell to block off all light to the flame sensor; then
plug the heater power-cord in.
Observe the time between covering the photo cell
and the actuation of the circuit breaker. If the tripping
of the breaker occurs in approximately 15 seconds, the
safety control circuit is operating normally. When
A3565-01
(See wiring diagram, figure
with the breaker unactuated (plunger in).
the circuit breaker contacts open, the light will go off
or the meter reading will drop to zero.
If the breaker does not trip after 20 fo 25 seconds
(as indicated by the light staying on or the meter con-
tinuing to register voltage), UNPLUG THE POWER
CORD and disconnect the blue lead of the photo cell
fromthe blue lead connected to the breaker. Plug the
heater in. The breaker should now trip within 15-20
seconds. If it does not, the flame sensor and circuit
breaker is faulty and should be replaced. If it does
tripwithin 15-20 seconds, the photo cell is faulty and
must be replaced.
UNPLUG THE HEATER. Reconnect the red wire
to terminal No. 4 of the circuit breaker. Reconnect
all leads in accordance with wiring diagram Figure
9.
Test fire the heater to make sure it will function
properly. If it does not, check all wiring connections
according to wiring diagram, Figure 9. Repeat the
testing procedure if necessary. An alternate method
of testing the safety control circuit is to use an ohm-
meter. Disconnectthe red wire connected to terminal
No. 4 and make the following measurements:
Terminal No. 1 to terminal No. 4 of the circuit
breaker. (See figure 9.) The reading should be 0
The reading
with the breaker actuated (plunger out) should be in-
finite. |
| Terminal No. 2 to the connection point of the white
wire at the circuit breaker and the safety control flame
sensor disconnected, very high (almost infinity).
~18-
Terminal No. 2 to the white wire and the cell in
the dark, approximately 500,000 ohms.
Terminal No. 2 to the blue wire connection point,
approximately 100,000 ohms.
2. Replacement.
To replace the photo cell, disconnect the wires at
the cell and work the cell out of it's bracket, Install
replacement in reverse order of removal. Use care to
prevent bending bracket when installing cell."
I trigger circuit has been determined to be de-
fective, disconnect black wire from circuit breaker.
Detach bracket to which circuit breaker is mounted.
Disconnect blue and white leads from electrical circuit,
then loosen ring and hex nuts and lift out trigger cir-
cuit. Install replacement in reverse order of removal.
‘Toreplace a defective circuit breaker, remove trigger
circuit. Disconnect the two leads to the load and line
terminals. Remove ring and hex nut and withdraw the
circuit breaker. Install replacement breaker in the
reverse order of removal. Check that all wiring con- .
forms to the wiring diagram, then test fire the heater.
5/73
5/73
-19-
Figure 13. Heater Exploded View
A3582-00