Desa BC70ET, RC115DT, RC165DT, BC165DT, BC55CT User Manual

...

CANADIAN PORTABLE FORCED AIR HEATERS

OWNER’S MANUAL

MODELS: BC40, RC40, BC55CT, RC55CT, UKC55CT, BC70ET,

RC70ET, UKC70ET, BC115DT, RC115DT, UKC115DT, BC165DT,

RC165DT AND UKC165DT

HEATER SIZES: 40/55/70/115/165,000 BTU/HR MODELS

H.S.I. SERIES

IMPORTANT: Read and understand this manual before assembling, starting or servicing heater. Improper use of heater can cause serious injury. Keep this manual for future reference.

TABLE OF CONTENTS

Safety Information ............................................... 2

Unpacking ........................................................... 3

Product Identiﬁcation ...........................................

Fuels .................................................................... 4

Ventilation ............................................................

Theory of Operation ............................................ 4

Assembly ............................................................. 5

Operation ............................................................. 6

Operation With Portable Generator ..................... 7

Fill In For Your Records

Model No. ___________________________ (Located on side panel)

Serial No. ____________________________ (Located on fuel tank)

Date of Purchase: _____________________

Save this manual for future reference.

For more information, visit www.desatech.com

Storing, Transporting or Shipping ........................

Preventative Maintenance Schedule ................... 8

Troubleshooting ...................................................

Service Procedures ........................................... 10

Speciﬁcations ....................................................

Illustrated Parts Breakdown and Parts List ....... 16

Wiring Diagrams ................................................ 25

Accessories ....................................................... 26

Warranty and Repair Service ..............Back Cover

SAFETY INFORMATION

WARNING: This product contains and/or generates chemicals known to the State of California to cause cancer or birth defects or other reproductive harm.

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 warn ings. Keep this manual for reference. It is your guide to safe and proper operation of this heater.

1. Use only kerosene, #1#2 diesel/fuel oil, JET A or JP-8 fuels to avoid risk of ﬁre or explosion. Never use gasoline, naphtha, paint thinners, alcohol or other highly ﬂammable fuels.

2. Fueling a) Personnel involved with fueling shall be

qualiﬁed and thoroughly familiar with the manufacturerʼs instructions and applicable regulations regarding the safe fueling of heating units.

b) Only the type of fuel specified on the

heaterʼs data plate shall be used.

c) All ﬂame, including the pilot light, if any,

shall be extinguished and the heater allowed to cool, prior to fueling.

d) 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.

e) At no time shall more than one dayʼs supply

of heater fuel be stored inside a building in the vicinity of the heater. Bulk fuel storage shall be outside the structure.

f) All fuel storage shall be located a minimum

of 25 feet (762 cm) from heaters, torches, welding equipment, and similar sources of ignition (exception: the fuel reservoir integral with the heater unit).

g) 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.

h) Fuel storage shall be in accordance with the

authority having jurisdiction.

3. Use only the electrical voltage and frequency speciﬁed on model plate.

4. Heater must be grounded. Use only a properly grounded three-wire extension cord. Plug into grounded outlet only.

5. Use only in areas free of ﬂammable vapors or high dust content.

6. Minimum clearance from any combustible materials: 8 feet (244 cm) from hot air outlet; 4 feet (122 cm) from top; and 4 feet (122 cm) from sides and inlet.

7. Locate heater on a stable and level surface while hot or operating or a ﬁre may occur.

8. Use only in well-vented areas. Before using heater, provide at least a three-square-foot

(2800 square cm) opening of fresh, outside air

for each 100,000 Btu/Hr (30 kw) of rating.

9. Keep children and animals away from heater at all times.

10. Never start heater when combustion chamber is hot or if fuel has accumulated in combustion chamber.

11. When used with thermostat, heater may start at anytime.

12. When heater is moved or stored, it must be in a level position or fuel spillage may occur.

13. Use heater only in accordance with local ordinances and codes.

14. Never use gasoline, crankcase drainings, naphtha, paint thinners, alcohol or other highly ﬂammable fuels.

15. Never use heater where gasoline, paint thinner or other highly ﬂammable vapors are present.

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SAFETY INFORMATION

Continued

16. Never use heater in living or sleeping areas.

17. Never leave a heater plugged in without adult supervision if children or animals are likely to be present.

18. Never move, handle, refuel or service a hot, operating or plugged-in heater.

19. Never attach duct work to front or rear of heater.

20. Never attach heater to external fuel tank.

21. Heaters used in the vicinity of tarpaulins, canvas or similar enclosure materials shall be located a safe distance from such materials. The recommended minimum safe distance is 10 feet (304.8 cm). It is further recommended that these enclosure materials be of a ﬁre retardant nature. These enclosure materials shall be securely fastened to prevent them from igniting or from upsetting the heater due to wind action.

22. Unplug heater when not in use.

23. Never block air inlet (rear) or air outlet (front) of heater.

UNPACKING

1. Remove all packing items applied to heater for shipment.

2. Remove all items from carton.

3. Check items for any shipping damage. If heater is damaged, promptly inform dealer where you bought heater.

PRODUCT

IDENTIFICATION

Hot Air Outlet

Fan Guard

Thermostat Knob

Hot Air Outlet

Fuel Tank

Side Cover

Ignition Control Assembly (On Inside of Side Cover)

Hot Air Outlet

Fuel Tank

Fuel Cap/ Gauge

Side Cover

Ignition Control Assembly (On Inside of Side Cover)

Hot Air Outlet

Fuel Tank

ON/OFF Switch with Light

Figure 2 - 55/70 Model

Figure 3 - 115 Model

Fuel Cap/ Gauge

Fan Guard

Fuel Cap/Gauge

Thermostat Knob

ON/OFF Switch with Light

Thermostat Knob

Fan Guard

Thermostat Knob

Air Filter End Cover

Fan Guard

Fuel Tank

Side Cover

Ignition Control Assembly (On Inside of Side Cover)

Figure 1 - 40 Model

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Fuel Cap

Air Filter End Cover

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Side Cover

Ignition Control Assembly (On Inside of Side Cover)

Figure 4 - 165 Model

ON/OFF Switch with Light

FUELS

VENTILATION

WARNING: Use only kerosene, #1/#2 diesel/fuel oil, JET A or JP-8 fuels to avoid risk of ﬁre or explosion. Never use gasoline, oil drained from crankcases, naphtha, paint thinners, alcohol or other highly ﬂammable fuels.

Use only kerosene, #1/#2 diesel/fuel oil, JET A or JP-8 fuels. Heavier fuels such as No. 2 fuel oil or No. 2 diesel fuel may also be used but will result in:

• noticeable odor

• additional fuel ﬁlter maintenance

• the need for nontoxic, anti-icer additives in very cold weather

Do not use fuels heavier than No. 2 grade or heavy oils such as oil drained from crankcases. These heavy oils will not ignite properly and will contaminate the heater.

IMPORTANT: Use a KEROSENE ONLY (blue) or DIESEL ONLY (yellow) storage container. Be sure storage container is clean. Foreign matter such as rust, dirt or water will cause the ignition control assembly to shut down heater. Foreign matter may also require heaterʼs fuel system to be frequently cleaned.

WARNING: Provide a fresh air opening of at least three square feet (2,800 square cm) for each 100,000 Btu/hr rating. Provide extra fresh air if more heaters are being used. The minimum ventilation requirements must be followed to avoid risks associated with carbon monoxide poisoning. Make certain these requirements are met prior to operating heater.

Example: A 200,000 Btu/Hr (58.6 kw) heater requires one of the following:

• a two-car garage door [16 feet (4.88 meter) opening] raised 5 inches (12.7 cm)

• a single-car garage door [9 feet (2.74 meter) opening] raised 8 inches (20.3 cm)

• two, 30 inch (76.2 cm) windows raised 15 inches (38.1 cm)

THEORY OF OPERATION

The Fuel System: The air pump forces air through the air line. The air is then pushed through the

nozzle. This air causes fuel to be lifted from the tank. A ﬁne mist of fuel is sprayed into the combustion chamber.

The Air System: The motor turns the fan. The fan pushes air into and around the combustion chamber.

This air is heated and provides a stream of clean, hot air.

The Ignition System: The ignition control assembly provides power to the ignitor. This ignites the

fuel/air mixture in the combustion chamber.

The Flame-Out Control System: This system causes the heater to shut down if the ﬂame goes out.

Fan

Motor

Combustion Chamber

Ignitor

Air Pump

Air Intake Filter

Clean Heated Air Out

Fuel Tank

Nozzle

Air For Fuel System

Figure 5 - Cross Section Operational View

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Fuel Filter

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Air Line To Burner

Air For Combustion And Heating

Ignition Control Assembly

Cool Air In

Air Output Filter

Fuel

ASSEMBLY

(FOR 40, 55 AND 70 MODELS ONLY)

These models are furnished with a nose cone guard. Nose cone guard and mounting screws are found in the shipping carton.

Tools Needed

• 5/16" nut driver or wrench

1. Place nose cone guard on top of upper shell ﬂange. Make sure nose cone guard is on hot air outlet end of heater.

2. Insert screws through nose cone guard and upper shell ﬂange.

3. Tighten screws ﬁrmly.

Nose Cone Guard

Screw Hot Air Outlet

Upper Shell Flange

Figure 6 - Nose Cone Guard Assembly,

40/55/70 Models Only

(FOR 115 AND 165 MODELS ONLY)

These models are furnished with wheels and a handle. Some models are furnished with a second handle also. Wheels, handle(s), and the mounting hardware are found in the shipping carton.

Tools Needed

• Medium Phillips Screwdriver

• 3/8" Open or Adjustable Wrench

• Hammer Slide axle through wheel support frame. Install

1. wheel spacers if provided. Install wheels on axle.

IMPORTANT: When installing wheels, point

extended hub of wheels toward wheel support frame (see Figure 7).

2. Place cap nuts on axle ends. Gently tap with hammer to secure.

3. Place heater on wheel support frame. Line up holes on fuel tank ﬂange with holes on wheel support frame. Be sure wheels are mounted under the air inlet of heater.

4. Place handle(s) on top of fuel tank ﬂange. In sert screws through handle(s), fuel tank ﬂange, and wheel support frame. Attach nut ﬁnger tight after each screw is inserted. If only one handle is provided, be sure to mount handle over outlet end of heater.

5. After all screws are inserted, tighten nuts ﬁrmly.

Handle

Screw

Hot Air Outlet

Fuel Tank Flange

Cord Cleat with Bolts and Nuts (If provided)

Handle (If provided)

Air Inlet

Wheel Support Frame

Nut

Extended

Axle

Cap Nut

Figure 7 - Wheel and Handle Assembly,

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Wheel Spacer (If Provided)

Wheel

115/165 Models Only

Hub

OPERATION

IMPORTANT: Review and understand the warnings in the Safety Information section, page 2. They are needed to safely operate this heater. Follow all local ordinances and codes when using this heater.

TO START HEATER

1. Follow all ventilation and safety information.

2. Locate heater to provide maximum circulation of the heated air. Follow all location require ments noted in Safety Information, page 2.

3. Fill fuel tank with kerosene, #1#2 diesel/fuel oil, JET A or JP-8 fuel.

4. Attach fuel cap.

5. For thermostat models, turn thermostat knob clockwise to the high position.

6. Plug heaterʼs power cord into approved, grounded, three-wire extension cord. Extension cord must be at least six feet (1.8 meters) long.

Extension Cord Size Requirement 6 to 10 feet (1.8 to 3 meters) long, use 18 AWG

(0.75 mm2) rated cord

11 to 100 feet (3.3 to 30.5 meters) long, use

16 AWG (1.0 mm2) rated cord

101 to 200 feet (30.8 to 61 meters) long, use

14 AWG (1.5 mm2) rated cord

7. Plug extension cord into standard 120 volt/60 hertz, 3-prong grounded outlet. Note: For heater without ON/OFF switch, ignitor will preheat for five seconds, then heater will start.

Note: For heater with ON/OFF switch, push

switch to ON(|) position and heater should start in 5 seconds. If heater does not start, see Troubleshooting, page 9.

8. For thermostat models, adjust thermostat knob to the desired setting. Note: A cold heater may affect the thermostat setting. This thermostat is a general-heating control. It is not intended for precise temperature control. Adjust thermostat until heater cycles at the desired setting.

TO STOP HEATER

Without ON/OFF Switch

Unplug extension cord from outlet.

With ON/OFF Switch

Push ON/OFF switch to OFF (O) position. Unplug heater when not in use.

TO RESTART HEATER

Without ON/OFF Switch

1. Unplug extension cord from outlet and wait 10 seconds. (Wait two minutes if heater has been running.)

2. Repeat steps under To Start Heater

With ON/OFF Switch

1. Push ON/OFF switch to OFF (O) position and wait 10 seconds (2 minutes if heater has been running).

2. Repeat steps under

ON/OFF Switch with Light

Figure 8 - ON/OFF Switch, 55/70 Models

ON/OFF Switch with Light

Figure 9 - ON/OFF Switch, 115/165

To Start Heater.

Models

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FUEL

OPERATION WITH

PORTABLE GENERATOR

WARNING: Before operating heater or any appliance from a portable generator, verify that generator has been properly connected to earth ground. Improper grounding or failure to ground generator can result in electrocution if a ground fault occurs. Refer to owner’s manual supplied by generator manufacturer for proper grounding procedures.

The operating voltage range of the heater is 108 to 132 Volts (120 Volts +/- 10%). Prior to plugging heater into generator the output voltage should be veriﬁed (if generator is equipped with the automatic idle feature, the output voltage should be measured with the generator running at full speed). If the voltage does not measure in this range the heater should not be plugged into the generator.

Operation, page 6, for starting, stopping,

Refer to and resetting heater procedures.

STORING,

TRANSPORTING OR

SHIPPING

Note: If shipping, transport companies require fuel tanks to be empty.

1. Drain fuel tank. Note: Some models have drain plug on underside of fuel tank. If so, re move drain plug to drain all fuel. If heater does not have drain plug, drain fuel through fuel cap opening. Be sure all fuel is removed.

2. Replace drain plug if provided.

3. If any debris is noted in old fuel, add 1 or 2 quarts of clean kerosene to tank, stir, and drain again. This will prevent excess debris from clogging ﬁlters during future use.

4. Replace fuel cap or drain plug. Properly dis pose of old and dirty fuel. Check with local automotive service stations that recycle oil.

5. If storing, store heater in dry place. Make sure storage place is free of dust and corrosive fumes.

IMPORTANT:

months for use during next heating season. Using old fuel could damage heater.

Do not store kerosene over summer

Alternator

Figure 10 - Typical Generator Grounding

Method (Generator construction may

vary from that shown)

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Ground Lug

Copper or Brass Grounding Point

Ground Wire (#10 AWG - StrandedCopper)

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PREVENTATIVE MAINTENANCE SCHEDULE

WARNING: Never service heater while it is plugged in, operating

or hot. Severe burns and electrical shock can occur.

Item

Fuel tank

Air output and lint ﬁlters

Air intake ﬁlter

Fuel ﬁlter

Ignitor

Fan blades

Motor

How Often

Flush every 150-200 hours of operation or as needed

Replace every 500 hours of operation or once a year

Wash and dry with soap and water every 500 hours of operation or as needed

Clean twice a heating season or as needed

No maintenance required

Clean every season or as needed

Not required/permanently lubricated

How To

See Storing, Transporting, or Shipping, page 7

See Air Output, Air Intake, and Lint Filters, page 10

See Fuel Filter, page 11

See Fan, page 10

TROUBLESHOOTING

WARNING: Never service heater while it is plugged in, operating

or hot. Severe burns and electrical shock can occur.

FAULT CONDITION

Motor does not start ﬁve seconds after heater is plugged in

POSSIBLE CAUSE

1. No power to heater

2. ON/OFF switch not in the ON(|) position

3. Thermostat setting is too low

REMEDY

1. Check circuit breaker in electrical panel

2. Verify the ON/OFF switch is in ON (|) position and light is on

3. Turn thermostat knob to a higher setting

WARNING: High voltage!

Bad electrical connection between motor and ignition con trol assembly or ignition control assembly and power cord

5. Binding pump rotor

6. Defective ignition control as sembly

7. Defective motor

8. Blown fuse or ignitor control assembly

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4. Check all electrical connec

tions. See Wiring Diagrams, page 25

5. If fan does not turn freely, see

Pump Rotor,

6 Replace ignition control as

sembly

7. Replace motor

8. See Ignition Control Assembly, page 15

page 14

FAULT CONDITION

Motor starts and runs but heater does not ignite

TROUBLESHOOTING

Continued

POSSIBLE CAUSE

1. No fuel in tank

2. Pump pressure incorrect

3. Dirty fuel ﬁlter

4. Obstruction in nozzle

5. Water in fuel tank

WARNING: High voltage!

REMEDY

1. Fill tank with kerosene

2. See Pump Pressure Adjust ment, page 11

3. See Fuel Filter, page 11

See Nozzle Assembly, page 13

5. Drain and ﬂush fuel tank with clean kerosene. See Storing, Tran sporting or Shipping, page 7

Heater ignites but ignition con trol assembly shuts heater off after a short period of time

6. Bad electrical connection between ignitor and ignition control assembly

7. Defective ignitor

8. Defective ignition control assembly

1. Pump pressure incorrect

2. Dirty air intake, air output, and/or lint ﬁlter

3. Dirty fuel ﬁlter

4. Obstruction in nozzle

5. Photocell assembly not properly installed (not seeing the ﬂame)

6. Dirty photocell lens

WARNING: High voltage!

7. Bad electrical connection between photocell and ignition control assembly

8. Defective photocell

9. Defective ignition control as sembly

Check electrical connections. See Wiring Diagrams, page 25

7. Replace ignitor, see page 12

8. Replace ignition control as sembly

1. See Pump Pressure Adjust ment, page 11

2. See Air Output, Air Intake, and Lint Filters, page 10

3. See Fuel Filter, page 11

See Nozzle Assembly, page 13

5. Make sure photocell boot is properly seated in bracket

6. Clean photocell lens

Check electrical connections. See Wiring Diagrams, page 25

8. Replace photocell

9. Replace ignition control as

sembly

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SERVICE PROCEDURES

WARNING: To avoid risk of burn and electrical shock, never attempt to service heater while it is plugged in, operating or hot.

UPPER SHELL REMOVAL

1. Remove screws along each side of heater using 5/16" nut-driver. These screws attach upper and lower shells together. See Figure 11 or 12.

2. Lift upper shell off.

3. Remove fan guard.

4. Clean fan using a soft cloth moistened with kerosene or solvent.

5. Dry fan thoroughly.

6. Replace fan on motor shaft. Place fan hub ﬂush with end of motor shaft (see Figure 14).

7. Place setscrew on ﬂat of shaft. Tighten setscrew ﬁrmly (40-50 inch-pounds/4.5-5.6 n-m).

8. Replace fan guard and upper shell.

Setscrew

Fan

Screw

Figure 11 - Upper Shell Removal,

40/55/70 Models Only

Upper Shell

Screw

Upper Shell

Fan Guard

Motor Shaft

Figure 13 - Fan, Motor Shaft, and

Setscrew Location

Motor

Setscrew

Motor Shaft

Figure 14 - Fan Cross Section

Fan

Flush

AIR OUTPUT, AIR INTAKE AND LINT FILTERS

1. Remove upper shell (see Figure 11 or 12).

Remove ﬁlter end cover screws using 5/16" nut-

Fan Guard

Figure 12 - Upper Shell Removal,

115/165 Models Only

FAN

IMPORTANT: Remove fan from motor shaft before removing motor from heater. The weight of the motor resting on the fan could damage the fan pitch (see Figure 13).

1. Remove upper shell (see Figure 11 or 12).

2. Use 1/8" allen wrench to loosen setscrew which holds fan to motor shaft.

3. Slip fan off motor shaft.

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driver (see Figure 15 or Figure 16, page 11).

3. Remove ﬁlter end cover.

4. Replace air output and lint ﬁlters.

5. Wash or replace air intake ﬁlter (see Preventa tive Maintenance Schedule, page 8).

Air Intake Filter

Filter End Cover

Lint Filter

Figure 15 - Air Output, Air Intake, and

Air Output Filter

Lint Filters, 40/55/70 Models Only

SERVICE PROCEDURES

Continued

6. Replace ﬁlter end cover.

7. Replace fan guard and upper shell. IMPORTANT: Do not oil ﬁlters.

Air Intake Filter

Filter End Cover

Lint Filter

Air Output Filter

Figure 16 - Air Output, Air Intake, and

Lint Filters, 115/165 Models Only

PUMP PRESSURE ADJUSTMENT

1. Remove pressure gauge plug from ﬁlter end cover (see Figure 17).

2. Install accessory pressure gauge (part number HA1180).

3. Start heater (see motor to reach full speed.

4. Adjust pressure. Turn relief valve to right to increase pressure. Turn relief valve to left to decrease pressure. See speciﬁcations correct pressure for each model (see Figure 18).

5. Remove pressure gauge. Replace pressure gauge plug in ﬁlter end cover.

Pressure Gauge Plug

Operation, page 6). Allow

Relief Valve

FUEL FILTER

1. Remove side cover screws using 5/16" nutdriver.

2. Remove side cover.

3. Pull upper fuel line off fuel ﬁlter neck (see Figure 19 or 20).

4. Carefully pry bushing, fuel ﬁlter, and lower fuel line (115/165 Models only) out of fuel tank (see Figure 20).

5. Wash fuel ﬁlter with clean fuel and replace in tank.

6. Attach upper fuel line to fuel ﬁlter neck.

7. Replace side cover.

Fuel Filter and Bushing

Upper Fuel Line

Side Cover

Figure 19 - Fuel Filter Removal,

40/55/70 Models

Fuel Filter, Bushing, and Lower Fuel Line

Side

Figure 17 - Pressure Gauge Plug

Removal (70 Model Shown)

Pump

Model Pressure

40 3.0 PSI 55 3.4 PSI 70 4.7 PSI 115 5.1 PSI 165 5.6 PSI

Figure 18 - Adjusting Pump Pressure

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Pressure Gauge

(70 Model Shown)

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Cover

Upper Fuel Line

Figure 20 - Fuel Filter Removal,

115/165 Models

SERVICE PROCEDURES

Continued

IGNITOR

1. Remove upper shell and fan guard (See Upper Shell Removal, page 10).

2. Remove fan (see page 10).

3. Remove 4 side cover screws with a 5/16" nut driver. Remove side cover (see Figures 19 or 20, page 11).

4. Disconnect ignitor wires from ignition control assembly (see Figure 21). Pull the ignitor wires up through the hole in the lower shell.

5. Disconnect fuel line hose and air line hose. Remove photocell from photocell bracket (see Figure 21).

6. Remove combustion chamber. Stand com bustion chamber on end with nozzle adapter bracket on top (see Figure 22).

7. Remove ignitor screw with a 1/4" nut driver. Carefully remove ignitor from nozzle adapter bracket.

Combustion Chamber

Air Line Hose

Fuel Line Hose

Photocell Bracket

Photocell Assembly

Side Cover

Figure 21 - Disconnecting Ignitor Wires

from Ignition Control Assembly

Ignitor Screw/ Washer Assembly

Nozzle Adapter Bracket

Ignitor

Ignitor Wire

Ignition Control Assembly

Ignitor

CAUTION: Do not bend or strike ignitor element. Handle with care.

8. Carefully remove replacement ignitor from packing.

9. Carefully guide ignitor into opening in nozzle adapter bracket. Do not strike ignitor element. Attach ignitor to nozzle adapter bracket with screw using a 1/4" nut driver (see Figure 23). Torque .90 to 1.69 N-m (8 to 15 in-lbs) Do not over torque.

10. Replace combustion chamber.

11. Route the ignitor wires back down through the hole in the lower shell. Connect wires to the ignition control assembly (see Figure 22).

12. Replace side cover (see Figures 19 or 20, page 11).

13. Connect and route fuel line hose and air line hose to nozzle adapter assembly. See Fuel and

Air Line Replacement and Proper Routing

page 14.

14. Replace photocell in photocell bracket. Route wires as shown in either (see Figure 23 or Figure 24, page 13).

15. Replace fan (see page 10).

16.

Replace fan guard and upper shell (see page 10).

Ignitor

Photocell Bracket

Combustion Chamber

Photocell

Bracket

Element

Nozzle Adapter Bracket Opening

Figure 22 - Ignitor Replacement

Nozzle Adapter Bracket

Air Line Hose

Figure 23 - Removing Air and Fuel Line

Hoses (40/55/70 Models Only)

Fuel Line Hose

Nozzle Adapter Bracket

Nozzle/ Adapter Assembly

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SERVICE PROCEDURES

Continued

Combustion Chamber

Nozzle Adapter Bracket

Air Line Hose

Fuel Line Hose

Figure 24 - Removing Air and Fuel Line

Hoses (115/165 Models Only)

NOZZLE ASSEMBLY

1. Remove upper shell (see Upper Shell Removal, page 10).

2. Remove fan (see

Remove fuel and air line hoses from nozzle assembly (see Figure 23, page 12 or Figure 24).

4. Turn nozzle assembly 1/4 turn to left and pull toward motor to remove (see Figure 25).

5. Place plastic hex-body into vise and lightly tighten.

6. Carefully remove nozzle from the nozzle adapter using 5/8" socket wrench (see Figure 26).

7. Blow compressed air through face of nozzle. This will free any dirt in nozzle area.

8. Inspect nozzle sleeve for damage.

9. Replace nozzle into nozzle adapter until nozzle seats. Tighten 1/3 turn more using 5/8" socket wrench 4.5 to 5.1 N-m (40 to 45 in-lbs). See Figure 26.

10. Attach nozzle assembly to burner strap (see Figure 25).

Fan, page 10).

Nozzle/ Adapter Assembly

Photocell Bracket

11. Attach fuel and airline hoses to nozzle assembly. See Fuel and Air Line Replacement and Proper Routing, page 14.

12. Replace fan (see

13. Replace fan guard and upper shell (see Upper Shell Removal, page 10).

Combustion Chamber

Figure 25 - Removing Nozzle/Adapter

Nozzle Face

Nozzle

Nozzle Adapter

Figure 26 - Nozzle and Nozzle Adapter

Fan, page 10).

Assembly

Nozzle Sleeve

Air Line Fitting

Fuel Line Fitting

Nozzle/ Adapter Assembly

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SERVICE PROCEDURES

Continued

FUEL AND AIR LINE REPLACEMENT AND PROPER ROUTING

1. Remove upper shell (see Upper Shell Removal, page 10).

2. Remove side cover screws using 5/16" nut driver (see Figure 19 or 20, page 11).

3. Remove side cover.

4. Inspect fuel and air line hoses for cracks and/or holes. If fuel line hose is damaged, disconnect from nozzle adapter (see Figure 23 or 24) and from fuel ﬁlter (see Fuel Filter, page 11). If air line hose is damaged, disconnect from nozzle adapter (see Figure 23, page 12 or Figure 24, page 13) and from barb ﬁtting on pump end cover (see Figure 27).

5. Install new air and/or fuel line. Attach one end of air line hose to barb ﬁtting on pump end cover (see Figure 27) and the other end to nozzle adapter (see Figure 23, page 12 or Figure 24, page 13). Attach one end of fuel line hose to fuel ﬁlter (see Fuel Filter, page

11) and the other end to nozzle adapter (see Figure 23, page 12 or Figure 24, page 13).

Note: Route hoses as shown in Figure 23, page

12 or Figure 24, page 13, according to model. Hoses are not to touch photocell bracket.

6. Replace side cover.

7. Replace upper shell and fan guard (see

Shell Removal, page 10).

Upper

PUMP ROTOR

(Procedure if Rotor is Binding)

1. Remove upper shell (see Upper Shell Re moval, page 10).

2. Remove ﬁlter end cover screws using 5/16" nut driver (see Figure 28 or 29).

3. Remove ﬁlter end cover and air ﬁlters.

4. Remove pump plate screws using 5/16" nut-driver.

5. Remove pump plate.

6. Remove rotor, insert, and blades (see Figure 28 or 29).

7. Check for debris in pump. If debris is found, blow out with compressed air.

8. Install insert and rotor.

Check gap on rotor. Adjust to .076/.101 mm (.003"/.004") if needed (see Figure 30, page 15).

Note: Rotate rotor one full turn to ensure the

gap is .076/.101 mm (.003"/.004") at tightest position. Adjust if needed.

10. Install blades, pump plate, air ﬁlters, and ﬁlter end cover.

11. Replace fan guard and upper shell (see Shell Removal, page 10).

12. Adjust pump pressure (see Pump Pressure Adjustment, page 11).

Blade

Pump Plate

Upper

Air Intake Filter

Filter End Cover

Pump End Cover

Barb Fitting

Air Hose

Figure 27 - Air Hose to Barb Fitting

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115/165 Models40/55/70 Models

Barb Fitting

Insert

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Insert

Rotor

Air Output Filter

Figure 28 - Rotor Location, 40/55/70

Rotor

Air Output Filter

Figure 29 - Rotor Location, 115/165

Models

Blade

Pump Plate

Air Intake Filter

Filter End Cover

Models

SERVICE PROCEDURES

Continued

Note: If rotor is still binding, proceed as follows.

13. Perform steps 1 through 6.

14. Place ﬁne grade sandpaper (600 grit) on ﬂat surface. Sand rotor lightly in “ﬁgure 8” motion four times (see Figure 31).

15. Reinstall insert and rotor.

16. Perform steps 10 through 12.

Blade

Gap Adjusting Screw

.003"/.004" (.076-.101 mm) Gap Measured With Feeler Gauge

IGNITION CONTROL ASSEMBLY

WARNING: High voltage!

1. Unplug heater.

2. Remove side cover screws (4) using 5/16" nutdriver to expose ignition control assembly.

3. Remove fuse cover (see Figure 32). Remove fuse from fuse clips (see Figure 32).

5. Replace fuse with fuse of the same type and rating (GMA-10). Do not substitute a fuse with a higher current rating.

6. Replace fuse cover (see Figure 32).

7. Replace side cover (see Figures 19 or 20, page 11).

Fuse Clips

Fuse Cover

Rotor

Gap Adjusting Screw

Figure 30 - Gap Adjusting Screw

Locations

Sandpaper

Figure 31 - Sanding Rotor

Figure 32 - Replacing Fuse

Fuse

SPECIFICATIONS

Model Size 40 55 70 115 165

Output Rating (Btu/Hr) 40,000 55,000 70,000 115,000 165,000 Fuel Use only kerosene, #1/#2 diesel/fuel oil, JET A or JP-8 fuels* Fuel Tank Capacity (U.S. Gal./Liters) 3/11.3 5/18.9 5/18.9 9/34 13.5/51 Fuel Consumption (Gal. Per Hr/Liters Per Hr) .3/1.14 .44/1.67 .52/1.97 .85/3.00 1.2/4.54 Pump Pressure (psi) 3.0 3.4 4.7 5.1 5.6 Electric Requirements 120 V/60 HZ (Same All Models) Amperage (Normal Run) 2.0 2.0 2.8 3.6 3.6 Motor RPM 1725 1725 3440 3440 3440 Hot Air Output (CFM) 170 180 360 490 575 Shipping Weight 32/14.5 35/15.9 35/15.9 54/24.5 65/29.5

(Approximate lbs./kg) Heater Weight without Fuel 28/12.2 30/14 30/14 46/21 55/25

(Approximate lbs./kg) * Use of #2 diesel & fuel oil will result in noticeable odor and could require additional fuel ﬁlter main

tenance. Use in extreme cold temperatures may require nontoxic anti-icer additives.

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ILLUSTRATED PARTS BREAKDOWN

9-2

9-1

9-3

9-4

9-5

9-6

MODELS BC40 AND RC40

16 116170-01A

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PARTS LIST

MODELS BC40 AND RC40

This list contains replaceable parts used in your heater. When ordering parts, be sure to provide the correct model and serial numbers (from the model plate), then the part number and description of the desired part.

KEY PART NO. NUMBER DESCRIPTION QTY.

1 M51104-01 Handle 1 2 098511-67 Upper Shell (Service Part Will Be Black) 1 3 M11084-29 Screw, #10-16 x 3/4" 2 4 108631-01 Screw, #10-16 x 1" 2 5 098512-58 Combustion Chamber 1 6 M10908-2 Screw, #6-32 x 3/8" 2 7 103154-03 Photocell Bracket 1 8 M16656-24 Photocell Assembly 1 9

(see page 22)

10 M11084-26 Screw, #10-16 x 3/8" 2 11 103684-01 Fan 1 12

(see page 22)

13 M51105-01 Fan Guard 1 14 098219-38 Power Cord 1 15 M11143-1 Strain Relief Bushing 1 16 NTC-4C Hex Lock Nut, 1/4-20 2 17 M11084-26 Screw, #10-16 x 3/8" 4 18 M50631 Rubber Bumper 2 19 097461-09 Side Cover 1 20 101205-01 Motor Bracket 1 21 M30865-02 Bushing 2 22 M11271-8 Clip Nut 6 23 M50104-02 Bushing 1 24 M11084-26 Screw, #10-16 x 3/8" 6 25 M10908-14 Screw, #8-32 x 3/8" 1 26 098511-234 Lower Shell (Service Part will be Black) 1 27 M50814-06 Rubber Airline 1 28 079973-01 Fuel Line 1 29 M50876-04 Fuel Filter with bushing 1 30 M10990-3 Rubber Bushing 1 31 079532-01 Guard, Nose Cone 1 32 102349-01 PCB Support 5 33 104068-02 Ignition Control Assembly 1 34 097702-01 Fuel Cap (Includes Gasket) 1 35 108088-01 Fuel Tank 1 36 M51108-01 Shell Heat-Shield 1 37 M15823-27 Screw, #10-16 x 1/2" 4

103814-01 Wire Tie 1 105550-01 Warning/Maintenance Decal 1 105550-02 Warning/Maintenance Decal 1

Burner Head Assembly 1

Motor 1

PARTS AVAILABLE - NOT SHOWN

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