Desa MA100 Construction Heaters Assembly Instructions

 PATENTED
MODEL MA100
Spec. No. 3059G30
BURNER
SYSTEM -
Form No, 4358
KOEHRING,
ATOMASTER DIVISION
BOWLING GREEN, KENTUCKY 42101
M29870-93
Litho in U.8. A.
- - 7 > ; e : - x -
The Heater Body is shipped assembled. Wheels and Handles are packed separately. Check to see that the following items
are included: | | о
A) Heater Body E) 8ea 10 x 24 Nuts
B) Handles and Wheel Support Frame F) 2 ea. Cap Nuts
C) 2 ea. Wheels, 1 ea. Axle G) 1 ea. Fuel Cap
D) 8ea 10x 24 x 1 3/4" Screws
IMPORTANT Screws, Nuts and Cap Nuts are standard hardware items.
TOOLS REQUIRED Medium Phillips Screwdiver, 3/8” Open or Adjustable Wrench, Lightweight Hammer.
ASSEMBLY INSTRUCTIONS | | :
Step 1 — Slide the Axle through the Wheel Support Frame. Install Wheels. IMPORTANT - The extended hub of
the Wheel should be positioned toward the Wheel Support Frame. Tap the Cap Nuts on the Axle ends.
Step 2 — Position the unit, Motor end over Wheels, on the Wheel Support Frame.
Step 3 — Use Screws and Nuts, attach Handles and Wheel Support Frame to Fuel Tank Flange with Screws and
Nuts. Install all Screws and Nuts before tightening. |
Step 4 — Tighten all Nuts.
Step 5 — Install Fuel Tank Cap. _
A3014-03
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SETI - - 55
Requirements
IMPORTANT: Read and Understand Instruction Manual before Starting or Servicing!
IMPROPER USE OF THIS HEATER CAN RESULT IN SERIOUS BODILY INJURY DUE TO HAZARDS OF FIRE OR
EXPLOSION, CARBON MONOXIDE POISONING, BURN, AND ELECTRICAL SHOCK.
e Use ONLY Kerosene or Number 1 Fuel Oil. NEVER BURN GASOLINE, NAPTHA, PAINT THINNERS, ALCOHOL OR
OTHER VOLATILE FUELS!
9 Use ONLY in areas FREE OF FLAMMABLE VAPOR OR HIGH DUST CONTENT. NEVER USE HEATER WHERE
GASOLINE, PAINT THINNER OR OTHER HIGHLY FLAMMABLE VAPORS ARE PRESENT.
® Make sure hot air outlet is AT LEAST 5 FEET from COMBUSTIBLE MATERIALS.
e Fill fuel tank or move heater ONLY when heater is UNPLUGGED.
® NEVER USE HEATER IN ROOMS USED FOR SLEEPING. |
* USE ONLY IN WELL VENTILATED ROOMS. Provide ventilation of AT LEAST 3 SQUARE FEET FOR EACH 100,000
BTU OF RATING. (For example, a 30,000 BTU Heáter would require a two foot wide window raised s six inches.)
* When used with THERMOSTAT, HEATER MAY START ANYTIME!
e KEEP CHILDREN AWAY FROM HEATER AT ALL TIMES—NEVER LEAVE A HEATER PLUGGED IN WITHOUT AN
ADULT PRESENT IF CHILDREN ARE LIKELY TO BE PRESENT. =
e Use ONLY with electrical voltage and frequency specified on model plate.
* Use ONLY a PROPERTY GROUNDED THREE— WIRE EXTENSION CORD. Safety requirements and model plate data
* Do NOT MOVE, HANDLE OR SERVICE WHILE HOT OR BURNING. comply with American National Stand-
* Use ONLY in accordance with local ordinaces and codes. ards Institute Safety requirements.
* NEVER ADD DUCT WORK TO FRONT OF HEATER. ANSI A10.10—1970
> 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 below:
Clean and flush fuel tank. .. ..... NU RAS After every 150 hours operation.
Clean and/or replace fuel filter ............... Clean at least twice a season. More often if heater performance
indicates the need. Replace if necessary.
Clean or replace air filters .............—...—... Check air filter frequently. If a film of dust is apparent on the filter,
remove and clean it. Replace after each 200 hours of heater operation.
—
Cleanfan ............... 0c. iin... Clean fan after every 500 hours of operation. ‘Clean more frequently if
heater is operating in dusty areas or if there i is a build-up of dirt on the
blades.
Clean burner nozzle ......................... Clean the nozzle at least once during the heater season or more often if
heater performance indicates the need.
Clean and adjust spark plug ...............—e. 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.
Clean photo cell ............................ 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.
A3229-04 -i-
SECTION I
INTRODUCTION
A. GENERAL
1. Purpose of Manual. This manual gives instructions for
operating, maintaining, trouble shooting and servicing the
heaters. A complete parts list in included at the end of the
manual.
2. Purpose of Heater, Use this heater wherever you need
temporary portable heat. It must be used with adequate
ventilation and proper electircal power.
B. THEORY OF OPERATION
There are four basic systems within the heater: the fuel
system, the air system, the ignition system, and the safety
control system. (Refer to figure 1 for-a schematic which
depicts the operation.)
An air pump on one end of the motor shaft forces air
through the air tube and out the burner nozzle. The moving
air creates a pressure differential in the burner head causing
fuel to be drawn from the tank. The fuel and a.- mix and the
mixture is sprayed into the combustion chamber in a fine
mist.
Additional air is supplied to the combustion chamber by a
fan on the opposite end of the motor shaft. Parts around the
burner head allow a portion of the air being moved by the
fan to enter the combustion chamber where it mixes with
the air and fuel entering the combustion chamber from the
nozzle. the remaining air is directed around and over the
combustion chamber. This. airiixes with the heated air from
the combustion chamber and is ejected as a jet of clean,
The ignition system consists of a transformer and spark
plug. The transformer increases the input voltage to a very
high potential which causes an arc to be drawn between the
electrodes of the spark plug. The arc is used to ignite the
“fuel and air mixture within the combustion chamber. The arc
fires constantly during operation.
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Figure 1 Schrmatic Dixgram Showing Principles of Hrater Operation
A5222-00
The safety control circuit essentially consists of three
parts: a light-sensitive cell (flame sensor), a trigger circuit,
and a circuit breaker. The circuit breaker automatically
trips if the flame fails, thereby causing the heater to shut
down. (See figure 2.)
C. POWER REQUIREMENTS
The heaters are manufactured for use on 230 volt, 50 cycle
power.
D. SPECIFICATIONS
Output Rating (BTU per hour) .."...... .....150,000
Amperage (During normal run) ................... 3
Air Pump Pressure (PSI) ......... еее J 5
Weight (Approx. Ibs.) Shipping ................ 90.5
о Dry(net) ................. 76
Fuel Tank Capacity, U.S. Gallons .............. 13.5
AirOQutput-CFM. .............. 0... 500
Fuel Consumption, approx. U.S. Gal. per hour ... 1.1
Electrical Requirements Voltage. ............... 230
Cycles.................. 50
Motor RPM ................... PT 2850
Fuel ................ Kerosene or Ng::1 Fuel Oil only
E. PREPARING FOR OPERATION
This heater is shipped with the wheel support frame,
handles, axle and wheels removed. To assemble these parts
refer to assembly instructions:
1. Check the heater for possible shipping damage. If any
damage is found, IMMEDIATELY notify the agent of the
carrier which delivered the heater to you, and make out a
claim for the damage. - os
A. 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
B. FUEL
Be sure the tank is clean. Fill it with clean kerosene or No.
1 fuel oil ONLY. Do not use any other fuel.
When the heater is operated at very low temperatures
(beyond 10°F below zero), the fuel may congeal.
To prevent this, add a non-toxic anti-icer to the fuel.
Follow the mixing instructions contained on the anti-icer
container. |
C. STARTING
1. Power Supply. Be sure that the power available to the
heater matches that shown on the instruction plate, in both
voltage and frequency (cycles).
2. Heaters Without Thermostat Accessory. The heater
will normally ignite as soon as it 1s plugged into the outlet.
a
SECTION II
OPERATION
3. Heaters With Thermostat Accessory. Set the tempera-
ture dial of the thermostat accessory to the desired
temperature. ,
A. If the dial is set to a temperature setting, 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
on the rear of the heater. The heater should start
immediately.
c. If the heater fails to start, the red button 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 to cool, then press the red
button agian, after checking 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.
D. 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.
SECTION III
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 maintenance fails to
return the heater to good operating condition, refer to
Section IV in this manual for checking and trouble shooting.
See Figure 2 for component identification.
A. FUEL TANK MAINTENANCE
Drain the fuel tank after every 150 hours of operation, and
flush it out with clean fuel. 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.
A5223-00
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 output air filter once each heating season.
4. To reach the output air filter, remove the four screws
which attach the filter housing end cover. Remove the
output air filter. See Figure 4.
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, paragraph L.
COMBUST
COMBUSTION C BURNER (%)
SPARK PLUG (%)
PHOTO CELL
o FAN
y A Xx MOTOR
INTAKE
AIR FILTER (x)
QUTPUT
AIR FILTER
JODE HOUSING)
X)
LINT FILTER
(INSIDE HOUSING)
{X}
SAFETY CONTROL/ >.
SAFETY CONTROL
RESET BUTTON
TRANSFORMER
Figure 2. Heater Component Identification
Symbol (*) indicates parts recommended as replaceable by uwner or user of brater.
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.
6. Replace the lint filter, the output air filter, the filter
housing end cover, and the screws and washers.
C. REMOVING UPPER SHELL
WARNING
With the upper shell removed and the service cord
plugged in, the heater can be 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.
Figure 3. Removing Intake Air Filter
COMBUSTION
CHAMBER -
BURNER
HEAD
Figure 7. Burner Hvad, Spark Pug. and Fuel Filter
A5224-00
D. CLEANING THE FAN
Clean the fan blades after every 500 hours of operation, or
whenever you see that they are getting dirty. A build-up of
dirt will reduct 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.
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.
OIL FAN-END MOTOR
BEARING HERE
Figure 5. lubrication of Motor Bearing
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.
Figure 4. Access to Air Filter Tor Maintaronce
BEND HERE TO
ADJUST GAP
050 =
Figure 6. Spark Plug Gap Setting
3. Adjust the gap by bending the outside electrode
where showninfigure 6. If you do not install the plug
immediately, protect it from damage until it is re-
installed.
4. Install the plug into the burner head, if no
further burner head maintenance is required. Make
sure the spark plug 15 svati-dfirmly in the burner head.
G. CLEANING THE FUEL FILTER
1. The fuel filter is in the tube which leads up from the fuel
tank to the burner. Clean it twice each season, or if the
trouble shooting. chart indicates.
2. To remove the fuel filter, loosen the hex nut attaching
the filter tube to the burner head.
3. Slide the tube down into the tank so that the tube will
clear the male connector in the nozzle adaptor. Remove the
entire tube from the tank.
4. The fuel filter (wire mesh) is cemented in the fuel tube.
This is a fine wire screen and can .be ssen by sighting
through the tube.
5. Clean as follows:
a) Rinse the filter several times in clean fuel.
b) Blow the filter dry through the fitting end.
6. Reinstall the filter tube in reverse order that you
removed it.
3. Adjust the gap by bending the outside electrode where
shown in figure 6. If you do not install the plug immediately,
protect it from damage until it is re-installed.
4. Install the plug into the burner head, if no further
burner head maintenance is required. Make sure the spark
plug is seated firmly in the burner head.
NOTE: If the burner head is to be removed for maintenance,
do not reinstall the fuel filter until ready to reinstall the
burner.
A5225
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eE. Y
- NUARALA SUELA
Sid WASMER
7 SPRING
VA - SEAL WASHER
„и NOZZLE FACE
~~~ NOILZILE MSSAGE
AIR HOSE
Figure 8. Blowing Out Nozzle *
H. BURNER REMOVAL, CLEANING AND
REPLACEMENT |
1. Be sure the heater cord is unplugged, and 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 adapter.
2. Remove the screws that fasten 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 cleaning agent. (DO
NOT use kerosene or fuel oil). Blow dry through the face
(OUTLET) end ONLY. See Fibure 8.
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 hole is just above center, on the right.
Install the attaching screws and tighten.
7. Conncet the fuel filter and the air line to their
respective fittings on the nozzle adapter.
I. SAFETY CONTROL SYSTEM
For servicing the safety control system, refer to Section
У.
J. REASSEMBLY AFTER MAINTENANCE
Put the heater back together in the reverse order of
disassembly.
SECTION IV
TROUBLE SHOOTING
A. GENERAL
WARNING
ALWAYS UNPLUG THE HEATER WHENEVER YOU
ARE SERVICING IT. USE EXTREME CARE WHEN
PERFORMING THOSE SERVICE OPERATIONS WHICH
REQUIRE THE HEATER TO BE PLUGGED INTO A -
POWER SOURCE.
If normal maintenance fails to keep a heater in good
operating condition, it probably requires repair or replace-
ment of some parts. Examine it and test fire it to gain
first-hand knowledge of why the service might be needed.
This section tells how to examine and test fire the heater. _
Jt also contains a Trouble Shooting Chart for help in
diagnosing heater troubles and finding the remedies.
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. Spin the fan to 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 cord for obvious breaks or other
unsafe conditions. If the cord is doubtful, repair it or install a
new one before test-firing.
LY
PROBLEM POSSIBLE CAUSE
Motor does not start. Electrical Troubles
a. No power or low voltage
at heater.
b. Damaged motor, motor
starting relay, binding
fan-end bearing;
Mechanical Troubles
c. Dry bearing on fan-end
of motor.
d. Pump rotor binding or
carbon blades worn out.
A5226-00 5
C. TEST-FIRING
1. Ciean the fuel tank and fill it with at least % gallon of
fuel. A minimum of % gallon of fuel must be in the tank for
proper test-firing.
2. Clean the air intake filter.
3. Check and adjust the air pressure,. as described in
Section V, Paragraph K.
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. Observe its
operation during the test-run.
5. After making the pressure check, adjustment, and
test-firing, remove the gage and reinstall the plug. Be sure
it is tight. |
6. If troubles show up during the test-firing, refer to the
Trouble Shooting Chart for remedy.
D. TROUBLE SHOOTING
The following chart lists problems, “Possible Causes” and
“Remedies,” to correct the problem or refers you to 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 pushed it through the nozzle.
REMEDY
Be sure voltage at outlet is same as shown on
heater instruction plate.
Use extension cord with wires heavy enough
“ to carry the electrical load of the heater.
Check motor.
Replace a defective motor (or motor starting
relay).
Lubricate motor (Fan-end only).
Rebuild or replace a binding pump.
PROBLEM
a - 2. Heater will not ignite,
“27 but môtor runs for a
- = short time.
3. Heater burns, but -
puffs of smoke can be
seen; heater will not
burn steady; heater
burns with odor;
heater smokes con-
tmuously.
A5227-00
POSSIBLE CAUSE
Fuel System Troubles
a. Fuel tank empty, water
in fuel, wrong fuel,
b. Air leak at fuel filter.
Ignition Troubles
c. Defective spark plug
(Wrong gap, plug wet
with fuel or electrodes
carboned, or plug dam-
aged.)
d. Defective transformer
REMEDY
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. .
Check fuel filter for air leaks and for tight-
ness of fitting where filter is connected to
burner head.
Measure gap between electrodes, using thick-
ness of a dime as a gage. Adjust electrode:
gap.
Inspect plug for worn or erroded electrodes.
Replace a damaged spark plut.
Disconnect spark plug wire from transformer,
and check transformer for spark; replace if
no spark can be obtained.
Improper Fuel-Air Mixture (Not enough fuel)
a.. Heater running out of fuel;
water condesnation in
— fuel tank; wrong fuel.
b. Dirty air filters causing
reduced air flow through
nozzle, resulting in low
fuel flow.
c. Fuel filter loose, dirty
or connection loose.
d. Dirty nozzle.
e. Low pump output pres-
sure. (Low motor speed,
~ worn pump, pump out
of adjustment.)
f. Loose air output line
connections between
filter housing and burner.
Shut heater off; check fuel tank. If you can
see globules of watex in the bottom, drain
and flush the tank and filter with clean fuel.
Refill with fresh, clean kerosene or No. 1
fuel oil.
Remove and clean the air filters.
Be sure air intake is not blocked.
Remove and wash fuel filter in clean fuel.
Check condition of connection between fuel
filter and burner head.
Replace with new filter tube, nut or fitting
if connection can’t be tightened without leaks.
Remove and clean the burner 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.
Check and adjust pump output pressure; re-
pair or replace pump if adjustment cannot be
made. |
Check to be sure that not dirt or trash (or
dirty fan blades) could be causing motor
slowdown.
Be sure connections are tight.
PROBLEM POSSIBLE CAUSE REMEDY
4, Flames come out | Improper Fuel-Air Mixture (Too much fuel, or not enough air for amount of fuel
front of heater. | being supplied.)
a. Dirty fan, or air passage - Clean the fan. Be sure the air passageway
way through heater blocked through the heater is clean. Keep the heater
by dirt or trash, clean.
b. Pump output pressure is Check and adjust pump output pressure.
too high, causing too much
fuel to be supplied.
с. Fan loose or improperly Check fan; correct if not right.
located on shaft. |
d. Bent or damaged fan. Replace. Do not attempt repair of fan.
5. Heater cycles inter- Electrical System Troubles Check power line voltage.
mittently. © a. Low voltage causing
tripout of motor over- Use extension cord with proper size
load protector. wire,
b. Defective electrical sup- Be sure extension cord and heater service
ply or defective con- cord are in good condition, without -
nections. intermittent open circuits.
Check mechanical and electrical sound-
ness of all wiring connections in the
heater and service cord.
6. Control System a. Defective photo cell. Check to see if glass face of cell is so
Troubles dirty it can’t “see” the flame; clean
glass if dirty.
a. Heater ignites,
but red button of Replace with a photo-cell that is known
circuit breaker to be good. :
pops out anyway. | о 2
b. Defective flame-out Replace with a control that is known
contro) to be good.
b. Flame-out Control circuit a. Defective circuit breaker. Replace with circuit breaker that is
. breaker fails to trip known to be good.
when a no-flame con-
dition exists.
WIRING DIAGRAM
_RED
BLACK —
TRANSFORMER
Figure 9, Wiring Diagram
A5228-01
A. GENERAL
>
This section covers 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 portion 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. HAU80, or any gage with a 15
SECTION V
SERVICE AND REPAIR -
1
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 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.
pound pressure range and % pound divisions. able to indi-
cate 4-% pounds accurately, plus fittings for installation in-
to a 1/8-inch standard pipe-threaded hole 3. Plug the heater cord into an outlet of the proper
oa - - .
voltage. Observe the spark between the plug’s electrodes. If
2. Oil Burner Nozzle Wrench, or any 5/8-inch socket
wrench. es
3. Clean fuel, either kerosene or No. 1 fuel oil.
4. Non-flammable, non-toxic liquid cleaning solvent.
CAUTION
и
Fumes given off by solvents may be toxic, therefore use .
solvents in a well ventilated area.
1. Compressed air is advisable, but not absolutely
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. Take the thermostat accessory out of the circuit by
unplugging the heater from the thermostat accessory.
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.
A5229-00
‘the ground is good and a spark does'not jump between the
electrodes, the transformer is defective. 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, Lo
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 move.
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, check the motor
and its starting circuit components as described in the
following paragraphs.
1. Mechanical Check. Spin the motor by turning the fan
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.
1/2. Electrical Check.
The heaters have 1/6 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
contacts on the bottom).
a. Take the 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
Avoid touching the bare wires on the exposed wire
terminals.
b. Take the black motor wire off its terminal of the
starting relay. Touch this wire to the terminal of the red
motor wire, at the relay. The motor should start. As soon as
the motor reaches operating speed, remove the black wire
from contact. The motor should continue to run.
ce. If the motor starts, :nstall a new relay, and reconnect
the wiring according to the Wiring diagram, Figure 9.
d. Failure of the motor to start could result 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.
(2) Failure of the staring relay.
e. If the 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 station for repair, or order a
replacement motor from the Master Service Parts Depart-
ment.
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 distrub the
pump body, which is the ring attached to the end of the
motor. (See paragraph K for pump service instructions).
G. MOTOR SERVICE “
1. Apply a 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 again
for stiffness. If stiffness still exists, rebuild the motor
according to the manufacturer’s instructions.
3. Whenever a motor has been rebuild, be sure to check
the pump rotor clearance as described in paragraph K-4 of
this Section, before reassembling the motor into the heater.
A5230-00
SETSCREWS MUST REST
IN INNER GROOVE |
MOTOR SHAFT
MOTOR SHAFT
OUTER GROOVE
FAN HUB INNER
es GROOVE
MOTOR
283
Figure 10. Location of Fan on Motor Shaft
4. When you install the motor, be sure it is not misaligned
after tightening the clamps.
H. FAN SERVICE
Replaces a damaged or bent fan. Do not attempt repair
except as a temporary emergency measure. Loosen two
setscrews to remove the fan from the motor 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 comustion characteristics of the
heater.
Check for proper fan location of the motor shaft. Make
sure tha 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 connecting
parts will not provide an air tight connection.
bie 3 BEE FRR MI MTR br Wr A IE
E
J, BURNER HEAD SERVICE
1. Take out the spark plug and remove the burner head.
Clean the entire burner head, as described in Section III,
paragraph H.
o If there is any sign of damage to the nozzle, or if it is
impossible to clean out the nozzle by blowing compressed air
into it through the outlet-end, replace with a new nozzle.
Always blow a nozzle out thoroughly with air, from the
outlet-end, before installing 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 operation, the rubber
sleeve is probably leaking and should be replaced.
4. Be sure the seal washer, spring, and second seal washer
are in piace on the nozzle before you install 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. Adjust the spark plug gap as described in Section Hi,
paragraph F.
K. AIR PUMP REPAIR
NOTE: Because of the close tolerances and critical
positioning of the parts, we recommend that only skilled
mechanics aitempt any repair of the air pump.
The heater's air pump consists of a rotor with four carbon
blades, rotating inside a pump body. The rotor is drive
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 complete
pump package, or individual parts, as shown in the Parts
List, Section VI.
A5231-00
10
1. Disassembly.
CAUTION
Do not take the pump apart any further than needed to
reach the parts which must be replaced.
a. Remove the end cover and take out the intake and
outlet air filters and the lint filter. Disconnect 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 loss of air
préssure. 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 uneven 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. Adjust the 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 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.
e. Insert carbon blades as described above.
d. Install the end cover, using the six screws which were
removed. Reconnect the air line.
CHECK FOR SQUARENESS
OF FIT ~~
7 ROTOR INSERT
yd 7 (FLAT SURFACE oN
TH!S SIDE
PUMP ROTOR ZZ 3 -
“MOTOR SHAFT
— MOTOR END SHIELD
- .005
006 CLEARANCE
MEASURED
WITH
FEELER
GAGE
GAP ADJUSTING SCREW
INSERT
END SHIELD
Figure 11. Checking Clearance of Air Pump Rotor
L. ADJUSTMENT OF PUMP PRESSURE
1. Remove the plug from the air filter housing, 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. Pump pressure must be 4 psi. 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 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.
A5232-00
Install gage finger tight, plus one
turn. Check for leakage before .
setting air pressure.
„”
Figure 12 Checking and Adjustment of
Air Pump Pressure
M. REASSEMBLY OF HEATER
1. Put the heater back together in the reverse order of
dissambley. |
2. Check all 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.
4. Make sure the electrode lead is snapped onto the spark
plug and the transformer output terminal.
5. Be sure all parts are in place and the screws are tight
before attempting to use the heater.
11
pa
FLAME-OUT CONTROL CIRCUIT
1. Testing
NOTE: The following test procedures should be performed
only if the trouble indicates the flame-out control circuit may
be at fault. Before starting any test procedure, always check
the wiring to be sure the connections are tight and it is in
accordance with the wiring diagram.
The flame-out control problems are in two categories.
A. The control does not shut off the heater while the unit
is running but no flame has been established.
B. The control shuts down the heater within 15 to 20
seconds although the heater is performing normally.
2. Testing for Category “A”
Disconnect the blue wire from the terminal on the control.
Connect the heater into an electrical outlet. If the unit starts
and burns for 15 to 20 seconds, then shuts down, the control
is good. The photocell should then be checked; this should be
done with the use of an ohmmeter:
A. Disconnect the heater.
B. Remove the photocell from the heater.
C. Measure the resistance while pointing the photocell toa
strong light. The reading should be less than 5,000 ohms.
D. Measure the resistance while placing the photocell
against a metal surface. The reading should be greater than
500,000 ohms. |
E. H “C” and “D” above do not read as indicated, the
photocell should be replaced.
A5233-00
12
3. Testing for Category “B”
A. Disconnect the heater.
B. Disconnect the blue wire from the terminal on the
control; and reconnect the wire to the group of five (5) white
wires. This will simulate a “light” condition within the
circuit.
C. Connect the heater in a proper electrical outlet and if
the circuit breaker trips, the flame-out control is defective
and must be replaced.
D. During this test if the heater does not shut down,
recheck the wiring and proceed through the photocell test;
as outlined in “A” above.
4. 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.
If trigger circuit has deen detdrmined to be defective,
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 circuit. Install replacement in
reverse order of removal. To repace 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 conforms
to the wiring diagram, then test fire the heater.
516C
Figure 13. Heater Exploded View
-13-
.HEATER GENERAL ASSEMBLY EXPLODED VIEW
Shell to Lower Shell)
Fig. 18
Index Part
- No. Number Part Name Qty.
1 M13134-3D Shell, Upper 1
2 M16781-4 Chamber, Combustion 1
| M11084-27* Screw (Combustion Chamber
attaching front) 2
M11084-29* Screw (Combustion Chamber
attacming rear) .. | 2
3 M16660 Bracket, Photocell 1
M10908-1* Screw (Photocell Bracket
to Combustion Chamber
rear head) 2
4 M16656-4 Cell and Bushing Assy.. 1
b M23150-2 Burner Head Assembly
(See Figure 14) 1
M11084-27* Screw (Burner Head to
Combustion Chamber) 3
6 M16879 Air Line 1
7 M12461-27 Screw, Slotted hex hd.
No. 10-32 x 1/2 in. 1
8 M24717 Clamp, Tube 1
9 WLM-3 Lockwasher, No. 10 1
10 NPF-3C Nut, Plain No. 10-32 1
11 M15807 Strap, Retainer 1
М11084-27* Screw (Retainer Strap to
| Lower Shell) 2
12 M23148 Fan 1
13 SF4-1/2K Setscrew, Soc. Hd.; cup
pt., 1/4-20 (Fan to
| a Motor Shaft) 2
14 M23149-2 Motor Package Assembly
(See Figure 16) | 1
15 M16661 Clamp, Motor 4
16 HC4-10C Screw (Motor Clamps) 2
17 WLM-4* Lockwasher, 1/4-20 (Motor
Clamps) 2
18 NPC-4C* Nut, Hex, 1/4-20 (Motor
Clamps) 2
19 M16777D Shell, Lower 1
20 M11084-27* Screw (Upper Shell to
| * Lower Shell) 6
21 M11271-6* Nut, Tinnerman (Upper
6
*Standard Hardware - Purchase Locally
A5296-00
Fig. 13
Index Part
No. Number Part Name Qty.
22 M12330 Bracket, Shell Support 1
M11084-27* Screw (Support Bracket to
Lower Shell and Fuel Tank) 4
- M11084-29* Screw (Lower Shell to Support
Bracket) 2
23 1000576 Grommet (Ignition cable
thru Lower shell) 2
24 M16646 Bracket, Motor Support 1
M11084-27* Screw (Motor Support
+ Bracket to Lower Shell
| and Fuel Tank) 6
25 M17921 Transformer, 5000 volt 1
M11084-27 Screw (Transformer to
| Motor Support Bracket) 2
26 M11143-1 Bushing, Strain Relief
| (Service Cord to Lower
Shell) 1
27 - M15779-22 Cord Assembly, Extension 1
28 M27552-01AA Tank Assembly, Fuel 1
29 M23284 Cap, Fuel Tank 1
30 M50323 Screen, Filler Neck 1
31 M10990-3 Bushing, Rubber (Fuel Filter
into Fuel Tank) 1
32 M27417 Plug. Drain 1
33 M50416-03 Safety Control Assembly 1
36 M25296-1 Bracket, Starting Relay Mtg. 1
37 M12462-11 Relay, Starting 1
RC2-2C* Screw (Starting Relay to
Mounting Bracket) 2
M11084-26 Screw (Grounding) 1
M11084-27 Screw (Relay Bracket to Shell) 1
M9900-62 Wire Assembly, Black
(To Starting Relay) 1
M9900-80 Wire Assy. (To Breaker) 1
Mi6615-1 Harness Assy. 1
M13942-7 Connector (Cell and Bushing
and Relay to Circuit Breaker) 1
M13942-5 4
Connector (Relay Leads)
-14-
3730
“a Figure 14. Motor Package Assembly
Fig. 14 Fig. 16
Index Part Index Part
No. Number Part Name Qty. No. Number Part Name Qty.
о * M23149-2 Motor Package Assembly Ref 10 M8643 ©. Blade 4
1 M16545 . End Cover, Filter 1 11 M22456-1 . Rotor 1
2 ‚ М12461-31* | Screw (Filter End Cover 12 M22009 . Insert 1
to Pump End cover) 4 13 M8645 . Pump Body 1
3 WLI-3 . Lockwasher, Internal No. 10 4 14 FHPF3-4C . Screw (Pump Body to Motor) 2
4 M12179 . Intake Air Filter 1 15 M5976 . Connector, Male 1
5 M12244-1 . Output Filter Assy 1 16 M22997 __. Plug, Hex hd. 1
6 M11637 . Filter, Lint 1 17 M27694 . Screw, Pressure Adjustment 1
7 M50545 . Front Cover, Pump (Port 18 M10993-1 . Spring, Compression
Plate) & 1 (Pressure Relief) 1
8 M12461-32* .Screw (End Cover to Motor) 6 19 M8940 . Ball, 1/4 in. dia. 1
9 WLI-3 . Lockwasher, Internal No, 10 6 20 M23107-2 . Motor 1
*Standard Hardware. Purchase Locally.
A5297-00 | -15-
Fig. 14
Index Part
No. Number Part Name Qty.
14- M23150-2 Burner Head Assembly Ref
1 M16789-6 ; Filter. Fuel Assy. 1
3 M13849 . Nut, Flared 1
4 M16741-18 . Ring, Retaining 1
M23151-1 . Nozzle Adapter Assy 1
5 M16791 . Connector, Male 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 M23103 ...Nozzle, Aspirating 0.66
GPH 1
I M16535 . . Adapter, Nozzle 1
12 M10962-2 . Spark Plug 1
13 M16534 . Body, Burner Head 1
WHEELS AND HANDLES
Fig. 15
. Index Part -
No. Number Part Name Qty.
1 M15131-3 Handle, Front and Rear 2
2 M12345-34* Screw, Handles and Wheel
Support Frame to Fuel Tank 8
3 M12342-3 Wheel Support Frame 1
4 NTC-3C* Nut, Hex 10-24, Torque Lock 8
5 M16801A Axle 1
6 M19294 Wheel 2
8 ‚ М28526 Nut, Cap 2
*Standard Hardware - Procure locally.
DECALS
Part
Number Part Name
M19457 Tradename
M22743 Warning
M22823 Flag
M31371 Wiring Diagram
M50623 Operation Instruction
M50624-57 Model Data
A5298-00
O pres
cu |
X IS
10
OD
9
—8
6
11
-3
-16-
Figure 15. Burner Head Assembly
Figure 16. Handles and Wheels.