SAFETY INFORMATION

WARNINGS

IMPORTANT: Read this owner's manual carefully and completely before trying to assemble, operate, or service this heater. Improper use of this heater can cause serious injury or death from burns, fire, explosion, electrical shock, and carbon monoxide poisoning.

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 serviced. 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
• 1. Personnel involved with fueling shall be qualified and thoroughly familiar with the manufacturer's instructions and applicable federal, state, and local regulations regarding the safe fueling of heating units.
  2. Only the type of fuel specified on the heater's data plate shall be used.
  3. All flame, including the pilot light, if any, shall be extinguished and the heater allowed to cool, prior to fueling.
  4. During fueling, all fuel lines and fuel-line connections shall be inspected for leaks. Any leaks shall be repaired prior to returning the heater to service.
  5. 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 structure.
  6. 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).
  7. 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.
  8. Fuel storage shall be in accordance with the federal, state, or local authority having jurisdiction.

TABLE OF CONTENTS

General Information

1. Arrangement of Manual
2. Technical Service Department
3. Service Preparation
4. Tools Required
5. Parts

Specifications

1. General Specifications
2. 1. Fuel Selection
   2. Electrical
   3. Ventilation
   4. Heater Sizing
   5. Heater Performance Specifications

Component Operation

1. I. Air System
2. 1. Air Pump
   2. Air Filters
   3. Nozzle
3. Electrical System
4. 1. Motors
   2. Solid State Relay
   3. Safety Control / Photocell
   4. Electronic ignitor
5. Fuel System
6. Combustion System
7. All Systems Working Together

Troubleshooting

1. Safety Requirements
2. Cautions
3. Using the Ohmmeter
4. 1. Setting Up the Ohmmeter
   2. Calibration
5. Diagnostic Charts

Diagrams and Charts

1. Wiring Diagrams
2. Motor Resistance Chart

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 throughout this manual.

*Available at any auto parts store.
**Available at most electronic stores.

Tune Up Center

The Tune Up Center (HA3025) shown below includes the parts listed.

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 I use?" A simple formula that can be used to determine heater BTU requirements follows:

Cu. Ft. of Area X .133 X Desired Temp. Rise °F = BTU Size Needed.

Example:
Area: 50' multiplied by 25' multiplied by 10' = 12,500 Cu. Ft.
Desired Temp. Rise: 30°F

12,500 (Cu. Ft.) multiplied by .133 (Factor) = 1662.5
1662.5 multiplied by 30 (Temp. Rise) 49,875 (Proper Heater Size)

ANSWER: A 50,000 BTU heater should be selected for this application.

COMPONENT OPERATION

I. AIR SYSTEM

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 it is 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.

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. (See drawings below).

30,000, 35,000, 50,000, 55,000, and 70,000 BTU Filter System

100,000, 110,000, 150,000, 155,000, 165,000, and 200,000 BTU Filter System

2. 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 approximately 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

4. Electronic Ignitor

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.

III. 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 sedimentation or dirt buildup. The filter's design is such that a possible restriction in the filter screen can be present during operation and be dislodged back into the tank when the heater is shut off.

TROUBLESHOOTING

I. SAFETY REQUIREMENTS

This service manual is intended for use by individuals with an adequate knowledge of electrical and mechanical skills. Attempts to repair this heater by individuals without those skills can result in personal injury, as well as property damage.

II. CAUTIONS

1. Before servicing, disconnect the heater from the electrical 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 necessary to complete the test.
2. Do not bypass safety devices.
3. If replacement parts are necessary, do not substitute with non-factory parts (use only factory authorized replacement parts).
4. Make sure all electrical connections are secure and all harness leads are in place prior to connection to electrical power source.

III. 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

1. Use a small screwdriver to adjust the plastic screw on the zero "0" mark to the far left of the scale.
2. With the battery installed, set the switch to the "RX1" position.
3. Plug in test wires and use insulated alligator clips.

Typical Ohmmeter

TEST PROCEDURE

Check Spark Plug for Proper Gap

See Heater Performance Specifications "Spark Plug Gap", page 6, for proper gap. Reset gap with feeler gauge.

Defective Transformer or Electronic Ignitor

Connect the transformer or electronic ignitor to a properly gapped spark plug. Establish a good ground between the spark plug and heater. 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.

Cracked Spark Plug

During the above test, if spark is observed at any portion of the plug, except at the electrodes, the porcelain insulator is cracked and the plug must be replaced.

Check 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 pressure. 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 increments for accurate measurement.

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). 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.

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. Filter Blocked

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.

TEST PROCEDURE

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.

Improper Rotor Clearance

Check rotor with feeler gauge for proper clearance between rotor and pump body. Rotate rotor and make sure all four quadrants of rotor have adequate clearance.

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 sanding on a flat surface making figure eight rotations. (Use the finest grade of sandpaper available).

Dry Motor Bearing

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

Open Motor Windings

Motors Without 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 resistance varies between motor types.

Note: Resistance's 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 allows 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 motor. If the needle does not move again or goes to full scale, the motor must be replaced. Actual resistance varies between motor types.

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 terminal. Connect this black wire to the male connection of jumper wire. Touch the test probe to the opposite terminal 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 replaced.

CAUTION: DO NOT TOUCH ELECTRICAL CONNECTIONS OR ALLOW THEM TO TOUCH METAL PARTS OF THE HEATER.

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 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 running, is necessary for proper operation. Refer to the Electrical Section of this manual (page 5) for proper extension cord sizing.

TEST PROCEDURE

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 operation.

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.

Check for Continuity of Circuit Breaker

Standard Safety Control (098205-04)
With the heater disconnected from AC source, disconnect the red and black wires connected to the safety control. 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 "0".

TEST PROCEDURE

Defective Safety Control (098205-04)

Make sure unit is disconnected from AC source. Disconnect the blue wire coming from safety control that is connected 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 control pops out and unit shuts off, the control is defective and must be replaced.

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 (RX1K) 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.

Restricted Fuel Flow continued

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). 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), inspect “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 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 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 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.

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 plug fouling with carbon or the plug becoming wet during the ignition cycle.

Wrong Fuel

Refer to Fuel Selection on page 5 of this manual.

II. MOTOR RESISTANCE CHART