Spark Plug Ignition Models Service Manual
Contents
1. 9 Troubleshooting l Safety Requirements 10 l CAU OS eder decet teca 10 III Using the Ohmmeter 1 Setting Up the Ohmmeter 10 2 Calibration 10 IV Diagnostic Charts 10 Diagrams and Charts l Wiring Diagrams eee 23 Il Motor Resistance Chart 23 For replacement parts contact GENERAL INFORMATION I ARRANGEMENT OF MANUAL This manual contains information and service procedures to assist the service technician in understanding and correcting problems on DESA International oil fired portable forced air heaters The first section of the manual contains basic infor mation concerning the operation of the different components in the heater This information should be reviewed by service personnel to provide a basic understanding of how the com ponents function in the working system Section four of this manual is intended to provide a quick reference concerning conditions which result in customer complaints These proce dures will help the service technician quickly diagnose a malfunctioning heater The illustrations in this manual may not necessarily depict the actual heater model and are intended for reference ONLY lll SERVICE PREPARATION A clean work area at the start of each job is essential for efficient2. 1 Air Pump The heater s air pump consists of a rotor with four carbon blades rotating inside a pump body The rotor is driven directly by the motor and is attached to the motor shaft by means of a plastic insert As the motor rotates the carbon blades travel outward rubbing against the inside surface of the steel pump body The rotor s position inside the pump body is such that itis not concentric with the pump body and a 003 004 of an inch gap is set at the uppermost quadrant As the motor rotates the air between the blades is compressed and routed to the nozzle through the air line Gap Adjusting Sere 003 004 E A Y Clearance Motor Shaft M Measured eB A P 9 o AT with Feeler Insert Gage Air Output Air Intake Side Side Rotor Pump Body Direction of Rotation Clockwise 2 Air Filters The air filtering system consists of an air input filter and an air output filter The air input filter is located at the right rear of the motor and its purpose is to filter all incoming air prior to entering the air pump The filter design is such that it can be cleaned in a mild soapy solution thoroughly dried and used over again The air output filter is located under the plastic end cover This filter s purpose is to prevent any carbon dust from rotor or blade wear from entering the air passages in the nozzle This filter is non cleanable and should be replaced when considerable buildup of carbon dust is observed Se
3. The ignition system consists of an electronic ignitor E and spark plug M The electronic ignitor increases the input voltage to a very high potential which causes and arc to jump 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 In the safety circuit the flame sensor detects the presence of light from the flame inside the combustion chamber I aum a 1 lt P 51 de Fuel lt lt Air For Fuel System de Air For Combustion www PartsFor com Spark Plug Ignition Models Service Manual TROUBLESHOOTING I SAFETY REQUIREMENTS This service manual is intended for use by individuals with an adequate knowledge of electrical and mechanical skills At tempts to repair this heater by individuals without those skills can result in personal injury as well as property damage Il CAUTIONS 1 Before servicing disconnect the heater from the electri cal power source by removing the electrical plug from the wall receptacle Note When certain tests require electrical power to be applied connect electrical power only for the time nec essary to complete the test 2 Do not bypass safety devices 3 If replacement parts are neces
4. Even the smallest air leak in this area can reduce flow rates and result in problems Note On smaller heaters 30 000 35 000 50 000 and 55 000 BTU inspect O ring do not remove Sai Nozzle Seal Install a new rubber seal to stem of nozzle Make sure the seal washer spring and second seal washer are in place before reinstalling nozzle in the burner head For replacement parts contact www PartsFor com Spark Plug Ignition Models Service Manual B Filter Bloched On certain models a drop in fuel filter is located in the copper or aluminum line that attaches to the fuel fitting on the back side of the burner head Lift the filter out of the copper or aluminum fuel line and clean if necessary C Restriction in Nozzle or Burner Head Using a compressed air source blow the compressed air through the outlet end of nozzle to dislodge any possible restriction CAUTION NEVER DRILL OUT OR TRY TO INCREASE NOZZLE SIZE Using compressed air also blow through passages in burner head The air should be directed form input fitting at rear of head to the center of burner head Many times the restriction to the flow is due to metal chips etc being present in the burner head assembly For replacement parts contact 6 Fuel Filter Restriction The fuel filter should be inspected and cleaned The fil ters are located in the fuel line either at tank location in the copper or aluminum tubing or in line vvith
5. motor If the needle does not move again or goes to full scale the motor must be re placed Actual resistance varies between motor types Note Motor may vary according to model For replacement parts contact www PartsFor com Spark Plug Ignition Models Service Manual 6 Defective Solid State Relay Defective Solid State Relay Prepare a jumper wire approximately 8 long with a male quick disconnect terminal at one end and a test probe at the other end Disconnect the black wire coming from the motor that is connected to the solid state relay termi nal Connect this black wire to the male connection of jumper wire Touch the test probe to the opposite termi nal of the solid state relay and plug in the heater As soon as the motor reaches speed remove the test probe from terminal The motor should continue to run If the motor operates correctly the solid state relay should be re placed Red Wire Solid State Jumper CAUTION DO NOT TOUCH ELECTRICAL CONNEC Wire TIONS OR ALLOW THEM TO TOUCH METAL PARTS OF THE HEATER Black Wire From Motor 7 Low Voltage to Heater In certain circumstance a heater may operate correctly when being tested in the service shop but the customer complains that it does not start at times on the job site It is important that the customer is made aware that if the heater is operated on an incorrectly sized extension cord or a low voltage outlet the heater s
6. service work Heaters which are extremely dirty should be cleaned prior to service Cleaning will occasionally uncover the problem area Tools needed for the job should be obtained before workis started Delays resulting from locating tools result in lost time and wages Clean fuel should always be used whentesting heaters Many problems are often traced to the use of the wrong type of fuel or dirty fuel Use caution and common sense when working on a heater Always remember that kerosene is flammable electrical parts can result in the potential shock and the heater parts are hot during operation which could result in burns if one is not careful www PartsFor com Spark Plug Ignition Models Service Manual IV TOOLS REQUIRED In addition to common hand tools the service shop should have the following tools and instruments for proper repairing of the heaters These instruments will be referred to through out this manual V PARTS Accessories In addition to the standard parts we now offer parts kits Listed below are the item numbers and the accessory description INSTRUMENT RANGE PART NUMBER Pressure Gauge 0 15 PSI HA1180 Feeler Gauge 001 to 1 inch None Volt Ohmmeter RX1 AC 250V None Available at any auto parts store Available at most electronic stores For replacement parts contact ITEM NUMB
7. surface making figure eight rotations Use the finest grade of sandpaper available Oil fan end motor 4 Dry Motor Bearing bearing here If the fan is difficult to turn with air pump parts removed apply 8 to 12 drops of a non detergent oil to the sleeve bearing on the fan of the motor The bearing located at the pump end is of the ball bearing type and should not be lubricated DO NOT OIL PUMP END BEARING Note Motor manufactured after 1978 have permanently lubricated sleeve bearing and cannot be oiled 6 Open Motor VVindings Motors VVithout Relay 30 000 35 000 50 000 and 55 000 BTU With the heater disconnected from AC plug connect the ohmmeter on the RX1 scale to the wires coming from motor On smaller heaters the leads from the motor should indicate a resistance of 6 to 8 ohms Actual resis tance varies between motor types Note Resistances may vary due to motor temperature Motors with Relays 70 000 100 000 110 000 150 000 165 000 and 200 000 BTU Start Winding Connect the ohmmeter on the RX1 scale to the white and black wires coming from motor This procedure al lows you to determine the condition of the start winding If the meter indicates infinity open circuit or the meter goes full scale zero ohms the winding is defective and the motor must be replaced Actual resistance varies between motor types Main Winding Connect the ohmmeter on the RX1 scale to the red and white wires coming from
8. 1 15 HP on the smallest heater to 1 4 HP on the largest heaters The motors used can be grouped into two categories The first category is the shaded pole motor The shaded pole motor contains a single winding and does not require an external start relay for operation These motors are easily identified by observing that only two wires usually red and white are necessary for operation The second category is the split phase motor This motor contains two separate windings The first winding being the auxiliary or start winding and the second being the main or run winding This motor requires and external means of switching the power off to the auxiliary winding after the motor reaches a predetermined speed This power off switching is accom plished by a motor start relay or solid state relay These motors are identified by observing that three wires black red and white are routed from the motor CAPACITOR AC LINE AC LINE Shaded Pole Motor Split Phase Motor www PartsFor com Spark Plug Ignition Models Service Manual 2 Solid State Relay Applicable models use 097061 01 Solid State Relay The solid state relay is used to de energize the start winding on split phase motors As mentioned in the Motor Section remember that split phase motors have both an auxiliary start and a main run winding For proper motor operation both the auxiliary and main winding are energized during start up After the motor starts and reaches app
9. 908 or 4909 To be used only at construction sites in accordance with applicable New York City Codes Regulations Rules Directives Permits etc Warning to New York City Residents For Use Only At Construction Sites in accordance with applicable NYC codes under NYCFD certificate of approval 4803 4899 4908 4909 or 4934 www PartsFor com Spark Plug Ignition Models Service Manual TABLE OF CONTENTS General Information Arrangement of Manual 3 11 Service Preparation 3 IV Tools Required u 4 R a n ETE E EEEE EE A 4 Specifications l General Specifications 1 Fuel Selection 5 2 Electrical eris 5 3 Ventilation 5 4 Heater SIZING irsinin ranea tete 6 Heater Performance Specifications 6 Component Operation l Air System T Air Pumps e 7 2 AIF ehe eiae 7 By tte eg re 7 ll Electrical System T MOItOIS iter eie 7 2 Solid State Relay 8 3 Safety Control Photocell 8 4 Electronic Ignitor 9 Ill Fuel System sese 9 IV Combustion System 9 V All Systems Working Together
10. ER ACCESSORY HA1180 Air Gauge All Models HA1210 Thermostat Forced Air 8 LP Forced Air HA1202 Heavy Duty Wheel Kit Fits 30 35 40 50 55 70 Models HA1206 Wheel Kit Fits 30 35 40 50 55 70 Models HA2203 Rear Handle Fits 100 110 Models HA2204 Rear Handle Fits 150 155 165 200 Models HA2210 Filler Neck Screen PP203 Flame Out Safety Control PP204 Rotor Kit 1 2 PP206 Nozzle 35 40 Models PP207 Nozzle 50 Models PP208 Nozzle 70 Models PP209 Nozzle 100 110 Models PP210 Nozzle 150 155 Models PP211 Spark Plug 70 100 150 155 165 200 Models PP212 Spark Plug 35 50 Models PP213 Air Filter Kit 80 50 70 Models PP214 Filter Kit 100 110 150 155 165 200 Models PP205 Rotor Kit 5 8 PP218 Nozzle 55 Models 100735 10 Nozzle 165 Models PP216 Photocell PP217 Pump Adjustment Kit www PartsFor com For replacement parts contact Spark Plug Ignition Models Service Manual SPECIFICATIONS I GENERAL SPECIFICATIONS 1 Fuel Selection One of the most critical specifications for trouble free opera tion is the use of a clean acceptable fuel Listed below are guidelines and comments concerning operation of heaters with different fuels RECOMMENDED COMMENTS FUELS Kerosene Bestoverall results Minimum odor and Fuel Oil No 1 minimum maintenance No additives Jet A necessary for cold weather operation ALTERNATE FUELS COMMENTS Fuel Oil No 2 Noticeable increase in odor Require
11. SECTION B SERVICE MANUAL LOW PRESSURE PORTABLE FORCED AIR HEATER SPARK PLUG IGNITION MODELS Spark Plug Ignition Models Service Manual SAFETY INFORMATION AX warnines IMPORTANT Read this owner s manual carefully and completely before trying to assemble operate or ser vice this heater Improper use of this heater can cause serious injury or death from burns fire explosion electrical shock and carbon monoxide poisoning A DANGER Carbon monoxide poisoning may lead to death Carbon Monoxide Poisoning Early signs of carbon monoxide poisoning resemble the flu with headaches dizziness and or nausea If you have these signs the heater may not be working properly Get fresh air at once Have heater ser viced Some people are more affected by carbon monoxide than others These include pregnant women persons with heart or lung disease or anemia those under the influence of alcohol and those at high altitudes Make certain you read and understand all warnings Keep this manual for reference It is your guide to safe and proper operation of this heater Use only kerosene or No 1 fuel oil to avoid risk of fire or explosion Never use gasoline naphtha paint thinners alcohol or other highly flammable fuels Fueling a Personnel involved with fueling shall be qualified and thoroughly familiar with the manufacturer s instructions and applicable federal stat
12. Unit does not ignite 11 Motor does not run or runs at slow speeds Spark is observed at plug 14 Heater does not start motor and transformer does not 17 Heater ignites and burns However Safety control trips and heater shuts off 19 Frequent plug fouling delayed ignition 22 www PartsFor com Spark Plug Ignition Models Service Manual OBSERVED FAULT Motor Starts Unit Does Not Ignite Check for Spark at Plug No Spark Observed Check Spark Plug for 2 Spark is Observed Check for Proper Pump Pressure Proper Gap 6 Check for Restricted Fuel Flow Defective Transformer or Due to Electronic Ignitor A Seal leak B Filter Blocked C Restriction in Nozzle of Burner Head 9 Cracked Spark Plug Fuel Filter Restriction TEST PROCEDURE Bend Here to Adjust O Check Spark Plug for Proper Gap Gap See Heater Performance Specifications Spark Plug i Gap page 6 for proper gap Reset gap with feeler gauge 2 Defective Transformer or Electronic Ignitor Connect the transformer or electronic ignitor to a prop erly gapped spark plug Establish a good ground between the spark plug and heate
13. ce is 10 feet It is further recommended that these enclosure materials be of a fire retardant nature These enclosure materials shall be securely fastened to pre vent them from igniting or from upsetting the heater due to wind action Use only in well vented areas Before using heater pro vide at least a three square foot opening of fresh outside air for each 100 000 Btu Hr of rating This heater produces carbon monoxide which is listed by the State of California as a reproductive toxin under Proposition 65 Use only in places free of flammable vapors or high dust content Use only the electrical voltage and frequency specified on model plate Use only a three prong grounded extension cord Minimum heater clearances from combustibles Outlet 8 Ft Sides 4 Ft 4 Ft Rear 4 Ft Locate heater on a stable and level surface if heater is hot or running or a fire may occur When moving or storing heater keep heater in a level position or fuel spillage may occur Keep children and animals away from heater Unplug heater when not in use When used with thermostat heater may start anytime Never use heater in living or sleeping areas Never block air inlet rear or air outlet front of heater Never move handle refuel or service a hot operating or plugged in heater Never attach duct work to front or rear of heater Approved by the New York City Fire Department under certificate of approval 4803 4860 4
14. d air through the outlet end of nozzle to dislodge any pos sible restriction Nozzle Seal CAUTION NEVER DRILL OUT OR TRY TO INCREASE NOZZLE SIZE Using compressed air also blow through passages in burner head The air should be directed from input fitting at rear of head to the center of burner head Many times the restriction to the flow is due to metal chips etc being present in the burner head assembly Fuel Filter Bushing and Lower Fuel Line k Note Fuel Filter Location May Vary According To Model For replacement parts contact www PartsFor com Spark Plug Ignition Models Service Manual Fuel Cap and Gasket Not Vented Inspect the vent hole and gasket under the fuel cap to make sure the passage is open Remember that since the fuel is being drawn from the tank the tank must be vented for proper operation Fuel Cap Has More Than One Gasket Make sure cap has only one gasket installed Mal OBSERVED FAULT Frequent Plug Fouling Delayed Igniton O Spark Plug Too Close to Spray Pattern of Nozzle 2 Wrong Fuel TEST PROCEDURE Spark Plug Too Close to Spray Pattern of Nozzle It may be necessary in some cases to move the spark plug back from spray pattern of nozzle The best method is to shim the plug back by placing a standard spark plug washer under the flat of the plug at threaded area This moves the plug back approximately 1 inch and reduces the possibility of the p
15. e and local regulations re garding the safe fueling of heating units b Only the type of fuel specified on the heater s data plate shall be used c All flame including the pilot light if any shall be ex tinguished and the heater allowed to cool prior to fu eling d During fueling all fuel lines and fuel line connections shall be inspected for leaks Any leaks shall be re paired prior to returning the heater to service At no time shall more than one day s supply of heater fuel be stored inside a building in the vicinity of the heater Bulk fuel storage shall be outside the struc ture f All fuel storage shall be located a minimum of 25 feet from heaters torches welding equipment and similar sources of ignition exception the fuel reservoir integral with the heater unit Whenever possible fuel storage shall be confined to areas where floor penetrations do not permit fuel to drip onto or be ignited by a fire at lower elevation For replacement parts contact h Fuel storage shall be in accordance with the federal state or local authority having jurisdiction Never use heater where gasoline paint thinner or other highly flammable vapors are present Follow all local ordinances and codes when using heater Heaters used in the vicinity of tarpaulins canvas or simi lar enclosure materials shall be located a safe distance from such materials The recommended minimum safe distan
16. e drawings below Air Output Filter Air Output Filter Air Input Filter Air Input FS 30 000 35 000 50 000 55 000 100 000 110 000 150 000 and 70 000 BTU Filter System 155 000 165 000 and 200 000 BTU Filter System For replacement parts contact 3 Nozzle As mentioned previousiy the purpose of the air pump is to compress air and deliver itto the nozzle The compressedair as it travels through the nozzle creates a negative pressure that extends bach through the center of the nozzle This negative pressure lifts the fuel from the fuel tank The fuel from the fuel tank and the compressed air are mixed at the nozzle which results in a very fine mist of fuel being sprayed into the combustion chamber The air pump nozzle combination eliminates the need for a conventional type fuel pump It is important for the service technician to understand the nozzle operation In many cases concerning improper operation of a heater the problem is the result of a seal leak or a restriction dust dirt being present within the nozzle It should also be pointed out that each model heater requires different nozzles due to different fuel flow rates Rubber Seal Separating Air Fuel Channels in Nozzle Compressed Air From Pump Nozzle Face t Fuel Lifted From Tank by Negative Pressure I ELECTRICAL SYSTEM 1 Motors The motors used on the low pressure heaters are fractional horsepower motors ranging from
17. emoved from the slot after any adjustment before taking a reading on the gauge See Heater Performance Specifications on page 6 for specified pressures Note Pressure gauge must be scaled in 1 4 pound in crements for accurate measurement 6 Check for Restricted Fuel Flow Remove the burner head from heater Using a socket wrench carefully remove the nozzle from burner head Be extremely careful not to scratch or score the face of the nozzle Burner Head www PartsFor com Spark Plug Ignition Models Service Manual Restricted Fuel Flow cont utlet A Seal Leak End Remove the rubber seal washer from stem of nozzle and discard To be safe always replace nozzle sleeve dur ing servicing of burner head Even the smallest air leak in this area can reduce flow rates and result in problems Note On smaller heaters 30 000 thru 55 000 BTU in spect O ring do not remove Install a new rubber seal to stem of nozzle Make sure the seal washer spring and second seal washer are in place before reinstalling nozzle in the burner head B Fuel Filter Clogged Clean or replace fuel filter as necessary filter is located at lower end of fuel pickup tube on 30 thru 70 and 200 models Filter is located on top of fuel tank on 100 thru 165 models On 200 model the filter is located at the end of fuel line inside fuel tank C Restriction in Nozzle or Burner Head Using a compressed air source blow the compresse
18. heck for Proper Pump Pressure Check for Restricted Fuel Flow Due to A Seal Leak B Fuel Filter Blocked C Restriction in Nozzle of Burner Head Fuel Cap and Gasket Not Vented Fuel Cap has More than one Gasket www PartsFor com 2 Defective Photocell Inspect the lens of the photocell for soot dirt etc If dirty wipe off with a clean damp cloth Remove photocell from heater and connect ohmmeter on the 1000 Ohm RX1R scale Hold the lens up to a light source 60 watt light bulb direct sunlight etc with the lens of the photocell pointed toward the light source The resistance of the meter should be low less than 500 ohms By blocking off the light source by putting thumb over opening of photocell the resistance on meter should be high Replace the photocell if a change in resistance is not observed during the above test J CH 2 U For replacement parts contact Spark Plug Ignition Models Service Manual Loose VVire Nut or Terminal Board Connection Physically check that all electrical connections are se cure and making electrical contact 4 Dirty Photocell See step 2 column 1 5 Chect for Proper Pump Pressure Install HA1180 Pressure Gauge or equivalent to rear of air filter housing Start heater and adjust air pressure to specified pressure Turning adjustment screw clockwise increases pressure counterclockwise decreases pres sure The screwdriver must be r
19. lacement parts contact www PartsFor com Spark Plug Ignition Models Service Manual 3 Check for Continuity of Circuit Breaker A Standard Safety Control PP203 098205 04 With the heater disconnected from AC source discon nect the red and black wires connected to the safety con trol Push reset button in With the ohmmeter on the 0 to 200 OHM scale check for continuity across terminals where wires were removed Meter should indicate O For replacement parts contact www PartsFor com Spark Plug Ignition Models Service Manual OBSERVED FAULT Safety Control Trips out Within the First Minute of Operation Defective Safety Control Defective Photocell Loose Wire Nut or Terminal Board Connection TEST PROCEDURE Defective Safety Control PP203 098205 04 Make sure unit is disconnected from AC source Discon nect the blue wire coming from safety control that is con nected to blue wire at photocell connection is made in smaller wire nut connection Connect the blue wire from control under the wire nut connection where the white wires are connected Plug unit into AC supply If the reset button on the safety con trol pops out and unit shuts off the control is defective and must be replaced For replacement parts contact Heater Ignites and Burns However Safety Control Trips and Heater Shuts Off Safety Control Trips out After Several Minutes of Operation 4 Dirty Photocell C
20. lug fouling with carbon or the plug becoming wet during the ignition cycle 2 Wrong Fuel Refer to Fuel Selection on page 5 of this manual For replacement parts contact www PartsFor com Spark Plug Ignition Models Service Manual DIAGRAMS AND CHARTS I WIRING DIAGRAMS Reset R Red Button ue Blue El Safety White Red Control Black Photocell W White Electronic gnitor Green Power Motor E Plug White ci ph Green 150V ale a White 60HZ p 30 000 35 000 50 000 amp 55 000 BTU Heaters E B WHITE WHITE ET SAFETY 4 E CONTROL g PHOTOCELL WHITE N MOTOR IGNITOR L WHITE e BLUE BLACK GREEN RED POWER PLUG RED SOLID GREEN STATE RELAY 120 V 60 HZ SPARK PLUG BLACK RED RED 70 000 200 000 BTU Heaters Heaters Equipped With Solid State Relay I MOTOR RESISTANCE CHART OHMS RED TO WHITE BLACK TO WHITE MOTOR MAIN 7 AUXILIARY 7 100088 01 6 2 097130 02 15 16 5 097134 02 3 5 18 3 101898 01 2 8 9 1 For replacement parts contact www PartsFor com DESA INTERNATIONAL www desatech com 079337 01 Rev D 08 00 For replacement parts contact www PartsFor com
21. motor will not start due to low voltage If the customer has the availability of a voltmeter have the customer check the voltage at the heater A minimum of 108 volts while the heater is run ning is necessary for proper operation Refer to the Elec trical Section of this manual page 5 for proper exten sion cord sizing For replacement parts contact www PartsFor com Spark Plug Ignition Models Service Manual OBSERVED FAULT Heater Does Not Start Motor and Transformer Ignitor Does Not Operate Possible Causes Internal to Heater Check That Reset Button on Safety Control is Fully Depressed Possible Causes External to Heater Check for Broken or Frayed Wires on Cord Check Wiring Connections at Safety Control and Wire Nuts for Proper Fit If External Thermostat is Used Plug Heater directly to AC Source Check for Continuity of Circuit Breaker TEST PROCEDURE 0 Check That Reset Button on Safety Control is Fully Depressed Visually inspect the black reset button on safety control The button must be fully depressed and latched in for Reset Button operation 2 Check Wiring Connections at Safety Control and Wire Nuts for Proper Fit Wire Nuts Physically check electrical connections at wire nuts and safety control for proper fit Check for continuity between male prongs of power cord to safety control Terminal Board Make sure connections are secure For rep
22. r Plug in the heater cord and observe for spark between electrodes If the ground is good and a spark does not jump the gap the transformer or ignitor is defective CAUTION DO NOT LET ANY PORTION OF YOUR BODY TOUCH ELECTRODES OR PLUG DUE TO HIGH VOLTAGE 3 Cracked Spark Plug During the above test if spark is observed at any portion of the plug except at the electrodes the porcelain insu lator is cracked and the plug must be replaced For replacement parts contact www PartsFor com Spark Plug Ignition Models Service Manual 4 Chect for Proper Pump Pressure Install HA1180 Pressure Gauge or equivalent to rear of air filter housing Start heater and adjust air pressure to specified pressure Turning adjustment screw clockwise increases pressure counterclockwise decreases pres sure The screwdriver must be removed from the slot after any adjustment before taking a reading on the gauge see Heater Performance Specifications on page 6 for specified pressures Note Pressure gauge must be scaled in 1 4 pound in crements for accurate measurement 6 Check for Restricted Fuel Flow Remove the burner head from heater Using a socket wrench carefully remove the nozzle from burner head Be extremely careful not to scratch or score the face of the nozzle A Seal Leak Remove the rubber seal washer from stem of nozzle and discard To be safe always replace nozzle sleeve during servicing of burner head
23. require ments follows Cu Ft of Area X 133 X Desired Temp Rise F BTU Size Needed Example Area 50 X 25 X 10 12 500 Cu Ft Desired Temp Rise 30 F 12 500 Cu Ft X 133 Factor 1662 5 X30 Temp Rise 49 875 Proper Heater Size ANSWER A 50 000 BTU heater should be selected for this application I HEATER PERFORMANCE SPECIFICATIONS SPARK PLUG MODELS Reddy Heater Brand Technical Service Heater Performance Data Heater Model Motor Motor Start Fuel AMPS Spark Plug Horsepower Relay or Tank Running Gap Solid State Capacity inches Relay Gal R30 M29681 102001 01 Not Used 050 060 R35 R35A 35 000 100735 02 102001 01 Not Used 3 050 060 5 R50 R50A 50 000 M50597 102001 01 Not Used 050 060 R50B R55 55 000 i 100735 17 102001 01 Not Used 050 060 R70 R70A 70 000 100235 04 097308 02 M25061 1 050 060 R70B R70BT R100 R100A 100 000 100735 06 097300 02 097061 01 070 080 R110 110 000 100735 06 097300 02 097061 01 070 080 R150B R150D 150 000 100735 07 097300 02 099061 01 070 080 R165 165 000 i 100735 10 102001 07 097061 01 070 080 R200 200 000 100735 13 102001 07 097061 01 105 115 102482 01 Transformer or Electronic Ignitor will apply to all models for service For replacement parts contact www PartsFor com Spark Plug Ignition Models Service Manual COMPONENT OPERATION l AIR SYSTEM
24. roximately 80 of rated speed the auxiliary winding must be de energized to prevent overheating This is accomplished by the use of a solid state relay The operation of the relay functions as a positive temperature coefficient resistor When voltage is applied to the motor the main and auxiliary windings are energized as current flows through the solid state relay which is connected in series with the auxiliary winding only The resistance is increased over time in the solid state relay where it eventually rises to the point that theoretically no current flows de energizing the auxiliary winding Solid State Relay For replacement parts contact 3 Safety Control Photocell The safety control circuit consists of a photocell light sensitive cell and a safety control The photocell is used to sense the presence of light inside the combustion chamber The photo cell varies its electrical resistance in relation to the light rays which contact its surface When the heater is operating properly the photocell sees sufficient and proper color light which keeps its resistance low When the photocell does not sense the proper color or amount of light the resistance of the photocell increases and forces an electrical current to flow through the solid state trigger circuit The current flows into the circuit breaker and heats a metal bar causing the bar to warp bimetal The warpage releases the spring loaded reset button which breaks all po
25. s Diesel No 1 frequent maintenance of fuel filter Diesel No 2 nozzle and spark plug Requires a winterizing additive at temperatures below 20 F 2 Electrical The heater must be connected to a standard electrical outlet 120V 60HZ For safety all heaters are equipped with athree prong power cord which must be grounded When selecting an extension cord for heater usage the following chart should be used in determining wire size LENGTH OF CORD WIRE SIZE AWG 100 Ft No 14 200 Ft No 12 300 Ft No 10 400 Ft No 8 No 6 3 Ventilation The heater should be used only in well ventilated areas Asa rule the following minimum requirements should be followed HEATER SIZE BTU SQUARE FOOT OPENING 30 000 35 000 1 0 Sq Ft 50 000 55 000 1 6 Sq Ft 70 000 2 1 Sq Ft 100 000 110 000 3 2 Sq Ft 150 000 155 000 4 5 Sq Ft 165 000 5 0 Sq Ft 200 000 6 0 Sq Ft The above is based on ventilation requirements of at least a 3 sq ft opening per 100 000 BTU If possible it is better to provide cross ventilation to achieve better air movement www PartsFor com Spark Plug Ignition Models Service Manual 4 Heater Sizing The user should be aware of the proper size heater needed for a particular application It is easy to see that a 30 000 BTU heater would not heat a large warehouse but the question is sometimes asked What size heater should use A simple formula that can be used to determine heater BTU
26. sary do not substitute with non factory parts use only factory authorized replace ment parts 4 Make sure all electrical connections are secure and all harness leads are in place prior to connection to electri cal power source 1 USING THE OHMMETER Continuity Check Throughout the diagnostic procedures you will be required to check continuity of the electrical circuits A brief description of how to set up the ohmmeter for these tests follows 1 Setting Up the Ohmmeter A use a small screwdriver to adjust the plastic screw on the zero 0 mark to the far left of the scale B With the battery installed set the switch to the RX1 position C Plug in test wires and use insulated alligator clips Screw Typical Ohmmeter For replacement parts contact 2 Calibration A Zero meter connect the alligator clips to each other The meter pointer should move to far right of ohms scale see Figure B B Usethe OHM thumb adjustment knob to set the pointer at the 0 mark on the scale If pointer will not zero replace battery Note If you are using a digital readout ohmmeter cali brate according to manufacturer s instructions Thumb Adjustment Range Switch IV DIAGNOSTIC CHARTS The follovving pages contain various diagnostic charts To use the charts find the Observed Fault that exists and follow test procedure Observed Fault Index Motor starts
27. that a possible restriction in the filter screen can be present during operation and be dislodged back into the tank when the heater EX cC Qe I For replacement parts contact IV COMBUSTION SYSTEM Burner Head The burner head is mounted to the rear of the combustion chamber The purpose ofthe burner head is to meter and mix the amount of air entering the chamber to obtain proper combustion characteristics The nozzle is mounted in the center of the burner head andis surrounded by fins sothatthe amount of air entering the chamber from the burner head is equal and balanced The size of the slots in the burner head differ between models V ALL SYSTEMS WORKING TOGETHER There are four basic systems within the heater the fuel system the air system the electrical system and the combus tion system An air pump A on one end ofthe motor shaft forces air through the air line G and out the burner nozzle I The moving air creates a pressure differential in the burner head N causing fuel to be drawn from the tank J The fuel air mixture is sprayed into the combustion chamber L in a fine mist Addition air is supplied to the combustion chamber by a fan O to enter the combustion chamber where it mixes with the air and fuel from the nozzle The remaining air is directed around and over the combustion chamber This air mixes with the heated air from the combustion chamber and is ejected as a jet of clean heated air K
28. the fuel line at access cover Fuel Filter Bushing and Lower Fuel Line b Note Fuel Filter Location May Vary According To Model www PartsFor com Spark Plug Ignition Models Service Manual OBSERVED FAULT Motor Does Not Run or Runs at Slow Speeds Spark is Observed at Plug Rotate Fan by Hand to Determine if Fan Rotates Easily Fan Rotates Easily by Hand Fan is Difficult to Rotate Dry Motor Bearing O Broken Rotor or Blades 6 Open Motor Winding 2 Improper Rotor Clearance 6 Defective Solid State Relay 3 Oversized Rotor 7 Low Voltage to Heater TEST PROCEDURE m Broken Rotor or Blades Disassemble the end cover filter and end pump cover from rear of motor Visually inspect the rotor and blades for breakage Make sure that the rotor and blades are free of any type of lubricant Rotor and blades must be clean and dry for proper operation 2 Improper Rotor Clearance Check rotor with feeler gauge for proper clearance be tween rotor and pump body Rotate rotor and make sure all four quadrants of rotor have adequate clearance For replacement parts contact www PartsFor com Spark Plug Ignition Models Service Manual 3 Oversized Rotor If the fan is hard to turn when the motor end cover is installed but easy to turn when loosened the rotor should be removed and lightly sanded Remove the rotor and lightly sand by placing rotor in the palm of hand and sand ing on a flat
29. wer to the heater As a service technician it is important to understand the operation of the safety control In the past it has been the single most misdiagnosed part of the heater It is suggested that all controls be checked per instructions listed in the Trouble shooting Section prior to replacement Flameout Safety Enclosed Design E Photocell www PartsFor com Spark Plug Ignition Models Service Manual 4 Electronic Ignitor All models use 102482 01 Electronic Ignitor Kit The electronic ignitor operates on 120V 60Hz It delivers approximately 6 000 volts average to the spark plug causing the kerosene sprayed from the nozzle assembly to ignite The ignitor operates on a pulse basis The ignitor has no internal service parts and must be replaced when found defective Note It is important for the service technician to be cautious when working with the electronic ignitor due to its high voltage output II FUEL SYSTEM Fuel filters There are several types of fuel filters used on different model heaters The filters are always located in line with the fuel pickup tube The purpose of the filter is to eliminate the possibility of dirt dust etc from entering the nozzle and restricting the flow The filters should be inspected and cleaned whenever a heater is brought in for service It is also important that the bottom of the tank be inspected for sedi mentation or dirt buildup The filter s design is such
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